Carrier 17, Start Up & Operation Manual

Page 1: ...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 DANGEROUSAND ILLEGAL When cylinder is emp tied evacuate remaining gas pressure loosen the collar and unscrew and discar...

Page 2: ...achines Only 36 Shaft Seal Oil Open Drive Machines Only 36 Ramp Loading Control 36 Capacity Override 36 High Discharge Temperature Control 36 Oil Sump Temperature Control 38 Oil Cooler 38 Remote Start Stop Controls 38 Spare Safety Inputs 38 Spare Alarm Contacts 38 Condenser Pump Control 39 Condenser Freeze Prevention 39 Tower Fan Relay 39 Auto Restart After Power Failure 39 Water Brine Reset 39 De...

Page 3: ...RT UP OPERATION AND MAINTENANCE MANUAL OPERATING INSTRUCTIONS 61 63 Operator Duties 61 Prepare the Machine for Start Up 61 To Start the Machine 61 Page Check the Running System 61 To Stop the Machine 61 After Limited Shutdown 61 Extended Shutdown 62 After Extended Shutdown 62 Cold Weather Operation 62 Manual Guide Vane Operation 62 Refrigeration Log 62 PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES 6...

Page 4: ...reme care when handling tools near boards and when connecting or disconnecting terminal plugs Circuit boards can easily be damaged Always hold boards by the edges and avoid touching components and connections This equipment uses and can radiate radio frequency energy If not installed and used in accordance with the instruction manual it may cause interference to radio communications It has been te...

Page 5: ... size 51 89 or 421 469 compressors Open drive motor codes UNDERWRITERS LABORATORIES CANADA ASME U STAMP UNDERWRITERS LABORATORIES ARI Air Conditioning and Refrigeration Institute PERFORMANCE CERTIFIED 60 Hz Only MODEL NUMBER NOMENCLATURE SERIAL NUMBER BREAKDOWN Fig 1 17 19EX Identification 5 ...

Page 6: ... Terminals 17 Oil Level Sight Glasses 18 Oil Drain and Charging Valve 19 Oil Heater Hidden 20 Oil Pump 21 Refrigerant Charging Service Valve 10 Not Shown 22 Cooler Relief Valves Not Shown 23 Economizer Storage Vessel 24 Oil Cooler 25 Control Center 26 Economizer Storage Vessel Relief Valves 27 Pumpout Unit 28 High Side Float Box Cover 29 Cooler 30 Cooler Waterbox Drain 31 Take Apart Connections Ty...

Page 7: ...18 Cooler Relief Valves Not Shown 19 Oil Heater Not Shown 20 Auxiliary Power Panel Field Wiring Terminals 21 Pumpdown Unit Not Shown 22 Low Side Float Box Cover 23 Refrigerant Liquid Line to Cooler 24 Oil Drain and Charging Valve 25 Oil Pump 26 Refrigerant Charging Service Valve 10 Not Shown 27 Oil Cooler 28 Isolation Valves Not Shown 29 Refrigerant Filter Drier 30 Local Interface Display Control ...

Page 8: ...or thereby cool ing the remaining liquid The vapor is then recondensed by the condenser water flowing through the FLASC chamber The subcooled liquid refrigerant drains into a high side valve chamber which meters the refrigerant liquid into a flash economizer chamber Pressure in this chamber is interme diate between condenser and cooler pressures At this lower pressure some of the liquid refrigeran...

Page 9: ...LEGEND TXV Thermostatic Expansion Valve Liquid Liquid Vapor Vapor The FA compressor has a water cooled oil cooler Fig 4 Refrigerant Motor Cooling and Oil Cooling Cycles 19EX Shown 9 ...

Page 10: ...ion flows to the motor end bearing Item 19 and seal The remainder lubricates the compressor transmission Item 2 and the thrust and journal bearings Item 3 Thrust bearing temperature is indicated at the Local Interface De vice LID Oil from each circuit returns by gravity to the reservoir A demister Items 17 and 18 by centrifugal action draws refrigerant gas from the transmission area to the motor s...

Page 11: ...upply Flow Oil Return Flow Pressure Control Lines Refrigerant Capillary Tubing Filled System The FA compressor has a water cooled oil cooler Oil temperature is manually controlled Fig 5 Hermetic Compressor Lubrication System EX Compressor Shown 11 ...

Page 12: ... even when the machine is not operating to prevent loss of refrigerant If the machine is not operating and the oil pump has not operated during the last 12 hours the control system will automatically run the oil pump for one minute in order to keep the contact seal filled with oil IMPORTANT If the control power is to be deener gized for more than one day the machine refrigerant should be pumped ov...

Page 13: ...Fig 6 Open Drive 17 Series Lubrication Cycle 13 ...

Page 14: ...ltage remote start contact spare safety condenser high pressure oil pump interlock motor current signal starter 1M and run contacts and kW trans ducer input optional The SMM contains logic capable of safely shutting down the machine if communication with the PSIO is lost LOCALINTERFACE DEVICE LID The LID is mounted to the control center and allows the operator to interface with the PSIO or other C...

Page 15: ...Fig 7 17EX Controls and Sensor Locations 15 ...

Page 16: ...Fig 7 17EX Controls and Sensor Locations cont 16 ...

Page 17: ...Fig 7 17EX Controls and Sensor Locations cont 17 ...

Page 18: ...Fig 8 19EX Controls and Sensor Locations MACHINE REAR COMPRESSOR SIDE VIEW COMPRESSOR END VIEW MACHINE REAR VIEW 18 ...

