Carrier 17EX manual

Start-Up, Operation, and Maintenance Instructions SAFETY CONSIDERA TIONS Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design speci- fications. When operating this equipment, use good judg- ment and safety precautions to avoid damage to equip- ment and property or injury to personnel. Be sure yo[...]

CONTENTS Page SAFETY CONSIDERA TIONS ...................... 1 INTRODUCTION ................................ 5 ABBREVIA TIONS ............................... 5 17EX CHILLER F AMILIARIZA TION ................. 5 Chiller Identification Label ....................... 5 System Components ............................ 5 Cooler ............................[...]

CONTENTS Page Inspect W ater Piping .......................... 50 Check Optional Pumpout Compressor W ater Piping .................................... 50 Check Relief Devices .......................... 50 Inspect Wiring ................................ 50 • CHECK INSULA TION RESIST ANCE Motor Pre-Start Checks ........................ 51 External [...]

CONTENTS (cont) Page Motor Handling/Rigging ........................ 81 Motor Storage ................................ 81 External Gear Storage ......................... 81 • SHOR T -TERM STORAGE (Indoors) • LONG-TERM STORAGE (Indoors) • EXTENDED DOWNTIME Compressor Bearing Maintenance ............... 82 External Gear Maintenance ............[...]

INTRODUCTION Before initial start-up of the 17EX unit, those involved in the start-up, operation, and maintenance should be thor- oughly familiar with these instructions and other necessary job data. This book is outlined so that you may become fa- miliar with the control system before performing start-up pro- cedures. Procedures in this manual are[...]

LEGEND NIH — Nozzle-In-Head *Any available cooler size can be combined with any available condenser size. NOTE: For details on motor size designations, see below . ASME ‘U’ ST AMP ARI (Air Conditioning and Refrigeration Institute) PERFORMANCE CERTIFIED (60 Hz Only) Fig. 1 — Model Number Identification 6[...]

1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 40 39 37 38 36 35 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 34 33 32 31 LEGEND 1— Condenser 2— Cooler Suction Pipe 3— Compressor Suction Elbow 4— Guide V ane Actuator 5— Condenser Discharge Pipe 6— Compressor Discharge Elbow 7— T wo-Stage Compressor 8— Economizer Gas Line to Compressor 9— Co[...]

The chiller compressor continuously draws large quanti- ties of refrigerant vapor from the cooler at a rate determined by the amount of guide vane opening. This compressor suc- tion reduces the pressure within the cooler , allowing the liq- uid refrigerant to boil vigorously at a fairly low temperature (typically 38 to 42 F [3 to 6 C]). The liquid [...]

External Gear Lubrication Cycle (Refer to Item numbers shown in Fig. 5) — Oil reservoir is con- tained in the gear base. The external gear oil pump is mounted below the gear with the cooler/filter . Oil is pumped through an oil cooler/filter to remove heat and any foreign particles. A portion of the oil is directed to the gear bearings and gear[...]

SHAFT DISPLACEMENT & BRG TEMP . CUTOUT CONNECTIONS COMPRESSOR OIL PRESSURE LEA VING FIL TER LINE JOURNAL BEARING CHECK V AL VE SIGHT GLASSES OIL PUMP & PRESS. REGULA T OR TO POWER P ANEL OIL THERMISTOR OIL HEA TER DRAIN & CHARGING V AL VE COMPRESSOR OIL SUCTION PRESSURE PUMP , SEAL OIL RETURN OIL CHARGING ELBOW THRUST BEARING COAST DOWN[...]

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.) DIGIT AL SIGNAL — A digital (discr ete) signal is a [...]

PIC System Components — The Product Integrated Control (PIC) is the control system on the chiller . See T able 1. The PIC controls the operation of the chiller by moni- toring all operating conditions. The PIC can diagnose a prob- lem and let the operator know what the problem is and what to check. It promptly positions the guide vanes to maintai[...]

LEGEND 1 3— Condenser Pressure Transducer 1 4— Condenser Entering W ater T emperature Sensor 1 5— Condenser Entering and Leaving W ater T emperature Cable 1 6— Oil Suction Pressure Sensor 1 7— Oil Pump Conduit 1 8— Oil Pump Sensor 1 9— PIC Control Panel 2 0— Condenser Leaving W ater T emperature Sensor 2 1— Gear Oil Cooler Solenoi[...]

Fig. 6 — 17EX Controls and Sensor Locations (cont) Fig. 7 — Control Sensors (T emperature) Fig. 8 — Control Sensors (Pressure T ransducer , T ypical) LEGEND LID — Local Interface Device PIC — Product Integrated Controls PSIO — Processor Sensor Input/Output Module 1— Optional 8-Input Module for Spare Inputs to Control Interface (One of[...]

LEGEND EQUIP GND — Equipment Ground GRD — Ground M— Motor TEW AC — T otally Enclosed W ater-to- Air Cooled Fig. 10 — 17EX Chiller Power Panel and Controls Connections 15[...]

PROCESSOR/SENSOR INPUT/OUTPUT MODULE (PSIO) — This module contains all the operating software needed to control the chiller . The 17EX uses 5 pressure transducers and 8 thermistors to sense pressures and temperatures. These inputs are connected to the PSIO module. The PSIO also provides outputs to the guide vane actuator , compressor and gear oil[...]

