3
INTRODUCTION
General —
All persons concerned with the start-up and op-
eration of the centrifugal refrigeration machine should be fa-
miliar with the equipment involved. This instruction book is in-
tended to cover general rules for start-up procedures, followed
by operation and maintenance instructions.
Because of machine variations it is not possible to prepare
an instruction book covering all minor details. This instruction
book will fulfill common requirements. Additional information
pertaining to this particular chiller is included in the special job
binder provided with the chiller upon delivery. This includes
the prime mover, custom controls, instruments, etc.
Special attention should be given to precautionary instruc-
tions emphasized in this book to avoid start-up difficulties.
These precautions are, in general, applicable to all sizes of
17DA centrifugal refrigeration machines.
Instructions for the prime mover if not included with Carrier
Air Conditioning instructions should be obtained from the
manufacturer.
Factory Test — Prior to shipment, the compressor is com-
pletely assembled and tested. Performance as to lubrication,
speed balance and general mechanical operation has been de-
termined to be satisfactory.
Job Data — The job consists of the following:
1. 17DA Start-Up, Operation and Maintenance Instructions
2. Job drawings showing:
a. Machine assembly
b. Machine wiring
c. Machine piping
d. Controls and related wiring
3. Manufacturer's Installation and Start-Up Instructions for:
a. Drive
b. Gear (if applicable)
Field-Supplied Tools — The following field-supplied
tools are need for installation and start up of the 17DA chiller:
• General mechanics tools
• Alignment tools consisting of a laser alignment instrument
or dial indicators and brackets and a low profile hydraulic
cylinder jack with hydraulic pump. These are used to
accomplish initial alignment and “hot check.”
• Digital volt-ohmmeter. This is used for instrument calibra-
tion. (Test voltage from analog ohmmeters can destroy RTD
[resistance temperature detector] sensors.)
• 4-20 mA signal generator. This is used for instrument cali-
bration including valve positioners.
• Portable vacuum pump capable of reaching dehydration
vacuum with a capacity of 5 cfm or greater used for chiller
evacuation and dehydration.
• Electronic or wet-bulb vacuum indicator for measurement
of vacuum level.
• Electronic leak detector suitable for non-chlorinated
refrigerants.
Inspect Machine Room — All installation work as
outlined in 17DA Installation Instructions book should be com-
pleted, and all construction debris must be removed from the
immediate area of the machinery prior to initial start-up of the
machine.
Drive Arrangement — Inspect drive mounting, loca-
tion, coupling, speed rating, etc., for agreement with job draw-
ings and specifications. Gear assembly (if used) must agree
with installation recommendations outlined in gear manufac-
turer's instructions.
Piping — Check the following piping installation locations:
1. Refrigerant pumpout system
2. External or auxiliary oil system
3. All bypass lines and valves
4. Turbine drive piping
a. Blowdown valves for each turbine stage installed
per manufacturer's instructions.
b. Trace all field installed piping to the turbine to
ensure that it conforms to the turbine manufactur-
ers installation instructions.
c. Steam supply line condensate traps must be prop-
erly installed to keep condensate out of the turbine.
A condensate drain should be located immediately
ahead of the trip and throttle valve so that all con-
densate may be cleared from the steam line imme-
diately before steam is admitted to the turbine.
d. Proper supports on steam supply and exhaust line
to prevent stress or strain on the turbine at operat-
ing temperatures.
e. Coupling alignment should be checked before and
after the steam pipe is heated and before the tur-
bine warm-up has begun. A change in alignment
indicates a possible pipe strain that must be
corrected.
5. Gas engine drive piping (check the following piping
for agreement with job blueprints):
a. Gas pressure reducing valves with shutoff valves.
b. Engine coolant piping with coolant thermostatic
valve installed so that water flows in direction
marked on valve.
c. Oil cooler package piping
d. Exhaust piping
NOTE: Exhaust piping is critical. Refer to drive manufac-
turer's recommendations for installation of exhaust piping.
Wiring — Refer to job wiring diagrams. All wiring must
agree with these drawings.
AUXILIARY EQUIPMENT WIRING — Check the
following:
1. Brine pump
2. Condenser water pump
3. Cooling tower fan motor
4. Auxiliary oil pump
5. Oil heater
6. Overload selections in all motor starters. Overload values
must agree with motor nameplate data.
TURBINE DRIVE WIRING — Check the following:
1. Turbine solenoid trip mechanism.
2. Auxiliary oil pump if used. Check pump starter for proper
voltage, amperage, and overload setting. Operate pump to
determine direction of rotation. Do not operate dry of oil.
3. Check job drawings for other electrical devices used with
the turbine. Ensure that their wiring agrees with the job
wiring blueprints.
GAS ENGINE DRIVE WIRING — All wiring must agree
with job wiring diagrams. Refer to engine manufacturer's in-
structions for starting techniques.
Safety Controls — Safety controls can be a combination
of electronic sensors supplying information to the programma-
ble logic controller (PLC), mechanical switches which supply
an open/closed signal to the PLC, and mechanical devices that
act directly on the equipment with follow-up action provided
by the PLC. The PLC is shown in Fig. 1. A turbine overspeed
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