Carrier 17, 17EX Series, 19EX Series Start Up & Operation Manual

Start-Up,Operation,andMaintenanceInstructions

SAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design speciﬁcations. Whenoperatingthisequipment, usegood judgmentand safety precautions to avoid damage to equipment and property or injury to personnel.

Besure youunderstand and follow the proceduresand safety precautions contained in the machine 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 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 func-

tioning before operating any machine. RISK OF INJURYOR DEATHby electrocution. High voltage is present

on motor leads even though the motor is not running when a solid-state or inside-delta mechanical starter is used. Open the power supply disconnect before touching motor leads or terminals.

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-voltage equipment 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 or solid-state components.

LOCK OPEN AND TAGelectrical 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 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 NOT ATTEMPT 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-up of 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.

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-CHECK that 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, 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-up of condensate or rain water.

17/19EX

Centrifugal Liquid Chillers

50/60 Hz

With HFC-134a

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

Book 2 2 Tab 5a 5d

PC 211 Catalog No. 531-750 Printed in U.S.A. Form 17/19EX-2SS Pg 1 1197 3-96 Replaces: 17/19EX-1SS

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CONTENTS

Page

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

INTRODUCTION

...............................4

ABBREVIATIONS

..............................4

17/19EX MACHINE FAMILIARIZATION

.............4-8

Machine Identiﬁcation Label

.....................4

System Components

...........................4

Cooler

........................................8

Condenser

....................................8

Motor-Compressor

.............................8

Control Center

.................................8

Motor Starter

..................................8

Utility Vessel

..................................8

REFRIGERATION CYCLE

........................8

MOTOR/OIL REFRIGERATION

COOLING CYCLE (19EX CHILLERS)

............8,9

HERMETIC MACHINES (19 SERIES) LUBRICATION

CYCLE

...................................10,11

Summary

....................................10

Details

......................................10

OPEN-DRIVE MACHINES (17 SERIES)

LUBRICATION CYCLE

........................12

Summary

....................................12

Details

......................................12

STARTERS

...................................12

CONTROLS

................................ 12-45

Deﬁnitions

...................................12

• ANALOG SIGNAL

• DIGITAL SIGNAL

• VOLATILE MEMORY

General

......................................12

PIC System Components

.......................14

• 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)

• 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

......................21

• 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

.........................35

• CAPACITY CONTROL

• ENTERING CHILLED WATER CONTROL

• DEADBAND

• PROPORTIONAL BANDS AND GAIN

• DEMAND LIMITING

• MACHINE TIMERS

• OCCUPANCY SCHEDULE

Safety Controls

...............................35

• SHUNT TRIP

Page

Default Screen Freeze .........................36

Motor Cooling Control (Hermetic Motors Only)

....36

Auxiliary Oil Pump Control (Open-Drive Machines

Only)

......................................36

Shaft Seal Oil (Open Drive Machines Only)

........36

Ramp Loading Control

.........................36

Capacity Override

.............................36

High Discharge Temperature Control

.............36

Oil Sump Temperature Control

..................38

Oil Cooler

....................................38

Remote Start/Stop Controls

.................... 38

Spare Safety Inputs

...........................38

Spare Alarm Contacts

.........................38

Condenser Pump Control

......................39

Condenser Freeze Prevention

...................39

Tower-Fan Relay

..............................39

Auto. Restart After Power Failure

................39

Water/Brine Reset

.............................39

Demand Limit Control, Option (Requires Optional

8-Input Module)

.............................40

Surge Prevention Algorithm

....................40

Surge Protection

..............................40

Lead/Lag Control

.............................40

• COMMON POINT SENSOR INSTALLATION

• MACHINE COMMUNICATION WIRING

• LEAD/LAG OPERATION

• FAULTED CHILLER OPERATION

• LOAD BALANCING

• AUTO. RESTART AFTER POWER FAILURE

Ice Build Control

..............................42

• 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

...............43

• ATTACHING TO OTHER CCN MODULES

Service Operation

.............................44

• TO LOG ON

• TO LOG OFF

• HOLIDAY SCHEDULING

START-UP/SHUTDOWN/RECYCLE SEQUENCE

...45,46

Local Start-Up

................................45

Shutdown Sequence

...........................46

Automatic Soft Stop Amps Threshold

............46

Chilled Water Recycle Mode

....................46

Safety Shutdown

..............................46

BEFORE INITIAL START-UP

...................47-57

Job Data Required

............................47

Equipment Required

...........................47

Using the Utility Vessel and Pumpout System

.....47

Remove Shipping Packaging

...................47

Open-Drive Motor Electrical Connection

..........47

Open-Drive Motor Auxiliary Devices

.............48

Open Oil Circuit Valves

........................48

Tighten All Gasketed Joints and Guide Vane

Shaft Packing

...............................48

Check Machine Tightness

......................48

Refrigerant Tracer

.............................48

Leak Test Machine

............................48

Standing Vacuum Test

.........................49

Machine Dehydration

..........................51

Inspect Water Piping

..........................52

Check Optional Pumpout Compressor Water

Piping

....................................52

Check Relief Devices

..........................52

CONTENTS

Page

Inspect Wiring ................................52

• CHECK INSULATION RESISTANCE

(HERMETIC MOTOR)

• CHECK INSULATION RESISTANCE

(OPEN-DRIVE MOTOR)

Open-Drive Motor Pre-Start Checks

..............53

Carrier Comfort Network Interface

...............53

Check Starter

.................................54

• MECHANICAL-TYPE STARTERS

• SOLID-STATE STARTERS

Oil Charge

...................................54

Power Up the Controls and

Check the Oil Heater

.........................54

• SOFTWARE VERSION

Set Up Machine Control Conﬁguration

...........55

Input the Design Set Points

.....................55

Input the Local Occupied Schedule

(OCCPC01S)

................................55

Input Service Conﬁgurations

....................55

• 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

........................57

High Altitude Locations

........................57

Charge Refrigerant Into Machine

................57

• TRIMMING REFRIGERANT CHARGE

INITIAL START-UP

...........................58-60

Preparation

..................................58

Manual Operation of the Guide Vanes

............58

Dry Run to Test Start-Up Sequence

..............58

Check Rotation (Open-Drive Motor)

..............58

• OPEN DRIVE MOTOR INITIAL START-UP

Check Rotation (Hermetic Motor)

................59

• IF ROTATION IS PROPER

• IF THE MOTOR ROTATION IS NOT CLOCKWISE

Check Oil Pressure and Compressor Stop

........59

Calibrate Motor Current Demand Setting

..........60

To Prevent Accidental Start-Up

..................60

Hot Alignment Check for Open-Drive Machines

....60

Doweling for Open-Drive Machines

..............60

Check Machine Operating Condition

.............60

Instruct the Customer Operator

.................60

• COOLER-CONDENSER

• UTILITY VESSEL

• PUMPOUT SYSTEM

• MOTOR COMPRESSOR ASSEMBLY

• MOTOR COMPRESSOR LUBRICATION SYSTEM

• CONTROL SYSTEM

• AUXILIARY EQUIPMENT

• DESCRIBE MACHINE CYCLES

• REVIEW MAINTENANCE

• SAFETY DEVICES AND PROCEDURES

• CHECK OPERATOR KNOWLEDGE

• REVIEW THE START-UP, OPERATION, AND

MAINTENANCE MANUAL

OPERATING INSTRUCTIONS

..................61-63

Operator Duties

...............................61

Prepare the Machine for Start-Up

................61

To Start the Machine

.......................... 61

Page

Check the Running System .....................61

To Stop the Machine

...........................61

After Limited Shutdown

........................61

Extended Shutdown

...........................62

After Extended Shutdown

......................62

Cold Weather Operation

........................62

Manual Guide Vane Operation

...................62

Refrigeration Log

.............................62

PUMPOUT AND REFRIGERANT TRANSFER

PROCEDURES

............................64-66

Preparation

..................................64

Operating the Optional Pumpout

Compressor

................................64

• TO READ REFRIGERANT PRESSURES

Transferring Refrigerant from Normal

Operation into the Utility Vessel

...............66

Transferring Refrigerant From Normal Operation into

the Cooler/Condenser/Compressor Section

.....66

Return Refrigerant to Normal Operating

Conditions

.................................66

GENERAL MAINTENANCE

....................67-75

Refrigerant Properties

.........................67

Adding Refrigerant

............................67

Removing Refrigerant

.........................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

.......................67

Checking Guide Vane Linkage

..................67

Contact Seal Maintenance (Open-Drive

Machines)

..................................68

• SEAL DISASSEMBLY

• SEAL REASSEMBLY

Machine Alignment (Open-Drive Machines)

.......70

• ALIGNMENT METHODS

• PRELIMINARY ALIGNMENT

• NEAR FINAL ALIGNMENT

• FINAL ALIGNMENT

• HOT ALIGNMENT CHECK

• DOWELING

WEEKLY MAINTENANCE

......................75,76

Check the Lubrication System

..................75

SCHEDULED MAINTENANCE

..................76-83

Service Ontime

...............................76

Inspect the Control Center

.....................76

Check Safety and Operating Controls Monthly

.....76

Changing Oil Filter

............................76

• 19EX COMPRESSORS

• FA STYLE COMPRESSORS

Oil Speciﬁcation

..............................77

Oil Changes

..................................77

• TO CHANGE THE OIL

Refrigerant Filter

..............................77

Oil Reclaim Filter

.............................77

Inspect Refrigerant Float System

................77

Inspect Relief Valves and Piping

................77

Coupling Maintenance (Open-Drive Machines)

.....77

• PROCEDURE

Motor Maintenance (Open-Drive Machines)

........78

• CLEANLINESS

• SLEEVE BEARINGS

Open-Drive Motor Handling/Rigging

..............81

Open-Drive Motor Storage

......................81

Compressor Bearing and Gear Maintenance

......81

CONTENTS (cont)

Page

Inspect the Heat Exchanger Tubes ...............81

• COOLER

• CONDENSER

Water Leaks

..................................82

Water Treatment

..............................82

Inspect the Starting Equipment

.................82

Check Pressure Transducers

...................82

Pumpout System Maintenance

..................82

• OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE

• PUMPOUT SAFETY CONTROL SETTINGS

Ordering Replacement Chiller Parts

..............83

• OPEN-DRIVE MOTOR RENEWAL PARTS

TROUBLESHOOTING GUIDE

..................83-97

Overview

....................................83

Checking the Display Messages

.................83

Checking Temperature Sensors

.................83

• RESISTANCE CHECK

• VOLTAGE DROP

• CHECK SENSOR ACCURACY

• DUAL TEMPERATURE SENSORS

Checking Pressure Transducers

.................84

• OIL DIFFERENTIAL PRESSURE/POWER SUPPLY

MODULE CALIBRATION

Page

• TROUBLESHOOTING TRANSDUCERS

• TRANSDUCER REPLACEMENT

Control Algorithms Checkout Procedure

..........85

Control Test

..................................85

Control Modules

..............................95

• RED LED

• GREEN LEDs

Notes on Module Operation

.....................95

Processor Module (PSIO)

.......................95

• INPUTS

• OUTPUTS

Starter Management Module (SMM)

..............96

• INPUTS

• OUTPUTS

Options Modules (8-Input)

......................96

Replacing Defective Processor Modules

..........96

• INSTALLATION OF NEW PSIO MODULE

17/19EX PHYSICAL DATA AND WIRING

SCHEMATICS

............................97-114

Compressor Fits and Clearances

...............102

INDEX

....................................115,116

INITIAL START-UP CHECKLIST FOR 17/19EX

CENTRIFUGAL LIQUID CHILLER

......CL-1 to CL-12

INTRODUCTION

Prior to initial start-up of the 17/19EX unit, those involved in the start-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 systembefore performing start-up procedures. Procedures in this manual are arranged in the sequence required for proper machine start-up and operation.

This unit uses a microprocessor control 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 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-static shipping bag.

ABBREVIATIONS

Frequently used abbreviations in this manual include:

CCN — Carrier Comfort Network CCW — Counterclockwise CHW — Chilled Water CHWR — Chilled Water Return CHWS — Chilled Water Supply CW — Clockwise ECW — Entering Chilled Water ECDW — Entering Condenser Water EMS — Energy Management System HGBP — Hot Gas Bypass I/O — Input/Output LCD — Liquid Crystal Display LCDW — Leaving Condenser Water LCW — Leaving Chilled Water LED — Light-Emitting Diode LID — Local Interface Device OLTA — Overload Trip Amps PIC — Product Integrated Control PSIO — Processor Sensor Input/

Output Module RLA — Rated Load Amps SCR — Silicon Control Rectiﬁer SMM — Starter Management Module TXV — Thermostatic Expansion Valve

17/19EX MACHINE FAMILIARIZATION

(Fig.1-3)

Machine Identiﬁcation Label —

The identiﬁcation label is located on the right side of the machine control center panel. The label contains information on model number, refrigerant charge, rated voltage, etc.

System Components — The components include the

cooler and condenser heat exchangers in separate vessels, motor-compressor, lubrication package, control center, utility vessel, and motor starter. All connections from pressure vessels have external threads to enable each component to be pressure tested with a threaded pipe cap during factory assembly.

NIH — Nozzle-In-Head *Motors beginning with ‘‘E’’ and open drive motors (FA-JD) cannot be used with size 51-89 or 421-469 compressors.

†Open-drive motor codes:

UNDERWRITERS’

LABORATORIES

CANADA

ASME

‘U’ STAMP

UNDERWRITERS’

LABORATORIES

ARI (Air Conditioning

and Refrigeration

Institute)

PERFORMANCE

CERTIFIED

(60 Hz Only)

MODEL NUMBER NOMENCLATURE

SERIAL NUMBER BREAKDOWN

Fig. 1 — 17/19EX Identiﬁcation

LEGEND

1—Condenser 2—Cooler Suction Pipe 3—Compressor Suction Elbow 4—Guide Vane Actuator 5—Condenser Discharge Pipe 6—Oil Filter (Hidden) 7—Two-Stage Compressor 8—Compressor Discharge Elbow

9—Gear Inspection Cover 10 — Economizer Gas Line to Compressor 11 — Open Drive Compressor Motor 12 — Compressor Motor Terminal Box 13 — Coupling Guard 14 — Low-Side Float Box Cover 15 — Refrigerant Liquid Line to Cooler 16 — Power Panel (Field Wiring Terminals) 17 — Oil Level Sight Glasses 18 — Oil Drain and Charging Valve 19 — Oil Heater (Hidden) 20 — Oil Pump

21 — Refrigerant Charging/Service Valve

10 (Not Shown)

22 — Cooler Relief Valves (Not Shown) 23 — Economizer/Storage Vessel 24 — Oil Cooler 25 — Control Center 26 — Economizer/Storage Vessel

Relief Valves

27 — Pumpout Unit 28 — High Side Float Box Cover 29 — Cooler 30 — Cooler Waterbox Drain 31 — Take-Apart Connections (Typical) 32 — Cooler Marine Waterbox Cover 33 — Cooler Waterbox 34 — Cooler Waterbox Vent 35 — Condenser Waterbox Drain 36 — Refrigerant Liquid Line to

Economizer/Storage Vessel

37 — Condenser Waterbox Vent

Fig.2—Typical 17EX Installation

LEGEND

1—Refrigerant Liquid Line to Economizer/Storage Vessel 2—Cooler Suction Pipe 3—Compressor Suction Elbow 4—Condenser 5—Condenser Discharge Pipe 6—Compressor Discharge Elbow 7—Guide Vane Actuator 8—Economizer Gas Line to Compressor

9—Gear Inspection Cover 10 — 2-Stage Hermetic Compressor 11 — Condenser Waterbox Vent (Not Shown) 12 — Condenser Marine Waterbox 13 — Hermetic Compressor Motor 14 — Compressor Motor Terminal Box (Not Shown) 15 — Motor Sight Glass (Not Shown) 16 — Oil Filter 17 — Oil Level Sight Glasses (2) 18 — Cooler Relief Valves (Not Shown) 19 — Oil Heater (Not Shown) 20 — Auxiliary Power Panel (Field Wiring Terminals)

21 — Pumpdown Unit (Not Shown) 22 — Low-Side Float Box Cover 23 — Refrigerant Liquid Line to Cooler 24 — Oil Drain and Charging Valve 25 — Oil Pump 26 — Refrigerant Charging/Service Valve 10

(Not Shown)

27 — Oil Cooler 28 — Isolation Valves (Not Shown) 29 — Refrigerant Filter Drier 30 — Local Interface Display Control Panel 31 — Economizer/Storage Vessel 32 — Rigging Guide (Not Shown) 33 — Economizer/Storage Vessel Relief Valves 34 — Cooler 35 — High-Side Float Box Cover 36 — Take-Apart Connections 37 — Cooler Waterbox Vent 38 — Cooler Marine Waterbox 39 — Cooler Waterbox Drain 40 — Condenser Waterbox Drain

Fig.3—Typical 19EX Installation

Cooler — This vessel (also known as the evaporator) is

located underneath the condenser, next to the utility vessel. The cooler is maintained at lower temperature/pressure so that evaporating refrigerant can remove heat from water ﬂowing through its internal tubes.

Condenser — The condenser operates at a higher

temperature/pressure than the cooler, and has water ﬂowing through its internal tubes in order to remove heat from the refrigerant.

Motor-Compressor — This component maintains sys-

tem temperature/pressure differences and moves the heat carrying refrigerant from the cooler to the condenser.

Control Center — The control center is the user inter-

face for controlling the machine and regulates the machine capacity as required to maintain proper leaving chilled water temperature. The control center:

• registers cooler, condenser, and lubricating system pressures

• shows machine operating condition and alarm shutdown conditions

• records the total machine operating hours and how many hours the machine has been running

• sequences machine start, stop, and recycle under microprocessor control

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

MotorStarter(PurchasedSeparately)— The starter

allows for the proper starting and disconnecting of the electrical energy for the compressor-motor, oil pump, oil heater, and control panels.

Utility Vessel — 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 utility vessel can serve as a storage tank for the refrigerant.

REFRIGERATION CYCLE (Fig. 4)

The machine 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 ﬁrst stage of the compressor, is compressed and ﬂows into the compressor second stage. Here it is mixed with ﬂash-economizer gas and is further compressed.

Compression raises the refrigerant temperature above that of the water ﬂowing 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 oriﬁce into the FLASC chamber.Because the coolest condenser water is ﬂowing through the FLASC, it is at a lower pressure and part of the entering liquid refrigerant will ﬂash to vapor,thereby cooling the remaining liquid. The vapor is then recondensed by the condenser water ﬂowing through the FLASC chamber.

The subcooled liquid refrigerant drains into a high-side valve chamber which meters the refrigerant liquid into a flash economizer chamber. Pressure in this chamber is intermediate between condenser and cooler pressures. At this lower pressure, some of the liquid refrigerant ﬂashes to gas, further cooling the remaining liquid. The ﬂash 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 ﬁrst-stage impeller. Since the ﬂash 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-side valve chamber into the cooler. Because pressure in the cooler is lower than economizer pressure, some of the liquid ﬂashes and cools the remainder to evaporator (cooler) temperature. The cycle is now complete.

MOTOR/OILREFRIGERATIONCOOLING CYCLE

(19EX CHILLERS)

The motor is cooled by liquid refrigerant taken from the bottom of the condenser vessel (Fig. 4). Flow of refrigerant is maintained by the pressure differential that exists due to compressor operation.After the refrigerant ﬂows past an isolation valve, an in-line ﬁlter, and a sight glass/moisture indicator, the ﬂow is split between motor cooling and oil cooling systems.

Flow to the motor moves through an oriﬁce and into the motor. On models with a solenoid valve, the valve will open if additional motor cooling is required. Once past the oriﬁce, the refrigerant is directed over the motor by a spray nozzle.

The refrigerant collects in the bottom of the motor casing and then is drained back into the cooler through the motor refrigerant drain line.An oriﬁce in this line maintains a higher pressure in the motor shell than in the cooler/oil sump. The motor is protected by a temperature sensor imbedded in the stator windings. On models with a solenoid valve, higher motor temperatures (above 125 F [51 C]) energize the solenoid to provide additional motor cooling. On all models, a further increase in temperature past the motor override set point will override the temperature capacity control to hold, and if the motor temperature rises 10° F (5.5° C) above this set point, will close the inlet guide vanes. If the temperature rises above the safety limit, the compressor will shut down.

On machines with EX compressors and 41-48 cooler sizes, the oil is also cooled by liquid refrigerant. Refrigerant that ﬂows to the oil cooling system is regulated by a thermostatic expansion valve. There is always a minimum ﬂow bypassing the TXV, which ﬂows through an oriﬁce. The TXV valve regulates ﬂow into the oil/refrigerant plate and frame-type heat exchanger. The bulb for the expansion valve controls oil temperature to the bearings. The refrigerant leaving the heat exchanger then returns to the cooler.

On machines with FAcompressors, the oil is water cooled. Water ﬂow 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).

LEGEND

TXV — Thermostatic Expansion Valve

Liquid Liquid/Vapor Vapor

*The FA compressor has a water cooled oil cooler.

Fig. 4 — Refrigerant, Motor Cooling, and Oil Cooling Cycles (19EX Shown)

HERMETIC MACHINES (19 SERIES)

LUBRICATION CYCLE

Summary —

The compressor oil pump and oil reservoir are located in the compressor base. Oil is pumped through an oil cooler and a ﬁlter to remove heat and any foreign particles. Part of the oil ﬂow is directed to the compressor motorend bearings and seal. The remaining ﬂow lubricates the compressor transmission, thrust and journal bearings and seal. Oil is then returned to the reservoir to complete the cycle (Fig. 5).

Details— Oil is charged into the reservoir (Item 1) through

a hand valve (Item 4) which also functions as an oil drain. If there is refrigerant in the machine, a pump is required for charging. Sight glasses (Item 10) on the reservoir wall permit observation of the oil level. The normal operating oil level is from the middle of the lower sight glass to the top of the lower sight glass.

The motor-driven oil pump (Item 8) discharges oil to an oil cooler (Item 12) at a rate and pressure controlled by an oil regulator (Item 7). The differential pressure (supply versus return) is registered at the control center. Oil differential pressure is maintained between 18 to 30 psi (124 to 207 kPa).

The oil pump discharges to the oil cooler and ﬁlter. On EX compressors, the ﬁlter is located ahead of the oil cooler. On FA compressors the oil cooler is located ahead of the ﬁlter. The ﬁlter is capable of being valved closed to permit removal of the ﬁlter without draining the entire oil system (see Scheduled Maintenance, Changing Oil Filter section, page 76 for details).

The oil cooler on the EX compressor is a plate-and-frame type, refrigerant cooled, heat exchanger. The EX compressor oil cooler heat exchanger uses refrigerant from the condenser as a coolant. The refrigerant cools the oil to a temperature between 110 and 120 F (43 and 49 C) supply oil temperature to the bearings.

The FAcompressor oil cooler heat exchanger is water cooled. The water ﬂow through the cooler is manually controlled by a plug valve. The valve should be adjusted to maintain approximately 145 F (63 C) in the oil sump during running conditions.

As the oil leaves the oil cooler, it passes the oil pressure transducer (Item 14) and then the thermostatic expansion valve bulb (Item 13). The oil ﬂow is then divided, and a portion ﬂows to the motor-end bearing (Item 19) and

seal. The remainder lubricates the compressor transmission (Item 2) and the thrust and journal bearings (Item 3). Thrust bearing temperature is indicated at the Local Interface Device (LID). Oil from each circuit returns by gravity to the reservoir.

Ademister (Items 17 and 18), by centrifugal action, draws refrigerant gas from the transmission area to the motor shell. The resulting pressure difference prevents oil in the transmission cavity from leaking into the motor shell.

Several safety features are part of the lubrication system:

In the event of power failure, a small oil reservoir (Item 16) supplies sufficient oil reserve to ensure continued lubrication until all compressor parts have come to a complete stop. The bearing temperature sensor (Item 15) monitors thrust bearing temperatures and shuts off the machine if the temperature rises above a selected point. Low-oil pressure will shut down the machine or prevent a start if oil pressure is not adequate.

The PIC (Product Integrated Control) measures the temperature of the oil in the sump and maintains the temperature during shutdown (see Controls, Oil Sump Temperature Control section, page 38). This temperature is read on the LID default screen.

During the machine start-up, the PIC will energize the oil pump and provide 15 seconds of prelubrication to the bearings after the oil pressure is veriﬁed and before the controls start the compressor. During shutdown, the oil pump will run for 60 seconds after the compressor actually shuts down for the purpose of post-lubrication. The oil pump can also be energized for testing purposes in controls test.

Ramp loading can slow the rate of guide vane opening to minimize oil foaming at start-up. If the guide vanes open quickly, the sudden drop in suction pressure can cause any refrigerant in the oil to ﬂash. The resulting oil foam cannot be pumped efficiently; oil pressure falls off, and lubrication is poor. If oil pressure falls below 15 psi (90 kPa) differential, the PIC will shut down the compressor.

Oil reclaim is accomplished by returning the system oil through the check valve/oriﬁce (Item 11). As oil builds up behind the second stage impeller, it is drained by the check valve/oriﬁce back into the oil reservoir.Anoil/refrigerant mixture is drawn up from the operating level of the cooler into the guide vane housing. This assists the oil return system at low load operating conditions.

LEGEND

TXV — Thermostatic Expansion Valve

Oil Supply Flow Oil Return Flow Pressure Control Lines Refrigerant

Capillary Tubing (Filled System)

*The FAcompressorhasa water-cooled oil cooler. Oil temperature is

manually controlled.

Fig. 5 — Hermetic Compressor Lubrication System (EX Compressor Shown)

OPEN-DRIVE MACHINES (17 SERIES)

LUBRICATION CYCLE

Summary —

The main oil pump and oil reservoir are contained in the compressor base. Oil is pumped through an oil cooler and a ﬁlter to remove heat and any foreign particles. A portion of the oil is then directed to shaft-end bearing and the shaft seal. The balance of the oil lubricates the compressor transmission and the thrust and journal bearings. The bearing and transmission oil returns directly to the reservoir to complete the cycle. Contact-seal oil leakage, however,is collected in an atmospheric ﬂoat chamber to be pumped back to the main reservoir as the oil accumulates.

Details (See Fig. 6) — Oil may be charged into the

reservoir (1) through a hand valve (2) which also functions as an oil drain. If there is refrigerant in the machine, however, a hand pump will be required for charging at this connection.

An oil-chargingelbow (Item 20) on the seal-oil return chamber allows oil to be added without pumping. The seal-oil return pump (Item 21) automatically transfers the oil to the main reservoir. Sight glasses (Item 6) on the reservoir wall permit observation of the oil level.

A motor-driven oil pump (Item 5) discharges oil to an oil cooler (Item 7) at a rate and pressure controlled by an oil regulator (Item 4). The differential oil pressure (bearing supply versus oil reservoir) is registered on the control panel.

Water ﬂow through the oil cooler is manually adjusted by a plug valve (Item 8) 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 3) in order to minimize absorption of refrigerant by the oil.

Upon leaving the oil cooler, the oil is ﬁltered (11) and a portion is directed to the seal-end bearing (17) and the shaft seal (18). The remainder lubricates the compressor transmission (15) and the thrust and journal bearings (10). Thrust bearing temperature is indicated by the PIC controls. Oil from both circuits returns by gravity to the reservoir.

A demister (13 and 16), by centrifugal action, draws refrigerant gas from the transmission area to a housing that is vented to the cooler (Item 19). The resulting pressure difference prevents oil from the transmission cavity from passing through the transmission shaft labyrinth into the demister outlet chamber.

The open compressor drive requires that the shaft seal (18) be kept full of lubrication oil, even when the machine is not operating, to prevent loss of refrigerant.

If the machine is not operating and the oil pump has not operated during the last 12 hours, the control system will automatically run the oil pump for one minute in order to keep the contact seal ﬁlled with oil.

IMPORTANT: If the control power is to be deenergized for more than one day, the machine refrigerant should be pumped over to the utility vessel.

STARTERS

All starters, whether supplied by Carrier or the customer, must meet Carrier Starter Speciﬁcation Z-375. This speciﬁcation can be obtained from the Carrier Sales Representative. The purpose of this speciﬁcation is to ensure the compatibility of the starter and the machine. Many styles of compatible starters are available, including solid-state starters, autotransformer, wye-delta closed transition starters, and full voltage starters.

CONTROLS

Deﬁnitions

ANALOG SIGNAL — An analog signal varies in proportion to the monitored source. It quantiﬁes values between operating limits. (Example: A temperature sensor is an analog device because its resistance changes in proportion to the temperature, generating many values.)

DIGIT ALSIGNAL— A digital (discrete) signal is a 2-position representation of the value of a monitored source. (Example: A switch is a digital device because it only indicates whether a value is above or below a set point or boundary by generating an on/off, high/low, or open/closed signal.)

VOLATILE MEMORY — Volatile memory is memory in- capable of being sustained if power is lost and subsequently restored.

The memory of the PSIO module is volatile. If the battery in a module is removed or damaged, all programming will be lost.

General — The 17/19EX centrifugal liquid chiller con-

tains a microprocessor-based control center that monitors and controls all operations of the machine. The microprocessor control system matches the cooling capacity of the machine to the cooling load while providing state-of-the-art machine protection. The system controls cooling load within the set point plus the deadband by sensing the leaving chilled water or brine temperature, and regulating the inlet guide vane via a mechanically linked actuator motor. The guide vane is a variable ﬂow prewhirl assembly that controls the refrigeration effect in the cooler by regulating the amount of refrigerant vapor ﬂow into the compressor. An increase in guide vane opening increases capacity. A decrease in guide vane opening decreases capacity. Machine protection is provided by the processor which monitors the digital and analog inputs and executes capacity overrides or safety shutdowns, if required.

Fig. 6 — Open-Drive (17 Series) Lubrication Cycle

PIC System Components — The Product Integrated

Control (PIC) is the control system on the machine. See Table 1. The PIC controls the operation of the machine by monitoring all operating conditions. The PIC can diagnose a problem and let the operator know what the problem is and what to check. It promptly positions the guide vanes to maintain leaving chilled water temperature. It can interface with auxiliary equipment such as pumps and cooling tower fans to turn them on only when required. It continually checks all safeties to prevent any unsafe operating condition. It also regulates the oil heater while the compressor is off, and the hot gas bypass valve, if installed.

The PIC can be interfaced with the Carrier Comfort Network (CCN) if desired. It can communicate with other PIC-equipped chillers and other CCN devices.

The PIC consists of 3 modules housed inside the 3 major components. The component names and the control voltage contained in each component are listed below (also see Table 1):

• control center

— all extra low-voltage wiring (24 v or less)

• power panel

— 115 v control voltage — up to 600 v for oil pump power

• starter cabinet

— machine power wiring (per job requirement)

Table 1 — Major PIC Components and

Panel Locations*

PIC COMPONENT

PANEL

LOCATION

Processor Sensor Input/Output Module (PSIO) Control Center Starter Management Module (SMM) Starter Cabinet Local Interface Device (LID) Control Center 6-Pack Relay Board Control Center 8-Input Modules (Optional) Control Center Oil Differential Pressure/Power Supply

Module

Control Center

Oil Heater Contactor (1C) Power Panel Oil Pump Contactor (2C) Power Panel Hot Gas Bypass Relay (3C) (Optional) Power Panel Control Transformers (T1-T4) Power Panel Control and Oil Heater Voltage Selector (S1) Power Panel Temperature Sensors See Fig. 10 Pressure Transducers See Fig. 11

*See Fig. 7-13.

PROCESSOR MODULE (PSIO) — This module contains all of the operating software needed to control the machine. The open-drive machines use a different software package within the PSIO than the hermetic machines. There are also control hardware differences between the two types of machines. The 19EX uses 3 pressure transducers and 8 thermistors to sense pressures and temperatures. The 17EX uses 4 pressure transducers and 7 thermistors to sense pressures and temperatures.

These inputs are connected to the PSIO module. The PSIO also provides outputs to the: guide vane actuator; oil pump; oil heater; hot gas bypass (optional); motor cooling solenoid; and alarm contact. The PSIO communicates with the LID, the SMM, and the optional 8-input modules for user interface and starter management.

ST ARTER MANAGEMENT MODULE (SMM) — This module is located within the starter cabinet. This module initiates PSIO commands for starter functions such as start/ stop of the compressor, start/stop of the condenser and chilled

water pumps, start/stop of the tower fan, spare alarm contacts, and the shunt trip. The SMM monitors starter inputs such as ﬂow switches, line voltage, remote start contact, spare safety, condenser high pressure, oil pump interlock, motor current signal, starter 1M and run contacts, and kW transducer input (optional). The SMM contains logic capable of safely shutting down the machine if communication with the PSIO is lost.

LOCALINTERFACEDEVICE (LID) — The LID is mounted to the control center and allows the operator to interface with the PSIO or other CCN devices. It is the input center for all local machine set points, schedules, set-up functions, and options. The LID has a STOP button, an alarm light, 4 buttons for logic inputs, and a display. The function of the 4 buttons or ‘‘softkeys’’ are menu driven and are shown on the display directly above the key.

6-PACK RELAY BOARD — This device is a cluster of 6 pilot relays located in the control center. It is energized by the PSIO for the oil pump, oil heater, alarm, optional hot gas bypass relay, and motor cooling solenoid (19EX machines) on auxiliary oil pump (17EX machines).

8-INPUT MODULES — One optional module is factory installed in the control center panel when ordered. There can be up to 2 of these modules per chiller with 8 spare inputs each. They are used whenever chilled water reset, demand reset, or reading a spare sensor is required. The sensors or 4 to 20 mA signals are ﬁeld-installed.

The spare temperature sensors must have the same temperature/resistance curve as the other temperature sensors on this unit. These sensors are rated 5,000 ohm at 75 F (25 C).

OIL HEATER CONTACTOR (1C) — This contactor is located in the power panel and operates the heater at 115 v. It is controlled by the PIC to maintain oil temperature during machine shutdown.

OIL PUMP CONTACTOR(2C) — This contactor is located in the power panel. It operates all 200 to 575-v oil pumps. The PIC energizes the contactor to turn on the oil pump as necessary.

HOT GAS BYPASS CONTACTOR RELAY (3C) (Optional) — This relay, located in the power panel, controls the opening of the hot gas bypass valve. The PIC energizes the relay during low load, high lift conditions.

OILAUXILIARYRELAY (4C) — This relay, supplied only with open-drive machines, opens the oil cooler solenoid valve and interlocks the oil pump with the compressor.

CONTROL TRANSFORMERS (T1-T4) — These transformers are located in the power panel and convert incoming control voltage to either 21 vac power for the PSIO module and options modules, or 24 vac power for 3 power panel contactor relays and a control solenoid valve.

CONTROLANDOIL HEATER VOL TAGE SELECTOR (S1) — It is necessary to use 115 v incoming control power in the power panel. The switch must be set to the 115-v position.

OIL DIFFERENTIAL PRESSURE/POWER SUPPLY MODULE — This module, which is located in the control center, provides 5 vdc power for the transducers and LID backlight.

On open-drive machines, this module outputs the difference between two pressure transducer input signals. The module subtracts oil supply pressure from transmission sump pressure and outputs the difference as an oil differentialpressure signal to the PSIO. The PSIO converts this signal to differential oil pressure. To calibrate this reading, refer to the Troubleshooting, Checking Pressure Transducers.

Fig. 7 — 17EX Controls and Sensor Locations

Fig. 7 — 17EX Controls and Sensor Locations (cont)

Fig. 8 — 19EX Controls and Sensor Locations

MACHINE REAR; COMPRESSOR SIDE VIEW

COMPRESSOR END VIEW

MACHINE REAR VIEW

Fig. 8 — 19EX Controls and Sensor Locations (cont)

LEGEND

LID — Local Interface Device PIC — Product Integrated Controls PSIO — Processor Sensor Input/Output Module

1—Optional 8-Input Module for Spare Inputs to Control

Interface (One of Two Available)

2—PSIO 3—LID Input/Output Interface Panel Display 4—Oil Differential Pressure/Power Supply Module (Hidden) 5—LID Light (Hidden) 6—6-Pack Relay Board 7—Circuit Breakers (4)

Fig. 9 — Control Center (Front View);

Shown with Options Module

Fig. 10 — Control Sensors (Temperature)

Fig. 11 — Control Sensors

(Pressure Transducer, Typical)

LEGEND

1—T2 — Power Transformer (Hot Gas

Bypass Relay, Oil Pump Relay and Oil Heater Relay)

2—T1 — Control Center Transformer

3—Oil Heater Contactor (1C) 4—Oil Pump Contactor (2C) 5—Factory Terminal Connections 6—Oil Auxiliary Relay (4C)

Fig. 12 — Power Panel Without Options (Open-Drive Machine Shown)

LID Operation and Menus (Fig. 14-20)

GENERAL

• The LID display will automatically revert to the default screen after 15 minutes if no softkey activity takes place and if the machine is not in the Pumpdown mode (Fig. 14).

• When not in the default screen, the upper right-hand corner of the LID always displays the name of the screen that you have entered (Fig. 15).

• The LID may be conﬁgured in English or SI units, through the LID conﬁguration screen.

• Local Operation — By pressing the LOCAL

softkey,the PIC is now in the LOCAL operation mode and the control will accept modiﬁcation to programming from the LID only. The PIC will use the Local Time Schedule to determine machine start and stop times.

• CCN Operation — By pressing the CCN

softkey, the

PIC is now in the CCN operation mode, and the control will accept modiﬁcations from any CCN interface or module (with the proper authority), as well as the LID. The PIC will use the CCN time schedule to determine start and stop times.

ALARMS AND ALERTS — Alarm (*) and alert (!) status are indicated on the Default screen and the Status tables. An alarm (*) will shut down the compressor.An alert (!) notiﬁes the operator that an unusual condition has occurred. The machine will continue to operate when an alert is shown.

Alarms are indicated when the control center alarm light (!) ﬂashes. The primary alarm message is viewed on the default screen and an additional, secondary, message and troubleshooting information are sent to the Alarm History table.

NOTE: When an alarm is detected, the LID default screen will freeze (stop updating) at the time of alarm. The freeze enables the operator to view the machine conditions at the time of alarm. The Status tables will show the updated information. Once all alarms have been cleared (by pressing

the RESET

softkey), the default LID screen will return to

normal operation.

LEGEND

1—T2 — Power Transformer (Hot Gas

Bypass Relay, Oil Pump Relay and Oil Heater Relay)

2—T4 — Transformer (8-Input Modules) 3—T1 — Control Center Transformer 4—3C Hot Gas Bypass Relay Location 5—Factory Terminal Connections 6—Oil Heater Contactor (1C) 7—Oil Pump Contactor (2C)

Fig. 13 — Power Panel with Options (Hermetic Machine Shown)

Fig. 14 — LID Default Screen

LID DEF AULT SCREEN MENU ITEMS — T operform any of the operations described below, the PIC must be powered up and have successfully completed its self test.

The Default screen menu selection offers four options (Status, Schedule, Setpoint, and Service). The Status menu allows for viewing and limited calibration/modiﬁcation of control points and sensors, relays and contacts, and the options board. The Schedule menu allows for the viewing and modiﬁcation of the Local Control, CCN Control, and Ice Build time schedules. Numerous set points including Base Demand Limit, LCW, ECW, and Ice Build can be adjusted under the Setpoint menu. The Service menu can be used to revise alarm history, control test, control algorithm status, equipment conﬁguration, equipment service, time and date, attach to network, log out of device, controller identiﬁcation, and LID conﬁgurations. Figures 16 and 17 provide additional information on the menu structure.

Press the MENU

softkey to select from the 4 options. To view or change parameters within any menu structure, use the SELECT

softkey to choose the desired table or

item. The softkey modiﬁcation choices displayed will depend on whether the selected item is a discrete point, analog point, or an override point. At this point, press the softkey that corresponds to your conﬁguration selection or press

the QUIT

softkey. If the QUIT softkey is depressed,

the conﬁguration will not be modiﬁed. Use the following softkeys to access and select the desired section.

MENU STRUCTURE — To perform any of the operations described below, the PIC must be powered up and have successfully completed its self test.

• Press MENU

to select from the four available options.

• Press the softkey that corresponds to the desired menu structure.

• Press NEXT or PREVIOUS to highlight the desired entry.

• Press SELECT to access the highlighted point.

• Press QUIT to leave the selected decision or ﬁeld without saving any changes.

• Or, press ENTER to leave the selected decision or ﬁeld and save changes.

TOVIEW OR CHANGE POINT STATUS (Fig. 18) — Point Status is the actual value of all of the temperatures, pressures, relays, and actuators sensed and controlled by the PIC.

