Carrier 17-19EX User Manual
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17/19EX

 

50/60 Hz

 

Centrifugal Liquid Chillers

®

with HFC-134a

 

Start-Up,Operation, and Maintenance Instructions

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

PC 211

Catalog No. 531-715

9-95

Form 17/19EX-1SS

Replaces: 19EX-1SS

Copyright © Carrier Corporation 1995

Safety Considerations

Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design specifications. When operating this equipment, use good judgement 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 machine instructions as well as those listed in this guide.

DANGER ! DANGER

DO NOT VENT refrigerant relief valves within a building. Outlet from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ASHRAE 15 (Safety Code for Mechanical Refrigeration). The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation. PROVIDE adequate ventilation in accordance with ASHRAE 15, especially for enclosed and low overhead spaces. Inhalation of high concentrations of vapor is harmful and may cause heart irregularities, 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 machine 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 pressures 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 machine.

WARNING ! WARNING

DO 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 machine sections or the entire assembly.

DO NOT work on high-voltageequipment unless you are a qualified electrician. DO NOT WORK ON electrical components, including control panels, switches, starters, or oil heater until you are sure ALL POWER IS OFF and no residual voltage can leak from capacitors orsolid-statecomponents.

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 any 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 overpressure can result. When 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

WARNING ! WARNING

gas pressure, loosen the collar and unscrew and discard the valve stem. DO NOT INCINERATE.

CHECK THE REFRIGERANT TYPE before adding refrigerant to the machine. The introduction of the wrong refrigerant can cause damage or malfunction to this machine.

Operation of this equipment with refrigerants other than those cited herein should comply with ASHRAE-15(latest edition). Contact Carrier for further information on use of this machine with other refrigerants.

DO NOTATTEMPT TO REMOVE fittings, covers, etc., while machine is under pressure or while machine 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 machine 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-upof 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.

CAUTION ! CAUTION

DO NOT STEP on refrigerant lines. Broken lines can whip about and cause personal injury.

DO NOT climb over a machine. Use platform, catwalk, or staging. Follow safe practices when using ladders.

USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move inspection covers or other heavy components. Even if components are light, use such equipment when there is a risk of slipping or losing your balance.

BE AWARE that certain automatic start arrangements CAN ENGAGE THE STARTER. Open the disconnect ahead of the starter in addition to shutting off the machine or pump.

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 permission of your process control group.

DO NOT LOOSEN waterbox cover bolts until the waterbox has been completely drained.

DOUBLE-CHECKthat 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.

CAUTION ! CAUTION

PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks, or damage.

PROVIDE A DRAIN connection in the vent line near each pressure relief device to prevent a build-upof condensate or rain water.

Contents

List of Tables

List of Figures

Safety Considerations

Introduction

Abbreviations

17/19EX Machine Familiarization

Machine Identification Label

System Components

Cooler

Condenser

Motor-Compressor

Control Center

Motor Starter

Utility Vessel

Contents

Refrigeration Cycle

Motor/Oil Refrigeration Cooling Cycle

Hermetic Machines (19 Series) Lubrication Cycle

Summary

Details

Open-Drive Machines (17 Series) Lubrication Cycle

Summary

Details

Starters

Controls

Definitions

Analog Signal

Digital Signal

Volatile Memory

Contents

General

PIC System Components

Processor Module (PSIO)

Starter Management Module (SMM)

Local Interface Device (LID)

6-Pack Relay Board

8-Input Modules

Oil Heater Contactor (1C)

Oil Pump Contactor (2C)

Hot Gas Bypass Contactor Relay (3C) (Optional)

Control Transformers (T1-T4)

Control and Oil Heater Voltage Selector (S1) Oil Differential Pressure/Power Supply Module

Contents

LID Operation and Menus

General

Alarms and Alerts

LID Default Screen Menu Items

Menu Structure

To View or Change Point Status

Override Operations

To View or Change Time Schedule Operation To View and Change Set Points

Service Operation

PIC System Functions

Capacity Control

Entering Chilled Water Control

Deadband

Proportional Bands and Gain

Contents

Demand Limiting

Machine Timers

Occupancy Schedule

Safety Controls

Shunt Trip

Default Screen Freeze

Motor Cooling Control (Hermetic Motors Only) Auxiliary Oil Pump Control (Open-Drive Machines Only) Shaft Seal Oil (Open Drive Machines Only)