NOTE: When an alarm is detected, the LID default screen freezes (stops updating) at the time of alarm. The freeze en- ables the operator to view the chiller conditions at the time of the alarm. The status tables show the updated informa- tion. Once all alarms have been cleared (by pressing the RESET softkey), the default LID screen returns to norma[...]

3. Press SELECT to view the desired Point Status table. 4. On the Point Status table press NEXT or PREVIOUS until desired point is displayed on the screen. For Discr ete Points — Press ST AR T or STOP , YES or NO ,O N or OFF , etc. to select the desired state. For Analog Points — Press INCREASE or DECREASE to select the desired value. 5. Press [...]

CCN LOCAL RESET MENU DEF AUL T SCREEN Start Chiller In CCN Control Start Chiller In Local Control Clear Alarms ST A TUS SCHEDULE SETPOINT SER VICE (SOFTKEYS) Access Main Menu List the Status T ables Display the Setpoint T able (ENTER A 4-DIGIT P ASSWORD) List the Service T ables NEXT PREVIOUS SELECT EXIT ST AR T STOP RELEASE ENTER (SELECT A T ABLE)[...]

NEXT PREVIOUS SELECT EXIT SERVICE T ABLE Display Alarm History (The table holds up to 25 alarms and alerts with the last alarm at the top of the screen.) • Automated T est • PSIO Thermistors • Options Thermistor • Transducers • Guide V ane Actuator • Pumps • Discrete Outputs • Pumpdown Lockout • T erminated Lockout • FX Gear Oil[...]

NEXT PREVIOUS SELECT EXIT SERVICE MENU CONTINUED FROM PREVIOUS P AGE EQUIPMENT SERVICE (See T able 2, Examples 8, 9, and 10) Service T ables: (See Note) • SERVICE1 • SERVICE2 • SERVICE3 Select a Service T able Select a Service T able Parameter NEXT PREVIOUS SELECT EXIT Modify a Service T able Parameter ENTER NO YES QUIT (ANALOG VALUES) (DISCR[...]

6. a. Press INCREASE or DECREASE to change the time values. Override values are in one-hour incre- ments, up to 4 hours. b. Press ENABLE to select days in the day-of-week fields. Press DISABLE to eliminate days from the period. 7. Press ENTER to register the values and to move horizontally (left to right) within a period. 8. Press EXIT to leave th[...]

T able 2 — LID Display Data NOTES: IMPORT ANT : The following notes apply to all T able 2 examples. 1. Only 12 lines of information appear on the LID screen at any one time. Press the NEXT or PREVIOUS softkey to highlight a point or to view items below or above the current screen. If you have a chiller with a backlit LID, press the NEXT softkey t[...]

T able 2 — LID Display Data (cont) EXAMPL E2—S T A TUS02 DISPLA Y SCREEN T o access this display from the LID default screen: 1. Press MENU . 2. Press ST A TUS . 3. Scroll down to highlight ST A TUS02 . 4. Press SELECT . DESCRIPTION POINT TYPE UNITS REFERENCE POINT NAME (ALARM HISTOR Y) INPUT OUTPUT Hot Gas Bypass Relay X OFF/ON HGBR *Chilled W[...]

T able 2 — LID Display Data (cont) EXAMPL E4—S T A TUS04 DISPLA Y SCREEN T o access this display from the LID default screen: 1. Press MENU . 2. Press ST A TUS . 3. Scroll down to highlight ST A TUS04 . 4. Press SELECT . DESCRIPTION RANGE UNITS REFERENCE POINT NAME (ALARM HISTOR Y) Main Gear Oil Pump OFF/ON MAINPMP1 Auxiliary Gear Oil Pump OFF/[...]

T able 2 — LID Display Data (cont) EXAMPLE 6 — CONFIGURA TION (CONFIG) DISPLA Y SCREEN T o access this display from the LID default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT CONFIGURA TION . 4. Press SELECT . 5. Scroll down to highlight CONFIG . 6. Press SELECT . DESCRIPTION CONFIGURABLE RANGE UNITS REFERE[...]

T able 2 — LID Display Data (cont) EXAMPLE 7 — LEAD/LAG CONFIGURA TION DISPLA Y SCREEN T o access this display from the LID default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT CONFIGURA TION . 4. Press SELECT . 5. Scroll down to highlight LEAD/LAG . 6. Press SELECT . LEAD/LAG CONFIGURA TION SCREEN DESCRIPTIO[...]

T able 2 — LID Display Data (cont) EXAMPLE 8 — SERVICE1 DISPLA Y SCREEN T o access this display from the LID default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT SERVICE . 4. Press SELECT . 5. Scroll down to highlight SERVICE1 . 6. Press SELECT . DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAU[...]

T able 2 — LID Display Data (cont) EXAMPLE 9 — SERVICE2 DISPLA Y SCREEN T o access this display from the LID default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT SERVICE . 4. Press SELECT . 5. Scroll down to highlight SERVICE2 . 6. Press SELECT . DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEF A[...]

T able 2 — LID Display Data (cont) EXAMPLE 1 1 — MAINTENANCE (MAINT01) DISPLA Y SCREEN T o access this display from the LID default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight CONTROL ALGORITHM ST A TUS . 4. Press SELECT . 5. Scroll down to highlight MAINT01 . DESCRIPTION RANGE/ST A TUS UNITS REFERENCE POINT NAME CAP [...]

