Carrier HFC-134a User Manual

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53170002-01 Printed in U.S.A. Form 17DA-3SS Pg 1 3-09 Replaces: 17DA-2SS,
17DA-3SO
Start-Up, Operation, and Maintenance Instructions
SAFETY CONSIDERATIONS
Centrifugal liquid chillers are designed to provide safe and
reliable service when operated within design specifica-
tions. 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 chiller instructions as
well as those listed in this guide.
DO NOT VENT refrigerant relief valves within a building. Outlet
from rupture disc or relief valve must be vented outdoors in accor-
dance with the latest edition of ANSI/ASHRAE 15 (American
National Standards Institute/American Society of Heating, Refrigera-
tion, and Air Conditioning Engineers). The accumulation of refriger-
ant in an enclosed space can displace oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/ASHRAE
15, especially for enclosed and low overhead spaces. Inhalation of
high concentrations of vapor is harmful and may cause heart irregular-
ities, unconsciousness, or death. Misuse can be fatal. Vapor is heavier
than air and reduces the amount of oxygen available for breathing.
Product causes eye and skin irritation. Decomposition products are
hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a chiller 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 pres-
sures on the equipment nameplate.
DO NOT USE air for leak testing. Use only refrigerant or dry
nitrogen.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed and
functioning before operating any chiller.
RISK OF INJURY OR DEATH by electrocution. High voltage is
present on motor leads even though the motor is not running when a
solid-state or inside-delta mechanical starter is used. Open the power
supply disconnect before touching motor leads or terminal
s.
D
O NOT WELD OR FLAMECUT any refrigerant line or vessel until
all refrigerant (liquid and vapor) has been removed from chiller.
Traces of vapor should be displaced with dry air or nitrogen and the
work area should be well ventilated. Refrigerant in contact with an
open flame produces toxic gases.
DO NOT USE eyebolts or eyebolt holes to rig chiller 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 pan-
els, 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.
LOCK OPEN AND TAG electrical circuits during servicing. IF
WORK IS INTERRUPTED, confirm that all circuits are deenergized
before resuming work.
AVOID SPILLING liquid refrigerant on skin or getting it into the
eyes. USE SAFETY GOGGLES. Wash any spills from the skin with
soap and water. If liquid refrigerant 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 over pressure can result. When it is necessary to heat
refrigerant, use only warm (110 F [43 C]) water.
DO NOT REUSE disposable (nonreturnable) cylinders or attempt to
refill them. It is DANGEROUS AND ILLEGAL. When cylinder is
emptied, evacuate remaining gas pressure, loosen the collar and
unscrew and discard the valve stem. DO NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding refrigerant to
the chiller. The introduction of the wrong refrigerant can cause dam-
age or malfunction to this chiller.
Operation of this equipment with refrigerants other than those
cited herein should comply with ANSI/ASHRAE 15 (latest edition).
Contact Carrier for further information on use of this chiller with other
refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while
chiller is under pressure or while chiller is running. Be sure pressure is
at 0 psig (0 kPa) before breaking any refrigerant connection.
CAREFULLY INSPECT all relief devices, rupture discs, and other
relief devices AT LEAST ONCE A YEAR. If chiller operates in a
corrosive atmosphere, inspect the devices at more frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief
device when corrosion or build-up of foreign material (rust, dirt, scale,
etc.) is found within the valve body or mechanism. Replace the
device.
DO NOT install relief devices 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.
DO NOT STEP on refrigerant lines. Broken lines can whip about and
release refrigerant, causing personal injury.
DO NOT climb over a chiller. Use platform, catwalk, or staging. Fol-
low safe practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or
move inspection covers or other heavy components. Even if compo-
nents are light, use mechanical equipment when there is a risk of slip-
ping or losing your balance.
BE AWARE that certain automatic start arrangements CAN
ENGAGE THE STARTER, TOWER FAN, OR PUMPS. Open the
disconnect ahead of the starter, tower fans, or pumps.
USE only repair or replacement parts that meet the code requirements
of the original equipment.
DO NOT VENT OR DRAIN waterboxes containing industrial brines,
liquid, gases, or semisolids without the permission of your process
control group.
DO NOT LOOSEN waterbox cover bolts until the waterbox 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 corro-
sion, rust, 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.
DANGER
WARNING
CAUTION
17DA
Open-Drive Centrifugal Liquid Chillers
50/60 Hz
HFC-134a

Carrier HFC-134a Specifications

General

Brand	Carrier
Model	HFC-134a
Category	Chiller
Language	English

Summary

SAFETY CONSIDERATIONS

INTRODUCTION

General

Overview of the instruction book's scope and applicability to 17DA chillers.

