Carrier 17/19EX User guide

17/19EX
50/60 Hz
Centrifugal Liquid Chillers
with HFC-134a
Start-Up, Operation, and Maintenance Instructions
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and
without incurring obligations.
PC 211 Catalog No. 531-715 9-95 Form 17/19EX-1SS Replaces: 19EX-1SS
Copyright © Carrier Corporation 1995
Safety Considerations
Centrifugal liquid chillers are designed to provide safe and reliable service when
operated within design specifications. When operating this equipment, use good
judgement and safety precautions to avoid damage to equipment and property or injury
to personnel.
Be sure you understand and follow the procedures and safety precautions contained
in the machine instructions as well as those listed in this guide.
®

DO NOT VENT refrigerant relief valves within a building. Outlet from rupture disc
or relief valve must be vented outdoors in accordance with the latest edition of
ASHRAE 15 (Safety Code for Mechanical Refrigeration). The accumulation of
refrigerant in an enclosed space can displace oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ASHRAE 15, especially for
enclosed and low overhead spaces. Inhalation of high concentrations of vapor is
harmful and may cause heart irregularities, unconsciousness, or death. Misuse
can be fatal. Vapor is heavier than air and reduces the amount of oxygen avail-
able for breathing. Product causes eye and skin irritation. Decomposition prod-
ucts are hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a machine for any purpose.
Oxygen gas reacts violently with oil, grease, and other common substances.
NEVER EXCEED specified test pressures, VERIFY the allowable test pressure by
checking the instruction literature and the design pressures on the equipment
nameplate.
DO NOT USE air for leak testing. Use only refrigerant or dry nitrogen.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed and functioning
before operating any machine.
DANGER !DANGER

DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all refrigerant
(
liquid and vapor
) has been removed from chiller. Traces of vapor should be dis-
placed withdry air or nitrogen and the work area should be well ventilated.
Refrig-
erant in contact with an open flame produces toxic gases
.
DO NOT USE eyebolts or eyebolt holes to rig machine sections or the entire
assembly.
DO NOT work on high-voltage equipment unless you are a qualified electrician.
DO NOT WORK ON electrical components, including control panels, switches,
starters, or oil heater until you are sure ALL POWER IS OFF and no residual volt-
age can leak from capacitors or solid-state components.
LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTER-
RUPTED, confirm that all circuits are deenergized before resuming work.
AVOID SPILLING liquid refrigerant on skin or getting it into the eyes. USE SAFETY
GOGGLES. Wash any spills from the skin with soap and water. If any enters the
eyes, IMMEDIATELY FLUSH EYES with water and consult a physician.
NEVER APPLY an open flame or live steam to a refrigerant cylinder. Dangerous
overpressure can result. When 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, evacuate remaining
WARNING !WARNING

gas pressure, loosen the collar and unscrew and discard the valve stem. DO NOT
INCINERATE.
CHECK THE REFRIGERANT TYPE before adding refrigerant to the machine. The
introduction of the wrong refrigerant can cause damage or malfunction to this
machine.
Operation of this equipmentwith refrigerantsother than those cited herein should
comply with ASHRAE-15 (latest edition). Contact Carrier for further information
on use of this machine with other refrigerants.
DO NOTATTEMPT TO REMOVE fittings, covers, etc., while machine is under pres-
sure or while machine is running. Be sure pressure is at 0 psig (0 kPa) before
breaking any refrigerant connection.
CAREFULLY INSPECT all relief devices, rupture discs, and other relief devices AT
LEAST ONCE A YEAR. If machine operates in a corrosive atmosphere, inspect the
devices at more frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief device when corro-
sion or build-up of foreign material (rust, dirt, scale, etc.) is found within the valve
body or mechanism. Replace the device.
DO NOT install relief devices in series or backwards.
USE CARE when working near or in line with a compressed spring. Sudden
release of the spring can cause it and objects in its path to act as projectiles.
WARNING !WARNING

CAUTION CAUTION
!
DO NOT STEP on refrigerant lines. Broken lines can whip about and cause per-
sonal injury.
DO NOT climb over a machine. Use platform, catwalk, or staging. Follow safe
practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move inspection cov-
ers or other heavy components. Even if components are light, use such equip-
ment when there is a risk of slipping or losing your balance.
BE AWARE that certain automatic start arrangements CAN ENGAGE THE
STARTER. Open the disconnect
ahead of
the starter in addition to shutting off
the machine or pump.
USE only repair or replacement parts that meet the code requirements of the
original equipment.
DO NOT VENT OR DRAIN waterboxes containing industrial brines, liquid, gases,
or semisolids without permission of your process control group.
DO NOT LOOSEN waterbox cover bolts until the waterbox has been completely
drained.
DOUBLE-CHECK that coupling nut wrenches, dial indicators, or other items have
been removed before rotating any shafts.
DO NOT LOOSEN a packing gland nut before checking that the nuthas a positive
thread engagement.

CAUTION CAUTION
!
PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks,
or damage.
PROVIDE A DRAIN connection in the vent line near each pressure relief device to
prevent a build-up of condensate or rain water.