T able 2 — LID Display Data (cont) EXAMPLE 13 — MAINTENANCE (MAINT03) DISPLA Y SCREEN T o access this display from the LID default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight CONTROL ALGORITHM ST A TUS . 4. Press SELECT . 5. Scroll down to highlight MAINT03 . 6. Press SELECT . DESCRIPTION RANGE/ST A TUS UNITS REFERENC[...]

PIC System Functions NOTE: In the rest of this manual, words not part of para- graph headings and printed in all capital letters can be viewed on the LID (e.g., LOCAL, CCN, RUNNING, ALARM, etc.). W ords printed both in capital letters and italics can also be viewed on the LID and are parameters ( CONTROL MODE, COOLING SETPOINT , OVERRIDE THRESHOLD,[...]

NOTE: This schedule is for illustration only , and is not in- tended to be a recommended schedule for chiller operation. Depending on its operating mode, the chiller uses the fol- lowing occupancy schedules: • LOCAL mode — Occupancy Schedule 01(OCCPC01 on the SCHEDULE screen). • ICE BUILD mode — Occupancy Schedule 02 (OC- CPC02 on the SCHED[...]

T able 3 — Protective Safety Limits and Control Settings MONITORED P ARAMETER LIMIT APPLICABLE COMMENTS TEMPERA TURE SENSORS OUT OF RANGE –40 to 245 F (–40 to 1 18.3 C) Must be outside range for 2 seconds PRESSURE TRANSDUCERS OUT OF RANGE 0.08 to 0.98 V oltage Ratio Must be outside range for 2 seconds. Ratio = Input V oltage ÷ V oltage Refer[...]

2. The motor load ramp loading rate is an operator-configured value that limits the rate at which the compressor motor current or compressor motor load increases. ( LOAD PULL- DOWN %/MIN on the CONFIG screen). T o select the ramp type, highlight the SELECT RAMP TYPE parameter on the CONFIG screen and select either 0( TEMP )o r1( LOAD ). Motor load [...]

Oil Cooler — The oil for the external gear and the com- pressor must be cooled while the compressor is running. The compressor oil cooler is a water-cooled, helical, tube-in- shell type heat exchanger . A plug valve is manually set to maintain proper temperatures. Set the valve to maintain a 145 F (63 C) oil sump temperature while the compressor [...]

W ater/Brine Reset — Three types of chilled water/ brine reset are available, Reset T ype 1, Reset T ype 2, and Reset T ype 3. They can be viewed or modified on the CON- FIG screen (accessed from the EQUIPMENT CONFIGU- RA TION table). See T able 2, Example 6. The LID default screen status message indicates when a reset is active. The W A TER/BRI[...]

Surge Protection — Compressor surge can be de- tected by the PIC based on operator configured settings. Surge causes amperage fluctuations of the compressor motor . The PIC monitors these amperage swings, and if the swing is greater than the configured setting ( SURGE DELT A PERCENT AMPS ) in one second, then one surge event has occurred. The [...]

LEAD/LAG OPERA TION — The PIC control has the ca- pability to operate 2 chillers in the lead/lag mode. It also has the additional capability to start a designated standby chiller when either the lead or lag chiller is not operating and capacity requirements are not being met. The lead/lag option operates in CCN mode only . If any other chiller co[...]

F AUL TED CHILLER OPERA TION — If the lead chiller shuts down because of an alarm (*) condition, it stops com- municating with the lag and standby chillers. After 30 sec- onds, the lag chiller becomes the acting lead chiller and starts and stops the standby chiller , if necessary . If the lag chiller faults when the lead chiller is also faulted, [...]

TEMPERA TURE CONTROL DURING ICE BUILD —During ice build, the capacity control algorithm uses the W A TER/BRINE CONTROL POINT minus 5 F (2.7 C) to con- trol the LEA VING CHILLED W A TER temperature. The ECW CONTROL OPTION (see CONFIG screen), the 20 mA DEMAND LIMIT , and any temperature reset option are ig- nored during ice build. TERMINA TION OF [...]

NOTE: The LID does not automatically re-attach to the PSIO module on the chiller . Access the A TT ACH TO NETWORK DEVICE table, scroll to LOCAL , and press the A TT ACH softkey to upload the local device. The software for the local chiller will now be uploaded. Service Operation — Figure 16 shows an overview of the service menu. TO ACCESS THE SER[...]

7. Press SELECT to access the holiday table. The LID screen now shows the holiday start month and day , and how many days the holiday period will last. See Fig. 24. 8. Press NEXT or PREVIOUS to highlight HOLIDA Y ST ART MONTH, ST ART DA Y ,o r DURA TION . 9. Press SELECT to modify the month, day , or duration. 10. Press INCREASE or DECREASE to chan[...]

If any of these requirements are not met, the PIC aborts the start and displays the applicable pre-start mode of failure on the LID default screen. A pre-start failure does not ad- vance the ST ARTS IN 12 HOURS counter (ST A TUS01 screen). Any failure after the 1CR relay has energized causes a safety shutdown, advances the ST ARTS IN 12 HOURS count[...]

Safety Shutdown — A safety shutdown is identical to a manual shutdown with the exception that the LID displays the reason for the shutdown, the alarm light blinks continu- ously , and the spare alarm contacts are energized. A safety shutdown requires that the RESET softkey be pressed in order to clear the alarm. If the alarm continues, the alarm [...]

