Carrier 19CB User Manual

Carrier
Airconditioning		V
Company
G

Hermetic Centrifugal Liquid Chillers

CONTENTS
	Page
INTRODUCTION
General
Job Data Required
Equipment Required
INITIAL PREPARATION
Machine Tightness	3
Check for Large Leaks	3
Check for Small Leaks	3
Check Leakage Rate	3
Machine Dehydration	3
Pumpout Procedures	4
Oil Charge	4
Oil Heater	4
Refrigerant Charge	5
Inspect Piping	5
Field Wiring	5
Check Starter	6
Check Operation of Safety Controls	6
Purge	7
Air Supply (Pneumatic Controls Only)	7
START-UP	7
Before Starting Machine	7
Compressor Rotation	7
Compressor Operation	7
Checking Safety Control Settings	7
Setting Operating Controls — Electronic	9
Motor Current Calibration	9
Chilled Water Calibration	10
Setting Operating Controls — Pneumatic	10
FINAL MACHINE ADJUSTMENT	12
Trimming Refrigerant Charge	12
INSTRUCTING THE CUSTOMER
OPERATOR	1 2

INTRODUCTION

General — All persons involved in start-up and operation of the 19CB machine should be famihar with these instructions and all necessary job data before initial start-up. Instructions are arranged in proper sequence for machine start-up.

Job Data Required

1.List of applicable design temperatures and pressures

2.Machine assembly, wiring and piping prints

319CB Installation Instructions

4.19CB Operating and Maintenance Instructions

Equipment Required

1. Mechanic’s tools

2 Volt-ohmmeter and clamp-on ammeter

3.Manometer, absolute pressure type

4.Leak detector, halide or electronic

5.Refrigerant drum charging valve (Fig. 5)

6.5/8-in. SAE X 3/4-in. MPT adapter

7.Five to ten ft of copper tubing or plastic hose to fit 5/8-in. SAE connections

8.Portable vacuum pump

INITIAL PREPARATION

CAUTION: Do noi start compr&ssox or oil pump, even for a rotation check, unless conv pxessor is charged with <ni and machine charged with refrigerant.

Do not apply voltage of my kina wihle machine is under dehydration vacuum.

© Carrier Corporation 1973

Form 19CB-2SS

ì —		Cooler		12 — Cooler-Econorttize: Epuati^iitg Damper		23	-	P'orge Conderising Chamber
2 — Cooler Ret:igerant Level Sight Glass					Access Cover	24	-	Riiter-Drier Shetoff Valve
3 — Low Refrigerant Temoerature Sulb				■ 53 - Refrigerant Connection, 1 1/2 NRT		25	-	Chilled Water Low-Temp Cutout
4	— Thermometer Well			14 — Cooler Charging Valve, 3/4 NPT		26	-	Chi lied Watsr Terr^p P: obe
5 — Machir.e Control Ceitter				15	— AS:Vi£ Nomepiats	27	-	Purge Refrigerant Level Sight Giass
		(See Rig.:«.)	,	1 6 : M a c h i n e informative Plate		28	-	Purge Water Level Sight Glass
6 ~ KnockouwforRieici Wiritts :				17 — Safety Code Sticker		23 - Purge Water Drain Valve
7	— Condenser			IS — Cooler Watsrbcx vent, 3/4 MPT		30	~	Rupture Disc Assembly
S — Cooler S'.jotion Pipe				13 — Condenser W'arerbox Drain, 3/4 MPT		31 -		Economizer Pioat Valve
3	— Condettser Discharge Ripe			20	— Condenser Waterdox Vent, 3/4 MPT	32	-	Moisture Indicator
ÎO —, Condenser Float Valve;				21	— iiconomizer	33 ~		Pilter-Drier
n	— iiconomiser Pipe			22	— Porge Operatirrg Switch

Fig. 1 — 19CB Machine Components (R-114 Unit Shown)

1 Serial Numlser idenritica-		16 Oit Cooler Wa‘-:-r-Oor
Tior> Piste		Gconeotion
2 Oil C^iarairvg Valve		17 Oil Pornp Nciirrepiate
3 Gii Heater Tl>erfr;ost3t		18 Gornoressor Nameplate
4 Oil Heater ; ern-.inal Sox		19 edmpt esser Joriction Sox
5 Oil Reservoir Siijf.t Glass		20 Economlter inlet
6 Oil-Pressare Regtila-rioó		21 Compressor Morof Terminai
Valve. : :		Sox (Par side on most ■ :
7 Oil Purtiii Temrinal Sox		rncdetsl: r:'.
8 •'!=•■ Solenoid Valve		22 Motor and Stg H i-Temp-
9 "G" Soteooici Vaive		C'-itout iluncticrn Sox ;
tO Gii Cooler		23Main Searing inspection Cove'
Water-Ir,	Conr>..Solenoid	24 EeonomiKer Darooer Ccn-
Valve and Plue COOK		r.ection .CR 014 dniy}■ T
12 Oli-Pressore Gage		25 Guide yiane indicator
13 OiPPrsssure Oiilerenrial		{gleotronte ConTrot) : :
Switoli		26 Hydrau lic V-ane Motcir
14 Bearing Temperature Gage		27 Oispharoe StuOouT- :
15 Oli XemperaTure Gage		28 DiscP-aige Pipe

Fig. 2 — Compressor (Electronic Capacity Control)

Machine Tightness — If machine leak testing and dehydration was not completed at installation, check machine tightness (including pumpout sys­ tem) as described below. Dehydration must be repeated if machine has been idle for several weeks after initial dehydration.

