Carrier 17CB User Manual

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Division ot Carrier Corporation

Carrier Parkway • Syracuse NY 13221

Open-Drive Centrifugal Liquid Chillers

SAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design speci fications. When operating this equipment, use good judgment and safety precautions to avoid damage to equipment and property or injury to personnel.

Be sure you understand and follow the procedures and

safety precautions contained in the machine instructions as well as those listed in this guide.

A DANGER

DO NOT USE OXYGEN to purge lines or to pressurize a

machine for any purpose. Oxygen gas reacts violently

with oil, grease and other common substances.

NEVER EXCEED specified test pressures. VERIFY the

allowable test pressure by checking the instruction literature and the design pressures on the equipment

nameplate. DO NOT VALVE OFF any safety device. BE SURE that all pressure relief devices are properly

installed and functioning before operating any machine.

A WARNING

DO NOT USE eyebolts or eyebolt holes to rig machine

sections or the entire assembly.

DO NOT woik on high voltage equipment unless you are

a qualified electrician DO NOT WORK ON electrical components, including

control panels, switches, starters or oil heater until you are sure ALL POWER IS OFF and no residual voltage can leak from capacitors or solid-state components

LOCK OPEN AND TAG electrical circuits during servic ing. IF WORK IS INTERRUPTED, confirm that all circuits are de-energized before resuming work.

DO NOT syphon refrigerant by mouth. AVOID SPILLING liquid refrigerant on skin or getting it

into the eyes USE SAFETY GOGGLES. Wash any spills

from the skin with soap and water. If any enters the eyes, IMMEDIATELY FLUSH EYES with water and consult a physician.

NEVER APPLY an open flame or live steam to a

refrigerant cylinder. Dangerous overpressure can result.

When necessary to heat refrigerant, use only warm

(llOF/43 C) water

DO NOT REUSE disposable (nonreturnable) cylinders

nor attempt to refill them. It is DANGEROUS AND

ILLEGAL. When cylinder is emptied, evacuate remain

ing gas pressure, loosen the collar and unscrew and

discard the valve stem. DO NOT INCINERATE.

CHECK THE REFRIGERANT TYPE before charging

machine. Higli pressure refrigerant in a low pressure

machine can cause vessels to rupture if the relief devices

cannot handle the refrigerant volume. DO NOT ATTEMPT TO REMOVE fittings, covers, etc.

while machine is under pressure or while machine is running. Be sure pressure is at zero psig before breaking any refrigerant connection.

CAREFULLY INSPECT all relief valves, rupture discs and other relief devices AT LEAST ONCE A YEAR. If machine operates in a corrosive atmosphere, inspect the

devices at more frequent intervals. DO NOT ATTEMPT TO REPAIR OR RECONDITION

any relief valve when corrosion or build-up of foreign material (rust, dirt, scale, etc.) is found within the valve

body or mechanism. Replace the valve.

DO NOT VENT refrigerant relief valves within a building, refer to ANSIB9.1. The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation.

DO NOT install relief valves in series or backwards. USE CARE when working near or in line with a

compressed spring. Sudden release of the spring can

cause it and objects in its path to act as projectiles.

A CAUTION

DO NOT STEP on refrigerant lines. Broken lines can whip about and cause personal injury.

DO NOT climb over a machine. Use platform, catwalk or staging. Follow safe practices when using ladders.

USE MECHANICAL EQUIPMENT (crane, hoist, etc ) to lift or move inspection covers or other heavy compo nents. Even if components are light, use such equipment when there is a risk of slipping or losing your balance.

DO NOT WELD OR FLAME CUT any refrigerant line or vessel until all refrigerant has been transferred from the vessel to storage.

BE AWARE that certain automatic start arrangements CAN ENGAGE THE STARTER. Open the disconnect

ahead of the starter in addition to shutting off the

machine or pump USE only lepair or replacement parts that meet the code

requirements of the original equipment DO NOT VENT OR DRAIN water boxes containing

industrial brines, liquid, gases or semisolids without permission of your Process Control Group.

