Carrier 17EX CONTROLS Denitions, General

CONTROLS

Deﬁnitions

ANALOG SIGNAL — An analog signal varies in propor-

tion to the monitored source. It quantiﬁes values between

operating limits. (Example: A temperature sensor is an ana-

log 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 value of a monitored source.

(Example: A switch is a digital device because it only in-

dicates whether a value is above or below a set point or bound-

ary by generating an on/off, high/low, or open/closed signal.)

VOLATILE MEMORY — Volatile memory is memory in-

capable of being sustained if power is lost and subsequently

restored.

The memories of the PSIO and LID modules are vola-

tile. If the battery in a module is removed or damaged,

all programming will be lost.

General — The 17EX externally geared open-drive cen-

trifugal liquid chiller contains a microprocessor-based con-

trol center that monitors and controls all operations of the

chiller. The microprocessor control system matches the cool-

ing capacity of the chiller to the cooling load while provid-

ing state-of-the-art chiller protection. The system controls

cooling load within the set point plus the deadband by sens-

ing the leaving chilled water or brine temperature and regu-

lating the inlet guide vane via a mechanically linked actua-

tor motor. The guide vane is a variable ﬂow prewhirl assembly

that controls the refrigeration effect in the cooler by regu-

lating the amount of refrigerant vapor ﬂow into the com-

pressor. An increase in guide vane opening increases capac-

ity.Adecrease in guide vane opening decreases capacity. Chiller

protection is provided by the processor which monitors the

digital and analog inputs and executes capacity overrides or

safety shutdowns, if required.

1—Gear Mesh

2—Bearings

3—Gear Mesh Spray

4—Oil Level Glass

5—Oriﬁce

6—Oil Supply Pressure

Transducer

7—Pressure Control Valve

8—Oil Supply Temperature Thermistor

9—Oil Pump Motor

10—Oil Pump and Pressure Regulator

11 — Oil Filter

12—Oil Cooler/Filter

13—Oil Cooler

14—Plug Valve

NOTE: The oil reservoir is at the base of the gear box.

Fig. 5 — External Gear Oil Lubrication Cycle (Plan View)

