| 17/19EX |
| 50/60 Hz |
| Centrifugal Liquid Chillers |
® | with |
|
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 211 | Catalog No. | Form | Replaces: |
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
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
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
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.
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
Contents
List of Tables
List of Figures
Safety Considerations
Introduction
Abbreviations
17/19EX Machine Familiarization
Machine Identification Label
System Components
Cooler
Condenser
Control Center
Motor Starter
Utility Vessel
Contents
Refrigeration Cycle
Motor/Oil Refrigeration Cooling Cycle
Hermetic Machines (19 Series) Lubrication Cycle
Summary
Details
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)
Oil Heater Contactor (1C)
Oil Pump Contactor (2C)
Hot Gas Bypass Contactor Relay (3C) (Optional)
Control Transformers
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
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
Auto. Restart After Power Failure
Water/Brine Reset
Demand Limit Control, Option (Requires Optional
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
Temperature Control During Ice Build
Termination of Ice Build
Return to
Attach to Network Device Control
Attaching to Other CCN Modules
Service Operation
To Log On
To Log Off
Holiday Scheduling
Contents
Local
Shutdown Sequence
Automatic Soft Stop Amps Threshold
Chilled Water Recycle Mode
Safety Shutdown
Before Initial
Job Data Required
Equipment Required
Using the Utility Vessel and Pumpout System
Remove Shipping Packaging
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
Carrier Comfort Network Interface
Contents
Check Starter
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
Preparation
Manual Operation of the Guide Vanes
Dry Run to Test
Check Rotation
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
Hot Alignment Check for
Check Machine Operating Condition
Instruct the Customer Operator
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
Operating Instructions
Operator Duties
Prepare the Machine for
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
Seal Disassembly
Seal Reassembly
Machine Alignment
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
Procedure
Motor Maintenance
Cleanliness
Sleeve Bearings
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
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
Replacing Defective Processor Modules
Installation of New PSIO Module
17/19EX Physical Data and Wiring Schematics
Compressor Fits and Clearances
Initial
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 | — | Pressure — Temperature (F) |
Table 5B | — | 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
B.Timing Out or Timed Out
C.In Recycle Shutdown
D.
E.Normal or
F.
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.
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 —
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List of Figures |
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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 | — | |||
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 | |||
|
| 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
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
Figure 33 — Pumpout Unit Wiring Schematic (19EX Shown) Figure 34 — Optional Pumpout Compressor
Figure 35 — Electronic Vane Actuator Linkage
Figure 36 — Compressor Contact Seal
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
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 —
Figure 57 — Electronic PIC Controls Wiring Schematic — Hermetic Machine
Figure 58 — Electronic PIC Controls Wiring Schematic —
Figure 59 — Machine Power Panel, Starter Assembly,
and Motor Wiring Schematic
Figure 60 — Hermetic Drive — Power Panel with
Figure 61 — Hermetic Drive — Power Panel with Motor Cooling Solenoid
Figure 62 — Open Drive — Power Panel