Contents
List of Tables
List of Figures
Safety Considerations
Introduction
Abbreviations
17/19EX Machine Familiarization
Machine Identification Label
System Components
Cooler
Condenser
Motor-Compressor
Control Center
Motor Starter
Utility Vessel

Contents
Refrigeration Cycle
Motor/Oil Refrigeration Cooling Cycle
Hermetic Machines (19 Series) Lubrication Cycle
Summary
Details
Open-Drive Machines (17 Series) Lubrication Cycle
Summary
Details
Starters
Controls
Definitions
Analog Signal
Digital Signal
Volatile Memory

Contents
General
PIC System Components
Processor Module (PSIO)
Starter Management Module (SMM)
Local Interface Device (LID)
6-Pack Relay Board
8-Input Modules
Oil Heater Contactor (1C)
Oil Pump Contactor (2C)
Hot Gas Bypass Contactor Relay (3C) (Optional)
Control Transformers (T1-T4)
Control and Oil Heater Voltage Selector (S1)
Oil Differential Pressure/Power Supply Module

Contents
LID Operation and Menus
General
Alarms and Alerts
LID Default Screen Menu Items
Menu Structure
To View or Change Point Status
Override Operations
To View or Change Time Schedule Operation
To View and Change Set Points
Service Operation
PIC System Functions
Capacity Control
Entering Chilled Water Control
Deadband
Proportional Bands and Gain

Contents
Demand Limiting
Machine Timers
Occupancy Schedule
Safety Controls
Shunt Trip
Default Screen Freeze
Motor Cooling Control (Hermetic Motors Only)
Auxiliary Oil Pump Control (Open-Drive Machines Only)
Shaft Seal Oil (Open Drive Machines Only)
Ramp Loading Control
Capacity Override
High Discharge Temperature Control
Oil Sump Temperature Control
Oil Cooler
Remote Start/Stop Controls

Contents
Spare Safety Inputs
Spare Alarm Contacts
Condenser Pump Control
Condenser Freeze Prevention
Tower-Fan Relay
Auto. Restart After Power Failure
Water/Brine Reset
Demand Limit Control, Option (Requires Optional 8-Input Module)
Surge Prevention Algorithm
Surge Protection
Lead/Lag Control
Common Point Sensor Installation
Machine Communication Wiring
Lead/Lag Operation
Faulted Chiller Operation

Contents
Load Balancing
Auto. Restart After Power Failure
Ice Build Control
Ice Build Initiation
Start-Up/Recycle 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 On
To Log Off
Holiday Scheduling

Contents
Start-Up/Shutdown/Recycle Sequence
Local Start-Up
Shutdown Sequence
Automatic Soft Stop Amps Threshold
Chilled Water Recycle Mode
Safety Shutdown
Before Initial Start-Up
Job Data Required
Equipment Required
Using the Utility Vessel and Pumpout System
Remove Shipping Packaging
Open-Drive Motor Electrical Connection
Open-Drive Motor Auxiliary Devices
Open Oil Circuit Valves

Contents
Torque All Gasketed Joints
Check Machine Tightness
Refrigerant Tracer
Leak Test Machine
Standing Vacuum Test
Machine Dehydration
Inspect Water Piping
Check Optional Pumpout Compressor Water Piping
Check Relief Devices
Inspect Wiring
Check Insulation Resistance (Hermetic Motor)
Check Insulation Resistance (Open-Drive Motor)
Open-Drive Motor Pre-Start Checks
Carrier Comfort Network Interface

Contents
Check Starter
Mechanical-Type Starters
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
Input the Local Occupied Schedule (OCCPC01S)
Input Service Configurations
Password
Input Time and Date
Change LID Configuration If Necessary
Modify Controller Identification If Necessary
Input Equipment Service Parameters If Necessary

Contents
Modify Equipment Configuration If Necessary
Check Voltage Supply
Perform an Automated Control Test
Check Pumpout System Controls and Optional Pumpout Compressor
High Altitude Locations
Charge Refrigerant into Machine
Trimming Refrigerant Charge
Initial Start-Up
Preparation
Manual Operation of the Guide Vanes
Dry Run to Test Start-Up Sequence
Check Rotation (Open-Drive Motor)
Check Rotation (Hermetic Motor)
If Rotation Is Proper
If the Motor Rotation Is Not Clockwise

Contents
Check Oil Pressure and Compressor Stop
Calibrate Motor Current Demand Setting
To Prevent Accidental Start-Up
Hot Alignment Check for Open-Drive Machines
Doweling for Open-Drive Machines
Check Machine Operating Condition
Instruct the Customer Operator
Cooler-Condenser
Utility Vessel
Pumpout System
Motor Compressor Assembly
Motor Compressor Lubrication System
Control System
Auxiliary Equipment
Describe Machine Cycles

Contents
Review Maintenance
Safety Devices and Procedures
Check Operator Knowledge
Review the Start-Up, Operation, and Maintenance Manual
Operating Instructions
Operator Duties
Prepare the Machine for Start-Up
To Start the Machine
Check the Running System
To Stop the Machine
After Limited Shutdown
Extended Shutdown
After Extended Shutdown
Cold Weather Operation
Manual Guide Vane Operation
Refrigeration Log

Contents
Pumpout and Refrigerant Transfer Procedures
Preparation
Operating the Optional Pumpout Compressor
To Read Refrigerant Pressures
Transferring Refrigerant from Normal Operation into the Utility Vessel
Transferring Refrigerant from Normal Operation into the
Cooler/Condenser/Compressor Section
Return Refrigerant to Normal Operating Conditions
General Maintenance
Refrigerant Properties
Adding Refrigerant
Removing Refrigerant
Adjusting the Refrigerant Charge
Refrigerant Leak Testing
Leak Rate