Carrier 17-19EX User Manual
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
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.
Carrier Corpor ation 1995
©
DANGER
DO NOT VENT refrigerant relief valves within a building. Outlet from rupture disc
or r elief v alve must be ve nte d outdoor s in accordanc e wit h the lat e st e dition of
ASHRAE 15 (Safety Code for Mechanical Refrigeration). The accumulation of
ref rigerant in an enclos ed space can displ ace oxygen and cause asphyxi at ion.
PR OVIDE adequate ventilation in accordan ce with ASHRAE 15, especial ly for
enclosed and low overhead spaces. Inhalation of high concentrations of vapor is
harmful an d may cause heart irregu larities, unconsci ou snes s, or death . Misuse
can be fat al. V apor is heavier t han air and reduc es t he 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 NO T VALVE O FF any safe t y device.
BE SURE that all pressure relief devices are properly installed and functioning
befor e ope r ati ng an y mac hine.
!
DANGER
WARNING
DO NO T W E LD OR FLAM E CUT any refrigerant li ne or vessel until al l refri gerant
(
liquid and vapor
placed with dry air or nitrogen and the work area should be well ventilated.
erant 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-voltage equipment unless you are a qualified electrician.
DO NOT WORK ON electrical components, including control panels, switches,
start ers, or o il heater un t il you are su re ALL POW E R IS OFF and n o residual voltage ca n l eak from capaci t ors or so li d-state compo nents.
LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTERRUP TED, con f irm that all circui t s are deenergized befo re resuming work.
AVOID S PILLI NG li quid ref r ige r an t on s ki n o r ge t ting i t into the e yes . U S E S A FETY
GOGGLES. Wash any spi lls from the skin wi t h soap and water. If any en t ers 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 ref rigerant , u se 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
) has been removed from chiller. Traces of vapor should be dis-
!
WARNING
Refrig-
.
WARNING
gas pr essure, loosen the collar and un screw and dis card the valve stem . DO NOT
INCI NE RATE .
CHECK THE REFRIGERANT TYPE before adding refrigerant to the machine. The
introduction of the wrong refrigerant can cause damage or malfunction to this
machine.
Oper a tion of t hi s eq uipment with r e fri ge ra nts othe r tha n those c ite d he r ei n s ho uld
comp ly with AS HRAE-15 ( lates t edi t ion). Con t act Carrier for further informati on
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
brea king an y ref rigerant con nection.
CAREFULLY INSPECT all relief devices, rupture discs, and other relief devices A T
LEAST ONCE A YEAR. If machine operates in a corrosive atmosphere, inspect the
devi ces at mo re f requen t in t ervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief device when corrosion or build-up of foreign material (rust, dirt, scale, etc.) is found within the valve
body or mechanism. Replace the device.
DO NO T i ns t all reli ef devices in ser ies or bac kwards.
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.
!
WARNING
CAUTION
DO NOT STEP on refrigerant lines. Broken lines can whip about and cause personal i nj ury.
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 t hat cer t ain auto mat ic star t arrangements CAN ENGA GE THE
STARTER. Open the disconnect
the machine or pump.
USE only repai r or repl acement parts th at meet the co de requirement s 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.
DOU B LE- C HEC K that co upl ing nu t wr e nc he s, di al indica t or s, or o t he r ite m s ha ve
been remove d b ef ore rotat ing any shafts.
DO NO T LOOSEN a pa c ki ng gland nu t be for e c he ck in g t h at the nut ha s a pos itive
thread enga gement.
!
CAUTION
ah ea d o f
the starter in addition to shutting off
CAUTION
PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks,
or da mage .
PROVIDE A DRAIN connection in the vent line near each pressure relief device to
prevent a build-up of condensate or rain water.
!