The rotation direction of the motor is shown either on the motor nameplate or on the certified drawing. Information on the required phase rotation of the incoming power for this motor may also be found on the nameplate or drawing. If either is unknown, the correct sequence can be determined as follows. While the motor is uncoupled from the load, s[...]

Fig. 25 — 17EX Leak T est Procedures 47[...]

T able 5A — HFC-134a Pressure — T emperature (F) TEMPERA TURE (F) PRESSURE (psi) 0 6.50 2 7.52 4 8.60 6 9.66 8 10.79 10 1 1.96 12 13.17 14 14.42 16 15.72 18 17.06 20 18.45 22 19.88 24 21.37 26 22.90 28 24.48 30 26.1 1 32 27.80 34 29.53 36 31.32 38 33.17 40 35.08 42 37.04 44 39.06 46 41.14 48 43.28 50 45.48 52 47.74 54 50.07 56 52.47 58 54.93 60[...]

4. Leak Determination — If an electronic leak detector in- dicates a leak, use a soap bubble solution, if possible, to confirm it. T otal all leak rates for the entire chiller . Leak- age for the entire chiller at rates greater than the EP A (En- vironmental Protection Agency) guidelines or local codes must be repaired. Note the total chiller le[...]

Inspect W ater Piping — Refer to the piping diagrams provided in the certified drawings and the piping instruc- tions in the 17EX Installation Instructions manual. Inspect the piping to the cooler and condenser . Be sure that flow directions are correct and that all piping specifications have been met. Piping systems must be properly vented, w[...]

2. Direct current (as from a welder) can be passed through the winding. The total current should not exceed approxi- mately 50% of the rated full load current. If the motor has only 3 leads, 2 must be connected together to form one circuit through the winding. In this case, one phase carries the full applied current and each of the others car- ries[...]

Fig. 27 — External Gear Lubrication System 52[...]

T able 7 — Recommended Compressor and External Gear Fastener Tightening T orques F ASTENER DIAMETER (in.) TORQUE* Lb.-Ft. (N • m) UNC Minimum Maximum 1 ⁄ 4 7 (9.5) 9 (12.2) 5 ⁄ 16 14 (19.0) 17 (23.1) 3 ⁄ 8 25 (33.9) 31 (42.0) 7 ⁄ 16 40 (54.2) 50 (67.8) 1 ⁄ 2 60 (81.4) 75 (101.7) 9 ⁄ 16 87 (1 18.0) 108 (137.0) 5 ⁄ 8 120 (162.7) 150[...]

1. Check that all wiring connections are properly termi- nated to the starter . 2. V erify that the ground wire to the starter is installed prop- erly and is of suf f icient size. 3. V erify that the motors are properly grounded to the starter . 4. Check that all the relays are properly seated in their sockets. 5. V erify that the proper AC input v[...]

5. After the last digit is changed, the LID goes to the BUS # parameter . Press the EXIT softkey to leave the screen, record your password change, and return to the SER VICE menu. BE SURE TO REMEMBER YOUR PASSWORD. Retain a copy of the password for future reference. If you forget your password, you will not be able to access the SERVICE menu unless[...]

If surge prevention occurs too soon or too late, make the following adjustments: LOAD SURGE PREVENTION SURGE PREVENTION OCCURS TOO SOON OCCURS TOO LA TE At low loads ( , 50%) Increase P1 by 10 psid (70 kPad) Decrease P1 by 10 psid (70 kPad) At high loads ( . 50%) Increase P2 by 10 psid (70 kPad) Decrease P2 by 10 psid (70 kPad) MODIFY EQUIPMENT CON[...]

T able 8 — Control T est Menu Functions TESTS TO BE DEVICES TESTED PERFORMED 1. Automated T ests* Operates the second through seventh tests 2. PSIO Thermistors Entering chilled water Leaving chilled water Entering condenser water Leaving condenser water Discharge temperature Bearing temperature Motor winding temperature Oil sump temperature 3. Op[...]

3. Chiller is charged with refrigerant and all refrigerant and all oil valves are in their proper operating position. 4. Gear oil, compressor oil, and motor bearing oil are at the proper levels in the reservoir sight glasses. 5. Compressor oil reservoir temperature is above 140 F (60 C) or refrigerant temperature plus 50° F (28° C). 6. V alves in[...]

Under normal conditions, for the self-lubricating bear- ing, the rate of temperature rise should be from 20° to 25° F (11° to 14° C) during the first 10 minutes after starting up and approximately 40° F (22° C) over 30 minutes. The rate of bearing temperature rise is a function of the natural ventilation and operating conditions. When the ra[...]

2. Of fset and Angular Alignment — Reverse dial indication or optical methods of alignment (such as lasers) are rec- ommended. A cold alignment and a hot check (with cor- rections, if necessary) are required. The hub flange OD can be used to mount the alignment equipment and is ma- chined to be concentric to the coupling bore. It can be used as [...]

4. General Recommendations a. Both disc couplings are designed to operate for ex- tended periods without the need for lubrication or main- tenance. V isual inspection of the disc packs is enough to assess the operational condition of the coupling. b. All machinery should be monitored to detect unusual or changing vibration levels. Both couplings, u[...]

Instruct the Operator — Check to be sure that the op- erator(s) understands all operating and maintenance proce- dures. Point out the various chiller parts and explain their function as part of the complete system. COOLER-CONDENSER — Relief devices, temperature sen- sor locations, pressure transducer locations, Schrader fit- tings, waterboxes [...]

