Carrier 17/19EX Start-Up, Operation And Maintenance Instructions Manual Download

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17/19EX

50/60 Hz

Centrifugal Liquid Chillers

with HFC-134a

Start-Up, Operation, and Maintenance Instructions

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

PC 211 Catalog No. 531-715

9-95

Form 17/19EX-1SS

Replaces: 19EX-1SS

Safety Considerations

Centrifugal liquid chillers are designed to provide safe and reliable service when

operated within design specifications. When operating this equipment, use good

judgement and safety precautions to avoid damage to equipment and property or injury

to personnel.

Be sure you understand and follow the procedures and safety precautions contained

in the machine instructions as well as those listed in this guide.

Summary of Contents for 17/19EX

Page 1: ... 19EX 1SS Replaces 19EX 1SS Copyright Carrier Corporation 1995 Safety Considerations Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design specifications When operating this equipment use good judgement and safety precautions to avoid damage to equipment and property or injury to personnel Be sure you understand and follow the procedures and safe...

Page 2: ...death Misuse can be fatal Vapor is heavier than air and reduces the amount of oxygen avail able for breathing Product causes eye and skin irritation Decomposition prod ucts 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 p...

Page 3: ...WER IS OFF and no residual volt age can leak from capacitors or solid state components LOCK OPEN AND TAG electrical circuits during servicing IF WORK IS INTER RUPTED 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 IMMEDIATE...

Page 4: ...er pres sure 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 corro sion or build up of f...

Page 5: ... 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 t...

Page 6: ...N 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 ...

Page 7: ...s List of Figures Safety Considerations Introduction Abbreviations 17 19EX Machine Familiarization Machine Identification Label System Components Cooler Condenser Motor Compressor Control Center Motor Starter Utility Vessel ...

Page 8: ...r Oil Refrigeration Cooling Cycle Hermetic Machines 19 Series Lubrication Cycle Summary Details Open Drive Machines 17 Series Lubrication Cycle Summary Details Starters Controls Definitions Analog Signal Digital Signal Volatile Memory ...

Page 9: ...t Module SMM Local Interface Device LID 6 Pack Relay Board 8 Input Modules Oil Heater Contactor 1C Oil Pump Contactor 2C Hot Gas Bypass Contactor Relay 3C Optional Control Transformers T1 T4 Control and Oil Heater Voltage Selector S1 Oil Differential Pressure Power Supply Module ...

Page 10: ...een Menu Items Menu Structure To View or Change Point Status Override Operations To View or Change Time Schedule Operation To View and Change Set Points Service Operation PIC System Functions Capacity Control Entering Chilled Water Control Deadband Proportional Bands and Gain ...

Page 11: ...lt Screen Freeze Motor Cooling Control Hermetic Motors Only Auxiliary Oil Pump Control Open Drive Machines Only Shaft Seal Oil Open Drive Machines Only Ramp Loading Control Capacity Override High Discharge Temperature Control Oil Sump Temperature Control Oil Cooler Remote Start Stop Controls ...

Page 12: ...ion Tower Fan Relay Auto Restart After Power Failure Water Brine Reset Demand Limit Control Option Requires Optional 8 Input Module Surge Prevention Algorithm Surge Protection Lead Lag Control Common Point Sensor Installation Machine Communication Wiring Lead Lag Operation Faulted Chiller Operation ...

Page 13: ...trol Ice Build Initiation Start Up Recycle Operation Temperature Control During Ice Build Termination of Ice Build Return to Non Ice Build Operations Attach to Network Device Control Attaching to Other CCN Modules Service Operation To Log On To Log Off Holiday Scheduling ...

Page 14: ... Stop Amps Threshold Chilled Water Recycle Mode Safety Shutdown Before Initial Start Up Job Data Required Equipment Required Using the Utility Vessel and Pumpout System Remove Shipping Packaging Open Drive Motor Electrical Connection Open Drive Motor Auxiliary Devices Open Oil Circuit Valves ...

Page 15: ...tanding Vacuum Test Machine Dehydration Inspect Water Piping Check Optional Pumpout Compressor Water Piping Check Relief Devices Inspect Wiring Check Insulation Resistance Hermetic Motor Check Insulation Resistance Open Drive Motor Open Drive Motor Pre Start Checks Carrier Comfort Network Interface ...

Page 16: ...Heater Software Version Set Up Machine Control Configuration Input the Design Set Points Input the Local Occupied Schedule OCCPC01S Input Service Configurations Password Input Time and Date Change LID Configuration If Necessary Modify Controller Identification If Necessary Input Equipment Service Parameters If Necessary ...

Page 17: ... and Optional Pumpout Compressor High Altitude Locations Charge Refrigerant into Machine Trimming Refrigerant Charge Initial Start Up Preparation Manual Operation of the Guide Vanes Dry Run to Test Start Up Sequence Check Rotation Open Drive Motor Check Rotation Hermetic Motor If Rotation Is Proper If the Motor Rotation Is Not Clockwise ...

Page 18: ...t Up Hot Alignment Check for Open Drive Machines Doweling for Open Drive Machines Check Machine Operating Condition Instruct the Customer Operator Cooler Condenser Utility Vessel Pumpout System Motor Compressor Assembly Motor Compressor Lubrication System Control System Auxiliary Equipment Describe Machine Cycles ...

Page 19: ...Operation and Maintenance Manual Operating Instructions Operator Duties Prepare the Machine for Start Up To Start the Machine Check the Running System To Stop the Machine After Limited Shutdown Extended Shutdown After Extended Shutdown Cold Weather Operation Manual Guide Vane Operation Refrigeration Log ...

Page 20: ... Refrigerant from Normal Operation into the Utility Vessel Transferring Refrigerant from Normal Operation into the Cooler Condenser Compressor Section Return Refrigerant to Normal Operating Conditions General Maintenance Refrigerant Properties Adding Refrigerant Removing Refrigerant Adjusting the Refrigerant Charge Refrigerant Leak Testing Leak Rate ...

Page 21: ...epair the Leak Retest and Apply Standing Vacuum Test Checking Guide Vane Linkage Contact Seal Maintenance Open Drive Machines Seal Disassembly Seal Reassembly Machine Alignment Open Drive Machines Alignment Methods Preliminary Alignment Near Final Alignment Final Alignment Hot Alignment Check Doweling ...

Page 22: ...tem Scheduled Maintenance Service Ontime Inspect the Control Center Check Safety and Operating Controls Monthly Changing Oil Filter 19EX Compressors FA Style Compressors Oil Specification Oil Changes To Change the Oil Refrigerant Filter Oil Reclaim Filter ...

Page 23: ... Maintenance Open Drive Machines Procedure Motor Maintenance Open Drive Machines Cleanliness Sleeve Bearings Open Drive Motor Handling Rigging Open Drive Motor Storage Compressor Bearing and Gear Maintenance Inspect the Heat Exchanger Tubes Cooler Condenser Water Leaks Water Treatment ...

Page 24: ...onal Pumpout Compressor Oil Charge Pumpout Safety Control Settings Ordering Replacement Chiller Parts Open Drive Motor Renewal Parts Troubleshooting Guide Overview Checking the Display Messages Checking Temperature Sensors Resistance Check Voltage Drop Check Sensor Accuracy Dual Temperature Sensors ...

Page 25: ...erential Pressure Power Supply Module Calibration Troubleshooting Transducers Transducer Replacement Control Algorithms Checkout Procedure Control Test Control Modules Red LED Green LEDs Notes on Module Operation Processor Module PSIO Inputs Outputs ...

Page 26: ...ts Outputs Options Modules 8 Input Replacing Defective Processor Modules Installation of New PSIO Module 17 19EX Physical Data and Wiring Schematics Compressor Fits and Clearances Initial Start Up Checklist for 17 19EX Centrifugal Liquid Chiller ...

Page 27: ...4 Setpoint Display Screen Example 5 Configuration Config Display Screen Example 6 Lead Lag Configuration Display Screen Example 7 Service1 Display Screen Example 8 Service2 Display Screen Example 9 Service3 Display Screen Example 10 Maintenance Maint01 Display Screen Example 11 Maintenance Maint02 Display Screen Example 12 Maintenance Maint03 Display Screen Example 13 Maintenance Maint04 Display S...

Page 28: ...ture C Table 6 Recommended Torque Table 7 Control Test Menu Functions Table 8 LID Primary and Secondary Messages and Custom Alarm Alert Messages with Troubleshooting Guides A Shutdown with ON OFF RESET OFF B Timing Out or Timed Out C In Recycle Shutdown D Pre Start Alerts E Normal or AUTO RESTART F Start Up Failures G Compressor Jumpstart and Refrigerant Protection ...

Page 29: ... Machine Protect Limit Faults L Machine Alerts M Spare Sensor Alert Messages N Other Problems Malfunctions Table 9A Thermistor Temperature F vs Resistance Voltage Drop Table 9B Thermistor Temperature C vs Resistance Voltage Drop Table 10 17 19EX Heat Exchanger Economizer Storage Vessel Piping and Pumpout Unit Weights Table 11 Additional Condenser Weights Table 12 Compressor Motor Suction Elbow Wei...

Page 30: ...le 14 Marine Waterbox Cover Weights Table 15 NIH Waterbox Cover Weights Table 16 Auxiliary Systems Electrical Data Table 17 Open Drive Compressor Fits and Clearances Table 18 Hermetic Compressor Fits and Clearances ...

Page 31: ... Compressor Lubrication System EX Compres sor Shown Figure 6 Open Drive 17 Series Lubrication Cycle Figure 7 17EX Controls and Sensor Locations Figure 8 19EX Controls and Sensor Locations Figure 9 Control Center Front View Shown with Options Module Figure 10 Control Sensors Temperature Figure 11 Control Sensors Pressure Transducer Typical Figure 12 Power Panel without Options Open Drive Machine Sh...

Page 32: ...re 18 Example of Point Status Screen Status01 Figure 19 Example of Time Schedule Operation Screen Figure 20 Example of Set Point Screen Figure 21 17 19EX Hot Gas Bypass Surge Prevention Figure 22 17 19EX with Default Metric Settings Figure 23 Example of Attach to Network Device Screen Figure 24 Example of Holiday Period Screen Figure 25 Control Sequence Figure 26 Typical Wet Bulb Type Vacuum Indic...

