Carrier 17EX User Manual

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17EX Externally Geared Centrifugal Liquid Chillers 50/60 Hz 1500 to 2250 Nominal Tons (5280 to 7910 kW)

Start-Up,Operation, and Maintenance Instructions

SAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design speci- ®cations. 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 accordance with the latest edition of ASHRAE (American Society of Heating, Refrigeration, and Air Conditioning Engineers) 15. 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 chiller for any purpose. Oxygen gas reacts violently with oil, grease, and other common substances.

NEVER EXCEED speci®ed 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.

DO NOT WELD OR FLAME CUT 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 ¯ame produces toxic gases.

DO NOT USE eyebolts or eyebolt holes to rig chiller sections or the entire assembly.

DO NOT work on high-voltageequipment unless you are a quali- ®ed 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 or solidstate components.

LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTERRUPTED, con®rm 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 ¯ame 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 re®ll 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 damage or malfunction to this chiller.

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 chiller with other refrigerants.

DO NOT ATTEMPT TO REMOVE ®ttings, 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-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.

RUN WATER PUMPS when removing, transferring, or charging refrigerant.

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

DO NOT climb over a chiller. 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.

PERIODICALLY INSPECT all valves, ®ttings, 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.

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

Book

2

 

PC 211

Catalog No. 531-721

Printed in U.S.A.

Form 17EX-1SS

Pg 1

7-97

Replaces: New

Tab

5d

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONTENTS

Page Page

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . .1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

17EX CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . .5

Chiller Identi®cation Label . . . . . . . . . . . . . . . . . . . . . . .5

System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Control Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Motor Starter (Purchased Separately) . . . . . . . . . . . . . . 5

Economizer/Storage Vessel . . . . . . . . . . . . . . . . . . . . . .5

REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . .5-8

OIL COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Compressor Oil Cooling . . . . . . . . . . . . . . . . . . . . . . . . .8

External Gear Oil Cooling . . . . . . . . . . . . . . . . . . . . . . . .8

LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . .8,9

Compressor Lubrication Cycle . . . . . . . . . . . . . . . . . . .8

External Gear Lubrication Cycle . . . . . . . . . . . . . . . . . .9

STARTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-43 De®nitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

·ANALOG SIGNAL

·DIGITAL SIGNAL

·VOLATILE MEMORY

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

PIC System Components . . . . . . . . . . . . . . . . . . . . . . .12

·PROCESSOR/SENSOR INPUT/OUTPUT MODULE (PSIO)

·STARTER MANAGEMENT MODULE (SMM)

·LOCAL INTERFACE DEVICE (LID)

·SIX-PACKRELAY BOARD

·EIGHT-INPUTMODULES

·FOUR-IN/TWO-OUT(4-IN/2-OUT)MODULE

·OIL HEATER CONTACTOR (1C)

·COMPRESSOR OIL PUMP CONTACTOR (2C) AND GEAR OIL PUMP CONTACTOR (5C)

·HOT GAS BYPASS CONTACTOR RELAY (3C) (Optional)

·OIL AUXILIARY RELAY (4C)

·CONTROL TRANSFORMERS (T1-T4)

·CONTROL AND OIL HEATER VOLTAGE SELECTOR (S1)

·OIL DIFFERENTIAL PRESSURE/POWER SUPPLY

MODULE

LID Operation and Menus . . . . . . . . . . . . . . . . . . . . . . .16

·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 . . . . . . . . . . . . . . . . . . . . . . . . . .32

·CAPACITY CONTROL

·ENTERING CHILLED WATER CONTROL

·DEADBAND

·PROPORTIONAL BANDS AND GAIN

·DEMAND LIMITING

·CHILLER TIMERS

·OCCUPANCY SCHEDULE

Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

· SHUNT TRIP

Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . .33

Auxiliary Compressor Oil Pump Control . . . . . . . . . . 33

Auxiliary Gear Oil Pump Control . . . . . . . . . . . . . . . . 33

Shaft Seal Oil Control . . . . . . . . . . . . . . . . . . . . . . . . . .33

Ramp Loading Control . . . . . . . . . . . . . . . . . . . . . . . . .33

Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

High Discharge Temperature Control . . . . . . . . . . . . . 35

Oil Sump Temperature Control . . . . . . . . . . . . . . . . . .35

Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . . . .36

Spare Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Spare Alarm Contacts . . . . . . . . . . . . . . . . . . . . . . . . .36

Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . .36

Condenser Freeze Prevention . . . . . . . . . . . . . . . . . . .36

Tower-Fan Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Auto. Restart After Power Failure . . . . . . . . . . . . . . . . 36

Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Demand Limit Control, Option (Requires Optional

8-Input Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Surge Prevention Algorithm . . . . . . . . . . . . . . . . . . . .37

Surge Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

·COMMON POINT SENSOR INSTALLATION

·CHILLER COMMUNICATION WIRING

·LEAD/LAG OPERATION

·FAULTED CHILLER OPERATION

·LOAD BALANCING

·AUTO. RESTART AFTER POWER FAILURE

Ice Build Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

·ICE BUILD INITIATION

·START-UP/RECYCLEOPERATION

·TEMPERATURE CONTROL DURING ICE BUILD

·TERMINATION OF ICE BUILD

·RETURN TO NON-ICEBUILD OPERATIONS

Attach to Network Device Control . . . . . . . . . . . . . . . 41

·

ATTACHING TO OTHER CCN MODULES

 

Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42

·

TO ACCESS THE SERVICE SCREENS

 

·

TO LOG OFF

 

·

HOLIDAY SCHEDULING

 

START-UP/SHUTDOWN/RECYCLESEQUENCE. . . 43-45

Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Automatic Soft Stop Amps Threshold . . . . . . . . . . . . 44

Chilled Water Recycle Mode . . . . . . . . . . . . . . . . . . . .44

Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . .45-57

Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Using the Economizer/Storage Vessel and Pumpout

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Remove Shipping Packaging . . . . . . . . . . . . . . . . . . .45

·MOTOR

·EXTERNAL GEAR

Motor Electrical Connection . . . . . . . . . . . . . . . . . . . .45

Motor Auxiliary Devices . . . . . . . . . . . . . . . . . . . . . . . .46

Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . .46

Tighten All Gasketed Joints and Guide Vane

Shaft Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . . .46

Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Leak Test the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . .49

Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

2

CONTENTS

Page 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-STATESTARTERS

Compressor Oil Charge . . . . . . . . . . . . . . . . . . . . . . . .54

Power Up the Controls and

Check the Compressor Oil Heater . . . . . . . . . . . . . 54

· SOFTWARE VERSION

Set Up Chiller Control Con®guration . . . . . . . . . . . . . 54

Input the Design Set Points . . . . . . . . . . . . . . . . . . . . .54

Input the Local Occupied Schedule

(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Input Service Con®gurations . . . . . . . . . . . . . . . . . . . .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 TestStart-UpSequence. . . . . . . . . . . . . . 58

Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . .58

· INITIAL MOTORSTART-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

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 Speci®cations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

CONTENTS (cont)

Page Page

Motor Handling/Rigging . . . . . . . . . . . . . . . . . . . . . . . .81

Motor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

External Gear Storage . . . . . . . . . . . . . . . . . . . . . . . . .81

·SHORT-TERMSTORAGE (Indoors)

·LONG-TERMSTORAGE (Indoors)

·EXTENDED DOWNTIME

Compressor Bearing Maintenance . . . . . . . . . . . . . . . 82

External Gear Maintenance . . . . . . . . . . . . . . . . . . . . .82

Inspect the Heat Exchanger Tubes . . . . . . . . . . . . . . . 82

·COOLER

·CONDENSER

Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Inspect the Starting Equipment . . . . . . . . . . . . . . . . .83

Check Pressure Transducers . . . . . . . . . . . . . . . . . . .83

Pumpout System Maintenance . . . . . . . . . . . . . . . . . .83

·OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE

·PUMPOUT SAFETY CONTROL SETTINGS

Ordering Replacement Chiller Parts . . . . . . . . . . . . . . 83

·MOTOR REPLACEMENT PARTS

·EXTERNAL GEAR REPLACEMENT PARTS

TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . .83-99

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

Checking the Display Messages . . . . . . . . . . . . . . . . .84

Checking Temperature Sensors . . . . . . . . . . . . . . . . .84

·RESISTANCE CHECK

·VOLTAGE DROP

·CHECK SENSOR ACCURACY

·DUAL TEMPERATURE SENSORS

Checking Pressure Transducers . . . . . . . . . . . . . . . .84

·OIL DIFFERENTIAL PRESSURE/POWER SUPPLY MODULE CALIBRATION

·TROUBLESHOOTING TRANSDUCERS

·TRANSDUCER REPLACEMENT

Control Algorithms Checkout Procedure . . . . . . . . . 85

Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

·RED LEDs

·GREEN LEDs

Notes on Module Operation . . . . . . . . . . . . . . . . . . . .96 Processor/Sensor Input/Output Module (PSIO) . . . .97

