Main
DANGER !DANGER
liquid and vapor
Refrig- erant in contact with an open flame produces toxic gases
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LID Operation and Menus
PIC System Functions
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Initial Start-Up
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Operating Instruction s
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Troubleshooting Gui de
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List of Tables
Table 1 Major PIC Components and Panel Locations Table 2 LID Screens
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List of Figures
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Introduction
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Abbreviations
Frequently used abbre viations in this manual in clude:
17/19EX Machine Fami liarization (Figure 1, Figure 2, and Figure 3)
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Motor Starter ( Purchased Separa tely)
Utility Vessel
Refrigeration Cy cle (Figure 4)
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Motor/Oil Refri geration Cooling C ycle
Hermetic Machines (19 Series) Lubrication Cycle
Click here for Figure 4 Refr igerant, Motor Cooling, and Oil Cooling Cycles
Summary
Details
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Open-Drive Machines (17 Series) Lubricati on Cycle
Summary
Details (See Figure 6)
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Starters
Controls
A digital (discrete) signal
An analog signal
Definitions
General
PIC System Components
Click here f or Figure 6 Open-Drive ( 17 Series) Lubricatio n Cycle
Processor M odule (PSIO)
Click here fo r Table 1 Major PIC Compo nents and Pane l Locations
Starter Management Module (SMM)
Local Inte rface Device (LID)
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Click here for Figure 13 Po wer Panel with Options (Herm et ic Machine Shown)
General
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LID Default Screen Menu Items
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For Discrete Points
Click here for Figure 17 17/19EX Service Menu Structure
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To View or Change Time Schedule Operation (Figure 19)
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To View and Change Set Points (Figure 20)
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PIC System Functions
Capacity Control
Entering Chilled Water Control
Deadband
Proportional Bands and Gain
Demand Limiting
Machine T imers
Occupancy Schedule
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Safety Controls
Shunt Trip
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Shaft Seal Oil Control (Open Drive Machines Only)
Ramp Loading Control
TEMP (Temperature) PULLDOWN, LOAD PULL DOWN,
SELECT RAMP TYPE
Capacity Override (See Table 4)
High Discharge Temperature Control
Oil Sump Temperature Control
Oil Cooler
Remote Start/Stop Controls
Spare Safety Inputs
Spare Alarm Contacts
Condenser Pump Control
Condenser Freeze Prevention
Tower-Fan Re lay
Auto. Restart After Power Failure
Water/Brine Reset
SELECT/ENABLE RESET TYPE
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Demand Limit Control, Option (Requires Optional 8-Input Module )
Surge Prevention Algorithm
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Surge Protection
Lead/Lag Control
Common Point Sensor Insta llation
Machine Communication Wiring
Lead/Lag Oper ation
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Faulted Chiller Operation
Load Balancing
Auto. Restart After Pow er Failure
Ice Build Control
Ice Build Initiation
Start-Up/Recyc le 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 Off
Holiday Scheduling (Figure 24)
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Start-Up/Shutd own/Recycle Sequenc e ( Figure 25)
Local Start- Up
WATER FLOW VERIFY TIME
CONTROL POINT
DEADBAND
Click here f or Figure 25 Control Sequence
Shutdown Sequence
Automatic Soft Stop Amps Threshold
Chilled Water Recycle Mode
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Before Initial Start-Up
Job Data Required
Equipment Required
Using the Utility Vessel and Pumpout System
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Open-Drive Motor Electrical Connection
Open-Drive Motor Auxiliary Devices
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Standing Vacuum Test
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Inspect Water Piping
Click here f or Figure 29 Dehydration Cold Trap
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Check Insulat ion Resistance (Hermetic M otor)
Check Insulat ion Resistan ce (Open-Dri ve Motor)
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Open-Drive Motor Pre-Start Checks
Carrier Comfort Network Inte r face
Click here f or Table 6 Re commended Tor que
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Mechanic al-Type Star ters
not main chiller power
Solid-State Starters
Oil Charge
Power Up the Controls and Check the Oil Heater
Software Version
Set Up Machine Control Configuration
Input the Design Set Points
either
or
Input the Local Occupied Schedule (OCCPC01S)
Input Service Configurations
Passwor d
Input Time and Date
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Estimated Minimum Loa d Conditions:
Estimated Maximu m Load Condit ions:
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Modify Equipment Configuration If Necessary
Check Voltage Supply
Perform an Automated Control Test
Click here f or Table 7 Control Test Men u Functions
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Charge Refrigerant into Ma chine
Trimming Refrigerant Charge
Initial Start-Up
Preparation
Manual Operation of the Guide Vanes
TARGET GUIDE VANE POSITION
TARGET GUIDE VANE POSITION
Dry Run to Test Start-Up Sequence
Check Rotation (Open-Dr ive Motor)
Open Drive Motor Initial Start-Up