1. On the Menu screen, press STATUS

to view the list of

Point Status tables.

2. Press NEXT or PREVIOUS to highlight the desired

status table. The list of tables is:

• Status01 — Status of control points and sensors

• Status02 — Status of relays and contacts

• Status03 — Status of both optional 8-input modules and sensors

Fig. 15 — LID Service Screen

Fig. 16 — 17/19EX LID Menu Structure

Fig. 17 — 17/19EX Service Menu Structure

3. Press SELECT to view the desired Point Status table.

4. On the Point Status table press NEXT or PREVIOUS

until desired point is displayed on the screen.

For Discrete Points — Press START or STOP ,

YES

or NO ,ONor OFF , etc. to select the desired

state.

For Analog Points — Press INCREASE or

DECREASE

to select the desired value.

5. Press ENTER to register new value.

OVERRIDE OPERATIONS NOTE: When overriding or changing metric values, it is nec-

essary to hold the softkey down for a few seconds in order to see a value change, especially on kilopascal values.

To Remove an Override

1. On the Point Status table press NEXT or PREVIOUS

to highlight the desired point.

2. Press SELECT to access the highlighted point.

3. Press RELEASE to remove the override and return the

point to the PIC’s automatic control.

Override Indication — An override value is indicated by ‘ ‘SUPVSR,’’‘‘SERVC,’’or‘‘BEST’’ﬂashing next to the point value on the Status table.

TO VIEW OR CHANGE TIME SCHEDULE OPERATION (Fig. 19)

1. On the Menu screen, press SCHEDULE

2. Press NEXT or PREVIOUS to highlight one of the following schedules.

OCCPC01S — LOCAL Time Schedule OCCPC02S — ICE BUILD Time Schedule OCCPC03-99S — CCN Time Schedule (Actual

number is deﬁned in Conﬁg table.)

3. Press SELECT to access and view the time schedule.

4. Press NEXT or PREVIOUS to highlight the desired period or override that you wish to change.

Fig. 18 — Example of Point Status Screen

(Status01)

5. Press SELECT to access the highlighted period or override.

6. a. Press INCREASE or DECREASE to change the

time values. Override values are in one-hour increments, up to 4 hours.

b. Press ENABLE to select days in the day-of-week

ﬁelds. Press DISABLE

to eliminate days from the

period.

7. Press ENTER to register the values and to move horizontally (left to right) within a period.

8. Press EXIT to leave the period or override.

9. Either return to Step 4 to select another period or override, or press EXIT

again to leave the cur-

rent time schedule screen and save the changes.

10. Holiday Designation (HOLIDEF table) may be found in the Service Operation section, page 44. You must assign the month, day,and duration for the holiday.The Broadcast function in the Brodefs table also must be enabled for holiday periods to function.

TO VIEW AND CHANGE SET POINTS (Fig. 20)

1. To view the Set Point table, at the Menu screen press SETPOINT

2. There are 4 set points on this screen: Base Demand Limit;

LCW Set Point (leaving chilled water set point); ECW Set Point (entering chilled water set point); and ICE BUILD set point. Only one of the chilled water set points can be active at one time, and the type of set point is activated in the Service menu. ICE BUILD is also activated and conﬁgured in the Service menu.

3. Press NEXT

or PREVIOUS to highlight the desired

set point entry.

4. Press SELECT to modify the highlighted set point.

5. Press INCREASE or DECREASE to change the se-

lected set point value.

6. Press ENTER to save the changes and return to the

previous screen.

SERVICE OPERATION — To view the menu-driven programs available for Service Operation, see Service Operation section, page 44. For examples of LID display screens, see Table 2.

Fig. 19 — Example of Time Schedule

Operation Screen

Fig. 20 — Example of Set Point Screen

Table 2 — LID Screens

NOTES:

1. Only 12 lines of information appear on the LID screen at any given time. Press NEXT

or PREVIOUS to highlight a point or to view points

below or above the current screen.

2. The LID may be conﬁgured in English or SI units, as required, through the LID conﬁguration screen.

3. Data appearing in the Reference Point Names column is used for CCN operations only.

EXAMPLE1—STATUS01 DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press STATUS

(STATUS01 will be highlighted).

3. Press SELECT

DESCRIPTION RANGE UNITS

REFERENCE POINT NAME

(ALARM HISTORY)

Control Mode Reset.Off.Local.CCN MODE Run Status Timeout.Recycle.Startup. STATUS

Ramping.Running.Demand. Override.Shutdown.Abnormal. Pumpdown

Occupied ? No/Yes OCC Alarm State Normal/Alarm ALM *Chiller Start/Stop Stop/Start CHIL S S Base Demand Limit 40-100 % DLM *Active Demand Limit 40-100 % DEM LIM Compressor Motor Load 0-999 % CA L

Current 0-999 % CA P

Amps 0-9999 AMPS CA A *Target Guide Vane Pos 0-100 % GV TRG Actual Guide Vane Pos 0-100 % GV ACT Water/Brine: Setpoint 10-120 (–12.2-48.9) DEG F (DEG C) SP * Control Point 10-120 (–12.2-48.9) DEG F (DEG C) LCW STPT Entering Chilled Water –40-245 (–40-118) DEG F (DEG C) ECW Leaving Chilled Water –40-245 (–40-118) DEG F (DEG C) LCW Entering Condenser Water –40-245 (–40-118) DEG F (DEG C) ECDW Leaving Condenser Water –40-245 (–40-118) DEG F (DEG C) LCDW Evaporator Refrig Temp –40-245 (–40-118) DEG F (DEG C) ERT Evaporator Pressure –6.7-420 (–46-2896) PSI (kPa) ERP Condenser Refrig Temp –40-245 (–40-118) DEG F (DEG C) CRT Condenser Pressure –6.7-420 (–46-2896) PSI (kPa) CRP Discharge Temperature –40-245 (–40-118) DEG F (DEG C) CMPD Bearing Temperature –40-245 (–40-118) DEG F (DEG C) MTRB Motor Winding Temp† –40-245 (–40-118) DEG F (DEG C) MTRW Motor Winding Hi

Temp Cutout**

Normal/Alarm MTRW

Oil Sump Temperature –40-245 (–40-118) DEG F (DEG C) OILT Oil Pressure Transducer† –6.7-420 (–46-2896) PSI (kPa) OILP Oil Pressure†† –6.7-420 (–46-2896) PSID (kPad) OILPD Line Voltage: Percent 0-999 % V P

Actual 0-9999 VOLTS V A *Remote Contacts Input Off/On REMCON Total Compressor Starts 0-65535 c starts Starts in 12 Hours 0-8 STARTS Compressor Ontime 0-500000.0 HOURS c hrs *Service Ontime 0-32767 HOURS S HRS *Compressor Motor kW 0-9999 kW CKW

NOTE: All values are variables available for read operation to a CCN. Descriptions shown with (*) support write operations for BEST programming language, data-transfer, and overriding.

†Information is applicable to hermetic machines only.

**Information is applicable to open-drive machines only.

††Oil pressure is read directly from a differential pressure module on 17EX machines.

Table 2 — LID Screens (cont)

EXAMPLE2—STATUS02 DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press STATUS

3. Scroll down to highlight STATUS02.

4. Press SELECT

DESCRIPTION

POINT TYPE

UNITS

REFERENCE POINT NAME

(ALARM HISTORY)

INPUT OUTPUT

Hot Gas Bypass Relay X OFF/ON HGBR *Chilled Water Pump X OFF/ON CHWP Chilled Water Flow X NO/YES EVFL *Condenser Water Pump X OFF/ON CDP Condenser Water Flow X NO/YES CDFL Compressor Start Relay X OFF/ON CMPR Compressor Start Contact X OPEN/CLOSED 1CR AUX Compressor Run Contact X OPEN/CLOSED RUN AUX Starter Fault Contact X OPEN/CLOSED STR FLT Pressure Trip Contact X OPEN/CLOSED PRS TRIP Single Cycle Dropout X NORMAL/ALARM V1 CYCLE Oil Pump Relay X OFF/ON OILR Oil Heater Relay X OFF/ON OILH Motor Cooling Relay† X OFF/ON MTRC Auxiliary Oil Pump Relay** X OFF/ON AUXOILR *Tower Fan Relay X OFF/ON TFR Compr. Shunt Trip Relay X OFF/ON TRIPR Alarm Relay X NORMAL/ALARM ALM Spare Prot Limit Input X ALARM/NORMAL SPR PL

NOTE: All values are variables available for read operation to a CCN. Descriptions shown with (*) support write operations from the LID only.

†Information is applicable to hermetic machines only.

**Information is applicable to open-drive machines only.

EXAMPLE3—STATUS03 DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press STATUS

3. Scroll down to highlight STATUS03.

4. Press SELECT

DESCRIPTION RANGE UNITS

REFERENCE POINT NAME

(ALARM HISTORY)

OPTIONS BOARD 1 *Demand Limit 4-20 mA 4-20 mA DEM OPT

*Temp Reset 4-20 mA 4-20 mA RES OPT *Common CHWS Sensor –40-245 (–40-118) DEG F (DEG C) CHWS *Common CHWR Sensor –40-245 (–40-118) DEG F (DEG C) CHWR *Remote Reset Sensor –40-245 (–40-118) DEG F (DEG C) R RESET *Temp Sensor — Spare 1 –40-245 (–40-118) DEG F (DEG C) SPARE1 *Temp Sensor — Spare 2 –40-245 (–40-118) DEG F (DEG C) SPARE2 *Temp Sensor — Spare 3 –40-245 (–40-118) DEG F (DEG C) SPARE3

OPTIONS BOARD 2 *4-20 mA — Spare 1 4-20 mA SPARE1 M

*4-20 mA — Spare 2 4-20 mA SPARE2 M *Temp Sensor — Spare 4 –40-245 (–40-118) DEG F (DEG C) SPARE4 *Temp Sensor — Spare 5 –40-245 (–40-118) DEG F (DEG C) SPARE5 *Temp Sensor — Spare 6 –40-245 (–40-118) DEG F (DEG C) SPARE6 *Temp Sensor — Spare 7 –40-245 (–40-118) DEG F (DEG C) SPARE7 *Temp Sensor — Spare 8 –40-245 (–40-118) DEG F (DEG C) SPARE8 *Temp Sensor — Spare 9 –40-245 (–40-118) DEG F (DEG C) SPARE9

NOTE: All values shall be variables available for read operation to a CCN network. Descriptions shown with (*) support write operations for BEST programming language, data-transfer, and overriding.

Table 2 — LID Screens (cont)

EXAMPLE 4 — SETPOINT DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SETPOINT

DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE

Base Demand Limit 40-100 % DLM 100 LCW Setpoint 20-120 (–6.7-48.9) DEG F (DEG C) lcw sp

50.0 (10.0)

ECW Setpoint 20-120 (–6.7-48.9) DEG F (DEG C) ecw sp 60.0 (15.6) ICE BUILD Setpoint 20- 60 (–6.7-15.6) DEG F (DEG C) ice sp 40.0 ( 4.4)

EXAMPLE 5 — CONFIGURATION (CONFIG) DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight EQUIPMENT CONFIGURATION.

4. Press SELECT

5. Scroll down to highlight CONFIG.

6. Press SELECT

DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE

RESET TYPE 1 Degrees Reset at 20 mA –30-30 (–17-17) DEG F (DEG C) deg 20ma

10D(6D)

RESET TYPE 2 Remote Temp (No Reset) –40-245 (–40-118) DEG F (DEG C) res rt1

85 (29)

Remote Temp (Full Reset) –40-245 (–40-118) DEG F (DEG C) res rt2

65 (18)

Degrees Reset –30-30 (–17-17) DEG F (DEG C) res rt 10D(6D) RESET TYPE 3

CHW Delta T (No Reset) 0-15 (0-8) DEG F (DEG C) restd 1

10D(6D)

CHW Delta T (Full Reset) 0-15 (0-8) DEG F (DEG C) restd 2 0D(0D) Degrees Reset –30-30 (–17-17) DEG F (DEG C) deg chw

5D(3D)

Select/Enable Reset Type 0-3 res sel

ECW CONTROL OPTION DISABLE/ENABLE ecw opt

DISABLE

Demand Limit At 20 mA 40-100 % dem 20ma

20mA Demand Limit Option DISABLE/ENABLE dem sel DISABLE Auto Restart Option DISABLE/ENABLE astart DISABLE Remote Contacts Option DISABLE/ENABLE r contact

DISABLE

Temp Pulldown Deg/Min 2-10 tmp ramp

Load Pulldown %/Min 5-20 kw ramp

Select Ramp Type: 0/1 ramp opt 1

Temp=0,Load=1

Loadshed Group Number 0-99 ldsgrp 0 Loadshed Demand Delta 0-60 % ldsdelta 20 Maximum Loadshed Time 0-120 MIN maxldstm 60

CCN Occupancy Conﬁg:

Schedule Number 3-99 occpcxxe 3 Broadcast Option DISABLE/ENABLE occbrcst DISABLE

ICE BUILD Option DISABLE/ENABLE ibopt DISABLE ICE BUILD TERMINATION

0 =Temp, 1 =Contacts, 2 =Both 0-2 ibterm 0

ICE BUILD Recycle Option DISABLE/ENABLE ibrecyc DISABLE

NOTE: D = delta degrees.

Table 2 — LID Screens (cont)

EXAMPLE 6 — LEAD/LAG CONFIGURATION DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight EQUIPMENT CONFIGURATION.

4. Press SELECT

5. Scroll down to highlight LEAD/LAG.

6. Press SELECT

LEAD/LAG CONFIGURATION SCREEN

DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE

LEAD/LAG SELECT

DISABLE =0, LEAD =1, LAG =2, STANDBY =3

0-3 leadlag 0

Load Balance Option DISABLE/ENABLE loadbal DISABLE Common Sensor Option DISABLE/ENABLE commsens DISABLE LAG Percent Capacity 25-75 % lag per

LAG Address 1-236 lag add

LAG START Timer 2-60 MIN lagstart 10 LAG STOP Timer 2-60 MIN lagstop 10 PRESTART FAULT Timer 0-30 MIN preﬂt 5 STANDBY Chiller Option DISABLE/ENABLE stndopt DISABLE STANDBY Percent Capacity 25-75 % stnd per

STANDBY Address 1-236 stnd add

Table 2 — LID Screens (cont)

EXAMPLE 7 — SERVICE1 DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight EQUIPMENT SERVICE.

4. Press SELECT

5. Scroll down to highlight SERVICE1.

6. Press SELECT

DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE

Motor Temp Override* 150-200 (66-93) DEG F (DEG C) mt over

200 (93)

Cond Press Override 90-200 (620-1379) PSI (kPa) cp over

125 (862)

Refrig Override Delta T 2-5 (1-3) DEG F (DEG C) ref over 3D (1.6D) Chilled Medium Water/Brine medium WATER Brine Refrig Trippoint 8-40 (–13.3-4) DEG F (DEG C) br trip

33 (1)

Compr Discharge Alert 125-200 (52-93) DEG F (DEG C) cd alert

200 (93)

Bearing Temp Alert 165-210 (74-99) DEG F (DEG C) tb alert 210 (99) Water Flow Verify Time 0.5-5 MIN wﬂow t

Oil Press Verify Time 15-300 SEC oilpr t 15 Water/Brine Deadband 0.5-2.0 (0.3-1.1) DEG F (DEG C) cw db

1.0 (0.6)

Recycle Restart Delta T 2.0-10.0 (1.1-5.6) DEG F (DEG C) rcycrdt 5 (2.8) Recycle Shutdown Delta† 0.5-4.0 (.27-2.2) rcycsdt 1.0 (0.6) Surge Limit/HGBP Option 0/1 srg hgbp

Select: Surge=0, HGBP=1 Surge/HGBP Delta T1 0.5-15 (0.3-8.3) DEG F (DEG C) hgb dt1

1.5 (0.8)

Surge/HGBP Delta P1 30-170 (207-1172) PSI (kPa) hgb dp1 50 (345) Min. Load Points (T1/P1) Surge/HGBP Delta T2 0.5-15 (0.3-8.3) DEG F (DEG C) hgb dt2

10 (5.6)

Surge/HGBP Delta P2 30-170 (207-1172) PSI (kPa) hgb dp2 85 (586) Full Load Points (T2/P2) Surge/HGBP Deadband 1-3 (0.6-1.6) DEG F (DEG C) hgb dp

1 (0.6)

Surge Delta Percent Amps 10-50 % surge a

Surge Time Period 1-5 MIN surge t 2 Demand Limit Source 0/1 dem src

Select: Amps=0, Load=1 Amps Correction Factor 1-8 corfact 3 Motor Rated Load Amps 1-9999 AMPS a fs

200

Motor Rated Line Voltage 1-9999 VOLTS v fs 460 Meter Rated Line KW 1-9999 kW kw fs 600

Line Frequency 0/1 HZ freq 0 Select: 0=60 Hz, 1=50 Hz

Compr Starter Type REDUCE/FULL starter REDUCE Condenser Freeze Point –20-35 (–28.9-1.7) DEG F (DEG C) cdfreeze 34 (1) Soft Stop Amps Threshold 40-100 % softstop 100 Stop to Start Timer† 3-50 MIN stopmtr 20

NOTE: D = delta degrees. *Information is applicable to hermetic machines only.

†Information is applicable to open-drive machines only.

31 1197

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Table 2 — LID Screens (cont)

EXAMPLE 8 — SERVICE2 DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight EQUIPMENT SERVICE.

4. Press SELECT

5. Scroll down to highlight SERVICE2.

6. Press SELECT

DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE OPTIONS BOARD 1 20 mA POWER CONFIGURATION

External = 0, Internal = 1 RESET 20 mA Power Source 0,1 res 20 ma

DEMAND 20 mA Power Source 0,1 dem 20 ma 0 SPARE ALERT ENABLE

Disable = 0, 1 = High Alert, 2 = Low Alert, 3 = High Alarm, 4 = Low Alarm Temp = Alert Threshold

CHWS Temp Enable 0-4 chws en

CHWS Temp Alert –40-245 (–40-118) DEG F (DEG C) chws al 245 (118) CHWR Temp Enable 0-4 chwr en 0 CHWR Temp Alert –40-245 (–40-118) DEG F (DEG C) chwr al

245 (118)

Reset Temp Enable 0-4 rres en 0 Reset Temp Alert –40-245 (–40-118) DEG F (DEG C) rres al 245 (118) Spare Temp 1 Enable 0-4 spr1 en

Spare Temp 1 Alert –40-245 (–40-118) DEG F (DEG C) spr1 al 245 (118) Spare Temp 2 Enable 0-4 spr2 en 0 Spare Temp 2 Alert –40-245 (–40-118) DEG F (DEG C) spr2 al

245 (118)

Spare Temp 3 Enable 0-4 spr3 en 0 Spare Temp 3 Alert –40-245 (–40-118) DEG F (DEG C) spr3 al

245 (118)

OPTIONS BOARD 2 20 mA POWER CONFIGURATION

External = 0, Internal = 1 SPARE 1 20 mA Power Source 0,1 sp1 20 ma

SPARE 2 20 mA Power Source 0,1 sp2 20 ma 0 SPARE ALERT ENABLE

Disable = 0, 1 = High Alert, 2 = Low Alert, 3 = High Alarm, 4 = Low Alarm Temp = Alert Threshold

Spare Temp 4 Enable 0-4 spr4 en

Spare Temp 4 Alert –40-245 (–40-118) DEG F (DEG C) spr4 al 245 (118) Spare Temp 5 Enable 0-4 spr5 en 0 Spare Temp 5 Alert –40-245 (–40-118) DEG F (DEG C) spr5 al

245 (118)

Spare Temp 6 Enable 0-4 spr6 en 0 Spare Temp 6 Alert –40-245 (–40-118) DEG F (DEG C) spr6 al

245 (118)

Spare Temp 7 Enable 0-4 spr7 en 0 Spare Temp 7 Alert –40-245 (–40-118) DEG F (DEG C) spr7 al 245 (118) Spare Temp 8 Enable 0-4 spr8 en

Spare Temp 8 Alert –40-245 (–0-118) DEG F (DEG C) spr8 al 245 (118) Spare Temp 9 Enable 0-4 spr9 en 0 Spare Temp 9 Alert –40-245 (–40-118) DEG F (DEG C) spr9 al

245 (118)

NOTE: This screen provides the means to generate alert messages based on exceeding the ‘‘Temp’’ threshold for each point listed. If the ‘‘Enable’’ is set to 1, a value above the ‘‘Temp’’ threshold shall generate an alert message. If the ‘‘Enable’’is set to 2, a value below the ‘‘Temp Alert’’threshold shall generate an alert message. If the ‘‘Enable’’is set to 0,alert generation is disabled. Ifthe ‘‘Enable’’isset to 3, a valueabove the ‘‘Temp’’threshold will generate an alarm. If the ‘‘Enable’’ is set to 4, a value below the ‘‘Temp’’ threshold will generate an alarm.

EXAMPLE 9 — SERVICE3 DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight EQUIPMENT SERVICE.

4. Press SELECT

5. Scroll down to highlight SERVICE3.

DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE

Proportional Inc Band 2-10 gv inc

6.5

Proportional Dec Band 2-10 gv de 6.0 Proportional ECW Gain 1-3 gv ecw 2.0

Guide Vane Travel Limit 30-100 % gv lim

Table 2 — LID Screens (cont)

EXAMPLE 10 — MAINTENANCE (MAINT01) DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight CONTROL ALGORITHM STATUS.

4. Press SELECT

5. Scroll down to highlight MAINT01.

DESCRIPTION RANGE/STATUS UNITS REFERENCE POINT NAME

CAPACITY CONTROL Control Point 10-120 (–12.2-48.9) DEG F (DEG C) ctrlpt Leaving Chilled Water –40-245 (–40-118) DEG F (DEG C) LCW Entering Chilled Water –40-245 (–40-118) DEG F (DEG C) ECW Control Point Error –99-99 (–55-55) DEG F (DEG C) cperr ECW Delta T –99-99 (–55-55) DEG F (DEG C) ecwdt ECW Reset –99-99 (–55-55) DEG F (DEG C) ecwres LCW Reset –99-99 (–55-55) DEG F (DEG C) lcwres Total Error + Resets –99-99 (–55-55) DEG F (DEG C) error Guide Vane Delta –2-2 % gvd Target Guide Vane Pos 0-100 % GV TRG Actual Guide Vane Pos 0-100 % GV ACT

Proportional Inc Band 2-10 gv inc Proportional Dec Band 2-10 gv dec Proportional ECW Gain 1-3 gv ecw Water/Brine Deadband 0.5-2 (0.3-1.1) DEG F (DEG C) cwdb

NOTE: Overriding is not supported on this maintenance screen.Active overrides show the associated point in alert (!). Only values with capital letter reference point names are variables available for read operation.

EXAMPLE 11 — MAINTENANCE (MAINT02) DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight CONTROL ALGORITHM STATUS.

4. Press SELECT

5. Scroll down to highlight MAINT02.

6. Press SELECT

DESCRIPTION RANGE/STATUS UNITS REFERENCE POINT NAME

OVERRIDE/ALERT STATUS MOTOR WINDING TEMP† –40-245 (–40-118) DEG F (DEG C) MTRW

Override Threshold 150-200 (66-93) DEG F (DEG C) mt over CONDENSER PRESSURE –6.7-420 (–42-2896) PSI (kPa) CRP Override Threshold 90-245 (621-1689) PSI (kPa) cp over EVAPORATOR REFRIG TEMP –40-245 (–40-118) DEG F (DEG C) ERT Override Threshold 2-45 (1-7.2) DEG F (DEG C) rt over DISCHARGE TEMPERATURE –40-245 (–40-118) DEG F (DEG C) CMPD Alert Threshold 125-200 (52-93) DEG F (DEG C) cd alert BEARING TEMPERATURE –40-245 (–40-118) DEG F (DEG C) MTRB Alert Threshold 175-185 (79-85) DEG F (DEG C) tb alert

†Information is applicable to hermetic machines only.

33 1197

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Table 2 — LID Screens (cont)

EXAMPLE 12 — MAINTENANCE (MAINT03) DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight CONTROL ALGORITHM STATUS.

4. Press SELECT

5. Scroll down to highlight MAINT03.

6. Press SELECT

DESCRIPTION RANGE/STATUS UNITS REFERENCE POINT NAME

SURGE/HGBP ACTIVE ? NO/YES Active Delta P 0-200 (0-1379) PSI (kPa) dp a

Active Delta T 0-200 (0-111) DEG F (DEG C) dt a Calculated Delta T 0-200 (0-111) DEG F (DEG C) dt c

Surge Protection Counts 0-12 spc

NOTE: Override is not supported on this maintenance screen. Only values with capital letter reference point names are variables available for read operation.

EXAMPLE 13 — MAINTENANCE (MAINT04) DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight CONTROL ALGORITHM STATUS.

4. Press SELECT

5. Scroll down to highlight MAINT04.

6. Press SELECT

DESCRIPTION RANGE/STATUS UNITS REFERENCE POINT NAME

LEAD/LAG: Conﬁguration DISABLE,LEAD,LAG,STANDBY, INVALID leadlag

Current Mode DISABLE,LEAD,LAG,STANDBY, CONFIG llmode Load Balance Option DISABLE/ENABLE loadbal LAG Start Time 0-60 MIN lagstart LAG Stop Time 0-60 MIN lagstop Prestart Fault Time 0-30 MIN preﬂt Pulldown: Delta T/Min x.xx D DEGF(DDEG C) pull dt

Satisﬁed? No/Yes pull sat LEAD CHILLER in Control No/Yes leadctrl LAG CHILLER: Mode Reset,Off,Local,CCN lagmode

Run Status Timeout,Recycle,Startup,Ramping,Running

Demand,Override,Shutdown,Abnormal,Pumpdown

lagstat

Start/Stop Stop,Start,Retain lag s s

Recovery Start Request No/Yes lag rec

STANDBY CHILLER: Mode Reset,Off,Local,CCN stdmode

Run Status Timeout,Recycle,Startup,Ramping,Running

Demand,Override,Shutdown,Abnormal,Pumpdown

stdstat

Start/Stop Stop,Start,Retain std s s

Recovery Start Request No/Yes std rec

NOTES:

1. Only values with capital letter reference point names are variables available for read operation. Forcing is not supported on this maintenance screen.

2. D = delta degrees.

PIC System Functions

NOTE: Throughout this manual, words printed in capital letters and italics are values that may be viewed on the LID. See Table 2 for examples of LID screens. Point names are listed in the Description column. An overview of LID operation and menus is given in Fig. 14-20.

CAPACITY CONTROL — The PIC controls the machine capacity by modulating the inlet guide vanes in response to chilled water temperature changes away from the CON- TROL POINT. The CONTROL POINT may be changed by a CCN network device, or is determined by the PIC adding any active chilled water reset to the chilled water SET POINT. The PIC uses the PROPORTIONAL INC (Increase) BAND,

PROPORTIONAL DEC (Decrease) BAND, and the PROPORTIONAL ECW (Entering Chilled Water) GAIN to de-

termine how fast or slow to respond. CONTROL POINT may be viewed/overridden on the Status table, Status01 selection.

ENTERING CHILLED WATER CONTROL — If this option is enabled, the PIC uses ENTERING CHILLED WATER temperature to modulate the vanes instead of LEAVING

CHILLED WATER temperature. ENTERING CHILLED WATER control option may be viewed/modiﬁed on the Equip-

ment Conﬁguration table, Conﬁg table. DEADBAND — This is the tolerance on the chilled water/

brine temperature CONTROL POINT. If the water tempera- ture goes outside of the DEADBAND, the PIC opens or closes the guide vanes in response until it is within tolerance. The PIC may be conﬁgured with a 0.5° to 2° F (0.3° to 1.1° C) deadband. DEADBAND may be viewed or modiﬁed on the Equipment Service1 table.

For example, a 1° F (0.6° C) deadband setting controls the water temperature within ±0.5° F (0.3° C) of the control point. This may cause frequent guide vane movement if the chilled water load ﬂuctuates frequently. A value of 1° F (0.6° C) is the default setting.

PROPORTIONALBANDSAND GAIN — Proportional band is the rate at which the guide vane position is corrected in proportion to how far the chilled water/brine temperature is from the control point. Proportional gain determines how quickly the guide vanes react to how quickly the temperature is moving from CONTROL POINT.

The Proportional Band can be viewed/modiﬁed on the LID. There are two response modes, one for temperature response above the control point, the other for response below the control point.

The ﬁrst type is called PROPORTIONAL INC BAND, and it can slow or quicken vane response to chilled water/brine temperature above DEADBAND. It can be adjusted from a setting of 2 to 10; the default setting is 6.5. PROPOR- TIONAL DEC BAND can slow or quicken vane response to chilled water temperature below deadband plus control point. It can be adjusted on the LID from a setting of 2 to 10, and the default setting is 6.0. Increasing either of these settings will cause the vanes to respond slower than a lower setting.

The PROPORTIONAL ECW GAIN can be adjusted at the LID display from a setting of 1.0 to 3.0, with a default setting of

2.0. Increase this setting to increase guide vane response to a change in entering chilled water temperature. The proportional bands and gain may be viewed/modiﬁed on the Equipment Service3 table.

DEMAND LIMITING — The PIC will respond to the AC- TIVE DEMAND LIMIT set point by limiting the opening of the guide vanes. It will compare the set point to either COM-

PRESSOR MOTOR LOAD or COMPRESSOR MOTOR CURRENT (percentage), depending on how the control is con-

ﬁgured for the DEMAND LIMIT SOURCE which is accessed on the SERVICE1 table. The default setting is current limiting.

MACHINE TIMERS — The PIC maintains 2 runtime clocks, known as COMPRESSOR ONTIME and SERVICE ONTIME. COMPRESSOR ONTIME indicates the total lifetime compressor run hours. This timer can register up to 500,000 hours before the clock turns back to zero. The SERV- ICE ONTIME is a resettable timer that can be used to indicate the hours since the last service visit or any other reason. The time can be changed through the LID to whatever value is desired. This timer can register up to 32,767 hours before it rolls over to zero.

The chiller also maintains a start-to-start timer and a stopto-start timer. These timers limit how soon the machine can be started. See the Start-Up/Shutdown/Recycle Sequence section, page 45, for operational information.

OCCUP ANCYSCHEDULE— This schedule determines when the chiller is either occupied or unoccupied.

Each schedule consists of from one to 8 occupied/unoccupied time periods, set by the operator. These time periods can be enabled to be in effect, or not in effect, on each day of the week and for holidays. The day begins with 0000 hours and ends with 2400 hours. The machine is in OCCUPIED mode unless an unoccupied time period is in effect.

The machine will shut down when the schedule goes to UNOCCUPIED. These schedules can be set up to follow the building schedule or to be 100% OCCUPIED if the operator wishes. The schedules also can be bypassed by forcing the Start/Stop command on the PIC Status screen to start. The schedules also can be overridden to keep the unit in an OCCUPIED mode for up to 4 hours, on a one-time basis.

Figure 19 shows a schedule for a typical office building time schedule, with a 3-hour, off-peak cool down period from midnight to 3 a.m., following a weekend shutdown. Example: Holiday periods are unoccupied 24 hours per day. The building operates Monday through Friday, 7:00 a.m. to 6:00 p.m., with a Saturday schedule of 6:00 a.m. to 1:00 p.m., and includes the Monday midnight to 3:00 a.m. weekend cool-down schedule.

NOTE: This schedule is for illustration only, and is not intended to be a recommended schedule for chiller operation.

Whenever the chiller is in the LOCAL mode, the machine uses Occupancy Schedule 01.

The Ice Build Time Schedule is Schedule 02. When in the CCN mode, Occupancy Schedule 03 is used.

The CCN schedule number is deﬁned on the Conﬁg table in the Equipment Conﬁguration table on page 29. The schedule number can change to any value from 03 to 99. If this schedule number is changed on the Conﬁg table, the operator must use the Attach to Network Device table to upload the new number into the Schedule screen. See Fig. 17.

Safety Controls — The PIC monitors all safety control

inputs, and if required, shuts down the machine or limits the guide vanes to protect the machine from possible damage from any of the following conditions:

• high bearing temperature

• high motor winding temperature

• high discharge temperature

• low oil pressure

• low cooler refrigerant temperature/pressure

• condenser high pressure or low pressure

• inadequate water/brine cooler and condenser ﬂow

• high, low, or loss of voltage

• excessive motor acceleration time

• excessive starter transition time

• lack of motor current signal

• excessive motor amps

• excessive compressor surge

• temperature and transducer faults

Starter faults or optional protective devices within the starter can shut down the machine. These devices are dependent on what has been purchased as options.

If compressor motor overload or ground fault occurs, check the motor for grounded or open phases before attempting a restart.

If the controller initiates a safety shutdown, it displays the fault on the LID with a primary and a secondary message, and energizes an alarm relay in the starter and blinks the alarm light on the control center.The alarm is stored in memory and can be viewed in the PIC Alarm History table along with a message for troubleshooting.

To give a better warning as to the operating condition of the machine, the operator also can deﬁne alert limits on various monitored inputs. Safety contact and alert limits are deﬁned in Table 3. Alarm and alert messages are listed in the Troubleshooting Guide section, page 83.

SHUNT TRIP — The optional shunt trip function of the PIC is a safety trip. The shunt trip is wired from an output on the SMM to the motor circuit breaker. If the PIC tries to shut down the compressor through normal shutdown procedure but is unsuccessful for 30 seconds, the shunt trip output is energized and causes the circuit breaker to trip off. If ground fault protection has been applied to the starter, the ground fault trip will also energize the shunt trip to trip the circuit breaker.

Default Screen Freeze — Whenever an alarm oc-

curs, the LID default screen will freeze displaying the condition of the machine at the time of alarm. Knowledge of the operating state of the chiller at the time an alarm occurs is useful when troubleshooting. Current machine information can be viewed on the Status tables. Once all existing alarms

are cleared (by pressing the RESET

softkey), the default

LID will return to normal operation.

Motor Cooling Control (Hermetic Motors Only) —

Motor temperature is reduced by refrigerant entering the motor shell and evaporating. The refrigerant is regulated by the motor cooling relay. This relay will energize when the compressor is running and motor temperature is above 125 F (51.7 C). The relay will close when motor temperature is below 100 F (37.8 C). Note that there is always a minimum ﬂow of refrigerant when the compressor is operating for motor cooling; the relay only controls additional refrigerant to the motor.

NOTE:An additional motor cooling relay is not required for Hermetic FA style compressors.

Auxiliary Oil Pump Control (Open Drive Machines Only) —

The auxiliary oil pump (optional) is controlled by the PIC. During start-up, if the main oil pump cannot raise pressure to 18 psid (124 kPa), the auxiliary oil pump will be energized. During compressor operation, the auxiliary oil pump will be energized if the oil pressure falls below the alert threshold (18 psid [124 kPa]). Once running, the auxiliary oil pump will remain on until the compressor is turned off and will deenergize with the main oil pump after the post-lube time period.

Shaft Seal Oil Control (Open Drive Machines Only) —

All open drive machines require that the shaft

seal be bathed in oil at all times, especially when the

machine is not running. This ensures that refrigerant does not leak past the seal. The PIC control will energize the oil pump for one minute if the oil pump has not operated during the past 12 hours.

It is important to note that if control power is to be turned offfor longer than this period, the refrigerant charge must be pumped over into the utility vessel. Because the oil heater will also be off during this time, storing the refrigerant will also prevent refrigerant migration into the oil.

Ramp Loading Control — The ramp loading control

slows down the rate at which the compressor loads up. This control can prevent the compressor from loading up during the short period of time when the machine is started, and the chilled water loop has to be brought down to normal design conditions. This helps reduce electrical demand charges by slowly bringing the chilled water to control point. However, the total power draw during this period remains almost unchanged.

There are 2 methods of ramp loading with the PIC. Ramp loading can be based on chilled water temperature or on motor load.

1. Temperature ramp loading limits the rate at which either

leaving chilled water or entering chilled water temperature decreases by an operator-conﬁgured rate. The lowest temperature ramp table will be used the ﬁrst time the machine is started (at commissioning). The lowest temperature ramp rate will also be used if machine power has been off for 3 hours or more (even if the motor ramp load is selected).

2. Motor load ramp loading limits the rate at which the com-

pressor motor current or compressor motor load increases by an operator-conﬁgured rate.

The TEMP (Temperature) PULLDOWN, LOAD PULL DOWN, and SELECT RAMP TYPE may be viewed/modified on the LID Equipment Conﬁguration table, Conﬁg table (see Table 2). Motor load is the default type.

Capacity Override (See Table4) — These can pre-

vent some safety shutdowns caused by exceeding motor amperage limit, refrigerant low temperature safety limit, motor high temperature safety limit, and condenser high pressure limit. In all cases there are 2 stages of compressor vane control.

1. The vanes are held from opening further, and the status

line on the LID indicates the reason for the override.

2. The vanes are closed until condition decreases below the

ﬁrst step set point, and then the vanes are released to normal capacity control.

Whenever the motor current demand limit set point is reached, it activates a capacity override, again with a 2-step process. Exceeding 110% of the rated load amps for more than 30 seconds will initiate a safety shutdown.

The compressor high lift (surge prevention) set point will cause a capacity override as well. When the surge prevention set point is reached, the controller normally will only hold the guide vanes from opening. If so equipped, the hot gas bypass valve will open instead of holding the vanes.

HighDischarge TemperatureControl — If the dis-

charge temperature increases above 200 F (93 C), the guide vanes are proportionally opened to increase gas ﬂow through the compressor.If the leaving chilled water temperature drops 5° F (2.8° C) below the control point temperature, machine will enter the recycle mode.

Table 3 — Protective Safety Limits and Control Settings

MONITORED PARAMETER LIMIT APPLICABLE COMMENTS

TEMPERATURE SENSORS OUT OF RANGE

–40 to 245 F (–40 to 118.3 C) Must be outside range for 2 seconds

PRESSURE TRANSDUCERS OUT OF RANGE

0.08 to 0.98 Voltage Ratio

Must be outside range for 2 seconds. Ratio = Input Voltage ÷ Voltage Reference

COMPRESSOR DISCHARGE TEMPERATURE

.220 F (104.4 C) Preset, alert setting conﬁgurable

MOTOR WINDING TEMPERATURE .220 F (104.4 C) Preset, alert setting conﬁgurable BEARING TEMPERATURE .220 F (104.4 C) Preset, alert setting conﬁgurable

EVAPORATOR REFRIGERANT TEMPERATURE (Temp converted from Pressure Reading)

,33 F (for water chilling) (0.6° C)

Preset, conﬁgure chilled medium for water (Service1 table)

,Brine Refrigerant Trippoint (set point adjustable from 0 to 40 F [–18 to 4 C] for brine chilling)

Conﬁgure chilled medium for brine (Service1 table). Adjust brine refrigerant trippoint for proper cutout

TRANSDUCER VOLTAGE ,4.5 vdc . 5.5 vdc

Preset (Read voltage at terminals 34 and 35 on PSIO module)

CONDENSER PRESSURE — SWITCH

.218 ± 7 psig (1503 ± 48 kPa), reset at 120 ± 10 (827 ± 69 kPa)

Preset

— CONTROL 215 psig (1482 kPa) Preset

OIL PRESSURE — SWITCH Cutout ,11 psid (76 kPad) ± 1.5 psid (10.3 kPad)

Cut-in .16.5 psid (114 kPad) ± 4 psid (27.5 kPad)

Preset, no calibration needed

— CONTROL

Cutout ,15 psid (103 kPad) Alert ,18 psid (124 kPad)

Preset

LINE VOLTAGE — HIGH .110% for one minute

Preset, based on transformed line voltage to 24 vac rated-input to the Starter Management Module. Also monitored at PSIO power input.

— LOW ,90% for one minute or <85% for 3 seconds — SINGLE-CYCLE ,50% for one cycle

COMPRESSOR MOTOR LOAD (% Compressor Amps)

.110% for 30 seconds Preset ,10% with compressor running Preset .10% with compressor off Preset

STARTER ACCELERATION TIME (Determined by inrush current going below 100% compressor motor load)

.45 seconds

For machines with reduced voltage mechanical and solid-state starters

.10 seconds

For machines with full voltage starters (Conﬁgured on Service1 table)

STARTER TRANSITION .75 seconds Reduced voltage starters only

CONDENSER FREEZE PROTECTION

Energizes condenser pump relay if condenser refrigerant temperature or condenser entering water temperature is below the conﬁgured condenser freeze point temperature. Deenergizes when the temperature is5F(3C)above condenser freeze point temperature.