Page 19: ...Fig 8 19EX Controls and Sensor Locations cont 19 ...

Page 20: ...den 5 LID Light Hidden 6 6 Pack Relay Board 7 Circuit Breakers 4 Fig 9 Control Center Front View Shown with Options Module Fig 10 Control Sensors Temperature Fig 11 Control Sensors Pressure Transducer Typical LEGEND 1 T2 Power Transformer Hot Gas Bypass Relay Oil Pump Relay and Oil Heater Relay 2 T1 Control Center Transformer 3 Oil Heater Contactor 1C 4 Oil Pump Contactor 2C 5 Factory Terminal Con...

Page 21: ...m and alert status are indicated on the Default screen and the Status tables An alarm will shut down the compressor An alert notifies the operator that an unusual condition has occurred The ma chine will continue to operate when an alert is shown Alarms are indicated when the control center alarm light flashes The primary alarm message is viewed on the de fault screen and an additional secondary m...

Page 22: ...e pend on whether the selected item is a discrete point ana log point or an override point At this point press the soft key that corresponds to your configuration selection or press the QUIT softkey If the QUIT softkey is depressed the configuration will not be modified Use the following soft keys to access and select the desired section MENU STRUCTURE To perform any of the operations described be...

Page 23: ...Fig 16 17 19EX LID Menu Structure 23 ...

Page 24: ...Fig 17 17 19EX Service Menu Structure 24 ...

Page 25: ...s NEXT or PREVIOUS to highlight the desired point 2 Press SELECT to access the highlighted point 3 Press RELEASE to remove the override and return the point to the PIC s automatic control Override Indication An override value is indicated by SUPVSR SERVC or BEST flashing next to the point value on the Status table TO VIEW OR CHANGE TIME SCHEDULE OPERATION Fig 19 1 On the Menu screen press SCHEDULE...

Page 26: ...riods to function TO VIEW AND CHANGE SET POINTS Fig 20 1 To view the Set Point table at the Menu screen press SETPOINT 2 There are 4 set points on this screen Base Demand Limit LCW Set Point leaving chilled water set point ECW Set Point entering chilled water set point and ICE BUILD set point Only one of the chilled water set points can be active at one time and the type of set point is activated ...

Page 27: ...18 DEG F DEG C ECW Leaving Chilled Water 40 245 40 118 DEG F DEG C LCW Entering Condenser Water 40 245 40 118 DEG F DEG C ECDW Leaving Condenser Water 40 245 40 118 DEG F DEG C LCDW Evaporator Refrig Temp 40 245 40 118 DEG F DEG C ERT Evaporator Pressure 6 7 420 46 2896 PSI kPa ERP Condenser Refrig Temp 40 245 40 118 DEG F DEG C CRT Condenser Pressure 6 7 420 46 2896 PSI kPa CRP Discharge Temperat...

Page 28: ...ormation is applicable to hermetic machines only Information is applicable to open drive machines only EXAMPLE 3 STATUS03 DISPLAY SCREEN To access this display from the LID default screen 1 Press MENU 2 Press STATUS 3 Scroll down to highlight STATUS03 4 Press SELECT DESCRIPTION RANGE UNITS REFERENCE POINT NAME ALARM HISTORY OPTIONS BOARD 1 Demand Limit 4 20 mA 4 20 mA DEM OPT Temp Reset 4 20 mA 4 ...

Page 29: ...Full Reset 40 245 40 118 DEG F DEG C res rt2 65 18 Degrees Reset 30 30 17 17 DEG F DEG C res rt 10D 6D RESET TYPE 3 CHW Delta T No Reset 0 15 0 8 DEG F DEG C restd 1 10D 6D CHW Delta T Full Reset 0 15 0 8 DEG F DEG C restd 2 0D 0D Degrees Reset 30 30 17 17 DEG F DEG C deg chw 5D 3D Select Enable Reset Type 0 3 res sel 0 ECW CONTROL OPTION DISABLE ENABLE ecw opt DISABLE Demand Limit At 20 mA 40 100...

Page 30: ... RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE LEAD LAG SELECT DISABLE 0 LEAD 1 LAG 2 STANDBY 3 0 3 leadlag 0 Load Balance Option DISABLE ENABLE loadbal DISABLE Common Sensor Option DISABLE ENABLE commsens DISABLE LAG Percent Capacity 25 75 lag per 50 LAG Address 1 236 lag add 92 LAG START Timer 2 60 MIN lagstart 10 LAG STOP Timer 2 60 MIN lagstop 10 PRESTART FAULT Timer 0 30 MIN preflt 5 STANDBY...

Page 31: ... 8 Recycle Shutdown Delta 0 5 4 0 27 2 2 rcycsdt 1 0 0 6 Surge Limit HGBP Option 0 1 srg hgbp 0 Select Surge 0 HGBP 1 Surge HGBP Delta T1 0 5 15 0 3 8 3 DEG F DEG C hgb dt1 1 5 0 8 Surge HGBP Delta P1 30 170 207 1172 PSI kPa hgb dp1 50 345 Min Load Points T1 P1 Surge HGBP Delta T2 0 5 15 0 3 8 3 DEG F DEG C hgb dt2 10 5 6 Surge HGBP Delta P2 30 170 207 1172 PSI kPa hgb dp2 85 586 Full Load Points ...