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Check Rotation (Hermeti c Motor)
If Rotation Is Proper If the Motor Rotation Is N ot Clockwise
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To Prevent Accidental Start-Up
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Check Machine Operating Condition
Instruct the Customer Operator
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Operating Instruc tions
Operator Duties
Prepare the Machine for Start-Up
To Start the M a chine
Do not restart
Check the Running System
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To Stop the Machine
Do not restart
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Cold Weather Operation
Manual Guide Vane Operation
TARGET GUIDE VANE POSITION
Refrigeration Log
Click here f or Figure 31 Refrigerat ion Log
Pumpout and Refrigerant Transfer Procedures
Preparation
Operating the Optional Pumpout Compressor
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Transferring Refrigerant from Normal Operation into the Utility Vessel
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Transferring Refrigerant from N ormal Operation into the C ooler/Condenser/ Compressor Section
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Return R e f rigeran t to Norma l O perating Conditio ns
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General Maintenan ce
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Refriger ant Tracer
To Pressurize with Dry N itrogen
Do not exceed
Repair the Leak, Retest, and Apply Standing Vacuum Test
Checking Guide Vane Linkage (Refer to Figure 35)
Contact Seal Maintenance (Open-Drive Machines) (Refer to Figure 36)
Click here fo r Figure 35 Electronic Va ne Actuator Link age
Seal Disassembly (Figure 36)
Protect seal faces at all times
Handle carefully
Protect seal faces of ring
Seal Reassembl y (Figure 36)
Tighten screws even ly against spring pressure
Click here for Figure 36 Compressor Contact Seal (Open-Drive Machines)
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Machine Alignment (Ope n-Drive Machines)
Alignment Metho d s
at operating temper at ures
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Preparation
Click here for Figure 38 Measurin g Angular Misalignment in Elevati on
Click here f or Figure 39 Measuring Angular Misalignm ent on Brackets
and
Adjustment
Click here fo r Figure 40 Alignment Formul a
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Click here f or Figure 41 Adjusting Angular Misalignment in Plan
Preparation
Measurement
Adjustment
on the same side
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Click here for Figure 42 Correcting Parallel Misalignment
Be sure that coupling guards are replaced after these checks.
Click here for Figure 43 Alignment Check Assembled Coupling
Doweling
Weekly Maintenance
Check the Lubrication System
must
Click here for Figur e 44 Removing the Oil Fi lter
Scheduled Maintenance
Check Safety and Operating Controls Monthly
Changing Oil Filter
19EX Compressors
FA Style Compresso rs
Oil Specification
Oil Changes
To Change the Oil
Refrigerant Filter
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Replace the valve
Coupling Maintenance (Open-Drive Machines)
Procedure
Motor Maintenance (O p en- Drive Machines)
Click here for Figure 45 Typical Float Valve Arrangement
Cleanliness
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Sleeve Be arings
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Open-Drive Motor Handling/Rigging
Click here for Figur e 46 Lifting Open-Drive Motor
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Compressor Bear i n g and Gear Ma in t en ance
Inspect the Heat Exchanger Tubes
Cooler
Condenser
Do not
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Check Pressure Transducers
Pumpout System Mainte nance
Optional Pumpout Compressor Oi l Charge
Pumpout Safety Control Settings (Figu r e 47)
Click here for Fig ure 47 Controls for Opti onal Pumpout Compressor
Ordering Replacement Chiller Parts
Open-Drive Motor Renewal Parts
Troubleshooting Gui de
Overview
Checking the Display Messages
Checking Temper a t ur e Sen sor s
Resistance C heck
Voltage Drop
Check Sens or Accuracy
Dual Temperature Sensors
Checking Pressure Transducers
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Troubleshooting Transducers
Transducer Re placement
Do not pull on the transducer wir es
Control Algorithms Checkout Procedure
Control Test
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Red LED
Green LEDs
Lower LED
Upper LED
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Notes on Module Operation
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Processor Module (PSIO) (Fig ure 51 )
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Options Modules (8-Input)
Replacing Defective Processor Modules
Click here f or Figure 53 Options Module
Installation of New PSIO Module
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17/19EX Physical Data and Wiring Schematics
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Table 1 Major PIC Components and Panel Locations*
Table 2 LID Screens
Table 2, Exa mple 1 Statu s01 Display Screen
Table 2, Example 1 Status01 Display Screen (Continued)
Description Range Units Reference Point Name (Alarm History)
Example 2 Status02 Dis pl ay Screen
2. Press STATUS. 3. Scroll down to highlight STATUS02.
Table 2, Example 2 Status02 Display Screen
Description Point Type Units Reference Point Name (Alarm History)
Input Output
Example 3 Status03 Dis pl ay Screen To access this display f ro m the LID default screen:
2. Press STATUS. 3. Scroll down to highlight STATUS03.
Table 2, Example 3 Status03 Display Screen
Description Range Units Reference Point Na me (Alarm History)
Table 2, Example 4 Setpoint Display Screen
3. Scroll down to highlight EQUIPMENT CONFIGURATION.
Point Name Default
5. Scroll down to highlight CONFIG.
Note: = delta degrees.
