Carrier 19EA User Manual

Carrier

ermetic Centrifugal Liquid Chillers

INTRODUCTION

persons concerned with the start-up and ope^ion of the 19EA machine should understand thteie instructions and all necessary job data before initial start-up. Instructions are in proper sequence for optimum machine performance.

Data and Equipment Required

PRINTS: Machine assembly and

wiring, piping Starter diagrams

Special controls and related

wiring (if any)

INSTRUCTIONS:

19EA Installation book 19EA Operating and Main

tenance book

Starter Instructions

MATERIALS:

Mechanics’ tools, electronic or halide leak detector, clamp-on ammeter, volt-ohmmeter

INITIAL PREPARATIONS

Machine Tightness — The 19EA is shipped with the

refrigerant charge in the utility vessel and a holding

charge (10 psig) in the unishell. Several levels of leak testing may be required depending on condition of machine on arrival and at start-up. Determine machine condition and follow pro

cedure indicated in Table 1.

For transferring refrigerant and evacuating vessels, follow the pumpout instructions on pages 3 and 4.

Table 1 — Selection of Leak Test Procedures

MACHINE CONDITION

1. Unishell holding charge and utility vessel refrig erant level unchanged.

2 Unishell holding charge

decreased slightly.

3. Utility vessel refrigerant level decreased slightly.

4. Unishell holding charge

completely gone Opened

valve or other open con nection suspected.

5 Unishell holding charge

completely gone Vessel

leak assumed

6 Refrigerant charge in

utility vessel completely gone. Opened valve or

, \ other open connection

suspected.

7 Refrigerant charge in

utility vessel completely

gone. Vessel leak assumed

PROCEDURE

3 and 4 on unishell Leak test with halide or

electronic leak detector.

'2., 3, and 4 on unishell

1 - Use nitrogen with R-12 tracer in pressur izing for leak test pro

cedures 2 and 3 2, 3/ and 4 on uti! ity

vessel. Use nitrogen with

R-12 tracer for pressuriz ing in 2 and 3

Nev«f charge Squid refr^erant into the unisheii if vessd isressarc is beiow 3S ps^.., or vtaife water pumps itoi op«ratirig. Cooler tube freeze-trp and. dam^e may rearlt,

PROCEDURE 1 — Standing Vacuum Test

1. Attach a mercury manometer (absolute pressure-type) to the refrigerant charging valve, (6) Fig. 1. A dial-type gage cannot indicate the small amount of leakage acceptable during a short period of time.

2. Pull a vacuum on the vessel (see evacuating procedures on page 3) equal to 25 in. Hg, ref 30-in. bar. (2.5 psia), using the pumpout system pump.

3. Valve off pump to hold vacuum, and record manometer reading.

4. If the leakage rate is less than 0.05 in. Hg/24 hours, perform procedure 3, aU steps under

Machine Dehydration and procedure 4.

5. If the leakage rate exceeds 0.05 in. Hg/24 hours, perform procedures 2, 3, all steps under Machine Dehydration, and procedure 4 in the order indicated.

6. Remove mercury manometer from refrigerant charging valve.

PROCEDURE 2 — Follow steps 1 thru 4 of Return Refrigerant to Normal Operating Conditions, page

3. Raise vessel pressure slowly to 5 psig by cracking

open valve 4. Perform leak test with hahde or electronic detector and repair any leaks.

PROCEDURE 3 — Following steps 1 thru 5 of Return Refrigerant to Normal Operating Condi tions, page 3, raise vessel pressure to 35 psig. Perform leak test with halide or electronic detector and repair any leaks.

PROCEDURE 4 — Equalize pressure between utility vessel and unishell following steps 1 thru 5 of Return Refrigerant to Normal Operating Conditions, page 3. Vessel pressure will be approxi mately 70 psig. Perform leak test with halide or electronic detector and repair any leaks.

If refrigerant charge was lost and nitrogen has

been used for pressurizing in procedures 2 and 3,

evacuate vessel and then charge 400 lb of R-12 for

procedure 4. If vessels are then leak tight, continue

charging refrigerant to the level indicated in

Charging Quantity Table below.

Table 2 — Charging Quantity

MACHINE SIZE

19EA 400, 430, 465 19EA 500, 550 19EA 590, 630

WEIGHT (lb R-12)

2000

2200

2400

Form 1PFA-1.S?;

COMPRESSOR MOTOR TERMINAL BOX

COMPRESSOR

MOTOR DRIVE

e, add

CONDENSER SECTION

CONTROL BOX

PUMPOUT UNIT

COMPRESSOR

1 Pumpout Service Valve 1 2 Pumpout Service Valve 2 3 Pumpout Service Valve 3

4. Pumpout Service Valve 4 5 Pumpout Service Valve 5 6 Pumpout Service Valve 6 and Refrigerant Charging Valve

7. Pumpout Service Valve 7 8 Pumpout Service Valve 8

9. Service Valve 9 (hidden between unishell and utility vessel)

10 Differential Pressure Gage (oil) 11 Condenser Pressure Gage 12 Cooler Pressure Gage

13. Dehydrator Water Valve 14 Oil Level Sight Glass 15 Oil Temperature Gage 16 Oil Heater (with indicator light)

17. Oil Heater Thermostat 18 Oil Pressure Regulating Valve 19 Oil Reservoir Charging Valve

COOLER

LEGEND

CONDENSER

REAR VIEW

COMPRESSOR

FRONT VIEW

UNISHELL

20.

