Specifications
73
2. Open the charging valve fully.
3. Slowly open the cylinder regulating valve.
4. Observe the pressure gage on the chiller and close the
regulating valve when the pressure reaches test level. Do
not exceed 140 psig (965 kPa).
5. Close the charging valve on the chiller. Remove the cop-
per tube if no longer required.
Repair the Refrigerant Leak, Retest, and
Apply Standing Vacuum Test —
After pressurizing
the chiller, test for leaks with a soap bubble solution, an elec-
tronic leak detector, a halide torch, or an ultrasonic leak detec-
tor. Bring the chiller back to atmospheric pressure, repair any
leaks found, and retest.
After retesting and finding no leaks, apply a standing vacu-
um test. Then dehydrate the chiller. Refer to the Chiller Dehy-
dration in the Before Initial Start-Up section, page 55.
Trim Refrigerant Charge — If it becomes necessary
to adjust the refrigerant charge to obtain optimum chiller per-
formance, operate the chiller at design load and then add or re-
move refrigerant slowly until the difference between LEAV-
ING CHILLED LIQUID chilled liquid temperature and the
EVAP REFRIG LIQUID TEMP reaches design conditions. Do
not overcharge. For superheat information, see the Trouble-
shooting section on page 78.
Refrigerant may be added either through the optional stor-
age tank or directly into the chiller as described in the section
entitled, Refrigerant Charging.
To remove any excess refrigerant, follow the procedure in
Transfer Refrigerant from Chiller to Pumpout Storage Tank
section, Steps 1a, b on page 70.
WEEKLY MAINTENANCE
Check the Lubrication System —
Mark the oil lev-
el on the oil sump sight glasses and observe the level each
week while the chiller is running. Check the moisture indicator
on the motor cooling line.
If the level goes below the bottom of the oil sump sight
glass, the oil reclaim system will need to be checked for proper
operation. The oil reclaim system is operating properly if the
level in the oil sump increases after running the chiller near full
load with a 95 F (35 C) or higher CONDENSER TEMPERA-
TURE for 1 hour. If additional oil is required, add it through the
oil charging valve (Fig. 2 and 3). A hand pump is required for
adding oil against refrigerant pressure. The oil charge for the
23XRV chiller is 7.5 gallons (28 L).
The oil must meet Carrier’s specifications for the 23XRV
chillers. Refer to Changing Oil and Oil Filter section. Any oil
that is added should be logged by noting the amount and date
in Fig. 40 on page 68. Any oil that is added due to oil loss not
related to service will eventually return to the sump. Excess oil
must be removed when the level is above the top of the oil
sump sight glass.
A 530-watt oil sump heater is controlled by the PIC III to
maintain oil temperature above 140 F (60 C) or CALC EVAP
SAT TEMP plus 53 F (29.4 C) when the compressor is off
(see the Controls section on page 12). The ICVC Status-
COMPRESS table displays whether the heater is energized or
not. If the PIC III shows that the sump heater is energized, but
the sump is not heating up, the power to the oil sump heater
may be off or the oil level may be too low. Check the oil level,
the sump oil heater contactor voltage, and oil heater resistance.
The PIC III will not permit compressor start-up if the oil tem-
perature is less than 140 F (60 C) or CALC EVAP SAT TEMP
plus 15 F (8.3 C), whichever is lower. The control will continue
with start-up only after the temperature is within limits.
SCHEDULED MAINTENANCE
Establish a regular maintenance schedule based on the actu-
al chiller requirements such as chiller load, run hours, and cool-
er and condenser liquid quality. The time intervals listed in this
section are offered as guides to service only. Jobsite conditions
may dictate that maintenance schedule is performed more often
than recommended.
Service Ontime — The ICVC will display a SERVICE
ONTIME value on the MAINSTAT table. This value should be
reset to zero by the service person or the operator each time
major service work is completed so that time between service
can be seen.
Inspect the Control Center — Maintenance is gener-
ally limited to general cleaning and tightening of connections.
Vacuum the control center enclosure to eliminate dust build-up.
In the event of chiller control malfunctions, refer to the Trou-
bleshooting Guide section for control checks and adjustments.
Power connections on newly installed equipment may relax
and loosen after a month of operation. Turn off power and
re-tighten, check annually thereafter.
Check Safety and Operating Controls
Monthly — To ensure chiller protection, the Automated
Control Test in the service menu should be done at least once
per month. See Table 5 for safety control settings.
Changing Oil and Oil Filter — If the OIL PRES-
SURE DELTA P approaches the 18 psid (124 kPad) LOW OIL
PRESSURE ALARM threshold, change oil filter as needed.
Otherwise, change the oil filter on a yearly basis.
Change the oil after the first year of operation. Then,
change the oil at least every three years, or as needed. Howev-
er, if a continuous oil monitoring system is present and/or a
yearly oil analysis is performed, the time between oil changes
may be extended. See Oil Specification section on page 74 for
additional information.
The 23XRV oil pump and filter can be isolated to change
the oil filter and oil while the refrigerant remains inside the
chiller. Use the following procedure to change the oil and oil
filter (if required):
CHANGING OIL
1. Make sure the compressor is off and the CB1 main circuit
breaker for the control center is open.
2. Open the CB2 control power and oil heater circuit break-
er in order to turn off the power to the oil heater.
DANGER
Be sure power to the control center is off when cleaning
and tightening connections inside the control center. Fail-
ure to be sure power is off will result in severe personal
injury or death.
CAUTION
Do not manually open the oil reclaim isolation valve when
the chiller is shut down. Doing so will flood the vaporizer
with refrigerant and severely degrade the viscosity of the
oil in the sump.
CAUTION
Compressor oil is hygroscopic. Containers should remain
tightly sealed in a clean and dry environment to prevent
moisture absorption from the air.