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 work 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
(110 F/43 C) water.
DO NOT REUSE disposable (nonreturnable) cylinders
nor attempt to refill them. It is DANGEROUS AND
ILLEGAL. When cylinder is emptied, bleed off remain
ing gas pressure, loosen the collar and unscrew and
discard the valve stem. DO NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before charging
machine. High 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.
A SAFETY GUIDE
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; vent to outside. The accumulation of refriger
ant 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 untü all refrigerant has been removed from the
vessel.
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 repair 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.
and operation of the centrifugal refrigeration
machine should be familiar with the equipment
involved. This instruction book is intended to
cover general rules for start-up procedures.
Because of machine variations it is not possible
to prepare an instruction book covering all minor
details. This instruction book will fulfill normal
requirements. Additional information may be ob
tained by application to Carrier Machinery and
Systems Division Service Supervisor in the nearest
district office.
Special attention should be given to precaution
ary instructions emphasized in this book to avoid
start-up difficulties. These precautions are, in
general, applicable to all sizes of 17DA centrifugal
refrigeration machines.
Instructions for the prime mover if not in
cluded with Carrier Air Conditioning instructions
should be obtained from the manufacturer.
Factory Test — Prior to shipment, the compressor
is completely assembled and tested. Performance as
to lubrication, speed balance and general mechani
cal operation has been determined to be
satisfactory.
Job Data — consists of:
1. 17DA Start-Up Instructions
2. Blueprints showing:
a. Machine assembly
b. Machine wiring
c. Machine piping
d. Special controls, if any, and related wiring
3. 17DA Installation Instructions
4. 17DA Operation and Maintenance Instructions
%
5. Manufacturer’s Installation and Start-Up In
structions for:
a. Drive
b. Gear (if applicable)
Page 3
Table 1 — Essential Tools
ITEMUSE
1. Mechanic's tools
2. Día! indicators
3. Volt-ohmmeter3. Calibrate controls
4. Drum charging valve
5. 5/8-inch SAE X 3/4-inch MPT adopter
6. 5 to 10 ft length of 5/8-lnch soft copper tubing with 5/8-inch
flare nut on each end
7. Halide leak detector or electronic leak detector'
8. Low-pressure indicator such as:
a. Absolute pressure manometer or
b. Vacuum indicator
completed, and all construction debris must be
removed from the immediate area of the
machinery prior to initial start-up of the machine.
Drive Arrangement — Inspect drive mounting,
location, couphng, speed rating, etc., for agreement
with job blueprints and specifications. Gear assem
bly (if used) must agree with installation recom
mendations outlined in gear manufacturer’s
instructions.
Piping — Check the following installations:
1. Refrigerant pumpout system
2. External or auxiliary oil system
3. All bypass lines and valves
4. Turbine drive piping, i.e.
a. Blowdown valves for each turbine stage
installed per manufacturer’s instructions.
b. Oil lubrication piping for speed control
installed in agreement with blueprints.
c. Steam supply Une condensate traps properly
installed to keep condensate out of turbine.
d. Proper supports on steam supply and ex
haust line to prevent stress or strain on the
turbine at operating temperatures.
5. Gas engine drive piping — Check the following
piping for agreement with job blueprints:
a. Gas pressure reducing valves with shutoff
valves.
Engine coolant piping with coolant thermo
b.
static valve installed so that water flows in
direction marked on valve.
c.
Oil cooler package piping
Exhaust piping
d.
WARNING: Exhaust piping is critical.
Refer to drive manufacturer’srecominendations for installation of exhaust piping.
Wiring — Refer to job wiring blueprints. All wiring
must agree with these prints.
AUXILIARY EQUIPMENT WIRING - Check the
following:
1. Brine pump
2. Condenser water pump
3. CooHng tower fan motor
4. Auxiliary oil pump
5. Oil heater
6. Overload selections in all motor starters. Over
load values must agree with motor nameplate
data.
setting. Operate pump to determine direction
of rotation. Do not operate dry of oil.
3.
Check job drawings for other electrical devices
used with the turbine. Ensure that their wiring
agrees with the job wiring blueprints.
GAS ENGINE DRIVE WIRING - All wiring must
agree with job wiring blueprints. Refer to engine
manufacturer’s instructions for starting techniques.
Safety Controls — It is good machinery practice to
preset safety controls using standard temperature
sources; i.e., ice baths, warm circulating oil baths
with standard calibrated thermometers. All con
trols must be rechecked during machine operation
and given final calibration as required. See Table 2
Control Settings and Fig. 1 17DA Safety Instru
ment Panel.