Page 32: ...mp Alert Threshold Spare Temp 4 Enable 0 4 spr4 en 0 Spare Temp 4 Alert 40 245 40 118 DEG F DEG C spr4 al 245 118 Spare Temp 5 Enable 0 4 spr5 en 0 Spare Temp 5 Alert 40 245 40 118 DEG F DEG C spr5 al 245 118 Spare Temp 6 Enable 0 4 spr6 en 0 Spare Temp 6 Alert 40 245 40 118 DEG F DEG C spr6 al 245 118 Spare Temp 7 Enable 0 4 spr7 en 0 Spare Temp 7 Alert 40 245 40 118 DEG F DEG C spr7 al 245 118 S...

Page 33: ...show the associated point in alert Only values with capital letter reference point names are variables available for read operation EXAMPLE 11 MAINTENANCE MAINT02 DISPLAY SCREEN To access this display from the LID default screen 1 Press MENU 2 Press SERVICE 3 Scroll down to highlight CONTROL ALGORITHM STATUS 4 Press SELECT 5 Scroll down to highlight MAINT02 6 Press SELECT DESCRIPTION RANGE STATUS ...

Page 34: ...light MAINT04 6 Press SELECT DESCRIPTION RANGE STATUS UNITS REFERENCE POINT NAME LEAD LAG Configuration DISABLE LEAD LAG STANDBY INVALID leadlag Current Mode DISABLE LEAD LAG STANDBY CONFIG llmode Load Balance Option DISABLE ENABLE loadbal LAG Start Time 0 60 MIN lagstart LAG Stop Time 0 60 MIN lagstop Prestart Fault Time 0 30 MIN preflt Pulldown Delta T Min x xx D DEG F D DEG C pull dt Satisfied ...

Page 35: ...ESSOR MOTOR LOAD or COMPRESSOR MOTOR CUR RENT percentage depending on how the control is con figured for the DEMAND LIMIT SOURCE which is accessed on the SERVICE1 table The default setting is current limiting MACHINE TIMERS The PIC maintains 2 runtime clocks known as COMPRESSOR ONTIME and SERVICE ONTIME COMPRESSOR ONTIME indicates the total life time compressor run hours This timer can register up...

Page 36: ...the shaft seal be bathed in oil at all times especially when the machine is not running This ensures that refrigerant does not leak past the seal The PIC control will energize the oil pump for one minute if the oil pump has not operated during the past 12 hours It is important to note that if control power is to be turned off for longer than this period the refrigerant charge must be pumped over i...

Page 37: ...to 24 vac rated input to the Starter Management Module Also monitored at PSIO power input LOW 90 for one minute or 85 for 3 seconds SINGLE CYCLE 50 for one cycle COMPRESSOR MOTOR LOAD Compressor Amps 110 for 30 seconds Preset 10 with compressor running Preset 10 with compressor off Preset STARTER ACCELERATION TIME Determined by inrush current going below 100 compressor motor load 45 seconds For ma...

Page 38: ...that may result from refrigerant migration into the oil sump during the power failure The vane opening will be slowed to a value of 2 F 1 1 C per minute with temperature ramp loading Oil Cooler The oil must be cooled when the compres sor is running EX Compressors This is accomplished through a small plate type heat exchanger The heat exchanger uses liquid con denser refrigerant as the cooling liqu...

Page 39: ...ol can be used to help prevent low condenser water temperatures and associated problems Auto Restart After Power Failure This option may be enabled or disabled and may be viewed modified in the Config table of Equipment Configuration If enabled the chiller will start up automatically after a single cycle drop out low high or loss of voltage has occurred and the power is within 10 of normal The 15 ...

Page 40: ...ng one of 2 choices If a hot gas bypass line is present and the hot gas is con figured on the Service1 table then the hot gas bypass valve can be energized If a hot gas bypass if not present then the action taken is to hold the guide vanes See Table 4 Capac ity Overrides Both of these corrective actions will reduce the lift experienced by the compressor and help to prevent a surge condition Surge ...

Page 41: ...en the LEAD LAG SELECT value for that chiller is configured to the value of 1 The configured lag chiller is identified when the LEAD LAG SELECT for that chiller is configured to the value of 2 The standby chiller is configured to a value of 3 A value of 0 disables the lead lag in that chiller To configure the LAG ADDRESS value on the LEAD LAG Configuration table always use the address of the other...

Page 42: ...shuts down If only one chiller is running the lead chiller will wait for a start request from the operating chiller When the configured lead chiller starts it assumes its role as lead chiller LOAD BALANCING When the LOAD BALANCE OP TION is enabled the lead chiller will set the ACTIVE DE MAND LIMIT in the lag chiller to the lead chiller s COM PRESSOR MOTOR LOAD value This value has limits of 40 to ...

Page 43: ...contacts are open In this case the contacts are provided for ice level termination control The remote contacts can still be opened and closed to start and stop the chiller when the Ice Build Time Schedule is UNOCCUPIED The con tacts are used to stop the ICE BUILD mode when the Ice Build Time Schedule is OCCUPIED 4 ECW TEMPERATURE and Remote Contacts Termi nation of compressor operation shall occur...

Page 44: ...y logging on again NOTE The initial factory set password is 1 1 1 1 TO LOG OFF Access the Log Out of Device table of the Service menu in order to password protect the Service menu The LID will automatically sign off and password protect itself if a key is not pressed for 15 minutes The LID default screen is then displayed HOLIDAY SCHEDULING Fig 24 The time schedules may be configured for special o...