CAUTION
Contents
List of Tables
List of Figures
Safety Considerations
Introduction
Abbreviations
17/19EX Machine Familiarization
Machine Identification Label
System C omponents
Cooler
Condenser
Moto r-Co m pr e ss o r
Control Center
Moto r S tarte r
Utility Vessel
Contents
Refrigeration Cycle
Motor/Oil Ref r ige r ati on Co oli ng Cy c le
Hermeti c M achine s ( 19 S eries ) Lu brication Cycle
Summary
Deta ils
Open-Dri ve Mach in es (17 Se ries) Lub rica t io n Cycle
Summary
Deta ils
Starter s
Controls
Definitions
Analo g Signal
Digit al Signal
Volatile Memory
General
PIC System Components
Pr ocessor Module (PSIO )
Starter Management Module (SMM)
Loca l Interface De vice ( LID)
6-Pack Relay Board
8-Input Modules
Oil Heater Contactor (1C)
Oil Pump Contactor (2C)
Hot Gas Bypa ss Contactor Relay (3C) (Opti onal)
Control Transformers (T1-T4)
Control and Oil Heater Volt age Sel ecto r (S1)
Oil Differential Pressure/Power Supply Module
Contents
LID Operation and Menus
General
Alar m s and Alerts
LID Defa ult Screen Menu I tems
Menu Structure
To View or Cha nge Poi nt S tatus
Override Operations
To View or Cha nge Time Schedule Opera tion
To View and Change Set Points
Service Operation
PIC System Funct ions
Capacity Control
Enteri ng Chilled Water Contro l
Contents
Deadband
Proportional Bands and Gain
Contents
Dema nd Limiting
Machine Timers
Occupancy Schedule
Safety Controls
Shunt Trip
Def a u lt Scr een Fr eeze
Moto r Cooling Control (Herme tic Motors Only)
Auxiliary Oil Pump Control (Open-Drive Machines Only)
Shaft Seal Oil (Open Drive Machines Only)
Ramp Loading Control
Capacity Ov erride
High Discharge Temperature Cont r ol
Oil Sump Temperature Control
Oil Cooler
Remote Start/ St op Contr ol s
Contents
Spare Safety Inputs
Spa re Al ar m Con t ac ts
Condenser Pump Control
Condenser Freeze Pr evention
Tower-Fan Relay
Auto. Restart After Power Failure
Water/Br ine Reset
Demand Limit Control, Option (Requi res Optional 8-Inp ut Module)
Surge Prevention Algor ithm
Surge Protection
Lead/Lag Control
Common Point Sensor Installation
Machi ne Communicati on Wir i ng
Lead/Lag Operation
Faulte d Chi ller Operation
Contents
Load Balancing
Auto. Restar t After Power Failure
Ice Build Control
Ice Build Initiation
Start-Up/Recycle Operation
Tempe rature Control Du ring Ice Build
Termination of Ice Build
Retu rn to Non-I ce Build Operations
Attach to Network De vice Contro l
Attachi ng to Other CCN Modules
Service Operation
To Log On
To Log Off
Holida y Scheduling
Contents
Start-Up/Shutdown/Recycle Sequence
Local Star t -Up
Shutdown Sequence
Automatic Soft St op Amps Threshold
Chilled Water Recycle Mode
Safety Shutdown
Before Initial Start-Up
Job Data Required
Equipment Requi r ed
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
Ref rigerant Tracer
Leak Test Machine
Standing Vacuum Te st
Machine Dehydration
Inspect Water Piping
Check Optional Pumpout Compress or Wat er P iping
Check Relief Devices
Inspect Wiring
Check Insulation Resistance (Hermetic Motor)
Check Insulation Resistance (Open-Drive Motor)
Open-Drive Motor Pre-Start Checks
Carrie r Comfort Ne twork Inte rface
Contents
Check Starter
Mechanical-T ype Star ters
Solid-State Starters
Oil Charge
Power Up the Controls and Check the Oil Heater
Softwa re Ver sio n
Set Up Machine Control Configurat ion
Input the Design Set P oi n ts
Input the Local Occupied Schedule (OCCPC01S)
Input Service Configurations
Password
Input Time and Date
Change LID Config ur ation If Necessa r y
Modify Controller Identi fi cati on If Necessa r y
Input Equipment Servi ce Pa r ameters If Necess ary
Modify Equipment Configuration If Necessary
Check V oltage Supply
Perform an Automated Control Test
Check Pumpout System Controls and Optional Pumpout Compr es sor
High Altitude Loca ti ons
Charg e Refriger ant into Machine
Trimmi ng Refrigerant Cha r ge
Initial Start-Up
Preparation
Manual Operation of th e Guid e Vane s
Dry Run to Test Start-Up Sequence
Check Ro tation (Open-Drive Motor)
Contents
Check Ro tation (Hermeti c 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
Cool er-Condenser
Utility Vessel
Pumpout Syst em
Motor Compressor Assembly
Motor Compressor Lubrication System
Control System
Auxiliary Equ ipment
Describe Machine Cycles
Review Maintenance
Safety Devices and Procedures
Check Operator Kn owledge
Review the Start-Up, Operation, and Maintenance Manual
Operating Inst r uc tions
Operator Duties
Prepare the Machine for Start-Up
To Start th e M achine
Check the Runni ng System
To Stop the Machine
After Limited Shutdow n
Extended Shutdown
After Extende d Shut down
Contents
Cold Weather Operation
Manual Guide Vane Operation
Refrigera ti on Log
Contents
Pump out and Refrigera nt Transfer Pro cedures
Pr epar ation
Operating the Optional Pumpout Compressor
To Read Re frige ran t Press u r es
Transferring Refrigerant from Normal Operation into the Utility Vessel
