All persons involved in start-up and operation
of the 19DG Machine should understand these
instructions and all applicable Job Data before
initial start-up. The instructions are arranged in the
proper sequence for machine start-up.
Job Data Required
1. Machine assembly, wiring and piping prints.
2. Starter details
3. 19DG Installation Instructions
4. 19DG Operating and Maintenance Ins
Equipment Required
1. Mechanic’s tools
2.
Volt-ohmmeter and clamp
3.
Manometer, absolute pressu'
4.
Leak detector, halide or el№tf^ic
5.
Refrigerant drum charging valve (F
6.
5/8-in. SAE X 3/4-in. MPT ada rter
7.
Five to ten ft of copper tub!
to fit 5/8-in. SAE connection;
INITIAL PREPIAR
CAUTION; Do not síai^iítempressor or oil
pump, even for a rotation check, unless
compressor has been charged with oil and
machine charged with refrigerant.
Machine Tightness — A shipping vacuum was
applied to the refrigerant side of the 19DG
Machine before shipment from the factory. Over a
period of time, during shipment or storage, part of
this vacuum may be lost. The loss of a small
amount of vacuum may be acceptable and within
Carrier’s machine tightness standards. To deter
mine if the vacuum loss is acceptable;
1. Record and date vacuum reading shown on the
compressor-mounted oil reservoir gage (Eig. 1).
2. Determine vacuum leak rate by comparing this
reading with reading taken when machine was
received. Use the formula:
^ , vacuum difference
Leak rate ==
3. If leak rate is 0.05 in. Hg or less per 24 hours,
machine is sufficiently tight. If leak rate
exceeds 0.05 in. Hg per 24 hours, perform
Refrigerant Pressure Test and correct leakage.
EXCESSIVE OR TOTAL VACUUM LOSS can be
caused by accidental opening of a valve or other
connection. If this is suspected, proceed as follows;
1. Install a mercury manometer (absolute pressure
type) at the cooler charging valve (Eig. 1). A
-----------------------------------no. of days between readings
plastic hose
/
)
dial gage
leakage act
time.\
Pull a\yaci|ium on the machin'd"equal to 25-in.
the leak rate is 0.05 in. Hg or less per 24
hours, the machine is sufficiently tight. Perform
Machine Dehydration.
If the leak rate exceeds 0.05 in. Hg per 24
hours, perform Refrigerant Pressure Test and
correct leakage. Perform all steps under
Machine Dehydration.
Remove the mercury manometer from cooler
charging valve.
REFRIGERANT PRESSURE TEST
Pull a vacuum equal to 5 in. Hg ref 30-in. bar.
(12.5 psia) using machine purge pump, and
following operation no. 2 described on the
purge valve operation plate (Fig. 1). An
external vacuum pump connected to the cooler
charging valve may be used, if desired.
2. Charge approximately one gallon of Refrigerant
11 thru the cooler charging valve. Refer to
Charging Refrigerant for procedure.
3. Increase pressure to 8 to 10 psig with dry air or
nitrogen thru the cooler charging valve. Do not
exceed 10 psig.
4. Test all joints, valves, fittings, etc., with a halide
or electronic leak detector.
5. Repair any leaks found. Retest to ensure repair.
MACHINE DEHYDRATION — The refrigerant
side of the 19DG Machine is dehydrated at the
factory. It is usually not necessary to repeat
dehydration at initial start-up. However, if the
machine has been open for a considerable length of
time due to compressor removal, or if there has
been excessive loss of shipping vacuum, it is
-
recommended that dehydration he repeated.
Dehydration is readily accomplished at normal
room temperature. If room temperature is high,
dehydration takes place more quickly. At low
room temperature, dehydration is extremely diffi
cult and special techniques must be applied.
Contact your Carrier representative.