·INPUTS

·OUTPUTS

Starter Management Module (SMM) . . . . . . . . . . . . . . 97

·INPUTS

·OUTPUTS

Options Modules (8-Input) . . . . . . . . . . . . . . . . . . . . .98

Four-In/Two-Out Module . . . . . . . . . . . . . . . . . . . . . . .98

·INPUTS

·OUTPUTS

Replacing Defective Processor Modules . . . . . . . . . 98

· INSTALLATION OF NEW PSIO MODULE

PHYSICAL DATA AND WIRING SCHEMATICS . . . . 99-114

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115-120

INITIAL START-UPCHECKLIST FOR 17EX EXTERNALLY GEARED CENTRIFUGAL LIQUID CHILLER. . . . . . . . . . . . . . . . . . . . . . . . . . CL-1 to CL-12

4

INTRODUCTION

Before initial start-upof the 17EX unit, those involved in thestart-up,operation, and maintenance should be thoroughly familiar with these instructions and other necessary job data. This book is outlined so that you may become familiar with the control system before performingstart-upprocedures. Procedures in this manual are arranged in the sequence required for proper chillerstart-upand operation.

This unit uses a microprocessor controlled system. Do not short or jumper between terminations on circuit boards or modules; control or board failure may result.

Be aware of electrostatic discharge (static electricity) when handling or making contact with circuit boards or module connections. Always touch a chassis (grounded) part to dissipate body electrostatic charge before working inside the control center.

Use extreme care when handling tools near boards and when connecting or disconnecting terminal plugs. Circuit boards can easily be damaged. Always hold boards by the edges and avoid touching components and connections.

This equipment uses, and can radiate, radio frequency energy. If not installed and used in accordance with the instruction manual, it may cause interference to radio communications. It has been tested and found to comply with the limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever measures may be required to correct the interference.

Always store and transport replacement or defective boards in anti-staticshipping bag.

ABBREVIATIONS

Frequently used abbreviations in this manual include:

CCN

Ð

Carrier Comfort Network

CCW

Ð

Counterclockwise

CHW

Ð

Chilled Water

CHWR

Ð

Chilled Water Return

CHWS

Ð

Chilled Water Supply

CW

Ð Clockwise

ECW

Ð

Entering Chilled Water

ECDW

Ð

Entering Condenser Water

EMS

Ð

Energy Management System

HGBP

Ð Hot Gas Bypass

I/O

Ð

Input/Output

LCD

Ð

Liquid Crystal Display

LCDW

Ð

Leaving Condenser Water

LCW

Ð

Leaving Chilled Water

LED

Ð

Light-EmittingDiode

LID

Ð

Local Interface Device

OLTA

Ð

Overload Trip Amps

PIC

Ð

Product Integrated Control

PSIO

Ð

Processor Sensor Input/

RLA

 

Output Module

Ð Rated Load Amps

SCR

Ð

Silicon Control Recti®er

SMM

Ð

Starter Management Module

TXV

Ð

Thermostatic Expansion Valve

17EX CHILLER FAMILIARIZATION

Chiller Identi®cation Label (Fig. 1) Ð The identi®cation label is located on the right side of the chiller control center panel. The label contains information on model number, refrigerant charge, rated voltage, etc.

System Components (Fig. 2) Ð The components include the cooler and condenser heat exchangers in separate vessels, compressor, compressor and gear lubrication packages, control center, speed increaser economizer/storage vessel, motor, and starter. The compressor drive consists of an external gear (speed increaser) and an electric motor. All connections from pressure vessels have external threads to enable each component to be pressure tested with a threaded pipe cap during factory assembly.

Cooler Ð This vessel (also known as the evaporator) is located underneath the condenser, next to the economizer/ storage vessel. The cooler is maintained at lower temperature and pressure so that evaporating refrigerant can remove heat from water ¯owing through its internal tubes.

Condenser Ð The condenser operates at a higher temperature and pressure than the cooler and has water ¯owing through its internal tubes in order to remove heat from the refrigerant.

Compressor Ð This component maintains system temperature and pressure differences and moves the heatcarrying refrigerant from the cooler to the condenser.

