Carrier 19EF Series, Start Up & Operation Manual

Page: 3 / 72

CONTENTS (cont)
Page
• MODIFY EQUIPMENT CONFIGURATION
IF NECESSARY
• CHECK VOLTAGE SUPPLY
• PERFORM AN AUTOMATED
CONTROLS TEST
High Altitude Locations
. . . . . . . . . . . . . . . . . . . . . 44
Charge Refrigerant Into Machine
. . . . . . . . . . . . . 44
• TRIMMING REFRIGERANT CHARGE
INITIAL START-UP
. . . . . . . . . . . . . . . . . . . . . . . . . 45,46
Preparation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Manual Operation of the Guide Vanes
. . . . . . . . 45
Dry Run to Test Start-Up Sequence . . . . . . . . . . 45
Check Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
• IF ROTATION IS PROPER
• IF THE MOTOR ROTATION IS NOT CLOCKWISE
Check Oil Pressure and Compressor Stop
. . . . 46
Calibrate Motor Current Demand Setting
. . . . . 46
To Prevent Accidental Start-Up
. . . . . . . . . . . . . . 46
Check Machine Operating Condition
. . . . . . . . . 46
Instruct the Customer Operator . . . . . . . . . . . . . . 46
• COOLER-CONDENSER
• ECONOMIZER
• MOTOR COMPRESSOR ASSEMBLY
• MOTOR COMPRESSOR LUBRICATION SYSTEM
• CONTROL SYSTEM
• AUXILIARY EQUIPMENT
• DESCRIBE MACHINE CYCLES
• REVIEW MAINTENANCE
• SAFETY DEVICES AND PROCEDURES
• CHECK OPERATOR KNOWLEDGE
• REVIEW THE START-UP, OPERATION,
AND MAINTENANCE MANUAL
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . 47,48
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Prepare the Machine for Start-Up . . . . . . . . . . . . 47
To Start the Machine
. . . . . . . . . . . . . . . . . . . . . . . . 47
Check the Running System
. . . . . . . . . . . . . . . . . . 47
To Stop the Machine
. . . . . . . . . . . . . . . . . . . . . . . . 47
After Limited Shutdown
. . . . . . . . . . . . . . . . . . . . . 47
Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 47
After Extended Shutdown . . . . . . . . . . . . . . . . . . . 48
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . 48
Manual Guide Vane Operation . . . . . . . . . . . . . . . 48
Refrigeration Log
. . . . . . . . . . . . . . . . . . . . . . . . . . . 48
REFRIGERANT TRANSFER PROCEDURE . . . . . 48
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . 50
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . 50
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Removing Refrigerant
. . . . . . . . . . . . . . . . . . . . . . . 50
Adjusting the Refrigerant Charge
. . . . . . . . . . . . 50
Refrigerant Leak Testing
. . . . . . . . . . . . . . . . . . . . 50
Refrigerant Leak Rate
. . . . . . . . . . . . . . . . . . . . . . . 50
Test After Service, Repair, or Major Leak . . . . . 50
• REFRIGERANT TRACER
• TO PRESSURIZE WITH DRY NITROGEN
Page
Repair the Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . 50
Checking Guide Vane Linkage . . . . . . . . . . . . . . . 50
Trim Refrigerant Charge
. . . . . . . . . . . . . . . . . . . . . 50
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . 50,51
Check the Lubrication System . . . . . . . . . . . . . . . 50
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . 51-53
Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Inspect the Control Center . . . . . . . . . . . . . . . . . . . 51
Check Safety and Operating Controls
Monthly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Change Oil and Oil Filter
. . . . . . . . . . . . . . . . . . . . 51
Oil Specification
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Change Refrigerant Filter or Strainer . . . . . . . . . 52
Inspect Refrigerant Float System . . . . . . . . . . . . 52
Inspect Relief Valves and Piping . . . . . . . . . . . . . 52
Compressor Bearing and Gear Maintenance
. . 52
Inspect the Heat Exchanger Tubes
. . . . . . . . . . . 52
• COOLER
• CONDENSER
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Inspect the Starting Equipment . . . . . . . . . . . . . . 52
Check Pressure Transducers . . . . . . . . . . . . . . . . 53
Ordering Replacement Chiller Parts
. . . . . . . . . . 53
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . 53-71
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Checking the Display Messages
. . . . . . . . . . . . . 53
Checking Temperature Sensors
. . . . . . . . . . . . . . 53
• RESISTANCE CHECK
• VOLTAGE DROP
• CHECK SENSOR ACCURACY
• DUAL TEMPERATURE SENSORS
Checking Pressure Transducers . . . . . . . . . . . . . 53
• TRANSDUCER REPLACEMENT
Control Algorithms Checkout Procedure
. . . . . 54
Control Test
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Control Modules
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
• RED LED
• GREEN LEDs
Notes on Module Operation . . . . . . . . . . . . . . . . . . 63
Processor Module (PSIO) . . . . . . . . . . . . . . . . . . . . 64
• INPUTS
• OUTPUTS
Starter Management Module (SMM)
. . . . . . . . . . 64
• INPUTS
• OUTPUTS
Options Modules (8-Input)
. . . . . . . . . . . . . . . . . . . 64
Replacing Defective Processor Modules
. . . . . . 65
• INSTALLATION OF NEW PSIO MODULE
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INITIAL START-UP CHECKLIST FOR
19EF HERMETIC CENTRIFUGAL
LIQUID CHILLER
. . . . . . . . . . . . . . . . . . . CL-1-CL-12
3