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CONTENTS
Page
Inspect Water Piping ..........................50
Check Optional Pumpout Compressor Water
Piping
....................................50
Check Relief Devices
..........................50
Inspect Wiring
................................50
• CHECK INSULATION RESISTANCE
Motor Pre-Start Checks
........................51
External Gear Pre-Start Checks
.................51
Carrier Comfort Network Interface
...............53
Check Starter
.................................53
• MECHANICAL STARTERS
• SOLID-STATE STARTERS
Compressor Oil Charge
........................54
Power Up the Controls and
Check the Compressor Oil Heater
.............54
• SOFTWARE VERSION
Set Up Chiller Control Configuration
.............54
Input the Design Set Points
.....................54
Input the Local Occupied Schedule
(OCCPC01S)
................................54
Input Service Configurations
....................54
• PASSWORD
• INPUT TIME AND DATE
• CHANGE LID CONFIGURATION IF NECESSARY
• MODIFY CONTROLLER IDENTIFICATION IF
NECESSARY
• INPUT EQUIPMENT SERVICE PARAMETERS IF
NECESSARY
• MODIFY EQUIPMENT CONFIGURATION IF
NECESSARY
• CHECK VOLTAGE SUPPLY
• PERFORM AN AUTOMATED CONTROL TEST
Check Pumpout System Controls and Optional
Pumpout Compressor
........................56
High Altitude Locations
........................57
Charge Refrigerant Into Chiller
..................57
• TRIMMING REFRIGERANT CHARGE
INITIAL START-UP
...........................57-62
Preparation
..................................57
Manual Operation of the Guide Vanes
............58
Dry Run to Test Start-Up Sequence
..............58
Check Motor Rotation
.........................58
• INITIAL MOTOR START-UP
Disc Coupling Installation and Alignment
.........59
• IMPORTANT INFORMATION
Check Oil Pressure and Compressor Stop
........61
Calibrate Motor Current Demand Setting
..........61
To Prevent Accidental Start-Up
..................61
Hot Alignment Check
.........................61
Doweling
....................................61
Check Chiller Operating Condition
...............61
Instruct the Operator
..........................62
• COOLER-CONDENSER
• ECONOMIZER/STORAGE VESSEL
• PUMPOUT SYSTEM
• COMPRESSOR ASSEMBLY
• COMPRESSOR LUBRICATION SYSTEM
EXTERNAL GEAR LUBRICATION SYSTEM
• CONTROL SYSTEM
• AUXILIARY EQUIPMENT
• CHILLER CYCLES
• MAINTENANCE
• SAFETY DEVICES AND PROCEDURES
• CHECK OPERATOR KNOWLEDGE
• THIS MANUAL
OPERATING INSTRUCTIONS
..................62,63
Operator Duties
...............................62
Page
Prepare the Chiller for Start-Up .................62
Starting the Chiller
........................... 62
Check the Running System
.....................62
Stopping the Chiller
...........................62
After Limited Shutdown
........................63
Extended Shutdown
...........................63
After Extended Shutdown
......................63
Cold Weather Operation
........................63
Manual Guide Vane Operation
...................63
Refrigeration Log
.............................63
PUMPOUT AND REFRIGERANT TRANSFER
PROCEDURES
............................63-67
Preparation
..................................63
Operating the Optional Pumpout
Compressor
................................63
• READING REFRIGERANT PRESSURES
Transferring Refrigerant into the
Economizer/Storage Vessel
...................66
Transferring Refrigerant into
the Cooler/Condenser/Compressor Section
.....67
Return Chiller to Normal Operating
Conditions
.................................67
GENERAL MAINTENANCE
....................67-75
Refrigerant Properties
.........................67
Adding Refrigerant
............................67
Removing Refrigerant
.........................67
Adjusting the Refrigerant Charge
................67
Refrigerant Leak Testing
.......................67
Leak Rate
....................................67
Test After Service, Repair, or Major Leak
.........67
• REFRIGERANT TRACER
• TO PRESSURIZE WITH DRY NITROGEN
Repair the Leak, Retest, and Apply
Standing Vacuum Test
.......................68
Checking Guide Vane Linkage
..................68
Contact Seal Maintenance
......................68
• SEAL DISASSEMBLY
• SEAL REASSEMBLY
Chiller Alignment
.............................71
• ALIGNMENT METHODS
• PRELIMINARY ALIGNMENT
• NEAR FINAL ALIGNMENT
• FINAL ALIGNMENT
• HOT ALIGNMENT CHECK
• DOWELING
WEEKLY MAINTENANCE
.......................76
Check the Lubrication System
..................76
SCHEDULED MAINTENANCE
..................76-83
Service Ontime
...............................76
Inspect the Control Center
.....................76
Check Safety and Operating Controls Monthly
.....76
Changing the Oil Filters
........................76
• COMPRESSOR OIL FILTER
• EXTERNAL GEAR OIL FILTER
Oil Specifications
.............................77
Oil Changes
..................................77
• COMPRESSOR OIL
• EXTERNAL GEAR OIL
• MOTOR SLEEVE BEARING AND PUMPOUT
COMPRESSOR OIL
Inspect Refrigerant Float System
................78
Inspect Relief Valves and Piping
................78
Coupling Maintenance
........................78
Motor Maintenance
............................78
• CLEANLINESS
• SLEEVE BEARINGS
3