Control Center Ð The control center is the user interface for controlling the chiller and regulates the chiller capacity as required to maintain proper leaving chilled water temperature. The control center:

·registers cooler, condenser, and lubricating system pressures

·shows chiller operating and alarm shutdown conditions

·records the total chiller operating hours and how many hours the chiller has been running

·sequences chiller start, stop, and recycle under microprocessor control

·provides access to other CCN (Carrier Comfort Network) devices

Motor Starter (Purchased Separately) Ð The starter allows the proper start and disconnect of electrical energy for the compressor-motor, oil pump, oil heater, and control panels.

Economizer/Storage Vessel Ð During normal operation, this vessel functions as an economizer, returning flash gas to the second stage of the compressor and increasing the efficiency of the refrigeration cycle. During periods of shutdown and service, the economizer/storage vessel can serve as a storage tank for the refrigerant.

REFRIGERATION CYCLE (Fig. 3)

The 17EX chiller can be used to chill either water or brine. The data in this book applies to either application. Applications using corrosive brines may require using special tubes, tubesheet, and waterbox materials which are special order items.

5

LEGEND

NIH Ð Nozzle-In-Head

*Any available cooler size can be combined with any available condenser size.

NOTE: For details on motor size designations, see below.

ASME

ARI (Air Conditioning

`U' STAMP

and Refrigeration

 

Institute)

 

PERFORMANCE

 

CERTIFIED

 

(60 Hz Only)

 

Fig. 1 Ð Model Number Identi®cation

6

40

1

2

3

4

5

6

7

8

9

10

11

12

13

14

39

38

37

36

35

15

 

34

33

32

31

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

 

 

 

 

 

LEGEND

 

 

 

 

 

 

 

 

 

 

 

 

 

1

Ð Condenser

 

 

 

 

 

 

22

Ð Oil Drain and Charging Valve

 

 

 

 

2

Ð Cooler Suction Pipe

 

 

 

 

 

23

Ð Oil Heater (Hidden)

 

 

 

 

 

 

3

Ð Compressor Suction Elbow

 

 

 

 

24

Ð Compressor Oil Pump

 

 

 

 

 

4

Ð Guide Vane Actuator

 

 

 

 

 

25

Ð Compressor Oil Cooler/Filter

 

 

 

 

5

Ð Condenser Discharge Pipe

 

 

 

 

26

Ð Local Interface Display Control Panel

 

 

6

Ð Compressor Discharge Elbow

 

 

 

 

27

Ð Cooler Relief Valves (Behind Compressor,

 

7

Ð Two-StageCompressor

 

 

 

 

 

 

Hidden)

 

 

 

 

 

 

 

 

 

8

Ð Economizer Gas Line to Compressor

 

 

 

28

Ð Economizer Storage Vessel

 

 

 

 

9

Ð Compressor Housing Access Cover

 

 

 

29

Ð Economizer/Storage Vessel Relief Valves

 

10

Ð High-SpeedCoupling (Hidden)

 

 

 

 

30

Ð Pumpout Unit

 

 

 

 

 

 

 

 

11

Ð External Gear (Speed Increaser)

 

 

 

31

Ð Cooler

 

 

 

 

 

 

 

 

 

12

Ð Low-SpeedCoupling (Hidden)

 

 

 

 

32

Ð High Side Float Box Cover

 

 

 

 

13

Ð Open-DriveCompressor Motor

 

 

 

 

33

Ð Cooler Waterbox Drain

 

 

 

 

 

14

Ð Compressor Motor Terminal Box

 

 

 

34

Ð Take-ApartConnections

 

 

 

 

 

15

Ð Low-SideFloat Box Cover

 

 

 

 

35

Ð Cooler Marine Waterbox

 

 

 

 

 

16

Ð Gear Oil Pump

 

 

 

 

 

36

Ð Cooler Waterbox Vent

 

 

 

 

 

17

Ð Gear Oil Cooler/Filter

 

 

 

 

 

37

Ð Condenser Waterbox Drain

 

 

 

 

18

Ð Refrigerant Charging/Service Valve

 

 

 

38

Ð Refrigerant Liquid Line to Economizer/

 

19

Ð Refrigerant Liquid Line to Cooler

 

 

 

 

 

Storage Vessel

 

 

 

 

 

 

 

20

Ð Power Panel

 

 

 

 

 

39

Ð Condenser Marine Waterbox

 

 

 

 

21

Ð Oil Level Sight Glasses (2)

 

 

 

 

40

Ð Condenser Waterbox Vent

 

 

 

 

17EX WITH EXTERNAL GEAR (SPEED INCREASER)

Fig. 2 Ð Typical 17EX Chiller Components

7

The chiller compressor continuously draws large quantities of refrigerant vapor from the cooler at a rate determined by the amount of guide vane opening. This compressor suction reduces the pressure within the cooler, allowing the liquid refrigerant to boil vigorously at a fairly low temperature (typically 38 to 42 F [3 to 6 C]).