Page 33: ...ment and Valve Number Locations 12 ft Vessel Shown Figure 33 Pumpout Unit Wiring Schematic 19EX Shown Figure 34 Optional Pumpout Compressor Figure 35 Electronic Vane Actuator Linkage Figure 36 Compressor Contact Seal Open Drive Machines Figure 37 Checking Preliminary Alignment Figure 38 Measuring Angular Misalignment in Elevation Figure 39 Measuring Angular Misalignment on Brackets Figure 40 Align...

Page 34: ... Arrangement Figure 46 Lifting Open Drive Motor Figure 47 Controls for Optional Pumpout Compressor Figure 48 Oil Differential Pressure Power Supply Module Figure 49 PSIO Module LED Locations Figure 50 LID Module Rear View and LED Locations Figure 51 Processor PSIO Module Figure 52 Starter Management Module SMM Figure 53 Options Module Figure 54 Model Number Nomenclature for Compressor Size See Fig...

Page 35: ...ls Wiring Schematic Hermetic Machine Figure 58 Electronic PIC Controls Wiring Schematic Open Drive Machine Figure 59 Machine Power Panel Starter Assembly and Motor Wiring Schematic Figure 60 Hermetic Drive Power Panel with Water Cooled Oil Cooler Figure 61 Hermetic Drive Power Panel with Motor Cooling Solenoid Figure 62 Open Drive Power Panel ...

Page 36: ... 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 con trol center Use e...

Page 37: ... 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 residen tial 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 rep...

Page 38: ... Return LID Local Interface Device CHWS Chilled Water Supply OLTA Overload Trip Amps CW Clockwise PIC Product Integrated Control ECW Entering Chilled Water PSIO Processor Sensor Input Output Module ECDW Entering Condenser Water RLA Rated Load Amps EMS Energy Management System SCR Silicon Control Rectifier HGBP Hot Gas Bypass SMM Starter Management Module I O Input Output TXV Thermostatic Expansion...

Page 39: ...onents 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 Click here for Figure 1 17 19EX Identification Click here for Figure...

Page 40: ...maintains system temperature pressure differences and moves the heat carrying refrigerant from the cooler to the condenser Control Center The control center is the user interface 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 ...

Page 41: ...ontinuously 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 bri...

Page 42: ...cooled 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 s...

Page 43: ...r 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 coolin...

Page 44: ...g valve to maintain an operating temperature at the reservoir of approximately 145 F 63 C 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 motor end bearings and seal The remain...

Page 45: ...pump discharges oil to the oil cooler Item 12 Oil is then piped to the oil filter assembly Item 9 This 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 for details The oil is then piped to the oil cooler Item 12 The oil cooler on the EX compressor is a plate and frame type refrigera...

Page 46: ... difference prevents oil in the trans mission 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 temperature...

Page 47: ... 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...

Page 48: ...back to the main reservoir as the oil accumulates Details See Figure 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 charging elbow Item 20 on the seal oil return chamber allows oil to be added without pumping The seal oil return p...

Page 49: ...rom 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 leaking into the seal The open compressor drive requires that the shaft seal 18 be kept full of lubrication oil even when t...

Page 50: ...tion 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 Digital Signal A digital discrete signal is a 2 position representation of the va...

Page 51: ... 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 cap...

Page 52: ...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 desire...

Page 53: ...b requirement 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 ...

Page 54: ...cts 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 Local Interface Device LID The LID is mounted...

Page 55: ...er 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...

Page 56: ...ming 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 Control and Oil Heater Voltage 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...

Page 57: ...essure Transducers section Click here for Figure 7 17EX Controls and Sensor Locations Click here for Figure 8 19EX Controls and Sensor Locations Click here for Figure 9 Control Center Front View Shown with Options Module Click here for Figure 10 Control Sensors Temperature Click here for Figure 11 Control Sensors Pressure Transducer Typical Click here for Figure 12 Power Panel Without Options Open...

Page 58: ...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 contro...

Page 59: ... 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...

Page 60: ... 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 Figure 16 and Figure 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 ...

Page 61: ... 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 CCN LOCAL RESET MENU STATUS SCHEDULE SETPOINT SERVICE NEXT PREVIOUS SELECT ENTER ...

Page 62: ... 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 NEXT PREVIOUS SELECT EXIT INCREASE DECREASE QUIT ENTER INCREASE DECREASE QUIT ENTER ...

Page 63: ...ess 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 STATUS SCHEDULE SETPOINT SERVICE NEXT PREVIOUS SELECT ENTER Click here for Figure 16 17 19EX Menu Structure ...

Page 64: ...NEXT or PREVIOUS until desired point is displayed on the screen For Discrete Points Press START or STOP YES or NO ON or OFF etc to select the desired state Click here for Figure 17 17 19EX Service Menu Structure NEXT PREVIOUS SELECT ENTER NEXT PREVIOUS SELECT ENTER START STOP RELEASE ENTER ...

Page 65: ...rride Operations Note When overriding or changing metric values it is necessary to hold the softkey down for a few seconds in order to see a value change especially on kilopascal values INCREASE DECREASE RELEASE ENTER INCREASE DECREASE RELEASE ENTER Click here for Figure 18 Example of Point Status Screen Status01 ...

Page 66: ...r 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 NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT INCREASE DECREASE RELEASE ENTER ...

Page 67: ...r Change Time Schedule Operation Figure 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 STATUS SCHEDULE SETPOINT SERVICE NEXT PREVIOUS SELECT EXIT ...

Page 68: ...me schedule 4 Press NEXT or PREVIOUS to highlight the desired period or override that you wish to change 5 Press SELECT to access the highlighted period or override NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT ...

Page 69: ...ments 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 INCREASE DECREASE ENTER EXIT ENABLE DISABLE ENTER EXIT ENABLE DISABLE ENTER EXIT ...

Page 70: ... save the changes 10 Holiday Designation HOLIDEF table may be found in the Service Operation section 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 NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT Click here for Figure 19 Example of Time Schedule Operation Screen ...

Page 71: ...er 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 STATUS SCHEDULE SETPOINT SERVICE NEXT PREVIOUS SELECT EXIT ...

Page 72: ...the changes and return to the previous screen Service Operation To view the menu driven programs available for Service Operation see Service Operation section For examples of LID display screens see Table 2 NEXT PREVIOUS SELECT EXIT INCREASE DECREASE QUIT ENTER INCREASE DECREASE QUIT ENTER Click here for Figure 20 Example of Set Point Screen ...

Page 73: ...onfiguration CONFIG Display Screen Example 6 Lead Lag Configuration Display Screen Example 7 Service1 Display Screen Example 8 Service2 Display Screen Example 9 Service3 Display Screen Example 10 Maintenance Maint01 Display Screen Example 11 Maintenance Maint02 Display Screen Example 12 Maintenance Maint03 Display Screen Example 13 Maintenance Maint04 Display Screen ...

Page 74: ...e CONTROL 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 determine how fast or slow to respond CONTROL POINT may be viewed overridden on the Status tabl...

Page 75: ... C is the default setting Proportional Bands and 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 Ther...

Page 76: ...ND LIMIT set point by limiting the opening of the guide vanes It will compare the set point to either COMPRESSOR MOTOR LOAD or COMPRESSOR MOTOR CURRENT percentage depending on how the control is configured 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 SERVI...

Page 77: ...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 ...

Page 78: ...ld 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 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 F...

Page 79: ...sure 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 th...

Page 80: ...ned in Table 3 Alarm and alert messages are listed in the Troubleshooting Guide section 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 t...

Page 81: ...ed 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 rela...

Page 82: ...portant to note that if control power is to be turned off for 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 c...

Page 83: ...tor 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 Table 4 These can prevent some safety shutdowns caused by exceeding motor amperage limit refrigerant low temperatu...

Page 84: ...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 High Discharge Temperature Control If the discharge 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...

Page 85: ...rature 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 com...

Page 86: ...ustable Oil sump temperature may be at a lower tempera ture FA Compressors The oil cooler is a water cooled tube in shell 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 Remote Start Stop Controls A remote device such as a timeclock which uses a set of contacts may be used to...

Page 87: ...may be wired to the spare protective limits input channel in place of the factory installed 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 n...

Page 88: ...ssure is less than the pressure override less 5 psi 34 kPa or the CONDENSER REFRIG Refrigerant TEMP is within 3 F 2 C of the ENTERING CONDENSER WATER temperature Condenser Freeze Prevention This control algorithm 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 free...

Page 89: ...n 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 ...

Page 90: ...or 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 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 temper...

Page 91: ...r temperature reset based on a 4 to 20 mA input signal This type permits up to 30 F 16 C of automatic reset to the chilled water or brine temperature set point based on the input from a 4 to 20 mA signal This signal is hardwired into the number one 8 input module If the 4 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 b...

Page 92: ...mperature difference This type of reset will add 30 F 16 C based on the temperature difference between 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 di...

Page 93: ...1 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 d...

Page 94: ...on of the default set points of the MINIMUM and MAXIMUM load points is described in the Input Service Configurations section 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 vane...

Page 95: ... 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...

Page 96: ...is required Note Lead lag configuration is viewed and edited under Lead Lag in the Equipment Configura tion 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 energi...

Page 97: ...hillers 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 re...

Page 98: ...configuration is viewed and edited in Lead Lag under the Equipment Configu ration 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 ...

Page 99: ... 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 sy...

Page 100: ...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 configur...

Page 101: ...rature pulldown rate of the CHILLED WATER temperature is less than 0 5 F 0 27 C per minute 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 th...

Page 102: ...psed The LAG STOP TIMER is started when the CHILLED WATER TEMPERATURE is less than the CHILLED WATER CONTROL POINT plus 1 2 of the WATER BRINE DEADBAND 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 l...

Page 103: ...il 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 OPTION is enabled the lead chiller will set the ACTIVE DE MAND LIMIT in the lag chiller to the lead chiller s COMPRESSOR MOTOR LOAD va...

Page 104: ...rs 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 machine from normal operation set point temperature to a temperature where an ice building operati...