NOTE: If the chiller fails to stop, in addition to action that the PIC initiates, the operator should close the guide vanes by overriding the guide vane target to zero (to reduce chiller load) and then by opening the main disconnect. Do not at- tempt to stop the chiller by opening an isolating knife switch. High intensity arcing may occur . Do not [...]

REFRIGERA TION LOG CARRIER 17EX EXTERNALL Y GEARED CENTRIFUGAL CHILLER Plant Chiller Serial No. Chiller Model No. Refrigerant T ype REC. 1 REC. 2 REC. 3 REC. 4 REC. 5 REC. 6 REC. 7 REC. 8 REC. 9 TIME DA TE OPERA TOR INITIALS COOLER Refrigerant Pressure T emperature W ater Pressure In Pressure Out Pressure GPM T emperature In T emperature Out CONDEN[...]

NOTE: Location of pumpout compressor may vary depending on ma- chine arrangement. DRIVE END COMPRESSOR END REAR VIEW COOLER ISOLA TION VA LV E 9 10 7 11 CHILLER CHARGER V AL VE Fig. 32 — Pumpout Unit Location and V alve Number Locations 65[...]

2. T o determine economizer/storage vessel pressure, attach a 30 in.-0-400 psi (-101-0-2760 kPa) gage to the vessel. 3. Refer to Fig. 32 for valve locations and numbers. Transfer, addition, or removal of refrigerant in spring- isolated chillers may place severe stress on external pip- ing if springs have not been blocked in both up and down directi[...]

T ransferring Refrigerant into the Cooler/ Condenser/Compressor Section — These steps de- scribe how to transfer refrigerant from the economizer/ storage vessel into the cooler/condenser/compressor section. This is normally done to prepare for service work on the economizer/storage vessel. 1. Isolate and push refrigerant into the cooler/condenser[...]

Refrigerant HFC-134a MUST NOT be mixed with air or oxygen and pressurized for leak testing. In general, this refrigerant should not be allowed to be present with high concentrations of air or oxygen above atmo- spheric pressures, because the mixture can undergo combustion. REFRIGERANT TRACER — Use an environmentally ac- ceptable refrigerant as a [...]

LEGEND 1— Lubricating Tube 2A — O-Ring 2B — O-Ring 3— Seal Housing 4— Coupling Guard Mounting Ring 5— Plain 1 ⁄ 2 -in. W asher (8 Required) 6— Hex Head Bolt, 1 ⁄ 2 - 1 3×4l g( 8 Required) 7— Windage Baffle 8— Shaft End Labyrinth 9— Screw 1 ⁄ 4 -2 0× 3 ⁄ 4 lg (4 Required) 10 — Screw, 10-24 × 1 ⁄ 2 lg 11 — Key , C[...]

9. Place a clean, lint-free cloth on a smooth, sturdy work surface. Place the seal housing assembly on the cloth with the face of the contact sleeve in contact with the cloth. While one person pushes down on the housing to compress the spring, another person must remove the snap ring. Then, slowly let the seal housing rise until the spring is fully[...]

Chiller Alignment ALIGNMENT METHODS — There are several established procedures for aligning shafts. The dial indicator method is presented here since it is considered to be one of the most accurate and reliable. Another faster and easier method for alignment involves using laser alignment tools and comput- ers. Follow the laser tool manufacturer [...]

2. Parallel in elevation — This alignment is also made with shims, but it cannot be made while there is angular mis- alignment in elevation. 3. Angular in plan — This position can easily be lost if placed ahead of the two adjustments in elevation. 4. Parallel in plan — This adjustment cannot be made while there is still angular misalignment i[...]

If the larger opening remains the same but changes from side to side, the shafts are in perfect alignment. The change in opening is due entirely to coupling runout, as above, or to a burr or other damage to the coupling face. If the larger opening remains the same, and remains on the same side, the amount is entirely shaft (net) misalignment. If th[...]

4. Loosen all holddown bolts except the pivot bolt. T urn the screw jack until the rear end of the equipment moves against the indicator by the desired amount. 5. T ighten 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 [...]

When using brackets, the diameter in the alignment for- mula (see Near Final Alignment, Connecting Angular Mis- alignment section) will be that of the circle through which the dial indicator rotates. 1. Shut down the chiller . 2. W ith chiller at operating temperature, quickly install brackets. 3. Check that alignment is within .002 in. TIR and .00[...]

WEEKL Y MAINTENANCE Check the Lubrication System — Mark the oil level on the compressor reservoir sight glass, and observe the level each week while the chiller is shut down. If the level goes below the lower sight glass, the oil re- claim system will need to be checked for proper operation. If additional oil is required, add oil as follows: Oil [...]

5. Open the drain located on the shell of the cooler/filter . Run a hose from the drain to a bucket to catch the oil. 6. Once the pressure has been relieved and the oil drained, loosen the bolts that hold the cover on the filter body . Remove the old filter cartridges and replace with a new filter cartridge. Assemble the filter assembly (filt[...]

The lubricant should be drained while the gear is at op- erating temperature. The gear drive should be cleaned with a flushing oil. Used lubricant and flushing oil should be com- pletely removed from the system to avoid contaminating new oil. T o change the oil in the external gear: 1. Make sure that the compressor is of f and the disconnect for [...]

CLEANLINESS — On open ventilated motors, screens and louvers over the inlet air openings should not be allowed to accumulate any build-up of dirt, lint, etc., that could restrict free air movement. Screens and louvers should never be cleaned or disturbed while the motor is in operation because any dis- lodged dirt or debris can be drawn directly [...]