Do not start compressor or oil pump even for a
rotation check while machine is und.er dehy
dration vacuum.
annot indicate the small amot
;eptable during a short p^ridd of
■in. bar. (2.^pS'ia). Use an external
mp or enprgize the purge pump (Pig.
jratira^Aio. 2 described on the purge
1. Connect dehydration pump to the cooler
charging valve (Fig. 1).
2. Ensure that all valves on the purge assembly are
closed. Valve identification numbers are listed
on the purge valve operation plate (Fig. 1).
3. Remove the A-B swing connection (see valve
operation plate) and connect a mercury
manometer (absolute pressure type) to the
bottom common connection.
4. Operate dehydration pump until manometer
reads 29.80 in. Hg ref 30-in. bar. (0.1 psia);
continue to operate pump for 2 more hours.
5. Close cooler charging valve; stop dehydration
pump; record manometer reading.
6. After a 2-hour wait, read manometer again. If
reading has not increased, dehydration is com
plete. If reading has increased, repeat steps 4
and 5.
7. If reading continues to rise after several dehy
dration attempts, check for a machine leak by
repeating the Refrigerant Pressure Test.
Inspect Piping — Refer to piping diagrams provided
in Job Data and inspect piping to cooler, condenser
and oil cooler. Ensure that flow direction is correct
in all cases and that all piping specifications are
met.
CHECK WATER ELOW — Water flow thru con
denser and cooler must meet job requirements.
Measure the water pressure drop across cooler or
condenser or across the pumps. Check to see that
water flow agrees with design flow.
Oil cooler water should meet the following
requirements:
Clean water
Max water temperature 85 F
Max inlet working pressure 200 psi
Water vel in tube, ft/sec 10 max — 6 min
Water flow, gal./min 7 max — 4 min
Water press, drop, psi diff 5 max — 2 min
Valves and/or controls Field supplied
Field Wiring — Prior to starting equipment,
refer to wiring diagrams in Job Data and check
power supply as follows:
1. Connect a voltmeter across power wires to
compressor motor starter and measure voltage.
Compare this reading with voltage rating on
compressor and starter nameplates.
WARNING; Do not attempt to check high
voltage supply without proper equipment.
Serious personal injury can result.
2. Check that ampere rating on starter nameplate
matches ampere rating on compressor motor
nameplate.
3. Ensure that voltage to oil pump starter agrees
with oil pump nameplate value.
4. Check that electrical supply to oil heater and
purge pump is 120 volts.
5. Test compressor motor and its power lead
insulation resistance with a 500-volt insulation
tester such as a megohmmeter. Proceed as
follows:
a. Open starter main disconnect switch.
b. Test the three phases of compressor motor,
phase-to-phase and phase-to-ground, with
tester connected on the motor side of the
starter contactor in the starter. Take a
resistance reading at a 10-second interval
and at a 60-second interval for each phase.
c. Divide the 60-second resistance reading by
the 10-second reading. This gives the polari
zation ratio. The polarization ratio must be
1.15:1 or higher. Both the 10-second and
60-second resistance reading must be 5.0
megohms or higher.
If readings are unsatisfactory, repeat tests at
motor terminals with motor power leads dis
connected. This will indicate whether fault is
in motor or in motor power leads.
Check Starter — Before starting the 19DG
Machine, open the main disconnect and then check
starter.
1. Remove contactor arc chutes. Be sure con
tactors move freely, and that shipping string is
removed. Replace arc chutes.
2. Check contactors for dirt and rust. Clean
contact magnet surfaces lightly with sandpaper.
Do not sandpaper or file silverplated contacts.
Apply a very thin coat of petroleum jelly to
magnet surfaces and then wipe it off. If starter
has been in a dusty atmosphere, vacuum clean
the cabinet and wipe with Unt-free cloth.
3. Remove fluid cups from magnetic overload
relays. Add dashpot oil to cups per instructions
on relay nameplate. Dashpot oil is shipped in
small vials usually attached to starter frame
near relays. Use only the dashpot oil shipped
with starter. Do not substitute. Overload relays
are factory set for 108% of motor full load
amperage and resetting is not normally
required.