Page 105: ...rom the ENTERING CHILLED WATER BRINE temperature being less than the ICE BUILD SETPOINT opening of the REMOTE CONTACT inputs 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...

Page 106: ... temperature is less than or equal to the ICE BUILD SETPOINT if ICE BUILD TERMINATION is set to the CONTACTS ONLY OPTION and the remote contacts are open if the ICE BUILD TERMINATION is set to the BOTH temperature and contacts option and ENTERING CHILLED WATER temperature is less than or equal to the ICE BUILD SETPOINT and remote contacts are open The ICE BUILD RECYCLE OPTION determines whether or...

Page 107: ...MAND 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 ECW TEMPERATURE Termination of compressor operation based on temperature shall occur if the ICE BUILD TERMINATION is set to the ICE BUILD TER...

Page 108: ...ION is set to BOTH temperature and contacts option and the previously described conditions for ECW 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 le...

Page 109: ...is change is reflected on the bus and address for the LOCAL DEVICE of the ATTACH TO DEVICE screen automatically See Figure 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 ...

Page 110: ...o move back to the ATTACH TO NETWORK DEVICE table If the module number is not valid the COMMUNICATION FAILURE 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 chec...

Page 111: ...erview of the menu driven programs available for Service Operation is shown in Figure 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 Click here for Figure 23 Example of Attach to Network Device Screen ENTER A 4 DIGIT PASSWORD 1 2 3 4 ...

Page 112: ...n 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 NEXT PREVIOUS SELECT EXIT INVALID PASSWORD 1 2 3 4 ...

Page 113: ...defs 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 daylight savings dates throughout the network To view or change ...

Page 114: ...on press NEXT until 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 NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT ...

Page 115: ...h to view or change Each table is one holiday period starting on a specific date and lasting up to 99 days 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 NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT ...

Page 116: ...o 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 NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT INCREASE DECREASE QUIT ENTER ...

Page 117: ...11 Press ENTER to save the changes 12 Press EXIT to return to the previous menu INCREASE DECREASE QUIT ENTER NEXT PREVIOUS SELECT EXIT Click here for Figure 24 Example of Holiday Period Screen ...

Page 118: ... 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...

Page 119: ...essure to reach 18 psid 124 kPad After oil pressure is verified the PIC waits 10 seconds and then the compressor start relay 1CR is energized to start the compressor 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 ...

Page 120: ...or by deactivating the start relay A status message of SHUTDOWN IN PROGRESS COMPRES SOR DEENERGIZED is displayed 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 OVERRI...

Page 121: ...eater than CONTROL POINT plus 5 F 3 C Automatic Soft Stop Amps 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 sh...

Page 122: ...and the LEAVING CHILLED WATER TEMP is below the CONTROL POINT and the CONTROL POINT has not increased 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 SERVICE 1 table and the ENTERING CHILLED WATER TEMPERATURE is below the CONTROL PO...

Page 123: ... 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 instal...

Page 124: ...es 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 or LOCAL softkeys to restart the machine CAUTION CAUTION 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...

Page 125: ...Required mechanic s tools refrigeration digital volt ohmmeter DVM clamp on ammeter electronic leak detector absolute pressure manometer or wet bulb vacuum indicator Figure 26 500 v insulation tester megohmmeter for compressor motors with nameplate volt age 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 Pump...

Page 126: ...ected for any temporary yellow caution tags whose legends convey information concerning actions necessary before the motor can be safely operated Any CAUTION CAUTION 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 Figure 27 Click here for Figure 26 Typical Wet Bulb Type Vacuu...

Page 127: ... 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...

Page 128: ...rds 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 dr...

Page 129: ...r sequence and procedures for leak testing 17 19EX chillers are 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 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...

Page 130: ...halide torch Ultrasonic leak detectors also can be used if the machine is under pressure Leak Test Machine Due to regulations regarding refrigerant emissions and the difficulties associated with separating contaminants from refrigerant Carrier recommends the following leak test procedures See Figure 28 for an outline of the leak test procedures Refer to Table 5A and Table 5B for refrigerant pressu...

Page 131: ... 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 Never charge liquid refrigerant into the machine if the pressure in the machine is less than 35 psig 241 kPa Charge a...

Page 132: ...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 m...

Page 133: ...ge 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 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 R...

Page 134: ...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 suffi ciently 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 Condi...

Page 135: ...lding charge or refrigerant pressure Click here for Table 5A HFC 134a Pressure Temperature F Click here for Figure 28 17 19EX Leak Test Procedures Click here for Table 5B HFC 134a Pressure Temperature C 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 break down and severe damage may result WARNING WA...

Page 136: ...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 Op...

Page 137: ... 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 Inspect Water Piping Refer to piping diagrams provided 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 ...

Page 138: ...utdoors 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 CAUTION CAUTION Water must be within design limits clean and treated to ensure proper machine performance ...

Page 139: ...ressor 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 Do not check voltage supply without proper equipment and precautions Serious injury may result Follow power company recommendations WARNING WARNING CAUTION CAUTION Do not apply any kind of test voltage even for a rotation ...

Page 140: ...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 selecto...

Page 141: ...6 leads together and test between 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 rea...

Page 142: ...f the stator winding insulation should be measured The test voltage based on the motor operating voltage is as follows 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 lea...

Page 143: ...rgized 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 one half each If the motor has 6 leads 3 mai...

Page 144: ...y 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 inhi...

Page 145: ...on 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 nega...

Page 146: ...perating temperature range of 20 C to 60 C is required See table below for cables that meet the requirements 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 Manufacturer Cable No Alpha 2413 or 5463 American A22503 Belden 8772 Columbia 02525 SIGNAL TY...

Page 147: ...ntains its output to the 1CR relay for 10 seconds after starter safety shutdown to determine the fault mode of failure CAUTION CAUTION 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 CAUTION CAUTION The main disconnect on the starter front panel may not deenergize all internal circuit...

Page 148: ...quipped 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 ove...

Page 149: ...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 This equipment is at line vo...

Page 150: ...dded 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 hea...

Page 151: ...e 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 As configuration of the 17 19EX unit is performed write down all configuration settings A log such as the one shown in Initial Start Up Checklist provides a convenient list for con figuration values Do not operate the machine before the control ...

Page 152: ...dule 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 schedule see the Controls section The CCN Occupied Schedule OCCPC03S should be configured if a CCN system is ...

Page 153: ...guration automated control test Password When accessing the Service tables a password 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 ...

Page 154: ...ge 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 job site Write the new address on the PSIO module for future ...

Page 155: ... is needed These points should be set based on individual machine operating conditions Chilled Medium Brine Refrigerant Trippoint Surge Limiting or Hot Gas Bypass Option Minimum Load Points T1 P1 Maximum Load Points T2 P2 Motor Rated Load Amps Motor Rated Line Voltage Motor Rated Line kW Line Frequency Compressor Starter Type Stop to Start Time Water or Brine Usually 3 F 1 7 C below design refrige...

Page 156: ...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 condensin...

Page 157: ... Temperature 98 F 36 7 C 120 psig 1827 kPa saturated refrigerant pressure HFC 134a Maximum Load T2 54 44 10 F 12 2 6 7 5 5 C Maximum Load P2 120 37 83 psid 827 255 572 kPad To avoid unnecessary surge prevention add about 10 psid 70 kPad to P2 from these conditions T2 10 F 5 5 C P2 93 psid 642 kPad ...

Page 158: ...sure 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 T1 at 20 Load 2 F 1 1 C Minimum Load P1 71 38 33 psid 490 262 228 kPad Again to avoid unnecessary surge prevention add 20 psid 140 kPad at P1 from these...

Page 159: ...le 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 Load Surge Prevention Occurs Too Soon Surge Prevention Occurs Too Late At low loads 50 Increase P1 by 10 psid 70 kPad Decre...

Page 160: ...avings 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 ...

Page 161: ... 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 d...

Page 162: ...bove a complete control test Check of all PSIO thermistors only Check of all options boards thermistors Check of all transducers Check of the guide vane operation Check operation of pump outputs either all pumps can be activated or indi vidual pumps The test will also test the associated input such as flow or pressure Activation of all on off outputs or individually Pumpdown prevents the low refri...

Page 163: ...onnected 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 and Pumpout System Maintenance sections for details on transfer of refrigerant oil specifications etc High Altitude Locations Recalibration of t...

Page 164: ...ign conditions indicated on the job data specifications An approximate charge may be found in 17 19EX Physical Data section 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 be...

Page 165: ...d 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 I...

Page 166: ...igerant 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 i...

Page 167: ...OSITION 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 Figure 18 If the compressor is off the value will read zero 2 Move the highlight bar to the TARGET GUIDE VA...

Page 168: ...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 th...

Page 169: ... c If the rotation direction must be changed refer to the Before Initial Start Up Open Drive Motor Electrical Connection section 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 vi...

Page 170: ...eed 185 F 85 C total temperature 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 CAUTION CAUTION 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 approxi...

Page 171: ...sening 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 CAUTION CAUTION 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 CAUTION CAUTION If the total bearing temperature exceeds 195 F 91 C the motor should b...

Page 172: ...oupling 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...

Page 173: ... 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 mot...

Page 174: ... 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 Figure 30 If Rotation Is Proper allow the compressor to come up to speed If the Motor Rotation Is Not Clockwise as viewed t...

Page 175: ...emand 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 CAUTION CAUTION Do not check motor rotation during ...

Page 176: ...e 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 Prevent Accidental 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 St...

Page 177: ... 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 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 instruct...

Page 178: ...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 refrigera...

Page 179: ...il 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 Auxiliary Equipment Starters and disconnects separate electrical sources pumps and cooling tower Describe Machine Cycles Refrigerant motor cooling lubrication ...

Page 180: ...ties 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 l...

Page 181: ...he compressor 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 bea...

Page 182: ...enser 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 5...

Page 183: ...link 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 softkey 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...

Page 184: ... 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 pump out condenser water circuits to avoid freeze up Keep the waterbox drains open Leave the oil ...

Page 185: ...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 condenser 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 contr...

Page 186: ...ols section Refrigeration Log A refrigeration log such as the one shown in Figure 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 Aut...

