Carrier 17EX - Page 47

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Fig. 25 — 17EX Leak Test Procedures

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Safety Considerations1
Table of Contents2
Introduction5
Abbreviations5
17Ex Chiller Familiarization5
Chiller Identiﬁcation Label5
System Components5
Cooler5
Condenser5
Compressor5
Control Center5
Motor Starter (Purchased Separately)5
Oil Cooling Cycle8
Compressor Oil Cooling8
External Gear Oil Cooling8
Lubrication Cycle8
Compressor Lubrication Cycle8
External Gear Lubrication Cycle9
Starters9
Controls11
Deﬁnitions11
- Analog Signal11
- Digital Signal11
- Volatile Memory11
General11
PIC System Components12
- Processor/Sensor Input/Output Module (Psio)12
- Starter Management Module (Smm)12
- Local Interface Device (Lid)12
- Six-Pack Relay Board16
- Four-In/Two-Out (4-In/2-Out) Module16
- Oil Heater Contactor (1C)16
- Compressor Oil Pump Contactor (2C) and Gear16
- Oil Pump Contactor (5C)16
- HOT GAS BYPASS CONTACTOR RELAY (3C) (Optional)16
- Oil Auxiliary Relay (4C)16
- Control Transformers (T1-T4)16
- Control and Oil Heater Voltage16
- Oil Differential Pressure/Power Supply16
- Lid Default Screen Menu Items17
- Menu Structure17
- To View or Change Point Status17
- Override Operations18
- To View or Change Time Schedule Operation18
- To View and Change Set Points22
- Service Operation22
PIC System Functions32
- Capacity Control32
- Entering Chilled Water Control32
- Deadband32
- Proportional Bands and Gain32
- Demand Limiting32
- Chiller Timers32
- Occupancy Schedule32
Safety Controls33
- Shunt Trip33
Default Screen Freeze33
Auxiliary Compressor Oil Pump Control33
Auxiliary Gear Oil Pump Control33
Shaft Seal Oil Control33
Ramp Loading Control33
Capacity Override35
High Discharge Temperature Control35
Oil Sump Temperature Control35
Oil Cooler36
Remote Start/Stop Controls36
Spare Safety Inputs36
Spare Alarm Contacts36
Condenser Pump Control36
Condenser Freeze Prevention36
Tower-Fan Relay36
Auto. Restart after Power Failure36
Water/Brine Reset37
Demand Limit Control Option37
- 8-Input Module)37
Surge Prevention Algorithm37
Surge Protection38
Lead/Lag Control38
- Common Point Sensor Installation38
- Chiller Communication Wiring38
- Lead/Lag Operation39
- Faulted Chiller Operation40
- Load Balancing40
- Auto. Restart after Power Failure40
Ice Build Control40
- Ice Build Initiation40
- Start-Up/Recycle Operation40
- Temperature Control During Ice Build41
- Termination of Ice Build41
- Return to Non-Ice Build Operations41
Attach to Network Device Control41
- Attaching to Other Ccn Modules41
Service Operation42
- To Access the Service Screens42
- To Log off42
- Holiday Scheduling42
Controls43
Start-Up/Shutdown/Recycle Sequence43
Local Start-Up43
Shutdown Sequence44
Automatic Soft Stop Amps Threshold44
Chilled Water Recycle Mode44
Safety Shutdown45
Before Initial Start-Up45
Job Data Required45
Equipment Required45
Using the Economizer/Storage Vessel and Pumpout System45
Remove Shipping Packaging45
- Motor45
- External Gear45
Motor Electrical Connection45
Motor Auxiliary Devices46
Open Oil Circuit Valves46
Tighten All Gasketed Joints and Guide Vane Shaft Packing46
Check Chiller Tightness46
Refrigerant Tracer46
Leak Test the Chiller46
Standing Vacuum Test49
Chiller Dehydration49
Inspect Water Piping50
Check Optional Pumpout Compressor Water Piping50
Check Relief Devices50
Inspect Wiring50
- Check Insulation Resistance50
