Carrier 17/19EX Replacing Defective Processor Modules

Terminal block connect io ns are provided on the opti ons modules. All sensor in puts are field

wired and installed. Op tions module 1 can be factor y or fi eld-installed. Opt ion s module 2 is

shipped separately and must be field installed. For installation, refer to the unit or field wiring

diagrams. Be sure to add r es s th e module for the proper modu le number (Figure 53) and to

configure the chille r for ea ch feature being used.

Replacing Defective Processor Modules

The replacement part number is printed in a sm all label on front of the PSI O module. The

model and serial numbers are print ed on the unit na meplate located o n an exterior cor ner post.

The proper software is factory-installed by Carrier in the replacement module. When ordering a

replacement processor module (PSIO), specify complete replacement part n umber, full unit

model number, and seri al nu mber. This new unit requ ir es r ec o nfiguration to the ori ginal

machine data by the inst all er. Follow the procedur es de scribed in the Set Up Mach ine Control

Configuration section.

Click here f or Figure 53 — Options Module

CAUTION CAUTION

!

Electrical shock can cause personal injury. Disconnect all electrical power

before servicing.

Contents

Main DANGER !DANGER liquid and vapor Refrig- erant in contact with an open flame produces toxic gases Page ahead of Page Page Page Page LID Operation and Menus PIC System Functions Page Page Page Page Page Page Initial Start-Up Page Operating Instruction s Page Page Page Page Troubleshooting Gui de Page Page List of Tables Table 1 Major PIC Components and Panel Locations Table 2 LID Screens Page Page Page List of Figures Page Page Page Page Introduction Page Abbreviations Frequently used abbre viations in this manual in clude: 17/19EX Machine Fami liarization (Figure 1, Figure 2, and Figure 3) Page Motor Starter ( Purchased Separa tely) Utility Vessel Refrigeration Cy cle (Figure 4) Page 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 Page Page Open-Drive Machines (17 Series) Lubricati on Cycle Summary Details (See Figure 6) Page 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) Page Page Page Click here for Figure 13 Po wer Panel with Options (Herm et ic Machine Shown) General Page LID Default Screen Menu Items Page Page Page For Discrete Points Click here for Figure 17 17/19EX Service Menu Structure Page Page To View or Change Time Schedule Operation (Figure 19) Page Page Page To View and Change Set Points (Figure 20) Page Page PIC System Functions Capacity Control Entering Chilled Water Control Deadband Proportional Bands and Gain Demand Limiting Machine T imers Occupancy Schedule Page Safety Controls Shunt Trip Page 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 Page Demand Limit Control, Option (Requires Optional 8-Input Module ) Surge Prevention Algorithm Page Surge Protection Lead/Lag Control Common Point Sensor Insta llation Machine Communication Wiring Lead/Lag Oper ation Page Page Page 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) Page Page Page Page 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 Page Page Before Initial Start-Up Job Data Required Equipment Required Using the Utility Vessel and Pumpout System Page Open-Drive Motor Electrical Connection Open-Drive Motor Auxiliary Devices Page Page Page Page Page Standing Vacuum Test Page Page Inspect Water Piping Click here f or Figure 29 Dehydration Cold Trap Page Page Page Check Insulat ion Resistance (Hermetic M otor) Check Insulat ion Resistan ce (Open-Dri ve Motor) Page Open-Drive Motor Pre-Start Checks Carrier Comfort Network Inte r face Click here f or Table 6 Re commended Tor que Page Page 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 Page Page Estimated Minimum Loa d Conditions: Estimated Maximu m Load Condit ions: Page Page Modify Equipment Configuration If Necessary Check Voltage Supply Perform an Automated Control Test Click here f or Table 7 Control Test Men u Functions Page 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 Page Page Page Page Check Rotation (Hermeti c Motor) If Rotation Is Proper If the Motor Rotation Is N ot Clockwise Page To Prevent Accidental Start-Up Page Check Machine Operating Condition Instruct the Customer Operator Page Operating Instruc tions Operator Duties Prepare the Machine for Start-Up To Start the M a chine Do not restart Check the Running System Page To Stop the Machine Do not restart Page 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 Page Transferring Refrigerant from Normal Operation into the Utility Vessel Page Transferring Refrigerant from N ormal Operation into the C ooler/Condenser/ Compressor Section Page Return R e f rigeran t to Norma l O perating Conditio ns Page General Maintenan ce Page Page 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) Page Machine Alignment (Ope n-Drive Machines) Alignment Metho d s at operating temper at ures Page Page Page Page 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 Page Click here f or Figure 41 Adjusting Angular Misalignment in Plan Preparation Measurement Adjustment on the same side Page 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 Page 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 Page Page Page Sleeve Be arings Page Page Page Page Page Page Page Open-Drive Motor Handling/Rigging Click here for Figur e 46 Lifting Open-Drive Motor Page Page Compressor Bear i n g and Gear Ma in t en ance Inspect the Heat Exchanger Tubes Cooler Condenser Do not Page Page Page 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 Page Page Page Troubleshooting Transducers Transducer Re placement Do not pull on the transducer wir es Control Algorithms Checkout Procedure Control Test Page Page Page Red LED Green LEDs Lower LED Upper LED Page Notes on Module Operation Page Processor Module (PSIO) (Fig ure 51 ) Page Options Modules (8-Input) Replacing Defective Processor Modules Click here f or Figure 53 Options Module Installation of New PSIO Module Page Page 17/19EX Physical Data and Wiring Schematics Page Page Page 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 Page 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 : Page Page Page Page 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 Page Table 8 LID Primary and Secondary Messages and Custom Alarm/Al ert Messages M. Spare Sensor Alert Messages Page Page 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 Page Page 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) Page Table 18 Hermetic Compressor Fits and Clearances 8 6 7 5 6 4 Code 19EX Shroud Code Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page 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 Page Page Page Page Page CL-9 Page Page MACHINE ALIGNMENT REPORT