4. Check transfer timer for proper time setting.
On Star-Delta starters, timers have adjustable
ranges of 10 seconds to 3 minutes and are
factory set at one minute. On Auto-
Transformer starters, timers have adjustable
ranges of zero to 60 seconds and are factory set
for 30 seconds.
5. With main disconnect switch open, manually
open and close main control relay (ICR) to be
sure it operates freely.
Oil Charge — The oil charge is shipped in the oil
reservoir. Check sight glass (Fig. 1) to be certain oil
is in the reservoir. If oil must be added, it must
meet Carrier’s oil specification as listed in the
19DG Operating and Maintenance Instructions.
Charge oil thru the oil reservoir charging valve
(Fig. 1). With machine at vacuum, oil is drawn
from the oil container. Continue charging until oil
reaches middle of sight glass (Fig. 1).
Oil Heater — Energize’ the oil heater to minimize
absorption of refrigerant by the oil. An indicator
light (Fig. 1) goes on when the oil heater is
energized. Set the oil heater thermostat to main
tain a minimum oil reservoir temperature of 145 F
at shutdown.
Charging Refrigerant — Proceed as follows.
1. Install a charging valve on the 3/4-m. drum
opening as shown in Fig. 2. When the 3/4-in.
pipe nipple is screwed in, the nipple forces the
bottle cap off its seat.
2. Connect a short piece of plastic hose or copper
tubing from drum valve to the cooler charging
valve located beside the float chamber (Fig. 1).
3. Circulate chilled water during the charging
process.
4. At a vacuum of IS in. Hg or greater, liquid
Refrigerant 1 i will flash mto gas and may
cause tube freeze-ap. If machine vacuum is
18 in. Hg or greater, keep refrigerant drum
upright, open valves and admut refrigerant to
cooler as a gas until machine vacuum is ies.s =
than 18 m. Kg.
Check Operation of Safety Controls — As checks
are made, the control panel lights should appear as
indicated.
1. Open main disconnect (all power off to starter
and controls). Then disconnect main motor
leads in starter.
2. Provide control circuit power.
CONTROL LIGHTS
□ OFF
□□
□□
□□
□
■
□
□
□□
□□
123
■□■■■
□□□□□
□
■■
■□□
■
□□□□□□
a
□
4
n■□
■■
■□
■□
□
5
■
ON-STOP
START
□
OIL PUMP
■
POWER
■
■
SAFETY CIRCUIT
□
LOAD RECYCLE
□
7
PROGRAM TIMER
8
6
3. Press ON-STOP button (light goes on). If
SAFETY CIRCUIT light does not go on, check
resets on condenser high-pressure safety, low-
refrigerant safety, bearing and motor hightemperature circuit breakers and compressor
overloads in starter. Check 3-amp fuse in
control center.
If SAFETY CIRCUIT light goes on but LOAD
RECYCLE light stays off, check the chilled
water recycle switch (Auto.-Reset).
If both lights go on, manually trip and reset
motor and bearing high-temperature circuit
breakers, compressor motor overloads in
starter, low-refrigerant temperature cutout and
high-condenser cutout to be sure they cut off
the safety light. Tripping the chilled water
recycle switch will cut off the LOAD RE
CYCLE light only.
5. The refrigerant supplied with the machine is in
excess of that required for initial charging.
Charge only that amount shown in Table 1
The
machine under vacuum will draw refrigerant
from the drum.
6. After the machine has been started, it may be
necessary to adjust the refrigerant charge for
optimum machine performance. Refer to
Trimming Refrigerant Charge (page 7) for full
load adjustment.
Table 1 — Charging Quantity
SIZE*
19DG11
19DG13400
19DG15
19DG17450
19DG20
*Unishe(i Size• Sec lower right corner of machine identification
WEIGHT
(lb R-11)
400
425
525
SIZE*
19DG21525
19DG23
19DG25575
19DG27
19DG31725
plate (Fig 1)
WEIGHT
(lb R-11)
550
575
SIZE*
19DG33
19DG35
19DG36
19DG37985
19DG39
WEIGHT
(lb R-11)
760
800
925
960
4. Press ON-STOP button (light goes out).
Remove and tag gray striped wire running
between terminal [1^ and Vl_ in control
center.