Motor Pre-Start Checks51
External Gear Pre-Start Checks51
Carrier Comfort Network Interface53
Check Starter53
Power up the Controls and Check the Compressor Oil Heater54
Compressor Oil Charge54
Set up Chiller Control Conﬁguration54
Input the Design Set Points54
Input Service Conﬁgurations54
- Password54
- Input Time and Date54
- Check Pumpout System Controls and Optional Pumpout Compressor56
Initial Start-Up57
High Altitude Locations57
Charge Refrigerant into Chiller57
Manual Operation of the Guide Vanes58
Dry Run to Test Start-Up Sequence58
Check Motor Rotation58
- Initial Motor Start-Up58
Disc Coupling Installation and Alignment59
Check Oil Pressure and Compressor Stop61
Calibrate Motor Current Demand Setting61
To Prevent Accidental Start-Up61
Hot Alignment Check61
Doweling61
Check Chiller Operating Condition61
Start-Up/Shutdown/Recycle Sequence62
Instruct the Operator62
Operating Instructions62
Prepare the Chiller for Start-Up62
Starting the Chiller62
Check the Running System62
Stopping the Chiller62
Initial Start-Up62
- Operating the Optional Pumpout Compressor63
- Procedures63
- Reading Refrigerant Pressures63
- Transferring Refrigerant into the Economizer/Storage Vessel66
- Procedures67
  - Return Chiller to Normal Operating Conditions67
  - Transferring Refrigerant into the Cooler/Condenser/Compressor Section67
After Limited Shutdown63
Extended Shutdown63
After Extended Shutdown63
Cold Weather Operation63
Manual Guide Vane Operation63
Refrigeration Log63
General Maintenance67
Refrigerant Properties67
Adding Refrigerant67
Removing Refrigerant67
Adjusting the Refrigerant Charge67
Refrigerant Leak Testing67
Leak Rate67
Repair the Leak, Retest, and Apply Standing Vacuum Test68
Checking Guide Vane Linkage68
Contact Seal Maintenance68
- Seal Disassembly68
Chiller Alignment71
- Alignment Methods71
- Preliminary Alignment71
  - Near Final Alignment71
  - Hot Alignment Check71
Weekly Maintenance76
Check the Lubrication System76
Scheduled Maintenance76
Service Ontime76
Inspect the Control Center76
Check Safety and Operating Controls Monthly76
Changing the Oil Filters76
- Compressor Oil Filter76
Oil Speciﬁcations77
Oil Changes77
Inspect Relief Valves and Piping78
Coupling Maintenance78
Motor Maintenance78
Motor Handling/Rigging81
Motor Storage81
External Gear Storage81
- SHORT-TERM STORAGE (Indoors81
- LONG-TERM STORAGE (Indoors81
- Extended Downtime82
Compressor Bearing Maintenance82
External Gear Maintenance82
Inspect the Heat Exchanger Tubes82
Water Leaks82
Water Treatment82
Inspect the Starting Equipment83
Check Pressure Transducers83
Pumpout System Maintenance83
- Optional Pumpout Compressor Oil Charge83
- Pumpout Safety Control Settings83
Ordering Replacement Chiller Parts83
- Motor Replacement Parts83
- External Gear Replacement Parts83
Troubleshooting Guide83
Overview83
Checking the Display Messages84
Checking Temperature Sensors84
Checking Pressure Transducers84
- Oil Differential Pressure/Power Supply85
Control Algorithms Checkout Procedure85
Control Test85
Troubleshooting Guide86
Control Modules96
- RED Leds96
Notes on Module Operation96
Processor/Sensor Input/Output Module (PSIO)97
Starter Management Module (SMM)97
- Inputs97
- Outputs97
Options Modules (8-Input)98
Four-In/Two-Out Module98
Replacing Defective Processor Modules98
- Installation of New Psio Module98
Physical Data and Wiring Schematics99
Index115

Carrier 17EX - Page 47

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