Page 45: ...ess than or equal to this value the PIC will turn off the condenser pump relay and go into a RECYCLE mode If the water brine tempera ture is high enough the start up sequence continues on to check the guide vane position If the guide vanes are more than 6 open the start up waits until the PIC closes the vanes If the vanes are closed and the oil pump pressure is less than 4 psid 28 kPad the oil pum...

Page 46: ...s shown Chilled Water Recycle Mode The machine may cycle off and wait until the load increases to restart again when the compressor is running in a lightly loaded condition This cycling of the chiller is normal and is known as recycle A recycle shutdown is initiated when any of the following conditions are true when in LCW control the difference between the LEAV ING CHILLED WATER temperature and E...

Page 47: ...for restraining the rotor the Westinghouse logo must be installed over the hole in the endcover The logo the gasket and hardware can be found with the parts that have been shipped loose Usu ally these are packed inside of the main power lead box Open Drive Motor Electrical Connection All interconnecting wiring for controls and grounding should be in strict accordance with both the National Electri...

Page 48: ...tors also can be used if the machine is under pressure Do not use air or oxygen as a means of pressurizing the machine Some mixtures of HFC 134a and air can un dergo combustion Leak Test Machine Due to regulations regarding re frigerant emissions and the difficulties associated with sepa rating contaminants from refrigerant Carrier recommends the following leak test procedures See Fig 28 for an ou...

Page 49: ...cedures section page 64 to at least 18 in Hg vac ref 30 in bar 41 kPa using a vacuum pump or the pump out unit 3 Valve off the pump to hold the vacuum and record the manometer or indicator reading 4 a If the leakage rate is less than 0 05 in Hg 17 kPa in 24 hours the machine is sufficiently tight b If the leakage rate exceeds 0 05 in Hg 17 kPa in 24 hours repressurize the vessel and test for leaks...

Page 50: ...Fig 28 17 19EX Leak Test Procedures 50 ...

Page 51: ...ired for boiling off any moisture If low ambient temperatures are involved contact a qualified service representative for the dehydration techniques required Perform dehydration as follows 1 Connect a high capacity vacuum pump 5 cfm 002 m3 s or larger is recommended to the refrigerant charging valve Fig 7 and 8 Tubing from the pump to the machine should be as short and as large a diameter as possi...

Page 52: ...rols are prop erly grounded in accordance with job drawings certi fied drawings and all applicable electrical codes 8 Make sure that the customer s contractor has verified proper operation of the pumps cooling tower fans and associated auxiliary equipment This includes ensuring that motors are properly lubricated and have proper elec trical supply and proper rotation 9 Tighten up all wiring connec...

Page 53: ... sulation temperature above the dew point temperature Open Drive Motor Pre Start Checks To pre vent damage to the motor the following steps must be taken prior to initial start up 1 Remove the shaft shipping brace if supplied 2 For sleeve bearing motors the oil reservoir must be filled with oil to the correct level The proper oil is a rust and oxidation inhibited turbine grade oil The viscosity of...

Page 54: ... set check that the starter with relay 1CR closed goes through a complete and proper start cycle SOLID STATE STARTERS This equipment is at line voltage when AC power is con nected Pressing the Stop button does not remove volt age Use caution when adjusting the potentiometers on the equipment 1 Check that all wiring connections are properly termi nated to the starter 2 Verify that the ground wire t...

Page 55: ...IF NECES SARY The controller identification screen is used to change the PSIO module address Change this address for each ma chine if there is more than one machine at the job site Write the new address on the PSIO module for future reference INPUT EQUIPMENT SERVICE PARAMETERS IF NEC ESSARY The Equipment Service table has 3 service tables Service1 Service2 and Service3 Configure SERVICE1 Table Acc...

Page 56: ...ual for more information on these tables These tables can only be defined through a CCN Building Supervisor CHECK VOLTAGE SUPPLY Access the Status 01 screen and read the LINE VOLTAGE ACTUAL value This reading should be equal to the incoming power to the starter Use a voltmeter to check incoming power at the starter power leads If the readings are not equal an adjustment can be made by selecting th...

Page 57: ...o allow free spring travel Open the compressor suction and discharge service valves Check that oil is visible in the compressor sight glass Add oil if necessary See Pumpout and Refrigerant Transfer Procedures page 64 and Pumpout System Maintenance sections page 82 for details on transfer of refrigerant oil specifi cations etc High Altitude Locations Recalibration of the pres sure transducers will ...

Page 58: ... Power to the controls oil pump and starter control circuit should still be energized 2 Look at the default screen on the LID the Status mes sage in the upper left hand corner will show a Manually Stopped message Press CCN or Local to start If not go to the Schedule screen and override the schedule or change the occupied time Press the LOCAL softkey to begin the start up sequences 3 Check that chi...

Page 59: ...nt of the oil ring If the bearing temperature rise and motor operation ap pear normal operation should continue until the bearing temperatures stabilize 7 If possible check the motor line currents for balance It should be recognized that each start of an induction mo tor subjects the motor to full inrush current with resulting heating of the stator and rotor windings Each acceleration and repeated...

Page 60: ...ve Never operate compressor or drive with coupling guards removed Serious injury can result from contact with ro tating equipment Doweling for Open Drive Machines The size quantity and location of dowels vary considerably with type and arrangement of gear and drive Check your job data for specific doweling instructions Typical doweling practices are described in the Maintenance section Check Machi...

Page 61: ...en 100 and 210 psig 690 to 1450 kPa with a cor responding temperature range of 60 to 105 F 15 to 41 C The condenser entering water temperature should be controlled below the specified design entering water temperature to save on compressor kilowatt require ments The leaving condenser water temperature should be at least 20 F 11 C above leaving chilled water temperature 7 Cooler pressure and temper...

