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Carrier 19EF Series, Start Up & Operation Manual

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Carrier 19EF Series Start Up & Operation Manual Download Page 69

Fig. 36 — Electronic PIC Controls Wiring Schematic

69

Summary of Contents for 19EF Series

Page 1: ...When it is necessary to heat refrigerant use only warm 110 F 43 C water DO NOT REUSE disposable nonreturnable cylinders or attempt to refill them It is DANGEROUS AND ILLEGAL When cylinder is emptied...

Page 2: ...ion 28 Tower Fan Relay 28 Auto Restart After Power Failure 28 Water Brine Reset 28 Demand Limit Control Option Requires Optional 8 Input Module 29 Surge Prevention Algorithm 29 Surge Protection 29 Lea...

Page 3: ...ant Charge 50 Refrigerant Leak Testing 50 Refrigerant Leak Rate 50 Test After Service Repair or Major Leak 50 REFRIGERANT TRACER TO PRESSURIZE WITH DRY NITROGEN Page Repair the Leak Retest and Apply S...

Page 4: ...RIZATION Fig 1 and 2 Machine Information Plate The information plate is located on the left side of the machine control center panel System Components The components include the cooler and condenser h...

Page 5: ...Actuator 6 Economizer Low Side Float Cover Hidden 7 Hot Gas Bypass Line 8 Condenser Waterbox Cover 9 Economizer 10 High Side Float Box Cover 11 Cooler Relief Valves Hidden 12 Motor Terminals Hidden 1...

Page 6: ...zer gas has to pass through only half the compres sion cycle to reach condenser pressure there is a savings in power hence the term economizer The cooled liquid refrigerant in the economizer is me ter...

Page 7: ...pressure difference prevents oil in the trans mission cavity from leaking into the motor shell Several safety devices monitor the lubrication system In the event of a power failure a small oil reservo...

Page 8: ...ity A decrease in guide vane opening decreases capacity Machine protection is provided by the processor which monitors the digital and analog inputs and executes capacity overrides or safety shut down...

Page 9: ...nsor 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 sen sors on this unit Thes...

Page 10: ...Fig 5 19EF Controls and Sensor Locations cont 10...

Page 11: ...klight Power Supply Not Shown Fig 8 Control Center Front View with Options Module 1 T2 Hot Gas Bypass Relay Oil Pump Relay and Oil Heater Relay Power Transformer 2 T4 8 Input Module Transformer Not Sh...

Page 12: ...me of alarm The Status tables will show the updated informa tion Once all alarms have been cleared by pressing the RESET softkey the default LID screen will return to normal operation LID DEFAULT SCRE...

Page 13: ...Fig 12 19EF Menu Structure 13...

Page 14: ...Fig 13 19EF Service Menu Structure 14...

Page 15: ...s 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 i...

Page 16: ...REASE or DECREASE to change the time values Override values are in one hour incre ments up to 4 hours b Press ENABLE to select days in the day of week fields Press DISABLE to eliminate days from the p...

Page 17: ...default screen 1 Press MENU 2 Press STATUS STATUS01 will be highlighted 3 Press SELECT DESCRIPTION RANGE UNITS REFERENCE POINT NAME ALARM HISTORY Control Mode Reset Off Local CCN MODE Run Status Timeo...

Page 18: ...screen 1 Press MENU 2 Press STATUS 3 Scroll down to highlight STATUS03 4 Press SELECT DESCRIPTION RANGE UNITS REFERENCE POINT NAME ALARM HISTORY OPTIONS BOARD 1 Demand Limit 4 20 mA 4 20 mA DEM OPT Te...

Page 19: ...3 Load Pulldown Min 5 20 kw ramp 10 Select Ramp Type 0 1 ramp opt 1 Temp 0 Load 1 Loadshed Group Number 0 99 ldsgrp 0 Loadshed Demand Delta 0 60 ldsdelta 20 Maximum Loadshed Time 0 120 MIN maxldstm 60...

Page 20: ...2 0 0 3 1 1 DEG F DEG C cw db 1 0 0 6 Recycle Restart Delta T 2 0 10 0 1 1 5 6 DEG F DEG C rcyc dt 5 2 8 Surge Limit HGBP Option 0 1 srg hgbp 0 Select Surge 0 HGBP 1 Surge HGBP Delta T1 0 5 15 0 3 8 3...

Page 21: ...LE ENABLE sp2 20 ma DISABLE SPARE ALERT ENABLE Disable 0 Low 1 High 2 Temp Alert Threshold Spare Temp 4 Enable 0 2 spr4 en 0 Spare Temp 4 Alert 40 245 40 118 DEG F DEG C spr4 al 245 118 Spare Temp 5 E...

Page 22: ...Brine Deadband 0 5 2 0 3 1 1 DEG F DEG C cwdb NOTE Overriding is not supported on this maintenance screen Active overrides show the associated point in alert Only values with capital letter reference...

Page 23: ...AD LAG Configuration DISABLE LEAD LAG STANDBY INVALID leadlag Current Mode DISABLE LEAD LAG STANDBY CONFIG llmode Load Balance Option DISABLE ENABLE loadbal LAG Start Time 0 60 MIN lagstart LAG Stop T...