Check for Large Leaks — Using one of the methods described below, pressurize the machine to the level listed in Table 1. Do not exceed test pressure

Listen for large leaks as the pressure builds up. If test pressure holds for one hour, proceed with Check for Small Leaks.

All 19CB machines may be pressurized with cylinders of dry air or nitrogen thni the cooler charging valve. Dry air or nitrogen charging is preferable to purge or pumpout charging as it ensures that moisture will not be introduced into the machine. To pressurize with nitrogen (or dry air):

1. Connect a copper tube from charging valve to

pressure cylinder. Never apply full cylinder pressure to the pressurizing line. Follow steps 2 thru 5 in proper sequence.

2.Open cooler charging valve fully.

3.Open cylinder regulating valve slowly.

4 Observe cooler or condenser pressure gage and close cylinder regulating valve when pressure reaches test pressure listed in Table 1.

Do not exceed test pressure!

5. Close cooler charging valve. Remove copper

tube.

R-11 machines may be pressurized with the purge pump. Ensure that electrical supply to purge pump is 120 volts. Then follow Operation 3 on the purge valve chart.

R-1 14 machines may be pressurized with the pumpout unit This method is detailed in the section entitled Pumpout Procedures.

Table 1 — Test Pressures

	REFRIGERANT		TEST
		PRESSURE
	R-11	8	- 1 0 psig
	R-114	30	- 35 psig

Check for Small Leaks

1. Pull a vacuum equal to 5 in. Hg (12 5 psia) by using purge pump Operation 2 (R-11 machines), pumpout unit (R-114 machines) or by applying a vacuum pump at the cooler charging valve.

2.Charge approximately 25 pounds of the proper refrigerant thru the cooler cliarging valve.

3Pressurize machine to test pressure (Table 1) using purge pump, pumpout unit, dry air or nitrogen. Do not exceed test pressure

4.Test all joints, valves, fittings etc. with a halide or electronic leak detector.

Check Leakage Rate

1 Install a mercury manometer (absolute pressure type) on a tee at the cooler charging valve.

2. Pull 25 in. of vacuum on the machine.

3Let machine stand with this vacuum for at least 8 hours

4.If leakage rate is less than 0.1 in. Hg in 24 hours (0.033 in. Hg in 8 hrs), machine is sufficiently tight. Perform Machine Dehydration.

5.If leakage rate exceeds 0.1 in. Hg per 24 hours, repeat Check for Small Leaks, repair leaks and repeat this Leakage Rate check.

6.Remove or valve off manometer before re­ peating any pressure test.

Machine Dehydration

W.^iRNlNG: Do not attempt to start compres­ sor, oil pump or purge motor even fox a rotation check, nor app.ly test voltage of any kind while machine is under dehydration vacuumMotor insuiation breakdown and serious damage tnav result.

SEPARABLE UNION

PIPING BY CARRIER

FIELD PIPING

Fig. 3 — Pumpout System Schematic (R-114 Units)

1. Connect dehydration pump to cooler charging valve.

2.Ensure that all valves on purge assembly are closed; valves on filter-drier system open.

3.Install mercury manometer (absolute pressure type) at charging valve.

4.Operate pump until manometer reads 0.20 in. Hg absolute. Continue to operate pump for 2 more hours.

5.Close cooler charging valve; stop pump; record manometer reading.

6.Wait 2 hours and read manometer again. If ab­ solute pressure reading has not increased, dehy­ dration is complete. If absolute pressure has increased, repeat steps 4, 5 and 6.

7.If vacuum fails to hold after several dehy­ dration attempts, check for machine leak by repeating the (?heck for Small Leaks.

Pumpout Procedures (R-114 Units) MACHINE EVACUATION (No refrigerant in system)

1. Set purge valves per Operation 5 on purge valve operation plate.

2.Jumper low-pressure cutout on pumpout compressor.

3.Close valves 1, 3, 7 and 10.

4.Open valves 2, 4, 5, 6, 8, 9 and 11

5.Disconnect separable union between pumpout condenser and oil separator.

6.Run pumpout compressor until desired machine vacuum is reached.

7.Close valve 5 and reassemble union.

8.Stop compressor.

9.Remove jumper.

PRESSURIZING THE MACHINE (No refrigerant in system)

1. Set purge valves per Operation 4 on purge valve operation plate.

2.Close valves 2, 4 and 10.

3.Open valves 1, 3, 5, 6, 7, 8, 9 and 1 1.

4.Disconnect separable union in pumpout com­ pressor suction Hne.

5.Operate pumpout compressor until desired pressure is reached. Do not exceed test pressure listed in Table 1.

6.Shut off pumpout compressor

7.Reassemble union.

8.Return purge valves to “Normal-Auto” condi­ tion when pressurizing is completed.

Oil Charge — Use oil shipped with machine. This oil conforms to Carrier’s oil specifications for hermetic centrifugal compressors.

Charge oil thru the oil reservoir charging valve. Machine vacuum will draw the oil from the container. Add oil until it reaches the middle of the oil sight glass. After charging, close valve completely to prevent air from entering machine.

R-114 machines containing refrigerant will require a small hand pump for oil charging.

On pneumatic machines, add oil to the vane seal chamber thru pipe plug opening (see Fig. 4) until level reaches bottom of rack and gear as seen thru Plexiglas cover.

Oil Heater — Check for 1 20 volt supply. Energize oil heater to minimize oil-refrigerant absorption. A light indicates when the heater is energized. The oil heater thermostat is set to maintain a temperature of 140 F ± 3 F at shutdown. Adjust if required.

Fig. 4 — Pneumatic Vane Shaft Seal Chamber