Page 187: ...pumpout compressor are open backseated 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 com...

Page 188: ...e Schrader connections on each vessel Figure 7 and Figure 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 Figure 32 for valve locations and numbers CAUTION CAUTION Transfer addition or removal of refrigerant in spring isolated machines may place severe stress on external piping if springs have n...

Page 189: ...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 b Turn off the machine water pumps and pumpout condenser water c Turn on pumpout compressor to push liquid out of the cooler condenser compressor section Valve 1 2 3 4 5 6 7 8 9 10 11 Condition C C C C C C Click here for Figure 33 ...

Page 190: ...e positions close valves 2 and 5 open valves 3 and 4 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 ...

Page 191: ... cooler condenser compressor section a Valve positions b Turn off machine water pumps and pumpout condenser 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 di...

Page 192: ...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 Valve 1 2 3 4 5 6 7 8 9 10 11 Condition C C C C C C C ...

Page 193: ...n valves 1 3 and 6 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 7 Open valves 9 and 10 8 Open valve 7 to equalize liquid refrigerant levels Valve 1 2 3 4 5 6 7 8 9 10 11 Condition C C C C C C C C Valve 1...

Page 194: ...lose valves 1 3 5 and 6 10 Continue on with the terminate lockout function on the LID to turn off water pumps and enable the compressor for operation Valve 1 2 3 4 5 6 7 8 9 10 11 Condition C C C C C C C C ...

Page 195: ... mixed with air This refrigerant is non combustible at atmospheric pressure Read the Material Safety Data Sheet and the latest ASHRAE 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 refr...

Page 196: ...tion when removing refrigerant Adjusting the Refrigerant Charge If the addition or removal of refrigerant is required for improved machine performance follow the procedures given under the Trim Refrigerant Charge section Always use the compressor pumpdown function in the Control Test mode to turn on the evaporator pump and lock out the compressor when transferring refriger ant Liquid refrigerant m...

Page 197: ...mends 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...

Page 198: ...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 HFC 134a MUST NOT be mixed with air or oxygen and pressurized for leak ...

Page 199: ...ehydrate the machine Refer to the Standing Vacuum Test and Machine Dehydration in the Before Initial Start Up section Checking Guide Vane Linkage Refer to Figure 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 sproc...

Page 200: ...ugh 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 the...

Page 201: ...nd 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...

Page 202: ...cked 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 ...

Page 203: ... 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 7 Insert O ring ...

Page 204: ...g 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...

Page 205: ... 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 General 1 Final shaft alignmen...

Page 206: ...ngs 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...

Page 207: ...bed 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 Click ...

Page 208: ...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 ...

Page 209: ...on 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 ...

Page 210: ...dicator 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 rea...

Page 211: ...t 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 Click here for Figure 39 Measuring An...

Page 212: ...lignment 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 ...

Page 213: ...or indicator button 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 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 S...

Page 214: ... coupling gap which always occurs in adjusting angular alignment By selecting the proper pivot point see Figure 40 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 fr...

Page 215: ...bout 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 shaf...

Page 216: ... 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 Figure 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 elevat...

Page 217: ...routing 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 operating 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 ...

Page 218: ...l Start Up Checklist 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 Click here fo...

Page 219: ...ent 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 m...

Page 220: ...e to final dimension 3 Fit dowel so that 1 16 in of taper is left above the equipment foot If dowel holes are rereamed as a result of re alignment 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 indic...

Page 221: ...ure 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 Chan...

Page 222: ...ntrol 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 Figure 44 Items 1 and 2 are fully open before operating...

Page 223: ...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 limited to general cleaning and tightening of connections Vacuum the cabinet to eliminate dust build up In the event of machine control malfunctions refer to the Troubleshooting Guide section for control checks and adj...

Page 224: ...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 Figure 44 Items 1 and 2 4 Loosen the filter holding clamp Figure 44 Item 3 5 Rotate the filter nut Figure 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 obtai...

Page 225: ...he 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 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...

Page 226: ...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 polyol ester based oil may be ordered from your local Carrier representative Carrier Part No PP23B2103 Oil Changes Carrier recommends changing the oil after the first year of operation and every three to five years thereafter as a minimum al...

Page 227: ...lass Figure 2 Item 17 and Figure 3 Item 19 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 ref...

Page 228: ... kPa by transferring the refrigerant charge to the utility vessel Inspect Refrigerant Float System Perform inspection 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...

Page 229: ...dition 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 h...

Page 230: ...ubrication Misalignment causes undue noise and wear Check alignment yearly or more often if vibration or heating occur Refer to Machine Alignment section Motor Maintenance Open Drive Machines A carefully 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 Never operate drive without cou...

Page 231: ... 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 ...

Page 232: ...he fan housing 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 CAUTION CAUTION Water spray washing of motors is not recommended Manual or compressed air cleaning is preferr...

Page 233: ...r 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...

Page 234: ...tion 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 gog gles aprons and sui...

Page 235: ...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 insu...

Page 236: ...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...

Page 237: ... 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 ...

Page 238: ...re when rolling out the lower bearing half Keep the hands and fin gers 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 per sonal injury could result WARNING WARNING CAUTION CAUTION Curil T is the only approved compound for use in the assembly of the bearings on this motor Other products may h...

Page 239: ...es of the bearing liner halves CAUTION CAUTION When seating the bearing shell apply a thin layer of lube oil at the spherical sur face of the liner Slowly roll the lower bearing liner into the bearing housing mak ing 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 bear ing liner so that the ...

Page 240: ...hat accumulating oil may drain back into the housing 7 Put a small head 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 ...

Page 241: ...upplied 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 T...

Page 242: ...should be repeated until the bearing cap seats prop erly 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 ...

Page 243: ...er the top air housing is provided with 3 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...

Page 244: ... 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 CAUTION CAUTION Uneven lifting must always be avoided When single point lifting is to be ...

Page 245: ...race 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 ...

Page 246: ...ive 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 ...

Page 247: ...eration 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...

Page 248: ...reated water 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 CAUTION CAUTION Hard scale may require chemical treatment for its prevention or removal Consult a water treatment specialist for proper treatment CAUTION CAUTION Machine must be dehydrated after repair of water leaks See ...

Page 249: ...treated to ensure proper machine performance and reduce the potential of tubing damage due to corro sion scaling erosion and algae Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated water The disconnect on the starter front panel does not deenergize all internal circuits Open all internal and remote disconnects before servicing the starter WARNING W...

Page 250: ... 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 Never open isolating knife switches while equipment is operating Electrical arc ing can cause serious injury WARNING WARNING CAUTION CAUTION Loose ...

Page 251: ... If there is a difference in readings the transducer can be calibrated as described in the Troubleshooting Guide section Pumpout System Maintenance For compressor maintenance details refer to the 06D 07D Installation Start Up and Service Instructions Optional Pumpout Compressor Oil Charge Use oil conforming to Carrier specifications for reciprocating compressor usage Oil requirements are as follow...

Page 252: ... 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 Figure 33 Add oil as required 6 Replace the connection and reopen the compressor service valves Pumpout Safety Control Settings Figure 47 The pumpout system high pressure switch should open at 161 psig...

Page 253: ...rt number of the part required delivery address and method of shipment Open Drive Motor Renewal Parts Renewal parts information for the motor and any auxiliary devices can be obtained from the nearest Westinghouse Motor Company sales office A complete description of the part s required is necessary together with the complete motor nameplate reading for positive motor identification ...

Page 254: ...trol 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 Oth...

Page 255: ...ght 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 temperature sensors are of the thermistor type This means that the resistance of the sensor varies with temper...

Page 256: ...ltage drop across any energized sensor can be measured while the control is energized Table 9A or Table 9B 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 se...

Page 257: ...r 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...

Page 258: ...he 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 ...

Page 259: ...rader fitting Note If the cooler or condenser vessels are at 0 psig 0 kPa or are open to atmospheric pres sure 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 SE...

Page 260: ...us01 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...

Page 261: ...n 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 p...

Page 262: ...ement 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...

Page 263: ... Schedules Status Water System Manager Status This table shows all values that are used to calculate the chilled water brine control point Details of all chilled water control override values are viewed here The surge and hot gas bypass control algorithm status is viewed from this screen All values dealing with this con trol are displayed This screen indicates LEAD LAG operation status The Local a...

Page 264: ...wn 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 a...

Page 265: ...or Table 8D Pre Start Alerts Click here for Table 8E Normal or Auto Restart Click here for Table 8F Start Up Failures Click here for Table 8G Compressor Jumpstart and Refrigerant Protection Click here for Table 8H Normal Run with Reset Temperature or Demand ...

Page 266: ...lerts Click here for Table 8J Out of Range Sensor Failures Click here for Table 8K Machine Protect Limit Faults Click here for Table 8L Machine Alerts Click here for Table 8M Spare Sensor Alert Messages Click here for Table 8N Other Problems Malfunctions ...

Page 267: ...ion of all modules is indicated by LEDs light emitting diodes located on the side of the LID and on the top horizontal surface of the PSIO SMM and 8 input modules Click here for Table 9A Thermistor Temperature F vs Resistance Voltage Drop Click here for Table 9B Thermistor Temperature C vs Resistance Voltage Drop CAUTION CAUTION Turn controller power off before servicing controls This ensures safe...

Page 268: ...e 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 netwo...

Page 269: ...ations Connection Communication 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 Green LED Communication with PSIO module will blink continuously ...

Page 270: ...odule is connected to Terminal 1 of each of the other modules Terminals 2 and 3 are connected in the same manner See Figure 49 Figure 50 Figure 51 Figure 52 and Figure 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 ...

Page 271: ...odules The PSIO monitors conditions using input ports on the PSIO the SMM and the 8 input modules Out puts 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 wi...

Page 272: ...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 Click here for Figure 49 PSIO Module LED Locations Click here for Figure 50 LID Module Rear View and LED Locations Click here for Figure 51 Processor PSIO Module ...

Page 273: ...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 Click here for Figure 52 Starter Management Module SMM ...

Page 274: ... 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...

Page 275: ... is printed in a small label on front of the PSIO module The model and serial numbers are printed on the unit nameplate located on an exterior corner post The proper software is factory installed 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 reconfigurat...