7. When removing the labyrinth seals, note the position of the anti-rotation button located on the inside of the top half of the seal. Pull up the garter spring surrounding the floating labyrinth seal and carefully slip out the top half. Rotate the garter spring until the lock is visible. T wist counterclockwise to disengage the lock, remove the g[...]

14. Reinstall the bearing housing split bolts. Before torqu- ing bearing housing cap bolts, rotate the shaft by hand while bumping the bearing housing with a rubber or raw- hide mallet in the horizontal and axial planes to allow the bearings to align themselves to the shaft journals. 15. T orque the bearing housing cap bolts by following the torque[...]

Fill the gear drive to the recommended oil level with heated Shell VSI grade 68 oil or its equivalent, heated between 1 10 and 120 F (43 and 49 C). Do not overfill. Immediately close the openings to keep the vapors in the housing. Inspect the unit every 30 days and spray or add rust in- hibitor suitable for anticipated storage conditions, as requi[...]

Water must be within design flow limits, clean, and treated to ensure proper chiller performance and reduce the po- tential of tube damage due to corrosion, scaling, ero- sion, and algae. Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated water. Inspect the Starting Equipment — Before work- ing on[...]

temperature control overrides, hot gas bypass, surge al- gorithm status, and time schedule operation. Refer to Fig. 14 and T able 2, Examples 1 1-14. • The control test feature checks for proper operation and tests the temperature sensors, pressure transducers, the guide vane actuator , oil pumps, water pumps, tower control, and other on/of f out[...]

4. A high pressure point can also be calibrated between 240 and 260 psig (1655 and 1793 kPa) by attaching a regu- lated 250 psig (1724 kPa) pressure (usually from a ni- trogen cylinder). The high pressure point can be calibrated by accessing the appropriate transducer on the ST A TUS01 screen, highlighting the transducer , pressing the SELECT softk[...]

LEGEND FOR T ABLE 12, A - N 1CR AUX — Compressor Start Contact CA P — Compressor Current CCN — Carrier Comfort Network CDFL — Condenser W ater Flow CHIL S S — Chiller Start/Stop CHW — Chilled W ater CMPD — Discharge T emperature CRP — Condenser Pressure ERT — Evaporator Refrigerant T emperature EVFL — Chilled W ater Flow GV TRG [...]

T able 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with T roubleshooting Guides (cont) D. PRE-ST ART ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary . PRIMAR Y MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY PREST ART ALE[...]

T able 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with T roubleshooting Guides (cont) G. ST ART -UP F AILURES: This is an alarm condition. A manual reset is required to clear . PRIMAR Y MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMAR Y CAUSE ADDITIONAL CAUSE/REMEDY F AILURE TO ST ART LOW OIL PRESSURE OILPD [V ALUE] exc[...]

T able 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with T roubleshooting Guides (cont) I. NORMAL RUN WITH RESET , TEMPERA TURE, OR DEMAND PRIMAR Y MESSAGE SECONDAR Y MESSAGE PROBABLE CAUSE/REMEDY RUNNING — RESET ACTIVE 4-20MA SIGNAL Reset program active based on CONFIG screen setup. RUNNING — RESET ACTIVE REMOTE SE[...]

T able 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with T roubleshooting Guides (cont) L. CHILLER PROTECT LIMIT F AUL TS Excessive numbers of the same fault can lead to severe chiller damage. Seek service expertise. PRIMAR Y MESSAGE SECONDAR Y MESSAGE ALARM MESSAGE/PRIMAR Y CAUSE ADDITIONAL CAUSE/REMEDY PROTECTIVE LIMI[...]

T able 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with T roubleshooting Guides (cont) L. CHILLER PROTECT LIMIT F AUL TS (cont) Excessive numbers of the same fault can lead to severe chiller damage. Seek service expertise. PRIMAR Y MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY PROTECTIVE[...]

T able 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with T roubleshooting Guides (cont) N. OTHER PROBLEMS/MALFUNCTIONS DESCRIPTION/MALFUNCTION PROBABLE CAUSE/REMEDY Chilled W ater/Brine T emperature T oo High (Chiller Running) Chilled water set point set too high. Access set point on LID and verify . Capacity override o[...]

T able 13 — External Gear T roubleshooting Guide PROBLEM POSSIBLE CAUSE — ITEM NO.s* Excessive Operating T emperature 1,2,3,4,5,6,7,9,12,18,20,21 Oil Leakage 1,2,3,4,5,7,9,12,13,18,19,21 Gear Wear 1,2,3,4,6,7,8,9,10,1 1,12,13,14,15,16,18,19,21,22 Bearing Failure 1,6,7,8,9,10,1 1,12,15,16,19,20,21 Unusual Noise 1,2,3,4,6,7,8,9,10,1 1,12,13,15,16[...]

T able 14A — Thermistor T emperature (F) vs Resistance/V oltage Drop TEMPERA TURE VOL T AGE RESIST ANCE (F) DROP (V) (Ohms) −25.0 4.821 98010 −24.0 4.818 94707 −23.0 4.814 91522 −22.0 4.806 88449 −21.0 4.800 85486 −20.0 4.793 82627 −19.0 4.786 79871 −18.0 4.779 77212 −17.0 4.772 74648 −16.0 4.764 72175 −15.0 4.757 69790 −1[...]

