Carrier 17CB User's Manual
Contents
1. 5 SUPPLY AIR CONNECTIONS 6 CONTROL AIR PRESSURE GAGE 7 CONTROL AIR CONNECTIONS 8 DIAL RETAINING SCREW 2 Preparation 1 Ensure 25 psi supply air to thermostat 2 Loosen Allen setscrew in sensitivity slider and move slider halfway between midpoint and DA Retighten screw Calibration 1 Turn thermostat dial until control air registers 15 psi 2 Operate machine to reach design chilled water temperature at design load Maintain 15 psi control air during pulldown by adjusting ther mostat dial as required 3 On reaching design chilled water temperature turn dial until control air pressure holds machine at design conditions 4 Hold setpoint adjusting screw stationary within the dial post and set the thermostat dial at design chilled water temperature Completion If vane hunting occurs move sensitivity slider away from DA Sensitivity decreases as slider is moved from 5 psi F to the lower limit of 0 1 psi F Trimming Refrigerant Charge After machine is placed in operation it may be necessary to adjust the refrigerant charge to obtain optimum machine performance When machine full load is available slowly add a sufficient amount of the remaining 200 lb of refrigerant until the difference between leaving chilled water temperature and cooler temperatures reaches design conditions or becomes a minimum Shut down machine Mark maximum refrigerant level Maintain refrigerant at this level Hot Alignment Chec2. Condenser water should enter the upper con denser nozzle and leave at the lower Ensure that pipes are vented and properly suspended with no stress on nozzles or water box covers Measure water pressure drop across cooler and condenser or across the pumps Check to see that water flow agrees with design flow Oil cooler water must be clean with 85 F maximum temperature and 200 psi maximum inlet pressure Refer to tag attached to cooler inlet connection for pressure drop and velocity limits Check that any drive piping is installed per manufacturer s instructions Field alee an m Refer to Job Daa wiring F and E field wiring as follows 1 Wiring voltage supply and rotation of all electrical equipment brine pump condenser water pump tower fan 2 Overload settings on all motor starters 3 Wiring on all electrical devices on drive auxil iary oil pumps pump starters etc 4 Wiring between drive and control center and compressor junction box 5 Wiring to pumpout compressor 6 Oil pump starter voltage against oil pump nameplate voltage Lubrication COMPRESSOR Drain and flush out all shipping oil then charge oil shipped with machine It conforms to Carrier oil specifications for centrif ugal compressors listed in the Operating and Maintenance Instructions Charge thru oil reser voir charging valve item 8 Fig 2 to middle of reservoir sight glass Machine vacuum draws oil from container
3. Chilled Water Low Temperature Cutout 2 Y amp Cooter Charging Valve 3 4 N M 1 Water Lo nperatu 9 35 ASME Nameplate 9 9 0i ZB Ched Water Temperature Probe T 16 Machine Informative Piate TES ei 17 Sefety Code Sticker c 18 Cooler Waxerbox Vent 9 4 NET BF Burge Operating Valves bs 28 Purge Refrigerant Level Sight Glass 29 Purge Water Level Sight Glass i rge Pipe 9 738 Condenser Waterbox Drain 3 4NPT 30 Purge Water Drain Valve o x Float Valve 20 Condenser Waterbox Vent 3 4 NPT 34 Buptare Disc Assembly Economizer Pipe 21 Economizer Fig 1 17CB Machine Components R 11 Unit shown BQ Economizer Float Valve cio i 3 h 9 ge Gearing oR R Gib Beater Terminal Box Thermometer 6 oit Pump Namenite 19 E Fitter Boe re a oe E Fig 2 17CB Centrifugal Compressor INITIAL PREPARATION pressor is ck ar with refrigerant DO RO ople machine 15 Under Gebydration v vacuum Machine Tightness If machine leak sline oa 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 pr