Factory Test

Details the compressor testing performed prior to shipment.

Job Data

Lists the components that constitute the job.

Field-Supplied Tools

Lists essential tools required for installation and start-up.

Inspect Machine Room

Instructions for verifying the condition of the installation site.

Drive Arrangement

Guidance on inspecting the drive mounting and specifications.

Piping

Checks for various piping installations, including refrigerant and steam.

Wiring

Checks for wiring of auxiliary equipment, turbine drive, and gas engine drive.

Safety Controls

Describes safety controls, including electronic and mechanical types.

START-UP

Pre-Operation Settings

Steps to complete before starting the compressor for the first time.

Drive Operation

Instructions for operating the drive unit according to manufacturer guidelines.

Initial Refrigerant Charge

Procedure for charging the machine with the initial refrigerant amount.

Initial Compressor Operation

Steps for the first operation of the compressor after initial charge.

START-UP

Adjust Refrigerant Charge

Process for fine-tuning the refrigerant charge for optimal performance.

Hot Alignment Check and Doweling

Performing alignment checks after the machine reaches operating temperature.

Operational Testing

Procedures for testing machine operation and determining heat balance.

Instruct Customer Operator

Ensuring the operator understands all operating and maintenance procedures.

OPERATING PROCEDURES

Log Sheets

Guidelines for recording operational data and identifying trends.

Operator Duties

Responsibilities and tasks for the machine operator.

Start Machine

OPERATION

Manual Operation

Controlling the machine manually via the PLC.

Cold Weather Operation

Specific procedures for operating the chiller in cold weather conditions.

Stop Machine

Steps to safely shut down the compressor and associated systems.

Extended Shutdown

Procedures for preparing the machine for long-term storage.

Pumpout System Operation

Lubrication

Details on the lubrication of the pumpout compressor.

Control Description

Explanation of the pumpout unit's control system and safety features.

Control Setting

Specifications for setting the pumpout unit's safety switches.

Machine and Storage Tank Evacuation

Remove Air After Opening Chiller To Atmosphere

Transfer Refrigerant Charge

Pressurize Machine and Storage Tank

Distill Refrigerant Charge

MAINTENANCE

Weekly Maintenance

Regular checks performed weekly for machine upkeep.

Yearly Maintenance

Scheduled maintenance tasks to be performed annually.

Yearly Maintenance

Check Oil Level

Procedure for checking the oil level in the machine's sight glass.

Check Purge Frequency

Verifying the operating frequency of the purge system.

Water in Purge Water Chamber

Discussion on water detection in refrigerants and purge systems.

Check/Calibrate Water Temperature Sensors

Procedure for verifying and calibrating water temperature sensors.

Check Refrigerant Low-Pressure Cutout

Testing the low-pressure safety cutout function.

Check Condenser High-Pressure Cutout

Testing the high-pressure safety cutout for the condenser.

Check Auxiliary Oil Pump Control

Verifying the operation of the auxiliary oil pump.

Check Starters and VFDs

Reviewing starter and VFD manufacturer instructions for specific checks.

Compressor Bearing Maintenance

Key aspects of maintaining compressor bearings through proper lubrication.

General Maintenance

Inspect Cooler Tubes

Inspection and cleaning of cooler tubes after the first season.

Inspect Condenser Tubes

Inspection and cleaning of condenser tubes, especially if pressure is high.

Inspect Purge Recovery Unit

Maintenance procedures for the purge recovery unit.

Refrigerant Level

Importance of correct refrigerant charge and its impact on performance.

Leak Testing

Methods for testing the machine for refrigerant leaks.

Check Leakage Rate

Procedure for verifying the machine's vacuum loss rate.

Breaking Vacuum

Using dry gas to break vacuum to prevent corrosion.

Preparing Machine for Charging Refrigerant

Steps to prepare the machine after servicing for refrigerant charging.

Chiller Dehydration

REMOVING REFRIGERANT

Water Treatment

Recommendations for water treatment in condensing water systems.

Clearances

Guide to clearances for compressor components.