Check the following safety controls as shown
on job blueprints:
1. Main drive de-energizing devices, i.e.
a. Starter holding coil
b. Turbine solenoid trip, etc.
2. Brine low-temperature cutout
3. Refrigerant low-pressure cutout
Page 4
Table 2 — Control Settings
CONTROL
Low Chilled Water Temperature
Cutout
High Discharge Gas Temperature Cutout
High Thrust Bearing Temperature
High Condenser Pressure Cutout
Low Cooler Pressure Cutout
Low Seal Oil Pressure Cutout
Low Bearing Oil Pressure CutoutControl Panel
Auxiliary Oil Pump
Differential Pressure
Control Switch
4.
Oil low-pressure switches
Condenser high-pressure cutout
5.
Check the following optional safety devices:
6.
Cooler Water Box
Compressor End Wall240 F115 C
Compressor Bearing Chamber 180 F82.5 C
Control Panel
Control Panel
Control Pane!
Control Panel
a. Brine flow switch
Condenser water flow switch
b.
Condenser refrigerant level switch
c.
Drive protection devices
d.
Pump interlocks
e.
f.
Special interlocks, timers, etc.
COOLER SEAL OILBEARING OIL
LOCATION
SETTING
British Values
38 F or 5 F lower than brine
temperature
165 psig
Vendor set at 35 psig. Reset 2 psi
below normal suction pressure.
Open 11 psid
Close 16 psid
Open 8 psig
Close 13 psig
Open 27 psid
Close 23 psid
Metric Values
1.7 C
11.6 kg/sq cm
2.45 kg/sq cm
. 14 kg/sq cm
.76 kg/sq cm
1.16 kg/sq cm
.56 kg/sq cm
.90 kg/sq cm
1.90 kg/sq cm
1.60 kg/sq cm
PUMPOUT SYSTEM — The low-pressure cutout
should be set at the saturated pressure of
Refrigerant-12 at 34 F. A manual bypass switch is
required to allow complete evacuation of the
cooler. See Table 3.
Table 3 — Pumpout System Settings
SATURATED CONDITIONS
PUMPOUT
SYSTEM
SETTING
Normal Condensing
Pressure
Low-Pressure Cutout
High-Pressure Cutout
Relief Valve181.0
REFRIGERANT 12
Pressure
(psig)
Maximum
T emperature
136.4no
31.5
157.7
(F)
34
120
130
COOLER AUXOIL LOW SEAL LOW BEARING
LOW-PRESS. PUMP OIL PRESS. OIL PRESS.
CUTOUT CONTROL CUTOUT CUTOUT
Fig. 1 — 17DA Safety Instrument Panel
MOTOR DRIVE — Disconnect the main motor
leads at the starter to check out the safety controls
without operating the motor. Disconnecting the
leads to the starter holding coil will accomplish the
same purpose. Place a volt-ohmmeter across the
open leads. The volt-ohmmeter will indicate when
the safety control circuit is de-energized as each
safety control is tripped.
TURBINE OR GAS ENGINE DRIVE - These
drives are shut down by interruption of power to
their respective control valves or other devices.
Apply a volt-ohmmeter across these open leads and
check out all safety controls as just described.
LEAK TEST AND DEHYDRATION
Check the absolute pressure on the refrigerant
side of the machine. The final operation of the
17DA Installation Instruction is to leak test the
machine and dehydrate it to the point where it
maintains a pressure of 0.21 psia (equivalent to
29.48 in. mercury vacuum referenced to a 30 in.
barometer). Refer to Carrier Standard Service Tech
niques, Form SM-1.
If the machine absolute pressure is higher than
the above values, repeat the Evacuation and De
hydration pumpdown operations until the machine
proves to have a leak rate or vacuum loss at a rate
less than 0.1 in. mercury column in 24 hr.
CHARGE MACHINE WITH WATER
When the machine has been proved leak tight
and dry, it may be filled with water, brine or other
process fluid as the case may be. Vent aU lines and
check for leaks.
It is advisable to install indicators on the
coupling halves between the compressor and drive
Page 5
or gear to check for alignment drift while charging
with water and refrigerant. The weight of these
materials will always cause a shift in the position of
the machine components. Before and after indi
cator readings will give a good clue to the direction
final alignment should take.
CHARGE MACHINE WITH OIL
The 17DA machine has an integral lubrication
system mounted on the common base with the
compressor. A parallel auxiliary oil pump system
may also be furnished. Charge the oil system with
35 gal. of oil per Carrier Specification PP16-0
(Table 4). If oil other than this is used, the
replacement oil must be nearly equivalent.
