Operating instructions
48
Another method of leak testing is to pressurize with nitrogen
and to use a soap bubble solution or an ultrasonic leak
detector to determine if leaks are present. This should only
be done if all refrigerant has been evacuated from the vessel.
1. Install a copper tube from the pressure relief device
on the cylinder to the refrigerant charging valve.
2. Never apply full cylinder pressure to the pressurizing
line. Follow the listed sequence:
- Open the charging valve fully.
- Slowly open the cylinder regulating valve.
- Observe the pressure gauge on the chiller and
close the regulating valve when the pressure
reaches test level. Do not exceed 965 kPa.
- Close the charging valve on the chiller.
- Remove the copper tube if no longer required.
7.1.7 - Repair the leak and apply standing vacuum test
After pressurizing the chiller, test for leaks with an electro-
nic leak detector, soap bubble solution, or an ultrasonic
leak detector. Bring the chiller back to atmospheric pressure,
repair any leaks found, and retest.
After retesting and finding no leaks, apply a standing vacuum
test, and then dehydrate the chiller. Refer to chapters 4.3
“Standing vacuum test” and 4.4 “Chiller Dehydration” in
the section 4 “Before initial start-up” .
7.1.8 - Checking guide vane linkage
When the chiller is off, the guide vanes are closed and the
actuator mechanism is in the position shown in Fig. 34 -
“Guide vane actuator linkage”.
If slack develops in the drive chain, backlash can be
eliminated as follows:
1. With the chiller shut down and the actuator fully closed,
remove the chain guard and loosen the actuator
bracket holddown bolts.
2. Loosen guide vane sprocket adjusting bolts.
3. Pry bracket upwards to remove slack, then retighten
the bracket holddown bolts.
4. Retighten the guide vane sprocket adjusting bolts.
Make sure that the guide vane shaft is rotated fully in
the clockwise direction in order for it to be fully closed.
7.1.9 - Trim refrigerant charge
If, to obtain optimal chiller performance, it becomes neces-
sary to adjust the refrigerant charge, operate the chiller at
design load and then add or remove refrigerant progressively
until the difference between leaving chilled water tempe-
rature and the saturated evaporating temperature becomes
optimal. Do not overcharge.
Refrigerant may be added either through the storage tank
(see chapters 4.11 “Chiller equalization without pumpout
unit” and 4.12 “Chiller equalization with pumpout unit”)
or directly into the chiller as described in chapter 4.10
“Charge refrigerant into chiller”.
To remove any excess refrigerant, follow the procedures in
the transfer unit installation manual, document order no.
19999, chapter “Transfer the refrigerant from chiller to
pumpout storage tank”, steps 1a and 1b or use the service
valve under the condenser (this transfers high-pressure
liquid refrigerant).
1. Actuator sprocket
2. Chain guard
3. Guide vane shaft
4. Electronic vane actuator
5. Drive chain
6. Actuator bracket hold-down bolts
7. Guide vane sprocket
8. Guide vane sprocket adjusting bolts
Check the lubrication system
Mark the oil level on the reservoir sight glass, and record
the level each week while the chiller is shut down.
If the level goes below the lower sight glass, check the oil
reclaim system for proper operation. If additional oil is
required, add it through the oil drain charging valve (see
Fig. 4 - “Lubrication system”). A pump is required to complete
the oil charge against refrigerant pressure. The oil charge is
approximately:
2 19
3 30
4 38
5 68
The oil used must meet Carrier specifications for the 19XR.
Refer to chapters 7.3.5 “Oil changes” and 7.3.7 “Oil reclaim
filter”. Any additional oil used should be logged by noting
the amount and date. Surplus oil will return to the sump
and must be removed.
A 1800-Watt oil heater is controlled by the PIC to maintain
oil temperature (see the Controls section) when the compres-
sor is off. The Status02 screen of the ICVC displays whether
the heater is energized or not. If the PIC shows that the
heater is energized, but the sump is not heating up, the
power to the oil heater may be off or the oil level may be
too low. Check the oil level, the oil heater contactor voltage,
and oil heater resistance.
The PIC will not permit compressor start-up if the oil tem-
perature is too low. The control will continue with start-up
only after the temperature is within limits.