4. Oil cooler plug cock item 16 Fig 2 partially open and any other valves in oil cooler line fully open 7 Valves in chilled water and condenser water circuits open and water circulating properly Do not permit water over 100 F to flow thru cooler 8 Air supply to pneumatic controls 9 Purge valves and switches in Normal Automatic position Refer to chart attached to purge cover Nn BWW Compressor Rotation and Operation Electronic Control Set capacity control switch to Hold Pneumatic Control Turn off supply air to chilled water thermostat and vane positioner Turn on OIL PUMP switch if gas engine or turbine drive Press machine ON STOP and START buttons lights go on As soon as the compressor shaft begins to turn note direction of rotation If not counterclockwise as viewed from drive end stop compressor by pressing ON STOP button light goes out and correct condition If rotation is counterclockwise let compressor come up to speed and press ON STOP button light goes out Listen for any unusual sounds as compressor coasts to a stop The program timer on electric drive units will allow compressor restart 15 minutes after stop Checking Safety Contro Settings While performing these checks carefully n m ni tor chilled water temperature to prevent freeze up Protection oe fuels controls caanot finned as follows Shut on gas or lon S t engine or turbine Open main d
5. Oil may also be added thru charging elbow item 2 in seal oil return chamber The pump item 3 automatically transfers oil to the oil reservoir Ok prieuniatte machines on add a srl amount of oil to the vane seal chamber thru 1 4 in pipe plug Fig 4 until level reaches bottom of rack and gear as seen thru Plexiglas cover PLEXIGLAS COVER COUPLINGS E couplings after hee have been reassembled Follow manufacturer s recommendations for type of lubricant and lubrication procedure NOTE Do not reassemble couplings until drive has been run separately SPEED INCREASING GEAR Fill gear casing with oil recommended by manufacturer DO NOT OVERFILL DRIVE Refer to drive manufacturer s instruc tions for proper lubrication AUXILIARIES Check all auxiliary pump motor bearings for proper lubrication Fill all oilers used on shaft seals bearings etc Refrigerant Charge 1 Install a charging valve in the 3 4 in drum opening as shown in Fig 5 2 Connect a short length of plastic hose R 11 only or copper tubing from drum valve to cooler charging valve 3 Circulate chilled water during the charging process gee N L Z may cause tube eeren Keep releen lt rams upright and admit refrigerant as a gas 700p cooler v vacuum is tess than ee listed in S i Table Z ee 7 2 5 The eee ee with Oe P is in excess of that required for initial charging Charge the
6. 9 and 11 Disconnect separable union in pumpout com pressor suction line 5 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 eS COD SEPARABLE UNION FIELD SUPPLIED y SUCTION GAGE UL oy Eal SEPARATOR SEPARABLE UNION CHEE OIL TRANSFER LINE 5F COMPRESSOR DISCHARGE GAGE WATER INLET 3 WATER OUTLET FLOAT VALVE i WITH STRAINER L__ 4 VALVES ARE NUMBERED FOR IDENTIFICATION IN TEXT PIPING BY CARRIER Ka FIELD PIPING Fig 3 Pumpout System Schematic R 114 Units 5 a Recheck Alignment Angular and parallel align ment must be within coupling manufacturer s specified tolerances before machine is operated Refer to Carrier Standard Service Techniques Manual Chapter 15 for checking methods Leave couplings disassembled until drive is tested and operated Check Grouting Make sure grouting was applied during installation Grouting should be completed before machine is operated Inspect Piping Refer to piping diagrams provided in Job Data and inspect piping to cooler condenser and oil cooler Chilled water should enter the lower nozzle of the cooler and leave at the upper nozzle Chilled water temperature probe should be installed in leaving chilled water line
7. 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 ANSI B9 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 o1 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 iepair 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