CONDENSER FREEZE POINT conﬁgured in Service01 table with a default setting of 34F(1C).

IMPELLER CLEARANCE Displacement switch open Thrust movement excessive MOTOR LEAK DETECTOR* Water from motor cooling is leaking

Water sensors are installed only on open-drive motors that use water cooling. (Totally enclosed, water-to-air cooled [TEWAC] motors)

Flow Switches (Field Supplied)

Operate water pumps with machine off. Manually reduce water ﬂow and observe switch for proper cutout. Safety shutdown occurs when cutout time exceeds 3 seconds.

CUT-OFF SETTING ADJUSTMENT SCREW

Carrier Part No. HK06ZC001

NOTE: Dimensions in parentheses are in millimeters.

Carrier Part No. HK06ZC033

*Applicable to open-drive machines only.

Table 4 — Capacity Overrides

OVERRIDE

CAPACITY CONTROL

FIRST STAGE SETPOINT

SECOND STAGE

SETPOINT

OVERRIDE

TERMINATION

View/Modify

on LID Screen

Default Value Conﬁgurable Range Value Value

HIGH CONDENSER

PRESSURE

Equipment

Service1

125 psig

(862 kPa)

90 to 200 psig

(620 to 1379 kPa)

.Override

Set Point

+ 4 psid (28 kPad)

,Override

Set Point

HIGH MOTOR

TEMPERATURE*

Equipment

Service1

.200 F

(93.3 C)

150 to 200 F

(66 to 93 C)

.Override

Set Point

+10° F (6° C)

,Override

Set Point

LOW REFRIGERANT

TEMPERATURE

(Refrigerant Override

Delta Temperature)

Equipment

Service1

,3° F (1.6° C)

(Above Trippoint)

2° to 5° F

(1° to 3° C)

<Trippoint + Override

DT –1° F (0.56° C)

.Trippoint + Override

DT +2° F

(1.2° C)

HIGH COMPRESSOR

LIFT

(Surge Prevention)

Equipment

Service1

Min: T1 — 1.5° F

(0.8° C) P1 — 50 psid (345 kPad)

Max: T2 — 10° F

(5.6° C) P2 — 85 psid (586 kPad)

0.5° to 15° F

(0.3° to 8.3° C)

30 to 170 psid

(207 to1172 kPad)

0.5° to 15° F

(0.3° to 8.3° C)

30 to 170 psid

(207 to 1172 kPad)

None

Within

Lift Limits

Plus Surge/

HGBP

Deadband

Setting

MANUAL

GUIDE VANE

TARGET

Control

Algorithm

Maint01

Automatic 0 to 100% None

Release of

Manual Control

MOTOR LOAD —

ACTIVE

DEMAND LIMIT

Status01 100% 40 to 100%

>5% of

Set Point

2% Lower

Than

Set Point

LEGEND

P1 — Minimum Pressure Load P2 — Maximum Pressure Load T1 — Minimum Temperature Load T2 — Maximum Temperature Load

*Not available on open drive machines.

OilSumpT emperatureControl — The oil sump tem-

perature control is regulated by the PIC which uses the oil heater relay when the machine is shut down.

As part of the pre-start checks executed by the controls, oil sump temperature is compared against evaporator refrigerant temperature. If the difference between these 2 temperatures is 50 F (27.8 C) or less, the start-up will be delayed until the oil temperature is 50 F (27.8 C) or more. Once this temperature is conﬁrmed, the start-up continues.

The oil heater relay is energized whenever the chiller compressor is off and the oil sump temperature is less than 150 F (65.6 C) or the oil sump temperature is less than the cooler refrigerant temperature plus 70° F (39° C). The oil heater is turned off when the oil sump temperature is either

1) more than 160 F (71.1 C); or 2) the oil sump temperature is more than 155 F (68.3 C) and more than the cooler refrigerant temperature plus 75° F (41.6° C). The oil heater is always off during start-up or when the compressor is running.

When a power failure to the PSIO module has occurred for more than 3 hours (i.e., initial start-up), the compressor guide vane opening will be slowed down to prevent excessive oil foaming that may result from refrigerant migration into the oil sump during the power failure. The vane opening will be slowed to a value of 2° F (1.1° C) per minute with temperature ramp loading.

Oil Cooler — The oil must be cooled when the compres-

sor is running. EX Compressors: This is accomplished through a small, plate-

type heat exchanger. The heat exchanger uses liquid condenser refrigerant as the cooling liquid. A refrigerant thermostatic expansion valve (TXV) regulates refrigerant ﬂow to control oil temperature entering the bearings. There is always a ﬂow of refrigerant bypassing the TXV. The bulb for the expansion valve is strapped to the oil supply line leaving the heat exchanger and the valve is set to maintain 110 F (43 C).

NOTE: The expansion valve is not adjustable. Oil sump temperature may be at a lower temperature.

FA Compressors: The oil cooler is a water cooled, tube-inshell type heat exchanger. A plug valve is manually set to maintain proper temperatures. Set the valve to maintain 145 F (63 C) oil sump temperatures while the compressor is running.

RemoteStart/StopControls— Aremote device, such

as a timeclock which uses a set of contacts, may be used to start and stop the machine. However, the device should not be programmed to start and stop the machine in excess of 2 or 3 times every 12 hours. If more than 8 starts in 12 hours occur, then an Excessive Starts alarm is displayed, preventing the machine from starting. The operator must reset the alarm at the LID in order to override the starts counter and start the machine. If Automatic Restart After a Power Failure is not activated when a power failure occurs, and the remote contact is closed, the machine will indicate an alarm because of the loss of voltage.

The contacts for Remote Start are wired into the starter at terminal strip TB5, terminals 8A and 8B. See the certiﬁed drawings for further details on contact ratings. The contacts must be dry (no power).

Spare Safety Inputs — Normally closed (NC) digital

inputs for additional ﬁeld-supplied safeties may be wired to the spare protective limits input channel in place of the factoryinstalled jumper. (Wire multiple inputs in series.) The opening of any contact will result in a safety shutdown and LID display. Refer to the certiﬁed drawings for safety contact ratings.

Analog temperature sensors may also be added to the options modules, if installed. These may be programmed to cause an alert on the CCN network, but will not shut the machine down.

SpareAlarm Contacts — Two spare sets of alarm con-

tacts are provided within the starter. The contact ratings are provided in the certiﬁed drawings. The contacts are located on terminal strip TB6, terminals 5A and 5B, and terminals 5C and 5D.

CondenserPump Control — The machine will moni-

tor the CONDENSER PRESSURE and may turn on this pump if the pressure becomes too high whenever the compressor is shut down. CONDENSER PRESSURE OVERRIDE is used to determine this pressure point. This value is found on the Equipment Service1 LID table and has a default value (Table 4). If the CONDENSER PRESSURE is greater than or equal to the CONDENSER PRESSURE OVERRIDE, and the ENTERING CONDENSER WATER TEMP (Tempera- ture) is less than 115 F (46 C), then the condenser pump will energize to try to decrease the pressure. The pump will turn offwhen the condenser pressure is less than the pressure override less 5 psi (34 kPa), or the CONDENSER REFRIG (Re-

frigerant) TEMP is within 3° F (2° C) of the ENTERING CONDENSER WATER temperature.

Condenser Freeze Prevention — This control al-

gorithm helps prevent condenser tube freeze-up by energizing the condenser pump relay. If the pump is controlled by the PIC, starting the pump will help prevent the water in the condenser from freezing. Condenser freeze prevention can occur whenever the machine is not running except when it is either actively in pumpdown or in Pumpdown Lockout with the freeze prevention disabled (refer to Table 7).

When the CONDENSER REFRIG TEMP is less than or equal to the CONDENSER FREEZE POINT,ortheENTER- ING CONDENSER WATER temperature is less than or equal to the CONDENSER FREEZE POINT, then the CON-

DENSER WATER PUMP shall be energized until the CONDENSER REFRIG TEMP is greater than the CONDENSER FREEZE POINT plus 5° F (2.7° C). An alarm will be gen-

erated if the machine is in PUMPDOWN mode and the pump is energized. An alert will be generated if the machine is not in PUMPDOWN mode and the pump is energized. If in recycle shutdown, the mode shall transition to a non-recycle shutdown.

Tower-Fan Relay — This control can be used to assist

the condenser water temperature control system (ﬁeld supplied). Low condenser water temperature can cause the chiller to shut down on low refrigerant temperature. The tower fan relay, located in the starter, is controlled by the PIC to energize and deenergize as the pressure differential between cooler and condenser vessels changes in order to prevent low condenser water temperature and to maximize machine efﬁciency.The tower-fan relay can only accomplish this if the relay has been added to the cooling tower temperature controller. The TOWER FAN RELAY is turned on whenever the CONDENSER WATER PUMP is running, ﬂow is veriﬁed, and the difference between cooler and condenser pressure is more than 30 psid (207 kPad) or entering condenser water temperature is greater than 85 F (29 C). The TOWER FAN RELAYis deenergized when the condenser pump is off, ﬂow is lost, the evaporator refrigerant temperature is less than the override temperature, or the differential pressure is less than 28 psid (193 kPad) and entering condensing water is less than 80 F (27 C).

IMPORTANT:Aﬁeld-supplied water temperature control system for condenser water should be installed. The system should maintain the leaving condenser water temperature at a temperature that is 20° F (11° C) above the leaving chilled water temperature.

The tower-fan relay control is not a substitute for a condenser water temperature control. When used with a Water Temperature Control system, the tower fan relay control can be used to help prevent low condenser water temperatures and associated problems.

Auto. Restart After Power Failure — This option

may be enabled or disabled, and may be viewed/modiﬁed in the Conﬁg table of Equipment Conﬁguration. If enabled, the chiller will start up automatically after a single cycle dropout, low,high, or loss of voltage has occurred, and the power is within ±10% of normal. The 15-min start-to-start timer and the stop-to-start timer are ignored during this type of start-up.

When power is restored after the power failure, and if the compressor had been running, the oil pump will be energized for one minute prior to the evaporator pump energizing. Auto restart will then continue like a normal start-up.

Water/Brine Reset — Three types of chilled water or

brine reset are available and can be viewed or modiﬁed on the Equipment Conﬁguration table Conﬁg selection.

The LID default screen status message indicates when the chilled water reset is active. The CONTROL POINT temperature on the Status01 table indicates the machine’s current reset temperature.

To activate a reset type, input all conﬁguration information for that reset type in the Conﬁg table. Then input the reset type number in the SELECT/ENABLE RESET TYPE input line.

1. Reset Type 1 (Requires optional 8-input module) — Au-

tomatic chilled water temperature reset based ona4to 20 mA input signal. This type permits up to ±30° F (±17° C) of automatic reset to the chilled water or brine temperature set point, based on the input froma4to 20 mA signal. This signal is hardwired into the number one 8-input module.

If the 4 to 20 mA signal is externally powered from the 8-input module, the signal is wired to terminals J1-5(+) and J1-6(–). If the signal is to be internally powered by the 8-input module (for example, when using variable resistance), the signal is wired to J1-7(+) and J1-6(–). The PIC must now be conﬁgured on the Service2 table to ensure that the appropriate power source is identiﬁed.

2. Reset Type 2 (Requires optional 8-input module) — Au-

tomatic chilled water temperature reset based on a remote temperature sensor input. This type permits ±30° F (±16° C) of automatic reset to the set point based on a temperature sensor wired to the number one 8-input module (see wiring diagrams or certiﬁed drawings).

The temperature sensor must be wired to terminal J1-19 and J1-20.

To conﬁgure Reset Type 2, enter the temperature of the remote sensor at the point where no temperature reset will occur.Next, enter the temperature at which the full amount of reset will occur. Then, enter the maximum amount of reset required to operate the machine. Reset Type 2 can now be activated.

3. Reset Type 3 — Automatic chilled water temperature re-

set based on cooler temperature difference. This type of reset will add ±30° F (±16° C) based on the temperature differencebetween entering and leaving chilled water temperature. This is the only type of reset available without the need of the number one 8-input module. No wiring is required for this type as it already uses the cooler water sensors.

To conﬁgure Reset Type 3, enter the chilled water temperature difference (the difference between entering and leaving chilled water) at which no temperature reset occurs. This chilled water temperature difference is usually the full design load temperature difference. The difference in chilled water temperature at which the full amount of reset will occur is now entered on the next input line. Next, the amount of reset is entered. Reset Type 3 can now be activated.

39 1197

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Demand Limit Control Option (Requires Optional 8-Input Module) —

The demand limit may be externally controlled witha4to20mAsignal from an energy management system (EMS). The option is set up on the Conﬁg table. When enabled, the control is set for 100% demand with 4 mA and an operator conﬁgured minimum demand set point at 20 mA.

The Demand Reset input from an energy management system is hardwired into the number one, 8-input module. The signal may be internally powered by the module or externally powered. If the signal is externally powered, the signal is wired to terminals J1-1(+) and J1-2(–). If the signal is internally powered, the signal is wired to terminals J1-3(+) and J1-2(–). When enabled, the control is set for 100% demand with 4 mA and an operator conﬁgured minimum demand set point at 20 mA.

Surge Prevention Algorithm — This is an operator

conﬁgurable feature which can determine if lift conditions are too high for the compressor and then take corrective action. Lift is deﬁned as the difference between the pressure at the impeller eye and the impeller discharge. The maximum lift that a particular impeller wheel can perform varies with the gas ﬂow across the impeller, and the size of the wheel.

The algorithm ﬁrst determines if corrective action is necessary. This is done by checking 2 sets of operator conﬁgured data points, which are the MINIMUM and the MAXIMUM Load Points, (T1/P1;T2/P2). These points have default settings as deﬁned on the Service1 table, or on Table4. These settings and the algorithm function are graphically displayed in Fig. 21 and 22. The 2 sets of load points on this graph (default settings are shown) describe a line which the algorithm uses to determine the maximum lift of the compressor. Whenever the actual differential pressure between the cooler and condenser, and the temperature difference between the entering and leaving chilled water are above the line on the graph (as deﬁned by the MINIMUM and MAXIMUM Load Points) the algorithm will go into a corrective action mode. If the actual values are below the line, the algorithm takes no action. Modiﬁcation of the default set points of the MINIMUM and MAXIMUM load points is described in the Input Service conﬁgurations section on page 55.

Corrective action can be taken by making one of 2 choices. If a hot gas bypass line is present, and the hot gas is conﬁgured on the Service1 table, then the hot gas bypass valve can be energized. If a hot gas bypass if not present, then the action taken is to hold the guide vanes. See Table 4, Capacity Overrides. Both of these corrective actions will reduce the lift experienced by the compressor and help to prevent a surge condition. Surge is a condition when the lift becomes so high that the gas ﬂow across the impeller reverses. This condition can eventually cause machine damage. The surge prevention algorithm is intended to notify the operator that machine operating conditions are marginal, and to take action, such as lowering entering condenser water temperature, to help prevent machine damage.

Surge Protection — Surging of the compressor can be

determined by the PIC through operator conﬁgured settings. Surge will cause amperage ﬂuctuations of the compressor motor. The PIC monitors these amperage swings, and if the swing is greater than the conﬁgurable setting in one second, then one surge count has occurred. The SURGE DELTA PER- CENTAMPS setting is displayed and conﬁgured on the Service1 screen. It has a default setting of 25% amps, SURGE PROTECTION COUNTS can be monitored on the Maint03 table.

A surge protection shutdown of the machine will occur whenever the surge protection counter reaches 12 counts within an operator speciﬁed time, known as the SURGE TIME

PERIOD. The SURGE TIME PERIOD is displayed and conﬁgured on the Service1 screen. It has a default of 2 minutes.

Lead/Lag Control — Lead/lag is a control system pro-

cess that automatically starts and stops a lag or second chiller in a 2-chiller water system. Refer to Fig. 16 and 17 for menu, table, and screen selection information. On machines that have PSIO software with Lead/Lag capability, it is possible to utilize the PIC controls to perform the lead/lag function on 2 machines. A third machine can be added to the lead/lag system as a standby chiller to start up in case the lead or lag chiller in the system has shut down during an alarm condition and additional cooling is required.

LEGEND

DP = (Condenser psi) − (Cooler psi) DT = (ECW) − (LCW)

ECW — Entering Chilled Water HGBP — Hot Gas Bypass LCW — Leaving Chilled Water

Fig. 21 — 17/19EX Hot Gas Bypass/Surge

Prevention (English)

LEGEND

DP = (Condenser kPa) − (Cooler kPa) DT = (ECW) − (LCW)

ECW — Entering Chilled Water HGBP — Hot Gas Bypass LCW — Leaving Chilled Water

Fig. 22 — 17/19EX Hot Gas Bypass/Surge

Prevention (SI)

401197

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NOTE: Lead/lag conﬁguration is viewed and edited under Lead/Lag in the Equipment Conﬁguration table (located in the Service menu). Lead/lag status during machine operation is viewed in the MAINT04 table in the Control Algorithm Status table. See Table 2.

Lead/Lag System Requirements:

• all machines must have PSIO software capable of performing the lead/lag function

• water pumps MUST be energized from the PIC controls

• water ﬂows should be constant

• CCN Time Schedules for all machines must be identical

Operation Features:

• 2 chiller lead/lag

• addition of a third chiller for backup

• manual rotation of lead chiller

• load balancing if conﬁgured

• staggered restart of the chillers after a power failure

• chillers may be piped in parallel or in series chilled water ﬂow

COMMON POINT SENSOR INSTALLATION — Lead/ lag operation does not require a common chilled water point sensor. Common point sensors can be added to the 8-input option module, if desired. Refer to the certiﬁed drawings for termination of sensor leads.

NOTE: If the common point sensor option is chosen on a chilled water system, both machines should have their own 8-input option module and common point sensor installed. Each machine will use its own common point sensor for control, when that machine is designated as the lead chiller. The PIC cannot read the value of common point sensors installed on other machines in the chilled water system.

When installing chillers in series, a common point sensor should be used. If a common point sensor is not used, the leaving chilled water sensor of the upstream chiller must be moved into the leaving chilled water pipe of the downstream chiller.

If return chilled water control is required on chillers piped in series, the common point return chilled water sensor should be installed. If this sensor is not installed, the return chilled water sensor of the downstream chiller must be relocated to the return chilled water pipe of the upstream machine.

To properly control the common supply point temperature sensor when chillers are piped in parallel,the water ﬂow through the shutdown chillers must be isolated so that no water bypass around the operating chiller occurs. The common point sensor option must not be used if water bypass around the operating chiller is occurring.

MACHINE COMMUNICATION WIRING — Refer to the machine’sInstallation Instructions and Carrier Comfort Network Interface section on page 53 for information on machine communication wiring.

LEAD/LAG OPERATION — The PIC control provides the ability to operate 2 chillers in the LEAD/LAG mode. It also provides the additional ability to start a designated standby chiller when either the lead or lag chiller is faulted and capacity requirements are not met. The lead/lag option operates in CCN mode only. If any other chiller conﬁgured for lead/lag is set to the LOCAL or OFF modes, it will be unavailable for lead/lag operation.

NOTE: Lead/lag conﬁguration is viewed and edited in Lead/ Lag, under the Equipment Conﬁguration table of the Service menu. Lead/lag status during machine operation is viewed in the MAINT04 table in the Control Algorithm Status table.

Lead/Lag Chiller Conﬁguration and Operation — The conﬁgured lead chiller is identiﬁed when the LEAD/LAG SELECT value for that chiller is conﬁgured to the value of ‘‘1.’ ’The conﬁgured lag chiller is identiﬁed when the LEAD/ LAG SELECT for that chiller is conﬁgured to the value of ‘‘2.’’ The standby chiller is conﬁgured to a value of ‘‘3.’’ A value of ‘‘0’’ disables the lead/lag in that chiller.

To conﬁgure the LAG ADDRESS value on the LEAD/ LAG Conﬁguration table, always use the address of the other chiller on the system for this value. Using this address will make it easier to rotate the lead and lag machines.

If the address assignments placed into the LAG ADDRESS and STANDBY ADDRESS values conﬂict, the lead/lag will be disabled and an alert (!) message will occur. For example, if the LAG ADDRESS matches the lead machine’s address, the lead/lag will be disabled and an alert (!) message will occur. The lead/lag maintenance screen (MAINT04) will display the message ‘INVALID CONFIG’ in the LEAD/LAG CONFIGURATION and CURRENT MODE ﬁelds.

The lead chiller responds to normal start/stop controls such as occupancy schedule, forced start/stop, and remote start contact inputs. After completing start up and ramp loading, the PIC evaluates the need for additional capacity. If additional capacity is needed, the PIC initiates the start up of the chiller conﬁgured at the LAG ADDRESS. If the lag chiller is faulted (in alarm) or is in the OFF or LOCAL modes, then the chiller at the STANDBY ADDRESS (if conﬁgured) is requested to start. After the second chiller is started and is running, the lead chiller shall monitor conditions and evaluate whether the capacity has reduced enough for the lead chiller to sustain the system alone. If the capacity is reduced enough for the lead chiller to sustain the CONTROL POINT temperatures alone, then the operating lag chiller is stopped.

If the lead chiller is stopped in CCN mode for any reason other than an alarm (*) condition, then the lag and standby chillers are stopped. If the conﬁgured lead chiller stops for an alarm condition, then the conﬁgured lag chiller takes the lead chiller’s place as the lead chiller and the standby chiller serves as the lag chiller.

If the conﬁgured lead chiller does not complete the start-up before the PREST ARTFAULT TIMER (user conﬁgured value) elapses, then the lag chiller shall be started and the lead chiller will shut down. The lead chiller then monitors the start request from the acting lead chiller to start. The PRESTART

FAULT TIMER is initiated at the time of a start request. The PRESTART FAULT TIMER’s function is to provide a time-

out in the event that there is a prestart alert condition preventing the machine from starting in a timely manner. The timer is conﬁgured under Lead/Lag, found in the Equipment Conﬁguration table of the Service menu.

If the lag chiller does not achieve start-up before the PRESTART FAULT TIMER elapses, then the lag chiller shall be stopped and the standby chiller will be requested to start, if conﬁgured and ready.

Standby Chiller Conﬁguration and Operation — The conﬁgured standby chiller is identiﬁed as such by having the LEAD/LAG SELECT conﬁgured to the value of ‘‘3.’’ The standby chiller can only operate as a replacement for the lag chiller if one of the other two chillers is in an alarm (*) condition (as shown on the LID panel). If both lead and lag chillers are in an alarm (*) condition, the standby chiller shall default to operate in CCN mode based on its conﬁgured Occupancy Schedule and remote contacts input.

Lag Chiller Start-Up Requirements — Before the lag chiller can be started, the following conditions must be met:

1. Lead chiller ramp loading must be complete.

2. Lead chiller CHILLED WA TERtemperature must begreater than the CONTROL POINT plus 1/2 the WATER/BRINE DEADBAND.

NOTE: The chilled water temperature sensor may be the leaving chilled water sensor, the return water sensor, the common supply water sensor, or the common return water sensor,depending on which options are conﬁgured and enabled.

3. Lead chiller ACTIVE DEMAND LIMIT value must be greater than 95% of full load amps.

4. Lead chiller temperature pulldown rate of the CHILLED WA TERtemperature is less than 0.5° F (0.27° C) perminute.

5. The lag chiller status indicates it is in CCN mode and is not faulted. If the current lag chiller is in an alarm condition, then the standby chiller becomes the active lag chiller, if it is conﬁgured and available.

6. The conﬁgured LAG START TIMER entry has elapsed. The LAG START TIMER shall be started when the lead chiller ramp loading is completed. The LAG STARTTIMER entry is accessed by selecting Lead/Lag from the Equipment Conﬁguration table of the Service menu.

When all of the above requirements have been met, the lag chiller is forced to a STARTmode. The PIC control then monitors the lag chiller for a successful start. If the lag chiller fails to start, the standby chiller, if conﬁgured, is started.

Lag Chiller Shutdown Requirements — The following conditions must be met in order for the lag chiller to be stopped.

1. Lead chiller COMPRESSOR MOTOR LOAD value is less

than the lead chiller percent capacity plus 15%. NOTE: Lead chiller percent capacity = 100 – LAG PER-

CENT CAPACITY

The LAG PERCENT CAPACITY value is conﬁgured on the Lead/Lag Conﬁguration screen.

2. The lead chiller chilled water temperature is less than

the CONTROL POINT plus 1/2 of the WATER/BRINE DEADBAND.

3. The conﬁgured LAG STOP TIMER entry has elapsed. The

LAG STOP TIMER is startedwhen the LEAVINGCHILLED WATER temperature is less than the CHILLED WATER CONTROL POINT plus 1/2 of the WATER/BRINEDEADBAND and the lead chiller COMPRESSOR MOTOR LOAD

is less than the lead chiller percent capacity plus 15%. The timer is ignored if the chilled water temperature reaches 3° F (1.67° C) below the CONTROL POINT and the lead chiller COMPRESSOR MOTOR LOAD value is less than the lead chiller percent capacity plus 15%.

FAULTED CHILLER OPERATION — If the lead chiller shuts down on an alarm (*) condition, it stops communication to the lag and standby chillers. After 30 seconds, the lag chiller will now become the acting lead chiller and will start and stop the standby chiller, if necessary.

If the lag chiller faults when the lead chiller is also faulted, the standby chiller reverts to a stand-alone CCN mode of operation.

If the lead chiller is in an alarm (*) condition (as shown on the LID panel), the RESET softkey is pressed to clear the alarm, and the chiller is placed in the CCN mode, the lead chiller will now communicate and monitor the RUN STATUS of the lag and standby chillers. If both the lag and standby chillers are running, the lead chiller will not attempt to start and will not assume the role of lead chiller until either the lag or standby chiller shuts down. If only one chiller is

running, the lead chiller will wait for a start request from the operating chiller. When the conﬁgured lead chiller starts, it assumes its role as lead chiller.

LOAD BALANCING — When the LOAD BALANCE OP-

TION is enabled, the lead chiller will set the ACTIVE DEMAND LIMIT in the lag chiller to the lead chiller’s COMPRESSOR MOTOR LOAD value. This value has limits of 40% to 100%. When setting the lag chiller ACTIVE DEMAND LIMIT, the CONTROL POINT shall be modiﬁed to a value of 3° F (1.67° C) less than the lead chiller’s CONTROL POINT value. If the LOAD BALANCE OPTION is disabled, the ACTIVE DEMAND LIMIT and the CONTROL POINT are forced to the same value as the lead chiller.

AUTO. RESTARTAFTER POWER FAILURE — When an autorestart condition occurs, each chiller may have a delay added to the start-up sequence, depending on its lead/lag conﬁguration. The lead chiller does not have a delay. The lag chiller has a 45-second delay. The standby chiller has a 90-second delay. The delay time is added after the chiller water ﬂow veriﬁcation. The PIC controls ensure that the guide vanes are closed. After the guide vane position is conﬁrmed, the delay for lag and standby chiller occurs prior to energizing the oil pump. The normal start-up sequence then continues. The auto. restart delay sequence occurs whether the chiller is in CCN or LOCAL mode and is intended to stagger the compressor motors from being energized simultaneously. This will help reduce the inrush demands on the building power system.

Ice Build Control — Ice build control automatically sets

the chilled WATER/BRINE CONTROL POINT of the ma- chine from normal operation set point temperature to a temperature where an ice building operation for thermal storage can be accomplished.

NOTE: For ice build control to properly operate, the PIC controls must be placed in CCN mode. See Fig. 16 and 17.

The PIC can be conﬁgured for ice build operation. Conﬁguration of ice build control is accomplished through entries in the Conﬁg table, Ice Build Setpoint table, and the Ice Build Time Schedule table. Figures 16 and 17 show how to access each entry.

The Ice Build Time Schedule deﬁnes the period during which ice build is active if the ice build option is ENABLED. If the Ice Build Time Schedule overlaps other schedules deﬁning time, then the Ice Build Time Schedule shall take priority. During the ice build period, the WATER/

BRINE CONTROL POINT is set to the ICE BUILD SETPOINT for temperature control. The ICE BUILD RECYCLE OPTION and ICE BUILD TERMINATIONentries from a screen

in the Conﬁg (conﬁguration) table provide options for machine recycle and termination of ice build cycle, respectively. Termination of ice build can result from the ENTER- ING CHILLED WATER (brine) temperature being less than the ICE BUILD SETPOINT, opening the REMOTE CON- TACTS INPUT from an ice level indicator, or reaching the end of the Ice Build Time Schedule.

ICE BUILD INITIATION — The Ice Build Time Schedule provides the means for activating ice build. The ice build time table is named OCCPC02S.

If the Ice Build Time Schedule is OCCUPIED and the ICE BUILD OPTION is ENABLED, then ice build is active and the following events automatically take place (unless overridden by a higher authority CCN device):

1. Force CHILLER START/STOP to START.

2. Force WA TER/BRINECONTROL POINTto the ICE BUILD

SETPOINT.

3. Remove any force (Auto) on the ACTIVE DEMAND LIMIT.

NOTE: Items 1-3 (shown above) shall not occur if the chiller is conﬁgured and operating as a lag or standby chiller for lead/lag and is actively controlled by a lead chiller. The lead chiller communicates the ICE BUILD SETPOINT, desired CHILLER ST ART/STOP state, and ACTIVE DEMAND LIMIT to the lag or standby chiller as required for ice build, if conﬁgured to do so.

START-UP/RECYCLE OPERATION — If the machine is not running when ice build activates, then the PIC checks the following parameters, based on the ICE BUILD TERMINATION value, to avoid starting the compressor unnecessarily:

•ifICE BUILD TERMINATION is set to the TEMPERA- TURE ONLY OPTION and the ENTERING CHILLED WA-

TER temperature is less than or equal to the ICE BUILD SETPOINT;

•ifICE BUILD TERMINATION is set to the CONTACTS ONLY OPTION and the remote contacts are open;

• if the ICE BUILD TERMINATIONis set to the BOTH (temperature and contacts) option and ENTERING CHILLED

W ATER temperature is less than or equal to the ICE BUILD SETPOINT and remote contacts are open.

The ICE BUILD RECYCLE OPTION determines whether or not the PIC will go into a RECYCLE mode. If the ICE BUILD RECYCLE OPTION is set to DSABLE (disable) when the ice build terminates, the PIC will revert back to normal temperature control duty. If the ICE BUILD RECYCLE OP- TION is set to ENABLE, when ice build terminates, the PIC will go into an ice build recycle mode and the chilled water pump relay will remain energized to keep the chilled water ﬂowing. If the ENTERING CHILLED WATER (brine) temperature increases above the ICE BUILD SETPOINT plus the RECYCLE RESTART DELTA T value, the compressor will restart and control the CHILLED WATER/BRINE TEMPERATURE to the ICE BUILD SETPOINT.

TEMPERATURE CONTROL DURING ICE BUILD —During ice build, the capacity control algorithm uses the WATER/BRINE CONTROL POINT minus 5 F (2.7 C) to control the LEAVING CHILLED WATERtemperature. The ECW CONTROL OPTION and any temperature reset option are ignored during ice build. The 20 mA DEMAND LIMIT option is also ignored during ice build.

TERMINATION OF ICE BUILD — Ice build termination occurs under the following conditions:

1. Ice Build Time Schedule — When the Ice Build Time

Schedule transitions to UNOCCUPIED, ice build operation shall terminate.

2. ECWTEMPERA TURE— T erminationof compressor op-

eration, based on temperature, shall occur if the ICE BUILD

TERMINATION is set to the ICE BUILD TERMINATION TEMP option and the ENTERING CHILLED WATER temperature is less than the ICE BUILD SETPOINT.

If the ICE BUILD RECYCLE OPTION is set to ENABLE, a recycle shutdown occurs and recycle startup shall be based on LEAVING CHILLED WATER temperature being greater than the WATER/BRINE CON- TROL POINT plus RECYCLE RESTART DELTA T.

3. Remote Contacts/Ice Level Input — Termination of com-

pressor operation occurs when ICE BUILD TERMINA- TION is set to CONTACTS ONLY OPTION and the remote contacts are open. In this case, the contacts are provided for ice level termination control. The remote contacts can

still be opened and closed to start and stop the chiller when the Ice Build Time Schedule is UNOCCUPIED. The contacts are used to stop the ICE BUILD mode when the Ice Build Time Schedule is OCCUPIED.

4. ECW TEMPERATURE and Remote Contacts — Termination of compressor operation shall occur when ICE BUILD TERMINATION is set to BOTH (temperature and contacts) option and the previously described conditions for ENTERING CHILLED WATER temperature and remote contacts have occurred.

NOTE: Overriding the CHILLER START/STOP, WATER/ BRINE CONTROL POINT, and ACTIVE DEMAND LIMIT variables by CCN devices (with a priority less than 4) during the ice build period is not possible. However, overriding can be accomplished with CCN during two chiller lead/lag.

RETURN TO NON-ICE BUILD OPERATIONS — Upon termination of ice build, the machine shall return to normal temperature control and start/stop schedule operation. If the CHILLER ST ART/ST OPor WATER/BRINECONTROL POINT has been forced (with a priority less than 4), prior to entering ice build operation, then CHILLER START/STOP and WATER/BRINE CONTROL POINT forces will be removed.

Attach to Network Device Control — On the Serv-

ice menu, one of the selections is ATTACHTO NETWORK DEVICE. This table serves the following purposes:

• to upload the Occupancy Schedule Number (if changed)

for OCCPC03S, as deﬁned in the Service01 table

• to attach the LID to any CCN device, if the machine has

been connected to a CCN Network. This may include other PIC controlled chillers.

• to change to a new PSIO or LID module or upgrade

software.

Figure 23 illustrates the ATTACH TO NETWORK DEVICE table. The Local description is always the PSIO module address of the machine the LID is mounted on. Whenever the controller identiﬁcation of the PSIO is changed, this change is reﬂected on the bus and address for the LOCAL DEVICE of the ATTACH TO DEVICE screen automatically. See Fig. 17.

Whenever the ATTACH TO NETWORK DEVICE table is entered, the LID erases information on the module to which it was attached in order to make room for another device. Therefore, it is then required to attach to a CCN module when this screen is entered, even if the LID is attached back to the original module. When the ATTACH softkey is pressed, the message ‘ ‘UPLOADINGTABLES, PLEASE WAIT’’flashes. The LID will then upload the highlighted device or module. If the module address cannot be found, the message ‘‘COMMUNICATION FAILURE’’ will appear. The LID will then revert back to the ATTACH TO DEVICE screen. The upload process time for various CCN modules is different for each module. In general, the uploading process will take 3 to 5 minutes.

ATTACHING TO OTHER CCN MODULES — If the machine PSIO has been connected to a CCN Network or other PIC controlled chillers through CCN wiring, the LID can be used to view or change parameters on the other controllers. Other PIC machines can be viewed and set points changed (if the other unit is in CCN control), if desired from this particular LID module.

To view the other devices, move to the ATTACHTO NETWORK DEVICE table. Move the highlight bar to any device number. Press SELECT softkey to change the bus number and address of the module to be viewed. Press EXIT softkey to move back to the ATTACHTO NETWORK DEVICE table. If the module number is not valid, the ‘‘COMMUNICATION F AILURE’’message will show and a new address number should be entered or the wiring checked. If the model is communicating properly, the ‘‘UPLOAD IN PROGRESS’’ message will ﬂash and the new module can now be viewed.

Whenever there is a question regarding which CCN module the LID is currently showing, check the device name descriptor on the upper left hand corner of the LID screen. See Fig. 23.

When the CCN device has been viewed, theATTACH TO NETWORK DEVICE table should now be used to attach to the PSIO that is on the machine. Move to the ATTACH TO NETWORK DEVICE table and press the ATTACH softkey to upload the LOCAL device. The PSIO for the 19XT will now be uploaded.

NOTE: The LID will not automatically re-attach to the PSIO module on the machine. Press the ATTACH softkey to attach to LOCAL DEVICE and view the machine PSIO.

Service Operation — An overview of the menu-

driven programs available for Service Operation is shown in Fig. 17.

TO LOG ON

1. On the Menu screen, press SERVICE

. The keys now

correspond to the numerals 1, 2, 3, 4.

2. Press the four digits of your password, one at a time. An

asterisk (*) appears as you enter each digit.

The menu bar (Next-Previous-Select-Exit) is displayed to indicate that you have successfully logged on.

If the password is entered incorrectly, an error message is displayed. If this occurs, return to Step 1 and try logging on again.

NOTE: The initial factory set password is 1-1-1-1.

TO LOG OFF — Access the Log Out of Device table of the Service menu in order to password-protect the Service menu. The LID will automatically sign off and password-protect itself if a key is not pressed for 15 minutes. The LID default screen is then displayed.

HOLIDAY SCHEDULING (Fig. 24) — The time schedules may be conﬁgured for special operation during a holiday period. When modifying a time period, the ‘‘H’’ at the end of the days of the week ﬁeld signiﬁes that the period is applicable to a holiday. (See Fig. 24.)

The Broadcast function must be activated for the holidays conﬁgured in the Holidef tables to work properly. Access the Brodefs table in the Equipment Conﬁguration table and answer ‘‘Yes’’to the activated function. However, when the machine is connected to a CCN Network, only one machine or CCN device can be conﬁgured to be the broadcast device. The controller that is conﬁgured to be the broadcaster is the device responsible for transmitting holiday, time, and daylightsavings dates throughout the network.

To view or change the holiday periods for up to 18 different holidays, perform the following operation:

1. At the Menu screen, press SERVICE

to access the Serv-

ice menu.

2. If not logged on, follow the instructions for To Log On or To Log Off. Once logged on, press NEXT

un-

til Equipment Conﬁguration is highlighted.

3. Once Equipment Conﬁguration is highlighted, press

SELECT

to access.

4. Press NEXT until Holidef is highlighted. This is the Holiday Deﬁnition table.

5. Press SELECT to enter the Data Table Select screen. This screen lists 18 holiday tables.

6. Press NEXT to highlight the holiday table that you wish to view or change. Each table is one holiday pe-

riod, starting on a speciﬁc date, and lasting up to 99 days.

NAME DESCRIPTOR

Fig. 23 — Example of Attach to Network

Device Screen

7. Press SELECT to access the holiday table. The Conﬁguration Select table now shows the holiday start month

and day,and how many days the holiday period will last.

8. Press NEXT or PREVIOUS to highlight the month, day, or duration.

9. Press SELECT to modify the month, day, or duration.

10. Press INCREASE or DECREASE to change the selected value.

11. Press ENTER to save the changes.

12. Press EXIT to return to the previous menu.

START-UP/SHUTDOWN/

RECYCLE SEQUENCE (Fig. 25)

Local Start-Up —

Local start-up (or a manual start-up)

is initiated by pressing the LOCAL

menu softkey which is

on the default LID screen. Local start-up can proceed when Time Schedule 01 is in OCCUPIED mode, and after the internal 15-minute start-to-start timer and the stop-to-start inhibit timer have expired.

The chiller start/stop status point on the Status01 table may be overridden to start, regardless of the time schedule, in order to locally start the unit. Also, the remote contacts may be enabled through the LID and closed to initiate a start-up.

Whenever the chiller is in LOCAL control mode, the PIC will wait for Time Schedule 01 to become occupied and the remote contacts to close, if enabled. The PIC will then perform a series of pre-start checks to verify that all pre-start alerts and safeties are within the limits shown in Table 3. The run status line on the LID now reads ‘‘Starting.’’ If the checks are successful, the chilled water/brine pump relay will be energized. Five seconds later, the condenser pump relay is energized.Thirty seconds later the PIC monitors the chilled water and condenser water ﬂow switches, and waits until the WATER FLOW VERIFY TIME (operator conﬁgured, default 5 minutes) to conﬁrm ﬂow.After ﬂow is veriﬁed, the chilled water/brine temperature is compared to CONTROL POINT plus DEADBAND. If the temperature is less than or equal to this value, the PIC will turn off the condenser pump relay and go into a RECYCLE mode. If the water/brine temperature is high enough, the start-up sequence continues on to check the guide vane position. If the guide vanes are more than 6% open, the start-up waits until the PIC closes the vanes. If the vanes are closed, and the oil pump pressure is less than 4 psid (28 kPad), the oil pump relay will then be energized. The PIC then waits until the OIL PRESS (Pressure) VERIFY TIME (operator conﬁgured, default 15 seconds) for oil pressure to reach 18 psid (124 kPad). After oil pressure is veriﬁed, the PIC waits 15 seconds, and then the compressor start relay (1CR) is energized to start the compressor. Compressor ontime and service ontime timers start. Compressor starts counter and number of starts over a 12-hour period counter advance by one.

