Operating instructions

2
CONTENTS
INITIAL START-UP CHECKLIST FOR 19XR HERMETIC CENTRIFUGAL LIQUID CHILLERS ......................... 5
19XR HERMETIC CENTRIFUGAL LIQUID CHILLER CONFIGURATION SETTINGS LOG ............................... 7
1 - SAFETY CONSIDERATIONS ............................................................................................................................................... 8
1.1 - Installation safety considerations ...........................................................................................................................................8
1.2 - Maintenance safety considerations ........................................................................................................................................8
1.3 - Operating checks, valves .......................................................................................................................................................... 9
1.4 - Equipment and components under pressure ........................................................................................................................9
1.5 - Repair safety considerations ...................................................................................................................................................9
2 - INTRODUCTION AND CHILLER FAMILIARISATION............................................................................................. 10
2.1 - CE marking .............................................................................................................................................................................10
2.2 - Abbreviations and explanations ...........................................................................................................................................10
2.3 - Chiller familiarization 19XR ................................................................................................................................................. 11
3 - INSTALLATION ...................................................................................................................................................................... 15
3.1 - Introduction ............................................................................................................................................................................15
3.2 - Receiving the machine ........................................................................................................................................................... 15
3.3 - Rigging the machine and dimensional information ...........................................................................................................16
3.4 - Install machine supports ........................................................................................................................................................22
3.5 - Connection of water piping ...................................................................................................................................................24
3.6 - Make electrical connections ..................................................................................................................................................27
3.7 - Install field insulation .............................................................................................................................................................32
3.8 - Installation of a refrigerant leak detection module (option 159) ......................................................................................34
4 - BEFORE INITIAL START-UP ............................................................................................................................................. 36
4.1 - Necessary checks ....................................................................................................................................................................36
4.2 - Chiller tightness ......................................................................................................................................................................37
4.3 - Standing vacuum test .............................................................................................................................................................38
4.4 - Chiller dehydration ............................................................................................................................................................... 38
4.5 - Inspect wiring .......................................................................................................................................................................... 40
4.6 - Oil charge ................................................................................................................................................................................40
4.7 - Power-up the controls and check the oil heater ..................................................................................................................40
4.8 - Check optional pumpout system controls and compressor ...............................................................................................41
4.9 - High altitude locations ........................................................................................................................................................... 41
4.10 - Charge refrigerant into chiller ............................................................................................................................................41
4.11 - 19XR Chiller equalization without pumpout unit ............................................................................................................41
4.12 - 19XR Chiller equalization with pumpout unit .................................................................................................................41
4.13 - Trimming refrigerant charge ..............................................................................................................................................42
5 - INITIAL START-UP ............................................................................................................................................................... 42
5.1 - Preparation..............................................................................................................................................................................42
5.2 - Dry run to test start-up sequence .........................................................................................................................................42
5.3 - Check rotation .......................................................................................................................................................................42
5.4 - Check oil pressure and compressor stop ............................................................................................................................43
5.5 - To prevent accidental start-up ..............................................................................................................................................43
5.6 - Check chiller operating condition ........................................................................................................................................ 43
5.7 - Instruct the customer operator .............................................................................................................................................43
6 - OPERATING INSTRUCTIONS ........................................................................................................................................... 44
6.1 - Operator duties ......................................................................................................................................................................44
6.2 - To start the chiller ...................................................................................................................................................................44
6.3 - Check the running system .....................................................................................................................................................44
6.4 - To stop the chiller ..................................................................................................................................................................44
6.5 - After limited shutdown ..........................................................................................................................................................44
6.6 - Extended shutdown ...............................................................................................................................................................44
6.7 - After extended shutdown ......................................................................................................................................................45
6.8 - Cold-weather operation.........................................................................................................................................................45
6.9 - Manual guide vane operation ...............................................................................................................................................45
6.10 - Refrigeration log .................................................................................................................................................................45
7 - MAINTENANCE ..................................................................................................................................................................... 47
7.1 - General maintenance .............................................................................................................................................................47
7.2 - Weekly maintenance ..............................................................................................................................................................48
7.3 - Scheduled maintenance ........................................................................................................................................................49
APPENDIX: PARTICULARS OF 19XRV PIC III MACHINES .........................................................................................53
8 - 19XRV PIC III - SAFETY CONSIDERATIONS FOR MAINTENANCE.................................................................... 53
8.1 Electrical maintenance ............................................................................................................................................................. 53
8.2 - Mechanical maintenance .......................................................................................................................................................53