Specifications

65
BEFORE INITIAL START-UP
Job Data Required
• list of applicable design temperatures and pressures
(product data submittal)
• chiller certified prints
• starting equipment details and wiring diagrams
• diagrams and instructions for special controls or options
• 19XR Installation Instructions
Equipment Required
• mechanic’s tools (refrigeration)
• digital volt-ohmmeter (DVM)
• true RMS digital multimeter with clamp-on current
probe or true RMS digital clamp-on ammeter for at least
480 vac or 700 vdc (19XRV only).
• electronic leak detector
• absolute pressure manometer or wet-bulb vacuum
indicator (see Fig. 31)
• 500-v insulation tester (megohmmeter) for compressor
motors with nameplate voltage of 600 v or less, or a
5000-v insulation tester for compressor motor rated
above 600 v
Using the Optional Storage Tank and Pump-
out System —
Refer to Positive Pressure Chillers with
Storage Tanks section, page 92 for pumpout system prepara-
tion, refrigerant transfer, and chiller evacuation.
Remove Shipping Packaging — Remove any pack-
aging material from the control center, power panel, guide vane
actuator, motor cooling and oil reclaim solenoids, motor and
bearing temperature sensor covers, and the factory-mounted
starter.
Open Oil Circuit Valves — Check to ensure the oil fil-
ter isolation valves (Fig. 4) are open by removing the valve cap
and checking the valve stem.
Tighten All Gasketed Joints and Guide Vane
Shaft Packing —
Gaskets and packing normally relax by
the time the chiller arrives at the jobsite. Tighten all gasketed
joints and the guide vane shaft packing to ensure a leak-tight
chiller. Gasketed joints (excluding O-rings) may include joints
at some or all of the following:
• Waterbox covers
• Compressor suction elbow flanges (at compressor and at the
cooler)
• Compressor discharge flange
• Compressor discharge line spacer (both sides) if no isolation
valve
• Cooler inlet line spacer (both sides) if no isolation valve
• Hot gas bypass valve (both sides of valve)
• Hot gas bypass flange at compressor
Refer to Table 10 for bolt torque requirements.
Check Chiller Tightness — Figure 32 outlines the
proper sequence and procedures for leak testing.
The 19XR chillers are shipped with the refrigerant con-
tained in the condenser shell and the oil charge in the compres-
sor. The cooler is shipped with a 15 psig (103 kPa) refrigerant
charge. Units may be ordered with the refrigerant shipped sepa-
rately, along with a 15 psig (103 kPa) nitrogen-holding charge
in each vessel.
To determine if there are any leaks, the chiller should be
charged with refrigerant. Use an electronic leak detector to
check all flanges and solder joints after the chiller is pressur-
ized. If any leaks are detected, follow the leak test procedure.
If the chiller is spring isolated, keep all springs blocked in
both directions to prevent possible piping stress and damage
during the transfer of refrigerant from vessel to vessel during
the leak test process, or any time refrigerant is being trans-
ferred. Adjust the springs when the refrigerant is in operating
condition and the water circuits are full.
Refrigerant Tracer — Carrier recommends the use of an
environmentally acceptable refrigerant tracer for leak testing
with an electronic detector.
Ultrasonic leak detectors can also be used if the chiller is
under pressure.
Leak Test Chiller — Due to regulations regarding refrig-
erant emissions and the difficulties associated with separating
contaminants from the refrigerant, Carrier recommends the
following leak test procedure. Refer to Tables 11A and 11B for
refrigerant pressure/temperature values.
1. If the pressure readings are normal for the chiller
condition:
a. Evacuate the holding charge from the vessels, if
present.
b. Raise the chiller pressure, if necessary, by adding
refrigerant until pressure is at the equivalent satu-
rated pressure for the surrounding temperature.
Follow pumpout procedures in the Transfer Refrig-
erant from Pumpout Storage Tank to Chiller sec-
tion, Steps 1a-e, page 93.
c. Leak test chiller as outlined in Steps 3 - 9.
Fig. 31 — Typical Wet-Bulb Type
Vacuum Indicator
WARNING
Do not use air or oxygen as a means of pressurizing the
chiller. Mixtures of HFC-134a and air can undergo
combustion.
WARNING
Never charge liquid refrigerant into the chiller if the pres-
sure in the chiller is less than 35 psig (241 kPa) for HFC-
134a. Charge as a gas only, with the cooler and condenser
pumps running, until this pressure is reached, using
PUMPDOWN LOCKOUT and TERMINATE LOCK-
OUT mode on the PIC II. Flashing of liquid refrigerant at
low pressures can cause tube freeze-up and considerable
damage.