Ramp Loading Control

Capacity Override

High Discharge Temperature Control

Oil Sump Temperature Control

Oil Cooler

Remote Start/Stop Controls

Contents

Spare Safety Inputs

Spare Alarm Contacts

Condenser Pump Control

Condenser Freeze Prevention

Tower-Fan Relay

Auto. Restart After Power Failure

Water/Brine Reset

Demand Limit Control, Option (Requires Optional 8-Input Module) Surge Prevention Algorithm

Surge Protection

Lead/Lag Control

Common Point Sensor Installation

Machine Communication Wiring

Lead/Lag Operation

Faulted Chiller Operation

Contents

Load Balancing

Auto. Restart After Power Failure

Ice Build Control

Ice Build Initiation

Start-Up/Recycle Operation

Temperature Control During Ice Build

Termination of Ice Build

Return to Non-Ice Build Operations

Attach to Network Device Control

Attaching to Other CCN Modules

Service Operation

To Log On

To Log Off

Holiday Scheduling

Contents

Start-Up/Shutdown/Recycle Sequence

Local Start-Up

Shutdown Sequence

Automatic Soft Stop Amps Threshold

Chilled Water Recycle Mode

Safety Shutdown

Before Initial Start-Up

Job Data Required

Equipment Required

Using the Utility Vessel and Pumpout System

Remove Shipping Packaging

Open-Drive Motor Electrical Connection

Open-Drive Motor Auxiliary Devices

Open Oil Circuit Valves

Contents

Torque All Gasketed Joints

Check Machine Tightness

Refrigerant Tracer

Leak Test Machine

Standing Vacuum Test

Machine Dehydration

Inspect Water Piping

Check Optional Pumpout Compressor Water Piping

Check Relief Devices

Inspect Wiring

Check Insulation Resistance (Hermetic Motor)

Check Insulation Resistance (Open-Drive Motor)

Open-Drive Motor Pre-Start Checks

Carrier Comfort Network Interface

Contents

Check Starter

Mechanical-Type Starters

Solid-State Starters

Oil Charge

Power Up the Controls and Check the Oil Heater

Software Version

Set Up Machine Control Configuration

Input the Design Set Points

Input the Local Occupied Schedule (OCCPC01S)

Input Service Configurations

Password

Input Time and Date

Change LID Configuration If Necessary

Modify Controller Identification If Necessary

Input Equipment Service Parameters If Necessary

Contents

Modify Equipment Configuration If Necessary

Check Voltage Supply

Perform an Automated Control Test

Check Pumpout System Controls and Optional Pumpout Compressor

High Altitude Locations

Charge Refrigerant into Machine

Trimming Refrigerant Charge

Initial Start-Up

Preparation

Manual Operation of the Guide Vanes

Dry Run to Test Start-Up Sequence

Check Rotation (Open-Drive Motor)

Check Rotation (Hermetic Motor)

If Rotation Is Proper

If the Motor Rotation Is Not Clockwise

Contents

Check Oil Pressure and Compressor Stop

Calibrate Motor Current Demand Setting

To Prevent Accidental Start-Up

Hot Alignment Check for Open-Drive Machines Doweling for Open-Drive Machines

Check Machine Operating Condition

Instruct the Customer Operator

Cooler-Condenser

Utility Vessel

Pumpout System

Motor Compressor Assembly

Motor Compressor Lubrication System

Control System

Auxiliary Equipment

Describe Machine Cycles

Contents

Review Maintenance

Safety Devices and Procedures

Check Operator Knowledge

Review the Start-Up, Operation, and Maintenance Manual

Operating Instructions

Operator Duties

Prepare the Machine for Start-Up

To Start the Machine

Check the Running System

To Stop the Machine

After Limited Shutdown

Extended Shutdown

After Extended Shutdown

Cold Weather Operation

Manual Guide Vane Operation

Refrigeration Log

Contents

Pumpout and Refrigerant Transfer Procedures

Preparation

Operating the Optional Pumpout Compressor

To Read Refrigerant Pressures

Transferring Refrigerant from Normal Operation into the Utility Vessel

Transferring Refrigerant from Normal Operation into the

Cooler/Condenser/Compressor Section

Return Refrigerant to Normal Operating Conditions

General Maintenance

Refrigerant Properties

Adding Refrigerant

Removing Refrigerant

Adjusting the Refrigerant Charge

Refrigerant Leak Testing

Leak Rate

Contents

Test After Service, Repair, or Major Leak

Refrigerant Tracer

To Pressurize with Dry Nitrogen

Repair the Leak, Retest, and Apply Standing Vacuum Test Checking Guide Vane Linkage

