Carrier 19CB User Manual

Carrier

Airconditioning

Company

Hermetic Centrifugal Liquid Chillers

CONTENTS

INTRODUCTION

General Job Data Required Equipment Required

INITIAL PREPARATION

Machine Tightness Check for Large Leaks Check for Small Leaks Check Leakage Rate Machine Dehydration Pumpout Procedures Oil Charge Oil Heater

Refrigerant Charge Inspect Piping Field Wiring Check Starter Check Operation of Safety Controls Purge Air Supply (Pneumatic Controls Only)

START-UP

Before Starting Machine

Compressor Rotation

Compressor Operation

Checking Safety Control Settings

Setting Operating Controls — Electronic

Motor Current Calibration Chilled Water Calibration

Setting Operating Controls — Pneumatic

FINAL MACHINE ADJUSTMENT

Trimming Refrigerant Charge

INSTRUCTING THE CUSTOMER OPERATOR

Page

3 3 3 3 4 4 4 5 5 5

7 7

7 7 7

9 9

10 12

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 3 19CB 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.

Form 19CB-2SS

— Cooler

— Cooler Ret:igerant Level Sight Glass

— Low Refrigerant Temoerature Sulb

— Thermometer Well

— Machir.e Control Ceitter

(See Rig.:«.) ,

~ KnockouwforRieici Wiritts :

— Condenser

— Cooler S'.jotion Pipe

— Condettser Discharge Ripe

—, Condenser Float Valve;

ÎO

— iiconomiser Pipe

12 — Cooler-Econorttize: Epuati^iitg Damper

Access Cover

■ 53 - Refrigerant Connection, 1 1/2 NRT

14 — Cooler Charging Valve, 3/4 NPT

15 — AS:Vi£ Nomepiats

16:Machine informative Plate 17 — Safety Code Sticker

IS — Cooler Watsrbcx vent, 3/4 MPT

13 — Condenser W'arerbox Drain, 3/4 MPT

20 — Condenser Waterdox Vent, 3/4 MPT

21 — iiconomizer

22 — Porge Operatirrg Switch

23 24 25 26 27 28 23 30 ~

31 -

32 -

33 ~

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

P'orge Conderising Chamber

Riiter-Drier Shetoff Valve Chilled Water Low-Temp Cutout Chi lied Watsr Terr^p P: obe

Purge Refrigerant Level Sight Giass

Purge Water Level Sight Glass Purge Water Drain Valve

Rupture Disc Assembly

Economizer Pioat Valve

Moisture Indicator

Pilter-Drier

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

1 Serial Numlser idenritica-

Tior> Piste

2 Oil C^iarairvg Valve 3 Gii Heater Tl>erfr;ost3t 4 Oil Heater ; ern-.inal Sox 5 Oil Reservoir Siijf.t Glass

6 Oil-Pressare Regtila-rioó

Valve. : :

7 Oil Purtiii Temrinal Sox 8 •'!=•■ Solenoid Valve

9 "G" Soteooici Vaive

tO Gii Cooler

Water-Ir, Conr>..Solenoid

Valve and Plue Cook

12 Oli-Pressore Gage 13 OiPPrsssure Oiilerenrial

Switoli

14 Bearing Temperature Gage 15 Oli XemperaTure Gage

Fig. 2 — Compressor (Electronic Capacity Control)

Machine Tightness — If machine leak testing and

16 Oit Cooler Wa‘-:-r-Oor

Gconeotion

17 Oil Pornp Nciirrepiate 18 Gornoressor Nameplate

19 edmpt esser Joriction Sox

20 Economlter inlet 21 Compressor Morof Terminai

Sox (Par side on most ■ : rncdetsl: r:'.

22 Motor and Stg H i-Temp-

C'-itout iluncticrn Sox ;

23Main Searing inspection Cove'

24 EeonomiKer Darooer Ccn-

r.ection .CR 014 dniy}■ T

25 Guide yiane indicator

{gleotronte ConTrot) : : 26 Hydrau lic V-ane Motcir 27 Oispharoe StuOouT- : 28 DiscP-aige Pipe

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

REFRIGERANT

R-11 R-114

Check for Small Leaks

TEST

PRESSURE

8-10 psig

30 - 35 psig

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.

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

nitrogen. Do not exceed test pressure Test all joints, valves, fittings etc. with a halide

4. or electronic leak detector.

Check Leakage Rate

1 Install a mercury manometer (absolute pressure

type) on a tee at the cooler charging valve.

Pull 25 in. of vacuum on the machine.

Let machine stand with this vacuum for at least

8 hours 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.

If leakage rate exceeds 0.1 in. Hg per 24 hours,

repeat Check for Small Leaks, repair leaks and

repeat this Leakage Rate check.

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 vacuum- Motor insuiation breakdown and serious damage tnav result.

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

SEPARABLE UNION

PIPING BY CARRIER FIELD PIPING

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.

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

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