Sight Glass — Rotation

21.

Sight Glass — Seal Oil

Sight Glass — Liquid Level

24. Sight Glass — Liquid Level 25 Sight Glass — Liquid Level

Refrigerant Drain Valve

27. Isolation Valve Isolation Valve (hidden)

29. Isolation Valve Isolation Valve — ball valve between unishell

30.

and utility vessel (hidden)

31 Chilled Water Control Element

32 Pumpout Vent Valve with Flare Cap

33. Bearing Return Oil Thermometer (hidden)

34 Dehydrator Pressure Gage 35 Dehydrator Discharge Hand Valve

36. Oil Cooler Plug Cock

Chilled Water Lo-Temp Cutout

/ MOTOR DRIVE

Fig. 1 — Machine Components

ISOLATION VALVE OPERATION

Opening — Compressor must be off and vessel pressures equalized (see Return Refrigerant to Normal Operating Condition, steps 1 thru 6).

^. Loosen packing nut 1/2 to 1 turn so valve stem

will rotate and slide smoothly in packing. Do not let refrigerant trapped in valve body escape.

2. Hold stem in against line pressure and rotate

stem counterclockwise as far as possible.

3. Slide stem out of body.

4i Rotate stem clockwise in the out position, until

snug.

5. Tighten packing nut.

Closing

1. Loosen packing nut 1/2 to 1 turn so valve stem will rotate and slide smoothly in packing. Do not let refrigerant trapped in valve body escape.

2. Rotate valve stem counterclockwise as far as possible.

3. Slide stem into valve until it bottoms.

4. Rotate stem clockwise, holding assembly in, until it is tight (25 ft-lb).

5. Tighten packing nut.

TRANSFER REFRIGERANT FROM UTILITY VESSEL TO UNI SHELL* from normal operating

condition.

1. Add manometer near charging valve 6.

2. Close isolation valves (27), (28), and (30).

3. Open valves 1, 3, 4, 6, 7 and 8.

4. Close valves 2, 5 and 9.

5. Ensure that pumpout condenser water is off.

6. Turn on pumpout compressor until liquid is out of utility vessel.

7. Turn off pumpout compressor.

8. Close isolation valve (29).

9. Close valves 3 and 4.

10. Open valves 1,2, 5 and 6.

11. Turn on pumpout condenser water.

12. Run pumpout compressor until utility vessel pressure reaches 25 in. Hg, ref 30-in. bar. (2.5 psia).

13. Turn off pumpout compressor.

14. Close valves 1, 2, 5 and 6.

15. Turn off pumpout condenser water.

TRANSFER REFRIGERANT FROM UNISHELL TO UTILITY VESSEL* from normal operating condition.

1. Open drain valve (26).

2. Wait one hour; close isolation valves (27), (28) and (30).

3. Open valves 1,2, 5, 6, 7 and 8.

4. Close valves 3 and 4.

5. Ensure that pumpout condenser water is off.

6. Turn on pumpout compressor for 20 minutes.

7. Turn off pumpout compressor.

8. Close isolation valve (29). Close valves 2 and 5.

10. Open valves 1, 3, 4 and 6.

11. Turn on cooler and condenser pumps and pumpout condenser water.

*See Fig 1 and 2 for all numbered references.

Fig. 2 — Pumpout System Schematic

(See Fig. 1 Legend for Item Ref)

12. Run pumpout compressor until unishell pres sure reaches 25 in. Hg, ref 30-in. bar. (2.5 psia). Use dehydrator gage (34) for pressure

reading.

13. Turn off pumpout compressor.

14. Close valves 1, 3, 4 and 6.

15. Turn off pumpout condenser water.

UTILITY VESSEL EVACUATING PROCEDURE*

1. Close valves 1,2, 3, 4 and 9.

2. Open valves 5,6,1 and 8.

3. Open vent valve (32) and remove flare cap.

4. Turn off pumpout condenser water.

5. Operate pumpout compressor until manometer reads 25 in. Hg, ref 30-in. bar. (2.5 psia).

6. Close valves 5, 6, 7 and 8.

7. Shut off pumpout compressor.

8. Close vent valve (32) and replace flare cap.

UNISHELL EVACUATING PROCEDURE*

1. Close valves 2, 4, 6 and 9.

2. Open valves 1, 3 and 5.

3. Open vent valve (32) and remove flare cap.

4. Turn off pumpout condenser water.

5. Operate pumpout compressor until manometer reads 25 in. Hg, ref 30-in. bar. (2.5 psia).

6. Close valves 1, 3 and 5.

7. Shut off pumpout compressor.

8. Close vent valve (32) and replace flare cap.

RETURN REFRIGERANT TO NORMAL OPER

ATING CONDITION *

1. Ensure that opened vessel has been evacuated.

2. Close valves 3, 4 and 5.

3. Open valves 1,2, 6, 7 and 8.

4. Run water pumps. 5a. If unishell has been evacuated — Crack open

valve 4, gradually increasing pressure in uni shell to 35 psig. Feed refrigerant slowly to prevent tube freeze-up.

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