74
11. Add oil (approximately 4.2 gal [15.9 L]) until it can be
seen at the lower edge of the oil sump sight glass. The
oil sight glass will not fill completely since a small
amount of gas will be trapped inside, even under vac-
uum conditions.
12. Open all 3 isolation valves (previously closed in
Step 3). Apply power to the controls and oil heater.
13. The oil level will rise once the refrigerant gets
absorbed into the oil.
TD FRAME 4 CHILLERS — Use the following procedures
to change the oil filter and/or oil on TD frame 4 chillers. Oil
can remain in TD frame 4 chillers when changing the oil filter.
Refer to Fig. 2B and 4.
Changing Oil Filter
1. Make sure the compressor is off and the disconnect for
the compressor starter is open.
2. Close both oil filter isolation valves. See Fig. 4.
3. Place a container underneath the oil filter assembly.
4. Slowly open the vent plug, located on top of the oil fil-
ter housing, to relieve pressure.
Do not remove the
plug
. When a Schrader valve is provided, use it to
relieve the pressure.
5. Remove the filter canisters by unscrewing the retainer
nut. The filter may now be removed and disposed of
properly.
6. Install new oil filter. Install the new O-ring. Tighten
the retainer nut.
7. Partially open the isolation valve located near the oil
separator. Bleed the excess air from the vent plug.
Once oil starts escaping from the vent plug, close the
isolation valve. Tighten the vent plug on top of the oil
filter housing.
8. If a Schrader valve is supplied, evacuate the oil filter
by connecting the vacuum pump to the Schrader valve.
Changing Oil
NOTE: A hand pump or portable electric oil pump will be
required to complete the following operation.
1. Transfer the refrigerant into the condenser (for vessel
that can be isolated) or storage tank.
2. When the chiller pressure equals a maximum of 5 psi
(34 kPa), drain the oil by opening the oil charging
valve, located on the bottom of the oil separator.
3. Change the oil filter as described in the Changing Oil
Filter section for TD frame 4 chillers.
4. Charge the oil separator with approximately 10 gal
(39 L) of oil. The oil level should be in the center of
the lower sight glass.
Oil Specification —
If oil is to be added, it must meet the
following Carrier specifications:
•
Carrier Part Number. . . . . . . . . . . . . . . . . . . . . . .PP23BZ104
•
Oil type . . . . . . . . . . . . . . . . . . . . Inhibited polyolester-based
synthetic compressor lubricant suitable for use
in screw compressors where high viscosity
and compatibility with HCFC-22 and HFC-134a
refrigerants is required.
•
ISO Viscosity Grade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
•
Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.981
•
Viscosity, cSt at 40 C (104 F) . . . . . . . . . . . . . . . . 210 to 230
cSt at 100 C (212 F) . . . . . . . . . . . . . . . . . 18 to 21
SSU at 100 F (38 C) . . . . . . . . . . . . . . . .1005 ± 45
SSU at 210 F (99 C) . . . . . . . . . . . . . . . . . . .91 ± 7
•
Floc Point (maximum). . . . . . . . . . . . . . . . . . . –90 F (–68 C)
•
Pour Point (maximum) . . . . . . . . . . . . . . . . . . . –6 F (–21 C)
•
Flash Point (minimum) . . . . . . . . . . . . . . . . . . 428 F (220 C)
•
Moisture Content (maximum). . . . . . . . . . . . . . . . . .100 ppm
•
Acid Number (maximum) . . . . . . . . . . . . 0.5 mg KOH/gram
•
Miscibility Range with HCFC-22. . . . . . . . . . . .–90 to 200 F
(–68 to 93 C)
with HFC-134a . . . . . . . . . . . . . .–4 to 180 F
(–2 to 82 C)
This oil (part number PP-23-BZ-104) may be ordered from
your local Carrier representative.
Oil Separator Coalescer
TC FRAME 1 AND 2 CHILLERS — The oil separator coa-
lescing element is replaceable and has an estimated life of
15 years. Proper maintenance procedures require the coalescer
to be changed approximately 100 hours after a major compres-
sor teardown or chiller overhaul.
TD FRAME 4 CHILLERS — TC frame 4 chillers do not
have a replaceable oil coalescer.
Refrigerant Filter/Drier —
A refrigerant filter/drier, lo-
cated on the motor cooling line should be changed once a year,
or as necessary, if filter condition indicates a need for less or
more frequent replacement. Change the filter with the chiller
pressure at 0 psig (0 kPa) by transferring the refrigerant to the
condenser vessel, (if isolation valves are present) or a storage
tank. A moisture indicator (dry eye) sight glass is located be-
yond this filter to indicate the volume of moisture in the refrig-
erant. If the moisture indicator indicates moisture, locate the
source of water immediately by performing a thorough leak
check.
Refrigerant Strainers (TC Frame 1 and 2 Chill-
ers Only) —
The oil reclaim system has two strainers. One
is located on the eductor suction line, and one on the condenser
gas line. Replace these strainers once per year, or as necessary
if strainer condition indicates a need for less or more frequent
replacement. Change these strainers with the cooler/compres-
sor vessel at 0 psig (0 kPa) by transferring the refrigerant
charge to a storage vessel or the condenser.
Inspect Refrigerant Float System —
Perform this
inspection every 5 years or when the condenser is opened for
service.
1. Transfer the refrigerant into the cooler vessel or into a
pumpout storage tank.
2. Remove the float access cover.
3. Clean the chamber and valve assembly thoroughly. Be
sure the valve moves freely. Ensure that all openings
are free of obstructions.
4. Examine the cover gasket and replace if necessary.
See Fig. 40 for a view of the float valve design. For linear
float valve designs, inspect the orientation of the float slide
pin. It must be pointed toward the bubbler tube for proper
operation.
Inspect Relief Valves and Piping —
The re-
lief valves on this chiller protect the system against the poten-
tially dangerous effects of overpressure. To ensure against
damage to the equipment and possible injury to personnel,
these devices must be kept in peak operating condition.
This product is hygroscopic. Containers should remain
tightly sealed in a clean and dry environment to prevent
moisture absorption from the air.
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