5. Start chilled water and condenser water
pumps. Press ON-STOP button (light goes on).
6. Press OIL PUMP button for several seconds.
Pump should raise oil pressure to 20-25 psi
differential between pump discharge gage on
control panel and oil reservoir gage. SAFETY
CIRCUIT and LOAD RECYCLE lights should
go on.
7. Release OIL PUMP button. SAFETY CIR
CUIT and LOAD RECYCLE lights should go
out.
8. Wi’th“OIL PUMP button depressed, alternately
stop and restart chilled water and condenser
water pumps. SAFETY CIRCUIT and LOAD
RECYCLE lights should go out as each pump
stops. (Continuous operation of oil pump is
unnecessary during these checks.)
CONTROL LIGHTS
□ OFF
□
□□
□
n■■■n
□
□□ ■□■
9
■■ □
□a■■
■■■□
10II12 1314
■ ON
ON-STOP
START
OIL PUMP
POWER
SAFETY CIRCUIT
LOAD RECYCLE
PROGRAM TIMER
9. Shut off water pumps. Release OIL PUMP
button. Press ON-STOP button (hght goes
13. Compressor motor start contacts will close 30
seconds later. Starter will transfer to run
condition 30 to 60 seconds after starter is
energized.
14. Open oil pump main disconnect. Starter must
de-energize. OIL PUMP hght will remain on for
approximately 30 seconds.
15. OIL PUMP light goes out.
16. Close oil pump disconnect. In approximately
15 minutes, the program timer will complete
the antirecycle portion of its cycle and the
machine is ready to restart.
17. Remove all power and reconnect motor leads.
Restore power.
Purge — Place the purge operating valves (Fig. 1) in
“Normal-Automatic” position as indicated in oper
ation no. 1 on the purge valve operation plate
(item 17, Fig. 1). Operate the purge pump momen
tarily by placing the purge switch in “Manual”
position; then place purge switch in “Auto.”
position.
START-UP
Preliminary Checks
1. Power on to main circuit breaker, control
circuit, water pumps and tower fan.
2. Cooling tower water level.
3. Oil reservoir level.
4. Oil reservoir temperature 145 F or warmer.
5. Oil cooler plug cock (Fig. 1) cracked open, and
any other valves in oil cooler line fully open.
COMPRESSOR ROTATION Set capacity con
trol switch (Fig. 3) to “Hold”. Press machine
ON-STOP and START buttons. As soon as motor
starts to turn, press machine ON-STOP button.
Check motor rotation thru sight glass in motor end
bell (Fig. 1). Motor rotation must be clockwise
when viewed from motor end. If not, reverse any 2
of 3 power leads coming into motor starter and
recheck rotation.
COMPRESSOR OPERATION ~ Press machine
ON-STOP and START buttons and let compressor
come up to speed. Press machine ON-STOP button
and listen for any unusual sounds coming from the
compressor and transmission housing as the com
pressor coasts to a stop.
The program timer prevents rapid recycling of
the compressor and allows restart 15 minutes after
stop.
Checking Safety Control Settings
While performing these checks, carefully
monitor chilled water temperature to prevent
freeze-up. Protection by safety cotrols cannot
be assumed until all settings have been con- .
firmed as follows.
Open main disconnect (all power off to starter
and controls). Set capacity control switch to
“Hold”. Place a clamp-on ammeter on one of the 3
starter leads. Install jumpers between 40 and [^,
and between (l^ and jj_. Close disconnect(s);
start compressor and check oil pressure and tem
perature (Pig. 1). With compressor running,
manually operate the guide vanes with the capacity
control switch. Do not exceed 100% of full load
amperage.