Page 276: ...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 con figuration 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 Caref...

Page 277: ...w 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 veri...

Page 278: ...e 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 so...

Page 279: ... regarding compressor fits and clearances physical and electrical data and wiring schematics for operator convenience during troubleshooting Click here for Figure 54 Model Number Nomenclature for Compressor Size See Figure 1 also Click here for Table 10 17 19EX Heat Exchanger Economizer Storage Vessel Piping and Pumpout Unit Weights Click here for Table 11 Additional Condenser Weights Click here f...

Page 280: ...he information in this section is included as a reference for such personnel only Click here for Table 13 Additional Cooler Weights Click here for Table 14 Marine Waterbox Cover Weights Click here for Table 15 NIH Waterbox Cover Weights Click here for Table 16 Auxiliary Systems Electrical Data Click here for Figure 55 Open Drive Compressor Fits and Clearances ...

Page 281: ...ances Click here for Table 18 Hermetic Compressor Fits and Clearances Click here for Figure 57 Electronic PIC Controls Wiring Schematic Hermetic Machine Click here for Figure 58 Electronic PIC Controls Wiring Schematic Open Drive Machine Click here for Figure 59 Machine Power Panel Starter Assembly and Motor Wiring Schematic ...

Page 282: ...r Panel With Water Cooled Oil Cooler Click here for Figure 61 Hermetic Drive Power Panel With Motor Cooling Solenoid Click here for Figure 62 Open Drive Power Panel Click here for Initial Start Up Checklist for 17 19EX Centrifugal Liquid Chiller ...

Page 283: ...t 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 ...

Page 284: ...TATUS STATUS01 will be highlighted 3 Press SELECT Table 2 Example 1 Status01 Display Screen Description Range Units Reference Point Name Alarm History Control Mode Run Status Occupied Alarm State Chiller Start Stop Base Demand Limit Active Demand Limit Compressor Motor Load Current Amps Target Guide Vane Pos Actual Guide Vane Pos Water Brine Setpoint Control Point Reset Off Local CCN Timeout Recyc...

Page 285: ...l Pressure Transducer Oil Pressure Line Voltage Percent Actual Remote Contacts Input Total Compressor Starts Starts in 12 Hours Compressor Ontime Service Ontime Compressor Motor kW 40 245 40 118 40 245 40 118 40 245 40 118 40 245 40 118 40 245 40 118 6 7 420 46 2896 40 245 40 118 6 7 420 46 2896 40 245 40 118 40 245 40 118 40 245 40 118 Normal Alarm 40 245 40 118 6 7 420 46 2896 6 7 420 46 2896 0 ...

Page 286: ...Output Hot Gas Bypass Relay Chilled Water Pump Chilled Water Flow Condenser Water Pump Condenser Water Flow Compressor Start Relay Compressor Start Contact Compressor Run Contact Starter Fault Contact Pressure Trip Contact Single Cycle Dropout Oil Pump Relay Oil Heater Relay Motor Cooling Relay Auxiliary Oil Pump Relay Tower Fan Relay Compr Shunt Trip Relay Alarm Relay Spare Prot Limit Input X X X...

Page 287: ...or Common CHWR Sensor Remote Reset Sensor Temp Sensor Spare 1 Temp Sensor Spare 2 Temp Sensor Spare 3 OPTIONS BOARD 2 4 20 mA Spare 1 4 20 mA Spare 2 Temp Sensor Spare 4 Temp Sensor Spare 5 Temp Sensor Spare 6 Temp Sensor Spare 7 Temp Sensor Spare 8 Temp Sensor Spare 9 4 20 4 20 40 245 40 118 40 245 40 118 40 245 40 118 40 245 40 118 40 245 40 118 40 245 40 118 4 20 4 20 40 245 40 118 40 245 40 11...

Page 288: ...e 2 Example 4 Setpoint Display Screen Description Configurable Range Units Reference Point Name Default Value Base Demand Limit LCW Setpoint ECW Setpoint ICE BUILD Setpoint 40 100 20 120 6 7 48 9 20 120 6 7 48 9 20 60 6 7 15 6 DEG F DEG C DEG F DEG C DEG F DEG C DLM lcw sp ecw sp ice sp 100 50 0 10 0 60 0 15 6 40 0 4 4 ...

Page 289: ...ldown Deg Min Load Pulldown Min Select Ramp Type Temp 0 Load 1 Loadshed Group Number Loadshed Demand Delta Maximum Loadshed Time CCN Occupancy Config Schedule Number Broadcast Option ICE BUILD Option ICE BUILD TERMINATION 0 Temp 1 Contacts 2 Both ICE BUILD Recycle Option 30 30 17 17 40 245 40 118 40 245 40 118 30 30 17 17 0 15 0 8 0 15 0 8 30 30 17 17 0 3 DISABLE ENABLE 40 100 DISABLE ENABLE DISAB...

Page 290: ...nge Units Reference Point Name Default Value LEAD LAG SELECT DISABLE 0 LEAD 1 LAG 2 STANDBY 3 Load Balance Option Common Sensor Option LAG Percent Capacity LAG Address LAG START Timer LAG STOP Timer PRESTART FAULT Timer STANDBY Chiller Option STANDBY Percent Capacity STANDBY Address 0 3 DISABLE ENABLE DISABLE ENABLE 25 75 1 236 2 60 2 60 0 30 DISABLE ENABLE 25 75 1 236 MIN MIN MIN leadlag loadbal ...

Page 291: ...BP Delta T1 Surge HGBP Delta P1 Min Load Points T1 P1 Surge HGBP Delta T2 Surge HGBP Delta P2 Full Load Points T2 P2 Surge HGBP Deadband Surge Delta Percent Amps Surge Time Period 150 200 66 93 90 200 620 1379 2 5 1 3 Water Brine 8 40 13 3 4 125 200 52 93 165 210 74 99 0 5 5 15 300 0 5 2 0 0 3 1 1 2 0 10 0 1 1 5 6 0 5 4 0 27 2 2 0 1 0 5 15 0 3 8 3 30 170 207 1172 0 5 15 0 3 8 3 30 170 207 1172 1 3...

Page 292: ...ne Frequency Select 0 60 Hz 1 50 Hz Compr Starter Type Condenser Freeze Point Soft Stop Amps Threshold Stop to Start Timer 0 1 1 8 1 9999 1 9999 1 9999 0 1 REDUCE FULL 20 35 28 9 1 7 40 100 3 50 AMPS VOLTS kW HZ DEG F DEG C MIN dem src corfact a fs v fs kw fs freq starter cdfreeze softstop stopmtr 0 3 200 460 600 0 REDUCE 34 1 100 20 Table 2 Example 7 Service1 Display Screen Continued Description ...

Page 293: ...BLE Disable 0 1 High Alert 2 Low Alert 3 High Alarm 4 Low Alarm Temp Alert Threshold CHWS Temp Enable CHWS Temp Alert CHWR Temp Enable CHWR Temp Alert Reset Temp Enable Reset Temp Alert Spare Temp 1 Enable Spare Temp 1 Alert Spare Temp 2 Enable Spare Temp 2 Alert Spare Temp 3 Enable Spare Temp 3 Alert 0 1 0 1 0 4 40 245 40 118 0 4 40 245 40 118 0 4 40 245 40 118 0 4 40 245 40 118 0 4 40 245 40 118...

Page 294: ...Power Source SPARE ALERT ENABLE Disable 0 1 High Alert 2 Low Alert 3 High Alarm 4 Low Alarm Temp Alert Threshold Spare Temp 4 Enable Spare Temp 4 Alert Spare Temp 5 Enable Spare Temp 5 Alert Spare Temp 6 Enable Spare Temp 6 Alert Spare Temp 7 Enable Spare Temp 7 Alert Spare Temp 8 Enable Spare Temp 8 Alert Spare Temp 9 Enable Spare Temp 9 Alert 0 1 0 1 0 4 40 245 40 118 0 4 40 245 40 118 0 4 40 24...

Page 295: ...ght EQUIPMENT SERVICE 4 Press SELECT 5 Scroll down to highlight SERVICE3 Table 2 Example 9 Service3 Display Screen Description Configurable Range Units Reference Point Name Default Value Proportional Inc Band Proportional Dec Band Proportional ECW Gain Guide Vane Travel Limit 2 10 2 10 1 3 30 100 gv inc gv de gv ecw gv lim 6 5 6 0 2 0 50 ...

Page 296: ...ription Range Status Units Reference Point Name CAPACITY CONTROL Control Point Leaving Chilled Water Entering Chilled Water Control Point Error ECW Delta T ECW Reset LCW Reset Total Error Resets Guide Vane Delta Target Guide Vane Pos Actual Guide Vane Pos Proportional Inc Band Proportional Dec Band Proportional ECW Gain Water Brine Deadband 10 120 12 2 48 9 40 245 40 118 40 245 40 118 99 99 55 55 ...

Page 297: ...plicable to hermetic machines only Table 2 Example 11 Maintenance Maint02 Display Screen Description Range Status Units Reference Point Name OVERRIDE ALERT STATUS MOTOR WINDING TEMP Override Threshold CONDENSER PRESSURE Override Threshold EVAPORATOR REFRIG TEMP Override Threshold DISCHARGE TEMPERATURE Alert Threshold BEARING TEMPERATURE Alert Threshold 40 245 40 118 150 200 66 93 6 7 420 42 2896 9...

Page 298: ...e Override is not supported on this maintenance screen Only values with capital letter reference point names are variables available for read operation Table 2 Example 12 Maintenance Maint03 Display Screen Description Range Status Units Reference Point Name SURGE HGBP ACTIVE Active Delta P Active Delta T Calculated Delta T Surge Protection Counts NO YES 0 200 0 1379 0 200 0 111 0 200 0 111 0 12 PS...

Page 299: ...ce Option LAG Start Time LAG Stop Time Prestart Fault Time Pulldown Delta T Min Satisfied LEAD CHILLER in Control LAG CHILLER Mode Run Status Start Stop Recovery Start Request STANDBY CHILLER Mode Run Status Start Stop Recovery Start Request DISABLE LEAD LAG STANDBY INVALID DISABLE LEAD LAG STANDBY CONFIG DISABLE ENABLE 0 60 0 60 0 30 x xx No Yes No Yes Reset Off Local CCN Timeout Recycle Startup ...