Gear and Drive

References for gear and drive maintenance requirements.

Pumpout System

Reference to Carrier Service Instructions for pumpout system maintenance.

GENERAL DATA

Machine Nameplate

Location and meaning of information on the machine nameplate.

Refrigerant Properties

Properties and safety of HFC-134a refrigerant.

Relief Valve Assembly

Location and purpose of the relief valve assembly.

System Components

Overview of the main components of the refrigeration system.

Controls

Drive

Information on the prime mover that powers the compressor.

Refrigeration Cycle

Explanation of the basic refrigeration cycle components and operation.

Oil Cycle

Description of the oil system, including pumps, filters, and regulators.

Purge Cycle

TROUBLESHOOTING

Compressor Will Not Start

Diagnosing reasons why the compressor fails to start.

Compressor Surge

Understanding and correcting compressor surge conditions.

Insufficient Load To Maintain Stability

Addressing issues where low load causes instability.

Condenser Water Temperature Is Too High

Troubleshooting high condenser water temperatures.

Fouled Tubes In Either Heat Exchanger

Identifying and resolving issues with fouled heat exchanger tubes.

Low Water Flow In Either Heat Exchanger

Diagnosing problems related to insufficient water flow.

Variable Speed Drive Operating Too Slowly

Troubleshooting VSDs operating too slowly for capacity needs.

Chilled Water Temperature Too High

Identifying causes for high chilled water temperatures.

High Condenser Pressure

Diagnosing and resolving high condenser pressure issues.

Cooler Waterbox Division Plate Gasket Out Of Place

Identifying and fixing a misplaced cooler waterbox division plate gasket.

Leaving Chilled Water Sensor Defective

Replacing a defective leaving chilled water sensor.

Excessive Water Flow Through The Cooler

Checking for excessive water flow through the cooler.

Excessive Difference Between Chilled Water Temperature And Refrigerant Temperature

Addressing large temperature differences between water and refrigerant.

Controls

Overview of safety and operating controls within the system.

Chilled Water Temperature Too Low With Compressor Running

Chilled Water Set Point In The Plc Set Too Low

Correcting a chilled water set point that is too low.

Low Cooling Load

Addressing issues when the cooling load is too low for stability.

Inaccurate Thermistor

Identifying and correcting inaccurate thermistor readings.

Sensors Outside Of The Chiller Controls Are Inaccurate

Checking calibration of external sensors against chiller controls.

Guide Vanes Not Closing

Troubleshooting guide vanes that are not closing properly.

Refrigerant Temperature Too Low

Cooler Waterbox Division Plate Gasket Out Of Place

Fixing a misplaced cooler waterbox division plate gasket.

Low Refrigerant Charge

Identifying low refrigerant charge as a cause of low refrigerant temperature.

Leaving Chilled Water Temperature Fluctuates

Capacity Control In Plc Needs Adjusting

Adjusting capacity controls within the PLC for stability.

Guide Vanes Moving Erratically

Troubleshooting erratic movement of guide vanes.

Condenser Pressure Too High

Low Water Flow Or High Water Temperature

Identifying low flow or high temperature as causes of high condenser pressure.

Oil Pressure Too Low

Plugged Filters

Checking for plugged filters as a cause of low oil pressure.

Pressure Regulator Set Too Low

Adjusting pressure regulators when set too low.

Faulty Pressure Regulator

Identifying and replacing a faulty pressure regulator.

Faulty Pump Or Motor

Diagnosing and replacing faulty pumps or motors.

Oil Pressure Too High

Oil Reservoir Temperature Too Low

Oil Reservoir Temperature Too High

Fouled Or Obstructed Oil Cooler Tubes

Temperature Of Oil Returning From Bearings Too High

Compressor Discharge Gas Temperature Too High

Extremely Low Load

Addressing high discharge temperatures during extremely low load conditions.

Low Cooler Refrigerant Level

Identifying low cooler refrigerant level as a cause.

Excessive Travel Of Diffuser Throttling Ring

Determining diffuser throttling ring travel through disassembly.

Controls

Safety Controls

Description of various safety controls and their functions.

Controls

Job Specific Safety Functions

Information on safety functions specific to the job installation.

Operating Controls

Description of the primary control devices for machine operation.

PLC - Programmable Logic Controller

Fig. 12 - Machine Configuration

Fig. 12 - Machine Configuration (cont)