1. Check controls 1,2 and 3 as indicated in T|^ 2.
2. Stop machine; open disconnect(s); remove
jumpers and check controls 4, 5 and 6 as
indicated in Table 2.
Table 2 — Setting Safety Controls
SAFETY OR CONTROL DEVICE
1. Chilled Water Low-Temperature Cutout and
Recycle Switch (Fig. 1)
-TEMPERATURE ADJUSTMENT
Set this switch to break at approximately 5 F below design
chilled water temperature, or at 36 F whichever is higher
Set the differential at 10 +1 F so that when the machine shuts
down automatically at approximately 5 F below the design
chilled water temperature it will restart at approximately 5 F
above the design water temperature.
This control must break ahead of the refrigerant low-temperature
cutout switch or the machine will not recycle automatically
2. Refrigerant Low-Temperature Cutout (Fig. 1)
CUTOUT
ADJUSTMENT
SAFETY OR CONTROL DEVICE
STOP MACHINE, REMOVE JUMPERS AND PERFORM RE
MAINING CHECKS
4. Oil Heater Thermostat (Fig. 1)
LOCKING
SCREW
Set the oil heater thermostat to maintain a minimum oil reservoir
temperature of 145 F at shutdown
5. Low Oil Pressure Cutout (Fig. 3)
RANGE
DIAL ADJUSTMEN'
REMOVE METAL
COVER
Set refrigerant low-temperature cutout at 33 F or one degree below
design refrigerant temperature, whichever is lower, while checking
temperature at thermowell near switch
3. Condenser High-Pressure Cutout (Fig. 3)
CUTOUT ADJUSTMENT
COVER
RESET
BUTTON
CUTOUT SCALE
The condenser high-pressure cutout is factory set to shut the ma
chine down when condenser pressure reaches approximately 1 5 psig.
Isolate the switch and check setting with a metered supply of air
DIFFERENTIAL-
OIL
PRESSURE
Low oil differential pressure switch is factory set to open at 9 5 ± 1
psi and close at 14 5 ±1 psi differential pressure
6. Vane-Close Oil Pressure Switch (Fig. 3)
RANGE ADJUSTMENT
Vane-close oil pressure switch is factory set to close at 18.5 psi dif
ferential pressure (on rise) and open on a 0.5 psi drop in dif
ferential pressure Switch does not require field calibration
Setting Operating Controls
AGITATOR VALVE CHECK - The refrigerant
agitator solenoid valve is open when the compres
sor guide vanes are closed. When opening.the guide
vanes manually in the following procedure, listen
for the sound of the agitator solenoid valve closing
as the vanes reach 20—28 deg of opening.
MOTOR CURRENT CALIBRATION
1. Establish a steady motor current value for this
calibration. Open guide vanes manually (capac
ity control to “Inc”) until full load current is
reached. Motor current calibration (Eig. 3) may
have to be turned counterclockwise to permit
vanes to open further. Do not exceed 105% of
nameplate full load amperes.
If system load is sufficient to maintain full-load
current for a period of time, calibrate at this
condition. With small loads, pull down to and
maintain (capacity control to “Hold”) design
leaving chilled water temperature and calibrate
at this condition.
2. Measure motor current at selected condition
and determine its percentage of full load motor
current.
3. Use this percentage figure to set the electrical
demand adjustment (Eig. 3) per the following
table:
Percent of Full
Load Motor Current
105
85 or above
65 to 84
45 to 64
below 45
Electrical Demand
Adjustment Setting
100 percent
80 percent
60 percent
40 percent
Control cannot be
calibrated
4. Turn the motor current calibration adjustment
fully clockwise. This will cause the guide vanes
to close part way.
5. Turn thermostat (Eig. 3) to “Cooler” (fully
counterclockwise).
6. Set capacity control to “Inc” position.
7. Slowly turn the motor current calibration
counterclockwise. Allow the guide vanes to
open until motor current reaches 5% above the
electrical demand setting.
