Carrier 19FA Series User Manual

2
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Factory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Job Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Field-Supplied Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspect Machine Room . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drive Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
• AUXILIARY EQUIPMENT WIRING
• TURBINE DRIVE WIRING
• GAS ENGINE DRIVE WIRING
Safety Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Motor Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Gas Engine Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Turbine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pumpout System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Leak Test and Dehydration . . . . . . . . . . . . . . . . . . . . . . . 4
Charge Machine with Water . . . . . . . . . . . . . . . . . . . . . . 5
Charge Machine with Oil . . . . . . . . . . . . . . . . . . . . . . . . . 5
Final Pre-Operation Alignment Check . . . . . . . . . . . . 5
Operate Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Set Purge Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Check Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Check Air Supply (Pneumatic Machines) . . . . . . . . . 6
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Pre-Operation Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Drive Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Initial Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 6
Initial Compressor Operation. . . . . . . . . . . . . . . . . . . . . 6
Adjust Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . 6
Hot Alignment Check and Doweling . . . . . . . . . . . . . . 7
Operational Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Instruct Customer Operator . . . . . . . . . . . . . . . . . . . . . . 7
• CONTROL PANEL
•VFD
• STEAM TURBINE
• GAS ENGINE
• OPERATING PROCEDURES
• LOG SHEETS
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Start Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . 10
Stop Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pumpout System Operation . . . . . . . . . . . . . . . . . . . . . 11
• LUBRICATION
• CONTROL DESCRIPTION
• CONTROL SETTING
• MACHINE AND STORAGE TANK EVACUATION
(No Refrigerant in System)
• REMOVE AIR AFTER OPENING CHILLER TO
ATMOSPHERE (Refrigerant Charge in Storage Tank)
• TRANSFER REFRIGERANT CHARGE (From Storage
Tank to Machine)
• TRANSFER REFRIGERANT CHARGE (From
Machine to Storage Tank Located Below Machine)
• TRANSFER REFRIGERANT CHARGE (From
Machine to Storage Tank Located Above or Level with
Machine)
• PRESSURIZE MACHINE AND STORAGE TANK (No
Refrigerant in System)
• DISTILL REFRIGERANT CHARGE
• CHARGE REFRIGERANT
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
Weekly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
• CHECK OIL LEVEL
Page
• CHECK PURGE FREQUENCY
• WATER IN PURGE WATER CHAMBER
Yearly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
• CHECK/CALIBRATE WATER TEMPERATURE
SENSORS
• CHECK REFRIGERANT LOW-PRESSURE CUTOUT
• CHECK CONDENSER HIGH-PRESSURE CUTOUT
• CHECK AUXILIARY OIL PUMP CONTROL
• CHECK SEAL OIL DIFFERENTIAL PRESSURE
TRANSDUCER
• CHECK THRUST BEARING OIL PRESSURE
TRANSDUCER
• CHECK DISCHARGE GAS HIGH-TEMPERATURE
CUTOUT
• CHECK THRUST BEARING OIL HIGH-TEMPERA-
TURE CUTOUT
• CHECK SHAFT MOVEMENT SWITCH
• CHECK COOLER AND CONDENSER MINIMUM
FLOW PROTECTION
• CHECK AUXILIARY INTERLOCKS
• CHECK CONDENSER SUBCOOLER LEVEL
CONTROL
• CHECK COMPRESSOR GUIDE VANE CONTROL
• CHECK STARTERS AND VFDS
• CHECK PRESSURE REGULATORS
• COMPRESSOR BEARING AND GEAR
MAINTENANCE
• CHANGE OIL AND OIL FILTER
• INSPECT COOLER TUBES
• INSPECT CONDENSER TUBES
• INSPECT PURGE RECOVERY UNIT
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
• REFRIGERANT LEVEL
• LEAK TESTING
• CHECK LEAKAGE RATE
• BREAKING VACUUM
• PREPARING MACHINE FOR CHARGING
REFRIGERANT
• CHILLER DEHYDRATION
• REMOVING REFRIGERANT
• WATER TREATMENT
• CLEARANCES
• GEAR AND DRIVE
• PUMPOUT SYSTEM
GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-20
Machine Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Refrigerant Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Relief Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Refrigeration Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Oil Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Purge Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . 20-22
Compressor Will Not Start. . . . . . . . . . . . . . . . . . . . . . . 20
Compressor Surge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chilled Water Temperature Too High . . . . . . . . . . . . 20
Chilled Water Temperature Too Low with
Compressor Running. . . . . . . . . . . . . . . . . . . . . . . . . . 22
Refrigerant Temperature Too Low . . . . . . . . . . . . . . . 22
Leaving Chilled Water Temperature Fluctuates . . 22
Condenser Pressure Too High. . . . . . . . . . . . . . . . . . . 22
Oil Pressure Too Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Oil Pressure Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Oil Reservoir Temperature Too Low . . . . . . . . . . . . . 22
Oil Reservoir Temperature Too High. . . . . . . . . . . . . 22
Compressor Discharge Gas Temperature
Too High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-27
Safety Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PRE-START UP CHECK LIST . . . . . . . . . . . . . . . . . CL-1

Carrier 19FA Series Specifications

General

Brand	Carrier
Model	19FA Series
Category	Chiller
Language	English