Page 62: ...l tempera ture is above 150 F 66 C or cooler refrigerant temperature plus 70 F 39 C Cold Weather Operation When the entering con denser water drops very low the PIC can automatically cycle the cooling tower fans off to keep the temperature up Piping may also have to be arranged to bypass the cooling tower as well as a tower temperature control system Manual Guide Vane Operation Manual opera tion o...

Page 63: ...efrigerant Water Refrigerant Water BEAR ING TEMP Oil Motor Press Temp Pressure Temp Press Temp Pressure Temp Press Diff Temp reser voir Level FLA In Out GPM In Out In Out GPM In Out Amperage or vane position REMARKS Indicate shutdowns on safety controls repairs made oil or refrigerant added or removed air exhausted and water drained from dehydrator Include amounts Fig 31 Refrigeration Log 63 ...

Page 64: ...ight glass under all operating conditions and during shutdown If oil is low add oil as described under Pumpout System Main tenance section page 82 The pumpout unit control wir ing schematic is detailed in Fig 33 The Optional Pum pout System is detailed in Fig 34 TO READ REFRIGERANT PRESSURES during pumpout or leak testing 1 The LID display on the machine control center is suitable for determining ...

Page 65: ...Fuse 3 Amps HP High Pressure Cutout OL Compressor Overload T stat Internal Thermostat Compressor Terminal Contactor Terminal Overload Terminal Pumpout Unit Terminal Bimetal thermal protector imbedded in motor winding Fig 33 Pumpout Unit Wiring Schematic 19EX Shown Fig 34 Optional Pumpout Compressor 65 ...

Page 66: ...ty vessel 1 Isolate and push refrigerant into the cooler condenser compressor section a Valve positions VALVE 1 2 3 4 5 6 7 8 9 10 11 CONDITION C C C C C C b Turn off machine water pumps and pumpout con denser water c Turn on pumpout compressor to push refrigerant out of the utility vessel d When all liquid is out of the utility vessel close cooler isolation valve 7 e Turn off pumpout compressor 2...

Page 67: ...for other service work Test After Service Repair or Major Leak If all refrigerant has been lost or if the machine has been opened for service the machine or the affected vessels must be pres sured and leak tested Refer to the Leak Test Machine sec tion page 48 to perform a leak test HFC 134a MUST NOT be mixed with air or oxygen and pressurized for leak testing In general this refrig erant should n...

Page 68: ...ct sleeve assembly face down on a soft cloth or clean cardboard Protect seal faces at all times 8 Press down on seal housing cover to compress the con tact sleeve spring 9 Maintain pressure and remove snap ring 10 Slowly release pressure on cover Spring tension will force contact sleeve out of housing For further inspec tion remove packing gland and O ring Item 12 11 Place contact sleeve in a prot...

Page 69: ...ly Tool Only See Text 12 O Ring 13 Packing Gland Gasket 14 Packing Gland 15 Outer Spring 16 Contact Sleeve 17 Outer Carbon Ring Seal 18 Contact Ring Key 19 Contact Ring 20 Inner Carbon Seal Ring 21 Retaining Ring 22 O Ring 23 Shim 24 Diaphragm 25 Guide Ring 26 Inner Spring 27 Inner Carbon Ring Key 28 Shut Down Seal Retainer 29 Spray Header Gasket Fig 36 Compressor Contact Seal Open Drive Machines ...

Page 70: ...es General 1 Final shaft alignment must be within 002 in TIR Total Indicated Runout in parallel Angular alignment must be within 00033 inches per inch of traverse across the cou pling face or inch of indicator swing diameter at oper ating temperatures For example if a bracket mounted indicator moves through a 10 in diameter circle when measuring angular misalignment the allowable dial move ment wi...

Page 71: ... be lost if elevation adjustments are made Correcting Angular Misalignment Preparation Shaft angular misalignment is measured on the face of the coupling hubs or on brackets attached to each shaft see Fig 38 and 39 Brackets are preferred since they extend the diameter of the face readings Attach a dial indicator to one coupling hub or shaft and place the indicator button against the face of the op...

Page 72: ... amount is entirely shaft net misalignment If the larger opening remains on the same side but changes amount misalignment and runout are present Add the two amounts and then divide by two to get the actual or net misalignment If the larger opening changes amount and also changes from side to side subtract the smaller amount from the larger and divide by two to obtain the net misalignment Adjustmen...

Page 73: ... indicator by the desired amount 5 Tighten the holddown bolts and recheck the indicator If the reading has changed loosen the three bolts and re adjust It may be necessary to over or undershoot the de sired reading to allow for the effect of bolt tightening Correcting Parallel Misalignment Preparation Attach the dial indicator to one shaft or cou pling hub and place the indicator button on the O D...

Page 74: ...quipment over Then with the rear holddown bolt on the same side acting as the pivot move the front end of the equipment over by the same amount FINAL ALIGNMENT The procedures and tolerance re quirements for final alignment are the same as those de scribed in the Near Final Alignment section Final alignment is performed just prior to grouting and machine hot check All piping including water and ste...

Page 75: ... alignment be sure dowels are tight and do not bottom 4 Place dowels as nearly vertical as possible 5 Coat the dowels with white lead or other lubricant to pre vent rusting 6 Tap dowel lightly into position with a small machinist s hammer A ringing sound will indicate proper seating Dowel the suction end of the compressor base the two feet at the high speed end of the gear and the drive feet in ac...