Ensure that there is adequate lubrication prior
to the operation of all equipment. Check the gear
and drive manufacturer’s instructions for proper
initial lubrication procedure. If the drive
machinery is to be operated before operating the
compressor, disconnect the shaft coupling and'
secure the shroud to prevent damage to the drive
shaft or the coupling.
Oil pressure from the main oil pump is set at a
pressure 35 psi greater than the back-of-seal oil
pressure. If, for any reason, the oil pressure falls to
23 psi above the back-of-seal oil pressure, the
auxiliary oil pump starts and maintains oil pressure
at a safe level.
Table 4 — Oil Specification (Carrier PP16-0)
CHARACTERISTICVALUE
Viscosity at 100 F
Viscosity at 210 F
Viscosity Index, minimum
Pour Point, maximum0 F
Flash Point, minimum
Neut. No., maximum.1 mg. KOFl/gm.
Rust Inhibiting Characteristics
Oxidation Resistance
SSU — Saybolt Seconds Universal
FINAL PREOPERATION ALIGNMENT CHECK
150 - 160 SSU
40 - 45 SSU
90
400 F
Thematerial shall passthe
ASTM Rust Test D665-54.
Procedure A will be used
with a test period of24hr.
Thematerial shall passthe
ASTM Oxidation Test
D943-54 for a minimum of
1500 hr. The acid number
at the end of the test
period shall not exceed
2.0 mg. of KOH per gram
of oil.
Prior to operating the compressor and speed
increasing gear (if used), coupling alignment and
separation must be checked.
1. Ensure that coupling alignment is within
coupling manufacturer’s specified tolerances.
2. The hub separation tolerances are normally
stamped on coupling and vary depending on
coupling size.
3. When checking hub separation, electric motor
shaft must be in center position of shaft float.
If realignment is required, follow instructions
supplied by coupling manufacturer. Carrier Standard
Service Techniques, Form SM-15, Rev A, also de
tails realignment techniques.
OPERATE DRIVE
It is good practice to operate the drive sep
arately before operating compressor. Refer to drive
manufacturer’s instructions for drive protection
devices and settings. Check turbine overspeed at
this time. Reassemble couplings after operating
drive separately.
SET PURGE VALVES AND SWITCHES
Open all the purge service valves behind purge
console. Place purge operating valves in NORMALAUTOMATIC position (shown on chart inside
console door). Place purge switch in AUTO,
position.
CHECK WATER SUPPLY
Be certain that chilled water, condensing water
and oil cooler water supplies are available and that
pumps will run before operating compressor.
CHECK AIR SUPPLY, PNEUMATIC MACHINES
Make sure that control air is 35 psig.
START-UP
Preoperation Settings — Complete these settings
before starting compressor for first time.
Drive Operation — Refer to drive manufacturer’s
start-up instructions. Complete drive starting
requirements before operating compressor.
If drive is wired for automatic starting, it will
start when compressor START button is pushed.
Starting procedure of manually started drives may
be initiated after START button is pushed.
Compressor Operation
1. Place control switch in ON position. Con
denser pressure, bearing temperature and
refrigerant temperature indicating lights on
control console should come on.
2. Place capacity control switch in MANUAL
position.
3. Open oil cooler water plug cock. Check fqr
water flow at open sight drain.
4. Open bleed valve on inboard side of the
compressor.
5. Open all valves and energize heater on seal oil
drain pot.
6. Open all valves in chilled water and condenser
water circuits.
Page 6
WARNING: No brine over lOOF must be
allowed to flow thru the cooler.
7. Ensure that there is water in the cooling tower.
8. If the auxiliary equipment such as chilled
water pump, condenser water pump, and
cooling tower fan are not wired into control
console circuit, start these items manually
before starting the compressor.
9. Start oil pump.
10. Close bleed valve on inboard side of the
compressor.
11.17DA compressors are equipped with an
AUTO-MANUAL control station. The initial
start should be on manual control from this
station.
12. Start compressor.
a. Bump electric motors by pushing the
START and STOP buttons in quick
succession. Compressor rotation must be
counterclockwise when viewed from drive
end.
b. Run turbine or engine drives at slow
speed.
13. Listen carefully for unusual mechanical noise
while coasting down.
14. Shut down.
Charge Refrigerant
WARNING: When liquid Refrigerant-12 is in
jected into a low vacuum of 29.48 in. mercury
it will unmediately flash to a gas at a tempera
ture lower than minus 100 F. It is for this
reason that water must be circulating before
charging liquid refrigerant. Non circulating
water would quickly freeze and damage the
machine. If an auxiUaiy' refrigerant storage tank
(receiver) is furnished, liquid refrigerant may be
charged directly into this evacuated receiver
without danger.