Page 24: ...nt Service3 table DEMAND LIMITING The PIC will respond to the AC TIVE DEMAND LIMIT set point by limiting the opening of the guide vanes It will compare the set point to either COM PRESSOR MOTOR LOAD o...

Page 25: ...trip to trip the circuit breaker Table 3 Protective Safety Limits and Control Settings MONITORED PARAMETER LIMIT APPLICABLE COMMENTS TEMPERATURE SENSORS OUT OF RANGE 40 to 245 F 40 to 118 3 C Must be...

Page 26: ...n table Config table see Table 2 Motor load is the default type Capacity Override Table 4 These can prevent some safety shutdowns caused by exceeding motor amper age limit refrigerant low temperature...

Page 27: ...ng The heat exchanger uses chilled or condenser water as the cooling liquid A solenoid and cock valve regulate flow to control oil temperature entering the bearings The valve is set to maintain 140 F...

Page 28: ...im ers are ignored during this type of start up When power is restored after the power failure and if the compressor had been running the oil pump will be ener gized for one minute prior to the evapor...

Page 29: ...ll go into a corrective action mode If the actual values are below the line the al gorithm takes no action Modification of the default set points of the MINIMUM and MAXIMUM load points is described in...

Page 30: ...d and capacity requirements are not met The lead lag option op erates in CCN mode only If any other chiller configured for lead lag is set to the LOCAL or OFF modes it will be un available for lead la...

Page 31: ...faulted the standby chiller reverts to a stand alone CCN mode of operation If the lead chiller is in an alarm condition as shown on the LID panel the RESET softkey is pressed to clear the alarm and t...

Page 32: ...ER temperature is less than the ICE BUILD SET POINT If the ICE BUILD RECYCLE OPTION is set to ENABLE a recycle shutdown occurs and recycle start up shall be based on LEAVING CHILLED WATER tem perature...

Page 33: ...e at a time An asterisk appears as you enter each digit The menu bar Next Previous Select Exit is displayed to indicate that you have successfully logged on If the password is entered incorrectly an e...

Page 34: ...switches and waits until the WATER FLOW VERIFY TIME operator configured default 5 minutes to confirm flow After flow is verified the chilled water brine temperature is compared to CONTROL POINT plus D...

Page 35: ...control point and the CONTROL POINT has not increased in the last 5 minutes when ECW CONTROL OPTION is enabled the ENTER ING CHILLED WATER temperature is more than 5 F 3 C below the CONTROL POINT and...

Page 36: ...shell and the oil charge shipped in the com pressor The cooler 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...

Page 37: ...record the manometer or indicator reading 4 a If the leakage rate is less than 0 05 in Hg 17 kPa in 24 hours the machine is sufficiently tight b If the leakage rate exceeds 0 05 in Hg 17 kPa in 24 hou...

Page 38: ...Fig 24 19EF Leak Test Procedures 38...

Page 39: ...6 55 138 222 76 140 229 09 Table 5B HFC 134a Pressure Temperature C TEMPERATURE C PRESSURE kPa 18 0 44 8 16 7 51 9 15 6 59 3 14 4 66 6 13 3 74 4 12 2 82 5 11 1 90 8 10 0 99 4 8 9 108 0 7 8 118 0 6 7 1...

Page 40: ...ded in accordance with job drawings certi fied drawings and all applicable electrical codes 8 Make sure that the customer s contractor has verified proper operation of the pumps cooling tower fans and...

Page 41: ...freely Check the mechanical interlock between contactors to ensure that 1S and 2M contactors cannot be closed at the same time Check all other electro mechanical devices e g relays timers for free mo...

Page 42: ...OCCPC03S should be con figured if a CCN system is being installed or if a secondary time schedule is required It is normally input through the CCN Building Supervisor but it can be configured at the L...

Page 43: ...bles to select and view or modify Carrier s certified drawings will have the configuration values required for the jobsite Modify these tables only if requested Config Table Modifications Change the v...

Page 44: ...to run after pumpdown lockout High Altitude Locations Recalibration of the pres sure transducers will be necessary as the machine was ini tially calibrated at sea level Refer to the calibration proce...

Page 45: ...f this value is overridden to stop in order to prevent accidental start up Manual Operation of the Guide Vanes Manual operation of the guide vanes is helpful to establish a steady motor current for ca...

Page 46: ...T and then the STOP and ENTER softkeys SUPVSR will ap pear after the value When attempting to restart remember to release the override The default machine message line will also state that the Start S...

Page 47: ...e of 60 to 105 F 15 to 41 C The condenser entering water temperature should be controlled below the specified design entering water temperature to save on compressor kilowatt requirements 7 Cooler pre...

Page 48: ...ase the guide vanes to AUTOMATIC mode press the RELEASE softkey NOTE Manual control will increase the guide vanes and override the pulldown rate during start up Motor current above the electrical dema...