8. amount shown in Table 3 less 200 pounds 6 After the machine has been started it may be necessary to adjust the charge for optimum machine performance For this adjustment see Trimming Refrigerant Charge Fig B Drum Charging Valve Table 2 Pressures Corresponding to 32 F Saturation Temperature erea RSA RENNER HIRANO ESM ORTON EISEN RGR ONDA SEES MANES ISIE S BOERS UTNE HIS PRESSURE in Hg ve vacuum hi BERRI MOIS NCC HERESY REFRIGERANT nre maane neo Oor SENET RRS AERC MINTO RO 11 18 05 114 385 re annoar er prinese prann peer Krr errant ve aree aine Sins beet LEER enero nre Table 3 Refrigerant Shipping Charges ASTRA HERE RSAC SHIPPING MACHINE SIZE kerre CHARGE UN 17CB1300 11 2800 17CB1400 3250 17CB1500 11 3250 l 17CB1600 dal 7 3500 a 17CB1800 114 4400 17CB2000 114 4400 BHT TT YH 90 Kp ROM SA GERAD SHES THY Some tte ANS Drive It is good practice to operate the drive separately before operating compressor Refer to drive manufacturer s instructions for drive pro tection devices and settings Check turbine over speed at this time Reassemble couplings after operating drive separately 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 Purge Place the purge operating valves Fig 1 in Normal Au
9. 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 ALTERNATE TRANSFER LINE OF ALTERNATE STORAGE TANK ji DRAIN VALVE K 4 een Ha SIGHT GLASS 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 machine vacuum is reached Close valve 5 and reassemble union Stop compressor Remove jumper until desired Se PRESSURIZING THE MACHINE No refrigerant in system l 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
10. of the faces are not problems The diameter used in the angular alignment formula is the circle thru which dial indicator rotates This method is more accurate since the diameter is larger Doweling After hot alignment is completed the compressor gear and drive must be doweled to their soleplates This permits repositioning of components if they have to be moved Compressor has four 3 4 in holes for doweling 1 Drill thru these holes into the soleplates Ream holes with a tapered reamer with straight flutes 2 Coat dowels with white lead or other lubricant to prevent rusting 3 Tap dowels lightly into position with a small hammer A ringing sound indicates the proper seating Repeat these steps with gear and drive keeping dowels as vertical as possible Dowel thru the four 3 4 in holes on suction end of compressor base the two feet on high speed end of gear and the drive feet adjacent to gear Refer to drive man ufacturer s instructions for additional details on doweling this equipment INSTRUCTING THE CUSTOMER OPERATOR Be sure the operator carefully reads and under stands the 17CB Operating and Maintenance In structions and any instructions on drive operation and maintenance Point out the following machine components explain their function and that of the system in which they are used 1 Compressor Motor Assembly a Guide Vanes Vane Motor and Linkage 2 Cooler Condenser Economizer a F
11. off the safety light Tripping the chilled water recycle switch will cut off the LOAD RECYCLE light only 4 Press ON STOP button light goes out Remove and tag gray striped wire from control center ter CIRCUIT RECYELE TIMER CIRCUIT RECYCLE TIMER minal 7 Refer to ma chine control schematic in the Operating and Maintenance Instructions for terminal location 5 6 Press OIL PUMP button 7 8 10 11 Start chilled water and condenser water pumps Press ON STOP button light goes on CIRCUIT RECYCLE TIMER for several seconds Pump should raise pressure 25 to 27 psi above refrigerant pressure at machine shutdown condition SAFETY CIRCUIT and LOAD RECYCLE lights should go on Release OIL PUMP button SAFETY CIR CUIT light and LOAD RECYCLE light should go out POWER SAFETY LOAD PROGRAM CIRCUIT RECYCLE TIMER POWER SAFETY LOAD PAOGRAM CIRCUIT RECYCLE TIMER With OIL PUMP button depressed alternately stop and restart chilled water and condenser water pumps SAFETY CIR CUIT and LOAD RE CYCLE lights should go out as each pump stops Continuous operation of oil pump is unnecessary during these checks POWER SAFETY LOAD PROGRAM CIRCUIT RECYCLE TIMER Shut off water pumps Re lease OIL PUMP button Press ON STOP button light out Replace tagged POWER SAFETY LOAD PROGRAM wire on terminal Press ON STOP button light goes on Press machine START bu
