Document Outline

• Contents
• Safety Considerations
• Introduction
• Abbreviations
• 17/19EX Machine Familiarization
  • Machine Identification Label
  • System Components
  • Cooler
  • Condenser
  • Motor-Compressor
  • Control Center
  • Motor Starter
  • Utility Vessel
• 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
  • 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)
    • Oil Auxiliary Relay (4C)
    • Control Transformers (T1-T4)
    • Control and Oil Heater Voltage Selector (S1)
    • Oil Differential Pressure/Power Supply Module
  • 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
    • 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 Control (Open Drive Machines Only)
  • Ramp Loading Control
  • Capacity Override
  • High Discharge Temperature Control
  • Oil Sump Temperature Control
  • Oil Cooler
  • Remote Start/Stop Controls
  • 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
    • 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
• 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
  • 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
  • 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
    • 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
  • 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
    • Review Maintenance
    • Safety
    • 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
• 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
  • Test After Service, Repair, or Major Leak
    • Refrigerant Tracer
    • To Pressurize with Dry Nitrogen
  • Repair the Leak, Retest, and Apply Standing Vacuum Test
  • Checking Guide Vane Linkage
  • Contact Seal Maintenance (Open-Drive Machines)
    • Seal Disassembly
    • Seal Reassembly
  • Machine Alignment (Open-Drive Machines)
    • Alignment Methods
    • Preliminary Alignment
    • Near Final Alignment
    • Final Alignment
    • Hot Alignment Check
    • Doweling
• Weekly Maintenance
  • Check the Lubrication System
• Scheduled Maintenance
  • Service Ontime
  • Inspect the Control Center
  • Check Safety and Operating Controls Monthly
  • Changing Oil Filter
    • 19EX Compressors
    • FA Style Compressors
  • Oil Specification
  • Oil Changes
    • To Change the Oil
  • Refrigerant Filter
  • Oil Reclaim Filter
  • Inspect Refrigerant Float System
  • Inspect Relief Valves and Piping
  • Coupling Maintenance (Open-Drive Machines)
    • Procedure
  • Motor Maintenance (Open-Drive Machines)
    • Cleanliness
    • Sleeve Bearings
  • Open-Drive Motor Handling/Rigging
  • Open-Drive Motor Storage
  • Compressor Bearing and Gear Maintenance
  • Inspect the Heat Exchanger Tubes
    • Cooler
    • Condenser
  • Water Leaks
  • Water Treatment
  • Inspect the Starting Equipment
  • Check Pressure Transducers
  • Pumpout System Maintenance
    • Optional Pumpout Compressor Oil Charge
    • Pumpout Safety Control Settings
  • Ordering Replacement Chiller Parts
    • Open-Drive Motor Renewal Parts
• Troubleshooting Guide
  • Overview
  • Checking the Display Messages
  • Checking Temperature Sensors
    • Resistance Check
    • Voltage Drop
    • Check Sensor Accuracy
    • Dual Temperature Sensors
  • Checking Pressure Transducers
    • Oil Differential Pressure/Power Supply Module Calibration
    • Troubleshooting Transducers
    • Transducer Replacement
  • Control Algorithms Checkout Procedure
  • Control Test
  • Control Modules
    • Red LED
    • Green LEDs
  • Notes on Module Operation
  • Processor Module (PSIO)
    • Inputs
    • Outputs
  • Starter Management Module (SMM)
    • Inputs
    • Outputs
  • Options Modules (8-Input)
  • Replacing Defective Processor Modules
    • Installation of New PSIO Module
• 17/19EX Physical Data And Wiring Schematics
• Initial Start-Up Checklist for 17/19EX Centrifugal Liquid Chiller
• List of Tables
• LIst of Figures