11

Contents

Main Start-Up, Operation, and Maintenance Instructions SAFETY CONSIDERATIONS RUN WATER PUMPS when removing, transferring, or charg- ing refrigerant. Page CONTENTS CONTENTS (cont) INTRODUCTION ABBREVIATIONS 17EX CHILLER FAMILIARIZATION Chiller Identication Label (Fig. 1) System Components (Fig. 2) Cooler Page 17EX WITH EXTERNAL GEAR (SPEED INCREASER) Fig.2Typical 17EX Chiller Components OIL COOLING CYCLE Compressor Oil Cooling External Gear Oil Cooling LUBRICATION CYCLE Compressor Lubrication Cycle (Refer to item numbers shown in Fig. 4) External Gear Lubrication Cycle (Refer to Item numbers shown in Fig. 5) STARTERS Fig. 4 17EX Compressor Lubrication Cycle CONTROLS Denitions General PIC System Components Fig. 6 17EX Controls and Sensor Locations (cont) Page Page LID Operation and Menus (Fig. 11-17) Page Page Fig. 15 17EX LID Menu Structure Fig. 16 17EX Service Menu Structure NOTE: SERVICE TABLES: Fig. 16 17EX Service Menu Structure (cont) LEGEND FOR TABLE 2 LID DISPLAY DATA Table 2 LID Display Data do not appear on the LID screen in the far right eld of a LID status screen Page Page Page Page Page Page Page Page PIC System Functions Safety Controls Default Screen Freeze Auxiliary Compressor Oil Pump Control Auxiliary Gear Oil Pump Control Shaft Seal Oil Control Table 3 Protective Safety Limits and Control Settings CUT-OFF SETTING ADJUSTMENT SCREW Capacity Override (See T able 4) High Discharge T emperature Control Oil Sump T emperature Control Oil Cooler Remote Start/Stop Controls Spare Safety Inputs Spare Alarm Contacts Condenser Pump Control W ater/Brine Reset Demand Limit Control Option (Requires Optional 8-Input Module) Surge Prevention Algorithm Surge Protection Lead/Lag Control Page Ice Build Control Attach to Network Device Control Service Operation START-UP/SHUTDOWN/ RECYCLE SEQUENCE (Fig. 22) Local Start-Up Shutdown Sequence Automatic Soft Stop Amps Threshold Chilled W ater Recycle Mode Safety Shutdown BEFORE INITIAL START-UP Job Data Required Equipment Required Using the Economizer/Storage Vessel and Pump- out System Remove Shipping Packaging Motor Auxiliary Devices Open Oil Circuit V alves Tighten All Gasketed Joints and Guide Vane Shaft Packing Check Chiller Tightness Refrigerant T racer Page Table 5A HFC-134a Pressure Temperature (F) Table 5B HFC-134a Pressure Temperature (C) Standing V acuum T est Chiller Dehydration Inspect W ater Piping Check Optional Pumpout Compressor Water Pip- ing Check Relief Devices Inspect Wiring Motor Pre-Start Checks External Gear Pre-Start Checks Page Carrier Comfort Network Interface Check Starter Compressor Oil Charge Power Up the Controls and Check the Com- pressor Oil Heater Set Up Chiller Control Conguration Input the Design Set Points Input the Local Occupied Schedule (OCCPC01S) Page Check Pumpout System Controls and Optional Pumpout Compressor High Altitude Locations Charge Refrigerant into Chiller INITIAL START-UP Preparation Manual Operation of the Guide V anes Dry Run to Test Start-Up Sequence Check Motor Rotation Disc Coupling Installation andAlignment Be- Page Check Oil Pressure and Compressor Stop Calibrate Motor Current Demand Setting T o Prevent Accidental Start-Up Hot Alignment Check Doweling Instruct the Operator OPERATING INSTRUCTIONS Operator Duties Prepare the Chiller for Start-Up Starting the Chiller Check the Running System After Limited Shutdown Extended Shutdown After Extended Shutdown Cold Weather Operation Manual Guide V ane Operation Fig. 31 Refrigeration Log REAR VIEW Transferring Refrigerant into the Economizer/ Storage V essel Transferring Refrigerant into the Cooler/ Condenser/Compressor Section Return Chiller to Normal Operating Conditions GENERAL MAINTENANCE Refrigerant Properties Adding Refrigerant Removing Refrigerant Repair the Leak, Retest, and Apply Standing V acuum T est Checking Guide V ane Linkage Contact Seal Maintenance (Refer to Fig. 36) Page Page Chiller Alignment Page Page Page Page WEEKLY MAINTENANCE Check the Lubrication System SCHEDULED MAINTENANCE Service Ontime Inspect the Control Center Check Safety and Operating Controls Monthly Oil Specications Oil Changes Inspect Refrigerant Float System Inspect Relief V alves and Piping Coupling Maintenance Motor Maintenance Page Page Motor Handling/Rigging Motor Storage External Gear Storage Compressor Bearing Maintenance External Gear Maintenance Inspect the Heat Exchanger Tubes W ater Leaks W ater T reatment Inspect the Starting Equipment Check Pressure T ransducers Pumpout System Maintenance Ordering Replacement Chiller Parts TROUBLESHOOTING GUIDE Overview Checking the Display Messages Checking T emperature Sensors Checking Pressure T ransducers Control Algorithms Checkout Procedure Control T est LEGEND FOR TABLE 12, A - N with Troubleshooting Guides E. NORMAL OR AUTO.-RESTART F. SPARE SENSOR ALERT MESSAGES G. START-UP FAILURES: This is an alarm condition. A manual reset is required to clear. H. COMPRESSOR JUMPSTART AND REFRIGERANT PROTECTION I. NORMAL RUN WITH RESET, TEMPERATURE, OR DEMAND J. NORMAL RUN OVERRIDES ACTIVE (ALERTS) K. OUT-OF-RANGE SENSOR FAILURES Page M. CHILLER ALERTS RECYCLE RE- START DELTA T N. OTHER PROBLEMS/MALFUNCTIONS PROPORTIONAL INC BAND LOCAL DEVICE PRO- PORTIONAL DEC BAND Table 13 External Gear Troubleshooting Guide Table 14A Thermistor Temperature (F) vs Resistance/Voltage Drop Table 14B Thermistor Temperature (C) vs Resistance/Voltage Drop Control Modules Notes on Module Operation Processor/Sensor Input/Output Module (PSIO) (Fig. 52) Starter Management Module (SMM) (Fig. 53) Options Modules (8-Input) Four-In/Two-Out Module (Fig. 55) Replacing Defective Processor Modules PHYSICAL DATA AND WIRING SCHEMATICS Table 15 17EX Heat Exchanger Economizer/Storage Vessel, Piping, and Pumpout Unit Weights* Table 16 Additional Cooler Weights* Fig. 56 Model Number Nomenclature for Compressor Size (See Fig. 1 Also) Table 17 Additional Condenser Weights* Table 18 Compressor Weight and Elbow Weight Table 19 Drive Component Weights* Table 20A Total Motor Weight, English (lb) Table 20B Total Motor Weight, SI (kg) Table 21 Marine Waterbox Cover Weights* Table 22 NIH Waterbox Cover Weights* Table 23 Approximate Refrigerant (HCFC-134a) Charge* Table 24 Auxiliary Systems, Electrical Data Table 25 Relief Valve Locations and Data Page Table 26 Compressor Fits and Clearances Tabulation Impeller Clearances (Open-Drive Compressors) Fig. 58 Typical 17EX Power Panel and Control Panel Wiring Schematic Fig. 58 Typical 17EX Power Panel and Control Panel Wiring Schematic (cont) Page Page Fig. 60 Field Wiring Diagram (Medium Voltage Motor, PIC Controls With Free-Standing Starter) NOTES FOR FIG. 60 Page INDEX