EF, EX, FA CHLR HOLDY01S CONFIGURATION SELECT

Fig. 24 — Example of Holiday Period Screen

A—START INITIATED — Prestart checks made; evaporator

pump started

B—Condenser water pump started (5 seconds after A) C—Water ﬂows veriﬁed (30 seconds to 5 minutes maximum

after B). Chilled water temperatures checked against controlpoint. Guide vanes checked forclosure. Oil pump started; tower fan control enabled.

D—Oil pressure veriﬁed (30 seconds minimum, 300 seconds

maximum after C) total compressor starts counter advances by one, number of starts over a 12-hour period advances by one.

E—Compressor motor starts, compressor ontime and service

ontime start, 15-minute inhibit timer starts (10 seconds after D)

F—SHUTDOWNINITIATED— Compressor motor stops, com-

pressor ontime and service ontime stops, stop-to-start inhibit timer starts.

G—Oil pump and evaporator pumps deenergized (60 seconds

after F). Condenser pump and tower fan control may continue to operate if condenser pressure is high. Evaporator pump may continue if in RECYCLE mode.

O/A — Restart permitted (both inhibit timers expired) (minimum of

15 minutes after E; minimum of 3 minutes after F).

Fig. 25 — Control Sequence

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Failure to verify any of the requirements up to this point will result in the PIC aborting the start and displaying the applicable pre-start mode of failure on the LID default screen. A pre-start failure does not advance the starts in 12 hours counter. Any failure after the 1CR relay has energized results in a safety shutdown, energizes the alarm light, and displays the applicable shutdown status on the LID display.

ShutdownSequence — Shutdown of the machine can

occur if any of the following events happen:

• the STOP button is pressed for at least one second (the

alarm light will blink once to conﬁrm stop command)

• recycle condition is present (see ChilledWaterRecycle Mode

section)

• time schedule has gone into UNOCCUPIED mode

• remote contact opens

• the start/stop status is overridden to stop from the CCN

network or the LID

When a stop signal occurs, the shutdown sequence ﬁrst stops the compressor by deactivating the start relay.A status message of ‘‘SHUTDOWN IN PROGRESS, COMPRESSOR DEENERGIZED’’ is displayed. Compressor ontime and service ontime stop. The guide vanes are then brought to the closed position. The oil pump relay and the chilled water/brine pump relay are shut down 60 seconds after the compressor stops. The condenser water pump will be shut down when the CONDENSER REFRIGERANT TEMP is less than the CONDENSER PRESSURE OVERRIDE minus 5 psi (34 kPa) or is less than or equal to the ENTERING CON- DENSER WATER TEMP plus 3° F (2° C). The stop-to-start timer will now begin to count down. If the start-to-start timer is still greater than the value of the start-to-stop timer, then this time is now displayed on the LID.

Certain conditions during shutdown will change this sequence:

• if the COMPRESSOR MOTOR LOAD is greater than 10%

after shutdown, or the starter contacts remain energized, the oil pump and chilled water pump remain energized and the alarm is displayed

• if the ENTERING CONDENSER WATER temperature is

greater than 115 F (46 C) at shutdown, the condenser pump will be deenergized after the 1CR compressor start relay

• if the machine shuts down due to low refrigerant tempera-

ture, the chilled water pump will stay running until the

LEAVING CHILLED WATER is greater than CONTROL POINT, plus 5° F (3° C)

AutomaticSoftStopAmps Threshold — The SOFT

STOP AMPS THRESHOLD closes the guide vanes of the

compressor automatically when a non-recycle, non-alarm stop signal occurs before the compressor motor is deenergized.

If the STOP button is pressed, the guide vanes close to a preset amperage percent or until the guide vane is less than 2% open. The compressor will then shut off.

If the machine enters an alarm state or if the compressor enters a RECYCLE mode, the compressor will be deenergized immediately.

To activate SOFT STOP AMPS THRESHOLD, view the bottom of Service1 table. Set the SOFT STOP AMPS THRESH- OLD value to the percentage amps at which the motor will shut down. The default setting is 100% amps (no Soft Stop).

When the SOFT STOP AMPS THRESHOLD is being applied, a status message ‘‘SHUTDOWNIN PROGRESS, COMPRESSOR UNLOADING’’ is shown.

Chilled Water Recycle Mode — The machine

may cycle off and wait until the load increases to restart again when the compressor is running in a lightly loaded

condition. This cycling of the chiller is normal and is known as recycle. A recycle shutdown is initiated when any of the following conditions are true:

• when in LCW control, the difference between the LEAV-

ING CHILLED WATER temperature and ENTERING CHILLED WATER temperature is less than the RECYCLE SHUTDOWN DELTA T (found in the Service1 table) and the LEAVINGCHILLED WA TERTEMP is below the CONTROL POINT, and the CONTROL POINT has not in-

creased in the last 5 minutes

• when ECW CONTROL OPTION is enabled, the difference between the ENTERING CHILLED WATER temperature and the LEAVING CHILLED WATER temperature is less than the RECYCLE SHUTDOWN DELTA T (found in the Service1 table) and the ENTERING CHILLED W A TERTEM-

PERATUREis below the CONTROL POINT, and the CONTROL POINT has not increased in the last 5 minutes

• when the LEAVINGCHILLED WA TERtemperature is within 3° F (2° C) of the BRINE REFRIG TRIPPOINT

When the machine is in RECYCLE mode, the chilled water pump relay remains energized so that the chilled water temperature can be monitored for increasing load. The recycle control uses RECYCLE RESTART DELTA T to check when the compressor should be restarted. This is an operatorconﬁgured function which defaults to 5° F (3° C). This value is viewed/modiﬁed on the Service1 table. The compressor will restart when:

• in LCW CONTROL the LEAVING CHILLED WATERtem-

perature is greater than the CONTROL POINT plus the RE- CYCLE RESTART DELTA T; or

• in ECW CONTROL, the ENTERING CHILLED WATER

temperature is greater than the CONTROL POINT plus the

RECYCLE RESTART DELTA T

Once these conditions are met, the compressor shall initiate a start-up, with a normal start-up sequence.

An alert condition may be generated if 5 or more RECYCLE STARTUPs occur in less than 4 hours. This excessive recycling can reduce machine life. Compressor recycling due to extremely low loads should be reduced. To reduce compressor recycling, use the time schedule to shut the machine down during low load operation or increase the machine load by running the fan systems. If the hot gas bypass is installed, adjust the values to ensure that hot gas is energized during light load conditions. Increase the RECYCLE RESTART DELTA T on the Service1 table to lengthen the time between restarts.

The machine should not be operated below design minimum load without a hot gas bypass installed on the machine.

Safety Shutdown — A safety shutdown is identical to

a manual shutdown with the exception that the LID will display the reason for the shutdown, the alarm light will blink continuously, and the spare alarm contacts will be ener-

gized. A safety shutdown requires that the RESET

softkey

be pressed in order to clear the alarm. If the alarm is still present, the alarm light will continue to blink. Once the alarm

is cleared, the operator must press the CCN

LOCAL

softkeys to restart the machine.

Do not reset starter loads or any other starter safety for 30 seconds after the compressor has stopped. Voltage output to the compressor start signal is maintained for 10 seconds to determine starter fault.

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BEFORE INITIAL START-UP

Job Data Required

• list of applicable design temperatures and pressures (product data submittal)

• machine certiﬁed drawings

• starting equipment details and wiring diagrams

• diagrams and instructions for special controls or options

• 17/19EX Installation Instructions

• pumpout unit instructions

Equipment Required

• mechanic’s tools (refrigeration)

• digital volt-ohmmeter (DVM)

• clamp-on ammeter

• electronic leak detector

• absolute pressure manometer or wet-bulb vacuum indicator (Fig. 26)

• 500 v insulation tester (megohmmeter) for compressor motors with nameplate voltage of 600 v or less, or a 5000-v insulation tester for compressor motor rated above 600 v

Using the Utility Vessel and Pumpout System —

Refer to Pumpout and Refrigerant Transfer Procedures section, page 64 for: pumpout system preparation, refrigerant transfer, and machine evacuation.

Remove Shipping Packaging — Remove any pack-

aging material from the control center, power panel, guide vane actuator, motor cooling and oil reclaim solenoids, motor and bearing temperature sensor covers, and the factorymounted starter.

OPEN DRIVE MOTOR

The motor may be provided with a shipping brace or shipping bolt (normally painted yellow) to prevent shaft movement during transit. It must be removed prior to operation. See Fig. 27.

The motor should be inspected for any temporary, yellow caution tags whose legends convey information concerning actions necessary before the motor can be safely operated. Any slushing compound on the shaft or other parts must be removed using a petroleum type solvent and observing proper safety precautions.

NOTE: If the motor utilized a shipping bolt for restraining the rotor, the Westinghouse logo must be installed over the hole in the endcover. The logo, the gasket, and hardware can be found with the parts that have been shipped loose. (Usually these are packed inside of the main power lead box.)

Open-Drive Motor Electrical Connection — All

interconnecting wiring for controls and grounding should be in strict accordance with both the National Electrical Code and any local requirements.

The main lead box furnished with the motor has been sized to provide adequate space for the make-up of the connections between the motor lead cables and the incoming power cables. The bolted joints between the motor lead and the power cables must be made and insulated in a workman-like manner following the best trade practices.

Fabricated motors are provided with 2 stainless steel grounding pads drilled and tapped with the NEMA 2-hole pattern (two

⁄2-13 tapped holes on 13⁄4in. centers). Fan cooled cast frames are provided with a special grounding bolt. The motor should be grounded by a proper connection to the electrical system ground.

The rotation direction of the motor will be as shown by either a nameplate on the motor or the certiﬁed drawing. The required phase rotation of the incoming power for this motor rotation may also be stated. If either is unknown, the correct sequence can be determined in the following manner: While the motor is uncoupled from the load, start the motor and observe the direction of rotation. Allow the motor to achieve full speed before disconnecting it from the power source. Refer to Open-Drive Motor Pre-Start Checks (page 53) for information concerning initial start-up. If resulting rotation is incorrect, it can be reversed by interchanging any 2 incoming cables.

Fig. 27 — Shipping Bolt on Open Drive Motor

Fig. 26 — Typical Wet-Bulb Type

Vacuum Indicator

Open-Drive Motor Auxiliary Devices — Auxil-

iary devices such as resistance temperature detectors, thermocouples, thermoguards, etc., will generally terminate on terminal blocks located in the auxiliary terminal box on the motor.Other devices may terminate on their own enclosures elsewhere on the motor. Such information can be obtained by referring to the certiﬁed drawing. Information regarding terminal designation and the connection of auxiliary devices can be obtained from auxiliary drawings referenced by the outline drawing.

If the motor is provided with internal space heaters, the incoming voltage supplied to them must be exactly as shown by either a nameplate on the motor or the outline drawing for proper heater operation. Caution must be exercised anytime contact is made with the incoming space heater circuit as space heater voltage is often automatically applied when the motor is shut down.

Open Oil Circuit Valves — Check that the oil ﬁlter

isolation valves are open by removing the valve cap and checking the valve stem. (See Scheduled Maintenance, Changing Oil Filter, page 76.)

Tighten All Gasketed Joints and Guide Vane Shaft Packing —

Gaskets and packings normally relax by the time the machine arrives at the jobsite. Tighten all gasketed joints and the guide vane shaft packing to ensure a leak-tight machine.

NOTE: On open-drive machines, check the machine cold alignment. Refer to Machine Alignment in the Maintenance section.

Check Machine Tightness — Figure 28 outlines the

proper sequence and procedures for leak testing.

17/19EX chillers may be shipped with the refrigerant contained in the utility vessel and the oil charge shipped in the compressor.The cooler/condenser vessels will have a 15 psig (103 kPa) refrigerant charge. Units may also be ordered with the refrigerant shipped separately, along with a 15 psig (103 kPa) nitrogen-holding charge in each vessel. To determine if there are any leaks, the machine should be charged with refrigerant. Use an electronic leak detector to check all ﬂanges and solder joints after the machine is pressurized. If any leaks are detected, follow the leak test procedure.

If the machine is spring isolated, keep all springs blocked in both directions in order to prevent possible piping stress and damage during the transfer of refrigerant from vessel to vessel during the leak test process, or any time refrigerant is transferred. Adjust the springs when the refrigerant is in operating condition, and when the water circuits are full.

Refrigerant Tracer — Carrier recommends the use of

an environmentally acceptable refrigerant tracer for leak testing with an electronic detector or halide torch.

Ultrasonic leak detectors also can be used if the machine is under pressure.

Do not use air or oxygen as a means of pressurizing the machine. Some mixtures of HFC-134a and air can undergo combustion.

Leak TestMachine — Due to regulations regarding re-

frigerant emissions and the difficulties associated with separating contaminants from refrigerant, Carrier recommends the following leak test procedures. See Fig. 28 for an outline of the leak test procedures. Refer to Tables 5A and 5B for refrigerant pressure/temperature values and to Pumpout and Refrigerant Transfer Procedures section, page 64.

1. If the pressure readings are normal for machine condition:

a. Evacuate the nitrogen holding charge from the ves-

sels, if present.

b. Raise the machine pressure, if necessary, by adding

refrigerant until pressure is at equivalent saturated pressure for the surrounding temperature. Follow the pumpout procedures in the Pumpout and Refrigerant Transfer Procedures section, page 64.

Never charge liquid refrigerant into the machine if the pressure in the machine is less than 35 psig (241 kPa). Charge as a gas only, with the cooler and condenser pumps running, until this pressure is reached, using PUMPDOWN LOCKOUT and TERMINATE LOCKOUT mode on the PIC. Flashing of liquid refrigerant at low pressures can cause tube freezeup and considerable damage.

c. Leak test machine as outlined in Steps3-9.

2. If the pressure readings are abnormal for machine condition:

a. Prepare to leak test machines shipped with refrigerant

(Step 2h).

b. Check for large leaks by connecting a nitrogen bottle

and raising the pressure to 30 psig (207 kPa). Soap test all joints. If the test pressure holds for 30 minutes,

prepare the test for small leaks (Steps 2g - h). c. Plainly mark any leaks which are found. d. Release the pressure in the system. e. Repair all leaks. f. Retest the joints that were repaired. g. After successfully completing the test for large leaks,

remove as much nitrogen, air, and moisture as pos-

sible, given the fact that small leaks may be present in

the system. This can be accomplished by following

the dehydration procedure, outlined in the Machine De-

hydration section, page 51. h. Slowly raise the system pressure to the equivalent satu-

rated pressure for the surrounding temperature but no

less than 35 psig (241 kPa) by adding HFC-134a

refrigerant. Proceed with the test for small leaks

(Steps 3-9).

3. Check the machine carefully with an electronic leak detector, halide torch, or soap bubble solution.

4. Leak Determination — If an electronic leak detector indicates a leak, use a soap bubble solution, if possible, to conﬁrm. Total all leak rates for the entire machine. Leakage at rates greater than 1 lb/year (0.45 kg/year) for the entire machine must be repaired. Note total machine leak rate on the start-up report. This leak rate repair is only for new start-ups. See page 67 for operating machine leak rate/repair recommendations.

5. If no leak is found during initial start-up procedures, complete the transfer of refrigerant gas (see Pumpout and Refrigerant Transfer Procedures section, page 64.)

6. If no leak is found after a retest: a. Transfer the refrigerant to the utility vessel or other

storage tank and perform a standing vacuum test as outlined in the Standing VacuumTestsection, this page.

b. If the machine fails this test, check for large leaks

(Step 2b).

c. Dehydrate the machine if it passes the standing vacuum

test. Follow the procedure in the Machine Dehydration section. Charge machine with refrigerant (see Pumpout and Refrigerant Transfer Procedures section, page 64.)

7. If a leak is found, pump the refrigerant back into the utility vessel or other storage tank.

8. Transfer the refrigerant until machine pressure is at 18 in. Hg (41 kPa absolute).

9. Repair the leak and repeat the procedure, beginning from Step 2g to ensure a leaktight repair.(If machine is opened to the atmosphere for an extended period, evacuate it before repeating leak test.)

StandingVacuumTest— When performing the stand-

ing vacuum test, or machine dehydration, use a manometer or a wet bulb indicator. Dial gages cannot indicate the small amount of acceptable leakage during a short period of time.

1. Attach an absolute pressure manometer or wet bulb indicator to the machine.

2. Evacuate the vessel (see Pumpout and Refrigerant Transfer Procedures section, page 64) to at least 18 in. Hg vac, ref 30-in. bar (41 kPa), using a vacuum pump or the pumpout unit.

3. Valve off the pump to hold the vacuum and record the manometer or indicator reading.

4. a. If the leakage rate is less than 0.05 in. Hg (.17 kPa) in

24 hours, the machine is sufficiently tight.

b. If the leakage rate exceeds 0.05 in. Hg (.17 kPa) in

24 hours, repressurize the vessel and test for leaks. If refrigerant is available in the other vessel, pressurize by following Steps 2-10 of Return Refrigerant To Normal Operating Conditions section, page 66. If not, use nitrogen and a refrigerant tracer. Raise the vessel pressure in increments until the leak is detected. If refrigerant is used, the maximum gas pressure is approximately 70 psig (483 kPa) at normal ambient temperature.

5. Repair leak, retest, and proceed with dehydration.

Table 5A — HFC-134a Pressure — Temperature (F)

TEMPERATURE (F) PRESSURE (psi)

0 6.50 2 7.52 4 8.60 6 9.66 8 10.79

10 11.96 12 13.17 14 14.42 16 15.72 18 17.06

20 18.45 22 19.88 24 21.37 26 22.90 28 24.48

30 26.11 32 27.80 34 29.53 36 31.32 38 33.17

40 35.08 42 37.04 44 39.06 46 41.14 48 43.28

50 45.48 52 47.74 54 50.07 56 52.47 58 54.93

60 57.46 62 60.06 64 62.73 66 65.47 68 68.29

70 71.18 72 74.14 74 77.18 76 80.30 78 83.49

80 86.17 82 90.13 84 93.57 86 97.09 88 100.70

90 104.40 92 108.18 94 112.06 96 116.02 98 120.08

100 124.23 102 128.47 104 132.81 106 137.25 108 141.79

110 146.43 112 151.17 114 156.01 116 160.96 118 166.01

120 171.17 122 176.45 124 181.83 126 187.32 128 192.93

130 198.66 132 204.50 134 210.47 136 216.55 138 222.76 140 229.09

Fig. 28 — 17/19EX Leak Test Procedures

Table 5B — HFC-134a Pressure — Temperature (C)

TEMPERATURE (C) PRESSURE (kPa)

-18.0 44.8

-16.7 51.9

-15.6 59.3

-14.4 66.6

-13.3 74.4

-12.2 82.5

-11.1 90.8

-10.0 99.4

-8.9 108.0

-7.8 118.0

-6.7 127.0

-5.6 137.0

-4.4 147.0

-3.3 158.0

-2.2 169.0

-1.1 180.0

0.0 192.0

1.1 204.0

2.2 216.0

3.3 229.0

4.4 242.0

5.0 248.0

5.6 255.0

6.1 261.0

6.7 269.0

7.2 276.0

7.8 284.0

8.3 290.0

8.9 298.0

9.4 305.0

10.0 314.0

11.1 329.0

12.2 345.0

13.3 362.0

14.4 379.0

15.6 396.0

16.7 414.0

17.8 433.0

18.9 451.0

20.0 471.0

21.1 491.0

22.2 511.0

23.3 532.0

24.4 554.0

25.6 576.0

26.7 598.0

27.8 621.0

28.9 645.0

30.0 669.0

31.1 694.0

32.2 720.0

33.3 746.0

34.4 773.0

35.6 800.0

36.7 828.0

37.8 857.0

38.9 886.0

40.0 916.0

41.1 946.0

42.2 978.0

43.3 1010.0

44.4 1042.0

45.6 1076.0

46.7 1110.0

47.8 1145.0

48.9 1180.0

50.0 1217.0

51.1 1254.0

52.2 1292.0

53.3 1330.0

54.4 1370.0

55.6 1410.0

56.7 1451.0

57.8 1493.0

58.9 1536.0

60.0 1580.0

Machine Dehydration — Dehydration is recom-

mended if the machine has been open for a considerable period of time, if the machine is known to contain moisture, or if there has been a complete loss of machine holding charge or refrigerant pressure.

Do not start or megohm test the compressor motor or oil pump motor, even for a rotation check, if the machine is under dehydration vacuum. Insulation breakdown and severe damage may result.

Dehydration is readily accomplished at room temperatures. Use of a cold trap (Fig. 29) may substantially reduce the time required to complete the dehydration. The higher the room temperature, the faster dehydration takes place. At low room temperatures, a very deep vacuum is required for boiling off any moisture. If low ambient temperatures are involved, contact a qualiﬁed service representative for the dehydration techniques required.

Perform dehydration as follows:

1. Connect a high capacity vacuum pump (5 cfm

[.002 m

/s] or larger is recommended) to the refrigerant charging valve (Fig. 7 and 8). Tubing from the pump to the machine should be as short and as large a diameter as possible to provide least resistance to gas ﬂow.

2. Use an absolute pressure manometer or a wet bulb vacuum indicator to measure the vacuum. Open the shutoff valve to the vacuum indicator only when taking a reading. Leave the valve open for 3 minutes to allow the indicator vacuum to equalize with the machine vacuum.

3. Open all isolation valves (if present), if the entire machine is to be dehydrated.

4. With the machine ambient temperature at 60 F (15.6 C) or higher, operate the vacuum pump until the manometer reads 29.8 in. Hg vac, ref 30 in. bar. (0.1 psia) (–100.61 kPa) or a vacuum indicator reads 35 F (1.7 C). Operate the pump an additional 2 hours.

Do not apply greater vacuum than 29.82 in. Hg vac (757.4 mm Hg) or go below 33 F (.56 C) on the wet bulb vacuum indicator. At this temperature/pressure, isolated pockets of moisture can turn into ice. The slow rate of evaporation (sublimination) of ice at these low temperatures/ pressures greatly increases dehydration time.

5. Valve off the vacuum pump, stop the pump, and record the instrument reading.

6. After a 2-hour wait, take another instrument reading. If the reading has not changed, dehydration is complete. If the reading indicates vacuum loss, repeat Steps 4 and 5.

7. If the reading continues to change after several attempts, perform a leak test up to the maximum 180 psig (1241 kPa) pressure. Locate and repair the leak, and repeat dehydration.

Fig. 29 — Dehydration Cold Trap

Inspect WaterPiping — Refer to piping diagrams pro-

vided in the certiﬁed drawings, and the piping instructions in the 17/19EX Installation Instructions manual. Inspect the piping to the cooler and condenser. Be sure that ﬂow directions are correct and that all piping speciﬁcations have been met.

Piping systems must be properly vented, with no stress on waterbox nozzles and covers. Waterﬂows through the cooler and condenser must meet job requirements. Measure the pressure drop across cooler and across condenser.

Water must be within design limits, clean, and treated to ensure proper machine performance and reduce the potential of tubing damage due to corrosion, scaling, or erosion. Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated water.

CheckOptionalPumpoutCompressorWaterPiping —

If the optional storage tank and/or pumpout system are installed, check to ensure the pumpout condenser water has been piped in. Check for ﬁeld-supplied shutoff valves and controls as speciﬁed in the job data. Check for refrigerant leaks on ﬁeld-installed piping.

Check Relief Devices — Be sure that relief devices

have been piped to the outdoors in compliance with the latest edition of ANSI/ASHRAE Standard 15 and applicable local safety codes. Piping connections must allow for access to the valve mechanism for periodic inspection and leak testing.

Relief valves are set to relieve at the 225 psig (1551 kPa)

machine design pressure.

Inspect Wiring

Do not check voltage supply without proper equipment and precautions. Serious injury may result. Follow power company recommendations.

Do not apply any kind of test voltage, even for a rotation check, if the machine is under a dehydration vacuum. Insulation breakdown and serious damage may result.

1. Examine wiring for conformance to job wiring diagrams and to all applicable electrical codes.

2. On low-voltage compressors (600 v or less) connect voltmeter across the power wires to the compressor starter and measure the voltage. Compare this reading with the voltage rating on the compressor and starter nameplates.

3. Compare the ampere rating on the starter nameplate with the compressor nameplate. The overload trip amps must be 108% to 120% of the rated load amps.

4. The starter for a centrifugal compressor motor must contain the components and terminals required for PIC refrigeration control. Check certiﬁed drawings.

5. Check the voltage to the following components and compare to the nameplate values: oil pump contact, pumpout compressor starter, and power panel.

6. Be sure that fused disconnects or circuit breakers have been supplied for the oil pump, power panel, and pumpout unit.

7. Check that all electrical equipment and controls are properly grounded in accordance with job drawings, certiﬁed drawings, and all applicable electrical codes.

8. Make sure that the customer’s contractor has veriﬁed proper operation of the pumps, cooling tower fans, and associated auxiliary equipment. This includes ensuring that motors are properly lubricated and have proper electrical supply and proper rotation.

9. Tighten up all wiring connections to the plugs on the SMM, 8-input, and PSIO modules.

10. Ensure that the voltage selector switch inside the power panel is switched to the incoming voltage rating.

11. On machines with free-standing starters, inspect the power

panel to ensure that the contractor has fed the wires into the bottom of the panel. Wiring into the top of the panel can cause debris to fall into the contactors. Clean and inspect the contactors if this has occurred.

Voltage to terminals LL1 and LL2 comes from a control transformer in a starter built to Carrier speciﬁcations. Do not connect an outside source of control power to the compressor motor starter (terminals LL1 and LL2). An outside power source will produce dangerous voltage at the line side of the starter, because supplying voltage at the transformer secondary terminals produces input level voltage at the transformer primary terminals.

CHECK INSULATION RESISTANCE (HERMETIC MOTOR) — Test the machine compressor motor and its power lead insulation resistance with a 500-v insulation tester such as a megohmmeter. (Use a 5000-v tester for motors rated over 600 v.) Factory-mounted starters do not require a megohm test.

1. Open the starter main disconnect switch and follow lockout/

tagout rules.

If the motor starter is a solid-state starter, the motor leads must be disconnected from the starter before an insulation test is performed. The voltage generated from the tester can damage the starter solidstate components.

2. With the tester connected to the motor leads, take

10-second and 60-second megohm readings as follows: 6-Lead Motor — Tie all 6 leads together and test be-

tween the lead group and ground. Next tie leads in pairs, 1 and 4, 2 and 5, and 3 and 6. Test between each pair while grounding the third pair.

3-Lead Motor — Tie terminals 1, 2, and 3 together and test between the group and ground.

3. Divide the 60-second resistance reading by the

10-second reading. The ratio, or polarization index, must be one or higher. Both the 10- and 60-second readings must be at least 50 megohms.

If the readings on a ﬁeld-installed starter are unsatisfactory,repeat the test at the motor with the power leads disconnected. Satisfactory readings in this second test indicate the fault is in the power leads.

NOTE: Unit-mounted starters do not have to be megohm tested.

CHECK INSULATION RESISTANCE (OPEN-DRIVE MOTOR) — Before operating voltages is applied to the motor, whether for checking rotation direction or for actual operation, the resistance of the stator winding insulation should be measured.

The test voltage, based on the motor operating voltage, is

as follows:

Operating Voltage DC Test Voltage

0- 900 500

901- 7000 1000

7001-14500 2500

This is particularly important if the motor may have been exposed to excessive dampness either during transit or while in storage. A ‘‘megger’’type instrument can be used to measure the insulation resistance. The test voltage should be applied between the entire winding (all winding leads connected together) and ground for approximately one minute with the winding at ambient temperature. The recommended minimum insulation resistance is determined as follows:

RM = KV + 1 Where RM = Recommended minimum insulation resis-

tance in megohms at 104° F (40° C) of the entire winding.

KV = Rated motor terminal to terminal voltage in

kilovolts (1000 volts = 1 KV).

On a new winding, where the contaminant causing low insulation resistance is generally moisture, drying the winding through the proper application of heat will normally increase the insulation resistance to an acceptable level. The following are several accepted methods for applying heat to a winding:

1. If the motor is equipped with space heaters, they can be

energized to heat the winding.

2. Direct current (as from a welder) can be passed through

the winding. The total current should not exceed approximately 50% of rated full load current. If the motor has only 3 leads, 2 must be connected together to form one circuit through the winding. In this case, one phase will carry the full applied current and each of the others, onehalf each. If the motor has 6 leads (3 mains and 3 neutrals), the 3 phases should be connected into one series circuit.

3. Heated air can be either blown directly into the motor or

into a temporary enclosure surrounding the motor. The source of heated air should preferably be electrical as opposed to fueled (such as kerosene) where a malfunction of the fuel burner could result in carbon entering the motor. Caution must be exercised, when heating the motor with any source of heat other than self contained space heaters, to raise the winding temperature at a gradual rate to allow any entrapped moisture to vaporize and escape without rupturing the insulation. The entire heating cycle should extend over 15 to 20 hours.

Insulation resistance measurements can be made while the winding is being heated. However, they must be corrected to 104 F (40 C) for evaluation since the actual insulation resistance will decrease with increasing temperature. As an approximation for a new winding, the insulation resistance will approximately halve for each 18° F (10° C) increase in insulation temperature above the dew point temperature.

Open-Drive Motor Pre-Start Checks — To pre-

vent damage to the motor, the following steps must be taken prior to initial start-up:

1. Remove the shaft shipping brace (if supplied).

2. For sleeve bearing motors, the oil reservoir must be ﬁlled with oil to the correct level. The proper oil is a rust and oxidation inhibited, turbine grade oil. The viscosity of the oil must be 32 ISO (150 SSU) at 100 F (37.7 C). Oil capacity in each of the two bearings is 0.6 gal. (2.3 L) per bearing. Use of Carrier Oil Speciﬁcation PP16-0 is approved (Mobil DTE Light or Sun Oil SUNVIS 916).

3. If possible, the shaft should be turned over by hand to ensure that there is free rotation. On sleeve bearing motors, the shaft should be moved to both extremes of its end play while it is being rotated, and the oil rings should be viewed through the viewing ports in the top of the bearing housing to verify free ring rotation.

4. On fan-cooled motors, the area around he external fan inlet should be checked for loose debris that could be drawn into the fan during operation.

5. All external, factory-made, bolted joints should be checked for any looseness that may have occurred in transit. Refer to Table 6 for recommended bolt torques.

Table 6 — Recommended Torque

Bolt size1⁄4(5⁄16(3⁄8(1⁄2(5⁄8(3⁄4(7⁄8( 1( 11⁄3( 11⁄2(

Grade SAE GR 5

Torque*

Ft-lbs 3.5 7 12 31 63 115 180 275 550 960

N.m 4.7 9.5 16 42 85 156 244 373 746 1302

Bolt size M4 M6 M8 M10 M12 M10 M12 M16

Grade DIN 8.8 DIN 12.9

Torque*

Ft-lbs 2 8 15 35 65 45 92 225

N.m 2.7 11 20 47 88 61 125 305

*Torque values based upon dry friction.

Carrier Comfort Network Interface — The Carrier

Comfort Network (CCN) communication bus wiring is supplied and installed by the electrical contractor. It consists of shielded, 3-conductor cable with drain wire.

The system elements are connected to the communication bus in a daisy chain arrangement. The positive pin of each system element communication connector must be wired to the positive pins of the system element on either side of it; the negative pins must be wired to the negative pins; the signal ground pins must be wired to signal ground pins.

To attach the CCN communication bus wiring, refer to the certiﬁed drawings and wiring diagrams. The wire is inserted into the CCN communications plug (COMM1) on the PSIO module. This plug also is referred to as J5.

NOTE: Conductors and drain wire must be 20 A WG(American Wire Gage) minimum stranded, tinned copper. Individual conductors must be insulated with PVC, PVC/nylon, vinyl, Teﬂon, or polyethylene.An aluminum/polyester 100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl or Teﬂon with a minimum operating temperature range of –20 C to 60 C is required. See table below for cables that meet the requirements.

MANUFACTURER CABLE NO.

Alpha 2413 or 5463

American A22503

Belden 8772

Columbia 02525

When connecting the CCN communication bus to a system element, a color code system for the entire network is recommended to simplify installation and checkout. The following color code is recommended:

SIGNAL

TYPE

CCN BUS CONDUCTOR

INSULATION COLOR

PSIO MODULE

COMM 1 PLUG (J5) PIN NO.

+ RED 1

Ground WHITE 2

– BLACK 3

Check Starter

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 the instruction and service manual supplied by the starter manufacturer to verify that the starter has been installed correctly.

The main disconnect on the starter front panel may not deenergize all internal circuits. Open all internal and remote disconnects before servicing the starter.

Whenever a starter safety trip device activates, wait at least 30 seconds before resetting the safety. The microprocessor maintains its output to the 1CR relay for 10 seconds after starter safety shutdown to determine the fault mode of failure.

MECHANICAL-TYPE STARTERS

1. Check all ﬁeld wiring connections for tightness, clear-

ance from moving parts, and correct connection.

2. Check the contactor(s) to be sure they move freely.Check

the mechanical interlock between contactors to ensure that 1S and 2M contactors cannot be closed at the same time. Check all other electro-mechanical devices, e.g., relays, timers, for free movement. If the devices do not move freely, contact the starter manufacturer for replacement components.

3. Some dashpot-type magnetic overload relays must be filled

with oil on the job site. If the starter is equipped with devices of this type, remove the ﬂuid cups from these magnetic overload relays. Add dashpot oil to cups per instructions supplied with the starter.The oil is usually shipped in a small container attached to the starter frame near the relays. Use only dashpot oil supplied with the starter. Do not substitute.

Factory-ﬁlled dashpot overload relays need no oil at start-up and solid-state overload relays do not have oil.

4. Reapply starter control power (not main chiller power)to

check electrical functions. When using a reduced-voltage starter (such as a wye-delta type) check the transition timer for proper setting. The factory setting is 30 seconds (±5 seconds), timed closing. The timer is adjustable in a range between 0 and 60 seconds and settings other than the nominal 30 seconds may be chosen as needed (typically 20 to 30 seconds are used).

When the timer has been set, check that the starter (with relay 1CR closed) goes through a complete and proper start cycle.

SOLID-STATE STARTERS

This equipment is at line voltage when AC power is connected. Pressing the Stop button does not remove voltage. Use caution when adjusting the potentiometers on the equipment.

1. Check that all wiring connections are properly terminated to the starter.

2. Verify that the ground wire to the starter is installed properly and is of sufficient size.

3. Verify that the motors are properly grounded to the starter.

4. Check that all of the relays are properly seated in their sockets.

5. Verify that the proper ac input voltage is brought into the starter per the certiﬁed drawings.

6. Verify the initial factory settings (i.e., starting torque, ramp potentiometers, etc. are set per the manufacturer’s instructions.

OilCharge — If oil is added, it must meet Carrier’s speci-

ﬁcation for centrifugal compressor usage as described in the Scheduled Maintenance, Oil Speciﬁcation section (page 77).

On hermetic machines, add oil through the oil drain charging valve (Fig. 3, Item 26).A pump is required for adding oil against refrigerant pressure. The pumping device must be able to lift from 0 to 150 psig (0 to 1034 kPa) or above unit pressure. On open-drive machines, oil may be added through the oil drain and charging valve (Fig. 2, Item 18) using a pump. However, an oil charging elbow on the seal-oil return chamber (Fig. 6) allows oil to be added without pumping. The seal oil return pump automatically transfers the oil to the main oil reservoir.

Oil should only be charged or removed when the machine is shut down. Maximum oil level is the middle of the upper sight glass.

Power Up the Controls and Check the Oil Heater —

Ensure that an oil level is visible in the compressor before energizing controls. A separate disconnect energizes the oil heater and the control circuit. When ﬁrst powered, the LID should display the default screen within a short period of time.

The oil heater is energized by powering the control circuit. This should be done several hours before start-up to minimize oil-refrigerant migration. The oil heater is controlled by the PIC and is powered through a contactor in the power panel. Starters contain a separate circuit breaker to power the heater and the control circuit. This set up allows the heater to energize when the main motor circuit breaker is offfor service work or extended shutdowns. The oil heater relay status can be viewed on the Status02 screen on the LID. Oil sump temperature can be viewed on the LID default screen.

SOFTWARE VERSION — The software version will always be labeled on the PSIO module, and on the back side of the LID module. On both the Controller ID and LID ID display screens, the software version number will also appear.

Set Up Machine Control Conﬁguration

Do not operate the machine before the control conﬁgurations have been checked and a Control Test has been satisfactorily completed. Protection by safety controls cannot be assumed until all control conﬁgurations have been conﬁrmed.

As conﬁguration of the 17/19EX unit is performed, write down all conﬁguration settings. A log, such as the one shown on pages CL-1 to CL-12, provides a convenient list for conﬁguration values.

Input the Design Set Points — Access the LID set

point screen and view/modify the base demand limit set point, and either the LCW set point or the ECW set point. The PIC can control a set point to either the leaving or entering chilled water.This control method is set in the Equipment Conﬁguration table, Conﬁg table.

Inputthe Local Occupied Schedule (OCCPC01S) —

Access the schedule OCCPC01S screen on the LID and set up the occupied time schedule per the customer ’s requirements. If no schedule is available, the default is factory set for 24 hours occupied 7 days per week including holidays.

For more information about how to set up a time sched-

ule, see the Controls section, page 12.

The CCN Occupied Schedule (OCCPC03S) should be conﬁgured if a CCN system is being installed or if a secondary time schedule is needed.

The Ice Build Occupied Schedule (OCCPC02S) should be conﬁgured for Ice Build applications.

Input Service Conﬁgurations — The following con-

ﬁgurations require the LID screen to be in the Service portion of the menu.

• password

• input time and date

• LID conﬁguration

• controller identiﬁcation

• service parameters

• equipment conﬁguration

• automated control test PASSWORD — When accessing the Service tables, a pass-

word must be entered. All LIDs are initially set for a password of 1-1-1-1. This password may be changed in the LID conﬁguration screen, if desired.

INPUT TIME AND DATE — Access the Time and Date table on the Service menu. Input the present time of day, date, and day of the week. ‘‘Holiday Today’’ should only be conﬁgured to ‘‘Yes’’ if the present day is a holiday.

CHANGE LID CONFIGURATION IF NECESSARY— The LID Conﬁguration screen is used to view or modify the LID CCN address, change to English or SI units, and to change the password. If there is more than one machine at the jobsite, change the LID address on each machine so that each machine has its own address. Note and record the new address. Change the screen to SI units as required, and change the password if desired. A copy of the password should be retained for future reference.

MODIFY CONTROLLER IDENTIFICATION IF NECESSARY—The controller identiﬁcation screen is used to change the PSIO module address. Change this address for each machine if there is more than one machine at the jobsite. Write the new address on the PSIO module for future reference.

INPUT EQUIPMENT SERVICE PARAMETERS IF NECESSARY—The Equipment Service table has 3 service tables: Service1, Service2, and Service3.

Conﬁgure SERVICE1 Table — Access Service1 table to modify/view the following to jobsite parameters:

Chilled Medium Water or Brine? Brine Refrigerant Trippoint Usually 3° F (1.7° C) below design

refrigerant temperature

Surge Limiting or

Hot Gas Bypass Option

Is HGBP installed?

Minimum Load Points

(T1/P1)

Per job data — See Modify Load

Points section

Maximum Load Points

(T2/P2)

Per job data — See Modify Load

Points section

Motor Rated Load Amps Per job data Motor Rated Line Voltage Per job data Motor Rated Line kW Per job data (if kW meter installed) Line Frequency 50 or 60 Hz Compressor Starter Type Reduced voltage or full? Stop-to-Start Time* Follow motor vendor recommenda-

tion for time between starts. See certiﬁed prints for correct value.

*Open-drive machines only. NOTE:Other values areleft at thedefault values. These maybe changed

bythe operatoras required. Service2 and Service3 tables canbe modiﬁed by the owner/operator as required.

Modify Minimum and Maximum Load Points (DT1/P1; D T2/P2) If Necessary —These pairs of machine load points,

located on the Service1 table, determine when to limit guide vane travel or to open the hot gas bypass valve when surge prevention is needed. These points should be set based on individual machine operating conditions.

If, after conﬁguring a value for these points, surge prevention is operating too soon or too late for conditions, these parameters should be changed by the operator.