Contact Seal Maintenance (Open-Drive Machines)

Seal Disassembly

Seal Reassembly

Machine Alignment (Open-Drive Machines)

Alignment Methods

Preliminary Alignment

Near Final Alignment

Final Alignment

Hot Alignment Check

Doweling

Contents

Weekly Maintenance

Check the Lubrication System

Scheduled Maintenance

Service Ontime

Inspect the Control Center

Check Safety and Operating Controls Monthly

Changing Oil Filter

19EX Compressors

FA Style Compressors

Oil Specification

Oil Changes

To Change the Oil

Refrigerant Filter

Oil Reclaim Filter

Contents

Inspect Refrigerant Float System

Inspect Relief Valves and Piping

Coupling Maintenance (Open-Drive Machines)

Procedure

Motor Maintenance (Open-Drive Machines)

Cleanliness

Sleeve Bearings

Open-Drive Motor Handling/Rigging

Open-Drive Motor Storage

Compressor Bearing and Gear Maintenance

Inspect the Heat Exchanger Tubes

Cooler

Condenser

Water Leaks

Water Treatment

Contents

Inspect the Starting Equipment

Check Pressure Transducers

Pumpout System Maintenance

Optional Pumpout Compressor Oil Charge

Pumpout Safety Control Settings

Ordering Replacement Chiller Parts

Open-Drive Motor Renewal Parts

Troubleshooting Guide

Overview

Checking the Display Messages

Checking Temperature Sensors

Resistance Check

Voltage Drop

Check Sensor Accuracy

Dual Temperature Sensors

Contents

Checking Pressure Transducers

Oil Differential Pressure/Power Supply Module Calibration

Troubleshooting Transducers

Transducer Replacement

Control Algorithms Checkout Procedure

Control Test

Control Modules

Red LED

Green LEDs

Notes on Module Operation

Processor Module (PSIO)

Inputs

Outputs

Contents

Starter Management Module (SMM)

Inputs

Outputs

Options Modules (8-Input)

Replacing Defective Processor Modules

Installation of New PSIO Module

17/19EX Physical Data and Wiring Schematics

Compressor Fits and Clearances

Initial Start-Up Checklist for 17/19EX Centrifugal Liquid Chiller

Contents

List of Tables

Table 1 — Major PIC Components and Panel Locations

Table 2 — LID Screens

Example 1 — Status01 Display Screen

Example 2 — Status02 Display Screen

Example 3 — Status03 Display Screen

Example 4 — Setpoint Display Screen

Example 5 — Configuration (Config) Display Screen Example 6 — Lead/Lag Configuration Display Screen Example 7 — Service1 Display Screen

Example 8 — Service2 Display Screen

Example 9 — Service3 Display Screen

Example 10 — Maintenance (Maint01) Display Screen Example 11 — Maintenance (Maint02) Display Screen Example 12 — Maintenance (Maint03) Display Screen Example 13 — Maintenance (Maint04) Display Screen

Contents

Table 3

— Protective Safety Limits and Control Settings

Table 4

— Capacity Overrides

Table 5A

HFC-134a

Pressure — Temperature (F)

Table 5B

HFC-134a

Pressure — Temperature (C)

Table 6

— Recommended Torque

Table 7

— Control Test Menu Functions

Table 8

— LID Primary and Secondary Messages and Custom Alarm/

 

Alert Messages with Troubleshooting Guides

A.Shutdown with ON/OFF/RESET-OFF

B.Timing Out or Timed Out

C.In Recycle Shutdown

D.Pre-Start Alerts

E.Normal or AUTO.-RESTART

F.Start-Up Failures

G.Compressor Jumpstart and Refrigerant Protection

Contents

Table 8 — LID Primary and Secondary Messages and Custom Alarm/ Alert Messages with Troubleshooting Guides (Continued)

H.Normal Run with Reset, Temperature, Or Demand

I.Normal Run Overrides Active (Alerts)

J.Out-of-Range Sensor Failures

K.Machine Protect Limit Faults

L.Machine Alerts

M.Spare Sensor Alert Messages

N.Other Problems/Malfunctions

Table 9A —

Thermistor Temperature (F) vs Resistance/Voltage Drop

Table 9B —

Thermistor Temperature (C) vs Resistance/Voltage Drop

Table 10

17/19EX Heat Exchanger, Economizer/Storage Vessel,

 

