Operating instructions
49
Any work must be done by authorised personnel. Establish
a regular maintenance schedule based on the actual chiller
requirements such as chiller load, run hours, and water
quality. The time intervals listed in this section are offered
as guides to service only.
7.3.1 - Service ontime
The ICVC will display a SERVICE ONTIME value on the
'MAINSTAT' status screen. This value should be reset by
the service person or the operator each time major service
work is completed so that time between service can be
viewed.
7.3.2 - Inspect the electrical equipment
Maintenance is limited to general cleaning and tightening of
connections. Vacuum the cabinet to eliminate dust build-up.
If the chiller control malfunctions, refer to the Trouble-
shooting Guide section in the controls manual for control
checks and adjustments.
CAUTION: Be sure power to the equipment is off when
cleaning and tightening connections inside the unit. Access
to the electrical equipment of 19XRV units requires special
precautions. Please refer to the appendix starting with
chapter 8.
Check safety and operating controls monthly
Carry out the “Control test” at least once per month. Refer
to the controls manual for safety control settings.
7.3.3 - Changing oil filter
Change the oil filter on a yearly basis or when the chiller is
opened for repairs. The 19XR has an isolatable oil filter so
that the filter may be changed with the refrigerant remaining
in the chiller. Use the following procedure (refer Fig. 4 -
“Lubribation system”):
1. Make sure that the power supply circuits for the
compressor and the oil pump are disconnected.
2. Close the oil filter isolation valves.
3. Connect an oil charging hose from the oil charging
valve and place the other end in a clean container for
used oil. The oil sample from the filter sump must be
sent to a laboratory for proper analysis. Do not
contaminate this sample.
4. Progressively open the charging valve to drain the oil
from the housing.
CAUTION: The oil filter housing is at a high pressure.
Relieve this pressure slowly.
5. Once all oil has been drained, place some rags or
absorbent material under the oil filter housing to catch
any drips once the filter is opened. Remove the 4 bolts
from the end of the filter housing and remove the
filter cover.
6. Remove the filter retainer by unscrewing the retainer
nut. The filter may now be removed and disposed of
properly.
7. Install a new filter. Install the filter retainer and tighten
down the retainer nut. Install the filter cover and
tighten the 4 bolts.
8. Evacuate the filter housing by placing a vacuum pump
on the charging valve. Follow the normal evacuation
procedures. Shut the charging valve when done and
reconnect the valve so that new oil can be pumped
into the filter housing. Fill with the same amount that
was removed, then close the charging valve.
9. Remove the hose from the charging valve, open the
isolation valves to the filter housing, and turn on the
power to the oil pump and thecompressor again.
7.3.4 - Oil specification
The oil must meet the following specifications:
• Oil that is compatible with R-134a
• Inhibited polyolester-based synthetic compressor oil
formatted for use with HFC, gear-driven, hermetic
compressors, viscosity grade 68.
7.3.5 - Oil changes
Carrier recommends changing the oil after the first year of
operation and every three years thereafter in addition to
an oil analysis. However, if a continuous oil monitoring
system is used and a yearly oil analysis is performed
(Periodic Oil Diagnosis), time between oil changes can be
extended.
To change the oil
1. Transfer the refrigerant into the chiller condenser (for
isolatable vessels) or a pumpout storage tank.
2. Mark the existing oil level.
3. Open the control and oil heater circuit breaker.
4. When the chiller pressure is 34 kPa or less, drain the
oil reservoir by opening the oil charging valve (refer
to Fig. 2 - “19XR machine components”). Progressively
open the valve against refrigerant pressure (see chapter
1 - “Safety considerations”).
5. Change the oil filter at this time.
6. Change the refrigerant filter at this time.
7. Charge the chiller with oil. The 19XR uses approxi-
mately 30/38 l (compressor size 3/compressor size 4),
so that the oil level is visible in the upper sight glass
(refer to Fig. 2 - “19XR machine components”). Turn
on the power to the oil heater and let the PIC warm it
up to at least 60°C. Access the control test mode and
operate the oil pump manually for 2 minutes. The oil
level should be half full between the lower sight glass
and the upper sight glass during shutdown.
7.3.6 - Refrigerant filter
A refrigerant filter/drier, located on the refrigerant cooling
line to the motor, should be changed once a year or more
often, if filter condition indicates a need for more frequent
replacement. Change the filter by closing the filter isolation
valves (refer to Fig. 3 - “Typical 19XR unit diagram”) and
progressively opening the flare fittings to relieve the pressure.
A moisture indicator sight glass is located beyond this filter
to indicate the volume and moisture in the refrigerant. If
the moisture indicator indicates moisture, locate the source
of water by performing a thorough leak check.