12. 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 1ust 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 Farm 17CR 2SS CONTENTS SAFETY CONSIDERATIONS 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 Recheck Alignment Check Grouting Inspect Piping Field Wiring Lubrication Refrigerant Charge Drive Purge Air Supply Pneumatic Control Only Check Safety Control Operation Electric Motor Drive Check Safety Control Operation Gas or Turbine Drive START UP Preliminary Checks Compressor Rotation and Operation Checking Safety Control Settings Setting Operating Controls Electronic Setting Operating Controls Pneumatic Trimming Refrigerant Charge Hot Alignment Check Doweling INSTRUCTING THE CUSTOMER OPERATOR ro pee UG C2 UJI d d AAAA C C Lh Lh Lh E ARARA NNNNA INTRODUCT
13. ION 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 Machine assembly wiring and piping prints Prints and instructions for special controls 17CB Installation Instructions 17CB Operating and Maintenance Instructions 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 Mechanic s tools Volt ohmmeter and clamp on ammeter Manometer absolute pressure type Leak detector halide or electronic Refrigerant drum charging valve Fig 5 5 8 in SAE x 3 4 in MPT adapter 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 NANRWN gt AT a 73 a REAR VIEW O LEGEND BF eRe ees 22 Purge Operating Switc 42 Cooter Economizer Equalizing Damper ce Des Sic it go uru Thergpat Purge cco 18 Betigerant Connection 1 1 2 NET 26 Purge Valve Operation Ploare o oin T BS
14. 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 1efrigerant 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 tefrigerant 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 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 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 Decei ng Maun nentinn T alaa while machine is under pressure or while machine is running Be sure pressure is at zero psig before breaking any refiigerant 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
15. Number One Air Conditioning Maker G Division of Carrier Corporation Carrier Parkway Syracuse N Y 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 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
16. SWITCH SA CUT APY PRESSURE ADJUSTMENT ONLY CUTOUT PRESSURE ADJUSTMENT ONLY High pressure switch to open on rise at 45 psig Low pressure switch to open on fall at 2 0 in Hg vacuum COMPRESSOR Z CONNECTIONS Set high pressure switch by operating compressor and throttling pump down condenser water while watching pressure gauge Set low pressure switch by operating compressor and gradually shutting suction valve while watching pressure gauge 11 Oil Safety Switch for R 114 Pump Down Compressor PRESSURE SWITCH PRESSURE SWITCH ARM RESISTANCE MANUAL RESET BUTTON CONNECT iN SERIES WITH CONTROL CIRCUIT SEE WIRING DIAGRAM CONNECT TO IISOR 230V SOURCE SEE WIRING DIAGRAM Contacts open on drop in oil pressure Cutout 11 14 psi cut in 16 19 psi differential between pump discharge and compressor suction Preset switch with an external air source 11 Setting Operating Controls Electronic MOTOR CURRENT CALIBRATION Electronic Capacity Control Motor Drive 1 Establish a steady motor current value for this calibration Open guide vanes manually capacity control to Inc until full load current is reached Motor current calibration Fig 8 may need to be turned counter clockwise 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 c