Tra n sf err i n g Ref ri ger a n t from No rmal Op eration in to the
Cooler/Con denser/Com pr essor Section
Return Refrige rant to Normal Operating Co nditions
Genera l Mai nt e na nc e
Refrigeran t Pro perti es
Adding Refri gera n t
Removing Refrigerant
Adjusting the Refrigeran t Charge
Refrigerant Leak Testing
Le ak Ra te
Contents
Test After Service, Repair, or Major Le ak
Ref rigerant Tr acer
To Press u rize with Dry Ni t rogen
Repair the Leak, Retest, and Apply Standing Vacuum Test
Checking Guide Vane Link age
Contact Seal Mainte nance (Open-Drive Machi nes)
Seal D isa ssem bly
Seal Reassembly
Machin e Alignment (Open-Dri ve Machines )
Align ment Methods
Preliminary Alignment
Near F in al Al i gnment
Final Alignment
Hot Al ignment Check
Doweling
Weekly Maintenance
Check the Lubrication System
Sched ule d Mai nt e na nc e
Service Ontime
Inspect the Co ntro l Center
Check Safety and O perating Controls Monthly
Changing Oil Filter
19EX Compressors
FA Style Compr essor s
Oil Specification
Oil Changes
To Change the Oil
Contents
Refrigeran t Filter
Oil Reclaim Filter
Contents
Inspect Refrigerant Float System
Inspect Relief Valves and Piping
Coupling Main tenance (Open-Driv e Machines)
Procedure
Moto r Mainten ance (O p en-Dri ve Machin es)
Cleanliness
Sleeve Bearings
Open-Drive Motor Handling/Rigging
Open-Drive Motor Storage
Com pr e sso r Be arin g and Gear Ma in t enan c e
Inspect the Hea t Exchanger Tubes
Cooler
Condenser
Water Leaks
Water Tre atmen t
Inspect the Starting Equipment
Check Pressure Transducers
Pumpout System Mai n tenanc e
Optional Pumpout Compressor Oil Charge
Pumpout Safe ty Control Settings
Ordering Replacement Chiller Parts
Ope n -Driv e Motor Renewal Parts
Troub le sh ooting Gui de
Overvi ew
Checking the Display Messages
Checkin g Te mp erat ur e Senso rs
Resistance Check
Contents
Voltage Drop
Check Sensor Ac curacy
Dual Tempe r ature Sensors
Contents
Checking Pressure Transducers
Oil Differential Pressure/Power Supply Module Cal ib ratio n
Troubleshooting Transd uce r s
Transducer Replacement
Control Algori thms Checkout Proce dure
Control Test
Control Modu les
Red LED
Green LE Ds
Notes on Module Operation
Processor Module (PSIO)
Inputs
Outputs
Contents
Starter Management Modul e ( SM M)
Inputs
Outputs
Options Modules (8-Input)
Replacing Defective Processor Modules
Insta lla ti on of Ne w PSIO Module
17/19EX Physical Data and Wiring Schematics
Compressor Fits and Clearances
Initial S t art - Up Checklist for 17/19EX Centri f ug al Liqui d Chiller
List of Tables
Table 1 — Major PIC Components and Panel Locations
Table 2 — LID Scre ens
Example 1 — Status01 Display Scre en
Example 2 — Status02 Display Scre en
Example 3 — Status03 Display Scre en
Example 4 — Setpoint Display Screen
Example 5 — Configur ation (Config) Di splay Screen
Example 6 — Le ad/Lag C onfig uration Displ ay Screen
Example 7 — Service1 Display Screen
Example 8 — Service2 Display Screen
Example 9 — Service3 Display Screen
Example 10 — Maintenance (Main t 01) Di splay Scre en
Contents
Example 11 — Maintenance (Main t 02) Di splay Scre en
Example 12 — Maintenance (Main t 03) Di splay Scre en
Example 13 — Maintenance (Main t 04) Di splay Scre en
Contents
Table 3 — Protective Safety Limits and Control Settings
Table 4 — Capacity O ve r rides
Table 5A — HFC-134 a Pressure — Temperature (F )
Table 5B — HFC-134 a Pressure — Temperature (C)
Table 6 — Recomm ended Tor que
Table 7 — Control Test Me nu Functions
Table 8 — LID Prima r y an d Seconda r y Messages and Custom Alarm/
Alert Messages with Troubleshooti ng Gu ides
A. Shutdown with ON/OFF/RE SET-OFF
B. Timing Ou t or Ti m ed Out
C. In Recycle Shutdown
D. Pre-Start Alerts
E. Nor mal or AUTO.-RES TART
F. Start-U p Fail ur es
G. Compressor Jumpstart and Refrigerant Protection
Contents
Table 8 — LID Primar y an d Seconda r y Messages and Custom Alarm/
Alert Messages with Troubleshooti ng Gu ides (Continued)
H. Normal Run with Reset, Temperature, Or Demand
I. Normal Run Overrides Active (Alerts)
J. Out-of-Range Sen sor Failures
K. Machi ne Protect Limit Faults
L. Machine Alerts
M. Spare Sensor Alert Messages
N. Other Problems/Malfun ctions
Table 9A — Thermistor Temperature (F) v s Re sistance/Voltage Drop
Table 9B — Thermistor Temperature (C) v s Resistance/Voltage Drop
Table 10 — 17/19EX Heat Exchanger, Economi z er/Storage Vessel,
Piping, and Pum pout Unit Weights
Table 11 — Addi ti onal Conde nser Weights
Table 12 — Com pr essor/Motor/Suction E lbow Wei ghts
Table 13 — Addi ti onal Cool er Weights
Contents
Table 14 — Marine Waterbox Cover Weights
Table 15 — NIH Waterbox Cover Weights
Table 16 — Auxiliary Systems, Electrical Data
Table 17 — Open-Dri ve Compressor Fit s a nd Cl ea r anc es
Table 18 — Hermetic Compressor Fits and Clearances
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