Example of conﬁguration: Machine operating parameters Refrigerant used: HFC-134a

Estimated Minimum Load Conditions:

44 F (6.7 C) LCW

45.5 F (7.5 C) EWC

43 F (6.1 C) Suction Temperature

70 F (21.1 C) Condensing Temperature

Estimated Maximum Load Conditions:

44 F (6.7 C) LCW

54 F (12.2 C) ECW

42 F (5.6 C) Suction Temperature

98 F (36.7 C) Condensing Temperature Calculate Maximum Load — To calculate maximum load

points, use design load condition data. If the machine full load cooler temperature difference is more than 15° F (8.3° C), estimate the refrigerant suction and condensing temperatures at this difference. Use the proper saturated pressure and temperature for the particular refrigerant used.

Suction Temperature:

42 F (5.6 C) = 37 psig (255 kPa) saturated

refrigerant pressure (HFC-134a)

Condensing Temperature:

98 F (36.7 C) = 120 psig (1827 kPa) saturated

refrigerant pressure (HFC-134a)

Maximum Load DT2:

54 – 44 = 10° F (12.2 – 6.7 = 5.5° C)

Maximum Load DP2:

120 – 37 = 83 psid (827 – 255 = 572 kPad)

To avoid unnecessary surge prevention, add about 10 psid (70 kPad) to DP2 from these conditions:

DT2 = 10° F (5.5° C) DP2 = 93 psid (642 kPad)

Calculate Minimum Load — Tocalculate minimum load conditions, estimate the temperature difference that the cooler will have at 20% load, then estimate what the suction and condensing temperatures will be at this point. Use the proper saturated pressure and temperature for the particular refrigerant used.

Suction Temperature:

43 F (6.1 C) = 38 psig (262 kPa) saturated

refrigerant pressure (HFC-134a)

Condensing Temperature:

70 F (21.1 C) = 71 psig (490 kPa) saturated

refrigerant pressure (HFC-134a)

Minimum Load DT1 (at 20% Load):

2° F (1.1° C)

Minimum Load DP1:

71 – 38 = 33 psid (490 – 262 = 228 kPad)

Again, to avoid unnecessary surge prevention, add 20 psid (140 kPad) at DP1 from these conditions:

DT1 = 2° F (1.1° C) DP1 = 53 psid (368 kPad)

If surge prevention occurs too soon or too late:

LOAD

SURGE PREVENTION SURGE PREVENTION

OCCURS TOO SOON OCCURS TOO LATE

At low loads

(,50%)

Increase P1 by

10 psid (70 kPad)

Decrease P1 by

10 psid (70 kPad)

At high loads

(.50%)

Increase P2 by

10 psid (70 kPad)

Decrease P2 by

10 psid (70 kPad)

MODIFY EQUIPMENT CONFIGURATION IF NECESSARY — The Equipment Conﬁguration table has tables to select and view or modify. Carrier’s certiﬁed drawings will have the conﬁguration values required for the jobsite. Modify these tables only if requested.

Conﬁg Table Modiﬁcations — Change the values in this table per job data. See certiﬁed drawings for values. Modiﬁcations include:

• chilled water reset

• entering chilled water control (Enable/Disable)

• 4-20 mA demand limit

• auto restart option (Enable/Disable)

• remote contact option (Enable/Disable) Owner-Modiﬁed CCN Tables— The following tables are de-

scribed for reference only. Occdef Table Modiﬁcations — The Occdef tables contain

the Local and CCN time schedules, which can be modiﬁed here, or in the Schedule screen as described previously.

Holidef Table Modiﬁcations — The Holidef tables conﬁgure the days of the year that holidays are in effect. See Holiday Scheduling in the Controls section for more details.

Brodefs Table Modiﬁcations — The Brodefs table deﬁnes the outside-air temperature sensor and humidity sensor if one is to be installed. It will deﬁne the start and end of daylight savings time. Enter the dates for the start and end of daylight savings if required for the location. Brodefs also will activate the Broadcast function which enables the holiday periods that are deﬁned on the LID.

Other Tables — The Alarmdef, Cons-def, and Runt-def contain tables for use with a CCN system. See the applicable CCN manual for more information on these tables. These tables can only be deﬁned through a CCN Building Supervisor.

CHECK VOLTAGE SUPPLY—Access the Status 01 screen and read the LINE VOLTAGE: ACTUAL value. This reading should be equal to the incoming power to the starter. Use a voltmeter to check incoming power at the starter power leads. If the readings are not equal, an adjustment can be made by selecting the LINE VOLTAGE: ACTUAL point and then in- creasing or decreasing the value so that the value appearing on the LID is calibrated to the incoming power voltage reading. Voltage can be calibrated only to between 90 and 100 percent of rated line voltage.

PERFORMAN AUTOMATEDCONTROLTEST — Check the safety controls status by performing an automated controls test. Access the Control Test table and select the Automated Tests function (Table 7).

The Automated Control Test will check all outputs and inputs for function. It will also set the refrigerant type. The compressor must be in the OFF mode in order to operate the controls test and the 24-v input to the SMM must be in range (per line voltage percent on Status01 table). The OFF mode is caused by pressing the STOP pushbutton on the LID. Each test will ask the operator to conﬁrm that the operation is occurring, and whether or not to continue. If an error occurs, the operator has the choice to try to address the problem as the test is being done, or to note the problem and proceed to the next test.

NOTE: If during the Control Test the guide vanes do not open, check to see that the low pressure alarm is not active. (This will cause the guide vanes to close.)

NOTE: The oil pump test will not energize energize the oil pump if cooler pressure is below –5 psig (–35 kPa).

When the test is ﬁnished, or the EXIT

softkey is pressed,

the test will be stopped and the Control Test menu will be displayed. If a speciﬁc automated test procedure is not completed, access the particular control test to test the function when ready. The Control Test menu is described as follows.

Automated Tests As described above, a complete

control test.

PSIO Thermistors Check of all PSIO

thermistors only.

Options Thermistors Check of all options

boards thermistors.

Transducers Check of all transducers.

Guide Vane Actuator Check of the guide vane

operation.

Pumps Check operation of pump outputs,

either all pumps can be activated, or individual pumps. The test will also test the associated input such as ﬂow or pressure.

Discrete Outputs Activation of all on/off

outputs or individually.

Pumpdown/Lockout Pumpdown prevents the low

refrigerant alarm during evacuation so refrigerant can be removed from the unit; locks the compressor off; and starts the water pumps.

Terminate Lockout To charge refrigerant and enable

the chiller to run after pumpdown lockout.

Table 7 — Control Test Menu Functions

TESTS TO BE DEVICES TESTED

PERFORMED

1. Automated Tests* Operates the second through seventh

tests

2. PSIO Thermistors Entering chilled water Leaving chilled water Entering condenser water Leaving condenser water Discharge temperature Bearing temperature Motor winding temperature Oil sump temperature

3. Options Thermistors Common chilled water supply sensor Common chilled water return sensor Remote reset sensor Temperature sensor — Spare 1

Spare 2 Spare 3 Spare 4 Spare 5 Spare 6 Spare 7 Spare 8 Spare 9

4. Transducers Evaporator pressure Condenser pressure Oil pressure differential† Oil pump pressure**

5. Guide Vane Actuator Open Close

6. Pumps All pumps or individual pumps may be activated:

Oil pump — Conﬁrm pressure Chilled water pump — Conﬁrm ﬂow Condenserwater pump —Conﬁrm flow Auxiliary oil pump — conﬁrm

pressure†

7. Discrete Outputs All outputs or individual outputs may be energized:

Hot gas bypass relay Oil heater relay Motor cooling relay** Tower fan relay Alarm relay Shunt trip relay

8. Pumpdown/Lockout When using pumpdown/lockout, observe freeze up precautions when removing charge:

Instructs operator as to which valves to close and when

Startschilled waterand condenserwater pumps and conﬁrms ﬂows

Monitors — Evaporator pressure

Condenser pressure Evaporator temperature during pumpout

procedures Turns pumps off after pumpdown Locks out compressor

9. Terminate Lockout Starts pumps and monitors ﬂows Instructs operator as to which values

to open and when Monitors — Evaporator pressure

Condenser pressure Evaporator temperature during charging process

Terminates compressor lockout

*During any of the tests thatare not automated, an out-of-range read-

ing will have an asterisk (*) next to the reading and a message will be displayed.

†On open-drive machines, differential pressure is the only oil pres-

sure displayed.

**Displayed only on hermetic machines.

Check Pumpout System Controls and Optional Pumpout Compressor —

Controls include an on/off switch, a 3-amp fuse, the compressor overloads, an internal thermostat, a compressor contactor, and a refrigerant high pressure cutout. The high pressure cutout is factory set to open at 161 psig (1110 kPa) and reset at 130 psig (896 kPa). Check that the water-cooled condenser has been connected. Loosen the compressor holddown bolts to allow free spring travel. Open the compressor suction and discharge service valves. Check that oil is visible in the compressor sight glass. Add oil if necessary.

See Pumpout and Refrigerant Transfer Procedures (page 64) and Pumpout System Maintenance sections (page 82) for details on transfer of refrigerant, oil speciﬁcations, etc.

HighAltitude Locations — Recalibration of the pres-

sure transducers will be necessary as the machine was initially calibrated at sea level. Please see the calibration procedure in the Troubleshooting Guide section.

Charge Refrigerant into Machine

The transfer, addition, or removal of refrigerant in spring isolated machines may place severe stress on external piping if springs have not been blocked in both up and down directions.

The 17/19EX machine may have the refrigerant already charged in the utility vessels. If machine is not shipped fully charged, refrigerant is shipped separately to conform with transportation regulations. The 17/19EX may be ordered with a nitrogen holding charge of 15 psig (103 kPa). Evacuate the entire machine, and charge machine from refrigerant cylinders.

The full refrigerant charge on the 17/19EX will vary with machine components and design conditions, indicated on the job data speciﬁcations.An approximate charge may be found in 17/19EX Physical Data section, page 97. The full machine charge is printed on the machine identiﬁcation label.

Always operate the condenser and chilled water pumps during charging operations to prevent freeze-ups. Use the Controls Test Terminate Lockout to monitor conditions and start the pumps.

If the machine has been shipped with a holding charge, the refrigerant will be added through the refrigerant charging valve (Fig. 8) or to the pumpout charging connection. First evacuate the nitrogen holding charge from the vessels. Charge the refrigerant as a gas until the system pressure exceeds 35 psig (141 kPa). After the machine is beyond this pressure the refrigerant should be charged as a liquid until all of the recommended refrigerant charge has been added.

TRIMMING REFRIGERANT CHARGE — The 17/19EX is shipped with the correct charge for the design duty of the machine. Trimming the charge can be best accomplished when design load is available. To trim, check the temperature difference between leaving chilled water temperature and cooler refrigerant temperature at full load design conditions. If necessary, add or remove refrigerant to bring the temperature difference to design conditions or a minimum differential.

INITIAL START-UP

Preparation —

Before starting the machine, check that

the:

1. Power is on to the main starter, oil pump relay, tower fan starter, oil heater relay, and the machine control center.

2. Cooling tower water is at proper level, and at or below design entering temperature.

3. Machine is charged with refrigerant and all refrigerant and oil valves are in their proper operating position.

4. Oil is at the proper level in the reservoir sight glasses.

5. Oil reservoir temperature is above 140 F (60 C) or refrigerant temperature plus 50° F (28° C).

6. Valves in the evaporator and condenser water circuits are open.

NOTE: If pumps are not automatic, make sure water is circulating properly.

7. Check the starter to ensure it is ready to start and that all safety circuits have been reset. Be sure to keep the starter door closed.

Do not permit water or brine that is warmer than 110 F (43 C) to ﬂow through the cooler or condenser. Refrigerant overpressure may discharge through the relief devices and result in the loss of refrigerant charge.

8. Press RELEASE to automate the chiller start/stop value on the Status01 screen to enable the chiller to start. The

initial factory setting of this value is overridden to stop in order to prevent accidental start-up.

Manual Operation of the Guide Vanes— Manual

operation of the guide vanes is helpful to establish a steady motor current for calibration of the motor amps value.

In order to manually operate the guide vanes, it is necessary to override the TARGET GUIDE VANE POSITION value which is accessed on the Status01 screen. Manual control is indicated by the word ‘‘SUPVSR!’’ ﬂashing after the target value position. Manual control is also indicated on the default screen on the run status line.

1. Access the Status01 screen and look at the target guide

vane position (Fig. 18). If the compressor is off,the value will read zero.

2. Move the highlight bar to the TARGET GUIDE VANE

POSITION line and press the SELECT

softkey.

3. Press ENTER

to override the automatic target.The screen

will now read a value of zero, and the word ‘‘SUPVSR!’’ will ﬂash.

4. Press the SELECT

softkey, and then press

RELEASE

softkey to release the vanes to AUTO-

MATIC mode. After a few seconds the ‘‘SUPVSR!’’ will disappear.

Dry Run to Test Start-Up Sequence

1. Disengage the main motor disconnect on the starter front panel. This should only disconnect the motor power. Power to the controls, oil pump, and starter control circuit should still be energized.

2. Look at the default screen on the LID: the Status message in the upper left-hand corner will show a ‘‘Manually Stopped’’ message. Press CCN or Local to start. If not, go to the Schedule screen and override the schedule or

change the occupied time. Press the LOCAL

softkey to

begin the start-up sequences.

3. Check that chilled water and condenser water pumps energize.

4. Check that the oil pump starts and pressurizes the lubrication system. After the oil pump has run about 15 seconds, the starter will be energized and go through its start-up sequence.

5. Check the main contactor for proper operation.

6. The PIC will eventually show an alarm for motor amps not sensed. Reset this alarm and continue with the initial start-up.

Check Rotation (Open-Drive Motor)

OPEN DRIVE MOTOR INITIAL START-UP Initial Uncoupled Start-Up — The initial start-up of the mo-

tor should be made with the motor uncoupled. Verify that oil has been added to each bearing housing to the correct level.

1. If the motor is equipped with unidirectional fans (refer to the certiﬁed drawing) and veriﬁcation of rotation direction is required, the following procedure should be followed:

a. Start the motor and observe the rotation direction. b. Allow the motor to achieve full speed before discon-

necting it from the power source.

c. If the rotation direction must be changed, refer to the

Before Initial Start-Up, Open Drive Motor Electrical Connection section, page 47. Otherwise, the motor can be restarted immediately after it has coasted to a stop.

2. Following the initial start-up, the bearing temperatures should be closely monitored. On sleeve bearings, the free rotation of the oil rings should be veriﬁed by observing them through the viewing port in the top of the housing. The rate of rise in bearing temperature is more indicative of impending trouble than the actual temperature. If the rate of rise in temperature is excessive or if the motor exhibits excessive vibration or noise, it should be shut down immediately and a thorough investigation made as to the cause before it is operated again.

If the bearing temperature rise and motor operation appear to be normal, operation should continue until the bearing temperatures stabilize. Recommended limits on bearing temperature rises over ambient temperature are as follows:

Sleeve Bearings

Temperature Rise

Over Ambient

Temperature

By permanently installed

detector

72° F (40° C)

By temporary detector on top

of the bearing sleeve near the oil ring

63° F (35° C)

NOTE: When operating ﬂood-lubricated sleeve bearings, the bearing temperature must not be allowed to exceed 185 F (85 C) total temperature.

Under normal conditions, for the self-lube bearing, the rate of temperature rise should be from 20° to 25° F (11° to 14° C) for the ﬁrst 10 minutes after starting up and approximately 40° F (22° C) at 30 minutes. The rate of bearing temperature rise is a function of the natural ventilation and operating conditions.

When the rate of bearing temperature rise is less than 2° F (1.1° C) per half-hour, the bearing temperature is considered to be stabilized.

If the total bearing temperature exceeds 195 F (91 C), the motor should be shut down immediately.

3. Any abnormal noise or vibration should be immediately investigated and corrected. Increased vibration (with the motor uncoupled from its load) can be indicative of a change in balance due to a mechanical failure or the loosening of a rotor part, a stator winding problem, foundation problem, or a change in motor alignment.

4. Verify that the magnetic center indicator aligns with the shaft.

Initial Coupled Start-Up — After initial uncoupled start-up, the following steps should be taken to ensure safe coupled operation:

1. Follow the procedure stated in General Maintenance, MachineAlignment section to align the motor to the driven machine.

2. Prepare the coupling for operation in accordance with the coupling manufacturer’sinstructions. Note any match marks on the couplings and assemble accordingly. For sleeve bearing motors, verify that the correct limited endﬂoat coupling has been installed. The endﬂoat limits can be found on the certiﬁed drawing.

3. Ensure that all personnel are at a safe distance from rotating parts. Start the motor in accordance with instructions supplied with the motor control.

4. If the motor rotor fails to start turning in a second or two, shut off the power supply immediately. This can result from:

a. Too low a voltage at the motor terminals. b. The load is too much for the rotor to accelerate. c. The load is frozen up mechanically. d. All electrical connections are not made. e. Single phase power has been applied. f. Any combination of the above.

Investigate thoroughly and take corrective action before attempting a restart.

5. Carefully observe the vibration of the bearing housing and any abnormal noise generator.

Note that motor vibration may not be identical to the uncoupled values. If coupled vibration is excessive, recheck the mounting and alignment.

6. Carefully observe the bearing temperature rise and the movement of the oil ring.

If the bearing temperature rise and motor operation appear normal, operation should continue until the bearing temperatures stabilize.

7. If possible, check the motor line currents for balance.

It should be recognized that each start of an induction motor subjects the motor to full inrush current with resulting heating of the stator and rotor windings. Each acceleration and repeated starts can produce more heat than is produced and dissipated by the motor under full load. The starting duty for which the motor is designed is shown by a nameplate mounted on the motor and must not be exceeded, if long motor life is expected. Abnormally low terminal voltage, excessive load torque and/or excessive load inertia during motor start-up can cause lengthened acceleration times during which rotor ventilation is reduced. This can cause rotor damage or can lead to shortened rotor life.

The temperature rating of the motor is shown on the main nameplate as a temperature rise above an ambient temperature. If there is a service factor, it is also shown. If the motor temperature switch opens, an investigation should be made before further operation is attempted.

If the motor is of TEWAC (Totally Enclosed Water-to-Air Cooled) design, the maximum inlet water temperature and the water ﬂow rate (GPM) at the air cooler must be as shown by the certiﬁed drawing. Otherwise, the discharge air temperature from the cooler (actually the ambient air for the motor as shown by the main nameplate) could be too high for the motor to properly cool.

Check Rotation (Hermetic Motor)

1. Engage the main motor disconnect on the front of the starter

panel. The motor is now ready for rotation check.

2. After the default screen Status message states ‘‘Ready

for Start’’ press the LOCAL

softkey; start-up checks

will be made by the control.

3. When the starter is energized and the motor begins to turn

over, check for clockwise rotation (Fig. 30).

IF ROTATION IS PROPER, allow the compressor to come up to speed.

IF THE MOTOR ROTATION IS NOT CLOCKWISE (as viewed through the sight glass), reverse any 2 of the 3 incoming power leads to the starter and recheck rotation.

NOTE: Starters may also have phase protection and will not allow a start if the phase is not correct. Instead, a Starter Fault message will occur if this happens.

Do not check motor rotation during coastdown. Rotation may have reversed during equalization of vessel pressures.

Check Oil Pressure and Compressor Stop

1. When the motor is up to full speed, note the differential

oil pressure reading on the LID default screen. It should be between 18 and 30 psid (124 to 206 kPad).

2. Press the Stop button and listen for any unusual sounds

from the compressor as it coasts to a stop.

Calibrate Motor Current Demand Setting

1. Make sure that the compressor motor rated load amps in the Service1 screen has been conﬁgured. Place an ammeter on the line that passes through the motor load current transfer on the motor side of the power factor correction capacitors (if provided).

2. Start the compressor and establish a steady motor current value between 70% and 100% RLA by manually overriding the guide vane target value on the LID and setting the chilled water set point to a low value. Do not exceed 105% of the nameplate RLA.

3. When a steady motor current value in the desired range is met, compare the compressor motor amps value on the Status01 screen to the actual amps shown on the ammeter on the starter. Adjust the amps value on the LID to the actual value seen at the starter if there is a differ-

ence. Highlight the amps value then press SELECT

Press INCREASE

or DECREASE to bring the value

to that indicated on the ammeter. Press ENTER

when

equal.

4. Make sure that the target guide vane position is released into AUTOMATIC mode.

To PreventAccidental Start-Up — The PIC can be

set up so that start-up of the unit is more difficult than just pressing the LOCAL

or CCN softkeys during machine service or when necessary. By accessing the Status01 screen, and highlighting the chiller Start/Stop line, the value

can be overridden to stop by pressing SELECT

and then

the STOP

and ENTER softkeys. ‘‘SUPVSR’’ will ap-

pear after the value. When attempting to restart, remember to release the override. The default machine message line will also state that the Start/Stop has been set to ‘‘Start’’or ‘‘Stop’’ when the value is overridden.

HotAlignment Check for Open-Drive Machines —

Alignment of compressor with heat exchangers, gear, and driver may be affected by the operating temperatures of the various components. When all machine components have reached operating temperature (after running near full load for 4 to 8 hours), make a hot alignment check.

With the proper equipment and procedure, hot check can be made with either assembled or disassembled couplings. The procedures are detailed in the Maintenance section.

A clamping tool, Part No. TS-170, is available for checking alignment without disassembling the couplings. Check with your local Carrier representative.

Never operate compressor or drive with coupling guards removed. Serious injury can result from contact with rotating equipment.

Doweling for Open-Drive Machines — The size,

quantity,and location of dowels vary considerably with type and arrangement of gear and drive. Check your job data for speciﬁc doweling instructions. Typical doweling practices are described in the Maintenance section.

Check Machine Operating Condition — Check to

be sure that machine temperatures, pressures, water ﬂows, and oil and refrigerant levels indicate that the system is functioning properly.

Instructthe Customer Operator — Check to be sure

that the operator(s) understands all operating and maintenance procedures. Point out the various machine parts and explain their function as part of the complete system.

COOLER-CONDENSER — Relief devices, temperature sensor locations, pressure transducer locations, Schrader ﬁttings, waterboxes and tubes, and vents and drains.

UTILITY VESSEL — Float chambers, relief valves, charging valve.

PUMPOUT SYSTEM — Transfer valves and pumpout system, refrigerant charging and pumpdown procedure, lubrication, and relief devices.

MOTOR COMPRESSOR ASSEMBLY — Guide vane actuator, transmission, motor cooling system, oil cooling system, temperature and pressure sensors, oil sight glasses, integral oil pump, isolatable oil ﬁlter, extra oil and motor temperature sensors, synthetic oil, and compressor serviceability.

MOTOR COMPRESSOR LUBRICATION SYSTEM — Oil pump, cooler ﬁlter, oil heater, oil charge and speciﬁcation, operating and shutdown oil level, temperature and pressure, oil charging connections, and seal oil chambers.

CONTROL SYSTEM — CCN and Local start, reset, menu, softkey functions, LID operation, occupancy schedule, set points, safety controls, and auxiliary and optional controls.

AUXILIARYEQUIPMENT— Starters and disconnects, separate electrical sources, pumps, and cooling tower.

DESCRIBE MACHINE CYCLES — Refrigerant, motor cooling, lubrication, and oil reclaim.

REVIEW MAINTENANCE — Scheduled, routine, and extended shutdowns, importance of a log sheet, importance of water treatment and tube cleaning, and importance of maintaining a leak-free machine.

SAFETYDEVICES AND PROCEDURES — Electrical disconnects, relief device inspection, and handling refrigerant.

CHECK OPERATOR KNOWLEDGE — Start, stop, and shutdown procedures, safety and operating controls, refrigerant and oil charging, and job safety.

REVIEW THE START-UP, OPERATION, AND MAINTENANCE MANUAL

Fig. 30 — Correct Motor Rotation

OPERATING INSTRUCTIONS

Operator Duties

1. Become familiar with refrigeration machine and related equipment before operating the machine.

2. Prepare the system for start-up, start and stop the machine, and place the system in a shutdown condition.

3. Maintain a log of operating conditions and document any abnormal readings.

4. Inspect the equipment, make routine adjustments, and perform a control test. Maintain the proper oil and refrigerant levels.

5. Protect the system from damage during shutdown periods.

6. Maintain the set point, time schedules, and other PIC functions.

Prepare the Machine for Start-Up — Follow the

steps described in the Initial Start-Up section, page 58.

To Start the Machine

1. Start the water pumps, if they are not automatic.

2. On the LID default screen, press the LOCAL

CCN

softkey to start the system. If the machine is in

the OCCUPIED mode, and the 3- and 15-minute start timers have expired, the start sequence will start. Follow

the procedure described in the Start-Up/Shutdown/ Recycle section, page 45.

Check the Running System — After the compres-

sor starts, the operator should monitor the LID display and observe the parameters for normal operating conditions:

1. The oil reservoir temperature should be above 150 F (66 C) or refrigerant temperature plus 70° F (38° C) during shutdown, and above 125 F (52 C) during compressor operation.

2. The bearing oil temperature accessed on the Status01 LID screen should be 150 to 200 F (65 to 93 C). If the bearing temperature reads more than 210 F (99 C) with the oil pump running, stop the machine and determine the cause of the high temperature. Do not restart the machine until corrected.

3. The oil level should be visible in the lower sight glass when the compressor is running.

At shutdown, oil level should be halfway in the lower sight glass.

4. The oil pressure should be between 18 and 30 psi (124 to 207 kPa) differential, as seen on the LID default screen. Typically the reading will be 18 to 25 psi (124 to 172 kPa) at initial start-up.

5. The moisture indicating sight glass on the refrigerant motor cooling line (Fig. 8) should indicate refrigerant flow and a dry condition.

6. The condenser pressure and temperature varies with the machine design conditions. Typicallythe pressure will range between 100 and 210 psig (690 to 1450 kPa) with a corresponding temperature range of 60 to 105 F (15 to 41 C). The condenser entering water temperature should be controlled below the speciﬁed design entering water temperature to save on compressor kilowatt requirements. The leaving condenser water temperature should be at least 20° F (11° C) above leaving chilled water temperature.

7. Cooler pressure and temperature also will vary with the design conditions. Typical pressure range will be between 60 and 80 psig (410 and 550 kPa), with temperature ranging between 34 and 45 F (1 and 8 C).

8. The compressor may operate at full capacity for a short time after the pulldown ramping has ended, even though the building load is small. The active electrical demand setting can be overridden to limit the compressor IkW, or the pulldown rate can be decreased to avoid a high demand charge for the short period of high demand operation. Pulldown rate can be based on kW rate or temperature rate. It is accessed on the Equipment Conﬁguration menu Conﬁg screen (Table 2, Example 5).

9. On open-drive machines, the oil pump will be energized once every 12 hours during shutdown periods to ensure that the shaft seal is ﬁlled with oil.

To Stop the Machine

1. The occupancy schedule will start and stop the machine automatically once the time schedule is set up.

2. By pressing the Stop button for one second, the alarm light will blink once to conﬁrm that the button has been

pressed, then the compressor will follow the normal shutdown sequence as described in the Controls section. The

machine will not restart until the CCN

or LOCAL soft-

key is pressed. The machine is now in the OFF mode.

NOTE: If the machine fails to stop, in addition to action that the PIC will initiate, the operator should close the guide vanes by overriding the guide vane target to zero to reduce machine load; then by opening the main disconnect. Do not attempt to stop the machine by opening an isolating knife switch. High intensity arcing may occur. Do not restart the machine until the problem is diagnosed and corrected.

After Limited Shutdown — No special preparations

should be necessary. Follow the regular preliminary checks and starting procedures. Control Power must be maintained in order to keep oil temperature hot and all control safeties operational. The oil pump on open-drive machines will operate occasionally to keep the contact seal ﬁlled with oil to prevent refrigerant loss.

ExtendedShutdown— The refrigerant should be trans-

ferred into the utility vessel (see Pumpout and Refrigerant TransferProcedures) in order to reduce machine pressure and possibility of leaks. Maintain a holding charge of 5 to 10 lbs (2.27 to 4.5 kg) of refrigerant within the cooler/condenser/ compressor sections, to prevent air from leaking into the machine.

If freezing temperatures are likely to occur in the machine area, drain the chilled water, condenser water, and the pumpout condenser water circuits to avoid freeze-up. Keep the waterbox drains open.

Leave the oil charge in the machine with the oil heater and controls energized to maintain the minimum oil reservoir temperature.

After Extended Shutdown — Be sure that the water

system drains are closed. It may be advisable to ﬂush the water circuits to remove any soft rust which may have formed. This is a good time to brush the tubes if necessary.

Check the cooler pressure on the LID default screen, and compare to the original holding charge that was left in the machine. If (after adjusting for ambient temperature changes) any loss in pressure is indicated, check for refrigerant leaks. See Check Machine Tightness section, page 48.

Recharge the machine by transferring refrigerant from the utility vessel. Follow the Pumpout and Refrigerant Transfer Procedures section, page 64. Observe freeze-up precautions.

Carefully make all regular preliminary and running system checks. Perform a controls test before start-up. If the compressor oil level appears abnormally high, the oil may have absorbed refrigerant. Make sure that the oil temperature is above 150 F (66 C) or cooler refrigerant temperature plus 70° F (39° C).

Cold Weather Operation — When the entering con-

denser water drops very low,the PIC can automatically cycle the cooling tower fans off to keep the temperature up. Piping may also have to be arranged to bypass the cooling tower as well as a tower temperature control system.

Manual Guide Vane Operation — Manual opera-

tion of the guide vanes in order to check control operation or control of the guide vanes in an emergency operation is possible by overriding the target guide vane position. Access the Status01 screen on the LID and highlight TARGET GUIDE VANE POSITION. To control the position, enter a percentage of guide vane opening that is desired. Zero percent is fully closed, 100% is fully open. To release the guide

vanes to AUTOMATIC mode, press the RELEASE softkey.

NOTE: Manual control will increase the guide vanes and override the pulldown rate during start-up. Motor current above the electrical demand setting, capacity overrides, and chilled water below control point will override the manual target and close the guide vanes. For descriptions of capacity overrides and set points, see the Controls section.

Refrigeration Log — A refrigeration log, such as the

one shown in Fig. 31, provides a convenient checklist for routine inspection and maintenance and provides a continuous record of machine performance. It is an aid in scheduling routine maintenance and in diagnosing machine problems.

Keep a record of the machine pressures, temperatures, and liquid levels on a sheet similar to that shown. Automatic recording of PIC data is possible through the use of CCN devices such as the Data Collection module and a Building Supervisor. Contact your Carrier representative for more information.

REFRIGERATION LOG CARRIER 17/19EX CENTRIFUGAL REFRIGERATION MACHINE

Plant

MACHINE MODEL NO. MACHINE SERIAL NO. REFRIGERANT TYPE

DATE

COOLER CONDENSER COMPRESSOR

OPER-

ATOR

INITIALS

REMARKS

TIME

Refrigerant Water Refrigerant Water

BEAR-

ING

TEMP

Oil Motor

Press. Temp

Pressure Temp

Press. Temp

Pressure Temp

Press.

Diff.

Temp

(reser-

voir)

Level

FLA

In Out GPM In Out In Out GPM In Out

Amperage

(or vane

position)

REMARKS: Indicate shutdowns on safety controls, repairs made, oil or refrigerant added or removed, air exhausted and water drained from dehydrator. Include amounts.

Fig. 31 — Refrigeration Log

PUMPOUT AND REFRIGERANT TRANSFER

PROCEDURES

Preparation —

The 17/19EX may come equipped with an optional pumpout compressor.The refrigerant can be pumped for service work to either the cooler/condenser/compressor sections or the utility vessel by using the pumpout system. The following procedures are used to describe how to transfer refrigerant from vessel to vessel and perform machine evacuations.

Operating the Optional Pumpout Compressor

1. Be sure that the suction and the discharge service valves

on the optional pumpout compressor are open (back seated) during operation. Figure 32 shows the location of these valves. Rotate the valve stem fully counterclockwise to open. Front seating the valve closes the refrigerant line and opens the gage port to compressor pressure.

2. Make sure that the compressor holddown bolts have been

loosened to allow free spring travel.

3. Open the refrigerant inlet valve on the pumpout compressor.

4. Oil should be visible in the compressor sight glass under

all operating conditions and during shutdown. If oil is

low, add oil as described under Pumpout System Maintenance section, page 82. The pumpout unit control wiring schematic is detailed in Fig. 33. The Optional Pumpout System is detailed in Fig. 34.

TO READ REFRIGERANT PRESSURES during pumpout or leak testing:

1. The LID display on the machine control center is suitable for determining refrigerant-side pressures and low (soft) vacuum. For evacuation or dehydration measurement, use a quality vacuum indicator or manometer to ensure the desired range and accuracy. This can be placed on the Schrader connections on each vessel (Fig. 7 and 8) by removing the pressure transducer.

2. To determine utility vessel pressure, a 30 in.-0-400 psi (-101-0-2760 kPa) gage is attached to the vessel.

3. Refer to Fig. 32 for valve locations and numbers.

Transfer, addition, or removal of refrigerant in springisolated machines may place severe stress on external piping if springs have not been blocked in both up and down directions.

NOTE: Location of pumpout compressor mayvary depending on machine arrangement.

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

Fig. 32 — Pumpout Arrangement and Valve Number Locations (12-ft Vessel Shown) (cont)

LEGEND

C—Contactor Fu — Fuse, 3 Amps HP — High-Pressure Cutout OL — Compressor Overload T’stat — Internal Thermostat

Compressor Terminal Contactor Terminal

Overload Terminal Pumpout Unit Terminal

*Bimetal thermal protector imbedded in motor winding.

Fig. 33 — Pumpout Unit Wiring Schematic

(19EX Shown)

Fig. 34 — Optional Pumpout Compressor

Transferring Refrigerant From Normal Operation into the Utility Vessel —

These steps describe the method of moving refrigerant from the cooler/condenser/ compressor sections into the utility vessel. This is normally performed for service work on the cooler, condenser, or the compressor components or for long-term machine shutdown.

1. Isolate and push refrigerant into the utility vessel with

the pumpout compressor. a. Valve positions: (Blank spaces indicate open valves).

VALVE 1 2 3 4 5 6 7 8 9 10 11 CONDITION CC CC C C

b. Turn off the machine water pumps and pumpout con-

denser water.

c. Turn on pumpout compressor to push liquid out of the

cooler/condenser/compressor section.

d. When all liquid has been pushed into the utility ves-

sel, close the cooler isolation valve 7.

e. Access the Control Test, Pumpdown function on the

LID display to turn on the machine water pumps and view the machine pressures.

f. Turn off pumpout compressor.

2. Evacuate refrigerant gas from the cooler/condenser/

compressor vessel. a. Valve positions: close valves 2 and 5, open valves 3

and 4.

VALVE 1 2 3 4 5 6 7 8 9 10 11 CONDITION C C CCC C C

b. Turn on pumpout condenser water. c. Run pumpout compressor until the suction reaches

15 in. Hg (50 kPa abs). Monitor pressures on the LID

and on the refrigerant gages. d. Close valve 1. e. Turn off pumpout compressor. f. Close valves 3, 4, and 6. (All valves are now closed.) g. Turn off pumpout condenser water. h. Continue pumpdown function on the LID to turn off

the machine water pumps and to lock out the machine compressor from operation.

Transferring Refrigerant from Normal Operationintothe Cooler/Condenser/Compressor Section —

These steps describe the method of moving refrigerant from the utility vessel into the cooler/condenser/ compressor section. This is normally performed for service work on the utility vessel.

1. Isolate and push refrigerant into the cooler/condenser/

compressor section: a. Valve positions:

VALVE 1 2 3 4 5 6 7 8 9 10 11 CONDITION CCCCCC

b. Turn off machine water pumps and pumpout con-

denser water.

c. Turn on pumpout compressor to push refrigerant out

of the utility vessel.

d. When all liquid is out of the utility vessel, close cooler

isolation valve 7.

e. Turn off pumpout compressor.

2. Evacuate refrigerant from the utility vessel. a. Access the Control Test, pumpout function on the LID

display to turn on the machine water pumps and monitor vessel pressures.

b. Valve positions: Close valves 3 and 4, open valves 2

and 5.

VALVE 1 2 3 4 5 6 7 8 9 10 11 CONDITION CC CCC C C

c. Turn on pumpout condenser water. d. Run the pumpout compressor until the suction reaches

15 in. Hg (50 kPa abs). Monitor pressures on the LID

and on refrigerant gages. e. Close valve 6. f. Turn off pumpout compressor. g. Close valves 1, 2, and 5 (all valves are now closed). h. Turn off pumpout condenser water. i. Continue pumpdown function on the LID to turn off

machine water pumps and lock out the machine compressor from operation.

Return Refrigerant to Normal Operating Conditions

1. Be sure that the vessel that was opened has been evacuated and dehydrated.

2. Access the Control Test, terminate lockout function to view vessel pressures and to turn on machine water pumps.

3. Open valves 1, 3, and 6.

VALVE 1234567891011 CONDITION CCCCCCCC

4. Slowly open valve 5, gradually increasing pressure in the evacuated vessel to 35 psig (141 kPa) for HFC-134a. Feed refrigerant slowly to prevent freezeup.

5. Perform leak test at 35 psig (141 kPa).

6. Open valve 5 fully. Let vessel pressures equalize.

VALVE 1 2 3 4 5 6 7 8 9 10 11 CONDITION C C CCC C C

7. Open valves 9 and 10.

8. Open valve 7 to equalize liquid refrigerant levels.

9. Close valves 1, 3, 5, and 6.

VALVE 1234567891011 CONDITION CCCCCC C C

10. Continue on with the terminate lockout function on the LID to turn off water pumps and enable the compressor for operation.

GENERAL MAINTENANCE

Refrigerant Properties —

HFC-134a is the standard refrigerant in the 17/19EX. At normal atmospheric pressure, HFC-134a will boil at −14 F (−25 C) and must, therefore, be kept in pressurized containers or storage tanks. The refrigerant is practically odorless when mixed with air. This refrigerant is non-combustible at atmospheric pressure. Read the Material Safety Data Sheet and the latestASHRAE Safety Guide for Mechanical Refrigeration to learn more about safe handling of this refrigerant.

HFC-134a will dissolve oil and some non-metallic materials, dry the skin, and, in heavy concentrations, may displace enough oxygen to cause asphyxiation. In handling this refrigerant, protect the hands and eyes and avoid breathing fumes.

Adding Refrigerant — Follow the procedures de-

scribed in Charge Refrigerant into Machine section, page 57.

Always use the compressor pumpdown function in the Control Test mode to turn on the evaporator pump and lock out the compressor when transferring refrigerant. Liquid refrigerant may ﬂash into a gas and cause possible freeze-up when the machine pressure is below 30 psig (207 kPa) for HFC-134a.

Removing Refrigerant — When the optional pump-

out system is used, the 17/19EX refrigerant charge may be transferred to a storage vessel, or within the utility vessel. Follow procedures in the Pumpout and Refrigerant Transfer Procedures section when removing refrigerant.

Refrigerant Leak Testing — Because HFC-134a is

above atmospheric pressure at room temperature, leak testing can be performed with refrigerant in the machine. Use an electronic detector, soap bubble solution, or ultra-sonic leak detector. Be sure that the room is well ventilated and free from concentration of refrigerant to keep false readings to a minimum. Before making any necessary repairs to a leak, transfer all refrigerant from the leaking vessel.

LeakRate— ASHRAE recommends that machines should

be immediately taken off line and repaired if the refrigerant leakage rate for the entire machine is more than 10% of the operating refrigerant charge per year.

Additionally,Carrier recommends that leaks totalling less than the above rate but more than a rate of 1 lb (0.5 kg) per year should be repaired during annual maintenance or whenever the refrigerant is pumped over for other service work.

Test After Service, Repair, or Major Leak — If

all refrigerant has been lost or if the machine has been opened for service, the machine or the affectedvessels must be pressured and leak tested. Refer to the Leak Test Machine section (page 48) to perform a leak test.

HFC-134a MUST NOT be mixed with air or oxygen and pressurized for leak testing. In general, this refrigerant should not be allowed to be present with high concentrations of air or oxygen above atmospheric pressures, as the mixture can undergo combustion.

REFRIGERANT TRACER — Use an environmentally acceptable refrigerant as a tracer for leak test procedures.

TO PRESSURIZE WITH DRY NITROGEN — Another method of leak testing is to pressurize with nitrogen only and use a soap bubble solution or an ultrasonic leak detector to determine if leaks are present. This should only be done if all refrigerant has been evacuated from the vessel.

1. Connect a copper tube from the pressure regulator on the cylinder to the refrigerant charging valve. Never apply full cylinder pressure to the pressurizing line. Follow the listed sequence.