17. c in the Operating and Maintenance Instructions for loca tion of electrical terminals listed As checks are made control panel lights should appear as indicated in the diagrams l Turn off main steam or gas supply to prevent drive from starting Place jumpers across oil switch a SAFETY terminals and CIACUIT and flow switch terminals and inside the control center 2 Provide control circuit power O SAFETY CIRCUIT 3 Press ON STOP button light on If SAFETY CIRCUIT light does not z E go on check resets on SAFETY condenser high pressure safety cooler low refrig erant safety bearing high temperature circuit breaker chilled water low temperature switch and driver overload in starter Check 3 amp fuse in control center Manually trip and reset the bearing high temperature circuit breaker driver overload low refrigerant safety and chilled water switch to be sure they cut off the safety light 4 Press ON STOP button light goes out Remove jumpers across terminals 67 and 63 and E 70 5 Start chilled water and condenser water pumps Press ON STOP button light goes on 6 Turn on OIL PUMP switch for several seconds Pump should raise oil pressure 25 to 27 psi above refrigerant pressure at machine shutdown con dition SAFETY CIRCUIT light should go on If oil pump operates but SAFETY CIRCUIT light is out check water flow switches SAFETY CIRCUIT 7 Turn
18. essure 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 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 rea neg test ee nee in Labi l ay Close me ada ane Remove copper tube Table 1 Test Pressures MACHINE SIZE REFRIG tet a oe PRESSURE 17CB1300 thru 1600 E 1 8 to 10 psig 17CB1800 thru 2000 i R 114 30 to S psig i eamnasasoneeaaaasananeaeaia anne sii ion a re yesasn are 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 p
19. etting 9 If control was calibrated at less than 100 load turn electrical demand adjustment setting to 100 Control is now automatically cali brated for 100 full load current 10 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 center must be 0 5 0 1 volts If not in this range check sizing of resistor in starter Both excess motor current and chilled water temperatures below the thermostat set point Fig 8 will override the capacity control setting If the capacity control knob is in the Inc position the guide vanes will stop opening With the knob in any of the other positions the vanes will close as needed The motor current limiting circuit operates in two steps 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 control again operates in response to chilled water temperature The electrical demand adjustment permits the operator to set the maximum current drawn by the motor and thus minimize the electrical demand rate during off season operation CHILLED WATER CALIBRATION Electronic Controls 1 Turn throttle range adjustment Fig 8 and 9 full
20. i and close at 15 1 psi differential pressure Operate oil pump manually Remove cap and gasket from regulating valve and loosen locknut Turn adjusting screw counterclockwise to lower oil pressure to 11 psi differential If safety does not trip turn range dial clockwise until cutout occurs SAFETY OR CONTROLI DEVIGE SAFETY OR CONTROL DEVICE 6 Oil Pressure Regulating Valve item 20 Fig 2 REFI RIG SETTING 11 15 psid 114 15 20 psid ee ae rt Settings given are above reservoir pressure ADJUSTING R SCREW SEALING GASKET Remove cap and washer and loosen Jocknut Turn adjusting screw clockwise to raise oil pressure 7 Vane Speed Valve Electronic Machine Only Angle valve is located between oil line to main bearing and F and G solenoid valves items 17 and 19 Fig 2 Set valve at full open position 8 Chilled Water Flow Switch Field supplied and installed Follow switch manufacturer s instruc tions for adjustment and maintenance rrer rea tn Krr i rre rar 9 Main Bearing Oil Temperature item 11 Fig 2 During machine operation gauge should read 160 to 165 F Adjust water flow thru oil cooler with plug cock item 16 Fig 2 Do not exceed 7 gpm or pressure drop of 5 psig Do not exceed 100 psi working pressure 10 Dual Pressurestat for R 114 Pump Down Compressor CUTOUT AND CUT IN PRESSURE g ADJUSTMENT HIGH PRESSURE