 

Piping, and Pumpout Unit Weights

Table 11

Additional Condenser Weights

Table 12

Compressor/Motor/Suction Elbow Weights

Table 13

Additional Cooler Weights

Contents

Table 14 — Marine Waterbox Cover Weights Table 15 — NIH Waterbox Cover Weights Table 16 — Auxiliary Systems, Electrical Data

Table 17 — Open-Drive Compressor Fits and Clearances Table 18 — Hermetic Compressor Fits and Clearances

 

 

 

Contents

 

List of Figures

 

 

 

 

 

Figure 1

17/19EX Identification

Figure 2

Typical 17EX Installation

Figure 3

Typical 19EX Installation

Figure 4

Refrigerant, Motor Cooling, and Oil Cooling Cycles

Figure 5

Hermetic Compressor Lubrication System (EX Compres-

 

 

sor Shown)

Figure 6

Open-Drive (17 Series) Lubrication Cycle

Figure 7

17EX Controls and Sensor Locations

Figure 8

19EX Controls and Sensor Locations

Figure 9

Control Center (Front View); Shown with Options Module

Figure 10 —

Control Sensors (Temperature)

Figure 11 —

Control Sensors (Pressure Transducer, Typical)

Figure 12 —

Power Panel without Options (Open-Drive Machine

 

 

Shown)

Contents

Figure 13 — Power Panel with Options (Hermetic Machine Shown) Figure 14 — LID Default Screen

Figure 15 — LID Service Screen

Figure 16 — 17/19EX Menu Structure

Figure 17 — 17/19EX Service Menu Structure

Figure 18 — Example of Point Status Screen (Status01) Figure 19 — Example of Time Schedule Operation Screen Figure 20 — Example of Set Point Screen

Figure 21 — 17/19EX Hot Gas Bypass/Surge Prevention Figure 22 — 17/19EX with Default Metric Settings

Figure 23 — Example of Attach to Network Device Screen Figure 24 — Example of Holiday Period Screen

Figure 25 — Control Sequence

Figure 26 — Typical Wet-Bulb Type Vacuum Indicator

Contents

Figure 27 — Shipping Bolt on Open Drive Motor

Figure 28 — 17/19EX Leak Test Procedures

Figure 29 — Dehydration Cold Trap

Figure 30 — Correct Motor Rotation

Figure 31 — Refrigeration Log

Figure 32 — Pumpout Arrangement and Valve Number Locations (12-ft Vessel Shown)

Figure 33 — Pumpout Unit Wiring Schematic (19EX Shown) Figure 34 — Optional Pumpout Compressor

Figure 35 — Electronic Vane Actuator Linkage

Figure 36 — Compressor Contact Seal (Open-Drive Machines) Figure 37 — Checking Preliminary Alignment

Figure 38 — Measuring Angular Misalignment in Elevation Figure 39 — Measuring Angular Misalignment on Brackets Figure 40 — Alignment Formula

Contents

Figure 41 — Adjusting Angular Misalignment in Plan Figure 42 — Correcting Parallel Misalignment Figure 43 — Alignment Check — Assembled Coupling Figure 44 — Removing the Oil Filter

Figure 45 — Typical Float Valve Arrangement

Figure 46 — Lifting Open-Drive Motor

Figure 47 — Controls for Optional Pumpout Compressor Figure 48 — Oil Differential Pressure/Power Supply Module Figure 49 — PSIO Module LED Locations

Figure 50 — LID Module (Rear View) and LED Locations Figure 51 — Processor (PSIO) Module

Figure 52 — Starter Management Module (SMM) Figure 53 — Options Module

Figure 54 — Model Number Nomenclature for Compressor Size (SeeFigure 1 also)

Contents

Figure 55 — Open-Drive Compressor Fits and Clearances Figure 56 — Hermetic Compressor Fits and Clearances

Figure 57 — Electronic PIC Controls Wiring Schematic — Hermetic Machine

Figure 58 — Electronic PIC Controls Wiring Schematic — Open-Drive Machine

Figure 59 — Machine Power Panel, Starter Assembly,

and Motor Wiring Schematic

Figure 60 — Hermetic Drive — Power Panel with Water-Cooled Oil Cooler

Figure 61 — Hermetic Drive — Power Panel with Motor Cooling Solenoid

Figure 62 — Open Drive — Power Panel