Large machines run with liquid refrigerant in
the cooler so refrigerant is charged into the cooler
or low-pressure side of the machine. For general
instructions on how to handle refrigerant refer to
Carrier Standard Service Techniques, Form SM-1.
Use the Charging by Weight method, cross check
ing with the machine’s refrigerant sight glass pro
vided on the back of the cooler shell, and the
suction pressure gage.
Charge refrigerant as follows:
1. Start Cooler and Condenser water circulating
pumps.
2. Charge the first refrigerant in the vapor state,
continuing until the machine pressure exceeds
35 psig. The refrigerant temperature corre
sponding to this pressure is high enough to
prevent water freezing damage and will also
satisfy the refrigerant low-pressure cutout
safety switch setting (31.5 psig). Now turn the
refrigerant bottles or drums over and begin
charging the refrigerant in the liquid phase.
Continue charging liquid refrigerant until about
2/3 of the estimated full load charge is in the
machine.
3. Adjust control station to operate at MANUAL.
Ensure that the guide vanes are closed as
indicated on the main guide vane indicator.
4. Set Subcooler Level Controller as follows:
a. Set Proportional Band at 35%.
b. Set Level-Set adjustment at 50%.
When stable operation is achieved, readjust
Level-Set to maintain the Hquid level at the
midpoint of the sight glass on the Level
Controller. Recheck this level when full load is
reached and reset if necessary.
5. Start the compressor. Observe the machine’s
operation for 15-20 min before increasing the
load. During this period, make the following
checks and adjustments :
a. Check oil pressure.
b. Adjust water flow thru oü cooler so that
bearing temperatures stay between 150 F
and 170 F approximately.
c. Watch bearing temperatures carefully. This
is the first time that the machine has been
run under refrigeration load. Bearing tem
peratures may level off at some temperature
slightly higher than 170 F hsted above. This
may be the normal stable condition for this
bearing. High thrust bearing temperature
will shut the machine down at 180 F.
6. Slowly open the guide vanes, by manual con
trol, thus increasing the load. Do not exceed
the current rating of the electric motor. Watch
for other signs of overloading a turbine or
engine drive.
7. Add Uquid refrigerant, trimming the charge off
at the point where the machine reaches design
operating temperature and pressure conditions.
WARNING: Excessive overcharge may cause
liquid refrigerant carry-over into the com
pressor, causing severe overload and possible
compressor damage.
8. Shut the machine off. When the refrigerant
level settles down, mark this optimum level on
the sight glass. Maintain this shutdown level. To
determine the approximate refrigerant charge
for your machine, add the cooler charge to the
applicable condenser charge as listed in Table 5.
Page 7
Table 5 — Typical 17DA Coder and Condenser
Refrigerant Charges (lb)
COOLER
SIZE
61
63
65
674,6005,600
651*3,500
671*
71
73
756,1007,300
81
83
85
879,500
* Refrigerant 500
HOT ALIGNMENT CHECK AND DOWELING
15-FT
TUBES
3,3003,900
4,0004,7005,800
4,000
4,200
5,1006,100
5,500
7,1008,500
7,600
8,500
18-FT
TUBES
4,700
4,200
5,000
6,500
9,200
10,100
11,400
22-FTCOND
TUBES
4,800612200
5,800 .
6,800 Î
5,100 '
6,100
7,500
8,00073
8,900
10,400
11,200
12,400
13,900
SIZEWT
651*2500
671*
REFRIG
63
65
67
712900
753400
813900
834400
855100
874900
2200
2700
2700
2500
2900
After the machine has been running at about
full load for four hours, its components will have
come up to steady state operating temperature
conditions and the final hot alignment check may
be made.
Realign component locations until angular and
parallel alignments are within coupling manu
facturer’s specified tolerances.
Dowel all equipment into place as soon as the
hot alignment check proves that the machine is
within these running tolerances.
See Carrier Standard Service Techniques, Form
SM-15, Rev A, for these operations.
INSTRUCT CUSTOMER OPERATOR
The following is an outline guide for giving
operating instructions to the customer’s operator.
1. Present operator with copy of Operating and
Maintenance Instructions.
2. Point out machine components and explain
function and settings for each.
a. Controls
(1) Safety panel, gages and safety
switches
(2) Control station, manual-automatic
modes
Compressor
b.
(1) Oil reservoir
(2) Seal
(3) Guide Vanes
(4) Auxiliary oil pump, filter and cooler
(5) Bleed valve