21. isconnect all power off to starter and controls Electronic Capacity Control Set capacity control switch on Hold Pneumatic Capacity Control Ensure that pilot positioner operates as described in Setting Oper ating Controls Pneumatic If compressor has electric motor drive set percent load knob on demand limit control at 100 and turn calibration screw fully clockwise Install jumpers across low refrigerant and low chilled water cutouts as follows Electric Motor Drive 40 to 4 09 43 10 to 11 11 Gas Engine or Turbine Drive Q to to Close disconnects start compressor and check oil pressure and temperature With compressor run ning operate the guide vanes with the capacity control switch or the pneumatic thermostat Do not exceed full load condition Check controls 1 and 2 as indicated in Table 4 2 Stop machine open disconnects remove jumpers and check controls 3 4 and 5 as indicated Table 4 Setting Safety Controls sa Gf ON EPA AA SLOAN SAMENESS ONSHORE AADC eH SAFETY OR CONTROL DEVICE meer 1 Chilled Water Low Temperature Cutout and Recycle Switch Fig 1 TEMPERATURE ADJUSTMENT a Set this switch to break at approximately 5f below design chilled water temperature or at 36 F whichever is higher b Set the differential at 10 1 F o that when the machine shuts down automatically at approximately 5F below the design chilled water temperature i
22. k When all machine com ponents have reached operating temperature after running near full load for approximately two hours a hot alignment check must be made 1 Shut down machine 2 Quickly disassemble couplings between com pressor and drive and gear if used 3 Check angular and parallel alignment in plan and elevation Indicators may be mounted as in Fig 10 Refer to coupling manufacturer s instruc tions and to Carrier Standard Service Tech niques Chapter 15 for applicable procedures d After making adjustments reassemble the couplings and run the machine until it reaches operating temperature 5 Repeat steps thru 3 until angular and parallel alignment is within coupling manufacturer s specified tolerances A one rate hates ER x es C Z E a ee SE ONMENT Fig 11 Alignment Check Assembled Coupling S an 2 T E e A second method of checking hot alignment can be used if there is room on the shafts between equipment and coupling to clamp a sturdy bracket Clamping tool Part No TS 170 is available for this purpose thru Carrier Service Parts Department Check with your local Carrier Office Dial indicator must be obtained separately Clamps must have space to rotate with the shaft This method is quicker because couplings do not have to be disassembled Mount brackets and dial indicators as in Fig 11 Since both shafts ar rotating together concentricity and condition
23. loat Chamber Sight Glasses b Thermowells c Rupture Disc d Refrigerant Charging Valve 3 Purge System a Importance of Proper Operation b Valves and System Operation c Sight Glasses Gage 4 Lubrication System Oil Pump Cooler Filter Solenoid Valve Plug Cock Heater Thermostat Temperature Gage Pressure Regulating Valve Oil Level Temperature n GP TP 5 Control System a Manual Switches ON STOP START OIL PUMP Gages and Lights Safety Controls Operating Controls Auxiliary and Special Controls 6 Auxiliary Equipment a Starter s b Pumps c Cooling Tower d Pumpout System if supplied 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 Coe For replacement items use Carrier Specified Parts Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Form 17CB 2SS Supersedes 17CB 1SS Book 2 Tab 5a Printed in U S A 3 79 PC 211 Catalog No 531 740
24. off OIL PUMP switch SAFETY CIR CUIT light should go off SAFETY CIRCUIT 8 With OIL PUMP switch on manually trip and reset water pump switches ON g SAFETY CIRCUIT light L SAFETY should go off as each switch is tripped Continuous operation of oil pump is unnecessary during these checks 10 11 12 POWER ON START CONDENSER STOP With OIL PUMP and ON STOP switches on and water pumps oper ating press machine START button gas or steam supply turned off Turn off OIL PUMP switch Oil pump must continue operating Open oil pump main dis connect Driver circuit control must de energize Oil pump will remain on for 3 minutes OIL PUMP light goes out Press ON STOP switch light goes off to drive Restore power ON A E ie OFF SAFETY OIL PUMP CIRCUIT Q g CAPACITY CONTROL MODULE SAFETY CIRCUIT SAFETY CIRCUIT SAFETY CIRCUIT SAFETY CIRCUIT DIL SAFETY PUMP CIRCUIT Remove all power Restore gas or steam supply POWER ON START STOP O O OFF SAFETY OIL PUMP CIRCUIT L CONDENSER PRESSURE CUT OUT ELAPSED TIME INDICATOR ELECTRONIC CONTROL PNEUMATIC CONTROL Fig 7 Control Center Components Gas Engine or Turbine Drive START UP Preliminary Checks 1 Power on to circuit prance water pumps cooling tower fans Cooling tower water level Refrigerant level Oil reservoir level Oil reservoir temperature 140 F or warmer