Page 300: ...t 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 Control 218 psig 7 psig 1503 48 kPa reset at 120 10 827 69 kPa Preset 215 psig 1482 kPa Preset Oil Pressure Switch ...

Page 301: ...ter tempera ture is below the configured con denser freeze point temperature Deenergizes when the temperature is 5 F 3 C above condenser freeze point temperature CONDENSER FREEZE POINT config ured in Service01 table with a default seting of 34 F 1 C Impeller Clearance Displacement switch open Thrust movement excessive Motor Leak Detector Water from motor cooling is leaking Water sensors are instal...

Page 302: ...66 to 93 C Override Set Point 10 F 6 C Override Set Point Low Refrigerant Temperature Refrigerant Override Delta Temperature Equip ment Service1 3 F 1 6 C Above Trippoint 2 to 5 F 1 to 3 C Trippoint Override T 1 F 0 56 C Trippoint Override T 2 F 1 2 C High Compressor LIft Surge Prevention Equip ment 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...

Page 303: ...14 42 15 72 17 06 20 22 24 26 28 18 45 19 88 21 37 22 90 24 48 30 32 34 36 38 26 11 27 80 29 53 31 32 33 17 40 42 44 46 48 35 08 37 04 39 06 41 14 43 28 50 52 54 56 58 45 48 47 74 50 07 52 47 54 93 60 62 64 66 68 57 46 60 06 62 73 65 47 68 29 70 72 74 76 78 71 18 74 14 77 18 80 30 83 49 80 82 84 86 88 86 17 90 13 93 57 97 09 100 70 ...

Page 304: ...28 47 132 81 137 25 141 79 110 112 114 116 118 146 43 151 17 156 01 160 96 166 01 120 122 124 126 128 171 17 176 45 181 83 187 32 192 93 130 132 134 136 138 140 198 66 204 50 210 47 216 55 222 76 229 09 Table 5A HFC 134a Pressure Temperature F Continued Temperature F Pressure psi ...

Page 305: ... 0 6 7 5 6 4 4 3 3 2 2 127 0 137 0 147 0 158 0 169 0 1 1 0 0 1 1 2 2 3 3 180 0 192 0 204 0 216 0 229 0 4 4 5 0 5 6 6 1 6 7 242 0 248 0 255 0 261 0 269 0 7 2 7 8 8 3 8 9 9 4 276 0 284 0 290 0 298 0 305 0 10 0 11 1 12 2 13 3 14 4 314 0 329 0 345 0 362 0 379 0 15 6 16 7 17 8 18 9 20 0 396 0 414 0 433 0 451 0 471 0 21 1 22 2 23 3 24 4 25 6 491 0 511 0 532 0 554 0 576 0 ...

Page 306: ...8 9 40 0 41 1 42 2 857 0 886 0 916 0 946 0 978 0 43 3 44 4 45 6 46 7 47 8 1010 0 1042 0 1076 0 1110 0 1145 0 48 9 50 0 51 1 52 2 53 3 1180 0 1217 0 1254 0 1292 0 1330 0 54 4 55 6 56 7 57 8 58 9 60 0 1370 0 1410 0 1451 0 1493 0 1536 0 1580 0 Table 5B HFC 134a Pressure Temperature C Continued Temperature C Pressure kPa ...

Page 307: ...1 4 5 16 3 8 1 2 5 8 3 4 7 8 1 1 1 3 1 1 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 ...

Page 308: ...mperature Bearing temperature Motor winding temperature Oil sump temperature 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 Evaporator pressure Condenser pressure Oil pressure differential Oil pump pressure Open Close All pumps or individual pumps may be activated O...

Page 309: ...unt trip relay When using pumpdown lockout observe freeze up precau tions when removing charge Instructs operator as to which valves to close and when Starts chilled water and condenser water pumps and con firms flows Monitors Evaporator pressure Condenser pressure Evaporator temperature during pumpout procedures Turns pumps off after pumpdown Locks out compressor Starts pumps and monitors flows I...

Page 310: ...tatic Expansion Valve MTRW Motor Winding Temperature V P Line Voltage Percent V REF Voltage Reference 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 ...

Page 311: ...cupied 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 con tacts 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...

Page 312: ...erature 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 ...

Page 313: ...ater for proper opera tion 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 dis charge temperature to cool Check for excessive starts Prestart Alert Low Refrigerant Temp ERT VALUE exceeded limit of LIMIT Check refrigerant tem perature Che...

Page 314: ...ess 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 E...

Page 315: ... 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 A starter protective device has faulted Check starter for ground fault voltage trip temperature trip etc Failure To Start Starter Overload Trip STR FLT Starter Overload Trip Check am...

Page 316: ...sformer Check main motor cir cuit breaker for trip Failure To Start Check Refriger ant Type Current Refrigerant Properties Abnormal Check Selection of refrigerant type Pressures at transducers indicate another refrigerant type in Contol Test Make sure to access the ATTACH TO NETWORK DEVICE table after specify ing HFC 134a refrigerant type Failure To Start Low Oil Pressure Low Oil Pressure LIMIT Ch...

Page 317: ...reeze up prevention Determine cause If pumping refrigerant out of machine stop operation and go over pumpout procedures Failure To Stop Disconnect Power RUN AUX Emergency DIS CONNECT POWER Starter and run and start con tacts are energized while control tried to shut down Disconnect power to starter Loss Of Communciation With Starter Loss of Communication with Starter Check machine Check wiring fro...

Page 318: ...g 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 Si...

Page 319: ...e Additional Cause Remedy Run Capacity Limited High Condenser Pres sure CRP VALUE exceeded limit of LIMIT Condenser pressure override See Capacity Over rides Table 4 Correct operating condition modify setpoint or release override Run Capacity Limited High Motor Temperature MTRW VALUE exceeded limit of LIMIT Motor temperature over ride Run Capacity Limited Low Evap Refrig Temp ERT VALUE exceeded li...

Page 320: ...ure 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 tem perature sensor Sensor Fault Motor Winding Temp Sensor Fault Check motor tem perature sensor Sensor Fault Discharge Temperature S...

Page 321: ... VALUE exceeded limit of LIMIT Check motor cooling and solenoid Check motor temperature immediately Check sensor for accuracy Check for proper condenser flow and temperature Check motor cooling system for restric tions Check motor cooling solenoid for proper operation Check refrigerant filter Protective Limit High Bearing Tem perature MTRB VALUE exceeded limit of LIMIT Check oil cooling control Ch...

Page 322: ...gh Condenser Pressure High Cond Pressure OPEN Check switch 2C aux and water temp flow Check the high presure switch Check for proper condenser pressures and con denser waterflow Check for fouled tubes Check the 2C aux contact and the oil pressure switch in the power panel This alarm is not caused by the transducer Protective Limit High Condenser Pressure High Cond Pressure VALUE Check switch water...

Page 323: ... Check condenser water temp and flow Check condenser flow and temperatures 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 calibra tion reset overload Reset overloads and...

Page 324: ...oper 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 exce...

Page 325: ... 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 DELTA T Table 8 LID Primary and Secondary Messages and Custom Alarm Alert Messages with Troubleshooting Guides L Machine Alerts Continued Primary Message Secondary Messag...

Page 326: ...re sensor Spare Sensor Alert Temp Sensor Spare 1 Sensor Fault Check temperature sen sor Spare 1 Spare Sensor Alert Temp Sensor Spare 2 Sensor Fault Check temperature sen sor Spare 2 Spare Sensor Alert Temp Sensor Spare 3 Sensor Fault Check temperature sen sor Spare 3 Spare Sensor Alert Temp Sensor Spare 4 Sensor Fault Check temperature sen sor Spare 4 Spare Sensor Alert Temp Sensor Spare 5 Sensor ...

Page 327: ...ator Check that sensor is in the proper ter minals Chilled Water 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 ...

Page 328: ... the Stop pushbutton The PIC must be in the OFF mode for the Control Test to 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 equalize pressure Check guide vane a...

Page 329: ...57 0 58 0 59 0 60 0 61 0 62 0 63 0 64 0 65 0 66 0 67 0 68 0 69 0 70 0 71 0 72 0 73 0 74 0 4 241 4 223 4 202 4 184 4 165 4 145 4 125 4 103 4 082 4 059 4 037 4 017 3 994 3 968 3 948 3 927 3 902 3 878 3 854 3 828 3 805 3 781 3 757 3 729 3 705 3 679 3 653 3 627 3 600 3 575 3 547 3 520 3 493 3 464 3 437 3 409 3 382 3 353 3 323 3 295 3 267 3 238 3 210 3 181 3 152 3 123 3 093 3 064 3 034 3 005 19960 1939...

Page 330: ... 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 0 838 0 824 0 810 0 797 0 783 0 770 0 758 0 745 0 734 0 722 0 710 0 700 0 689 0 678 0 668 0 659 0 649 0 640 0 632 0 623 0 615 0 607 0 600 0 592 0 585 0 579 0 572 0 566 0 560 0 554 0 548 0 542 0 537 0 531 0 526 0 520 0 515 0 510 0 505 0 499 0 494 0 488 719 705 690 677 663 650 638 626 614 602 591 581 570 561 551 542 533 524 516 508 501 494...

Page 331: ... 54 555 51 450 48 536 45 807 43 247 40 845 38 592 38 476 34 489 32 621 30 866 29 216 27 633 26 202 24 827 23 532 22 313 21 163 20 079 19 058 18 094 17 184 16 325 15 515 14 749 14 026 13 342 12 696 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 3 860 3 816 3 771 3 726 3 680 3 633 3 585 3 537 3 487 3 438 3 387 3 3...

Page 332: ...079 1 041 1 006 971 938 906 876 836 805 775 747 719 693 669 645 623 602 583 564 547 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 0 648 0 632 0 617 0 603 0 590 0 577 0 566 0 555 0 545 0 535 0 525 0 515 0 506 0 496 0 486 0 476 0 466 0 454 0 442 0 429 0 416 0 401 0 386 0 370 531 516 502 489 477 466 456 446 436 427 419 410 402 393 385 376 367 357 346 335 324 312 299 ...