T able 14B — Thermistor T emperature (C) vs Resistance/V oltage Drop TEMPERA TURE VOL T AGE RESIST ANCE (C) DROP (V) (Ohms) −40 4.896 168 230 −39 4.889 157 440 −38 4.882 147 410 −37 4.874 138 090 −36 4.866 129 410 −35 4.857 121 330 −34 4.848 1 13 810 −33 4.838 106 880 −32 4.828 100 260 −31 4.817 94 165 −30 4.806 88 480 −29[...]

Control Modules Turn the controller power of f before servicing the con- trols. This ensures safety and prevents damage to the controller. The Processor/Sensor Input/Output module (PSIO), 8-input (Options) modules, Starter Management Module (SMM), 4-in/2-out module, and the Local Interface Device (LID) mod- ule perform continuous diagnostic evaluat[...]

If all modules indicate a communications failure, check the communications plug on the PSIO module for proper seating. Also check the wiring (CCN bus — 1:red, 2:wht, 3:blk; Sensor bus — 1:red, 2:blk, 3:clr/wht). If a good connection is assured and the condition persists, replace the PSIO module. If only one 8-input module, the SMM, or the 4-in/[...]

Options Modules (8-Input) — The options modules are optional additions to the PIC, and are used to add tem- perature reset inputs, spare sensor inputs, and demand limit inputs. Each option module contains 8 inputs, each input meant for a specific duty . See the wiring diagram for exact module wire terminations. Inputs for each of the options mod[...]

6. Restore control system power (the LID displays, COM- MUNICA TION F AILURE at the bottom of the screen). 7. Access the SER VICE menu. Highlight and select the A TT ACH TO NETWORK DEVICE screen. Press the A TT ACH softkey . (The LID displays, UPLOAD- ING T ABLES. PLEASE W AIT ; then, COMMUNICA- TION F AILURE.) Press the EXIT softkey . 8. T urn of [...]

T able 15 — 17EX Heat Exchanger Economizer/Storage V essel, Piping, and Pumpout Unit W eights* COOLER SIZE† COOLER TOT AL WEIGHT COOLER CHARGE ECONOMIZER/ STORAGE VESSEL ECONOMIZER REFRIGERANT MISCELLANEOUS PIPING PUMPOUT UNIT Dry** Operating†† Refrigerant Water lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb gal kg L 45 25,032 1 1 355 30,098 [...]

T able 17 — Additional Condenser Weights* COMPONENT HEA T EXCHANGER SIZE W A TERBOX TYPE NUMBER OF P ASSES DESIGN MAXIMUM W A TER PRESSURE ADDITIONAL DR Y WEIGHT ADDITIONAL W A TER WEIGHT psig kPa lb kg lb kg CONDENSER 4 5-4 7 NIH 1, 3 150 1034 344 156 — — NIH 1, 3 300 2068 1652 749 — — NIH 2 300 2068 1 132 513 — — Marine 1, 3 150 103[...]

T able 20A — T otal Motor W eight, English (lb) ENCLOSURE TYPE HERTZ VOL T AGE SIZE (HP) Open-Drip Proof (ODP) 60 Hz F A, FF (1250) FB, FG (1500) FH (1600) FC, FJ (1750) FD, FK (2000) 2400 4836 5721 5900 5900 7160 3300 4824 5832 5832 5832 7127 4160 4836 5721 5900 5900 7160 6900 5596 6577 8776 8776 8990 50 Hz 3000 5518 5878 7148 7148 9048 3300 551[...]

T able 21 — Marine W aterbox Cover Weights* HEA T EXCHANGER SIZE DESIGN MAXIMUM W A TER PRESSURE COOLER CONDENSER psi kPa lb kg lb kg 4 5-4 8 150 1034 2236 1015 1275 579 300 2068 3060 1389 1660 754 5 5-5 7 150 1034 — — 1643 746 300 2068 — — 2243 1018 *Heat exchangers with marine waterboxes have heavier dry and operating weights than heat [...]

T able 24 — Auxiliary Systems, Electrical Data POWER SOURCE ITEM A VERAGE kW DESIGN CENTER VOL T AGE SUPPL Y V -PH-Hz FLA LRA 1 Seal Leakage Pump 0.23 1 15 1 15-1-50/60 4.78 21.7 Motor Space Heater 0.50 1 15 1 15-1-50/60 4.35 4.35 Control Module and Actuator 0.40 1 15 1 15-1-60 3.50 — 1 15-1-50 Oil Sump Heater 1.00 1 15 1 15-1-60 8.70 — 1 15-[...]

NOTE: Refer to T able 26 for item number references. Fig. 57 — Compressor Fits and Clearances 105[...]

T able 26 — Compressor Fits and Clearances ITEM DESCRIPTION CLEARANCE TYPE OF MEASURE Minimum Maximum in. mm in. mm 1 1st Stage Impeller to Diaphragm See T abulation Axial 2 Interstage Labyrinth 0.012 0.305 0.016 0.406 Diametral 3 2nd Stage Impeller to Discharge W all See T abulation Axial 4 Thrust End Journal Bearing 0.0035 0.0889 0.0055 0.1397 [...]