The liquid refrigerant obtains the energy needed to vaporize by removing heat from the water or brine in the cooler tubes. The cold water or brine can then be used in air conditioning and/or other processes.

After removing heat from the water or brine, the refrigerant vapor enters the ®rst stage of the compressor, is compressed, and ¯ows into the compressor second stage. Here it is mixed with ¯ash-economizergas and is further compressed.

Compression raises the refrigerant temperature above that of the water ¯owing through the condenser tubes. When the warm (typically 98 to 102 F [37 to 40 C]) refrigerant vapor comes into contact with the condenser tubes, the relatively cool condensing water (typically 85 to 95 F [29 to 35 C]) removes some of the heat, and the vapor condenses into a liquid.

The liquid refrigerant passes through an ori®ce into the FLASC chamber. The coolest condenser water ¯ows through the FLASC and allows a lower saturated temperature and pressure. Part of the entering liquid refrigerant will ¯ash to vapor once it has passed through the FLASC ori®ce, thereby cooling the remaining liquid. The vapor is then recondensed by the condenser water ¯owing through the FLASC chamber.

The subcooled liquid refrigerant drains into a high-sidevalve chamber that meters the refrigerant liquid into a ¯ash economizer chamber. Pressure in this chamber is intermediate between condenser and cooler pressures. At this lower pressure, some of the liquid refrigerant ¯ashes to gas, further cooling the remaining liquid. The ¯ash gas, having absorbed heat, is returned directly to the compressor second stage. Here it is mixed with discharge gas that is already compressed by the®rst-stageimpeller. Since the ¯ash gas has to pass through only half the compression cycle to reach condenser pressure, there is a savings in power.

The cooled liquid refrigerant in the economizer is metered through the low-sidevalve chamber, reducing the refrigerant pressure. Pressure in the cooler is lower than in the economizer. Some of the liquid ¯ashes as it passes through the low side ¯oat valve. The cycle is now complete.

OIL COOLING CYCLE

Compressor Oil Cooling Ð The compressor oil is water cooled. Water ¯ow through the oil cooler is manually adjusted by a plug valve to maintain an operating temperature at the reservoir of approximately 145 F (63 C). An oil heater in the reservoir helps to prevent oil from being diluted by the refrigerant. The heater is controlled by the PIC (Product Integrated Control) and is energized when the oil temperature is outside the operating temperature range of 150 to 160 F (66 to 71 C).

External Gear Oil Cooling Ð The external gear oil is also water cooled. Water ¯ow through the gear oil cooler is manually adjusted by a plug valve to maintain an operating temperature of approximately 130 F (54 C). If so equipped, an oil heater in the reservoir helps to maintain the oil temperature under cold ambient operating conditions. The heater is controlled by an internal thermostat.

LUBRICATION CYCLE

Compressor Lubrication Cycle (Refer to item numbers shown in Fig. 4) Ð The compressor oil pump and oil reservoir are contained in the compressor base. Oil is pumped through an oil cooler and ®lter to remove heat and any foreign particles. A portion of the oil is then directed to the shaft-end bearing and the shaft seal. The balance of the oil lubricates the thrust and journal bearings and the thrust end seal. The bearing and transmission oil returns directly to the reservoir to complete the cycle. Contact-seal oil leakage, however, is collected in an atmospheric ¯oat chamber to be pumped back to the main reservoir as the oil accumulates.

Oil may be charged into the compressor oil reservoir (Item 8) through a charging valve (Item 6) which also functions as an oil drain. If there is refrigerant in the chiller, however, a hand pump will be required for charging at this connection.

An oil-chargingelbow (Item 3) on theseal-oilreturn chamber allows oil to be added without pumping. Theseal-oilreturn pump (Item 4) automatically transfers the oil to the main reservoir. Sight glasses (11) on the reservoir wall permit observation of the oil level.

A motor-drivenoil pump (Item 10) discharges oil to an oil cooler/®lter (Item 16) at a rate and pressure controlled by an oil regulator (Item 10). The differential oil pressure (bearing supply versus oil reservoir) is registered on the control panel.

