Carrier 17EX Start-up, Operation And Maintenance Instructions Manual

Also see for 17EX Series: Start up & operation manual Start-up, operation and maintenance instructions

Contents

CONTENTSPageSAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517EX CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . . 5Chiller Identification Label . . . . . . . . . . . . . . . . . . . . . . . 5System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Control Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Motor Starter (Purchased Separately) . . . . . . . . . . . . . . 5Economizer/Storage Vessel . . . . . . . . . . . . . . . . . . . . . . 5REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . 5-8OIL COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Compressor Oil Cooling . . . . . . . . . . . . . . . . . . . . . . . . . 8External Gear Oil Cooling . . . . . . . . . . . . . . . . . . . . . . . . 8LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . 8,9Compressor Lubrication Cycle . . . . . . . . . . . . . . . . . . . 8External Gear Lubrication Cycle . . . . . . . . . . . . . . . . . . 9STARTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-43Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11• ANALOG SIGNAL• DIGITAL SIGNAL• VOLATILE MEMORYGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11PIC System Components . . . . . . . . . . . . . . . . . . . . . . . 12• PROCESSOR/SENSOR INPUT/OUTPUT MODULE (PSIO)• STARTER MANAGEMENT MODULE (SMM)• LOCAL INTERFACE DEVICE (LID)• SIX-PACK RELAY BOARD• EIGHT-INPUT MODULES• FOUR-IN/TWO-OUT (4-IN/2-OUT) MODULE• OIL HEATER CONTACTOR (1C)• COMPRESSOR OIL PUMP CONTACTOR (2C) AND GEAROIL PUMP CONTACTOR (5C)• HOT GAS BYPASS CONTACTOR RELAY (3C) (Optional)• OIL AUXILIARY RELAY (4C)• CONTROL TRANSFORMERS (T1-T4)• CONTROL AND OIL HEATER VOLTAGESELECTOR (S1)• OIL DIFFERENTIAL PRESSURE/POWER SUPPLYMODULELID Operation and Menus . . . . . . . . . . . . . . . . . . . . . . . 16• 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 OPERATIONPIC System Functions . . . . . . . . . . . . . . . . . . . . . . . . . . 32• CAPACITY CONTROL• ENTERING CHILLED WATER CONTROL• DEADBAND• PROPORTIONAL BANDS AND GAIN• DEMAND LIMITING• CHILLER TIMERS• OCCUPANCY SCHEDULESafety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33• SHUNT TRIPPageDefault Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . 33Auxiliary Compressor Oil Pump Control . . . . . . . . . . 33Auxiliary Gear Oil Pump Control . . . . . . . . . . . . . . . . 33Shaft Seal Oil Control . . . . . . . . . . . . . . . . . . . . . . . . . . 33Ramp Loading Control . . . . . . . . . . . . . . . . . . . . . . . . . 33Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35High Discharge Temperature Control . . . . . . . . . . . . . 35Oil Sump Temperature Control . . . . . . . . . . . . . . . . . . 35Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . . . . 36Spare Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Spare Alarm Contacts . . . . . . . . . . . . . . . . . . . . . . . . . 36Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . 36Condenser Freeze Prevention . . . . . . . . . . . . . . . . . . . 36Tower-Fan Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Auto. Restart After Power Failure . . . . . . . . . . . . . . . . 36Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Demand Limit Control, Option (Requires Optional8-Input Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Surge Prevention Algorithm . . . . . . . . . . . . . . . . . . . . 37Surge Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38• COMMON POINT SENSOR INSTALLATION• CHILLER COMMUNICATION WIRING• LEAD/LAG OPERATION• FAULTED CHILLER OPERATION• LOAD BALANCING• AUTO. RESTART AFTER POWER FAILUREIce Build Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40• ICE BUILD INITIATION• START-UP/RECYCLE OPERATION• TEMPERATURE CONTROL DURING ICE BUILD• TERMINATION OF ICE BUILD• RETURN TO NON-ICE BUILD OPERATIONSAttach to Network Device Control . . . . . . . . . . . . . . . 41• ATTACHING TO OTHER CCN MODULESService Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42• TO ACCESS THE SERVICE SCREENS• TO LOG OFF• HOLIDAY SCHEDULINGSTART-UP/SHUTDOWN/RECYCLE SEQUENCE . . . 43-45Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Automatic Soft Stop Amps Threshold . . . . . . . . . . . . 44Chilled Water Recycle Mode . . . . . . . . . . . . . . . . . . . . 44Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . . 45-57Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Using the Economizer/Storage Vessel and PumpoutSystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Remove Shipping Packaging . . . . . . . . . . . . . . . . . . . 45• MOTOR• EXTERNAL GEARMotor Electrical Connection . . . . . . . . . . . . . . . . . . . . 45Motor Auxiliary Devices . . . . . . . . . . . . . . . . . . . . . . . . 46Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . . 46Tighten All Gasketed Joints and Guide VaneShaft Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . . . 46Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Leak Test the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . . 49Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492