T abulation — Impeller Clearances (Open-Drive Compressors) COMPRESSOR SIZE SHROUD DIAM CODE IMPELLER DIAMETER DIMENSION* Item 1 Item 3 in. mm in. mm in. mm 17FX 3 1 12.00 304.8 .837 21.26 .638 16.21 3 12.38 314.5 .797 20.24 .609 15.47 5 12.75 323.8 .757 19.23 .579 14.71 7 13.25 336.6 .717 18.21 .541 13.74 9 13.75 349.2 .690 17.53 .541 13.74 4 1 1[...]

LEGEND BRG — Bearing C— Contactor CB — Circuit Breaker CH — Channel COM — Communications COMP’R — Compressor COND — Condenser DETR — Detector DIFF — Differential DISCH — Discharge ENT — Entering EV AP — Evaporator EXT — External G.V . — Guide V ane HGBP — Hot Gas Bypass HTR — Heater INT — Internal J— Junction K[...]

LEGEND PH — Phase PRESS. — Pressure PSIO — Processor/Sensor Input/Output Module R— T erminal Designation SMM — Starter Management Module T— T erminal t* — Thermistor TB — T erminal Block TEMP — T emperature TEW AC — T otally Enclosed W ater-to-Air Cooled TG — T erminal Designation TS — T erminal Strip Required Power Wiring R[...]

LEGEND CB — Circuit Breaker COMM — Communications N.O. — Normally Open N.C. — Normally Closed O.L. — Overload PR — Pilot Relay RLA — Rated Load Amps SMM — Starter Management Module TB — T erminal Block Starter V endor Supplied Wiring Field Wiring Carrier Factory Wiring NOTE: V oltage to terminals LL1 and LL2 comes from a control t[...]

Fig. 59 — Elementary Wiring Diagram for Starter Management Module (SMM) and Control Interface Between Starter and Chiller Power Panel (For Low and Medium V oltage Free-Standing Starters) (cont) 111[...]

LEGEND D P— Differential Pressure C— Contactor COMP’R — Compressor G— Ground L— Line T erminal LL — Control Power Line T erminal M— Motor OL ’ s — Overloads OS — 3-Phase Current Power Source PR — Pilot Relay SP — Open T erminal Designation (Open Space) SW — Switch T— T erminal TB — T erminal Board Required Power Wiri[...]

NOTES FOR FIG. 60 I GENERAL 1.0 Starters shall be designed and manufactured in accordance with Carrier Engineering requirement Z-375. 1.1 All field-supplied conductors and devices, field-installation wir- ing, and termination of conductors and devices must be in com- pliance with all applicable codes and job specifications. 1.2 The routing of ?[...]

LEGEND EQUIP — Equipment GND — Ground HGBP — Hot Gas Bypass S— Switch T1-T4 — Power Panel Transformers TS — T erminal Strip Fig. 61 — Oil Pump and Control Power Panel (Interior View) 11 4[...]

INDEX Abbreviations, 5 Access the Service Screen, T o (Service Operation), 42 Accidental Start-Up, T o Prevent, 61 Accuracy , Check Sensor (Checking T emperature Sensors), 84 Adding Refrigerant, 67 Adjusting the Refrigerant Charge, 67 After Extended Shutdown, 63 After Limited Shutdown, 63 After Power Failure, Auto. Restart (Lead/Lag Control), 40 Au[...]

INDEX (cont) Control, Auxiliary Compressor Oil Pump, 33 Auxiliary Gear Oil Pump, 33 Capacity , 32 Condenser Pump, 36 Entering Chilled W ater, 32 High Discharge T emperature, 35 Ice Build, 40 Lead/Lag, 38 Oil Sump T emperature, 35 Ramp Loading, 33 Control Algorithms Checkout Procedure, 85 Control and Oil Heater V oltage Selector (S1), 16 Control Cen[...]

INDEX (cont) Initial Start-Up, Before, 45 Motor , 58 Initiation, Ice Build (Ice Build Control), 40 Input Equipment Service Parameters If Necessary , 55 Input/Output Module (PSIO), Processor/Sensor , 16 Input Service Configurations, 54 Input the Design Set Points, 54 Input the Local Occupied Schedule (OCCPC01S), 54 Input T ime and Date, 55 Inputs, [...]

INDEX (cont) OCCPC01S, Input the Local Occupied Schedule, 54 Occupancy Schedule, 32 Occupied Schedule (OCCPC01S), Input the Local, 54 Oil, Compressor , 77 External Gear , 77 Oil Auxiliary Relay (4C), 16 Oil Changes (Scheduled Maintenance), 77 Oil Charge, Compressor , 54 Oil Charge, Optional Pumpout Compressor , 83 Oil Circuit V alves, Open, 46 Oil [...]

INDEX (cont) Refrigerant Float System, Inspect (Scheduled Maintenance), 78 Refrigerant Leak T esting, 67 Refrigerant Pressures, Reading, 63 Refrigerant Properties, 67 Refrigerant T racer (T est After Service, Repair, or Major Leak), 68 Refrigerant T racer , 46 Refrigerant T ransfer Procedures, Pumpout and, 63 Refrigeration Cycle, 5 Refrigeration Lo[...]

INDEX (cont) T est, Control (T roubleshooting Guide), 85 Perform and Automated Control, 56 Standing V acuum, 49 T esting, Refrigerant Leak, 67 This Manual (Instruct the Operator), 62 Threshold, Automatic Soft Stop Amps, 44 T ighten All Gasketed Joints and Guide V ane Shaft Packing, 46 T ightness, Check Chiller , 46 T ime and Date, Input, 55 T ime S[...]