25. ondition With small loads pull down to and maintain design leaving chilled water temperature capacity control at Hold and calibrate at this condition Fig 8 Capacity Control Module Electric Motor Drive 2 Measure motor current at selected condition Determine its percentage of full load motor current 3 Use this percentage figure to set the electrical demand adjustment Fig 8 per the following table Percent of Full Load Motor Current Electrical Demand Adjustment Setting 105 100 percent 85 or above 80 percent 65 to 84 60 percent 45 to 64 40 percent below 45 Control cannot be calibrated 4 Turn the motor current calibration adjustment fully clockwise The guide vanes will close part way 5 Turn the thermostat adjustment Fig 8 to COOLER fully counterclockwise 6 Set capacity control at 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 cali bration 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 s
26. output signal of 3 psi at 6 volts d c to 18 psi at 15 volts d c Field recalibration should not be necessary If calibration is required Establish 15 volt d c input with 25 psi supply air 2 Turn sensitivity screw to obtain 18 psi or higher output 3 Adjust setpoint screw if required to set output at 18 1 4 psi 4 Reduce input to 6 volts Output should be 3 1 4 psi If low turn sensitivity screw carefully clockwise If high turn screw counterclockwise 5 Re check output at 15 volts Repeat steps 3 and 4 if necessary DEMAND LIMIT CONTROL CALIBRATION ADJUSTMENT BAND WIDTH DIAL LOAD DIAL TERMINAL BOARD HIDDEN 1 Set percent load dial at 100 2 Set Band Width dial at 3 Adjustment screw fully 3 Turn Calibration clock wise 4 Run machine at 100 FLA by adjusting dial on chilled water thermostat 5 Turn Calibration Adjustment screw counter clockwise until guide vanes just begin to close 6 If hunting occurs increase band width and repeat steps 4 and 5 7 If control cannot be calibrated with above procedure check voltage signal from resistor in starter At 100 full load voltage between terminals 23 and 24 inside control center must be 3 0 0 1 volts If not in this range check sizing of resistor in starter gt CHILLED WATER THERMOSTAT PNEUMATIC DESCRIPTION 1 SET POINT ADJUSTING SCREW 2 THERMOSTAT DIAL 3 SENSITIVITY SLIDER 4 SUPPLY AIR PRESSURE GAGE
27. t will restart at approximately 5 F above the design water temperature C This control must break ahead of the refrigerant low temperature cutout switch or the machine will not recycle automatically ROS LAS MEL SC DM ASS EEE NMEA SEEDERS aaaea REREAD EEE RM SAFETY OR CONTROL DEVICE 2 Refrigerant Low Temperature Cutout Fig 6 and 7 CUTOUT ADJUSTMENT Set refrigerant low temperature cutout at 33 F or one degree below design refrigerant temperature whichever is lower while checking temperature at thermowell near control center areas Table 4 ee Saree Controls Gai STOP MACHINE REMOVE JUMPERS AND PERFORM RE MAINING CHECKS YU vern 3 Condenser High Pressure Cutout Fig 6 and 7 REFRIG SETTING CUTOUT ADJUSTMENT me 6 a 15 psig p 114 45 psig RESET BUTTON CUTOUT SCALE The condenser high pressure cutout is factory set to shut the machine down when condenser pressure reaches setting listed Isolate the switch and check setting with a metered supply of air 4 Oil Heater Thermostat Fig 2 ADJUSTING SCREW LOCKING SCREW Set the oil heater thermostat to maintain a minimum oil reservoir temperature of 140 F at shutdown 5 Low Oil Pressure Cutout Fig 2 RESERVOIR 4 PRESSURE E RANGE a DIAL ADJUSTMENT REMOVE METAL COVER DIFFERENTIAL OIL PRESSURE Low oil differential pressure switch is factory set to open at 11 1 ps