Water ¯ow through the oil cooler is manually adjusted by a plug valve (Item 17) to maintain the oil at an operating temperature of approximately 145 F (63 C). During shutdown, the oil temperature is also maintained at 150 to 160 F (65 to 71 C) by an immersion heater (Item 7) in order to minimize absorption of refrigerant by the oil.

Upon leaving the cooler section of the oil cooler/®lter, the oil is ®ltered (Item 15) and a portion is directed to the sealend bearing (Item 1) and the shaft seal (Item 2). The remainder lubricates thrust (Item 14) and journal bearings (Item 12). Thrust bearing temperature is indicated on the PIC controls. Oil from both circuits returns by gravity to the reservoir.

The shaft seal of the open compressor drive must be kept full of lubrication oil, even when the chiller is not operating, to prevent loss of refrigerant.

If the chiller is not operating and the oil pump has not operated during the last 12 hours, the control system automatically runs the oil pump for one minute in order to keep the contact seal ®lled with oil.

IMPORTANT: If the control power is to be deenergized for more than one day, the chiller refrigerant should be pumped over to the economizer/storage vessel.

8

LEGEND

TXV Ð Thermostatic Expansion Valve Liquid

Liquid/Vapor

Vapor

*The FX compressor and the gear have a water cooled oil cooler.

Fig. 3 Ð Refrigeration, Cycle

External Gear Lubrication Cycle (Refer to Item numbers shown in Fig. 5) Ð Oil reservoir is contained in the gear base. The external gear oil pump is mounted below the gear with the cooler/®lter. Oil is pumped through an oil cooler/®lter to remove heat and any foreign particles. A portion of the oil is directed to the gear bearings and gear mesh spray. The remainder is bypassed to the sump. The bearing and transmission oil returns directly to the reservoir to complete the cycle.

Oil may be charged into the external gear oil reservoir as described in the section, External Gear Pre-StartChecks, page 51. Observe the oil level in the oil level glass (Item 4) on the reservoir wall.

A motor driven oil pump (Item 10) discharges oil to the oil cooler/®lter (Item 12). The pump has an internal pressure regulator to protect the pump in the event of an obstruction downstream. Water ¯ow through the oil cooler is manually adjusted by a plug valve (Item 14) to maintain the oil at an operating temperature of approximately 130 F (54 C).

Upon leaving the cooler section (Item 13) of the oil cooler/ ®lter, the oil is ®ltered (Item 11) and is directed to the pressure control valve (Item 7). Before entering the pressure control valve, the oil pressure (Item 16) and temperature (Item 8) are monitored by the PIC.

A portion of the oil then lubricates the gear bearings (Item 2). Another portion is directed through an ori®ce (Item 5) to the gear mesh spray (Item 3) to lubricate the gear mesh (Item 1) during operation. Oil from both circuits returns by gravity to the reservoir.

STARTERS

All starters, whether supplied by Carrier or the customer, must meet Carrier Starter Speci®cation Z-375.This speci- ®cation can be obtained from a Carrier Sales Representative. The purpose of this speci®cation is to ensure the compatibility of the starter and the chiller. Many styles of compatible starters are available, includingsolid-state ,auto-transformer,full-voltage,and, in the case oflow-voltagemain power supply,wye-deltaclosed transition.

9

SHAFT DISPLACEMENT

 

 

& BRG TEMP. CUTOUT

 

1

CONNECTIONS

COAST DOWN

SEAL-END

 

 

RESERVOIRS

BEARING

13

 

 

COMPRESSOR OIL

 

 

PRESSURE LEAVING

 

 

FILTER LINE

 

 

12

 

2

 

SHAFT

JOURNAL

 

 

SEAL

BEARING

 

 

 

 

14

 

 

THRUST

 

 

BEARING

CHECK VALVE

 

 

15

 

 

OIL FILTER

 

 

16

 

 

OIL COOLER/

 

 

FILTER

TO PIC

 

 

 

17

CONTROLLER

3

 

PLUG VALVE

8

OIL CHARGING

 

MAIN OIL

 

ELBOW

 

RESERVOIR

 

11

 

 

 

 

4

 

 

 

 

PUMP, SEAL

SIGHT

 

 

 

 

 

 

 

 

OIL RETURN

GLASSES

 

 

 

 

 

10

TO POWER

9

7

6

5

 

PANEL

 

 

 

OIL PUMP

OIL

OIL

DRAIN &

COMPRESSOR OIL

 

& PRESS. REGULATOR

 

THERMISTOR

HEATER

CHARGING VALVE

SUCTION PRESSURE

Fig. 4 Ð 17EX Compressor Lubrication Cycle

10