2. Open the charging valve fully.

3. Slowly open the cylinder regulating valve.

4. Observe the pressure gage on the machine and close the regulating valve when the pressure reaches test level. Do not exceed 140 psig (965 kPa).

5. Close the charging valve on the machine. Remove the copper tube if no longer required.

Repair the Leak, Retest, and Apply Standing VacuumTest—

After pressurizing the machine, test for leaks with an electronic leak detector, soap bubble solution, or an ultrasonic leak detector. Bring the machine back to atmospheric pressure, repair any leaks found, and retest.

After retesting and ﬁnding no leaks, apply a standing vacuum test, and then dehydrate the machine. Refer to the Standing Vacuum Test and Machine Dehydration in the Before Initial Start-Up section, pages 49 and 51.

Checking Guide VaneLinkage — Refer to Fig. 35.

If slack develops in the drive chain, backlash can be eliminated as follows:

1. With machine shut down (guide vanes closed), remove

chain guard, loosen actuator holddown bolts and remove chain.

2. Loosen vane sprocket set screw and rotate sprocket wheel

until set screw clears existing spotting hole.

3. With set screw still loose, replace chain and move vane

actuator to the left until all chain slack is taken up.

4. Tighten actuator holddown bolts and retighten set screw

in new position.

5. Realign chain guard as required to clear chain.

67 1197

→

Contact Seal Maintenance (Open-Drive Machines) (Refer to Fig. 36) —

During machine operation, a few drops of oil per minute normally seeps through the space between the contact sleeve (Item 16) and the shaft locknut (Item 8). This oil slowly accumulates in an atmospheric oil chamber and is automatically returned to the system by a seal oil return pump.

Oil should never leak between the contact sleeve and the packing gland (Item 14). If oil is found in this area, the O-ring (Item 12) should be checked and replaced.

The oil passing through the shaft seal carries with it some absorbed refrigerant. As the oil reaches the atmosphere, the absorbed refrigerant ﬂashes to gas because of the reduction in pressure. For this reason, a detector will indicate the presence of a slight amount of refrigerant around the compressor shaft whenever the machine is running.

During machine shutdown, however, no refrigerant should be detected nor should there be any oil seepage. If oil ﬂow or the presence of refrigerant is noted while the machine is shut down, a seal defect is indicated. Arrange for a sealassembly inspection by a qualiﬁed serviceman to determine the cause of the leakage and make the necessary repairs.

SEAL DISASSEMBLY (Fig. 36) — Contact seal disassembly and repair should be performed only by well qualiﬁed compressor maintenance personnel. These disassembly instructions are included only as a convenient reference for the authorized serviceman.

For ease of disassembly, refer to Fig. 36 while following these instructions.

1. Remove refrigerant.

2. Remove shaft coupling and spacer (if any).

3. Remove screws holding windage baffle (Item 4) and remove baffle.

4. Remove shaft-end labyrinth (Item 7), gasket (Item 5) and necessary piping.

5. Remove snap ring (Item 11) from shaft-end baffle and assemble to contact sleeve (Item 16).

6. Remove seal housing cover (Item 2). The contact sleeve, spring (Item 15) and packing gland (Item 14) will come out with the cover.

7. Place assembly on bench with contact sleeve assembly face down on a soft cloth or clean cardboard. Protect

seal faces at all times.

8. Press down on seal housing cover to compress the contact sleeve spring.

9. Maintain pressure and remove snap ring.

10. Slowly release pressure on cover. Spring tension will force contact sleeve out of housing. For further inspection, remove packing gland and O-ring (Item 12).

11. Place contact sleeve in a protected area to avoid damage to lapped face.

12. Remove outer carbon ring (Item 17). Handle carefully.

13. Remove spray header (Item 3).

14. Use a spanner wrench to remove shaft nut (Item 8).

15. Remove shaft sleeve (Item 9) and contact ring key (Item 18).

16. Carefully remove contact ring (Item 19), avoiding a jammed or cocked position. If binding occurs, reinstall shaft sleeve and nut to free the ring.

17. Replace O-ring (Item 10) if damaged or deformed.

18. Remove inner carbon ring key (Item 27) and retaining ring (Item 21). Screws must be loosened evenly against guide-ring spring pressure.

19. Remove guide ring assembly consisting of inner carbon ring (Item 20), diaphragm (Item 24) and guide ring (Item 25). Protect seal faces of ring.

20. Remove guide-ring spring (Item 26).

Clean all parts to be reused with solvent, coat with oil and

place in a protected area until needed. NOTE: Items 22, 23, and 28 are not part of the seal disas-

sembly process. They are removed only if the journal bearing is removed.

SEAL REASSEMBLY (Fig. 36) — Be sure that all gasket surfaces are clean and that all holes, including oil holes, are properly aligned between gasket and mating ﬂange. Coat gasket with oil-graphite mixture to prevent sticking.

1. Assembly guide-ring spring (Item 26) and guide-ring assembly (Items 20, 24 and 25). Check that travel of inner carbon seal ring (Item 20) is .06 in. minimum in each direction.

2. Install retaining ring (Item 21) and inner carbon ring key (Item 27). Tighten screws evenly against spring

pressure.

3. Replace O-ring (Item 10) in shaft shoulder groove.

4. Install spray header gasket (Item 29) and spray header (Item 3).

5. Install contact ring (Item 19), contact ring key (Item 18), shaft sleeve (Item 9) and shaft nut (Item 8).

6. Carefully install outer carbon ring (Item 17).

Fig. 35 — Electronic Vane Actuator Linkage

LEGEND

1—Housing Cover Gasket 2—Seal Housing Cover 3—Spray Header 4—Windage Baffle 5—Shaft-End Labyrinth Gasket 6—Key 7—Shaft-End Labyrinth 8—Shaft Locknut 9—Shaft Sleeve

10 — O-Ring

11 — Snap Ring (Assembly Tool Only. See Text.) 12 — O-Ring 13 — Packing Gland Gasket 14 — Packing Gland 15 — Outer Spring 16 — Contact Sleeve 17 — Outer Carbon Ring Seal 18 — Contact Ring Key 19 — Contact Ring 20 — Inner Carbon Seal Ring

21 — Retaining Ring 22 — O-Ring 23 — Shim 24 — Diaphragm 25 — Guide Ring 26 — Inner Spring 27 — Inner Carbon Ring Key 28 — Shut Down Seal Retainer 29 — Spray Header Gasket

Fig. 36 — Compressor Contact Seal (Open-Drive Machines)

7. Insert O-ring (Item 12) into packing gland (Item 14).

8. Place contact sleeve (Item 16) face down on clean cloth or cardboard.

9. Place outer spring (Item 15) over sleeve.

10. Separately assemble seal housing cover (Item 2), packing gland gasket (Item 13), packing gland (Item 14), and O-ring (Item 12).

11. Oil the contact sleeve and the O-ring and place the housing and gland assembly over the sleeve.

12. Carefully depress the spring until snap ring (Item 11) can be attached to the sleeve.

13. Position key (Item 6) to complete the bench assembly.

14. Install seal housing cover gasket (Item 1) and cover assembly on the compressor.

15. Remove the snap ring.

16. Install shaft-end labyrinth gasket (Item 5) and labyrinth (Item 7).

17. Install windage baffle (Item 4).Attach snap ring to baffle for safekeeping.

Machine Alignment (Open-Drive Machines)

ALIGNMENT METHODS — There are several established procedures for aligning shafts. The dial indicator method is presented here since it is considered to be one of the most accurate and reliable. Another faster and easier method for alignment involves the use of laser alignment tools and computers. Follow the laser tool manufacturer’s guidelines when using the laser technique.

Where job conditions such as close-spaced shafts prohibit the use of dial indicators for coupling face readings, other instruments such as a taper gage may be used. The same procedures described for the dial indicator may be used with the taper gage.

Shafts placed in perfect alignment in the nonoperating (cold) condition will always move out of alignment to some extent as the machine warms to operating temperature. In most cases, this shaft misalignment is acceptable for the initial run-in period before hot check and alignment can be made (see Hot Alignment Check section, page 60.)

NOTE: The physical conﬁguration of the 17FAcompressor makes the oil sump temperature a more signiﬁcant factor in alignment than the suction and dischargetemperatures. Therefore, warm the sump oil to operating temperature (approximately 140 F [60 C]), if possible, before beginning alignment procedures.

General

1. Final shaft alignment must be within .002-in. TIR (Total Indicated Runout) in parallel. Angular alignment must be within .00033 inches per inch of traverse across the coupling face (or inch of indicator swing diameter) at oper- ating temperatures. For example, if a bracket-mounted indicator moves through a 10-in. diameter circle when measuring angular misalignment, the allowable dial movement will be 10 times .00033 for a total of .0033 inches.

2. Follow the alignment sequence speciﬁed in the Near Final Alignment section.

3. All alignment work is performed on gear and drive equipment. Once the compressor is bolted in a perfectly level position and is piped to cooler and condenser, it must not be moved prior to hot check.

4. All alignment checks must be made with equipment holddown bolts tightened.

5. In setting dial indicators on zero and when taking readings, both shafts should be tight against their respective thrust bearings.

6. Space between coupling hub faces must be held to coupling manufacturer’s recommendations.

7. Accept only repeatable readings.

Gear and Drive Coupling Alignment

1. Move gear with coupling attached into alignment with compressor coupling. Adjust jackscrews to reach close alignment. Follow procedures outlined in Correcting Angular Misalignment and Correcting Parallel Misalignment sections.

2. Generally, a 5-in. long spacer hub is supplied between gear and compressor. Maintain exact hub-to-hub distance speciﬁed on job drawings.

3. Where shaft ends are very close, a taper gage may be used in place of the dial indicator.

4. Get drive alignment as close as possible by jackscrew adjustment.

NOTE: Drive shaft end-ﬂoat at ﬁnal drive position must not allow coupling hub faces to contact, or the coupling shroud to bind.

PRELIMINARYALIGNMENT — To get within dial indicator range, roughly align the equipment as shown in Fig. 37 and as described below.

Place a straight edge across the OD of one coupling to the OD of the other. Measure the gap between the straight edge and the OD of the second coupling with a feeler gage. Then, by adding or removing shims at each corner, raise or lower the equipment by the measured amount.

In a similar manner, measure the shaft offset from side to side and jack the equipment over as required to correct.

NEAR FINAL ALIGNMENT — Once the machine components are within dial indicator range, the adjustments for misalignment should be made in a speciﬁc sequence. The four positions of alignment described below are arranged in the recommended order.

1. Angular in elevation — This alignment is adjusted with shims and is not readily lost in making the other adjustments.

2. Parallel in elevation — This alignment is also made with shims, but it cannot be made while there is angular misalignment in elevation.

3. Angular in plan — This position can easily be lost if placed ahead of the two adjustments in elevation.

4. Parallel in plan — This adjustment cannot be made while there is still angular misalignment in plan, and can easily be lost if elevation adjustments are made.

Correcting Angular Misalignment Preparation — Shaft angular misalignment is measured on

the face of the coupling hubs or on brackets attached to each shaft (see Fig. 38 and 39). Brackets are preferred since they extend the diameter of the face readings.

Attach a dial indicator to one coupling hub or shaft and place the indicator button against the face of the opposite hub. Position the indicator so that the plunger is at approximately mid-position when the dial is set to zero. Both shafts should be held tightly against their thrust bearings when the dial is set and when readings are taken.

To be sure that the indicator linkage is tight and the button is on securely, rotate the coupling exactly 360 degrees. The dial reading should return to zero. Accept only repeatable readings.

Fig. 37 — Checking Preliminary Alignment

Fig. 38 — Measuring Angular Misalignment

in Elevation

Measurement— Occasionally, coupling faces may not be perfectly true, or may have been damaged in handling. To compensate for any such runout, determine the actual or ‘‘net’’ shaft misalignment as follows:

Check the opening at the top and at the bottom of the coupling faces (or at each side when making plan adjustment). Rotate both shafts exactly 180 degrees and recheck the openings. Record the difference. (Example below is in inches.)

If the larger opening remains the same but changes from side to side, the shafts are in perfect alignment. The change in opening is due entirely to coupling runout, as above, or to a burr or other damage to the coupling face.

If the larger opening remains the same, and remains on the same side, the amount is entirely shaft (net) misalignment.

If the larger opening remains on the same side but changes amount, misalignment and runout are present. Add the two amounts and then divide by two to get the actual or net misalignment.

If the larger opening changes amount and also changes from side to side, subtract the smaller amount from the larger and divide by two to obtain the net misalignment.

Adjustment — Having obtained the net misalignment, the amount by which the equipment must be moved can now be calculated.

To determine:

S — amount of movement (in plan) or the thickness of

shim (in elevation) required.

Obtain:

D — coupling face diameter in inches (or indicator but-

ton circle)

L — distance between front and rear holddown bolts

(inches)

M — net misalignment in inches And:

Divide L, the bolt distance, by D, the coupling diameter.

Multiply the result by M, the net misalignment.

S= × M

Fig. 39 — Measuring Angular Misalignment

in Elevation

Example: Face diameter 5 in. (D). Distance between front

and rear holddown bolts 30 in. (L). Net misalignment in elevation .012 in. (M).

30 divided by 5 is 6 6 multiplied by .012 is .072 in. S = .072 in.

If the larger opening between coupling faces is at the top, place .072 in. of shim under each rear foot or remove .072 in. from the front footings to bring the couplings into angular alignment in elevation.

Tighten the holddown bolts and recheck the net misalignment.

The height of the shaft above the footings and the distance the shaft extends beyond the equipment will not affect the calculations.

Determine the angular adjustment in plan by the same method of calculation. At this point, however, the procedure should include a correction for the change in coupling gap which always occurs in adjusting angular alignment (Fig. 40). By selecting the proper pivot point (Fig. 41), the coupling gap can be kept at the dimension speciﬁed in the job data.

1. Pivot on the front bolt at the closed side of the couplings

to shorten the gap; pivot on the front bolt at the open side to lengthen it. It may sometimes be advantageous to pivot half the required amount on one front footing and half on the other.

2. Place a dial indicator against the rear foot as indicated in

Fig. 41.

3. Place a screw jack on the other rear foot to move the equip-

ment towards the indicator.

4. Loosen all holddown bolts except the pivot bolt. Turn the

screw jack until the rear end of the equipment moves against the indicator by the desired amount.

5. Tighten the holddown bolts and recheck the indicator. If the reading has changed, loosen the three bolts and readjust. It may be necessary to over or undershoot the desired reading to allow for the effect of bolt tightening.

Correcting Parallel Misalignment Preparation — Attach the dial indicator to one shaft or cou-

pling hub and place the indicator button on the O.D. of the other hub. The reach of the dial from one hub to the other should be parallel to the shafts, and the dial button shaft should point directly through the center of the shaft on which it rests. Compress the plunger to about mid-position and set the dial at zero.

Check the tightness of the dial button and the indicator linkage by rotating the shaft to which the indicator is attached 360 degrees. The dial should return to zero. Check for repeatability.

Check for runout by rotating the hub on which the dial button rests 180 degrees. If the runout exceeds .001 total indicator reading, the hub should be removed and the shaft checked. Shaft runout must not exceed .001 TIR.

The effect of hub runout can be eliminated by locating a position on the half coupling where two readings 180 degrees apart read zero. Rotate the coupling so that one zero point is at the top and the other at the bottom when checking for misalignment in elevation. Place the zero points side to side in a similar manner when checking for misalignment in plan.

Fig. 41 — Adjusting Angular Misalignment in Plan

S—Thickness of Shim Required L—Distance Between Front and

Rear Holddown Bolt in Inches

D—Diameter of Coupling in Inches M—Net Misalignment in Inches

Fig. 40 — Alignment Formula

Measurement — With dial set at zero in the top position, rotate the shaft to which the indicator is attached 180 degrees. If the dial reading is plus, the shaft on which the button rests is low. If the reading is minus, the shaft on which the button rests is high.

Never accept a single reading. Look for repeatability. Rotate the shaft several times to see if the reading remains the same. It is good practice to reverse the procedure and read from zero at the bottom.

Always rotate the shafts in the same direction when taking readings. Backlash in the coupling teeth could cause some differences.

Adjustment — Divide the total indicator reading by two to obtain the exact amount of shaft offset. As illustrated in Fig. 42, the indicator will read the total of A plus B but the required shaft adjustment is only half of this as indicated by C.

Add or remove identical amounts of shims at all footings to bring the shaft to the proper elevation. Tighten all the holddown bolts and recheck the readings. Parallel alignment must be within .002 TIR.

To correct parallel misalignment in plan, use a screw jack and dial indicator as shown in Fig. 42. With a front holddown bolt as the pivot, move the rear of the equipment over. Then, with the rear holddown bolt on the same side acting as the pivot, move the front end of the equipment over by the same amount.

FINAL ALIGNMENT — The procedures and tolerance requirements for ﬁnal alignment are the same as those described in the Near Final Alignment section. Final alignment is performed just prior to grouting and machine hot check. All piping, including water and steam, must be completed, but the water and refrigerant charges need not be in place.

HOT ALIGNMENT CHECK General — When all machine components have reached op-

erating temperature (after running near full load for from 4 to 8 hours), a hot alignment check must be made. Hot alignment check may be made with couplings assembled or disassembled.

Disassembled Couplings

1. Shut down machine.

2. With machine hot, quickly disassemble couplings.

3. Check angular and parallel alignment in plan and eleva-

tion as described in the Near Final Adjustment section. Record the indicator readings (see page CL-12) and make necessary adjustments to bring alignment within .002 TIR and .00033 inches per in. of coupling face traverse (or in. of indicator swing). Follow procedures described in the Near Final Alignment section.

4. Reinstall couplings and run machine until it again reaches

operating temperature.

5. Repeat steps 1 through 4 until alignment remains within speciﬁed tolerances.

Fig. 42 — Correcting Parallel Misalignment

Assembled Couplings — If there is room on the shaft between coupling and component to clamp a sturdy bracket, the arrangement illustrated in Fig. 43 may be used. The clamps must have room to rotate with the shaft.

This method is quicker because the couplings do not have to be disassembled. In addition, eccentricity or coupling face runout are not problems since both shafts rotate together.

When using brackets, the diameter in the alignment formula (see Near Final Alignment, Connecting Angular Misalignment section) will be that of the circle through which the dial indicator rotates.

1. Shut down the machine.

2. With machine at operating temperature, quickly install

brackets.

3. Check that alignment is within .002 TIR and .00033 per

in. of traverse across the diameter of measurement. Adjust alignment as required. (Refer to Near Final Alignment section.)

4. Remove brackets and run machine until operating tem-

perature is again reached.

5. Recheck the alignment per steps 1 through 4 until it re-

mains within the speciﬁed tolerances.

Be surethat coupling guardsare replacedafter these checks.

DOWELING Techniques — After hot alignment check has been com-

pleted, the compressor, gear and drive must be doweled to their soleplates. Doweling permits exact repositioning of components if they have to be moved.

1. Doweling must be completed with equipment at maximum operating temperature (full load).

2. Use no. 8 taper dowels to dowel compressor, gear and drive to the base. Use a

⁄32-in. drill and no. 8 taper reamer with straight ﬂutes. Drill pilot hole and then expand the pilot hole to ﬁnal dimension.

3. Fit dowel so that

⁄16-in. of taper is left above the equipment foot. If dowel holes are rereamed as a result of realignment, be sure dowels are tight and do not bottom.

4. Place dowels as nearly vertical as possible.

5. Coat the dowels with white lead or other lubricant to prevent rusting.

6. Tap dowel lightly into position with a small machinist’s hammer. A ringing sound will indicate proper seating.

Dowel the suction end of the compressor base, the two feet at the high speed end of the gear, and the drive feet in accordance with the drive manufacturer’s instructions. The number of dowels used in the drive is usually four, but some manufacturers require more.

WEEKLY MAINTENANCE

Check the Lubrication System —

Mark the oil level on the reservoir sight glass, and observe the level each week while the machine is shut down.

If the level goes below the lower sight glass, the oil reclaim system will need to be checked for proper operation. If additional oil is required, add oil as follows:

On hermetic machines, add oil through the oil drain charging valve (Fig. 3, Item 26.)A pump is required for adding oil against refrigerant pressure. On open-drive machines, oil may be added through the oil drain and charging valve (Fig. 2, Item 18) using a pump. However, an oil charging elbow on the seal-oil return chamber (Fig. 6) allows oil to be added without pumping.The seal oil return pump automatically transfers the oil to the main oil reservoir. A pump is required for adding oil against refrigerant pressure. The oil charge is approximately 15 gallons (57 L) for EX and FA(size 421-469) style compressors; 20 gallons (76 L) for EA (size 531-599) style compressors. The added oil must meet Carrier’s speciﬁcations. Refer to Changing Oil Filter and Oil Changes sections. Any additional oil that is added should be logged by noting the amount and date. Any oil that is added due to oil loss that is not related to service will eventually return to the sump, and must be removed when the level is high.

Fig. 43 — Alignment Check — Assembled Coupling

An oil heater is controlled by the PIC to maintain oil temperature above 150 F (65.5 C) or refrigerant temperature plus 70° F (38.9° C) (see the Controls section) when the compressor is off.The LID Status02 screen displays whether the heater is energized or not. If the PIC shows that the heater is energized, but the sump is not heating up, the power to the oil heater may be off or the oil level may be too low. Check the oil level, the oil heater contactor voltage, and oil heater resistance.

The PIC will not permit compressor start-up if the oil temperature is too low. The control will continue with start-up only after the temperature is within limits.

After the initial start or a 3 hour power failure, the controls will allow the machine to start once the oil is up to proper temperature, but a slow ramp load rate of 2° F (1.6° C) per minute is used.

Be sure that the hand isolation valves on the oil line near the ﬁlter(s) (Fig. 44, Items 1 and 2) are fully open before operating the compressor.

Lubrication requirements for the FA coupling and drive are contained in the manufacturer’s instructions for these components.

SCHEDULED MAINTENANCE

Establish a regular maintenance schedule based on the actual machine requirements such as machine load, run hours, and water quality.The time intervals listed in this section are offered as guides to service only.

Service Ontime — The LID will display a SERVICE

ONTIME value on the Status01 screen. This value should

be reset to zero by the service person or the operator each time major service work is completed so that time between service can be viewed.

Inspect the Control Center — Maintenance is lim-

ited to general cleaning and tightening of connections. V acuum the cabinet to eliminate dust build-up. In the event of machine control malfunctions, refer to the Troubleshooting Guide section for control checks and adjustments.

Be sure power to the control center is off when cleaning and tightening connections inside the control center.

Check Safety and Operating Controls Monthly —

To ensure machine protection, the Control Test Automated Test should be done at least once per month. See Table 3 for safety control settings.

Changing Oil Filter

19EX COMPRESSORS — Change the oil ﬁlter on an annual basis or when the machine is opened for repairs. The 19EX compressor has an isolatable oil ﬁlter so that the ﬁlter may be changed with the refrigerant remaining in the machine. See Fig. 44. Use the following procedure:

1. Make sure that the compressor is off, and the disconnect

for the compressor is open.

2. Disconnect the power to the oil pump.

3. Close the oil ﬁlter isolation valves (Fig. 44, Items 1

and 2).

4. Loosen the ﬁlter holding clamp, (Fig. 44, Item 3).

5. Rotate the ﬁlter nut, (Fig. 44, Item 4), counterclockwise

to remove the ﬁlter housing. Keep the ﬁlter housing upright to avoid an oil spill.

6. Drain the oil; use this oil to obtain an oil analysis; re-

move and replace the ﬁlter cartridges. Do not use any of the extra felt washers supplied with the ﬁlters.

7. Bench assemble Items A-D upside down, then slide the

ﬁlter housing (Item 5) over the stack to ensure that the spring (Item D) is centered in the bottom of the housing as indicated. Screw the assembly into the locking ring.

8. Evacuate the ﬁlter/piping assembly.

9. Open the isolation valves. FA STYLE COMPRESSORS

1. Turn off oil heater.

2. Close the line valve (Fig. 44, Item 1) to isolate the oil ﬁlter(s).

NOTE: FA STYLE COMPRESSORS DO NOT HAVE ISOLATION VALVENO. 2, ONLYACHECK VALVE. Vent the pressure in the oil ﬁlter by opening the Schrader valve on the oil ﬁlter housing. Run a hose from the valve to a bucket to catch the oil. Check to ensure that the check valve is properly seating.

3. Loosen the ﬁlter holding clamp (Item 3).

Fig. 44 — Removing the Oil Filter

4. Rotate ﬁlter nut (Item 4) counterclockwise to remove ﬁlter housing. Keep the ﬁlter housing upright to avoid oil spill.

5. Drain the oil; remove and replace ﬁlter cartridges. Do not use any of the extra felt washers supplied with the ﬁlters.

6. Bench assemble Items A-D upside down. Then slide ﬁlter housing (Item 5) over the stack to ensure that spring (Item D) is centered in the bottom of the ﬁlter housing as indicated.

7. Evacuate air from the ﬁlter assembly. Open the isolation valve.

8. Turn on oil heater and warm the oil to 140 to 150 F (60 to 66 C). Operate the oil pump for 2 minutes. Add oil if required to keep level up to lower sight glass.

Oil should be visible in the reservoir sight glass during all operating and shutdown conditions.

Oil Speciﬁcation — If oil is to be added, it must meet

the following Carrier speciﬁcations:

• Oil Type for units using HFC-134a .........Inhibited

polyol ester-based synthetic compressor

oil formatted for use with HCFC

and HFC, gear-driven, hermetic

compressors.

• ISO Viscosity Grade ..........................68

The polyolester-based oil may be ordered from your local

Carrier representative (Carrier Part No. PP23BZ103).

Oil Changes — Carrier recommends changing the oil

after the ﬁrst year of operation and every three to ﬁve years thereafter as a minimum along with a yearly oil analysis. However, if a continuous oil monitoring system is functioning and a yearly oil analysis is performed, time between oil changes can be extended.

TO CHANGE THE OIL

1. Open the control and oil heater circuit breaker.

2. Drain the oil reservoir by opening the oil charging valve,

(Fig. 2, Item 18 or Fig. 3, Item 26). Slowly open the valve against refrigerant pressure.

3. Change the oil ﬁlter at this time. See Changing Oil Filter

section.

4. Change the refrigerant ﬁlter at this time, see the next sec-

tion, Refrigerant Filter.

5. Charge the machine with oil. The EX uses approximately

15 gallons (57 L), for EX and FA (size 421-469) style compressors; 20 gallons (76 L) for FA(size 531-599) style compressors in order to bring the level to the middle of the upper sight glass (Fig. 2, Item 17 and Fig. 3, Item 17). Turn on the power to the oil heater and let the PIC warm it up to at least 140 F (60 C). Operate the oil pump manually,through the Control Test, for 2 minutes. The oil level should be between the lower sight glass and one-half full in the upper sight glass for shutdown conditions.

Refrigerant Filter — On hermetic machines with EX

compressor, a replaceable core refrigerant ﬁlter drier is located on the refrigerant cooling line to the motor (Fig. 3, Item 29). On FA style machines, the refrigerant ﬁlter is located behind the compressor.The ﬁlter core should be changed once a year, or more often if ﬁlter condition indicates a need for more frequent replacement. Change the ﬁlter with the

machine pressure at 0 psig (0 kPa) by transferring the refrigerant to the utility vessel.A moisture indicating sight glass is located beyond this ﬁlter to indicate the volume and moisture in the refrigerant. If the dry-eye indicates moisture, locate the source of water immediately by performing a thorough leak check.

Oil Reclaim Filter — The oil reclaim system has a ﬁl-

ter on the cooler scavenging line. Replace this ﬁlter once per year, or more often if ﬁlter condition indicates a need for more frequent replacement. Change this ﬁlter with the cooler/ condenser/compressor vessel at 0 psig (0 kPa) by transferring the refrigerant charge to the utility vessel.

Inspect Refrigerant Float System — Perform in-

spection once every 5 years or when the utility vessel is opened for service. Transfer the refrigerant into the cooler vessel, or into a storage tank. There are two ﬂoats on the 17/19EX, one on each side of the utility vessel. Remove the ﬂoat access covers. Clean the chambers and valve assembly thoroughly. Be sure that the valves move freely. Make sure that all openings are free of obstructions. Examine the cover gaskets and replace if necessary. See Fig. 45 for a view of both ﬂoats.

InspectReliefValvesand Piping — The relief valves

on this machine protect the system against the potentially dangerous effectsof overpressure. To ensure against damage to the equipment and possible injury to personnel, these devices must be kept in peak operating condition.

As a minimum, the following maintenance is required.

1. At least once a year, disconnect the vent piping at the valve outlet and carefully inspect the valve body and mechanism for any evidence of internal corrosion or rust, dirt, scale, leakage, etc.

2. If corrosion or foreign material is found, do not attempt to repair or recondition. Replace the valve.

3. If the machine is installed in a corrosive atmosphere or the relief valves are vented into a corrosive atmosphere, make valve inspections at more frequent intervals.

Coupling Maintenance (Open-Drive Machines) —

Proper maintenance of the coupling is important since the coupling supports the outboard end of the compressor low speed shaft. Only the compressor end of the coupling has gear teeth and these are manufactured with special tolerances for this application.

PROCEDURE — Clean and inspect the gear teeth in the compressor end coupling for wear yearly. If the teeth are worn, replace the tapered coupling hub, sleeve and O-ring. Repack the gear teeth and spacer with 8 oz. of Kop-Flex KHP high performance coupling grease (Carrier Part No. 17DK 680 001). Install new gaskets.

When the coupling assembly is removed for scheduled service of the carbon seal, replace the O-ring, spacer gaskets, and hex bolts.

Operating conditions such as high temperatures or severe environments may require more frequent inspection and relubrication.

Misalignment causes undue noise and wear. Check alignment yearly, or more often if vibration or heating occur. Refer to Machine Alignment section, page 70.

Never operate drive without coupling guards in place. Contact with moving shaft or coupling can cause serious injury.

Motor Maintenance (Open-Drive Machines) —

Acarefully planned and executed program of inspection and maintenance will do much to ensure maximum motor availability and minimum maintenance cost. If it becomes necessary to repair, recondition, or rebuild the motor, it is recommended that the nearest Westinghouse apparatus repair facility be consulted.

In addition to a daily observation of the appearance and operation of the motor, it is recommended that a general inspection procedure be established to periodically check the following items:

1. Cleanliness, both external and internal

2. Stator and rotor (squirrel-cage) windings

3. Bearings CLEANLINESS — On open ventilated motors, screens and

louvers over the inlet air openings should not be allowed to accumulate any build-up of dirt, lint, etc. that could restrict free air movement. Screens and louvers should never be cleaned or disturbed while the motor is in operation because any dislodged dirt or debris can be drawn directly into the motor.

If the motor is equipped with air ﬁlters, they should be replaced (disposable type) or cleaned and reconditioned (permanent type) at a frequency that is dictated by conditions. It is better to replace or recondition ﬁlters too often than not often enough.

Totally enclosed, air-to-air cooled (TEAAC) motors and totally enclosed, fan-cooled (TEFC) motors require special cleaning considerations. The external fan must be cleaned thoroughly since any dirt build-up not removed can lead to imbalance and vibration.All of the tubes of the air-to-air heat exchanger of TEAAC motors should be cleaned using a supplied tube brush having synthetic ﬁber bristles (not wire of any type). The standard cooler is equipped with steel tubes, however, in special cases aluminum tubes may be used and wire brushes can seriously erode the tube interiors over several cleanings. All tube brushing should be conducted from the front (fan end) toward the drive end of the motor such that dislodged dirt will not fall into the fan housing.

Water spray washing of motors is not recommended. Manual or compressed air cleaning is preferred. If it becomes necessary to spray wash a motor, it should be done with extreme care. Do not aim high pressure sprays directly at air inlet openings, conduit connections, shaft seals, or gasketed surfaces to prevent the possibility of forcing water inside the machine.

The stator windings of motors with open ventilation systems can become contaminated with dirt and other substances brought into the motor by the ventilating air. Such contaminants can impair cooling of the winding by clogging the air passages in the winding end-turns and vent ducts through the stator core and by reducing heat transfer from the winding insulation surfaces to the cooling air. Conducting contaminants can change or increase electrical stresses on the insulation and corrosive contaminants can chemically attack and degrade the insulation. This may lead to shortened insulation life and failure.

Several satisfactory methods of cleaning stator windings and stator cores are offered below:

Compressed Air — Low pressure (30 psi max.), clean (no oil) and dry air can be used to dislodge loose dust and particles in inaccessible areas such as air vent ducts in the stator core and vent passages in the winding end-turns. Excessive air pressure can damage insulation and can drive contaminants into inaccessible cracks and crevices.

Vacuum — Vacuum cleaning can be used, both before and after other methods of cleaning, to remove loose dirt and debris. It is a very effective way to remove loose surface contamination from the winding without scattering it. Vacuum cleaning tools should be nonmetallic to avoid any damage to the winding insulation.

Fig. 45 — Typical Float Valve Arrangement

Wiping — Surface contamination on the winding can be removed by wiping, using a soft, lint-free wiping material. If the contamination is oily, the wiping material can be moistened (not dripping wet) with a safety-type petroleum solvent, such as Stoddard solvent. In hazardous locations, a solvent such as inhibited methyl chloroform may be used, but must be used sparingly and immediately removed. While this solvent is non-ﬂammable under ordinary conditions, it is toxic and proper health and safety precautions should be followed while using it.

Solvents of any type should never be used on windings provided with abrasion protection. Abrasion protection is a grey, rubber-like coating applied to the winding end-turns.

Adequate ventilation must always be provided in any area where solvents are being used to avoid the danger of ﬁre, explosion or health hazards. In conﬁned areas (such as pits) each operator should be provided with an air line respirator, a hose mask or a self-contained breathing apparatus. Operators should wear goggles, aprons and suitable gloves. Solvents and their vapors should never be exposed to open ﬂames or sparks and should always be stored in approved safety containers.

SLEEVE BEARINGS Oil Changing — The oil reservoirs of the self lubricated bear-

ings should be drained and reﬁlled every 6 months. More frequent changes may be needed if severe oil discoloration or contamination occurs. In conditions where contamination does occur, it may be advisable to ﬂush the reservoir with kerosene to remove any sediment before new oil is added. Proper care must be taken to thoroughly drain the reservoir of the ﬂushing material before reﬁlling with the new oil.

Reﬁll the reservoir to the center of the oil sight glass with a rust and oxidation inhibited, turbine grade oil. The viscosity of the oil must be 32 ISO (150 SSU) at 100 F (37.7 C). Oil capacity in each of the 2 bearings is 0.6 gal. (2 l) per bearing. Use of Carrier Oil Speciﬁcation PP16-0 is approved (Mobil DTE Light or Sun Oil SUNVIS 916).

Disassembly — The bearing sleeve is of the spherically seated, self-aligning type. The opposite drive end bearing is normally insulated for larger motors (or when speciﬁed). On some motors, the insulation is bonded to the spherical seat of the bearing housing. Use extreme care when removing the sleeve from the insulated support to avoid damaging this insulation.

Note that some bolts and tapped holes associated with the bearing housings, bearing sleeves, and seals are metric.

The following is the recommended procedure for removing the bearing sleeve:

1. Remove the oil drain plug in the housing bottom and drain the oil sump.

2. Remove all instrumentation sensors that are in contact with the bearing sleeve. These would include resistance temperature detectors, thermocouples, temperature relay bulbs, thermometers, etc.

3. Remove the end cover.

4. Remove the socket head bolts holding the bearing cap and the inner air seal together at the horizontal split. The front end cover plate must also be removed if the front bearing is being disassembled. Remove the bearing cap and top half of the inner air seal by lifting straight up to avoid damaging the labyrinth seals. Place them on a clean, dry surface to avoid damage to the parting surfaces.

5. Remove any split bolts that may be holding the two bearing halves together. Remove the top half of the bearing sleeve using suitable eye-bolts in the tapped holes provided. Lift the bearing top straight up and avoid any contact with the shoulders of the shaft journals that might damage the thrust faces of the bearing. Place on a clean, dry surface taking care to prevent damage to either the parting surfaces or the locating pins that are captive in the top bearing half.

6. Remove the 4 screws at the partings in the oil ring and dismantle the ring by gently tapping the dowel pin ends with a soft face mallet. Remove the ring halves and immediately reassemble them to avoid any mix up in parts or damage to the surfaces at the partings.

7. When removing the labyrinth seals, make note of the position of the anti-rotation button located on the inside of the top half of the seal. Pull up the garter spring surrounding the ﬂoating labyrinth seal and carefully slip out the top half. Rotate the garter spring until the lock is visible. Twist counterclockwise to disengage the lock, remove the garter spring, then rotate the lower half of the seal out of the groove in the bearing housing while noting the orientation of the oil drain holes. Note the condition of these ﬂoating labyrinth seals. If they are cracked or chipped, they must be replaced. Do not attempt to reuse a damaged seal.

8. To remove the bottom bearing half, the shaft must be raised a slight amount to relieve pressure on the bearing. On the rear end, this can be done by jacking or lifting on the shaft extension. (Care must be taken to protect the shaft from damage). On the front end, jacking or lifting can be done using bolts threaded into the tapped holes provided in the shaft end.

NOTE: Lift only enough to free the bearing; overlifting the shaft can cause difficulty in removal of the bearing.

9. Roll the bottom bearing half to the top of the shaft journal and then lift it using suitable eyebolts threaded into the holes provided. Again avoid any contact with the shaft shoulders that could damage the bearing thrust faces. Place the lower bearing half on a clean, dry surface to protect the parting surfaces.

Use extreme care when rolling out the lower bearing half. Keep the hands and ﬁngers well clear of any position where they might be caught by the bearing half if it were accidentally released and rotated back to its bottom position. Serious personal injury could result.

10. Protect the shaft journal by wrapping it with clean, heavy paper or cardboard.

Reassembly — Bearing reassembly is basically a reversal of the disassembly procedures outlined above, with the following additional steps.

Curil-T is the only approved compound for use in the assembly of the bearings on this motor. Other products may harden and impede the operation.

During the reassembly of the bearing parts, a thin layer of Curil-T should be applied to all gasketed and machined interface surfaces. This suggestion does not apply to the machined surfaces of the bearing liner halves.

When seating the bearing shell, apply a thin layer of lube oil at the spherical surface of the liner. Slowly roll the lower bearing liner into the bearing housing making sure that the split surfaces of the liner and the housing are ﬂush. Gradually lower the shaft onto the bearing. The weight of the shaft will help rotate the bearing liner so that the babbitt surface of the liner will match the slope of the journal. Sometimes it is required to use a rubber mallet to tap lightly on the bearing housing while slowly rolling the shaft to help this seating operation.

1. The interior of the bearing housing should be cleaned and then ﬂushed with clean oil or kerosene.

2. The bearing halves and the shaft journal should be wiped clean using lint-free cloth soaked with clean oil.

3. All parts should be carefully inspected for nicks, scratches, etc., in any contact surfaces. Such imperfections should be removed by an appropriate method such as stoning, scraping, ﬁling, etc., followed by thorough cleaning.

4. Apply a few drops of oil to the journal and bearing saddles.

5. Roll the bottom half of the bearing into place and lower the shaft.

6. Before installing the ﬂoating labyrinth seal halves, observe their condition. Do not attempt to use a cracked or chipped seal. The bottom half seal has a set of drilled holes in its side face. These must be placed at the bottom toward the inside of the bearing so that accumulating oil may drain back into the housing.

7. Put a small bead of Curil-T around the bottom seal half outside diameters on both sides adjacent to the garter spring groove. This will prevent oil by-passing the seal around its outside.

8. Place the bottom seal half on top of the shaft (ensuring that the proper orientation of the drain holes is provided and roll it into position. Install the top half of the seal making sure that the anti-rotation button is located in the proper position on the inboard side of the bearing. Insert the garter spring pulling up on both ends to permit engaging the lock. Run a small bead of Curil-T around the outside diameters on both sides adjacent to the garter spring groove on this half also.

9. Carefully reassemble the two oil ring halves. Inspect the dowel pins for burrs and straightness and make any corrections required. Do not force the ring halves together. Excessive force may alter the roundness or ﬂatness of the ring which can change its oil delivery performance. Apply locking compound to the oil ring screws prior to reassembly.

10. Assemble the top half of the bearing liner making sure that the match marks on the liner halves align with one another.Failure to ensure alignment of match marks can cause misalignment and possible damage to bearings and journal surfaces. Reinstall any split bolts, if supplied, between the bearing halves.