DO NOT LOOSEN water box cover bolts until the water box has been completely drained.

DOUBLE-CHECK that coupling nut wrenches, dial indicators or other items have been removed before rotating any shafts.

DO NOT LOOSEN a packing gland nut before checking

that the nut has a positive thread engagement. PERIODICALLY INSPECT all valves, fittings and piping

for corrosion, rust, leaks or damage PROVIDE A DRAIN connection in the vent line near

each pressure relief device to prevent a build-up of condensate or rain water.

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Page

SAFETY CONSIDERATIONS 1

INTRODUCTION 2

General 2 Job Data Required 2 Equipment Required 2

INITIAL PREPARATION 4

Machine Tightness 4 Check for Large Leaks 4 Check for Small Leaks 4 Check Leakage Rate 5 Machine Dehydration 5 Pumpout Procedures 5 Recheck Alignment 6 Check Grouting 6 Inspect Piping 6

Field Wiring 6 Lubrication 6

Refrigerant Charge 6 Drive 7 Purge 7 Air Supply (Pneumatic Control Only) 7 Check Safety Control Operation

(Electric Motor Drive) 7

Check Safety Control Operation

(Gas or Turbine Drive) 8

START-UP 10

Preliminary Checks 10

Compressor Rotation and Operation 10 Checking Safety Control Settings 10 Setting Operating Controls — Electronic 12 Setting Operating Controls — Pneumatic 13 Trimming Refrigerant Charge 14 Hot Alignment Check 14 Doweling 15

INSTRUCTING THE CUSTOMER

OPERATOR 15

INTRODUCTION

General — All persons involved in start-up and

operation of the 17CB machine should be familiar with these instructions and all necessary job data before initial start-up. Instructions are arranged in

the proper sequence for machine start-up. MACHINES WITH SPECIAL COMPONENTS AND/OR CONTROLS MAY REQUIRE SPECIAL

START-UP PROCEDURES OR ADJUSTMENTS. CHECK YOUR INDIVIDUAL JOB

REQUIREMENTS.

Job Data Required

1. List of applicable design temperatures and pressures

2. Machine assembly, wiring and piping prints

3. Prints and instructions for special controls

4. 17CB Installation Instructions

5. 17CB Operating and Maintenance Instructions

6. Manufacturer’s Installation and Start-Up In structions for:

a. Drive b. Gear (if applicable)

7. 5F,H Installation Instructions (Refrigerant 114 machines only)

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

8. Portable vacuum pump, 5 to 7.5 cfm or larger

î, Cooier

2. Cooter Befngeranî Lev«} Sight Giass

3. tow Refrigerant Temoerature SiiJb

4. TheroKxneter Weii

5. îv/iachioe Controf Cerner {See P .g. 8 end 9,)

8. Knockouts for P ie!c! Wiring

7. Condenser

S. Cooler Suction Pipe

a. Coocte:Ker Discharge Pipe

■JO. CondenserPloat Veive

■J t. Ecottomizer P'lpe

Fig. 1 — 17CB Machine Components (R-11 Unit shown)