Page 76: ... malfunctions refer to the Troubleshooting Guide section for control checks and adjustments Be sure power to the control center is off when cleaning and tightening connections inside the control center Check Safety and Operating Controls Monthly To ensure machine protection the Control Test Auto mated Test should be done at least once per month See Table 3 for safety control settings Changing Oil ...

Page 77: ...lity vessel Amoisture indicating sight glass is located beyond this filter to indicate the volume and mois ture in the refrigerant If the dry eye indicates moisture lo cate the source of water immediately by performing a thor ough leak check Oil Reclaim Filter The oil reclaim system has a fil ter on the cooler scavenging line Replace this filter once per year or more often if filter condition indi...

Page 78: ...hes can seriously erode the tube interiors over sev eral cleanings All tube brushing should be conducted from the front fan end toward the drive end of the motor such that dislodged dirt will not fall into the fan housing Water spray washing of motors is not recommended Manual or compressed air cleaning is preferred If it be comes necessary to spray wash a motor it should be done with extreme care...

Page 79: ...and drain the oil sump 2 Remove all instrumentation sensors that are in contact with the bearing sleeve These would include resistance temperature detectors thermocouples temperature re lay bulbs thermometers etc 3 Remove the end cover 4 Remove the socket head bolts holding the bearing cap and the inner air seal together at the horizontal split The front end cover plate must also be removed if the...

Page 80: ...utside 8 Place the bottom seal half on top of the shaft ensuring that the proper orientation of the drain holes is provided and roll it into position Install the top half of the seal making sure that the anti rotation button is located in the proper position on the inboard side of the bearing Insert the garter spring pulling up on both ends to per mit engaging the lock Run a small bead of Curil T ...

Page 81: ... result This motor has been provided with a shaft shipping brace or shipping bolt normally painted yellow to prevent shaft movement during transit it must be removed to allow shaft rotation refer to Before Initial Start Up Remove Shipping Packaging section page 47 It is very important that this brace be reinstalled exactly as it was originally before the motor is moved from storage or any time whe...

Page 82: ...ll internal circuits Open all internal and re mote disconnects before servicing the starter Never open isolating knife switches while equipment is operating Electrical arcing can cause serious injury Inspect starter contact surfaces for wear or pitting on mechanical type starters Do not sandpaper or file silver plated contacts Follow the starter manufacturer s instruc tions for contact replacement...

Page 83: ...red into the Alarm History table Checking the Display Messages The first area to check when troubleshooting the 17 19EX is the LID dis play If the alarm light is flashing check the primary and secondary message lines on the LID default screen Fig 14 These messages will indicate where the fault is occurring The Alarm History table on the LID Service menu will also carry an alarm message to further ...

Page 84: ...e 0 psig 0 kPa and between 240 and 260 psig 1655 to 1793 kPa To calibrate these transducers 1 Shut down the compressor 2 Disconnect the transducer in question from its Schrader fitting NOTE If the cooler or condenser vessels are at 0 psig 0 kPa or are open to atmospheric pressure the trans ducers can be calibrated for zero without removing the transducer from the vessel 3 Access the Status01 table...

Page 85: ...IED mode or not WSMDEFME Water System Manager Status The water system manager is a CCN module which can turn on the chiller and change the chilled water control point This screen indicates the status of this system These maintenance tables are very useful in determining guide vane position reaction from load changes control point overrides hot gas bypass reaction surge prevention etc Control Test ...

Page 86: ... to start RECYCLE RESTART PENDING REMOTE CONTACT CLOSED Unit in recycle mode chilled water temperature is not high enough to start RECYCLE RESTART PENDING START COMMAND IN EFFECT Chiller START STOP on Status01 manually forced to start chilled water temperature is not high enough to start RECYCLE RESTART PENDING ICE BUILD MODE Machine in ICE BUILD mode Chilled Water Brine Temperature is satisfied f...

Page 87: ...arter Overload Trip Check amps calibration reset overload Reset overloads check ICR relay before restarting machine FAILURE TO START LINE VOLTAGE DROPOUT V P Single Cycle Dropout Detected Check volt age supply Check voltage supply Check transformers for sup ply Check with utility if voltage supply is erratic Moni tor must be installed to confirm consistent single cycle dropouts Check low oil press...

Page 88: ...ater in the con denser tubes Check for condenser refrigerant leaks bad transducers or transferred refrigerant Place the unit in Pumpdown mode to eliminate ALARM if vessel is evacuated LIMIT is shown on the LID as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual pressure temperature voltage etc at which...

Page 89: ...re voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual temperature pressure voltage etc at which the control tripped J OUT OF RANGE SENSOR FAILURES PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY SENSOR FAULT LEAVING CHW TEMPERATURE Sensor Fault Check leaving CHW sensor See sensor test proced...

Page 90: ...orm pumps Control Test and verify proper switch operation Check all water valves and pump operation PROTECTIVE LIMIT LOW CONDENSER WATER FLOW CDFL Flow Fault Check cond pump flow switch PROTECTIVE LIMIT HIGH CONDENSER PRESSURE High Cond Pressure OPEN Check switch oil pressure contact and water temp flow Check the high pressure switch Check for proper con denser pressures and condenser waterflow Ch...

Page 91: ... pressure Check ambient conditions Check con denser pressure for accuracy RECYCLE ALERT EXCESSIVE RECYCLE STARTS Excessive recycle starts The machine load is too small to keep the machine on line and there have been more than 5 restarts in 4 hours Increase ma chine load adjust hot gas bypass increase RECYCLE RESTART DELTA T LIMIT is shown on the LID as the temperature pressure voltage etc set poin...