Page 333: ...own condensing unit weight is 210 lb 95 kg For compressor and motor weights refer to Table 12 Operating weight includes dry weight refrigerant weight and water weight Table 10 17 19EX Heat Exchanger Economizer Storage Vessel Piping and Pumpout Unit Weights Page 1 of 2 Cooler Size Cooler Total Weight Cooler Charge Economizer Storage Vessel Economizer Refrigerant Miscellaneous Piping Pumpout Unit Dr...

Page 334: ...ensing unit weight is 210 lb 95 kg For compressor and motor weights refer to Table 12 Operating weight includes dry weight refrigerant weight and water weight Table 10 17 19EX Heat Exchanger Economizer Storage Vessel Piping and Pumpout Unit Weights Continued Condenser Size Condenser Total Weight Condenser Charge Dry Operating Refrigerant Water lb kg lb kg lb kg lb kg 41 42 43 45 46 47 51 52 53 55 ...

Page 335: ...mponent HeatExchanger Size Waterbox Type Number of Passes Design Maximum Additional Dry Weight Additional Water Weight psig kPa lb kg lb kg Condenser 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 1 542 Marine 2 150 1034 674 306 1 700 771 Marine 1 3 300 2068 2651 1 202 3 400 1 542 Marine 2 300 2068 1630 739 1 700 771 51 53 ...

Page 336: ...uction 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 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 ...

Page 337: ...er weight Table 13 Additional Cooler Weights Component Waterbox Type Number of Passes Design Maximum Water Pressure Additional Dry Weight Additional Water Weight psig kPa lb kg lb kg Condenser 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 2314 Marine 2 150 1034 792 359 2551 1157 Marine 1 3 300 2068 3844 1744 5102 2314 Marine 2 300 206...

Page 338: ...han heat exchangers with nozzle in head waterboxes Table 14 Marine Waterbox Cover Weights Heat Exchanger Size Design Maximum Water Pressure Cooler Condenser psi kPa lb kg lb kg 41 48 150 1034 2236 1015 1275 579 300 2068 3060 1389 1660 754 51 57 150 1034 1643 746 300 2068 2243 1018 ...

Page 339: ...weight of the blank waterbox cover is identical to the weight of the same size marine waterbox cover Refer to Table 14 Table 15 NIH Waterbox Cover Weights Heat Exchanger Size Passes Design Maximum Water Pressure Cooler Condenser psi kPa lb kg lb kg 41 48 1 150 1034 2997 1361 1735 788 300 2068 4225 1918 2510 1140 2 150 1034 2984 1355 1885 856 300 2068 4188 1901 2590 1176 3 150 1034 3035 1378 1777 8...

Page 340: ...starter is disconnected Table 16 Auxiliary Systems Electrical Data Power Source Item Supply V PH HZ FLA LRA 1 Control Module and Actuator 115 1 60 115 1 50 3 50 Oil Sump Heater 115 1 60 115 1 50 8 70 2 Oil Pump 200 240 3 60 380 480 3 60 507 619 3 60 4 32 2 15 2 13 24 5 12 2 25 0 220 240 3 50 346 440 3 50 4 83 2 59 28 0 12 2 3 Optional Pumpout Compressor 200 208 3 60 220 240 3 60 440 480 3 60 550 6...

Page 341: ...ft jour nal bearing 0020 0510 0035 0889 0030 0762 0045 1143 Diametral 8 Thrust end float 010 2540 015 381 010 2540 015 381 Axial 9 Counterthrust bear ing seal ring 002 0510 004 1020 002 0510 004 1020 Diametral 10 Gear bearing to gear 0040 1016 0055 1397 0050 1270 0065 1651 Diametral 10a Gear bearing to gear 010 2540 0185 4699 010 2540 0185 4699 Axial 11 Gear bearing to bearing housing 0005 0127 00...

Page 342: ...17 Windage baffle to shaft 083 2 108 104 2 642 079 2 007 100 2 540 Diametral 18 Inner carbon ring travel 06 MIN Each Direction 06 MIN Each Direction Axial Table 17 Open Drive Compressor Fits and Clearances Continued Item Description Clearance Type of Measure 17FA4 17FA5 Min Max Min Max in mm in mm in mm in mm ...

Page 343: ... 7 13 25 336 6 717 18 21 541 13 74 9 13 75 349 2 690 17 53 541 13 74 4 1 12 00 304 8 977 24 82 760 19 30 3 12 38 314 5 937 23 80 726 18 44 5 12 75 323 8 897 22 78 688 17 48 7 13 25 336 6 837 23 62 639 16 23 9 13 75 349 2 810 20 57 632 16 05 5 1 12 00 304 8 1 177 29 90 895 25 02 3 12 38 314 5 1 137 28 88 852 21 64 5 12 75 323 8 1 077 27 36 809 20 55 7 13 25 336 6 1 017 25 83 750 19 05 9 13 75 349 2...

Page 344: ...30 3050 Diametral 7 Impeller Shaft Journal Bearing 0030 0045 0762 1143 Diametral 8 Thrust end Float 0100 0150 2540 3810 Axial 9 Counterthrust Bearing Seal Ring 0020 0040 0510 1020 Diametral 10 Gear Bearing to Gear 0050 0065 1270 1651 Diametral 11 Gear Bearing to Gear 0100 0185 2540 4699 Axial 12 Gear Bearing to Bearing Housing 0005 0025 0127 0635 Diametral 13 Pinion Bearing to Pinion 0040 0055 101...

Page 345: ...0 541 0 541 16 21 15 47 14 71 13 74 13 74 6 4 1 3 5 7 9 12 00 12 38 12 75 13 25 13 75 304 8 314 5 323 8 336 6 349 2 0 977 0 937 0 897 0 837 0 810 24 82 23 80 22 78 23 62 20 57 0 760 0 726 0 688 0 639 0 632 19 30 18 44 17 48 16 23 16 05 7 5 1 3 5 7 9 12 00 12 38 12 75 13 25 13 75 304 8 314 5 323 8 336 6 349 2 1 177 1 137 1 077 1 017 0 970 29 90 28 88 27 36 25 83 24 64 0 895 0 852 0 809 0 750 0 731 ...

Page 346: ...Figure 1 17 19EX Identification ...

Page 347: ...Figure 2 Typical 17EX Installation ...

Page 348: ...Figure 3 Typical 19EX Installation ...

Page 349: ...Figure 4 Refrigerant Motor Cooling and Oil Cooling Cycles ...

Page 350: ...v Figure 5 Hermetic Compressor Lubrication System EX Compressor Shown ...

Page 351: ...Figure 6 Open Drive 17 Series Lubrication Cycle ...

Page 352: ...Figure 7 17EX Controls and Sensor Locations Figure 7 continued on next page Machine Rear Compressor Side View ...

Page 353: ...Compressor End View Figure 7 17EX Controls and Sensor Locations Figure 7 continued on next page ...

Page 354: ...Machine Front View Figure 7 17EX Controls and Sensor Locations Figure 7 continued on next page ...

Page 355: ...Motor End View Figure 7 17EX Controls and Sensor Locations Figure 7 continued on next page ...

Page 356: ...Figure 7 17EX Controls and Sensor Locations ...

Page 357: ...Machine Rear Compressor Side View Figure 8 19EX Controls and Sensor Locations Figure 8 continued on next page ...

Page 358: ...Compressor End View Figure 8 19EX Controls and Sensor Locations Figure 8 continued on next page ...

Page 359: ...Machine Rear View Figure 8 19EX Controls and Sensor Locations Figure 8 continued on next page ...

Page 360: ...Motor End View Figure 8 19EX Controls and Sensor Locations Figure 8 continued on next page ...

Page 361: ...Figure 8 19EX Controls and Sensor Locations ...

Page 362: ...Figure 9 Control Center Front View Shown with Options Module ...

Page 363: ...Figure 10 Control Sensors Temperature ...

Page 364: ...Figure 11 Control Sensors Pressure Transducer Typical ...

Page 365: ...Figure 12 Power Panel without Options Open Drive Machine Shown ...

Page 366: ...Figure 13 Power Panel with Options Hermetic Machine Shown ...

Page 367: ...Figure 14 LID Default Screen ...

Page 368: ...Figure 15 LID Service Screen ...

Page 369: ...Figure 16 17 19EX Menu Structure ...

Page 370: ...Figure 17 17 19EX Service Menu Structure ...

Page 371: ...Figure 18 Example of Point Status Screen Status01 ...

Page 372: ...Figure 19 Example of Time Schedule Operation Screen ...

Page 373: ...Figure 20 Example of Set Point Screen ...

Page 374: ...Figure 21 17 19EX Hot Gas Bypass Surge Prevention ...

Page 375: ...Figure 22 17 19EX with Default Metric Settings ...

Page 376: ...Figure 23 Example of Attach to Network Device Screen ...

Page 377: ...Figure 24 Example of Holiday Period Screen ...

Page 378: ...Figure 25 Control Sequence ...

Page 379: ...Figure 26 Typical Wet Bulb Type Vacuum Indicator ...

Page 380: ...Figure 27 Shipping Bolt on Open Drive Motor ...

Page 381: ...Figure 28 17 19EX Leak Test Procedures ...

Page 382: ...Figure 29 Dehydration Cold Trap ...

Page 383: ...Figure 30 Correct Motor Rotation ...

Page 384: ...Figure 31 Refrigeration Log ...

Page 385: ...Figure 32 Pumpout Arrangement and Valve Number Locations 12 ft Vessel Shown Figure 32 continued on next page ...

Page 386: ...Figure 32 Pumpout Arrangement and Valve Number Locations 12 ft Vessel Shown Continued ...

Page 387: ...Figure 33 Pumpout Unit Wiring Schematic 19EX Shown ...

Page 388: ...Figure 34 Optional Pumpout Compressor ...

Page 389: ...Figure 35 Electronic Vane Actuator Linkage ...

Page 390: ...Figure 36 Compressor Contact Seal Open Drive Machines ...