12. Cooter-Êconcmizer Ecualiziitg Damper Access Cover

13. Refrigerant Connection, 1-t/2:MPT

14. Cooter Charging Valve, 3/4 MPT

: 15. ASME Nameplate

16. Machine informative Plate

17. Safety Code Sticker

18. Cooier Waterixix Vent, 3/4 NPT

19. Condenser WaterOox Drain, 3.'4 NPT

20. Condenser Water'oox Vent, 3/4MPT

21. Economizer

22. Purge Operating Switch

23. Tnormal Purge

24. Purge Vaive Operation Plate

25. Chilled Water Low-TemperatureCutout

26. Chilled Water Temperature Probe

27. Purge Operatirig Valves

28. Purge Refrigerant Level Sight Giass

29. Pu:^ Water Level Sight Glass

30. Purge Water Drai n Vaive

31. Rupture Disc Assembl'y

32. Economizer float Vaive

1, OS fieservoif S5g,fit:G:!ass-

2- Oii^C^iargjng EJdow,

Sc&i 01} Return

Sea! Cii Return Pomi>

Oil Reservoir Thermosneter

5, Oii Beater Terrninaf Sox

6. Ot! Pump !\tamep!ate

INITIAL PREPARATION

7. 0:i Pomp Terminai Box a Oii Ciwrging Vatve

■9. Oil Beater Thermostat

10. Oil Pressure Gege tt. Main Searing Oi!

Thermometer

12. Git Pilte;

Fig. 2 — 17CB Centrifugal Compressor

C.AUTION: Do not start compressor or oil purap, even for a rotation check, tmiess com pressor is charged with oil and machine charged

with refri^rant.

Do not apply Yoitage of any kind while

machine is under dehydration vacuum.

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 or more 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 17CB machines may be pressurized with cylinders of dry air or nitrogen thru 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 hne. Follow steps 2 thru 5 in proper sequence.

15. Oii Pressure Oifferenirai Switch

14. Oi! Cooler

: IS. Gii C>x>}er Solertoid Valve

16. Oil Cooler Plug Cock

T7. Porm "G" Solenoid Valve

15. Vai'te Speed Valve

Open cooler charging valve fully.

Open cylinder regulating valve slowly.

Observe cooler or condenser pressure gage and

IS. form "W' SoiShoid Valve

20. pii PressureReguiating Valve

21. Compressor Controi Wiring dunctiott 8ox

22. i nspection Cover

23. Economizer Stubout

24. Oischarge Stt:i50ut

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.

Table 1 — Test Pressures

MACHINE SIZE

17CB1300 thru 1600 R-11 17CB1800 thru 2000 R-114

REFRIG

TEST

PRESSURE

8 to 10 psig

30 to 35 psig

Refrigerant 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 (item 24, Fig. 1).

Refrigerant 114 machines may be pressurized with the pumpout unit. This method is detailed in the section entitled Pumpout Procedures.

Check for Small Leaks

1. Pull a vacuum equal to 5 in. Hg (12.5 psia) by using purge pump operation 2 (Refrigerant 11 machines), pumpout unit (Refrigerant 114 machines) or by applying a vacuum pump at

the cooler charging valve.

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2. Charge approximately 25 lb of the proper refrigerant thru the cooler charging valve.

3. Pressurize machine to test pressure (Table 1) using dry air or nitrogen, or purge or pumpout unit. 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.

3. Let 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 hours), machine is suffi ciently 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

Before dehydration, drain shipping oil and flush oil reservoir. Shipping oil vaporizes under vacuum and can greatly inhibit dehydration.

6. Wait 2 hours and read manometer again. If vacuum has not decreased, dehydration is com plete. If vacuum has decreased, repeat steps 4, 5 and 6.

7. If vacuum fails to hold after several dehydra tion attempts, check for machine leak by repeating the refrigerant pressure test.

Pumpout Procedures, Refrig 114 Units (See Fig. 3)

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.

CAUTION: Do not attempt to start oil pump or purge motor even for a rotation check, nor

apply test voltage of any kind while machine is

under dehydration vacuum. Motor insulation

breakdown and serious damage may result,

1. Connect dehydration pump to cooler charging valve.

2. Ensure that all valves on purge assembly are closed.

3. Install mercury thermometer (absolute pressure

type) at charging valve tee.

4. Operate pump until manometer reads 29.80 in. Hg vacuum (0.1 psia). Continue to operate

pump for 2 more hours.

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

PRESSURIZING THE MACHINE (No refrigerant in system)

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

Close valves 2, 4 and 10. Open valves 1,3, 5, 6, 7, 8, 9 and 11.

Disconnect separable union in pumpout com pressor suction line.

Operate pumpout compressor until desired pressure is reached. Do not exceed test pressure

listed in Table 1.

Shut off pumpout compressor.

Reassemble union. Return purge valves to Normal-Auto condition

when pressurizing is completed.

SEPARABLE UNION

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

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