Page 49: ...IME Refrigerant Water Refrigerant Water BEARING TEMP Oil Motor Press Temp Pressure Temp Press Temp Pressure Temp Press Diff Temp reservoir Level FLA In Out GPM In Out In Out GPM In Out Amperage or van...

Page 50: ...lly ac ceptable refrigerant as a tracer for leak test procedures TO PRESSURIZE WITH DRY NITROGEN Another method of leak testing is to pressurize with nitrogen only and use a soap bubble solution or an...

Page 51: ...7 for Control Test functions Change Oil and Oil Filters 1 Transfer refrigerant into storage tanks 2 Turn off oil heater 3 When machine pressure is 5 psig 35 kPa or less drain the oil reservoir by open...

Page 52: ...e tubes have internal ridges a rotary type tube cleaning system is necessary to fully clean the tubes Upon inspection the tube condition will de termine the scheduled frequency for cleaning and will i...

Page 53: ...ype This means that the resistance of the sensor varies with temperature All sensors have the same resistance characteristics Determine sensor temperature by measuring voltage drop if the con trols ar...

Page 54: ...ires Unscrew the transducer from the Schrader fitting When installing a new transducer do not use pipe sealer which can plug the sensor Put the plug connector back on the sensor and snap into place Ch...

Page 55: ...TART 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 fo...

Page 56: ...ation Check guide vane closure at start up Check that guide vanes are closed at start up Check starter for proper operation Reduce unit pressure if possible FAILURE TO START STARTER TRANSITION FAULT R...

Page 57: ...ndenser pressure override See Capacity Overrides Table 4 Correct operating condition modify set point or release override RUN CAPACITY LIMITED HIGH MOTOR TEMPERATURE MTRW VALUE exceeded limit of LIMIT...

Page 58: ...valves and pump operation PROTECTIVE LIMIT LOW CONDENSER WATER FLOW CDFL Flow Fault Check cond pump flow switch PROTECTIVE LIMIT HIGH CONDENSER PRESSURE High Cond Pressure OPEN Check switch 2C aux an...

Page 59: ...reduce pressure Check ambient conditions Check con denser pressure for accuracy Check pump operation in Control Test table RECYCLE ALERT EXCESSIVE RECYCLE STARTS Excessive recycle starts The machine...

Page 60: ...heck through Control Test Defective temperature sensor Check sensor accuracy Low Oil Sump Temperature While Running Less than 100 F 38 C Check for proper oil level not enough oil Check for proper refr...

Page 61: ...797 4 511 82 2 766 4 403 83 2 738 4 298 84 2 708 4 196 85 2 679 4 096 86 2 650 4 000 87 2 622 3 906 88 2 593 3 814 89 2 563 3 726 90 2 533 3 640 91 2 505 3 556 92 2 476 3 474 93 2 447 3 395 94 2 417 3...

Page 62: ...5 971 22 3 076 5 710 23 3 023 5 461 24 2 970 5 225 25 2 917 5 000 26 2 864 4 786 27 2 810 4 583 28 2 757 4 389 29 2 704 4 204 30 2 651 4 028 31 2 598 3 861 32 2 545 3 701 33 2 493 3 549 34 2 441 3 40...

Page 63: ...rminal strips Terminal 1 of PSIO mod ule is connected to Terminal 1 of each of the other mod ules Terminals 2 and 3 are connected in the same man ner If a Terminal 2 wire is connected to Terminal 1 th...

Page 64: ...sensor inputs and demand limit inputs Each option module contains 8 inputs each input meant for a specific duty See the wiring diagram for exact module wire terminations Inputs for each of the option...

Page 65: ...o prevent the new PSIO module from uploading incorrect run hours into memory 3 Check that all power to the unit is off Carefully dis connect all wires from the defective module by unplug ging the 6 co...

Page 66: ...AT EXCHANGER CODE WATERBOX TYPE DESIGN WATER PRESSURE COVER WEIGHT psi kPa lb kg Cooler 26 56 NIH 150 1034 640 290 250 1723 860 390 Marine 150 1034 250 1723 760 345 Condenser 26 NIH 150 1034 850 386 2...

Page 67: ...VIEW A VIEW B Refer to Table 14 for dimensions DIM 2 1 9 SEE VIEW A 3 4 5 6 7 15 16 17 18 8 SEE VIEW B Fig 35 Compressor Fits and Clearances 67...

Page 68: ...ing to Bearing Housing 0005 0020 0127 0508 Diametral See Fig 35 for item callouts Clearances represent factory tolerances for new components Table 15 Impeller Clearances FRAME CODE SHROUD CODE IMPELLE...

Page 69: ...Fig 36 Electronic PIC Controls Wiring Schematic 69...

Page 70: ...Fig 36 Electronic PIC Controls Wiring Schematic cont 70...

Page 71: ...Fig 37 Machine Power Panel Starter Assembly and Motor Wiring Schematic 71...

Page 72: ...r Duties 47 Options Module 64 Overview Troubleshooting Guide 53 Physical Data 66 PIC System Components 8 PIC Systems Functions 24 Power Up the Controls and Check the Oil Heater 42 Preparation Initial...

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