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