Table 2, Example 5 Configuration (Config) Display Screen
Description Configurable Range Units Reference
3. Scroll down to highlight EQUIPMENT CONFIGURATION.
Point Name Default
5. Scroll down to highlight Lead/Lag. 6. Press SELECT.
Table 2, Example 6 Lead/Lag Configuration Screen
Description Configurable Range Units Reference
Example 7 Service1 Disp l ay Screen To access this display f ro m the LID default screen:
3. Scroll down to highlight EQUIPMENT SERVICE.
5. Scroll down to highlight SERVICE1.
Table 2, Example 7 Service1 Display Screen
Description Configurable Range Units Reference
Point Name Default Value
Table 2, Example 7 Service1 Display Screen (Continued)
Description Configurable Range Units Reference
Point Name Default Value
Example 8 Service2 Disp l ay Screen
3. Scroll down to highlight EQUIPMENT SERVICE.
Table 2, Example 8 Serv ic e2 Di sp la y S cre en
Description Configurable Range Units Referen ce
Point Name
Default
Table 2, Example 8 Service2 Display Screen (Continued)
Description Configurable Range Units Reference
Point Name
Default
Table 2, Exa mple 9 Servic e3 Display Scr een
3. Scroll down to highlight ALGORITHM STATUS.
5. Scroll down to highlight MAINT01.
Table 2, Exa mple 10 Main tenance (M aint01) Dis play Scree n
Description Range/Status Units Reference Point Name
Table 2, Exa mple 11 Maint enance (M ai nt02) Displ ay Screen
Table 2, Example 12 Maintenance (Maint03) Display Screen
Table 2, Example 13 Maintenance (Maint04) Display Screen
Table 3 Protective Safety Limits and Control Settings
Table 3 Protective Safety Limits and Control Settings (Continued)
Table 4 Capacity Overrides
Table 5A HFC-134a Pressure Temperature (F)
Temperature (F) Pressure (psi)
Table 5A HFC-134a Pressure Temperature (F) (Continued)
Temperature (F) Pressure (psi)
Table 5B HFC-134a Pressure Temperature (C)
Temperature (C) Pressure (kPa)
Table 5B HFC-134a Pressure Temperature (C) (Continued)
Temperature (C) Pressure (kPa)
Table 6 Recommended Torque
Table 7 Control Test Menu Functions
Table 7 Control Test Menu Functions (Continued)
Table 8 LID Primary and Secondary Messages and Custom Alarm/Alert Messages
A. Shutdown with ON/OFF/RESET-OFF
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Table 8 LID Primary and Secondary Messages and Custom Alarm/Alert Messages
C. In Recycle Shutdown
Table 8 LID Primary and Secondary Messages and Custom Alarm/Aler t Me ss ages
D. Pre-St art Alerts :
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Table 8 LID Primary and Secondary Messages and Custom Alarm/Aler t Messages
H. Normal Run with Reset, Temperature, Or Demand
Table 8 LID Primary and Secondary Messages and Custom Alarm/A lert Me ss ages
I. Normal Run Overrides Active (Alerts)
Table 8 LID Primary and Secondary Messages and Custom Alarm/A lert Me ss ages
J. Out-of-Range Sensor Failures
Table 8 LID Primary and Secondary Messages and Custom Alarm/Al ert Messages
K. Machine Protect Limit Faults
Table 8 LID Primary and Secondary Messages and Custom Alarm/Al ert Messages
K. Machine Protect Limit Faults (Continued)
Table 8 LID Primary and Secondary Messages and Custom Alarm/Al ert Messages
K. Machine Protect Limit Faults (Continued)
Table 8 LID P rimary and Se condary Mes sa ges and Cust om Alarm/Ale rt Messages
L. Machine Alerts
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Table 8 LID Primary and Secondary Messages and Custom Alarm/Al ert Messages
M. Spare Sensor Alert Messages
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Table 9A Thermistor Temperature (F) vs Resistance/Voltage Drop
Table 9A Thermistor Temperature (F) vs Resistance/Voltage Drop (Continued)
Table 9B Thermistor Temperature (C) vs Resistance/Voltage Drop
Temperature (C) Voltage Drop (V) Resistance
Drop (V) Resistance
(Ohms) Temperature (C) Voltage
(Ohms)
Table 9B Thermistor Te mperature (C) vs Resistance/Vol tage Drop (Continued)
Temperature (C) Voltage Drop (V) Resistance
(Ohms)
Drop (V) Resistance
(Ohms) Temperature (C) Voltage
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Table 11 Additional Condenser Weights*
Table 12 Compressor/Motor/Suction Elbow Weights (English)
Table 13 Additional Cooler Weights*
Table 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 17 Open-Drive Compressor Fits and Clearances (Continued)
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Table 18 Hermetic Compressor Fits and Clearances
8 6
7 5
6 4
Code
19EX Shroud Code
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INITIAL START-UPCHECKLIST FOR 17/19EX CENTRIFUGAL LIQUID CHILLER
(Remove and use for job le.) MACHINE INFORMATION:
START-UPTO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UP INSTRUCTIONS
CL-2
17/19EX CENTRIFUGAL LIQUID CHILLER CONFIGURATION SETTINGS LOG
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CL-9
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MACHINE ALIGNMENT REPORT
