FORM 160.72-O1 (810)
JOHNSON CONTROLS
134
SECTION 5 - SYSTEM COMMISSIONING
GENERAL
The compressor driveline supplied with each liquid
chilling unit will vary due to application preferences
and requirements. Refer to the driveline manufactur-
er’s starting and operating instructions for procedures
that must be completed before the unit can be started.
PRE-START COMPRESSOR CHECK
The following paragraphs describe the procedures pri-
or to starting and operating a TURBOMASTER Com-
pressor.
OIL HEATER
If the heater is de-energized during a
shutdown period, it must be energized for
12 hours prior to starting the compressor
or the compressor oil charge must be re-
placed with new oil.
Before actually starting the compressor, the fol-1.
lowing steps should be carefully checked.
(a) Check the compressor oil level (See
CHECKING THE OIL LEVEL).
(b) Add new oil, if necessary.
(c) Completely open all shutoff water valves
to the oil cooler. A full flow of water is
required through the oil cooler at all times
during starting and operation to inhibit
foaming in the oil.
(d) Check the compressor oil sump tempera-
ture. The oil temperature must be a mini-
mum of 10°F above the condenser satu-
ration temperature (50°F if the unit has
been shut down for less than 30 minutes)
before the unit will be allowed to start.
(e) Open or adjust all shutoff valves neces-
sary for the operation of the hot gas by-
pass and liquid injection systems and oil
return systems
(f) Verify the compressor pre-rotation vanes are
closed to unload the motor during starting.
CHILLER STARTING AND STOPPING PROCEDURE
CHECKING THE OIL LEVEL
Two oil level sight glasses are located on the oil sump
end of the compressor. During operation the oil level
should be visible in approximately the middle of the
lower sight glass or ¼ of the upper sight glass, but
should not fill the upper sight glass.
If the oil level is excessively high, the compressor may
tend to lose some oil under starting conditions or con-
ditions of rapidly changing load. In this case, oil may
be drained from the compressor oil charging valve,
while the unit is running.
Rapid withdrawal of oil will cause jet
pump cavitation.
If the oil level is too low, pump cavitation and low
oil pressure may occur. The machine will then shut
down automatically and oil should be added to the
compressor.
When the unit has been shut down for a prolonged pe-
riod oil level above the top sight glass is normal.
UNIT START-UP
The following step-by-step procedure should be used
to start-up the system (Refer to Operating Instructions
(Form 160.72-O1) for OptiView
TM
Control Center Op-
erating Instructions):
1. Set the Pre-Rotation Vanes Control to AUTO.
2. Set the Hot Gas Control to AUTO.
3. Set the Interstage Valve Control to AUTO.
4. Set the Subcooler Level Valve Control to
AUTO.
5. Select the desired Control Source (LOCAL or
ANALOG REMOTE).
6. Set the Leaving Chilled Liquid Temperature
Setpoint.
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