Page 92: ...ntinually Appears Check for proper communications wiring on PSIO module Check that the COMM1 communications wires from the LID are terminated to the COMM1 PSIO connection Check for ground or short on CCN system wiring SMM Communications Failure Check that PSIO communication plugs are connected correctly Check SMM communication plug Check for proper SMM power supply See Control Mod ules section on ...

Page 93: ... 4403 83 2 738 4298 84 2 708 4196 85 2 679 4096 86 2 650 4000 87 2 622 3906 88 2 593 3814 89 2 563 3726 90 2 533 3640 91 2 505 3556 92 2 476 3474 93 2 447 3395 94 2 417 3318 95 2 388 3243 96 2 360 3170 97 2 332 3099 98 2 305 3031 99 2 277 2964 100 2 251 2898 101 2 217 2835 102 2 189 2773 103 2 162 2713 104 2 136 2655 105 2 107 2597 106 2 080 2542 107 2 053 2488 108 2 028 2436 109 2 001 2385 110 1 ...

Page 94: ... 5 971 22 3 076 5 710 23 3 023 5 461 24 2 970 5 225 25 2 917 5 000 26 2 864 4 786 27 2 810 4 583 28 2 757 4 389 29 2 704 4 204 30 2 651 4 028 31 2 598 3 861 32 2 545 3 701 33 2 493 3 549 34 2 441 3 404 35 2 389 3 266 36 2 337 3 134 37 2 286 3 008 38 2 236 2 888 39 2 186 2 773 40 2 137 2 663 41 2 087 2 559 42 2 039 2 459 43 1 991 2 363 TEMPERATURE VOLTAGE RESISTANCE C DROP V Ohms 44 1 944 2 272 45 ...

Page 95: ...nal 1 of each of the other mod ules Terminals 2 and 3 are connected in the same man ner See Fig 49 53 If a Terminal 2 wire is connected to Terminal 1 the system does not work 2 If a green LED is solid on check communication wiring If a green LED is off check the red LED operation If the red LED is normal check the module address switches Fig 49 53 Proper addresses are MODULE ADDRESS SW1 SW2 SMM St...

Page 96: ...vided on the options modules All sensor inputs are field wired and installed Options module 1 can be factory or field installed Options module 2 is shipped separately and must be field installed For installation refer to the unit or field wiring diagrams Be sure to address the module for the proper module number Fig 53 and to configure the chiller for each feature being used Replacing Defective Pr...

Page 97: ...hillips screwdriver and the screw saved in Step 4 above Make sure that the green grounding wire is reinstalled along with the mounting screw 10 Connect the LID communication wires CCN bus and the power wires If CCN wiring has been attached to the CCN bus disconnect the wires Attach the sensor bus plug and the input and output plugs 11 Carefully check all wiring connections before restoring power 1...

Page 98: ... 14 118 6 404 17 498 7 937 1 090 494 2 282 274 1 035 1 035 43 14 468 6 563 17 978 8 155 1 090 494 2 419 290 1 097 1 097 45 16 676 7 564 20 800 9 435 1 400 635 2 720 326 1 234 1 234 46 17 172 7 789 21 489 9 747 1 400 635 2 908 348 1 319 1 319 47 17 669 8 015 22 178 10 060 1 400 635 3 096 371 1 404 1 404 51 17 188 7 796 20 993 9 522 1 100 499 2 707 325 1 228 1 228 52 17 848 8 096 21 923 9 944 1 100 ...

Page 99: ...ne 2 150 1034 25 11 1 734 208 787 787 Marine 2 300 2068 1225 555 1 734 208 787 787 NIH Nozzle In Head When using a machine configuration other than 2 pass NIH water boxes with 150 psig 1034 kPa covers add the weights listed in this table to the appropriate weights in Table 10 to obtain the correct con denser weight Subtract 228 lb 103 kg from the weight shown in Table 10 Table 12 Compressor Motor ...

Page 100: ...1034 792 359 2551 306 1157 1 157 Marine 1 3 300 2068 3844 1744 5102 612 2314 2 314 Marine 2 300 2068 2536 1150 2551 306 1157 1 157 NIH Nozzle In Head When using a machine configuration other than 2 pass NIH water boxes with 150 psig 1038 kPa covers add the weights listed in this table to the appropriate weights in Table 10 to obtain the correct cooler weight Table 14 Marine Waterbox Cover Weights ...

Page 101: ...esents the weight of the waterbox cover that contains the nozzles Ablank waterbox cover is also present on 2 pass units The weight of the blank waterbox cover is identical to the weight of the same size marine waterbox cover Refer to Table 14 Table 16 Auxilliary Systems Electrical Data POWER SOURCE ITEM SUPPLY V PH Hz FLA LRA 1 Control Module and Actuator 115 1 60 115 1 50 3 50 Oil Sump Heater 115...

Page 102: ...rmed only by fully trained and qualified service personnel The information in this section is included as a reference for such personnel only SEE VIEW B SEE VIEW A SEE VIEW C DIM SEE TABLE 17 TABULATION VIEW A VIEW B NOTE See Table 17 for dimensions Fig 55 Open Drive Compressor Fits and Clearances 102 ...