28. tomatic position as indicated in operation on the purge valve operation plate item 24 Fig 1 Operate the purge momentarily by placing the purge switch in Manual position then place purge switch in Auto position Air Supply Pneumatic Control Only Check 25 psi air supply to pneumatic temperature controller and pilot positioner Check Safety Control Operation Electric Motor Drive NOTE Motor high temperature cutout is field supplied only per customer s request As the following checks are made control panel lights should appear as indicated in the diagrams LJ OFF W ON 1 Open main disconnect all power off to starter and controls Disconnect main motor leads in starter POWER SAFETY LOAD PROGRAM CIRCUIT RECYCLE TIMER 2 Provide control circuit power POWER SAFETY LOAD PROGRA CIRCUIT RECYCLE TIMER 3 Press ON STOP button light goes on If SAFETY CIRCUIT light does not go on check resets on condenser high pressure safety low refrig erant safety bearing and motor high tempera ture 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 and low refrigerant temperature cutout to be sure they cut
29. tton motor leads disconnected POWER SAFETY LOAD PROGRAM CIRCUIT RECYCLE TIMER Oil pump starts within 30 seconds POWER SAFETY LOAD PROGRAM CIRCUIT RECYCLE TIMEA Compressor motor start contacts will close 30 seconds later Starter will transfer to its run condi tion 30 to 60 seconds after starter is energized POWER SAFETY LOAO FAOGAAM CIRCUIT RECYCLE TIMER LZ 13 14 OlL CONDENSER STOP PUMP Open oil pump main dis connect Starter must de energize OIL PUMP light will remain on for approxi mately 5 minutes OIL PUMP light goes out POWER SAFETY LOAD PROGRAM CIRCUIT RECYCLE TIMER POMER CIRCUIT RECYCLE TIMER Close oil pump discon nect In approximately 10 minutes the program timer will complete the anti recycle portion of its cycle and machine is ready to restart Total recycle time is 15 minutes Remove all power Reconnect motor leads Restore power POWEA SAFETY LOAD PROGRAM CIACUIT RECYCLE TIMER LK E L DN START 0D DUD U ON START oiL CONDENSER STOP PUMP p popop L D U U POWER SAFETY LOAD PROGRAM POWER SAFETY LOAD PROGRAM CIRCUIT RECYCLE TIMER CIRCUIT RECYCLE TIMER COOLER COOLER ELAPSED INDICATOR CAPACITY CONTROL MODULE RELAY MODULE ELECTRONIC CONTROL PNEUMATIC CONTROL Fig 6 Control Center Components Electric Motor Drive Check Safety Control Operation Gas Engine or Turbine Drive Refer to machine control schemati
30. urge pump operation 2 Refrigerant 11 machines pumpout unit Refrigerant 114 machines or by applying a vacuum pump at the cooler charging valve ee a 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 Smali 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 dehy CAUTION Do not attempt to start of pump OF pu ven 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
31. y clockwise e L IX XRROTTLE Rance VBCRCASC Te TMERMOSIAY atini Fig 9 Capacity Control Module Gas Engine or Turbine Drive 2 Turn chilled water thermostat until design chilled water temperature is maintained Mark thermostat at this position If capacity control vanes hunt turn throttle range adjustment counterclockwise in small increments until hunting ceases Chilled water thermostat may require resetting Setting Operating Controls Pneumatic G w e wc e e N Ne e e Ne Y we y we e Y ITEM DESCRIPTION MAIN AIR CONNECTION 25 PSIG STARTING POINT ADJUSTMENT NUT LEVER ARM FOLLOWER SPRING PILOT AIR CONNECTION FROM CONTROL CENTER a fkWN Preparation 1 Place jumper between terminals ED and 7 2 Open 25 lb air supply valve 3 Remove cover from pilot positioner Calibration Rotate dial on chilled water thermostat to vary pilot pressure Observe pressure gage in pilot supply line near pilot positioner and adjust starting point nut 2 until piston operator Fig 4 begins to move at 5 psi pilot pressure Place follower spring 4 in proper hole in level arm so that piston operator opens 100 at 15 psi pilot pressure Completion 1 Remove jumper from terminals L and 7 2 Replace positioner cover ELECTRO PNEUMATIC RELAY Electric Motor Drive Only SENSITIVITY SCREW SET POINT SCREW This control is factory calibrated to provide a linear
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