NOTE: There is a time lag of several seconds
due to feedback capacitance in the motor
current circuit. When the motor current
calibration setting is adjusted, allow for this
time lag.
8. Check the foregoing motor current calibrations
with machine under “Auto.” control as
follows:
a. Close vanes manually (capacity control to
“Dec”).
b. Turn capacity control to “Auto.” Vanes
should stop opening at electrical demand
setting.
9. If control was calibrated at less than 100% load,
turn electrical demand adjustment setting to
100%. Control is now automatically calibrated
for 100% full load motor current.
This is a two-step motor current limiting
circuit. At 100% full load motor current, the
vanes will stop opening further. If the motor
current should increase to 105% due to some
change in load conditions, the vanes will close
until the motor current is reduced to about
102%. If the motor current is reduced to 98%
or below, the control will respond to leaving
chilled water temperature. The electrical de
mand adjustment allows the operator to reduce
the maximum current drawn by the motor,
minimizing the electrical demand rate during
off-season operation.
If control cannot be calibrated with above
procedure, check voltage signal from signal
resistor in starter. At 100% full load current,
voltage between terminals 23 and 24 inside
control panel must be 0.5 ± 0.1 volts. If not in
this range, check sizing of resistor in starter.
CHILLED WATER CALIBRATION
1. Turn throttle range adjustment (Eig. 3) fully
clockwise.
2. Turn chilled water thermostat (Eig. 3) until
design chilled water temperature is maintained.
Mark thermostat at this position. If capacity
control vanes hunt, turn throttle range adjust
ment counterclockwise in small increments
until hunting ceases. Chilled water thermostat
may require resetting.
TRIMMING REERIGERANT CHARGE - After
the machine has been placed in operation, it may
be necessary to adjust the refrigerant charge for
optimum machine performance.
When machine full load is available, add refrig
erant slowly until the difference between the
leaving chilled water temperature and the cooler
temperature reaches design conditions or becomes
a minimum. Shut the machine down and allow the
refrigerant to drain to the cooler. Mark the level at
the bull’s-eye glasses on the float chamber and
maintain that shutdown refrigerant level.
INSTRUCTING THE CUSTOMER OPERATOR
Be sure the operator carefully reads and under
stands the 19DG Operating and Maintenance
Instructions.
Compressor-Motor-Transmission Assembly
1. Guide Vanes, Vane Motor and Linkage
2. Refrigerant-Cooled Motor
3. Transmission
Unishell Cooler-Condenser
1. Float Chamber, Sight Glasses
2. Thermowells
3. Rupture Disc
4. Refrigerant Charging Valve
Purge System
1. Importance of Proper Operation
2. Valves and System Operation
3. Sight Glasses, Gage
Lubrication System
1. Oil Pump, Cooler, Filter
2. Solenoid Valve, Plug Cock
3. Heater, Thermostat, Temperature Gage
4. Pressure Regulating Valve
5. Oil Level, Temperature
Control System
1. Manual Switches (ON-STOP, START, OIL-PUMP)
2. Gages and Lights
3. Safety Controls
4. Operating Controls
5. Auxiliary and Special Controls
Auxiliary Equipment
1. Starter(s)
2. Pumps
3. Cooling Tower
Describe Refrigeration Cycle
Review Maintenance
1. Scheduled
2. Extended Shutdown
3. Importance of Log Sheet
4. Importance of Water Treatment
Check Operator Knowledge
1. Start-Stop Procedure
2. Safety and Operating Controls
Discuss Carrier Service
1. Availability
2. Method of Ordering Parts
Review Operating and Maintenance Instructions
Point out the following machine components;
explain their function and that of the system in
which they are used.
For replacement items use Carrier Specified Parts
Manufacturer reserves the right to change any product specifications without notice.
CARRIER AIR CONDITIONING COMPANY • SYRACUSE, NEW YORK
Tab15 Form 19DG-3SS Supersedes 19DG-2SS Printed in U.S.A. 5-71 Codes MA and ML Catalog No. 531-914
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