11. Some of the pipe plugs in the housing are metric thread type. These are identiﬁed as those which have a copper, lead, or similar material washer. If these plugs are removed, be careful not to lose the washers. Before reassembly, inspect the washers and replace them as required.

12. Before installing the bearing cap, observe the position of the ﬂoating labyrinth seal. The ‘‘tab’’ must be on top to engage the pocket. Failure to position the seal properly will result in damage when the cap is assembled.

13. Carefully lower the bearing housing cap over the ﬂoating seals. Keep the bearing cap level to avoid binding and possibly damaging the seals. The bearing cap should seat evenly on the bearing housing base.

Do not force bearing cap down. Damage could occur to the labyrinth seals.

If the bearing cap does not seat completely, remove and reset the ﬂoating labyrinth seal position. When installing upper bearing cap the ﬂoating labyrinth seals sometimes rotate and the anti-rotation ‘‘tab’’ does not seat in its holder,thus preventing the bearing housing from seating properly. This procedure should be repeated until the bearing cap seats properly.

14. Reinstall the bearing housing split bolts. Before torquing bearing housing cap bolts, rotate shaft by hand while bumping bearing housing with a rubber or rawhide mallet in the horizontal and axial planes to allow the bearings to align themselves to the shaft journals.

15. Torque the bearing housing cap bolts by following the torque values as provided in Table 6 on page 53.

Open-Drive Motor Handling/Rigging — Each mo-

tor is provided with lifting lugs, welded to the four corners of the motor frame, for lifting the assembled machine. The motor should always be lifted by using the lifting lugs located on all four corners of the motor frame. (See Fig. 46.)

Spreader bars of adequate capacity and number must be used to avoid applying any pressure against the top air housing with the lifting plugs.

If the motor is lifted with the top air housing removed, the angle of the lifting slings with the horizontal should never be less than 45 degrees.

Withthe exclusion of the TEWAC cooler, the top air housing is provided with

⁄4-10 tapped holes for lifting devices to be installed in order to remove the air housing from the motor. The top air housing can be detached by removing the enclosure holddown bolts, located in the inside corners of the enclosure. These enclosure holddown bolts are accessed through the louver/screens located on the front and rear end of the machine or through access panels bolted to the sides of the enclosure.

Uneven lifting must always be avoided. When single point lifting is to be used, slings of equal lengths must always be used to avoid uneven lifting.

Under no circumstances should the motor be lifted using the shaft as an attachment point.

NOTE: Refer to weights speciﬁed on certiﬁed drawing to determine proper lifting equipment required for speciﬁc components or assemblies.

Open-Drive Motor Storage — If the machine is to

be placed in extended shutdown, certain precautions must be taken to provide proper protection while the motor is being stored. The motor should be stored under cover in a clean, dry location and should be protected from rapid temperature changes.

Since moisture can be very detrimental to electrical components, the motor temperature should be maintained at approximately 5° F (3° C) above the dew point temperature by providing either external or internal heat. If the motor is equipped with space heaters, they should be energized at the voltage shown by the space heater nameplate attached to the motor.Incandescent light bulbs can be placed within the motor to provide heat. However, if used, they must not be allowed to come in contact with any parts of the motor because of the concentrated hot spot that could result.

This motor has been provided with a shaft shipping brace or shipping bolt (normally painted yellow) to prevent shaft movement during transit, it must be removed to allow shaft rotation (refer to Before Initial Start-Up, Remove Shipping Packaging section, page 47.) It is very important that this brace be reinstalled exactly as it was originally, before the motor is moved from storage or any time when the motor is being transported. This prevents axial rotor movement that might damage the bearings.

Motors equipped with sleeve bearings are shipped from the factory with the bearing oil reservoirs drained. In storage, the oil reservoirs should be properly ﬁlled to the center of the oil level gage with a good grade of rust inhibiting oil (refer to the certiﬁed drawing for oil viscosity and any special requirements). To keep the bearing journals well oiled and to prevent rusting, the motor shaft should be rotated several revolutions every 2 weeks. While the shaft is rotating it should be pushed to both extremes of the endplay to allow for oil ﬂow over the entire length of the journals.

Compressor Bearing and Gear Maintenance —

The key to good bearing and gear maintenance is proper lubrication. Use the proper grade of oil, maintained at recommended level, temperature, and pressure. Inspect the lubrication system regularly and thoroughly.

Only a trained service technician should remove and examine the bearings. The bearings and gears should be examined on a scheduled basis for signs of wear. The frequency of examination is determined by the hours of machine operation, load conditions during operation, and the condition of the oil and the lubrication system. Excessive bearing wear can sometimes be detected through increased vibration or increased bearing temperature. If either symptom appears, contact an experienced and responsible service organization for assistance.

Inspect the Heat Exchanger Tubes

COOLER — Inspect and clean the cooler tubes at the end of the ﬁrst operating season. Because these tubes have internal ridges, a rotary-type tube cleaning system is necessary to fully clean the tubes. Upon inspection, the tube condition will determine the scheduled frequency for cleaning, and will indicate whether water treatment is adequate in the chilled water/ brine circuit. Inspect the entering and leaving chilled water temperature sensors for signs of slime, corrosion, or scale. Replace the sensor if corroded or remove any scale if found.

Fig. 46 — Lifting Open-Drive Motor

CONDENSER — Since this water circuit is usually an opentype system, the tubes may be subject to contamination and scale. Clean the condenser tubes with a rotary tube cleaning system at least once per year, and more often if the water is contaminated. Inspect the entering and leaving condenser water sensors for signs of slime, corrosion, or scale. Replace the sensor if corroded or remove any scale if found.

Higher than normal condenser pressures, together with the inability to reach full refrigeration load, usually indicate dirty tubes or air in the machine. If the refrigeration log indicates a rise above normal condenser pressures, check the condenser refrigerant temperature against the leaving condenser water temperature. If this reading is more than what the design difference is supposed to be, then the condenser tubes may be dirty, or water ﬂow may be incorrect. Because HFC134-a is a high-pressure refrigerant, air usually does not enter the machine, rather, the refrigerant leaks out.

During the tube cleaning process, use brushes especially designed to avoid scraping and scratching the tube wall. Contact your Carrier representative to obtain these brushes. Do not use wire brushes.

Hard scale may require chemical treatment for its prevention or removal. Consult a water treatment specialist for proper treatment.

WaterLeaks — Water in the refrigerant is indicated dur-

ing machine operation by the refrigerant moisture indicator on the refrigerant motor cooling line (Fig. 8). Water leaks should be repaired immediately.

Machine must be dehydrated after repair of water leaks. See Machine Dehydration section, page 51.

WaterTreatment— Untreated or improperly treated wa-

ter may result in corrosion, scaling, erosion, or algae. The services of a qualiﬁed water treatment specialist should be obtained to develop and monitor a treatment program.

Water must be within design ﬂow limits, clean, and treated to ensure proper machine performance and reduce the potential of tubing damage due to corrosion, scaling, erosion, and algae. Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated water.

Inspect the Starting Equipment — Before work-

ing on any starter, shut off the machine, and open all disconnects supplying power to the starter.

The disconnect on the starter front panel does not deenergize all internal circuits. Open all internal and remote disconnects before servicing the starter.

Never open isolating knife switches while equipment is operating. Electrical arcing can cause serious injury.

Inspect starter contact surfaces for wear or pitting on mechanical-type starters. Do not sandpaper or ﬁle silverplated contacts. Follow the starter manufacturer’s instructions for contact replacement, lubrication, spare parts ordering, and other maintenance requirements.

Periodically vacuum or blow off accumulated debris on the internal parts with a high-velocity, low-pressure blower.

Power connections on newly installed starters may relax and loosen after a month of operation. Turn power off and retighten. Recheck annually thereafter.

Loose power connections can cause voltage spikes, overheating, malfunctioning, or failures.

Check Pressure Transducers — Once a year, the

pressure transducers should be checked against a pressure gage reading. Check all three transducers: oil pressure, condenser pressure, cooler pressure.

Note the evaporator and condenser pressure readings on the Status01 screen on the LID. Attach an accurate set of refrigeration gages to the cooler and condenser Schrader ﬁttings. Compare the two readings. If there is a difference in readings, the transducer can be calibrated, as described in the Troubleshooting Guide section.

Pumpout System Maintenance — For compres-

sor maintenance details, refer to the 06D, 07D Installation, Start-Up, and Service Instructions.

OPTIONALPUMPOUT COMPRESSOR OIL CHARGE — Use oil conforming to Carrier speciﬁcations for reciprocating compressor usage. Oil requirements are as follows:

HFC-134a

ISO Viscosity ................................68

Carrier Part Number ..................PP23BZ103

The total oil charge, 4.5 pints (2.6 L), consists of

3.5 pints (2.0 L) for the compressor and one additional pint (0.6 L) for the oil separator.

Oil should be visible in the compressor sight glass both during operation and at shutdown. Always check the oil level before operating the compressor. Before adding or changing oil, relieve the refrigerant pressure as follows:

1. Attach a pressure gage to the gage port of either com-

pressor service valve (Fig. 34).

2. Close the suction service valve and open the discharge

line to the storage tank or the machine.

3. Operate the compressor until the crankcase pressure drops

to 2 psig (13 kPa).

4. Stop the compressor and isolate the system by closing

the discharge service valve.

5. Slowly remove the oil return line connection (Fig. 34).

Add oil as required.

6. Replace the connection and reopen the compressor serv-

ice valves.

PUMPOUT SAFETY CONTROL SETTINGS (Fig. 47) — The pumpout system high-pressure switch should open at 161 psig (1110 kPa) and closes at 130 psig (896 kPa). Check the switch setting by operating the pumpout compressor and slowly throttling the pumpout condenser water.

Ordering Replacement Chiller Parts — When or-

dering Carrier speciﬁed parts, the following information must accompany an order:

• machine model number and serial number

• name, quantity, and part number of the part required

• delivery address and method of shipment OPEN-DRIVE MOTORRENEW ALPARTS— Renewal parts

information for the motor and any auxiliary devices can be obtained from the nearestWestinghouseMotor Company sales office. A complete description of the part(s) required is necessary, together with the complete motor nameplate reading for positive motor identiﬁcation.

TROUBLESHOOTING GUIDE

Overview —

The PIC has many features to aid the operator and the technician in troubleshooting a 17/19EX machine.

• By using the LID display, the chiller actual operating con-

ditions can be viewed while the unit is running.

• The Control Algorithm Status screens will display various

screens of information in order to diagnose problems with chilled water temperature control, chilled water temperature control overrides, hot gas bypass, surge algorithm status, and time schedule operation.

• The Control Test feature allows proper operation and testing of temperature sensors, pressure transducers, the guide vane actuator, oil pump, water pumps, tower control, and other on/off outputs while the compressor is stopped. It also has the ability to lock off the compressor and turn on water pumps for pumpout operation. The display will show the required temperatures and pressures during these operations.

• Other Service menu tables can access conﬁgured items, such as chilled water resets, override set points, etc.

• If an operating fault is detected, an alarm message is generated and displayed on the LID default screen. A more detailed message — along with a diagnostic message — also is stored into the Alarm History table.

Checking the Display Messages — The ﬁrst area

to check when troubleshooting the 17/19EX is the LID display. If the alarm light is ﬂashing, check the primary and secondary message lines on the LID default screen (Fig. 14). These messages will indicate where the fault is occurring. The Alarm History table on the LID Service menu will also carry an alarm message to further expand on this alarm. For a complete listing of messages, see Table 8. If the alarm light starts to ﬂash while accessing a menu screen,

depress EXIT

to return to the Default screen to read the

failure message. The compressor will not run with an alarm condition existing, unless the alarm type is an unauthorized start or a failure to shut down.

Checking Temperature Sensors — All tempera-

ture sensors are of the thermistor type. This means that the resistance of the sensor varies with temperature. All sensors have the same resistance characteristics. Determine sensor temperature by measuring voltage drop if the controls are powered, or resistance if the controls are powered off. Compare the readings to the values listed in Table 9A or B.

RESISTANCE CHECK — Turn off the control power and disconnect the terminal plug of the sensor in question from the module. Measure sensor resistance between receptacles designated by the wiring diagram with a digital ohmmeter. The resistance and corresponding temperature is listed in Table 9A or B. Check the resistance of both wires to ground. This resistance should be inﬁnite.

VOLTAGE DROP — Using a digital voltmeter, the voltage drop across any energized sensor can be measured while the control is energized. Table 9A or B lists the relationship between temperature and sensor voltage drop (volts dc measured across the energized sensor). Exercise care when measuring voltage to prevent damage to the sensor leads, connector plugs, and modules. Sensor wire should also be checked at the sensor plug connection. Check the sensor wire by removing the condenser at the sensor and measure for 5 vdc back to the module if the control is powered.

Relieve all refrigerant pressure or drain the water prior to replacing the temperature sensors.

Fig. 47 — Controls for Optional Pumpout

Compressor

CHECK SENSOR ACCURACY — Place the sensor in a medium of a known temperature and compare that temperature to the measured reading. The thermometer used to determine the temperature of the medium should be of laboratory quality with 0.5° F (.25° C) graduations. The sensor in question should be accurate to within 2° F (1.2° C).

See Fig. 7 and 8 for sensor locations. The sensors are immersed directly in the refrigerant or water circuits. The wiring at each sensor is easily disconnected by unlatching the connector.These connectors allow only one-way connection to the sensor. When installing a new sensor, apply a pipe sealant or thread sealant to the sensor threads.

DUAL TEMPERATURE SENSORS — There are 2 sensing elements on each of the bearing temperature sensors (hermetic and open-drive machines) and motor temperature sensors (hermetic machines only) for servicing convenience. In case one of the dual sensors is damaged, the other one can be used by moving a wire.

The number 1 terminal in the sensor terminal box is the common line. To use the second sensor, move the wire from the number 2 position to the number 3 position.

CheckingPressureT ransducers— There are 3 pres-

sure transducers on hermetic machines. These determine cooler, condenser,and oil pressure. Open-drive machines have 4 transducers. These transducers sense cooler pressure, condenser pressure, oil supply pressure, and oil sump pressure. The oil supply pressure and the oil transmission sump pressure difference is calculated by a differential pressure power supply module on open-drive machines. The PSIO then reads this differential. In effect, then, the PSIO reads 3 pressure inputs for open-drive machines and 3 pressure inputs for hermetic machines. The cooler and condenser transducers are used by the PIC to determine refrigerant temperatures.

All pressure inputs can be calibrated, if necessary.It is not usually necessary to calibrate at initial start-up. However, at high altitude locations, calibration of the transducer will be necessary to ensure the proper refrigerant temperature/ pressure relationship. Each transducer is supplied with 5 vdc power from a power supply.If the power supply fails, a transducer voltage reference alarm will occur. If the transducer reading is suspected of being faulty, check the supply voltage. It should be 5 vdc ± .5 v. If the supply voltage is correct, the transducer should be recalibrated or replaced.

IMPORTANT: For hermetic machines, whenever the oil pressure or the cooler pressure transducer is calibrated, the other sensor should be calibrated to prevent problems with oil differential pressure readings.

To calibrate oil pressure differential on open-drive machines, refer to Oil Pressure Differential Calibration at the end of this section.

Calibration can be checked by comparing the pressure readings from the transducer against an accurate refrigeration gage. These readings are all viewed or calibrated from the Status01 table on the LID. The transducer can be checked and calibrated at 2 pressure points. These calibration points are 0 psig (0 kPa) and between 240 and 260 psig (1655 to 1793 kPa). To calibrate these transducers:

1. Shut down the compressor.

2. Disconnect the transducer in question from its Schrader ﬁtting.

NOTE: If the cooler or condenser vessels are at 0 psig (0 kPa) or are open to atmospheric pressure, the transducers can be calibrated for zero without removing the transducer from the vessel.

3. Access the Status01 table, and view the particular transducer reading; it should read 0 psi (0 kPa). If the reading is not 0 psi (0 kPa), but within ± 5 psi (35 kPa), the

value may be zeroed by pressing the SELECT

softkey while the highlight bar is located on the transducer, and then by pressing the ENTER

. The value will now go

to zero. If the transducer value is not within the calibration range,

the transducer will return to the original reading. If the LID pressure value is within the allowed range (noted above), check the voltage ratio of the transducer. To obtain the voltage ratio, divide the voltage (dc) input from the transducer by the supply voltage signal, measured at the PSIO terminals J7-J34 and J7-J35. For example, the condenser transducer voltage input is measured at PSIO terminals J7-1 and J7-2. The voltage ratio must be between

0.80 vdc and 0.11 vdc for the software to allow calibration. Pressurize the transducer until the ratio is within range. Then attempt calibration again.

4. A high pressure point can also be calibrated between 240 and 260 psig (1655 and 1793 kPa) by attaching a regulated 250 psig (1724 kPa) pressure (usually from a nitrogen cylinder). The high pressure point can be calibrated by accessing the transducer on the Status01 screen,

highlighting the transducer, pressing the SELECT

softkey, and then increasing or decreasing the value to the exact pressure on the refrigerant gage. Press ENTER

to ﬁnish. High altitude locations must compensate the pressure so that the temperature/pressure relationship is correct.

If the transducer reading returns to the previous value and the pressure is within the allowed range, check the voltage ratio of the transducer. Refer to Step 3 above. The voltage ratio for this high pressure calibration must be between 0.585 and 0.634 vdc to allow calibration. Change the pressure at the transducer until the ratio is within the acceptable range. Then attempt calibrate to the new pressure input.

The PIC will not allow calibration if the transducer is too far out of calibration. A new transducer must be installed and re-calibrated.

OILDIFFERENTIAL PRESSURE/POWER SUPPLY MODULE CALIBRATION — (See Fig. 48.) The oil reservoir in the 17EX machine is not common to cooler pressure. Therefore, a comparison of pump output to cooler pressure could not be used to provide differential oil pressure information. A different method has been developed.

Oil transmission sump pressure and oil supply pressure are fed to a comparator circuit on a 5V power supply board. The output of this circuit, which represents differential oil pressure, is fed to the PSIO. The oil differential pressure is calibrated to zero PSIO (0 kPad) by selecting the oil pressure input on the Service1 screen. Then, with the oil pump turned OFF and the transducers CONNECTED, press ENTER to zero the point. No high end calibration is needed or possible.

TROUBLESHOOTING TRANSDUCERS — When troubleshooting transducers, keep the negative lead of your voltohmmeter on terminal U4 of the power supply (or terminal 4 on power supplies without the comparator circuit).

voltage VO1 = (VH1-VL1) + .467 ± .1 V For all PIC transducers:

Measured pressure = (507.97 × (V

out/Vin

)) − 47.33

out

= transducer output ref. to neg. terminal

(4 or U4) i.e., VH1 to U4 or VL1 to U4

Vin= power supply output, i.e., U3 to U4

TRANSDUCER REPLACEMENT — Since the transducers are mounted on Schrader-type ﬁttings, there is no need to remove refrigerant from the vessel. Disconnect the transducer wiring by pulling up on the locking tab while pulling up on the weather-tight connecting plug from the end of the transducer. Do not pull on the transducer wires. Unscrew the transducer from the Schrader ﬁtting. When installing a new transducer, do not use pipe sealer, which can plug the sensor. Put the plug connector back on the sensor and snap into place. Check for refrigerant leaks.

Make sure to use a backup wrench on the Schrader ﬁtting whenever removing a transducer.

Control Algorithms Checkout Procedure — In

the LID Service menu, one of the tables is Control Algorithm Status. This table contains 6 sceens that may be viewed in order to see how the particular control algorithm is operating.

MAINT01 Capacity

Control

Thistable shows allvalues that areused tocalculate thechilled water/brinecontrol point.

MAINT02 Override

Status

Detailsof all chilled water control override values are viewed here.

MAINT03 Surge/

HGBP Status

The surge and hot gas bypass control algorithm status is viewed from this screen.Allvalues dealing with this control are displayed.

MAINT04 LEAD/LAG

Status

This screen indicates LEAD/LAG operation status.

OCCDEFM Time

Schedules Status

The Local and CCN occupied schedules are displayed here in a manner that allows the operator to quickly determine whether the schedule is in the OCCUPIED mode or not.

WSMDEFME Water

System Manager Status

The water system manager is a CCN module which can turn on the chiller and change the chilled water control point. This screen indicates the status of this system.

These maintenance tables are very useful in determining guide vane position, reaction from load changes, control point overrides, hot gas bypass reaction, surge prevention, etc.

Control Test — The Control Test feature can check all

of the thermistor temperature sensors, including those on the Options modules, pressure transducers, pumps and their associated ﬂow switches, the guide vane actuator, and other control outputs, such as hot gas bypass. The tests can help to determine whether a switch is defective, or a pump relay is not operating, among other useful troubleshooting tests. During pumpdown operations, the pumps are energized to prevent freeze-up and the vessel pressures and temperatures are displayed. The lockout feature will prevent start-up of the compressor when no refrigerant is present in the machine, or if the vessels are isolated. The lockout is then terminated by the operator by using the Terminate Lockout function after the pumpdown procedure is reversed and refrigerant is added.

LEGEND FOR TABLE 8, A - N

1CR AUX — Compressor Start Contact CA P

— Compressor Current CCN — Carrier Comfort Network CDFL — Condenser Water Flow CHIL S S

— Chiller Start/Stop CHW — Chilled Water CMPD — Discharge Temperature CRP — Condenser Pressure ECW — Entering Chilled Water ERT — Evaporator Refrigerant Temperature EVFL — Chilled Water Flow GV TRG

— Target Guide Vane Position LID — Local Interface Device MTRB — Bearing Temperature MTRW — Motor Winding Temperature OILPD — Oil Pressure OILT — Oil Sump Temperature PIC — Product Integrated Control PRS TRIP

— Pressure Trip Contact PSIO — Processor Sensor Input/Output Module RLA — Rated Load Amps RUN AUX

— Compressor Run Contact SMM — Starter Management Module SPR PL

— Spare Protective Limit Input STR FLT

— Starter Fault TXV — Thermostatic Expansion Valve VP

—Line Voltage: Percent V REF

— Voltage Reference

Fig. 48 — Oil Differential Pressure/Power

Supply Module

17EX OIL PRESSURE INPUT

85 1197

→

Table 8 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides

A. SHUTDOWN WITH ON/OFF/RESET-OFF

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

MANUALLY STOPPED — PRESS CCN OR LOCAL TO START

PIC in OFF mode, press the CCN or local softkey to start unit.

TERMINATE PUMPDOWN MODE TO SELECT CCN OR LOCAL

Enter the Control Test table and select Terminate Lockout to unlock compressor.

SHUTDOWN IN PROGRESS COMPRESSOR UNLOADING Machine unloading before shutdown due to Soft Stop feature. SHUTDOWN IN PROGRESS COMPRESSOR DEENERGIZED

Machine compressor is being commanded to stop. Water pumps are deenergized within one minute.

ICE BUILD OPERATION COMPLETE Machine shutdown from Ice Build operation.

B. TIMING OUT OR TIMED OUT

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

READY TO START IN XX MIN UNOCCUPIED MODE

Time schedule for PIC is unoccupied. Machines will start only when occupied.

READY TO START IN XX MIN REMOTE CONTACTS OPEN Remote contacts have stopped machine. Close contacts to start. READY TO START IN XX MIN STOP COMMAND IN EFFECT

Chiller START/STOP on Status01 manually forced to stop. Release value to start.

READY TO START IN XX MIN RECYCLE RESTART PENDING Machine in recycle mode. READY TO START UNOCCUPIED MODE

Time schedule for PIC is UNOCCUPIED. Machine will start when occupied. Make sure the time and date have been set on the Service menu.

READY TO START REMOTE CONTACTS OPEN Remote contacts have stopped machine. Close contacts to start. READY TO START STOP COMMAND IN EFFECT

Chiller START/STOP on Status01 manually forced to stop. Release value to start.

READY TO START IN XX MIN REMOTE CONTACTS CLOSED Machine timer counting down unit. Ready for start. READY TO START IN XX MIN OCCUPIED MODE Machine timer counting down unit. Ready for start. READY TO START REMOTE CONTACTS CLOSED Machine timers complete, unit start will commence. READY TO START OCCUPIED MODE Machine timers complete, unit start will commence. STARTUP INHIBITED LOADSHED IN EFFECT CCN loadshed module commanding chiller to stop.

READY TO START IN XX MIN START COMMAND IN EFFECT

Chiller START/STOP on Status01 has been manually forced to start. Machine will start regardless of time schedule or remote contact status.

C. IN RECYCLE SHUTDOWN

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

RECYCLE RESTART PENDING OCCUPIED MODE

Unit in recycle mode, chilled water temperature is not high enough to start.

RECYCLE RESTART PENDING REMOTE CONTACT CLOSED

Unit in recycle mode, chilled water temperature is not high enough to start.

RECYCLE RESTART PENDING START COMMAND IN EFFECT

Chiller START/STOP on Status01 manually forced to start, chilled water temperature is not high enough to start.

RECYCLE RESTART PENDING ICE BUILD MODE

Machine in ICE BUILD mode. Chilled Water/Brine Temperature is satisﬁed for Ice Build Setpoint temperature.

D. PRE-STARTALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary.

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY PRESTART ALERT STARTS LIMIT EXCEEDED STARTS EXCESSIVE Compressor Starts (8 in

12 hours)

Depress the RESET softkeyif additional startis required. Reassess start-up requirements.

PRESTART ALERT HIGH MOTOR TEMPERATURE MTRW [VALUE] exceeded limit of [LIMIT]*.

Check motor temperature.

Check motor cooling line for proper operation. Check for excessive starts within a short time span.

PRESTART ALERT HIGH BEARING TEMPERATURE MTRB [VALUE] exceeded limit of [LIMIT]*.

Check thrust bearing temperature.

Check oil heater for proper operation, check for low oil level, partially closed oil supply valves, etc. Check sensor accuracy.

PRESTART ALERT HIGH DISCHARGE TEMP CMPD [VALUE] exceeded limit of [LIMIT]*.

Check discharge temperature.

Check sensor accuracy. Allow discharge temperature to cool. Check for excessive starts.

PRESTART ALERT LOW REFRIGERANT TEMP ERT [VALUE] exceeded limit of [LIMIT]*. Check

refrigerant temperature.

Checktransducer accuracy.Checkforlowchilled water/brine supply temperature.

PRESTART ALERT LOW OIL TEMPERATURE OILT [VALUE] exceeded limit of [LIMIT]*.

Check oil temperature.

Check oil heater power, oil heater relay. Check oil level.

PRESTART ALERT LOW LINE VOLTAGE V P [VALUE] exceeded limit of [LIMIT]*.

Check voltage suppy.

Checkvoltage supply.Check voltage transformers. Consult power utility if voltage is low. Calibrate voltage reading on STATUS01 Table.

PRESTART ALERT HIGH LINE VOLTAGE V P [VALUE] exceeded limit of [LIMIT]*.

Check voltage supply.

Checkvoltage supply.Check voltage transformers. Consult power utility if voltage is low. Calibrate voltage reading on STATUS01 table.

PRESTART ALERT HIGH CONDENSER PRESSURE CRP [VALUE] exceeded limit of [LIMIT]*. Check

condenser water and transducer.

Check for high condenser water temperature. Check transducer accuracy.

*[LIMIT] is shown on the LID as temperature, pressure, voltage, etc., set point predeﬁned or selected by the operator as an override, alert, or alarm condition. [VALUE]

is the actual pressure, temperature, voltage, etc., at which the control tripped.

Table 8 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides (cont)

E. NORMAL OR AUTO.-RESTART

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

STARTUP IN PROGRESS OCCUPIED MODE Machine starting. Time schedule is occupied. STARTUP IN PROGRESS REMOTE CONTACT CLOSED Machine starting. Remote contacts are closed.

STARTUP IN PROGRESS START COMMAND IN EFFECT

Machine starting. Chiller START/STOP on Status01 manually forced to start.

AUTORESTART IN PROGRESS OCCUPIED MODE Machine starting. Time schedule is occupied. AUTORESTART IN PROGRESS REMOTE CONTACT CLOSED Machine starting. Remote contacts are closed.

AUTORESTART IN PROGRESS START COMMAND IN EFFECT

Machine starting. Chiller START/STOP on Status01 manually forced to start.

F. START-UP FAILURES: This is an alarm condition. A manual reset is required to clear.

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY FAILURE TO START LOW OIL PRESSURE OILPD [VALUE] exceeded limit of [LIMIT]*. Check

oil pump system.

Check for closed oil supply valves. Check oil ﬁlter. Check for low oil temperature. Check transducer accuracy.

FAILURE TO START OIL PRESS SENSOR FAULT OILPD [VALUE] exceeded limit of [LIMIT]*. Check

oil pressure sensor.

Check for excessive refrigerant in oil sump. Run oil pump manually for 5 minutes. For hermetic compressors, check both oil pressure and cooler pressure. For open-drive units, check calibration of oil pressure differential ampliﬁer modules. Check wiring. Replace transducers if necessary.

FAILURE TO START LOW CHILLED WATER FLOW EVFL Evap Flow Fault: Check water pump/ﬂow

switch.

Check wiring to ﬂow switch. Check through Control Test for proper switch operation.

FAILURE TO START LOW CONDENSER

WATER FLOW

CDFL Cond. Flow Fault: Check water pump/ﬂow switch.

Check wiring to ﬂow switch. Check through Control Test for proper switch operation.

FAILURE TO START STARTER FAULT STR FLT Starter Fault: Check Starter for Fault

Source.

Astarterprotectivedevice has faulted. Checkstarter for ground fault, voltage trip, temperature trip, etc.

FAILURE TO START STARTER OVERLOAD TRIP STR FLT Starter Overload Trip: Check amps

calibration/reset overload.

Reset overloads, check ICR relay before restarting machine.

FAILURE TO START LINE VOLTAGE DROPOUT V P Single-Cycle Dropout Detected: Check volt-

age supply.

Check voltage supply. Check transformers for supply.Checkwithutilityifvoltage supply is erratic. Monitor must be installed to conﬁrm consistent, singlecycle dropouts. Check low oil pressure switch.

FAILURE TO START HIGH CONDENSER

PRESSURE

High Condenser Pressure [LIMIT]:* Check switch 2C aux, and water temperature/ﬂow.

Check for proper design condenser ﬂow and temperature.Checkcondenser approach. Check 2C auxiliary contacts on oil sump starter. Check high pressure switch.

FAILURE TO START EXCESS ACCELERATION

TIME

CA PExcessAcceleration:Check guide vane closure at start-up.

Checkthat guide vanes are closedat start-up. Check starter for proper operation. Reduce unit pressure if possible.

FAILURE TO START STARTER TRANSITION

FAULT

RUN AUX Starter Transition Fault: Check 1CR/ 1M/Interlock mechanism.

Check starter for proper operation. Run contact failed to close.

FAILURE TO START 1CR AUX CONTACT FAULT 1CR AUX Starter Contact Fault: Check 1CR/1M

aux. contacts.

Check starter for proper operation. Start contact failed to close.

FAILURE TO START MOTOR AMPS NOT SENSED CA P Motor Amps Not Sensed: Check motor load

signal.

Checkfor proper motor amps signal to SMM. Check wiringfrom SMM to currenttransformer.Checkmain motor circuit breaker for trip.

FAILURE TO START CHECK REFRIGERANT TYPE Current Refrigerant Properties Abnormal — Check

Selection of refrigerant type

Pressures at transducers indicate another refrigerant type in Control Test. Make sure to access the ATTACH TO NETWORK DEVICE table after specifying HFC-134a refrigerant type.

FAILURE TO START LOW OIL PRESSURE LowOilPressure[LIMIT]:*Checkoil pressure switch/

pump and 2C aux.

The oil pressure differentialswitchis open when the compressor tried to START. Check the switch for proper operation.Also, check the oil pump interlock (2C aux) in the power panel and the high condenser pressure switch.

*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set point predeﬁned or selected by the operator as an override, alert, or alarm condition. [VALUE]

is the actual pressure, temperature, voltage, etc., at which the control tripped.

Table 8 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides (cont)

G. COMPRESSOR JUMPSTARTAND REFRIGERANT PROTECTION

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

UNAUTHORIZED OPERATION

UNIT SHOULD BE STOPPED

CA P Emergency: Compressor running without control authorization.

Compressor is running with more than 10% RLA and control is trying to shut it down. Throw power offtocompressorif unable to stop. Determine cause before repowering.

POTENTIAL FREEZE-UP EVAP PRESS/TEMP

TOO LOW

ERT Emergency: Freeze-up prevention.

Determinecause. If pumping refrigerant outof machine, stop operation and go over pumpout procedures.

FAILURE TO STOP DISCONNECT POWER RUN AUX Emergency: DISCONNECT

POWER.

Starter and run and start contacts are energized whilecontrol tried to shutdown. Disconnect power to starter.

LOSS OF COMMUNCIATION

WITH STARTER Loss of Communication with Starter: Check

machine.

Checkwiringfrom PSIO to SMM. Check SMM module troubleshooting procedures.

STARTER CONTACT FAULT

ABNORMAL 1CR OR RUN AUX

1CR AUX Starter Contact Fault: Check 1CR/1M aux. contacts.

Starter run and start contacts energized while machine was off. Disconnect power.

POTENTIAL FREEZE UP COND PRESS/TEMP

TOO LOW

CRT [VALUE] exceeded limit of [LIMIT]* Emergency: Freeze-up prevention.

The condenser pressure transducer is reading a pressure that could freeze the water in the condensertubes.Checkforcondenserrefrigerant leaks, bad transducers, or transferred refrigerant. Place the unit in Pumpdown mode to eliminate ALARM if vessel is evacuated.

*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set point predeﬁned or selected by the operator as an override, alert, or alarm condition. [VALUE]

is the actual pressure, temperature, voltage, etc., at which the control tripped.

H. NORMAL RUN WITH RESET, TEMPERATURE, OR DEMAND

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

RUNNING — RESET ACTIVE 4-20MA SIGNAL

Reset program active based upon Conﬁg table setup.RUNNING — RESET ACTIVE REMOTE SENSOR CONTROL RUNNING — RESET ACTIVE CHW TEMP DIFFERENCE RUNNING — TEMP CONTROL LEAVING CHILLED WATER Default method of temperature control. RUNNING — TEMP CONTROL ENTERING CHILLED WATER ECW control activated on Conﬁg table. RUNNING — TEMP CONTROL TEMPERATURE RAMP LOADING Ramp loading in effect. Use Service1 table to modify. RUNNING — DEMAND LIMITED BY DEMAND RAMP LOADING Ramp loading in effect. Use Service1 table to modify. RUNNING — DEMAND LIMITED BY LOCAL DEMAND SETPOINT Demand limit setpoint is , actual demand. RUNNING — DEMAND LIMITED BY 4-20MA SIGNAL

Demand limit is active based on Conﬁg table setup.RUNNING — DEMAND LIMITED BY CCN SIGNAL RUNNING — DEMAND LIMITED BY LOADSHED/REDLINE

RUNNING — TEMP CONTROL HOT GAS BYPASS

Hot Gas Bypass is energized. See surge prevention in the control

section.

RUNNING — DEMAND LIMITED BY LOCAL SIGNAL Active demand limit manually overridden or Status01 table. RUNNING — TEMP CONTROL ICE BUILD MODE Machine is running under Ice Build temperature control.

Table 8 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides (cont)

I. NORMAL RUN OVERRIDES ACTIVE (ALERTS)

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

RUN CAPACITY LIMITED HIGH CONDENSER PRESSURE CRP [VALUE] exceeded limit of [LIMIT]*.

Condenser pressure override.

See Capacity Overrides, Table 4. Correct operating condition, modify setpoint, or release override.

RUN CAPACITY LIMITED HIGH MOTOR TEMPERATURE MTRW [VALUE] exceeded limit of [LIMIT]*.

Motor temperature override.

RUN CAPACITY LIMITED LOW EVAP REFRIG TEMP ERT[VALUE]exceededlimitof [LIMIT]*. Check

refrigerant charge level.

RUN CAPACITY LIMITED HIGH COMPRESSOR LIFT Surge Prevention Override; lift too high for

compressor.

RUN CAPACITY LIMITED MANUAL GUIDE VANE TARGET GV TRG RunCapacity Limited: Manual guide

vane target.

*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set point predeﬁned or selected by the operator as an override, alert, or alarm condition. [VALUE]

is the actual temperature, pressure, voltage, etc., at which the control tripped.

J. OUT-OF-RANGE SENSOR FAILURES

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY SENSOR FAULT LEAVING CHW TEMPERATURE Sensor Fault: Check leaving CHW

sensor.

See sensor test procedure and check sensors for proper operation and wiring.

SENSOR FAULT ENTERING CHW TEMPERATURE Sensor Fault: Check entering CHW

sensor.

SENSOR FAULT CONDENSER PRESSURE Sensor Fault: Check condenser pressure

transducer.

SENSOR FAULT EVAPORATOR PRESSURE Sensor Fault: Check evaporator pressure

transducer.

SENSOR FAULT BEARING TEMPERATURE Sensor Fault: Check bearing temperature

sensor.

SENSOR FAULT MOTOR WINDING TEMP Sensor Fault: Check motor temperature

sensor.

SENSOR FAULT DISCHARGE TEMPERATURE Sensor Fault: Check discharge temperature

sensor.

SENSOR FAULT OIL SUMP TEMPERATURE Sensor Fault: Check oil sump temperature

sensor.

SENSOR FAULT OIL PRESSURE TRANSDUCER Sensor Fault: Check oil pressure

transducer.

Table 8 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides (cont)

K. MACHINE PROTECT LIMIT FAULTS

Excessive numbers of the same fault can lead to severe machine damage. Seek service expertise.

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY PROTECTIVE LIMIT HIGH DISCHARGE TEMP CMPD [VALUE] exceeded limit of [LIMIT]*.

Check discharge temperature.

Checkdischarge temperature immediately.Checksensor for accuracy; check for proper condenser ﬂowand temperature; check oil reservoir temperature. Check condenser for fouled tubes or air in machine. Check for proper guide vane actuator operation.

PROTECTIVE LIMIT LOW REFRIGERANT TEMP ERT[VALUE] exceeed limit of[LIMIT]*.Check

evap pump and ﬂow switch.

Check for proper amount of refrigerant charge; check for proper water ﬂow and temperatures. Check for proper guide vane actuator operation.

PROTECTIVE LIMIT HIGH MOTOR TEMPERATURE MTRW [VALUE] exceeded limit of [LIMIT]*.

Check motor cooling and solenoid.

Check motor temperature immediately. Check sensorfor accuracy.Check for proper condenser ﬂowand temperature. Check motor cooling system for restrictions. Check motor cooling solenoid for proper operation. Check refrigerant ﬁlter.

PROTECTIVE LIMIT HIGH BEARING TEMPERATURE MTRB [VALUE] exceeded limit of [LIMIT]*.

Check oil cooling control.

Check for throttled oil supply isolation valves. Valves should be wide open. Check oil cooler thermal expansion valve. Check sensor accuracy. Check journaland thrust bearings. Check refrigerant ﬁlter. Check for excessive oil sump level.

PROTECTIVE LIMIT LOW OIL PRESSURE OILPD [VALUE]exceeded limit of [LIMIT]*.

Check oil pump and transducer.

Check power to oil pump and oil level. Check for dirty ﬁltersor oil foaming at start-up.Check for thermal overload cutout. Reduce ramp load rate if foaming noted. NOTE: This alarm is not related to pressure switch problems.

Low Oil Pressure [OPEN]*. Check oil pressure switch/pump and 2C aux.

Check the oil pressure switch for proper operation. Check oil pump for proper pressure. Check for excessive refrigerant in oil system.

PROTECTIVE LIMIT NO MOTOR CURRENT CA P Loss of Motor Current: Check

sensor.

Checkwiring:Checktorque setting on solid-state starter. Check for main circuit breaker trip. Check power supply to PSIO module.

PROTECTIVE LIMIT POWER LOSS V P Power Loss: Check voltage

supply.

Check 24-vac input on the SMM (terminals 23 and

24).Checktransformers to SMM. Check power toPSIO module. Check distribution bus. Consult power company.

PROTECTIVE LIMIT LOW LINE VOLTAGE V P [VALUE] exceeded limit of [LIMIT]*.

Check voltage supply.

PROTECTIVE LIMIT HIGH LINE VOLTAGE V P [VALUE] exceeded limit of [LIMIT]*.

Check voltage supply.

PROTECTIVE LIMIT LOW CHILLED WATER FLOW EVFL Flow Fault: Check evap pump/ﬂow

switch.