Page 103: ...t end labyrinth 001 0254 005 1270 001 0254 005 1270 Diametral 16 Drive end journal bearing 003 0762 005 1270 0035 0889 0055 1397 Diametral 17 Windage baffle to shaft 083 2 108 104 2 642 079 2 007 100 2 540 Diametral 18 Inner carbon ring travel 06 MIN Each Direction 06 MIN Each Direction Axial See Fig 55 for item callouts Tabulation Impeller Clearances Open Drive Compressors COMPRESSOR SIZE SHROUD ...

Page 104: ...VIEW A VIEW B Refer to Table 18 for dimensions DIM SEE VIEW A SEE VIEW B FIRST SHROUD ON FA8 AND FA9 COMPRESSORS VIEW C Fig 56 Hermetic Compressor Fits and Clearances SEE VIEW C 104 ...

Page 105: ... Bearing Housing 0005 0020 0127 0508 Diametral See Fig 56 for item callouts Clearances represent factory tolerances for new components Tabulation Impeller Clearances Hermetic Compressors 19EX SHROUD CODE FA SHROUD CODE IMPELLER CODE IMPELLER DIAMETER DIMENSION Item 1 Item 2 in mm in mm in mm 5 3 1 12 00 304 8 0 837 21 26 0 638 16 21 3 12 38 314 5 0 797 20 24 0 609 15 47 5 12 75 323 8 0 757 19 23 0...

Page 106: ... T2 T4 Power Panel Transformers TB Terminal Board Power Panel Connection Denotes Component Terminal Denotes Wire Crimp Joint Denotes Conductor Male Female Connector Option Wiring Fig 57 Electronic PIC Controls Wiring Schematic Hermetic Machine CONT D ON NEXT PAGE IMPORTANT Wiring shown is typical and not intended to show detail for a specific installation Refer to certified field wiring diagrams 1...

Page 107: ... Electronic PIC Controls Wiring Schematic Hermetic Machine cont IMPORTANT Wiring shown is typical and not intended to show detail for a specific installation Refer to certified field wiring diagrams 107 1197 ...

Page 108: ...T2 T4 Power Panel Transformers TB Terminal Board Power Panel Connection Denotes Component Terminal Denotes Wire Crimp Joint Denotes Conductor Male Female Connector Option Wiring Fig 58 Electronic PIC Controls Wiring Schematic Open Drive Machine CONT D ON NEXT PAGE IMPORTANT Wiring shown is typical and not intended to show detail for a specific installation Refer to certified field wiring diagrams ...

Page 109: ...Electronic PIC Controls Wiring Schematic Open Drive Machine cont IMPORTANT Wiring shown is typical and not intended to show detail for a specific installation Refer to certified field wiring diagrams 109 1197 ...

Page 110: ...er in a starter built to Carrier specifications Do not connect an outside source of control power to the compressor motor starter ter minals LL1 and LL2 An outside power source will produce danger ous voltage at the line side of the starter because supplying voltage at the transformer secondary terminals produces input level voltage at the transformer primary terminals Fig 59 Elementary Wiring Dia...

Page 111: ...ule SMM and Control Interface Between Starter and Machine Power Panel For Low and Medium Free Standing Starters cont IMPORTANT Wiring shown is typical and not intended to show detail for a specific installation Refer to certified field wiring diagrams 111 1197 ...

Page 112: ...p Terminal Denotes Power Panel Terminal Denotes Component Terminal Wire Splice Option Wiring FW Field Wiring By Others Denotes Mach Control Panel Conn Denotes Motor Starter Panel Conn Denotes 3 Conductor Connector Fig 60 Hermetic Drive Power Panel With Water Cooled Oil Cooler IMPORTANT Wiring shown is typical and not intended to show detail for a specific installation Refer to certified field wiri...

Page 113: ...mp Terminal Denotes Power Panel Terminal Denotes Component Terminal Wire Splice Option Wiring FW Field Wiring By Others Denotes Mach Control Panel Conn Denotes Motor Starter Panel Conn Denotes 3 Conductor Connector Fig 61 Hermetic Drive Power Panel With Motor Cooling Solenoid IMPORTANT Wiring shown is typical and not intended to show detail for a specific installation Refer to certified field wiri...

Page 114: ...ir Cooled Denotes Oil Pump Terminal Denotes Power Panel Terminal Denotes Component Terminal Wire Splice Option Wiring FW Field Wiring By Others Denotes Male Female Q C Denotes Mach Control Panel Conn Denotes Motor Starter Panel Conn Denotes 3 Conductor Connector Denotes 2 Conductor Connector Fig 62 Open Drive Power Panel IMPORTANT Wiring shown is typical and not intended to show detail for a speci...

Page 115: ... 10 Lubrication Cycle Open Drive Machines Details 12 Lubrication Cycle Open Drive Machines Summary 12 Lubrication System Check 75 Machine Familiarization 17 19EX 4 Manual Guide Vane Operation 62 Manual Operation of the Guide Vanes 58 Module Operation 95 Motor Compressor 8 Motor Cooling Control Hermetic Motors Only 36 Motor Maintenance Open Drive Motors 78 Motor Oil Refrigeration Cooling Cycle 8 Mo...

Page 116: ...he Machine 61 Start Up Required Equipment 47 Start Up Shutdown Recycle Sequence 45 Stop the Machine 61 Surge Prevention Algorithm 40 Surge Protection 40 System Components 4 Temperature Sensors Checking 83 Test After Service Repair or Major Leak 67 Tighten All Gasketed Joints and Guide Vane Shaft Packing 48 Tightness Check 48 Tower Fan Relay 39 Transferring Refrigerant 66 Troubleshooting Guide 83 T...