Page 391: ...Figure 37 Checking Preliminary Alignment ...

Page 392: ...Figure 38 Measuring Angular Misalignment in Elevation ...

Page 393: ...Figure 39 Measuring Angular Misalignment on Brackets ...

Page 394: ...Figure 40 Alignment Formula ...

Page 395: ...Figure 41 Adjusting Angular Misalignment in Plan ...

Page 396: ...Preparation Figure 42 Correcting Parallel Misalignment Figure 42 continued on next page ...

Page 397: ...Measurement Figure 42 Correcting Parallel Misalignment Figure 42 continued on next page ...

Page 398: ...Adjustment Figure 42 Correcting Parallel Misalignment ...

Page 399: ...To Check Angular Alignment Figure 43 Alignment Check Assembled Coupling Figure 43 continued on next page ...

Page 400: ...To Check Parallel Alignment Figure 43 Alignment Check Assembled Coupling ...

Page 401: ...Figure 44 Removing the Oil Filter ...

Page 402: ...Figure 45 Typical Float Valve Arrangement ...

Page 403: ...Figure 46 Lifting Open Drive Motor ...

Page 404: ...Figure 47 Controls for Optional Pumpout Compressor ...

Page 405: ...Figure 48 Oil Differential Pressure Power Supply Module ...

Page 406: ...Figure 49 PSIO Module LED Locations ...

Page 407: ...Figure 50 LID Module Rear View and LED Locations ...

Page 408: ...Figure 51 Processor PSIO Module ...

Page 409: ...Figure 52 Starter Management Module SMM ...

Page 410: ...Switch Setting Options Module 1 Options Module 2 S1 S2 6 4 7 2 Figure 53 Options Module ...

Page 411: ...Figure 54 Model Number Nomenclature for Compressor Size See Figure 1 Also ...

Page 412: ...Note See Table 17 for dimensions Figure 55 Open Drive Compressor Fits and Clearances Figure 55 continued on next page ...

Page 413: ...Figure 55 Open Drive Compressor Fits and Clearances Figure 55 continued on next page Note See Table 17 for dimensions ...

Page 414: ...Figure 55 Open Drive Compressor Fits and Clearances Note See Table 17 for dimensions ...

Page 415: ...View B Refer to Table 18 for dimensions View A Figure 56 Hermetic Compressor Fits and Clearances Figure 56 continued on next page ...

Page 416: ...Figure 56 Hermetic Compressor Fits and Clearances ...

Page 417: ...Figure 57 Electronic PIC Controls Wiring Schematic Hermetic Machine Figure 57 continued on next page ...

Page 418: ...Figure 57 Electronic PIC Controls Wiring Schematic Hermetic Machine ...

Page 419: ...Figure 58 Electronic PIC Controls Wiring Schematic Open Drive Machine Figure 58 continued on next page ...

Page 420: ...Figure 58 Electronic PIC Controls Wiring Schematic Open Drive Machine ...

Page 421: ...Figure 59 Machine Power Panel Starter Assembly and Motor Wiring Schematic Figure 59 continued on next page ...

Page 422: ...Figure 59 Machine Power Panel Starter Assembly and Motor Wiring Schematic ...

Page 423: ...Figure 60 Hermetic Drive Power Panel with Water Cooled Oil Cooler ...

Page 424: ...Figure 61 Hermetic Drive Power Panel with Motor Cooling Solenoid ...

Page 425: ...Figure 62 Open Drive Power Panel ...

Page 426: ...RUCTIONS JOB DATA REQUIRED 1 Machine Installation Instructions Yes M No M 2 Machine Assembly Wiring and Piping Diagrams Yes M No M 3 Starting Equipment Details and Wiring Diagrams Yes M No M 4 Applicable Design Data see above Yes M No M 5 Diagrams and Instructions for Special Controls Yes M No M INITIAL MACHINE PRESSURE YES NO Was Machine Tight If Not Were Leaks Corrected Was Machine Dehydrated Af...

Page 427: ...CK TO THE EARTH GROUND IN THE STARTER IN ACCORDANCE WITH BULLETIN C 8912 Yes RUN MACHINE Do these safeties shut down machine Condenser Water Flow Switch Yes M No M Chilled Water Flow Switch Yes M No M Pump Interlocks Yes M No M INITIAL START Line Up All Valves in Accordance With Instruction Manual Start Water Pumps and Establish Water Flow Oil Level OK and Oil Temperature OK Check Oil Pump Rotatio...

Page 428: ...ITS DEFAULT VALUE Base Demand Limit 40 to 100 100 0 LCW Setpoint 20 to 120 6 7 to 48 9 DEG F DEG C 50 0 ECW Setpoint 20 to 120 6 7 to 48 9 DEG F DEG C 60 0 ICE BUILD Setpoint 20 to 60 6 7 to 15 6 DEG F DEG C 40 0 PSIO Software Version Number LID Software Version Number PSIO Controller Identification BUS ADDRESS LID Identification BUS ADDRESS CL 3 ...

Page 429: ... TIME SCHEDULE CONFIGURATION SHEET OCCPC02S Day Flag Occupied Unoccupied M T W T F S S H Time Time Period 1 Period 2 Period 3 Period 4 Period 5 Period 6 Period 7 Period 8 NOTE Default setting is UNOCCUPIED 24 hours day CCN MODE TIME SCHEDULE CONFIGURATION SHEET OCCPC S Day Flag Occupied Unoccupied M T W T F S S H Time Time Period 1 Period 2 Period 3 Period 4 Period 5 Period 6 Period 7 Period 8 NOT...

Page 430: ...able Reset Type 0 to 3 0 ECW Control Option Disable Enable Disable Demand Limit at 20 mA 40 to 100 40 20 mA Demand Limit Option Disable Enable Disable Auto Restart Option Disable Enable Disable Remote Contacts Option Disable Enable Disable Temp Pulldown Deg Min 2 to 10 3 Load Pulldown Min 5 to 20 10 Select Ramp Type Temp 0 Load 1 0 1 1 Loadshed Group Number 0 to 99 0 Loadshed Demand Delta 0 to 60 ...

Page 431: ...e Option Disable Enable Disable Common Sensor Option Disable Enable Disable LAG Percent Capacity 25 to 75 50 LAG Address 1 to 236 92 LAG START Timer 2 to 60 Min 10 LAG STOP Timer 2 to 60 Min 10 PRESTART FAULT Timer 0 to 30 Min 5 STANDBY Chiller Option Disable Enable Disable STANDBY Percent Capacity 25 to 75 50 STANDBY Address 1 to 236 93 CL 6 ...

Page 432: ...s Verify Time 15 to 300 SEC 15 Water Brine Deadband 0 5 to 2 0 0 3 to 1 1 DEG F DEG C 1 0 0 6 Recycle Restart Delta T 2 0 to 10 1 1 to 5 5 DEG F DEG C 5 2 8 Recycle Shutdown Delta T 0 5 to 4 0 0 27 to 2 2 DEG F DEG C 1 0 0 6 Surge Limit HGBP Option Surge 0 HGBP 1 0 1 0 Surge HGBP Delta T1 0 5 to 15 0 3 to 8 3 DEG F DEG C 1 5 0 8 Surge HGBP Delta P1 30 to 170 206 to 1172 psi kPa 50 345 Surge HGBP D...

Page 433: ...TS 460 Meter Rated Line kW 1 to 9999 kW 600 Line Frequency 0 60 Hz 1 50 Hz 0 1 0 Compressor Starter Type REDUCE FULL REDUCE Condenser Freeze Point 20 to 35 28 9 to 1 7 DEG F DEG C 34 1 1 Soft Stop Amps Threshold 40 to 100 100 Stop to Start Timer 3 to 50 MIN 20 Open drive machines only Standard stop to start time for hermetic machines is 3 minutes CL 8 ...

Page 434: ...to 4 0 DISABLE 1 HIGH ALERT 2 LOW ALERT 3 HIGH ALARM 4 LOW ALARM 0 Spare Temp 3 Alert 40 to 245 40 to 118 DEG F DEG C 245 118 SPARE 1 20 mA Power Source 0 1 0 EXTERNAL 1 INTERNAL 0 SPARE 2 20 mA Power Source 0 1 0 EXTERNAL 1 INTERNAL 0 Spare Temp 4 Enable 0 to 4 0 DISABLE 1 HIGH ALERT 2 LOW ALERT 3 HIGH ALARM 4 LOW ALARM 0 Spare Temp 4 Alert 40 to 245 40 to 118 DEG F DEG C 245 118 Spare Temp 5 Ena...

Page 435: ...TS VALUE Holiday Start Month 1 to 12 Start Day 1 to 31 Duration 0 to 99 DAYS HOLIDAY HOLIDEF CONFIGURATION SHEET HOLIDEF S DESCRIPTION RANGE UNITS VALUE Holiday Start Month 1 to 12 Start Day 1 to 31 Duration 0 to 99 DAYS HOLIDAY HOLIDEF CONFIGURATION SHEET HOLIDEF S DESCRIPTION RANGE UNITS VALUE Holiday Start Month 1 to 12 Start Day 1 to 31 Duration 0 to 99 DAYS NOTE There are no HOLIDAYS defined ...

Page 436: ...t Number 0 to 239 SE s 0 OARH Broadcast Controller Name 8 characters Text Bus Number 0 to 239 Bus s 0 Element Number 0 to 239 SE s 0 Daylight Savings Start Month 1 to 12 4 Day 1 to 31 15 Time 00 00 to 23 59 HH MM 02 00 Minutes To Add 1 to 1440 MIN 60 Daylight Savings Stop Month 1 to 12 10 Day 1 to 31 15 Time 00 00 to 23 59 HH MM 02 00 Minutes To Subtract 1 to 1440 MIN 60 CL 11 ...

Page 437: ...ngular in Plan Gear In Drive Out Step 4 Parallel in Plan Drive Hi Lo Open On In Out Diam Drive In Out KEY In Side toward compressor discharge side next to cooler Out Side opposite compressor discharge side furthest from cooler SIGNED DATE Copyright 1995 Carrier Corporation Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incu...

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Carrier 17/19EX, Start-Up, Operation And Maintenance Instructions Manual

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