Perform pumps Control Test and verify proper switch operation. Check all water valves and pump operation.

PROTECTIVE LIMIT LOW CONDENSER WATER FLOW CDFL Flow Fault: Check cond pump/ﬂow

switch.

PROTECTIVE LIMIT HIGH CONDENSER PRESSURE High Cond Pressure [OPEN]*: Checkswitch,

oil pressure contact, and water temp/ﬂow.

Checkthe high-pressure switch. Check forproper condenserpressures and condenser waterﬂow.Checkfor fouled tubes. Check the 2C aux. contact and the oil pressure switch in the power panel. This alarm is not caused by the transducer.

HighCondPressure[VALUE]*:Checkswitch, water ﬂow, and transducer.

Checkwater ﬂow in condenser. Check for fouled tubes. Transducershouldbechecked for accuracy.Thisalarm is not caused by the high pressure switch.

PROTECTIVE LIMIT HIGH CONDENSER PRESSURE HighCondPressure[V ALUE]*:Checkswitch,

water ﬂow, and transducer.

Checkwater ﬂow in condenser. Check for fouled tubes. Transducershouldbechecked for accuracy.Thisalarm is not caused by the high pressure switch.

PROTECTIVE LIMIT 1CR AUX CONTACT FAULT CR AUX Starter Contact Fault: Check

1CR/1M aux contacts.

1CR auxiliary contact opened while machine was running. Check starter for proper operation.

PROTECTIVE LIMIT RUN AUX CONTACT FAULT RUN AUX Starter Contact Fault: Check

1CR/1M aux contacts.

Run auxiliary contact openedwhile machine was running. Check starter for proper operation.

PROTECTIVE LIMIT CCN OVERRIDE STOP CHIL S S CCN Override Stop while in

LOCAL run mode.

CCN has signaled machine to stop. Reset and restart when ready.If the signal was sent by the LID, release the Stop signal on STATUS01 table.

PROTECTIVE LIMIT SPARE SAFTY DEVICE SPR PL Spare Safety Fault: Check

contacts.

Sparesafetyinputhastripped or factory-installed jumper not present.

PROTECTIVE LIMIT EXCESSIVE MOTOR AMPS CA P[VALUE]exceeded limit of [LIMIT]*.

High Amps; Check guide vane drive.

Checkmotorcurrent for proper calibration. Check guide vane drive and actuator for proper operation.

PROTECTIVE LIMIT EXCESSIVE COMPR SURGE Compressor Surge: Check condenser wa-

ter temp and ﬂow.

Check condenser ﬂow andtemperatures. Check conﬁguration of surge protection.

PROTECTIVE LIMIT STARTER FAULT STR FLT Starter Fault: Check starter for

fault source.

Check starter for possible ground fault, reverse rotation, voltage trip, etc.

PROTECTIVE LIMIT STARTER OVERLOAD TRIP STR FLT Starter Overload Trip: Check

amps calibration/reset overload.

Reset overloads and reset alarm. Check motor current calibration or overload calibration (do not ﬁeldcalibrate overloads).

PROTECTIVE LIMIT TRANSDUCER VOLTAGE FAULT V REF [VALUE]exceeded limit of [LIMIT]*.

Check transducer power supply.

Check transformer power (5 vdc) supply to transducers. Power must be 4.5 to 5.5 vdc.

*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set point predeﬁned or selected by the operator as an override, alert, or alarm condition. [VALUE]

is the actual temperature, pressure, voltage, etc., at which the control tripped. [OPEN] indicates that an input circuit is open.

Table 8 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides (cont)

L. MACHINE ALERTS

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

RECYCLE ALERT HIGH AMPS AT SHUTDOWN High Amps at Recycle: Check guide vane drive. Check that guide vanes are closing. Check

motor amps correction calibration is correct. Check actuator for proper operation.

SENSOR FAULT ALERT LEAVING COND WATER

TEMP

SensorFault: Check leaving condenser watersensor.

Check sensor. See sensor test procedure.

SENSOR FAULT ALERT ENTERING COND WATER

TEMP

SensorFault:Check entering condenser water sensor.

LOW OIL PRESSURE ALERT

CHECK OIL FILTER Low Oil Pressure Alert: Check oil Check oil ﬁlter. Check for improper oil level

or temperature.

AUTORESTART PENDING POWER LOSS V P Power Loss: Check voltage

supply.

Check power supply if there are excessive compressor starts occurring.

AUTORESTART PENDING LOW LINE VOLTAGE V P [VALUE] exceeded limit of [LIMIT]*. Check

voltage supply.

AUTORESTART PENDING HIGH LINE VOLTAGE V P [VALUE]exceeded limit of [LIMIT]*. Check

voltage supply.

SENSOR ALERT HIGH DISCHARGE TEMP CMPD[VALUE]exceededlimitof [LIMIT]*. Check

discharge temperature.

Discharge temperature exceeded the alert threshold. Check entering condenser water temperature.

SENSOR ALERT HIGH BEARING

TEMPERATURE

MTRB [VALUE]exceededlimit of [LIMIT]*.Check thrust bearing temperature.

Thrust bearing temperature exceeded the alert threshold. Check for closed valves, improper oil level or temperatures.

CONDENSER PRESSURE ALERT

PUMP RELAY ENERGIZED CRP High Condenser Pressure [LIMIT]*.

Pump energized to reduce pressure.

Check ambient conditions. Check condenser pressure for accuracy.

RECYCLE ALERT EXCESSIVE RECYCLE

STARTS

Excessive recycle starts. The machine load is too small to keep the

machine on line and there have been more than 5 restarts in 4 hours. Increase machine load, adjust hot gas bypass, increase RECYCLE RESTART DELTAT.

*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set point predeﬁned or selected by the operator as an override, alert, or alarm condition. [VALUE]

is the actual temperature, pressure, voltage, etc., at which the control tripped.

M. SPARE SENSOR ALERT MESSAGES

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

SPARE SENSOR ALERT COMMON CHWS SENSOR SensorFault:Check common CHWSsensor.

Check alert temperature set points on Equipment Service, SERVICE2 LID table. Check sensor for accuracy if reading is not accurate.

SPARE SENSOR ALERT COMMON CHWR SENSOR Sensor Fault: Check common CHWR

sensor.

SPARE SENSOR ALERT REMOTE RESET SENSOR Sensor Fault: Check remote reset tempera-

ture sensor.

SPARE SENSOR ALERT TEMP SENSOR — SPARE 1 Sensor Fault: Check temperature sensor —

Spare 1.

SPARE SENSOR ALERT TEMP SENSOR — SPARE 2 Sensor Fault: Check temperature sensor —

Spare 2.

SPARE SENSOR ALERT TEMP SENSOR — SPARE 3 Sensor Fault: Check temperature sensor —

Spare 3.

SPARE SENSOR ALERT TEMP SENSOR — SPARE 4 Sensor Fault: Check temperature sensor —

Spare 4.

SPARE SENSOR ALERT TEMP SENSOR — SPARE 5 Sensor Fault: Check temperature sensor —

Spare 5.

SPARE SENSOR ALERT TEMP SENSOR — SPARE 6 Sensor Fault: Check temperature sensor —

Spare 6.

SPARE SENSOR ALERT TEMP SENSOR — SPARE 7 Sensor Fault: Check temperature sensor —

Spare 7.

SPARE SENSOR ALERT TEMP SENSOR — SPARE 8 Sensor Fault: Check temperature sensor —

Spare 8.

SPARE SENSOR ALERT TEMP SENSOR — SPARE 9 Sensor Fault: Check temperature sensor —

Spare 9.

Table 8 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides (cont)

N. OTHER PROBLEMS/MALFUNCTIONS

DESCRIPTION/MALFUNCTION PROBABLE CAUSE/REMEDY

Chilled Water/Brine Temperature Too High (Machine Running)

Chilled water set point set too high. Access set point on LID and verify. Capacity override or excessive cooling load (machine at design capacity).

Check LID status messages. Check for outside air inﬁltration into conditioned space.

Condenser temperature too high. Check for proper ﬂow, examine cooling tower operation, check for air or water leaks, check for fouled tubes.

Refrigerant level low. Check for leaks, add refrigerant, and trim charge. Liquid bypass in waterbox. Examine division plates and gaskets for leaks. Guide vanes fail to open. Use Control Test to check operation. Chilledwater controlpoint toohigh.Access control algorithm status and check

chilled water control operation. Guide vanes fail to open fully.Be sure that the guide vane target is released.

Check guide vane linkage. Check limit switch in actuator. Check that sensor is in the proper terminals.

Chilled Water/Brine Temperature Too Low (Machine Running)

Chilled water set point set too low. Access set point on LID and verify. Chilled water control point too low.Access control algorithm status and check

chilled water control for proper resets. High discharge temperature keeps guide vanes open. Guide vanes fail to close. Be sure that guide vane target is released. Check

chilled water sensor accuracy. Check guide vane linkage. Check actuator operation.

Chilled Water Temperature Fluctuates. Vanes Hunt Deadband too narrow. Conﬁgure LID for a larger deadband.

Proportional bands too narrow. Either INC or DEC proportionalbands should be increased.

Loose guide vane drive. Adjust chain drive. Defective vane actuator. Check through Control Test. Defective temperature sensor. Check sensor accuracy.

Low Oil Sump Temperature While Running (Less than 100 F [38 C])

Check for proper oil level (not enough oil).

AtPower Up, DefaultScreen Does NotAppear,‘‘Tables Loading’’ Message Continually Appears

Check for proper communications wiring on PSIO module. Check that the COMM1 communications wires from the LID are terminated to the COMM1 PSIO connection. Check for ground or short on CCN system wiring.

SMM Communications Failure Check that PSIO communication plugs are connected correctly.CheckSMM

communicationplug. Check for proper SMM power supply.See ControlModules section on page 95.

High Oil Temperature While Running Check forproper oillevel (too much oil). On hermetic EX compressors, check

that TXV valve is operating properly. On hermetic or open-drive FA compressors, check water supply to oil cooler.

Blank LID Screen (Minimal Contrast Visible) Increase contrast potentiometer. See Fig. 50. Check red LED on LID for

proper operation, (power supply). If LED is blinking, but green LED’s are not, replace LID module, (memory failure). Check light bulb if backlit model.

‘‘Communications Failure’’ Highlighted Message At Bottom of LID Screen

LID is not properly addressed to the PSIO. Make sure that ‘‘Attach to Network Device,’’‘‘Local Device’’is set to read the PSIO address. Check LED’s on PSIO. Is red LED operating properly? Are green LED’s blinking? See control module troubleshooting section.

Control Test Disabled Press the ‘‘Stop’’ pushbutton. The PIC must be in the OFF mode for the

Control Testto operate. Clear all alarms. Check line voltage percent on Status01 screen. The percent must be within 90% to 110%. Check voltage input to SMM, calibrate starter voltage potentiometer for accuracy.

Vanes Will Not Open in Control Test Low pressure alarm is active. Put machine into pumpdown mode or equal-

ize pressure. Check guide vane actuator wiring.

Oil Pump Does Not Run Check oil pump voltage supply. Cooler vessel pressure under vacuum.

Pressurize vessel. Check temperature overload cutout switch.

LID Default Screen Does Not Update This is normal operation when an alarm is present. The screen freezes the

moment the alarm is activated to aid in troubleshooting. The Status01 screen provides current information.

Machine Does Not Stop When the STOP Button is Pressed The STOP button wiring connector on the LID module is not properly con-

nected or the machine is in soft stop mode and the guide vanes are closing.

LID Screen Dark Light bulb burned out. Replace as needed.

Table 9A — Thermistor Temperature (F) vs Resistance/Voltage Drop

TEMPERATURE VOLTAGE RESISTANCE

(F) DROP (V) (OHMS)

−25.0 4.821 98010

−24.0 4.818 94707

−23.0 4.814 91522

−22.0 4.806 88449

−21.0 4.800 85486

−20.0 4.793 82627

−19.0 4.786 79871

−18.0 4.779 77212

−17.0 4.772 74648

−16.0 4.764 72175

−15.0 4.757 69790

−14.0 4.749 67490

−13.0 4.740 65272

−12.0 4.734 63133

−11.0 4.724 61070

−10.0 4.715 59081

−9.0 4.705 57162

−8.0 4.696 55311

−7.0 4.688 53526

−6.0 4.676 51804

−5.0 4.666 50143

−4.0 4.657 48541

−3.0 4.648 46996

−2.0 4.636 45505

−1.0 4.624 44066

0.0 4.613 42679

1.0 4.602 41339

2.0 4.592 40047

3.0 4.579 38800

4.0 4.567 37596

5.0 4.554 36435

6.0 4.540 35313

7.0 4.527 34231

8.0 4.514 33185

9.0 4.501 32176

10.0 4.487 31202

11.0 4.472 30260

12.0 4.457 29351

13.0 4.442 28473

14.0 4.427 27624

15.0 4.413 26804

16.0 4.397 26011

17.0 4.381 25245

18.0 4.366 24505

19.0 4.348 23789

20.0 4.330 23096

21.0 4.313 22427

22.0 4.295 21779

23.0 4.278 21153

24.0 4.258 20547

25.0 4.241 19960

26.0 4.223 19393

27.0 4.202 18843

28.0 4.184 18311

29.0 4.165 17796

30.0 4.145 17297

31.0 4.125 16814

32.0 4.103 16346

33.0 4.082 15892

34.0 4.059 15453

35.0 4.037 15027

36.0 4.017 14614

37.0 3.994 14214

38.0 3.968 13826

39.0 3.948 13449

40.0 3.927 13084

41.0 3.902 12730

42.0 3.878 12387

43.0 3.854 12053

44.0 3.828 11730

45.0 3.805 11416

46.0 3.781 11112

47.0 3.757 10816

48.0 3.729 10529

49.0 3.705 10250

50.0 3.679 9979

51.0 3.653 9717

52.0 3.627 9461

53.0 3.600 9213

54.0 3.575 8973

55.0 3.547 8739

56.0 3.520 8511

57.0 3.493 8291

58.0 3.464 8076

59.0 3.437 7868

60.0 3.409 7665

61.0 3.382 7468

62.0 3.353 7277

63.0 3.323 7091

64.0 3.295 6911

65.0 3.267 6735

66.0 3.238 6564

67.0 3.210 6399

68.0 3.181 6238

69.0 3.152 6081

70.0 3.123 5929

TEMPERATURE VOLTAGE RESISTANCE

(F) DROP (V) (OHMS)

71 3.093 5781 72 3.064 5637 73 3.034 5497 74 3.005 5361 75 2.977 5229 76 2.947 5101 77 2.917 4976 78 2.884 4855 79 2.857 4737 80 2.827 4622 81 2.797 4511 82 2.766 4403 83 2.738 4298 84 2.708 4196 85 2.679 4096 86 2.650 4000 87 2.622 3906 88 2.593 3814 89 2.563 3726 90 2.533 3640 91 2.505 3556 92 2.476 3474 93 2.447 3395 94 2.417 3318 95 2.388 3243 96 2.360 3170 97 2.332 3099 98 2.305 3031

99 2.277 2964 100 2.251 2898 101 2.217 2835 102 2.189 2773 103 2.162 2713 104 2.136 2655 105 2.107 2597 106 2.080 2542 107 2.053 2488 108 2.028 2436 109 2.001 2385 110 1.973 2335

111 1.946 2286 112 1.919 2239 113 1.897 2192 114 1.870 2147 115 1.846 2103 116 1.822 2060 117 1.792 2018 118 1.771 1977 119 1.748 1937 120 1.724 1898 121 1.702 1860 122 1.676 1822 123 1.653 1786 124 1.630 1750 125 1.607 1715 126 1.585 1680 127 1.562 1647 128 1.538 1614 129 1.517 1582 130 1.496 1550 131 1.474 1519 132 1.453 1489 133 1.431 1459 134 1.408 1430 135 1.389 1401 136 1.369 1373 137 1.348 1345 138 1.327 1318 139 1.308 1291 140 1.291 1265 141 1.289 1240 142 1.269 1214 143 1.250 1190 144 1.230 1165 145 1.211 1141 146 1.192 1118 147 1.173 1095 148 1.155 1072 149 1.136 1050 150 1.118 1029 151 1.100 1007 152 1.082 986 153 1.064 965 154 1.047 945 155 1.029 925 156 1.012 906 157 0.995 887 158 0.978 868 159 0.962 850 160 0.945 832 161 0.929 815 162 0.914 798 163 0.898 782 164 0.883 765 165 0.868 750 166 0.853 734

TEMPERATURE VOLTAGE RESISTANCE

(F) DROP (V) (OHMS)

167 0.838 719 168 0.824 705 169 0.810 690 170 0.797 677 171 0.783 663 172 0.770 650 173 0.758 638 174 0.745 626 175 0.734 614 176 0.722 602 177 0.710 591 178 0.700 581 179 0.689 570 180 0.678 561 181 0.668 551 182 0.659 542 183 0.649 533 184 0.640 524 185 0.632 516 186 0.623 508 187 0.615 501 188 0.607 494 189 0.600 487 190 0.592 480 191 0.585 473 192 0.579 467 193 0.572 461 194 0.566 456 195 0.560 450 196 0.554 445 197 0.548 439 198 0.542 434 199 0.537 429 200 0.531 424 201 0.526 419 202 0.520 415 203 0.515 410 204 0.510 405 205 0.505 401 206 0.499 396 207 0.494 391 208 0.488 386 209 0.483 382 210 0.477 377 211 0.471 372 212 0.465 367 213 0.459 361 214 0.453 356 215 0.446 350 216 0.439 344 217 0.432 338 218 0.425 332 219 0.417 325 220 0.409 318 221 0.401 311 222 0.393 304 223 0.384 297 224 0.375 289 225 0.366 282

Table 9B — Thermistor Temperature (C) vs Resistance/Voltage Drop

TEMPERATURE VOLTAGE RESISTANCE

−40 4.896 168 230

−39 4.889 157 440

−38 4.882 147 410

−37 4.874 138 090

−36 4.866 129 410

−35 4.857 121 330

−34 4.848 113 810

−33 4.838 106 880

−32 4.828 100 260

−31 4.817 94 165

−30 4.806 88 480

−29 4.794 83 170

−28 4.782 78 125

−27 4.769 73 580

−26 4.755 69 250

−25 4.740 65 205

−24 4.725 61 420

−23 4.710 57 875

−22 4.693 54 555

−21 4.676 51 450

−20 4.657 48 536

−19 4.639 45 807

−18 4.619 43 247

−17 4.598 40 845

−16 4.577 38 592

−15 4.554 38 476

−14 4.531 34 489

−13 4.507 32 621

−12 4.482 30 866

−11 4.456 29 216

−10 4.428 27 633

−9 4.400 26 202

−8 4.371 24 827

−7 4.341 23 532

−6 4.310 22 313

−5 4.278 21 163

−4 4.245 20 079

−3 4.211 19 058

−2 4.176 18 094

−1 4.140 17 184 0 4.103 16 325 1 4.065 15 515 2 4.026 14 749 3 3.986 14 026 4 3.945 13 342 5 3.903 12 696 6 3.860 12 085 7 3.816 11 506 8 3.771 10 959 9 3.726 10 441

10 3.680 9 949

11 3.633 9 485 12 3.585 9 044 13 3.537 8 627 14 3.487 8 231 15 3.438 7 855 16 3.387 7 499 17 3.337 7 161 18 3.285 6 840 19 3.234 6 536 20 3.181 6 246 21 3.129 5 971 22 3.076 5 710 23 3.023 5 461 24 2.970 5 225 25 2.917 5 000 26 2.864 4 786 27 2.810 4 583 28 2.757 4 389 29 2.704 4 204 30 2.651 4 028 31 2.598 3 861 32 2.545 3 701 33 2.493 3 549 34 2.441 3 404 35 2.389 3 266 36 2.337 3 134 37 2.286 3 008 38 2.236 2 888 39 2.186 2 773 40 2.137 2 663 41 2.087 2 559 42 2.039 2 459 43 1.991 2 363

TEMPERATURE VOLTAGE RESISTANCE

44 1.944 2 272 45 1.898 2 184 46 1.852 2 101 47 1.807 2 021 48 1.763 1 944 49 1.719 1 871 50 1.677 1 801 51 1.635 1 734 52 1.594 1 670 53 1.553 1 609 54 1.513 1 550 55 1.474 1 493 56 1.436 1 439 57 1.399 1 387 58 1.363 1 337 59 1.327 1 290 60 1.291 1 244 61 1.258 1 200 62 1.225 1 158 63 1.192 1 118 64 1.160 1 079 65 1.129 1 041 66 1.099 1 006 67 1.069 971 68 1.040 938 69 1.012 906 70 0.984 876 71 0.949 836 72 0.920 805 73 0.892 775 74 0.865 747 75 0.838 719 76 0.813 693 77 0.789 669 78 0.765 645 79 0.743 623 80 0.722 602 81 0.702 583 82 0.683 564 83 0.665 547 84 0.648 531 85 0.632 516 86 0.617 502 87 0.603 489 88 0.590 477 89 0.577 466 90 0.566 456 91 0.555 446 92 0.545 436 93 0.535 427 94 0.525 419 95 0.515 410 96 0.506 402 97 0.496 393 98 0.486 385

99 0.476 376 100 0.466 367 101 0.454 357 102 0.442 346 103 0.429 335 104 0.416 324 105 0.401 312 106 0.386 299 107 0.370 285

Control Modules

Turn controller power offbefore servicing controls. This ensures safety and prevents damage to controller.

The Processor module (PSIO), 8-input (Options) modules, Starter Management Module (SMM), and the Local Interface Device (LID) module perform continuous diagnostic evaluations of the hardware to determine its condition. Proper operation of all modules is indicated by LEDs (lightemitting diodes) located on the side of the LID, and on the top horizontal surface of the PSIO, SMM, and 8-input modules.

RED LED — If the LED is blinking continuously at a 2-second rate, it is indicating proper operation. If it is lit continuously it indicates a problem requiring replacement of the module. Offcontinuously indicates that the power should be checked. If the red LED blinks 3 times per second, a software error has been discovered and the module must be replaced. If there is no input power, check fuses and the circuit breaker. If fuse is good, check for shorted secondary of transformer, or if power is present to the module, replace the module.

GREEN LEDs — There are 1 or 2 green LEDs on each type of module. These LEDs indicate communication status between different parts of the controller and the network modules as follows:

LID Module Upper LED — Communication with CCN network, if present;

blinks when communication occurs. Lower LED — Communication with PSIO module; must blink

every 5 to 8 seconds when the LID default screen is displayed.

PSIO Module GreenLED Closest to Communications Connection — Com-

munication with SMM and 8-input module; must blink continuously.

Other Green LED — Communication with LID; must blink every 3 to 5 seconds.

8-Input Modules and SMM GreenLED — Communication with PSIO module; will blink

continuously.

Notes on Module Operation

1. The machine operator monitors and modiﬁes conﬁgura-

tions in the microprocessor through the 4 softkeys and the LID. Communication with the LID and the PSIO is accomplished through the CCN bus. The communication between the PSIO, SMM, and both 8-input modules is accomplished through the sensor bus, which is a 3-wire cable.

On sensor bus terminal strips, Terminal 1 of PSIO module is connected to Terminal 1 of each of the other modules. Terminals 2 and 3 are connected in the same manner. See Fig. 49-53. If a Terminal 2 wire is connected to Terminal 1, the system does not work.

2. If a green LED is solid on, check communication wiring.

If a green LED is off, check the red LED operation. If the red LED is normal, check the module address switches (Fig. 49-53). Proper addresses are:

MODULE

ADDRESS

SW1 SW2

SMM (Starter Management Module) 32

8-input Options Module 1 64 8-input Options Module 2 72

If all modules indicate communications failure, check communications plug on the PSIO module for proper seating. Also check the wiring (CCN bus — 1:red, 2:wht, 3:blk; Sensor bus — 1:red, 2:blk, 3:clr/wht). If a good connection is assured and the condition persists, replace the PSIO module.

If only one 8-input module or SMM indicates communication failure, check the communications plug on that module. If a good connection is assured and the condition persists, replace the module.

All system operating intelligence rests in the PSIO module. Some safety shutdown logic resides in the SMM in case communications are lost between the 2 modules. The PSIO monitors conditions using input ports on the PSIO, the SMM, and the 8-input modules. Outputs are controlled by the PSIO and SMM as well.

3. Power is supplied to modules within the control panel via 21-vac power sources.

The transformers are located within the power panel, with the exception of the SMM, which operates from a 24-vac power source and has its own 24-vac transformer located within the starter.

Within the power panel, T1 supplies power to the LID, the PSIO, and the 5-vac power supply for the transducers. The other 21-vac transformer is T4, which supplies power to both 8-input modules (if present). T4 is capable of supplying power to two modules; if additional modules are added, another power supply will be required.

Power is connected to Terminals 1 and 2 of the power input connection on each module.

Processor Module (PSIO) (Fig. 51)

INPUTS — Each input channel has 3 terminals; only 2 of the terminals are used. Application of machine determines which terminals are normally used. Always refer to individual unit wiring for terminal numbers.

OUTPUTS — Output is 20 vdc. There are 3 terminals per output, only 2 of which are used, depending on the application. Refer to the unit wiring diagram.

Fig. 49 — PSIO Module LED Locations

Starter Management Module (SMM) (Fig. 52)

INPUTS — Inputs on strips J2 and J3 are a mix of analog and discrete (on/off) inputs. Application of the machine determines which terminals are used. Always refer to the individual unit wiring diagram for terminal numbers.

OUTPUTS — Outputs are 24 vdc and wired to strip J1. There are 2 terminals used per output.

Options Modules (8-Input) — The options modules

are optional additions to the PIC, and are used to add temperature reset inputs, spare sensor inputs, and demand limit

inputs. Each option module contains 8 inputs, each input meant for a speciﬁc duty. See the wiring diagram for exact module wire terminations. Inputs for each of the options modules available include the following:

OPTIONS MODULE 1

4 to 20 mA Auto. Demand Reset 4 to 20 mA Auto. Chilled Water Reset Common Chilled Water Supply Temperature Common Chilled Water Return Temperature Remote Temperature Reset Sensor Spare Temperature 1 Spare Temperature 2 Spare Temperature 3

OPTIONS MODULE 2 4 to 20 mA Spare 1

4 to 20 mA Spare 2 Spare Temperature 4 Spare Temperature 5 Spare Temperature 6 Spare Temperature 7 Spare Temperature 8 Spare Temperature 9

Terminal block connections are provided on the options modules. All sensor inputs are ﬁeld wired and installed. Options module 1 can be factory or ﬁeld-installed. Options module 2 is shipped separately and must be ﬁeld installed. For installation, refer to the unit or ﬁeld wiring diagrams. Be sure to address the module for the proper module number (Fig. 53) and to conﬁgure the chiller for each feature being used.

Replacing Defective Processor Modules — The

replacement part number is printed in a small label on front of the PSIO module.The model and serial numbers are printed on the unit nameplate. The proper software is factoryinstalled by Carrier in the replacement module. When ordering a replacement processor module (PSIO), specify complete replacement part number, full unit model number, and serial number. This new unit requires reconﬁguration to the original machine data by the installer. Follow the procedures described in the Set Up Machine Control Conﬁguration section on page 55.

NOTE: Address switches on this module can be at any position. Addresses are only changed through the LID screen or CCN.

Fig. 50 — LID Module (Rear View) and

LED Locations

NOTE: Address switches on this module can be at any position. Addresses can only be changed through the LID or CCN.

Fig. 51 — Processor (PSIO) Module

NOTE: SMM address switches should be set as follows: S1 set at 3; S2 set at 2.

Fig. 52 — Starter Management Module (SMM)

Electrical shock can cause personal injury. Disconnect all electrical power before servicing.

INSTALLATION OF NEW PSIO MODULE

1. Verify if the existing PSIO module is defective, by using the procedure described in the Notes on Module Operation section, page 95, and Control Modules section, page 95. Do not select the Attach to Network Device table if the LID displays communication failure.

2. Data regarding the PSIO conﬁguration should have been recorded and saved. This data will have to be reconﬁgured into the LID. If this data is not available, follow the procedures described in the Set Up Machine Control Conﬁguration section. Record the TOTAL COMPRESSOR STARTS and the COMPRESSOR ONTIME from the STATUS01 table on the LID.

If a CCN Building Supervisor or Service Tool is present, the module conﬁguration should have already been uploaded into memory; then, when the new module is installed, the conﬁguration can be downloaded from the computer (if the software version is the same).

Any communication wires from other machines or CCN modules must be disconnected.

3. Check that all power to the unit is off. Carefully disconnect all wires from the defective module by unplugging the 6 connectors. It is not necessary to remove any of the individual wires from the connectors.

4. Remove defective PSIO by removing its mounting screw with a long-shaft Phillips screwdriver, and removing the module from the control box. Save the screw for later use. The green ground wire is held in place with the module mounting screw.

5. Package the defective module in the carton of the new module for return to Carrier.

6. Restore control system power (LID will show ‘‘COMMUNICATION FAILURE’’ at bottom of screen).

7. Access the SERVICE menu. Highlight and select ‘‘ATTACH TO NETWORK DEVICE.’’ Push the ‘‘ATTACH’’ softkey. (The LID will show ‘‘UPLOADING TABLES. PLEASE WAIT,’’ then show ‘‘COMMUNICATION FAILURE.’’) Press the EXIT softkey.

8. Turn off control power.

9. Mount the new module in the unit control box using a long-shaft Phillips screwdriver and the screw saved in Step 4 above. Make sure that the green grounding wire is reinstalled along with the mounting screw.

10. Connect the LID communication wires (CCN bus) and the power wires. If CCN wiring has been attached to the CCN bus, disconnect the wires. Attach the sensor bus plug and the input and output plugs.

11. Carefully check all wiring connections before restoring power.

12. Restore control power and verify that the red and green LEDs on the PSIO are functioning properly.

13. The LID should indicate ‘ ‘AVAILABLE MEMORY’ ’and a value. This value should start to decrease. (If not, check LID wiring to PSIO, ensure connection to the proper plug.) The bottom of the screen will indicate ‘‘UPLOADING TABLES, PLEASE WAIT.’’

14. After the PSIO tables have been uploaded into the LID, access the STATUS01 screen. Move the highlight bar to the ‘‘TOTAL COMPRESSOR STARTS’’ value. Select this value and increase the value until it is the same as the value from the old module. Press ENTER to save this value.

15. Move the highlight bar to the ‘‘COMPRESSOR ONTIME’’value. Select this point and increase the value until it matches the old module run hours. Press SELECT to save this value.

16. Change the address of the PSIO in the Controller Identiﬁcation table back to the previous value. Write the address on the PSIO.

17. Use the conﬁguration sheets to input setpoint, conﬁguration, and schedule information into the PSIO. The Time and Date table also must be set. A Building Supervisor can be used to download, the old conﬁguration into the PSIO.

18. Perform a Control Test and verify all tests. If the software version has been updated, a CCN down-

load of the conﬁguration will not be allowed. Conﬁgure the PSIO by hand, and upload the PSIO into the network by using the Attach to Network Device table.

19. Restore chiller to normal operation, calibrate motor amps.

17/19EX PHYSICAL DATA AND WIRING

SCHEMATICS

Tables 10-18 and Fig. 54-62 provide additional information regarding compressor ﬁts and clearances, physical and electrical data, and wiring schematics for operator convenience during troubleshooting.

SWITCH SETTING OPTIONS MODULE 1 OPTIONS MODULE 2

S1 67 S2 42

Fig. 53 — Options Module

Table 10 — 17/19EX Heat Exchanger, Economizer/Storage Vessel, Piping, and Pumpout Unit Weights*

COOLER

SIZE†

COOLER

TOTAL

WEIGHT

COOLER

CHARGE

ECONOMIZER/

STORAGE

VESSEL**

ECONOMIZER

REFRIGERANT

MISCELLANEOUS

PIPING

PUMPOUT

UNIT

Dry Operating†† Refrigerant Water

lb kg lb kg lb kg lb kg

lb kg lb kg lb kg lb gal kg L

31 14,173 6 429 17,518 7 946 1,540 699 1,810 217 821 821

7,169 3252 610 277 820 372

210 95

32 14,538 6 594 18,117 8 218 1,640 744 1,944 233 882 882 33 14,904 6 760 18,722 8 492 1,740 789 2,078 249 943 943 41 21,674 9 831 26,120 11 848 1,900 862 2,441 293 1 107 1 107

7,169 3 252 610 277 1,095 497

42 22,019 9 988 26,736 12 127 2,000 907 2,575 309 1 168 1 168 43 22,364 10 144 27,322 12 393 2,100 953 2,709 325 1 229 1 229 44 23,841 10 814 29,836 13 533 2,190 993 3,285 394 1 490 1 490 45 25,032 11 354 30,790 13 966 2,260 1 025 3,006 361 1 363 1 363

7,900 3 583 840 381 1,149 521

46 25,529 11 580 31,658 14 360 2,360 1 070 3,192 383 1 448 1 448 47 26,025 11 805 32,496 14 740 2,460 1 116 3,378 405 1 532 1 532 48 28,153 12 770 36,053 16 353 2,540 1 152 4,173 500 1 893 1 893

CONDENSER

SIZE†

CONDENSER TOTAL WEIGHT CONDENSER CHARGE

Dry Operating†† Refrigerant Water

lb kg lb kg lb kg lb gal kg L

31 10,454 4 742 13,022 5 907 950 431 1,613 193 732 732 32 10,809 4 903 13,514 6 130 950 431 1,750 210 794 794 33 11,164 5 064 14,000 6 350 950 431 1,886 226 855 855 41 13,768 6245 16,999 7 711 1,090 494 2,146 257 973 973 42 14,118 6404 17,498 7 937 1,090 494 2,282 274 1 035 1 035 43 14,468 6563 17,978 8 155 1,090 494 2,419 290 1 097 1 097 45 16,676 7564 20,800 9 435 1,400 635 2,720 326 1 234 1 234 46 17,172 7789 21,489 9 747 1,400 635 2,908 348 1 319 1 319 47 17,669 8015 22,178 10 060 1,400 635 3,096 371 1 404 1 404 51 17,188 7796 20,993 9 522 1,100 499 2,707 325 1 228 1 228 52 17,848 8096 21,923 9 944 1,100 499 2,964 355 1 344 1 344 53 18,400 8346 22,682 10 288 1,100 499 3,178 381 1 442 1 442 55 20,725 9401 25,598 11 611 1,420 644 3,453 412 1 566 1 566 56 21,663 9826 26,896 12 199 1,420 644 3,808 457 1 727 1 727 57 22,446 10 181 27,980 12 691 1,420 644 4,105 492 1 862 1 862

*If a machine conﬁguration other than 2-pass, 150 psig (1034 kPa), NIH water-

box conﬁguration is used, refer to Tables11 and 13 to obtain the additional dry and water weights that must be added to the values shown in this table.

†Cooler and condenser weights shown are basedupon 2-pass, nozzle-in-head

(NIH) waterboxes with 150 psig (1034 kPa) covers. Includes components attached to cooler, but does not include suction/discharge, elbow, or other interconnecting piping.

**Dry weight includes all components attached to economizer: Covers, ﬂoat

valves, brackets, control center (31 lb [14 kg]), and power panel (20 lb [9 kg]). Dry weight does not include compressor weight, motor weight, or pumpout condensing unit weight. The pumpout condensing unit weight is 210 lb (95 kg). For compressor and motor weights, refer to Table 12.

††Operating weight is the sum of the dry weight, refrigerant weight, and water

weight.

Fig. 54 — Model Number Nomenclature for Compressor Size (See Fig. 1 Also)

Table 11 — Additional Condenser Weights*

COMPONENT

HEAT EXCHANGER

SIZE

WATERBOX TYPE

NUMBER OF

PASSES

DESIGN MAXIMUM

WATER PRESSURE

ADDITIONAL DRY WEIGHT

ADDITIONAL

WATER WEIGHT

psig kPa lb kg lb gal kg L

CONDENSER

31-33

NIH 3 150 1034 262 119 — — — — NIH 3 300 2068 1328 602 — — — —

NIH 2 300 2068 872 396 — — — — Marine 3 150 1034 842 382 2 276 273 1 032 1 032 Marine 2 150 1034 421 191 1 138 136 516 516 Marine 3 300 2068 1520 689 2 276 273 1 032 1 032 Marine 2 300 2068 1099 498 1 138 136 516 516

41-43 45-47

NIH 1, 3 150 1034 344 156 — − — —

NIH 1, 3 300 2068 1652 749 — − — —

NIH 2 300 2068 1132 513 — − — — Marine 1, 3 150 1034 1692 767 3 400 408 1 542 1 542 Marine 2 150 1034 674 306 1 700 204 771 771 Marine 1, 3 300 2068 2651 1 202 3 400 408 1 542 1 542 Marine 2 300 2068 1630 739 1 700 204 771 771

51-53 55-57

NIH 1 150 1034 † † — — — —

NIH 1 300 2068 1588 720 — — — —

NIH 2 300 2068 1591 721 — — — — Marine 2 150 1034 25 11 1 734 208 787 787 Marine 2 300 2068 1225 555 1 734 208 787 787

NIH — Nozzle-In-Head *When using a machine conﬁguration other than 2-pass, NIH water-

boxes with 150 psig (1034 kPa) covers, add the weights listed in this table to the appropriate weights inTable10to obtainthe correct condenser weight.

†Subtract 228 lb (103 kg) from the weight shown in Table 10.

Table 12 — Compressor/Motor/Suction Elbow Weights

(English)

COMPRESSOR/ MOTOR/

SUCTION ELBOW

WEIGHT

(lb)

17 Series, All Compressor Sizes* 14,650 19 Series, 51-89 Compressor Sizes† 8,853 19 Series, 421-469 Compressor Sizes** 6,352 19 Series, 531-599 Compressor Sizes†† 9,950

*Based on 4160 v, FD motor.

†Based on 6900 v, DQ motor.

**Based on 6900 v, DP motor.

††Based on 6900 v, EE motor.

(SI)

COMPRESSOR/ MOTOR/

SUCTION ELBOW

WEIGHT

(kg)

17 Series, All Compressor Sizes* 6 645 19 Series, 51-89 Compressor Sizes† 4 081 19 Series, 421-469 Compressor Sizes** 2 927 19 Series, 531-599 Compressor Sizes†† 4 638

*Based on 3300 v, FD motor.

†Based on 6300 v, DQ motor.

**Based on 6300 v, DP motor.

††Based on 6300 v, EE motor.

Table 13 — Additional Cooler Weights*

COOLER

FRAME

WATERBOX

TYPE

NUMBER

OF PASSES

DESIGN MAXIMUM

WATER PRESSURE

ADDITIONAL DRY WEIGHT

ADDITIONAL

WATER WEIGHT

psig kPa lb kg lb gal kg L

NIH 1, 3 150 1034 655 297 — — — — NIH 1, 3 300 2068 2226 1010 — — — —

NIH 2 300 2068 1406 638 — — — — Marine 1, 3 150 1034 780 354 3192 383 1448 1 448 Marine 2 150 1034 390 177 1596 191 724 724 Marine 1, 3 300 2068 3412 1548 3192 383 1448 1 448 Marine 2 300 2068 1706 774 1596 191 724 724

NIH 1, 3 150 1034 515 234 — — — —

NIH 1, 3 300 2068 2941 1334 — — — —

NIH 2 300 2068 2085 946 — — — — Marine 1, 3 150 1034 2100 953 5102 612 2314 2 314 Marine 2 150 1034 792 359 2551 306 1157 1 157 Marine 1, 3 300 2068 3844 1744 5102 612 2314 2 314 Marine 2 300 2068 2536 1150 2551 306 1157 1 157

NIH — Nozzle-In-Head

*When using a machine conﬁguration other than 2-pass, NIH water-

boxes with 150 psig (1038 kPa) covers, add the weights listed in this tableto theappropriate weightsin Table10to obtainthe correct cooler weight.

Table 14 — Marine Waterbox Cover Weights*

HEAT EXCHANGER

SIZE

DESIGN MAXIMUM WATER PRESSURE COOLER CONDENSER

psi kPa lb kg lb kg

31-33

150 1034 1667 756 1092 495 300 2068 2280 1034 1436 651

41-48

150 1034 2236 1015 1275 579 300 2068 3060 1389 1660 754

51-57

150 1034 — — 1643 746 300 2068 — — 2243 1018

*Heat exchangers with marine waterboxes have heavier dry and operating weights than heat exchangers with nozzle-

in-head waterboxes.

100

Carrier 17, 17EX Series, 19EX Series Start Up & Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual