Carrier Air Conditioner 17EX User Manual
17EX  
Externally Geared Centrifugal Liquid Chillers  
50/60 Hz  
1500 to 2250 Nominal Tons (5280 to 7910 kW)  
Start-Up, Operation, and Maintenance Instructions  
SAFETY CONSIDERATIONS  
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.  
DO NOT REUSE disposable (nonreturnable) cylinders or  
attempt to refill them. It is DANGEROUS AND ILLEGAL. When  
cylinder is emptied, evacuate remaining gas pressure, loosen  
the collar and unscrew and discard the valve stem. DO NOT  
INCINERATE.  
Be sure you understand and follow the procedures and  
safety precautions contained in the chiller instructions  
as well as those listed in this guide.  
CHECK THE REFRIGERANT TYPE before adding refrigerant to  
the chiller. The introduction of the wrong refrigerant can cause dam-  
age or malfunction to this chiller.  
Operation of this equipment with refrigerants other than those  
cited herein should comply with ASHRAE-15 (latest edition). Con-  
tact Carrier for further information on use of this chiller with other  
refrigerants.  
DO NOTATTEMPT TO REMOVE fittings, covers, etc., while chiller  
is under pressure or while chiller is running. Be sure pressure is at  
0 psig (0 kPa) before breaking any refrigerant connection.  
CAREFULLY INSPECT all relief devices, rupture discs, and other  
relief devices AT LEAST ONCE A YEAR. If chiller operates in a  
corrosive atmosphere, inspect the devices at more frequent  
intervals.  
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief  
device when corrosion or build-up of foreign material (rust, dirt,  
scale, etc.) is found within the valve body or mechanism. Replace  
the device.  
DO NOT VENT refrigerant relief valves within a building. Outlet  
from rupture disc or relief valve must be vented outdoors in ac-  
cordance with the latest edition of ASHRAE (American Society of  
Heating, Refrigeration, and Air Conditioning Engineers) 15. The  
accumulation of refrigerant in an enclosed space can displace oxy-  
gen and cause asphyxiation.  
PROVIDE adequate ventilation in accordance with ASHRAE 15,  
especially for enclosed and low overhead spaces. Inhalation of high  
concentrations of vapor is harmful and may cause heart irregulari-  
ties, unconsciousness, or death. Misuse can be fatal. Vapor is heavier  
than air and reduces the amount of oxygen available for breathing.  
Product causes eye and skin irritation. Decomposition products are  
hazardous.  
DO NOT install relief devices in series or backwards.  
DO NOT USE OXYGEN to purge lines or to pressurize a chiller  
for any purpose. Oxygen gas reacts violently with oil, grease, and  
other common substances.  
NEVER EXCEED specified test pressures, VERIFY the allowable  
test pressure by checking the instruction literature and the design  
pressures on the equipment nameplate.  
USE CARE when working near or in line with a compressed spring.  
Sudden release of the spring can cause it and objects in its path to  
act as projectiles.  
RUN WATER PUMPS when removing, transferring, or charg-  
ing refrigerant.  
DO NOT USE air for leak testing. Use only refrigerant or dry  
nitrogen.  
DO NOT VALVE OFF any safety device.  
BE SURE that all pressure relief devices are properly installed and  
functioning before operating any machine.  
DO NOT STEP on refrigerant lines. Broken lines can whip about  
and cause personal injury.  
DO NOT climb over a chiller. Use platform, catwalk, or staging.  
Follow safe practices when using ladders.  
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or  
move inspection covers or other heavy components. Even if com-  
ponents are light, use such equipment when there is a risk of slip-  
ping or losing your balance.  
DO NOT WELD OR FLAME CUT any refrigerant line or vessel  
until all refrigerant (liquid and vapor) has been removed from chiller.  
Traces of vapor should be displaced with dry air or nitrogen and  
the work area should be well ventilated. Refrigerant in contact with  
an open flame produces toxic gases.  
DO NOT USE eyebolts or eyebolt holes to rig chiller sections or  
the entire assembly.  
DO NOT work on high-voltage equipment unless you are a quali-  
fied electrician.  
DO NOT WORK ON electrical components, including control pan-  
els, switches, starters, or oil heater until you are sure ALL POWER  
IS OFF and no residual voltage can leak from capacitors or solid-  
state components.  
BE AWARE that certain automatic start arrangements CAN EN-  
GAGE THE STARTER. Open the disconnect ahead of the starter  
in addition to shutting off the machine or pump.  
USE only repair or replacement parts that meet the code require-  
ments of the original equipment.  
DO NOT VENT OR DRAIN waterboxes containing industrial brines,  
liquid, gases, or semisolids without permission of your process con-  
trol group.  
DO NOT LOOSEN waterbox cover bolts until the waterbox has  
been completely drained.  
DOUBLE-CHECK that coupling nut wrenches, dial indicators, or  
other items have been removed before rotating any shafts.  
LOCK OPENAND TAG electrical circuits during servicing. IF WORK  
IS INTERRUPTED, confirm that all circuits are deenergized be-  
fore resuming work.  
AVOID SPILLING liquid refrigerant on skin or getting it into the  
eyes. USE SAFETY GOGGLES. Wash any spills from the skin  
with soap and water. If any enters the eyes, IMMEDIATELY FLUSH  
EYES with water and consult a physician.  
NEVER APPLY an open flame or live steam to a refrigerant cyl-  
inder. Dangerous overpressure can result. When necessary to heat  
refrigerant, use only warm (110 F [43 C]) water.  
DO NOT LOOSEN a packing gland nut before checking that the  
nut has a positive thread engagement.  
PERIODICALLY INSPECT all valves, fittings, and piping for cor-  
rosion, rust, leaks, or damage.  
PROVIDE A DRAIN connection in the vent line near each pres-  
sure relief device to prevent a build-up of condensate or rain  
water.  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Book 2  
PC 211  
Catalog No. 531-721  
Printed in U.S.A.  
Form 17EX-1SS  
Pg 1  
7-97  
Replaces: New  
Tab 5d  
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CONTENTS  
Page  
Page  
Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 50  
Check Optional Pumpout Compressor Water  
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50  
Check Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 50  
Inspect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50  
• CHECK INSULATION RESISTANCE  
Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 62  
Starting the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . 62  
Check the Running System . . . . . . . . . . . . . . . . . . . . . 62  
Stopping the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . 62  
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 63  
Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . 63  
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . 63  
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . 63  
Manual Guide Vane Operation . . . . . . . . . . . . . . . . . . . 63  
Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63  
Motor Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . 51  
External Gear Pre-Start Checks . . . . . . . . . . . . . . . . . 51  
Carrier Comfort Network Interface . . . . . . . . . . . . . . . 53  
Check Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53  
• MECHANICAL STARTERS  
PUMPOUT AND REFRIGERANT TRANSFER  
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-67  
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63  
Operating the Optional Pumpout  
• SOLID-STATE STARTERS  
Compressor Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . 54  
Power Up the Controls and  
Check the Compressor Oil Heater . . . . . . . . . . . . . 54  
• SOFTWARE VERSION  
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63  
• READING REFRIGERANT PRESSURES  
Set Up Chiller Control Configuration . . . . . . . . . . . . . 54  
Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 54  
Input the Local Occupied Schedule  
Transferring Refrigerant into the  
Economizer/Storage Vessel . . . . . . . . . . . . . . . . . . . 66  
Transferring Refrigerant into  
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54  
Input Service Configurations . . . . . . . . . . . . . . . . . . . . 54  
• PASSWORD  
the Cooler/Condenser/Compressor Section . . . . . 67  
Return Chiller to Normal Operating  
Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67  
• INPUT TIME AND DATE  
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . 67-75  
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . . 67  
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67  
Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . 67  
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . . 67  
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . 67  
Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67  
Test After Service, Repair, or Major Leak . . . . . . . . . 67  
• REFRIGERANT TRACER  
• 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 . . . . . . . . . . . . . . . . . . . . . . . . 56  
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . 57  
Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 57  
• TRIMMING REFRIGERANT CHARGE  
• TO PRESSURIZE WITH DRY NITROGEN  
Repair the Leak, Retest, and Apply  
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . 68  
Checking Guide Vane Linkage . . . . . . . . . . . . . . . . . . 68  
Contact Seal Maintenance . . . . . . . . . . . . . . . . . . . . . . 68  
• SEAL DISASSEMBLY  
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . 57-62  
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57  
Manual Operation of the Guide Vanes . . . . . . . . . . . . 58  
Dry Run to Test Start-Up Sequence . . . . . . . . . . . . . . 58  
Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . 58  
• INITIAL MOTOR START-UP  
• SEAL REASSEMBLY  
Chiller Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71  
• ALIGNMENT METHODS  
• PRELIMINARY ALIGNMENT  
• NEAR FINAL ALIGNMENT  
• FINAL ALIGNMENT  
Disc Coupling Installation and Alignment . . . . . . . . . 59  
• IMPORTANT INFORMATION  
• HOT ALIGNMENT CHECK  
• DOWELING  
Check Oil Pressure and Compressor Stop . . . . . . . . 61  
Calibrate Motor Current Demand Setting . . . . . . . . . . 61  
To Prevent Accidental Start-Up . . . . . . . . . . . . . . . . . . 61  
Hot Alignment Check . . . . . . . . . . . . . . . . . . . . . . . . . 61  
Doweling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61  
Check Chiller Operating Condition . . . . . . . . . . . . . . . 61  
Instruct the Operator . . . . . . . . . . . . . . . . . . . . . . . . . . 62  
• COOLER-CONDENSER  
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 76  
Check the Lubrication System . . . . . . . . . . . . . . . . . . 76  
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . 76-83  
Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76  
Inspect the Control Center . . . . . . . . . . . . . . . . . . . . . 76  
Check Safety and Operating Controls Monthly . . . . . 76  
Changing the Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . 76  
• COMPRESSOR OIL FILTER  
• ECONOMIZER/STORAGE VESSEL  
• PUMPOUT SYSTEM  
• EXTERNAL GEAR OIL FILTER  
• COMPRESSOR ASSEMBLY  
Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77  
Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77  
• COMPRESSOR OIL  
• COMPRESSOR LUBRICATION SYSTEM  
EXTERNAL GEAR LUBRICATION SYSTEM  
• CONTROL SYSTEM  
• EXTERNAL GEAR OIL  
• MOTOR SLEEVE BEARING AND PUMPOUT  
COMPRESSOR OIL  
• AUXILIARY EQUIPMENT  
• CHILLER CYCLES  
• MAINTENANCE  
Inspect Refrigerant Float System . . . . . . . . . . . . . . . . 78  
Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . 78  
Coupling Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 78  
Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78  
• CLEANLINESS  
• SAFETY DEVICES AND PROCEDURES  
• CHECK OPERATOR KNOWLEDGE  
• THIS MANUAL  
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . 62,63  
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62  
• SLEEVE BEARINGS  
3
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CONTENTS (cont)  
Page  
Page  
Motor Handling/Rigging . . . . . . . . . . . . . . . . . . . . . . . . 81  
Motor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81  
External Gear Storage . . . . . . . . . . . . . . . . . . . . . . . . . 81  
• SHORT-TERM STORAGE (Indoors)  
Checking Pressure Transducers . . . . . . . . . . . . . . . . 84  
• OIL DIFFERENTIAL PRESSURE/POWER SUPPLY  
MODULE CALIBRATION  
• TROUBLESHOOTING TRANSDUCERS  
• TRANSDUCER REPLACEMENT  
• LONG-TERM STORAGE (Indoors)  
Control Algorithms Checkout Procedure . . . . . . . . . 85  
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85  
Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96  
• RED LEDs  
• EXTENDED DOWNTIME  
Compressor Bearing Maintenance . . . . . . . . . . . . . . . 82  
External Gear Maintenance . . . . . . . . . . . . . . . . . . . . . 82  
Inspect the Heat Exchanger Tubes . . . . . . . . . . . . . . . 82  
• COOLER  
• GREEN LEDs  
Notes on Module Operation . . . . . . . . . . . . . . . . . . . . 96  
Processor/Sensor Input/Output Module (PSIO) . . . . 97  
• INPUTS  
• CONDENSER  
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82  
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82  
Inspect the Starting Equipment . . . . . . . . . . . . . . . . . 83  
Check Pressure Transducers . . . . . . . . . . . . . . . . . . . 83  
Pumpout System Maintenance . . . . . . . . . . . . . . . . . . 83  
• OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE  
• PUMPOUT SAFETY CONTROL SETTINGS  
Ordering Replacement Chiller Parts . . . . . . . . . . . . . . 83  
• MOTOR REPLACEMENT PARTS  
• OUTPUTS  
Starter Management Module (SMM) . . . . . . . . . . . . . . 97  
• INPUTS  
• OUTPUTS  
Options Modules (8-Input) . . . . . . . . . . . . . . . . . . . . . 98  
Four-In/Two-Out Module . . . . . . . . . . . . . . . . . . . . . . . 98  
• INPUTS  
• OUTPUTS  
• EXTERNAL GEAR REPLACEMENT PARTS  
Replacing Defective Processor Modules . . . . . . . . . 98  
• INSTALLATION OF NEW PSIO MODULE  
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . 83-99  
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83  
Checking the Display Messages . . . . . . . . . . . . . . . . . 84  
Checking Temperature Sensors . . . . . . . . . . . . . . . . . 84  
• RESISTANCE CHECK  
PHYSICAL DATA AND WIRING SCHEMATICS . . . . 99-114  
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115-120  
• VOLTAGE DROP  
INITIAL START-UP CHECKLIST FOR 17EX  
EXTERNALLY GEARED CENTRIFUGAL LIQUID  
CHILLER . . . . . . . . . . . . . . . . . . . . . . . . . . CL-1 to CL-12  
• CHECK SENSOR ACCURACY  
• DUAL TEMPERATURE SENSORS  
4
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INTRODUCTION  
17EX CHILLER FAMILIARIZATION  
Chiller Identification Label (Fig. 1) — The iden-  
tification label is located on the right side of the chiller con-  
trol center panel. The label contains information on model  
number, refrigerant charge, rated voltage, etc.  
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 arranged in the se-  
quence required for proper chiller start-up and  
operation.  
System Components (Fig. 2) — The components  
include the cooler and condenser heat exchangers in sepa-  
rate vessels, compressor, compressor and gear lubrication pack-  
ages, control center, speed increaser economizer/storage vessel,  
motor, and starter. The compressor drive consists of an ex-  
ternal gear (speed increaser) and an electric motor. All con-  
nections from pressure vessels have external threads to en-  
able each component to be pressure tested with a threaded  
pipe cap during factory assembly.  
This unit uses a microprocessor controlled system. Do  
not short or jumper between terminations on circuit boards  
or modules; control or board failure may result.  
Be aware of electrostatic discharge (static electricity) when  
handling or making contact with circuit boards or mod-  
ule connections. Always touch a chassis (grounded) part  
to dissipate body electrostatic charge before working in-  
side the control center.  
Cooler — This vessel (also known as the evaporator) is  
located underneath the condenser, next to the economizer/  
storage vessel. The cooler is maintained at lower tempera-  
ture and pressure so that evaporating refrigerant can remove  
heat from water flowing through its internal tubes.  
Use extreme 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.  
Condenser — The condenser operates at a higher tem-  
perature and pressure than the cooler and has water flowing  
through its internal tubes in order to remove heat from the  
refrigerant.  
Compressor — This component maintains system tem-  
perature and pressure differences and moves the heat-  
carrying refrigerant from the cooler to the condenser.  
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 tested and found to  
comply with the limits for a Class A computing device  
pursuant to Subpart J of Part 15 of FCC Rules, which  
are designed to provide reasonable protection against such  
interference when operated in a commercial environ-  
ment. Operation of this equipment in a residential area  
is likely to cause interference, in which case the user, at  
his own expense, will be required to take whatever mea-  
sures may be required to correct the interference.  
Control Center — The control center is the user inter-  
face for controlling the chiller and regulates the chiller ca-  
pacity as required to maintain proper leaving chilled  
water temperature. The control center:  
• registers cooler, condenser, and lubricating system  
pressures  
• shows chiller operating and alarm shutdown conditions  
• records the total chiller operating hours and how many hours  
the chiller has been running  
• sequences chiller start, stop, and recycle under micro-  
processor control  
• provides access to other CCN (Carrier Comfort Network)  
devices  
Always store and transport replacement or defective boards  
in anti-static shipping bag.  
ABBREVIATIONS  
Motor Starter (Purchased Separately) — The starter  
allows the proper start and disconnect of electrical energy  
for the compressor-motor, oil pump, oil heater, and control  
panels.  
Frequently used abbreviations in this manual include:  
CCN  
— Carrier Comfort Network  
CCW — Counterclockwise  
CHW — Chilled Water  
Economizer/Storage Vessel — During normal op-  
eration, this vessel functions as an economizer, returning flash  
gas to the second stage of the compressor and increasing the  
efficiency of the refrigeration cycle. During periods of shut-  
down and service, the economizer/storage vessel can serve  
as a storage tank for the refrigerant.  
CHWR — Chilled Water Return  
CHWS — Chilled Water Supply  
CW  
— Clockwise  
ECW — Entering Chilled Water  
ECDW — Entering Condenser Water  
EMS — Energy Management System  
HGBP — Hot Gas Bypass  
I/O — Input/Output  
LCD — Liquid Crystal Display  
LCDW — Leaving Condenser Water  
LCW — Leaving Chilled Water  
LED — Light-Emitting Diode  
LID — Local Interface Device  
OLTA — Overload Trip Amps  
PIC — Product Integrated Control  
PSIO — Processor Sensor Input/  
Output Module  
— Rated Load Amps  
— Silicon Control Rectifier  
SMM — Starter Management Module  
TXV — Thermostatic Expansion Valve  
REFRIGERATION CYCLE (Fig. 3)  
The 17EX chiller can be used to chill either water or brine.  
The data in this book applies to either application. Appli-  
cations using corrosive brines may require using special tubes,  
tubesheet, and waterbox materials which are special order  
items.  
RLA  
SCR  
5
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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’ STAMP  
ARI (Air Conditioning  
and Refrigeration  
Institute)  
PERFORMANCE  
CERTIFIED  
(60 Hz Only)  
Fig. 1 — Model Number Identification  
6
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1
2
3
4
5
6
7
8
9
10  
11  
12  
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40  
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36  
35  
15  
33  
34  
27  
20  
19  
31  
30  
28  
25  
29  
23 22 21  
18 17  
32  
26  
24  
16  
LEGEND  
1
2
—
Condenser  
Cooler Suction Pipe  
22  
—
Oil Drain and Charging Valve  
Oil Heater (Hidden)  
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
23  
24  
25  
26  
27  
—
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—
—
3
Compressor Suction Elbow  
Guide Vane Actuator  
Compressor Oil Pump  
4
Compressor Oil Cooler/Filter  
5
Condenser Discharge Pipe  
Compressor Discharge Elbow  
Two-Stage Compressor  
Local Interface Display Control Panel  
Cooler Relief Valves (Behind Compressor,  
Hidden)  
6
7
8
Economizer Gas Line to Compressor  
Compressor Housing Access Cover  
High-Speed Coupling (Hidden)  
External Gear (Speed Increaser)  
Low-Speed Coupling (Hidden)  
Open-Drive Compressor Motor  
Compressor Motor Terminal Box  
Low-Side Float Box Cover  
Gear Oil Pump  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
—
—
—
—
—
—
—
—
—
—
—
Economizer Storage Vessel  
Economizer/Storage Vessel Relief Valves  
Pumpout Unit  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
Cooler  
High Side Float Box Cover  
Cooler Waterbox Drain  
Take-Apart Connections  
Cooler Marine Waterbox  
Cooler Waterbox Vent  
Gear Oil Cooler/Filter  
Condenser Waterbox Drain  
Refrigerant Liquid Line to Economizer/  
Storage Vessel  
Condenser Marine Waterbox  
Condenser Waterbox Vent  
Refrigerant Charging/Service Valve  
Refrigerant Liquid Line to Cooler  
Power Panel  
39  
40  
—
—
Oil Level Sight Glasses (2)  
17EX WITH EXTERNAL GEAR (SPEED INCREASER)  
Fig. 2 — Typical 17EX Chiller Components  
7
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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 refrigerant obtains the energy needed to va-  
porize by removing heat from the water or brine in the cooler  
tubes. The cold water or brine can then be used in air con-  
ditioning and/or other processes.  
After removing heat from the water or brine, the refrig-  
erant vapor enters the first stage of the compressor, is  
compressed, and flows into the compressor second stage. Here  
it is mixed with flash-economizer gas and is further  
compressed.  
Compression raises the refrigerant temperature above  
that of the water flowing through the condenser tubes.  
When the warm (typically 98 to 102 F [37 to 40 C]) refrig-  
erant vapor comes into contact with the condenser tubes, the  
relatively cool condensing water (typically 85 to 95 F  
[29 to 35 C]) removes some of the heat, and the vapor con-  
denses into a liquid.  
External Gear Oil Cooling — The external gear oil  
is also water cooled. Water flow through the gear oil cooler  
is manually adjusted by a plug valve to maintain an oper-  
ating temperature of approximately 130 F (54 C). If so equipped,  
an oil heater in the reservoir helps to maintain the oil tem-  
perature under cold ambient operating conditions. The heater  
is controlled by an internal thermostat.  
LUBRICATION CYCLE  
Compressor Lubrication Cycle (Refer to item  
numbers shown in Fig. 4) — The compressor oil  
pump and oil reservoir are contained in the compressor base.  
Oil is pumped through an oil cooler and filter to remove heat  
and any foreign particles. A portion of the oil is then di-  
rected to the shaft-end bearing and the shaft seal. The bal-  
ance of the oil lubricates the thrust and journal bearings and  
the thrust end seal. The bearing and transmission oil returns  
directly to the reservoir to complete the cycle. Contact-seal  
oil leakage, however, is collected in an atmospheric float cham-  
ber to be pumped back to the main reservoir as the oil  
accumulates.  
Oil may be charged into the compressor oil reservoir  
(Item 8) through a charging valve (Item 6) which also func-  
tions as an oil drain. If there is refrigerant in the chiller, how-  
ever, a hand pump will be required for charging at this  
connection.  
An oil-charging elbow (Item 3) on the seal-oil return cham-  
ber allows oil to be added without pumping. The seal-oil re-  
turn pump (Item 4) automatically transfers the oil to the main  
reservoir. Sight glasses (11) on the reservoir wall permit ob-  
servation of the oil level.  
A motor-driven oil pump (Item 10) discharges oil to an oil  
cooler/filter (Item 16) at a rate and pressure controlled by an  
oil regulator (Item 10). The differential oil pressure (bearing  
supply versus oil reservoir) is registered on the control panel.  
Water flow through the oil cooler is manually adjusted by  
a plug valve (Item 17) to maintain the oil at an operating  
temperature of approximately 145 F (63 C). During shut-  
down, the oil temperature is also maintained at 150 to  
160 F (65 to 71 C) by an immersion heater (Item 7) in order  
to minimize absorption of refrigerant by the oil.  
The liquid refrigerant passes through an orifice into the  
FLASC chamber. The coolest condenser water flows through  
the FLASC and allows a lower saturated temperature and  
pressure. Part of the entering liquid refrigerant will flash to  
vapor once it has passed through the FLASC orifice, thereby  
cooling 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 that 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 refrigerant flashes to gas, fur-  
ther cooling the remaining liquid. The flash gas, having ab-  
sorbed heat, is returned directly to the compressor second  
stage. Here it is mixed with discharge gas that is already com-  
pressed by the first-stage impeller. Since the flash gas has to  
pass through only half the compression cycle to reach con-  
denser pressure, there is a savings in power.  
The cooled liquid refrigerant in the economizer is me-  
tered through the low-side valve chamber, reducing the re-  
frigerant pressure. Pressure in the cooler is lower than in the  
economizer. Some of the liquid flashes as it passes through  
the low side float valve. The cycle is now complete.  
Upon leaving the cooler section of the oil cooler/filter, the  
oil is filtered (Item 15) and a portion is directed to the seal-  
end bearing (Item 1) and the shaft seal (Item 2). The remain-  
der lubricates thrust (Item 14) and journal bearings (Item 12).  
Thrust bearing temperature is indicated on the PIC controls.  
Oil from both circuits returns by gravity to the reservoir.  
OIL COOLING CYCLE  
The shaft seal of the open compressor drive must be kept  
full of lubrication oil, even when the chiller is not operating,  
to prevent loss of refrigerant.  
If the chiller is not operating and the oil pump has not  
operated during the last 12 hours, the control system auto-  
matically runs the oil pump for one minute in order to keep  
the contact seal filled with oil.  
Compressor Oil Cooling — The compressor oil is  
water cooled. Water flow through the oil cooler is manually  
adjusted by a plug valve to maintain an operating tempera-  
ture at the reservoir of approximately 145 F (63 C). An oil  
heater in the reservoir helps to prevent oil from being di-  
luted by the refrigerant. The heater is controlled by the PIC  
(Product Integrated Control) and is energized when the oil  
temperature is outside the operating temperature range of 150  
to 160 F (66 to 71 C).  
IMPORTANT: If the control power is to be deener-  
gized for more than one day, the chiller refrigerant should  
be pumped over to the economizer/storage vessel.  
8
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LEGEND  
TXV  
—
Thermostatic Expansion Valve  
Liquid  
Liquid/Vapor  
Vapor  
*The FX compressor and the gear have a water cooled oil cooler.  
Fig. 3 — Refrigeration, Cycle  
Upon leaving the cooler section (Item 13) of the oil cooler/  
filter, the oil is filtered (Item 11) and is directed to the pres-  
sure control valve (Item 7). Before entering the pressure control  
valve, the oil pressure (Item 16) and temperature (Item 8)  
are monitored by the PIC.  
A portion of the oil then lubricates the gear bearings  
(Item 2). Another portion is directed through an orifice  
(Item 5) to the gear mesh spray (Item 3) to lubricate the gear  
mesh (Item 1) during operation. Oil from both circuits re-  
turns by gravity to the reservoir.  
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  
mesh spray. The remainder is bypassed to the sump. The bear-  
ing and transmission oil returns directly to the reservoir to  
complete the cycle.  
Oil may be charged into the external gear oil reservoir as  
described in the section, External Gear Pre-Start Checks,  
page 51. Observe the oil level in the oil level glass (Item 4)  
on the reservoir wall.  
A motor driven oil pump (Item 10) discharges oil to the  
oil cooler/filter (Item 12). The pump has an internal pressure  
regulator to protect the pump in the event of an obstruction  
downstream. Water flow through the oil cooler is manually  
adjusted by a plug valve (Item 14) to maintain the oil at an  
operating temperature of approximately 130 F (54 C).  
STARTERS  
All starters, whether supplied by Carrier or the customer,  
must meet Carrier Starter Specification Z-375. This speci-  
fication can be obtained from a Carrier Sales Representa-  
tive. The purpose of this specification is to ensure the com-  
patibility of the starter and the chiller. Many styles of compatible  
starters are available, including solid-state , auto-transformer,  
full-voltage, and, in the case of low-voltage main power sup-  
ply, wye-delta closed transition.  
9
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SHAFT DISPLACEMENT  
& BRG TEMP. CUTOUT  
CONNECTIONS  
1
SEAL-END  
BEARING  
COAST DOWN  
RESERVOIRS  
13  
COMPRESSOR OIL  
PRESSURE LEAVING  
FILTER LINE  
2
12  
SHAFT  
SEAL  
JOURNAL  
BEARING  
14  
THRUST  
BEARING  
CHECK VALVE  
15  
OIL FILTER  
16  
OIL COOLER/  
FILTER  
TO PIC  
CONTROLLER  
17  
3
8
PLUG VALVE  
OIL CHARGING  
ELBOW  
MAIN OIL  
RESERVOIR  
4
11  
PUMP, SEAL  
OIL RETURN  
SIGHT  
GLASSES  
TO POWER  
PANEL  
10  
5
6
7
9
OIL  
OIL  
DRAIN &  
CHARGING VALVE  
COMPRESSOR OIL  
SUCTION PRESSURE  
OIL PUMP  
& PRESS. REGULATOR  
THERMISTOR  
HEATER  
Fig. 4 — 17EX Compressor Lubrication Cycle  
10  
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1
2
3
4
5
6
—
—
—
—
—
—
Gear Mesh  
8
9
10  
11  
12  
13  
14  
—
—
—
—
—
—
—
Oil Supply Temperature Thermistor  
Oil Pump Motor  
Bearings  
Gear Mesh Spray  
Oil Level Glass  
Orifice  
Oil Supply Pressure  
Transducer  
Pressure Control Valve  
Oil Pump and Pressure Regulator  
Oil Filter  
Oil Cooler/Filter  
Oil Cooler  
Plug Valve  
7
—
NOTE: The oil reservoir is at the base of the gear box.  
Fig. 5 — External Gear Oil Lubrication Cycle (Plan View)  
CONTROLS General — The 17EX externally geared open-drive cen-  
trifugal liquid chiller contains a microprocessor-based con-  
trol center that monitors and controls all operations of the  
chiller. The microprocessor control system matches the cool-  
ing capacity of the chiller to the cooling load while provid-  
ing state-of-the-art chiller protection. The system controls  
cooling load within the set point plus the deadband by sens-  
ing the leaving chilled water or brine temperature and regu-  
lating the inlet guide vane via a mechanically linked actua-  
tor motor. The guide vane is a variable flow prewhirl assembly  
that controls the refrigeration effect in the cooler by regu-  
lating the amount of refrigerant vapor flow into the com-  
pressor. An increase in guide vane opening increases capac-  
ity. Adecrease in guide vane opening decreases capacity. Chiller  
protection is provided by the processor which monitors the  
digital and analog inputs and executes capacity overrides or  
safety shutdowns, if required.  
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.)  
DIGITAL SIGNAL — A digital (discrete) signal is a 2-position  
representation of the value of a monitored source.  
(Example: A switch is a digital device because it only in-  
dicates whether a value is above or below a set point or bound-  
ary by generating an on/off, high/low, or open/closed signal.)  
VOLATILE MEMORY — Volatile memory is memory in-  
capable of being sustained if power is lost and subsequently  
restored.  
The memories of the PSIO and LID modules are vola-  
tile. If the battery in a module is removed or damaged,  
all programming will be lost.  
11  
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• power panel  
PIC System Components — The Product Integrated  
Control (PIC) is the control system on the chiller. See  
Table 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 maintain  
leaving chilled water temperature. It can interface with aux-  
iliary equipment such as pumps and cooling tower fans to  
turn them on only when required. It continually checks all  
safeties to prevent any unsafe operating condition. It also  
regulates the oil heater while the compressor is off and the  
hot gas bypass valve, if installed. See Fig. 6-10 for the lo-  
cations of sensors, transducers, and other devices controlled  
and/or monitored by the PIC system.  
— 115 v control voltage  
— up to 600 v for oil pump power  
• starter cabinet  
— chiller power wiring (per job requirement)  
Table 1 — Major PIC Components and  
Panel Locations*  
PANEL  
PIC COMPONENT  
LOCATION  
Processor Sensor Input/Output Module  
(PSIO)  
Starter Management Module (SMM)  
Local Interface Device (LID)  
6-Pack Relay Board  
8-Input Modules (Optional)  
4-In/2-Out Module  
Oil Differential Pressure/Power Supply  
Module  
Control Center  
Starter Cabinet  
Control Center  
Control Center  
Control Center  
Power Panel  
The PIC can be interfaced with the Carrier Comfort  
Network (CCN) if desired. It can communicate with other  
PIC-equipped chillers and other CCN devices.  
Control Center  
Oil Heater Contactor (1C)  
Compressor Oil Pump Contactor (2C)  
Gear Oil Pump Contactor (5C)  
Hot Gas Bypass Relay (3C) (Optional)  
Control Transformers (T1-T4)  
Power Panel  
Power Panel  
Power Panel  
Power Panel  
Power Panel  
The PIC consists of 4 modules housed inside one of 3 lo-  
cations: the control center, the power panel, or the starter  
cabinet. The component names and the control voltage of  
each location are listed below (also see Table 1):  
• control center  
— all extra low-voltage wiring (24 v or less)  
Control and Oil Heater Voltage Selector (S1) Power Panel  
Temperature Sensors  
Pressure Transducers  
See Fig. 7  
See Fig. 7  
*See Fig. 6-10.  
REAR  
LEGEND  
1
2
—
—
Gear Oil Pressure Sensor  
6
—
Compressor Oil Cooler  
11  
12  
—
—
Motor Water Cooling Leak Detector  
Cable (TEWAC Motor Only)  
Thrust Bearing Temperature and  
Impeller Displacement Cable  
Discharge Temperature Sensor  
Guide Vane Conduit and Cable  
High Pressure Cutout Switch  
Solenoid Conduit  
7
8
—
—
—
—
Oil Heater Conduit  
Discharge Oil Pressure Sensor  
3
4
5
—
—
—
Motor Space Heater Conduit  
Gear Oil Temperature Sensor  
Motor High Temperature Switch Cable  
TEWAC — Totally Enclosed Water-to-Air Cooled  
9
10  
Fig. 6 — 17EX Controls and Sensor Locations  
12  
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LEGEND  
13  
14  
—
—
Condenser Pressure Transducer  
Condenser Entering Water  
Temperature Sensor  
17  
18  
19  
20  
—
—
—
—
Oil Pump Conduit  
Oil Pump Sensor  
PIC Control Panel  
15  
16  
—
—
Condenser Entering and Leaving Water  
Temperature Cable  
Condenser Leaving Water  
Temperature Sensor  
Gear Oil Cooler Solenoid Cond
Oil Suction Pressure Sensor  
21  
—
LEGEND  
22  
23  
24  
25  
26  
—
—
—
—
—
Cooler Temperature Cable  
Cooler Leaving Water Temperature Sensor  
Cooler Entering Water Temperature Sensor  
Cooler Pressure Sensor  
Refrigerant Charging Valve  
Fig. 6 — 17EX Controls and Sensor Locations (cont)  
13  
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Fig. 6 — 17EX Controls and Sensor Locations (cont)  
Fig. 7 — Control Sensors (Temperature)  
Fig. 8 — Control Sensors  
(Pressure Transducer, Typical)  
LEGEND  
LID  
—
—
—
Local Interface Device  
Product Integrated Controls  
Processor Sensor Input/Output Module  
PIC  
PSIO  
1
—
Optional 8-Input Module for Spare Inputs to Control  
Interface (One of Two Available)  
PSIO  
2
3
4
5
6
7
—
—
—
—
—
—
LID Input/Output Interface Panel Display  
Oil Differential Pressure/Power Supply Module (Hidden)  
LID Light (Hidden)  
6-Pack Relay Board  
Circuit Breakers (4)  
Fig. 9 — Control Center (Front View);  
Shown with Options Module  
14  
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LEGEND  
EQUIP GND  
GRD  
—
Equipment Ground  
—
—
—
Ground  
M
Motor  
TEWAC  
Totally Enclosed Water-to-  
Air Cooled  
Fig. 10 — 17EX Chiller Power Panel and Controls Connections  
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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 pumps, oil heater, hot gas bypass (optional), and alarm  
contact. The PSIO communicates with the LID, the SMM,  
and the optional 8-input modules for user interface and starter  
management.  
incoming control voltage to either 21 vac power for the PSIO  
module and options modules, or 24 vac power for 3 power  
panel contactor relays and a control solenoid valve.  
CONTROL AND OIL HEATER VOLTAGE SELECTOR  
(S1) — It is necessary to use 115 v incoming control power  
in the power panel. The switch must be set to the 115-v  
position.  
OIL DIFFERENTIAL PRESSURE/POWER SUPPLY  
MODULE — This module, which is located in the control  
center, provides 5 vdc power for the transducers and LID  
backlight. This module outputs the difference between two  
pressure transducer input signals. The module subtracts oil  
supply pressure from transmission sump pressure and out-  
puts the difference as an oil differential pressure signal to the  
PSIO. The PSIO converts this signal to differential oil pres-  
sure. To calibrate this reading, refer to the Troubleshooting,  
Checking Pressure Transducers section on page 84.  
STARTER MANAGEMENT MODULE (SMM) — This mod-  
ule is located within the starter cabinet. This module ini-  
tiates PSIO commands for starter functions such as start/  
stop of the compressor; start/stop of the condenser and chilled  
water pumps; start/stop of the tower fan, spare alarm con-  
tacts, and the shunt trip. The SMM monitors starter inputs  
such as flow switches, line voltage, remote start contact, spare  
safety, condenser high pressure, oil pump interlock, motor  
current signal, starter 1M and run contacts, and the kW trans-  
ducer input (optional). The SMM contains logic capable of  
safely shutting down the chiller if communication with  
the PSIO is lost.  
LID Operation and Menus (Fig. 11-17)  
GENERAL  
• The LID display automatically reverts to the default screen  
(Fig. 11) after 15 minutes if no softkey activity takes place  
and if the chiller is not in PUMPDOWN mode  
• When not displaying the default screen, the upper right-  
hand corner of the LID displays the name of the screen  
that you have entered (Fig. 12).  
• The LID may be configured in English or SI units, through  
the LID configuration screen.  
• Local Operation — Pressing the LOCAL softkey places  
LOCAL INTERFACE DEVICE (LID) — The LID is mounted  
to the control center and allows the operator to interface with  
the PSIO or other CCN devices. It is the input center for all  
local chiller set points, schedules, set-up functions, and op-  
tions. The LID has a STOP button, an alarm light, 4 buttons  
for logic inputs, and a display. The function of the 4 buttons  
or ‘‘softkeys’’ are menu driven and are shown on the display  
directly above the key.  
SIX-PACK RELAY BOARD (6-Pack Relay Board) — This  
device is a cluster of 6 pilot relays located in the control  
center. It is energized by the PSIO for the compressor oil  
pump, oil heater, alarm, optional hot gas bypass relay, aux-  
iliary oil pump.  
the PIC in LOCAL operation mode, and the control ac-  
cepts modification to programming from the LID only. The  
PIC uses the Local Time Schedule to determine chiller start  
and stop times.  
• CCN Operation — Pressing the CCN softkey places the  
EIGHT-INPUT (8-Input) MODULES — One optional mod-  
ule is factory installed in the control center panel when or-  
dered. There can be up to 2 of these modules per chiller with  
8 spare inputs each. They are used whenever chilled water  
reset, demand reset, or reading a spare sensor is required.  
The sensors or 4 to 20 mA signals are field-installed.  
PIC in the CCN operation mode, and the control accepts  
modifications from any CCN interface or module (with the  
proper authority), as well as the LID. The PIC uses the  
CCN time schedule to determine start and stop times.  
The spare temperature sensors must have the same  
temperature/resistance curve as the other temperature sen-  
sors on this unit. These sensors are rated 5,000 ohm at 75 F  
(25 C).  
FOUR-IN/TWO-OUT (4-IN/2-OUT) MODULE — This mod-  
ule monitors and controls the external gear lubrication sys-  
tem. It energizes the gear oil pump and is located in the power  
panel.  
OIL HEATER CONTACTOR (1C) — This contactor is lo-  
cated in the power panel and operates the heater at 115 v. It  
is controlled by the PIC to maintain oil temperature during  
chiller shutdown.  
COMPRESSOR OIL PUMP CONTACTOR (2C)AND GEAR  
OIL PUMP CONTACTOR (5C) — These contactors are lo-  
cated in the power panel. They operate all 200 to 575-v oil  
pumps. The PIC energizes the contactor to turn on the oil  
pumps as necessary.  
HOT GAS BYPASS CONTACTOR RELAY (3C)  
(Optional) — This relay, located in the power panel, con-  
trols the opening of the hot gas bypass valve. The PIC en-  
ergizes the relay during low load, high lift conditions.  
OIL AUXILIARY RELAY (4C) — This relay opens the oil  
cooler solenoid valve and interlocks the oil pump with the  
compressor (special order).  
CONTROL TRANSFORMERS (T1-T4) — These trans-  
formers are located in the power panel and convert  
Fig. 11 — LID Default Screen  
ALARMS AND ALERTS — An alarm (*) or alert (!) status  
is indicated on the default screen and the status tables. An  
alarm (*) shuts down the compressor. An alert (!) notifies  
the operator that an unusual condition has occurred. The chiller  
continues 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, message and  
troubleshooting information are sent to the ALARM HIS-  
TORY table.  
16  
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• Press NEXT or PREVIOUS to highlight the desired  
entry
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 normal  
operation.  
• PresStsig
• Press QUIT to leave the selected decision or field with-  
out sving ny changes.  
• Or, press ENTER to leave the selected decision or field  
and save changes.  
Fig. 12 — LID Service Screen  
LID DEFAULT SCREEN MENU ITEMS — To perform  
any of the operations described below, the PIC must be pow-  
ered up and have successfully completed its self test.  
TO VIEW OR CHANGE POINT STATUS (Fig. 13) — Point  
Status is the actual value of all of the temperatures, pres-  
sures, relays, and actuators sensed and controlled by the PIC.  
1. On the Menu screen, press STATUS to view the list of  
Point Status tables.  
The default screen menu selection offers four options  
(STATUS, SCHEDULE, SETPOINT, and SERVICE). The  
STATUS menu allows viewing and limited calibration/  
modification of control points and sensors, relays and con-  
tacts, and the options board. The SCHEDULE menu allows  
viewing and modification of the Local Control, CCN Con-  
trol, and Ice Build time schedules. Numerous set points in-  
cluding Base Demand Limit, LCW, ECW, and Ice Build can  
be adjusted under the SETPOINT menu. The SERVICE menu  
can be used to revise alarm history, control test, control al-  
gorithm status, equipment configuration, equipment service,  
time and date, attach to network, log out of device, control-  
ler identification, and LID configurations. Figures 15 and 16  
provide additional information on the menu structure.  
2. Press NEXT or PREVIOUS to highlight the desired  
status table. The list of tables is:  
• STATUS01 — Status of control points and sensors  
• STATUS02 — Status of relays and contacts  
• STATUS03 — Status of both optional 8-input modules  
and sensors  
Press the MENU softkey to select from the 4 options.  
To view or change parameters within any menu structure,  
use the SELECT softkey to choose the desired table or  
• STATUS04 — Gear oil temperature and pressure  
item. The softkey modification choices displayed will de-  
pend on whether the selected item is a discrete point, ana-  
log point, or an override point. Press the softkey that cor-  
responds 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 below, the PIC must be powered up and have suc-  
cessfully completed its self test.  
• Press MENU to select from the four available options.  
• Press the softkey that corresponds to the desired menu  
structure.  
Fig. 13 — Example of Point Status Screen  
(Status01)  
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Override Indication — An override value is indicated by  
‘‘SUPVSR,’’‘‘SERVC,’’or ‘‘BEST’’flashing next to the point  
value on the Status table.  
3. Pre
TO VIEW OR CHANGE TIME SCHEDULE OPERATION  
(Fig. 14)  
4. On the Point Status table press NEXT or  
PRIS isit
1. On the Menu screen, press SCHEDULE .  
2. Press NEXT or PREVIOUS to highlight one of the  
following schedules.  
For Discrete Points — Press START or STOP ,  
YES or NO , ON or OFF , etc. to select the desired  
state.  
OCCPC01S — LOCAL Time Schedule  
OCCPC02S — ICE BUILD Time Schedule  
OCCPC03-99S — CCN Time Schedule (Actual  
number is defined in CONFIG table.)  
For Analog Points  
—
Press INCREASE or  
DECREASE to select the desired value.  
3. Press SELECT to access and view the time schedule.  
5. Press ENTER to register new value.  
4. Press NEXT or PREVIOUS to highlight the de-  
sir
OVERRIDE OPERATIONS  
NOTE: When overriding or changing metric values, it is nec-  
essary to hold the softkey down for a few seconds in order  
to see a value change, especially on kilopascal values.  
5. Press SELECT to access the highlighted period or  
override.  
To Remove an Override  
1. On the Point Status table press NEXT or  
PR
2. Preln
3. Press RELEASE to remove the override and return the  
poio tPC’mttl
Fig. 14 — Example of Time Schedule  
Operation Screen  
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DEFAULT SCREEN  
LOCAL RESET  
MENU  
(SOFTKEYS)  
CCN  
Start Chiller In CCN Control  
Start Chiller In Local Control  
Clear Alarms  
Access Main Menu  
SCHEDULE  
SETPOINT  
STATUS  
SERVICE  
1 2  
(ENTER A 4-DIGIT PASSWORD)  
3
4
List the  
Status Tables  
List the Service Tables  
Display the Setpoint Table  
STATUS01  
STATUS02  
STATUS03  
STATUS04  
List the Schedules  
•
•
•
•
Base Demand Limit  
LCW Setpoint  
ECW Setpoint  
Ice Build Setpoint  
SELECT  
SELECT  
(SELECT A TABLE)  
PREVIOUS  
PREVIOUS  
EXIT  
EXIT  
NEXT  
NEXT  
(SELECT A POINT  
ON THE TABLE)  
Select the Setpoint  
PREVIOUS  
Modify the Setpoint  
INCREASE  
(MODIFY A  
DISCRETE POINT) or  
SELECT  
QUIT  
EXIT  
START  
ENTER  
ENTER  
ENTER  
NEXT  
STOP  
RELEASE  
RELEASE  
RELEASE  
(MODIFY AN  
ANALOG POINT) or  
INCREASE  
DECREASE  
DISABLE  
ENTER  
DECREASE  
(MODIFY CONTROL  
OPTIONS)  
ENABLE  
OCCPC01S - Local Time Schedule  
OCCPC02S - Ice Build Time Schedule  
OCCPC03S-99S - CCN Time Schedule  
Select a Schedule  
SELECT  
PREVIOUS  
EXIT  
NEXT  
1
2
3
4
5
6
7
8
Override  
Select a Time Period/Override  
SELECT  
ENTER  
ENTER  
PREVIOUS  
EXIT  
EXIT  
EXIT  
NEXT  
Modify a Schedule Time  
INCREASE  
DECREASE  
(ANALOG VALUES)  
(DISCRETE VALUES)  
Add/Eliminate a Day  
DISABLE  
ENABLE  
• ALARM HISTORY  
• CONTROL TEST  
• CONTROL ALGORITHM STATUS  
• EQUIPMENT CONFIGURATION  
• EQUIPMENT SERVICE  
• TIME AND DATE  
• ATTACH TO NETWORK DEVICE  
• LOG OUT OF DEVICE  
• CONTROLLER IDENTIFICATION  
• LID CONFIGURATION  
Select a Service Table  
PREVIOUS  
SELECT  
EXIT  
NEXT  
SEE FIGURE 16  
Fig. 15 — 17EX LID Menu Structure  
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SERVICE TABLE  
PREVIOUS  
ALARM HISTORY  
SELECT  
EXIT  
NEXT  
Display Alarm History  
(The table holds up to 25 alarms  
and alerts with the last alarm at  
the top of the screen.)  
CONTROL TEST  
List the Control Tests  
• Automated Test  
• PSIO Thermistors  
• Options Thermistor  
• Transducers  
CONTROL ALGORITHM STATUS  
• Guide Vane Actuator  
• Pumps  
List the Control Algorithm Status Tables  
MAINT01 (Capacity Control)  
MAINT02 (Override Status)  
MAINT03 (Surge/HGBP Status)  
MAINT04 (Lead/Lag Status)  
WSMDEFME (Water System Manager Control Status)  
OCCDEFM (Time Schedule Status)  
• Discrete Outputs  
• Pumpdown Lockout  
• Terminated Lockout  
• FX Gear Oil Pump I/O  
Select a Test  
NEXT  
SELECT  
PREVIOUS  
EXIT  
Select a Table:  
SELECT  
PREVIOUS  
EXIT  
NEXT  
MAINT01 (Capacity Control Algorithm)  
MAINT02 (Override Status)\  
OCCDEFM (Time Schedule Status)  
MAINT03 (Surge/HGBP Status)  
MAINT04 (LEAD/LAG Status)  
WSMDEFM2 (Water System Manager Control Status)  
Data Select Table  
PREVIOUS  
SELECT  
EXIT  
NEXT  
Maintenance Table Data  
OCCPC01S (Local Status)  
OCCPC02S (CCN, ICE BUILD Status)  
OCCPC03S (CCN Status)  
EQUIPMENT CONFIGURATION  
List the Equipment Configuration Tables  
• CONFIG  
• LEAD/LAG  
• OCCDEFCS  
• HOLIDEF  
• BRODEF  
• WSMALMDF  
• ALARMDEF  
• CONS_DEF  
• RUNT_DEF  
Select a Table  
SELECT  
PREVIOUS  
EXIT  
NEXT  
Select a Parameter  
SELECT  
PREVIOUS  
EXIT  
NEXT  
Modify a Parameter  
CONTINUED  
ON NEXT PAGE  
(ANALOG  
VALUES)  
(DISCRETE  
VALUES)  
(DISCRETE  
VALUES)  
INCREASE  
ENTER  
ENTER  
ENTER  
DECREASE  
QUIT  
QUIT  
QUIT  
DISABLE  
NO  
ENABLE  
YES  
Fig. 16 — 17EX Service Menu Structure  
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SERVICE MENU CONTINUED  
FROM PREVIOUS PAGE  
EQUIPMENT SERVICE (See Table 2, Examples 8, 9, and 10)  
Service Tables: (See Note)  
• SERVICE1  
• SERVICE2  
• SERVICE3  
Select a Service Table  
SELECT  
Select a Service Table Parameter  
SELECT  
PREVIOUS  
EXIT  
EXIT  
NEXT  
PREVIOUS  
NEXT  
Modify a Service Table Parameter  
INCREASE  
ENTER  
ENTER  
ENTER  
(ANALOG VALUES)  
(DISCRETE VALUES)  
(DISCRETE VALUES)  
DECREASE  
DISABLE  
YES  
QUIT  
QUIT  
QUIT  
ENABLE  
NO  
TIME AND DATE  
Display Time and Date Table:  
• To Modify — Time  
— Day of Week  
— Holiday Today  
— Date  
ATTACH TO NETWORK DEVICE  
INCREASE  
EXIT  
DECREASE  
ENTER  
List Network Devices  
• Local  
• Device 6  
• Device 1 • Device 7  
• Device 2 • Device 8  
• Device 3 • Device 9  
• Device 4  
• Device 5  
Select a Device  
SELECT  
ENTER  
ATTACH  
EXIT  
PREVIOUS  
NEXT  
Modify Device Address  
INCREASE  
DECREASE  
• Use to attach LID to another CCN network or device  
• Attach to "LOCAL" to enter this machine  
• To upload new tables  
LOG OUT OF DEVICE  
Default Screen  
LOCAL  
RESET  
MENU  
CCN  
CONTROLLER IDENTIFICATION  
PSIO Controller  
Identification Table  
INCREASE  
DECREASE  
ENTER  
EXIT  
• To modify — PSIO CCN Address  
• To View — PSIO Software Version  
(last 2 digits on part number indicate software version)  
LID CONFIGURATION  
LID Configuration Table  
INCREASE  
DECREASE  
ENTER  
EXIT  
• To View — LID Software Version  
(last 2 digits of part number  
indicate software version)  
• To Modify — LID CCN Address  
— English or S.I. Metric Units  
— Password  
LEGEND  
CCN  
HGBP  
LID  
—
—
—
Carrier Comfort Network  
Hot Gas Bypass  
Local Interface Device  
NOTE: SERVICE TABLES:  
SERVICE1:  
—
—
—
—
—
—
—
—
—
—
—
—
—
Capacity Override  
SERVICE2:  
SERVICE3:  
—
—
8-input Modules  
Type of Chilled Medium  
Alert Temperature  
20 mA Power Source  
Flow Verification  
Deadband  
Recycle Restart Time  
Surge/HGBP Operation  
Motor Voltage, RLA, and Frequency  
Starter Type  
—
—
—
—
Proportional Inc each Band  
Proportional Dec each Band  
Proportional ECW Gain  
Maximum Guide Vane Opening  
Condenser Freeze Safety  
Soft Stop Configuration  
Start to Stop Timer  
Gear Oil Pump Configuration  
Fig. 16 — 17EX Service Menu Structure (cont)  
21  
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6. a. Press INCREASE or DECREASE to change the  
4. Pre
time values. Override values are in one-hour incre-  
5. Press INCREASE or DECREASE to change the se-  
lecti
b. Press ENABLE to select days in the day-of-week  
fields. Press DISABLE to eliminate days from the  
6. Press ENTER to save the changes and return to the  
previous sceen.  
7. Press ENTER to register the values and to move  
ho
8. Pr
9. Either return to Step 4 to select another period or  
override, or press EXIT again to leave the cur-  
re
10. Holiday Designation (HOLIDEF table) may be found in  
the Service Operation section, page 42. You must assign  
the month, day, and duration for the holiday. The Broad-  
cast function in the BRODEF table also must be en-  
abled for holiday periods to function.  
Fig. 17 — Example of Set Point Screen  
SERVICE OPERATION — To view the menu-driven pro-  
grams available for Service Operation, see the Service Op-  
eration section, page 42. For examples of LID display screens,  
see Table 2.  
TO VIEW AND CHANGE SET POINTS (Fig. 17)  
1. To view the Set Point table, at the Menu screen press  
SETPOINT .  
LEGEND FOR TABLE 2 — LID DISPLAY DATA  
CCN  
CHWR  
CHWS  
Compr  
Dec  
Ecw  
HGBP  
Inc  
LCW  
mA  
P
PIC  
Refrig  
T
Temp  
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Carrier Comfort Network  
Chilled Water Return  
Chilled Water Supply  
Compressor  
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  
in the Service menu. ICE BUILD is also activated and  
configured in the Service menu.  
Decrease  
Entering Chilled Water  
Hot Gas Bypass  
Increase  
Leaving Chilled Water  
Milliamps  
Pressure  
Product Integrated Controls  
Refrigerant  
Temperature  
Temperature  
3. Press NEXT or PREVIOUS to highlight the desired  
set ponenry.  
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Table 2 — LID Display Data  
NOTES:  
5. The items in the Reference Point Name column do not appear on  
the LID screen. They are data or variable names used in CCN or  
Building Supervisor software. They are listed in these tables as a  
convenience to the operator if it is necessary to cross reference  
CCN/BS documentation or use CCN/BS programs. For more in-  
formation, see the 17EX CCN literature.  
IMPORTANT: The following notes apply to all Table  
examples.  
2
6. Reference Point Names shown in these tables in all capital letters  
can be read by CCN and Building Supervisor software. Of these  
capitalized names, those preceded by an asterisk can also be  
changed (that is, written to) by the CCN, Building Supervisor soft-  
ware and the LID. Capitalized Reference Point Names preceded  
by two asterisks can be changed only from the LID. Reference  
Point Names in lower case type can be viewed by CCN or Build-  
ing Supervisor software only by viewing the whole table.  
7. Alarms and Alerts: An asterisk in the far right field of a LID status  
screen indicates that the chiller is in an alarm state; an exclama-  
tion point in the far right field of the LID screen indicates an alert  
state. The asterisk (or exclamation point) indicates that the value  
on that line has exceeded (or is approaching) a limit. For more  
information on alarms and alerts, see the Alarms and Alerts sec-  
tion, page 16.  
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 twice to page  
forward; press the PREVIOUS softkey twice to page back.  
2. To access the information shown in Examples 6 through 14, enter  
your 4-digit password after pressing the SERVICE softkey. If no  
softkeys are pressed for 15 minutes, the LID automatically logs off  
(to prevent unrestricted access to PIC controls) and reverts to the  
default screen. If this happens, you must reenter your password  
to access the tables shown in Examples 6 through 14.  
3. Terms in the Description column of these tables are listed as they  
appear on the LID screen.  
4. The LID may be configured in English or Metric (SI) units using  
the LID CONFIGURATION screen. See the Service Operation sec-  
tion, page 42, for instructions on making this change.  
EXAMPLE 1 — STATUS01 DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
.
2. Press STATUS (STATUS01 will be highlighted).  
3. Press SELECT .  
REFERENCE POINT NAME  
DESCRIPTION  
RANGE  
UNITS  
(ALARM HISTORY)  
Control Mode  
Run Status  
Reset.Off. Local. CCN  
MODE  
Timeout. Recycle. Startup.  
Ramping. Running. Demand.  
STATUS  
Override. Shutdown. Abnormal.  
Pumpdown  
Occupied ?  
Alarm State  
No/Yes  
OCC  
ALM  
CHIL  
DLM  
Normal/Alarm  
Stop/Start  
*Chiller Start/Stop  
Base Demand Limit  
*Active Demand Limit  
Compressor Motor Load  
Current  
S
S
40-100  
%
40-100  
%
DEM LIM  
0-999  
%
%
CA  
CA  
CA  
L
P
A
0-999  
Amps  
0-9999  
AMPS  
*Target Guide Vane Pos  
Actual Guide Vane Pos  
Water/Brine: Setpoint  
0-100  
%
%
GV TRG  
GV ACT  
SP  
LCW STPT  
ECW  
LCW  
0-100  
10-120 (–12.2-48.9)  
10-120 (–12.2-48.9)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–6.7-420 (–46-2896)  
–40-245 (–40-118)  
–6.7-420 (–46-2896)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
PSI (kPa)  
*
Control Point  
Entering Chilled Water  
Leaving Chilled Water  
Entering Condenser Water  
Leaving Condenser Water  
Evaporator Refrig Temp  
Evaporator Pressure  
Condenser Refrig Temp  
Condenser Pressure  
Discharge Temperature  
Bearing Temperature  
Motor Winding Temp†  
Motor Winding Hi  
ECDW  
LCDW  
ERT  
ERP  
DEG F (DEG C)  
PSI (kPa)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
CRT  
CRP  
CMPD  
MTRB  
MTRW  
Normal/Alarm  
MTRW  
Temp Cutout  
Oil Sump Temperature  
Oil Pressure Transducer†  
Oil Pressure**  
Line Voltage: Percent  
Actual  
*Remote Contacts Input  
Total Compressor Starts  
Starts in 12 Hours  
–40-245 (–40-118)  
–6.7-420 (–46-2896)  
–6.7-420 (–46-2896)  
0-999  
DEG F (DEG C)  
PSI (kPa)  
PSID (kPad)  
%
OILT  
OILP  
OILPD  
V
V
P
A
0-9999  
VOLTS  
Off/On  
REMCON  
0-65535  
c
starts  
0-8  
STARTS  
Compressor Ontime  
*Service Ontime  
*Compressor Motor kW  
0-500000.0  
0-32767  
HOURS  
HOURS  
kW  
c
S
hrs  
HRS  
0-9999  
CKW  
†Information is applicable to hermetic chillers (19EX) only.  
**Oil pressure is read directly from a differential pressure module on 17EX chillers.  
NOTE: values preceded by an asterisk (*) can be forced (changed by an operator) from the LID screen  
or from another control device (such as a Carrier Comfort Network [CCN] terminal).  
23  
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Table 2 — LID Display Data (cont)  
EXAMPLE 2 — STATUS02 DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
.
2. Press STATUS .  
3. Scroll down to highlight STATUS02.  
4. Press SELECT .  
POINT TYPE  
UNITS  
REFERENCE POINT NAME  
(ALARM HISTORY)  
DESCRIPTION  
INPUT  
OUTPUT  
Hot Gas Bypass Relay  
*Chilled Water Pump  
Chilled Water Flow  
X
X
OFF/ON  
HGBR  
OFF/ON  
CHWP  
X
X
NO/YES  
EVFL  
*Condenser Water Pump  
Condenser Water Flow  
Compressor Start Relay  
Compressor Start Contact  
Compressor Run Contact  
Starter Fault Contact  
Pressure Trip Contact  
Single Cycle Dropout  
Oil Pump Relay  
X
X
OFF/ON  
CDP  
NO/YES  
CDFL  
OFF/ON  
CMPR  
X
X
X
X
X
OPEN/CLOSED  
OPEN/CLOSED  
OPEN/CLOSED  
OPEN/CLOSED  
NORMAL/ALARM  
OFF/ON  
1CR AUX  
RUN AUX  
STR FLT  
PRS TRIP  
V1 CYCLE  
OILR  
X
X
X
X
X
X
X
Oil Heater Relay  
OFF/ON  
OILH  
MTRC  
Motor Cooling Relay†  
Auxiliary Oil Pump Relay  
*Tower Fan Relay  
OFF/ON  
OFF/ON  
AUXOILR  
TFR  
OFF/ON  
Compr. Shunt Trip Relay  
Alarm Relay  
Spare Prot Limit Input  
OFF/ON  
TRIPR  
NORMAL/ALARM  
ALARM/NORMAL  
ALM  
X
SPR PL  
†Information is applicable to hermetic machines only.  
NOTE: values preceded by an asterisk (*) can be forced (changed by an operator) from the LID screen  
or from another control device (such as a Carrier Comfort Network [CCN] terminal).  
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 .  
REFERENCE POINT NAME  
(ALARM HISTORY)  
DESCRIPTION  
RANGE  
UNITS  
OPTIONS BOARD 1  
*Demand Limit 4-20 mA  
*Temp Reset 4-20 mA  
4-20  
4-20  
mA  
mA  
DEM OPT  
RES OPT  
CHWS  
*Common CHWS Sensor  
*Common CHWR Sensor  
*Remote Reset Sensor  
*Temp Sensor — Spare 1  
*Temp Sensor — Spare 2  
*Temp Sensor — Spare 3  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
CHWR  
R
RESET  
SPARE1  
SPARE2  
SPARE3  
OPTIONS BOARD 2  
*4-20 mA — Spare 1  
4-20  
mA  
SPARE1  
SPARE2  
SPARE4  
SPARE5  
SPARE6  
SPARE7  
SPARE8  
SPARE9  
M
M
*4-20 mA — Spare 2  
4-20  
mA  
*Temp Sensor — Spare 4  
*Temp Sensor — Spare 5  
*Temp Sensor — Spare 6  
*Temp Sensor — Spare 7  
*Temp Sensor — Spare 8  
*Temp Sensor — Spare 9  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
NOTE: values preceded by an asterisk (*) can be forced (changed by an operator) from the LID screen  
or from another control device (such as a Carrier Comfort Network [CCN] terminal).  
24  
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Table 2 — LID Display Data (cont)  
EXAMPLE 4 — STATUS04 DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
.
2. Press STATUS .  
3. Scroll down to highlight STATUS04.  
4. Press SELECT .  
REFERENCE POINT NAME  
(ALARM HISTORY)  
DESCRIPTION  
RANGE  
UNITS  
Main Gear Oil Pump  
Auxiliary Gear Oil Pump  
Gear Oil Pressure  
OFF/ON  
MAINPMP1  
AUXPMP2  
GEAROILP  
GEAROILT  
OFF/ON  
−6.7 to 420 (−46 to 2896)  
−40 to 245 (−40 to 118)  
psi (kPa)  
DEG F (DEG C)  
Gear Oil Temperature  
EXAMPLE 5 — SETPOINT DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
.
2. Press SETPOINT .  
DESCRIPTION  
CONFIGURABLE RANGE  
UNITS  
REFERENCE POINT NAME  
DEFAULT VALUE  
Base Demand Limit  
LCW Setpoint  
40-100  
%
DLM  
100  
20-120 (–6.7-48.9)  
20-120 (–6.7-48.9)  
20- 60 (–6.7-15.6)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
lcw sp  
ecw sp  
ice sp  
50.0 (10.0)  
60.0 (15.6)  
40.0 ( 4.4)  
ECW Setpoint  
ICE BUILD Setpoint  
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Table 2 — LID Display Data (cont)  
EXAMPLE 6 — CONFIGURATION (CONFIG) DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
2. Press SERVICE .  
.
3. Scroll down to highlight EQUIPMENT CONFIGURATION.  
4. Press SELECT .  
5. Scroll down to highlight CONFIG.  
6. Press SELECT .  
DESCRIPTION  
CONFIGURABLE RANGE  
UNITS  
REFERENCE POINT NAME  
DEFAULT VALUE  
RESET TYPE 1  
Degrees Reset at 20 mA  
–30-30 (–17-17)  
DEG F (DEG C)  
deg 20ma  
10⌬(6⌬)  
RESET TYPE 2  
Remote Temp (No Reset)  
Remote Temp (Full Reset)  
Degrees Reset  
–40-245 (–40-118)  
–40-245 (–40-118)  
–30-30 (–17-17)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
res rt1  
res rt2  
res rt  
85 (29)  
65 (18)  
10⌬(6⌬)  
RESET TYPE 3  
CHW Delta T (No Reset)  
CHW Delta T (Full Reset)  
Degrees Reset  
0-15 (0-8)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
restd  
restd  
1
2
10⌬(6⌬)  
0⌬(0⌬)  
5⌬(3⌬)  
0-15 (0-8)  
–30-30 (–17-17)  
deg chw  
Select/Enable Reset Type  
0-3  
res sel  
0
ECW CONTROL OPTION  
Demand Limit At 20 mA  
20 mA Demand Limit Option  
DISABLE/ENABLE  
40-100  
DISABLE/ENABLE  
ecw opt  
dem 20ma  
dem sel  
DISABLE  
40  
DISABLE  
%
Auto Restart Option  
DISABLE/ENABLE  
DISABLE/ENABLE  
astart  
DISABLE  
DISABLE  
Remote Contacts Option  
r
contact  
Temp Pulldown Deg/Min  
Load Pulldown %/Min  
Select Ramp Type:  
2-10  
5-20  
0/1  
tmp ramp  
kw ramp  
ramp opt  
3
10  
1
Temp = 0, Load = 1  
Loadshed Group Number  
Loadshed Demand Delta  
Maximum Loadshed Time  
0-99  
0-60  
0-120  
ldsgrp  
ldsdelta  
maxldstm  
0
20  
60  
%
MIN  
CCN Occupancy Config:  
Schedule Number  
Broadcast Option  
3-99  
occpcxxe  
occbrcst  
3
DISABLE/ENABLE  
DISABLE  
ICE BUILD Option  
DISABLE/ENABLE  
ibopt  
DISABLE  
ICE BUILD TERMINATION  
0 =Temp, 1 =Contacts, 2 =Both  
0-2  
ibterm  
0
ICE BUILD Recycle Option  
DISABLE/ENABLE  
ibrecyc  
DISABLE  
NOTE: ⌬ = delta degrees.  
26  
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Table 2 — LID Display Data (cont)  
EXAMPLE 7 — LEAD/LAG CONFIGURATION DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
2. Press SERVICE .  
.
3. Scroll down to highlight EQUIPMENT CONFIGURATION.  
4. Press SELECT .  
5. Scroll down to highlight LEAD/LAG.  
6. Press SELECT .  
LEAD/LAG CONFIGURATION SCREEN  
DESCRIPTION  
CONFIGURABLE 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  
Common Sensor Option  
LAG Percent Capacity  
LAG Address  
LAG START Timer  
LAG STOP Timer  
PRESTART FAULT Timer  
STANDBY Chiller Option  
STANDBY Percent Capacity  
STANDBY Address  
DISABLE/ENABLE  
DISABLE/ENABLE  
25-75  
1-236  
2-60  
2-60  
0-30  
DISABLE/ENABLE  
25-75  
1-236  
loadbal  
DISABLE  
DISABLE  
50  
92  
10  
10  
5
DISABLE  
50  
93  
commsens  
lag per  
lag add  
lagstart  
lagstop  
preflt  
stndopt  
stnd per  
stnd add  
%
MIN  
MIN  
MIN  
%
27  
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Table 2 — LID Display Data (cont)  
EXAMPLE 8 — SERVICE1 DISPLAY SCREEN  
To 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  
DEFAULT VALUE  
Motor Temp Override*  
Cond Press Override  
Refrig Override Delta T  
Chilled Medium  
150-200 (66-93)  
90-200 (620-1379)  
2-5 (1-3)  
DEG F (DEG C)  
PSI (kPa)  
mt over  
cp over  
ref over  
medium  
200 (93)  
125 (862)  
3⌬ (1.6⌬)  
WATER  
33 (1)  
DEG F (DEG C)  
Water/Brine  
Brine Refrig Trippoint  
8-40 (–13.3-4)  
DEG F (DEG C)  
br trip  
Compr Discharge Alert  
Bearing Temp Alert  
125-200 (52-93)  
165-210 (74-99)  
DEG F (DEG C)  
DEG F (DEG C)  
cd alert  
tb alert  
200 (93)  
175 (79)  
Water Flow Verify Time  
Oil Press Verify Time  
0.5-5  
15-300  
MIN  
SEC  
wflow  
oilpr  
t
5
15  
t
Water/Brine Deadband  
Recycle Restart Delta T  
Recycle Shutdown Delta  
Surge Limit/HGBP Option  
Select: Surge=0, HGBP=1  
Surge/HGBP Delta T1  
Surge/HGBP Delta P1  
Min. Load Points (T1/P1)  
Surge/HGBP Delta T2  
Surge/HGBP Delta P2  
Full Load Points (T2/P2)  
Surge/HGBP Deadband  
0.5-2.0 (0.3-1.1)  
2.0-10.0 (1.1-5.6)  
0.5-4.0 (.27-2.2)  
0/1  
DEG F (DEG C)  
DEG F (DEG C)  
cw db  
rcycrdt  
rcycsdt  
1.0 (0.6)  
5 (2.8)  
1.0 (0.6)  
0
srg hgbp  
0.5-15 (0.3-8.3)  
30-170 (207-1172)  
DEG F (DEG C)  
PSI (kPa)  
hgb dt1  
hgb dp1  
1.5 (0.8)  
50 (345)  
0.5-15 (0.3-8.3)  
30-170 (207-1172)  
DEG F (DEG C)  
PSI (kPa)  
hgb dt2  
hgb dp2  
10 (5.6)  
85 (586)  
1-3 (0.6-1.6)  
DEG F (DEG C)  
hgb dp  
1 (0.6)  
Surge Delta Percent Amps  
Surge Time Period  
10-50  
1-5  
%
MIN  
surge  
surge  
a
t
25  
2
Demand Limit Source  
Select: Amps=0, Load=1  
Amps Correction Factor  
Motor Rated Load Amps  
Motor Rated Line Voltage  
Meter Rated Line kW  
0/1  
dem src  
0
1-8  
corfact  
3
1-9999  
1-9999  
1-9999  
AMPS  
VOLTS  
kW  
a
v
fs  
fs  
200  
460  
600  
kw fs  
Line Frequency  
Select: 0=60 Hz, 1=50 Hz  
0/1  
HZ  
freq  
0
Compr Starter Type  
REDUCE/FULL  
–20-35 (–28.9-1.7)  
40-100  
starter  
REDUCE  
34 (1)  
100  
Condenser Freeze Point  
Soft Stop Amps Threshold  
DEG F (DEG C)  
%
cdfreeze  
softstop  
Stop to Start Timer  
3-50  
MIN  
stopmtr  
20  
External Gear Option  
ENABLE/DSABLE  
ENABLE/DSABLE  
ENABLE/DSABLE  
PSI (kPa)  
exg opt  
mech pmp  
aux pmp  
gearp al  
geart al  
ENABLE  
DSABLE  
DSABLE  
15 (103)  
130 (54)  
Mechanical Gear Oil Pump  
Auxiliary Gear Oil Pump  
Gear Oil Pressure Alert  
Gear Oil Temperature Alert  
15-20 (103-138)  
130-145 (54-63)  
DEG F (DEG C)  
*Information is applicable to hermetic machines (19EX) only.  
NOTE: ⌬ = delta degrees.  
28  
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Table 2 — LID Display Data (cont)  
EXAMPLE 9 — SERVICE2 DISPLAY SCREEN  
To 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  
OPTIONS BOARD 1  
CONFIGURABLE RANGE  
UNITS  
REFERENCE POINT NAME DEFAULT VALUE  
20 mA POWER CONFIGURATION  
External = 0, Internal = 1  
RESET 20 mA Power Source  
DEMAND 20 mA Power Source  
0,1  
0,1  
res 20 ma  
dem 20 ma  
0
0
SPARE ALERT ENABLE  
Disable = 0, 1 = High Alert, 2 = Low Alert,  
3 = High Alarm, 4 = Low Alarm  
Temp = Alert Threshold  
CHWS Temp Enable  
CHWS Temp Alert  
CHWR Temp Enable  
CHWR Temp Alert  
Reset Temp Enable  
Reset Temp Alert  
Spare Temp 1 Enable  
Spare Temp 1 Alert  
Spare Temp 2 Enable  
Spare Temp 2 Alert  
Spare Temp 3 Enable  
Spare Temp 3 Alert  
0-4  
chws en  
0
–40-245 (–40-118)  
DEG F (DEG C) chws al  
chwr en  
245 (118)  
0-4  
0
–40-245 (–40-118)  
0-4  
DEG F (DEG C) chwr al  
rres en  
245 (118)  
0
–40-245 (–40-118)  
0-4  
DEG F (DEG C) rres al  
spr1 en  
245 (118)  
0
–40-245 (–40-118)  
0-4  
DEG F (DEG C) spr1 al  
spr2 en  
245 (118)  
0
–40-245 (–40-118)  
0-4  
DEG F (DEG C) spr2 al  
spr3 en  
245 (118)  
0
–40-245 (–40-118)  
DEG F (DEG C) spr3 al  
245 (118)  
OPTIONS BOARD 2  
20 mA POWER CONFIGURATION  
External = 0, Internal = 1  
SPARE 1 20 mA Power Source  
SPARE 2 20 mA Power Source  
0,1  
0,1  
sp1 20 ma  
sp2 20 ma  
0
0
SPARE ALERT ENABLE  
Disable = 0, 1 = High Alert, 2 = Low Alert,  
3 = High Alarm, 4 = Low Alarm  
Temp = Alert Threshold  
Spare Temp 4 Enable  
Spare Temp 4 Alert  
Spare Temp 5 Enable  
Spare Temp 5 Alert  
Spare Temp 6 Enable  
Spare Temp 6 Alert  
Spare Temp 7 Enable  
Spare Temp 7 Alert  
Spare Temp 8 Enable  
Spare Temp 8 Alert  
Spare Temp 9 Enable  
Spare Temp 9 Alert  
0-4  
spr4 en  
DEG F (DEG C) spr4 al  
spr5 en  
0
–40-245 (–40-118)  
245 (118)  
0-4  
0
–40-245 (–40-118)  
0-4  
DEG F (DEG C) spr5 al  
spr6 en  
245 (118)  
0
–40-245 (–40-118)  
0-4  
DEG F (DEG C) spr6 al  
spr7 en  
245 (118)  
0
–40-245 (–40-118)  
0-4  
DEG F (DEG C) spr7 al  
spr8 en  
245 (118)  
0
–40-245 (–0-118)  
0-4  
DEG F (DEG C) spr8 al  
spr9 en  
245 (118)  
0
–40-245 (–40-118)  
DEG F (DEG C) spr9 al  
245 (118)  
NOTE: This screen provides the means to generate alert messages based on exceeding the ‘‘Temp’’ threshold for each point listed. If the ‘‘Enable’’  
is set to 1, a value above the ‘‘Temp’’ threshold generates an alert message. If the ‘‘Enable’’ is set to 2, a value below the ‘‘Temp Alert’’ threshold  
generates an alert message. If the ‘‘Enable’’ is set to 0, alert generation is disabled. If the ‘‘Enable’’ is set to 3, a value above the ‘‘Temp’’ threshold  
generates an alarm. If the ‘‘Enable’’ is set to 4, a value below the ‘‘Temp’’ threshold generates an alarm.  
EXAMPLE 10 — SERVICE3 DISPLAY SCREEN  
To 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 SERVICE3.  
DESCRIPTION  
CONFIGURABLE RANGE  
UNITS  
REFERENCE POINT NAME  
DEFAULT VALUE  
Proportional Inc Band  
Proportional Dec Band  
Proportional ECW Gain  
2-10  
2-10  
1-3  
gv inc  
gv de  
gv ecw  
6.5  
6.0  
2.0  
Guide Vane Travel Limit  
30-100  
%
gv lim  
50  
29  
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Table 2 — LID Display Data (cont)  
EXAMPLE 11 — MAINTENANCE (MAINT01) 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 MAINT01.  
DESCRIPTION  
RANGE/STATUS  
UNITS  
REFERENCE POINT NAME  
CAPACITY CONTROL  
Control Point  
Leaving Chilled Water  
Entering Chilled Water  
Control Point Error  
ECW Delta T  
ECW Reset  
LCW Reset  
Total Error + Resets  
Guide Vane Delta  
Target Guide Vane Pos  
Actual Guide Vane Pos  
10-120 (–12.2-48.9)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–99-99 (–55-55)  
–99-99 (–55-55)  
–99-99 (–55-55)  
–99-99 (–55-55)  
–99-99 (–55-55)  
–2-2  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
%
ctrlpt  
LCW  
ECW  
cperr  
ecwdt  
ecwres  
lcwres  
error  
gvd  
0-100  
%
GV  
GV  
TRG  
ACT  
0-100  
%
Proportional Inc Band  
Proportional Dec Band  
Proportional ECW Gain  
Water/Brine Deadband  
2-10  
gv inc  
gv dec  
gv ecw  
cwdb  
2-10  
1-3  
0.5-2 (0.3-1.1)  
DEG F (DEG C)  
NOTE: Overriding is not supported on this maintenance screen. Active overrides show the associated point in alert (*). Reference point names with  
capital letters can be read by CCN and Building Supervisor software.  
EXAMPLE 12 — 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  
UNITS  
REFERENCE POINT NAME  
OVERRIDE/ALERT STATUS  
MOTOR WINDING TEMP†  
Override Threshold  
–40-245 (–40-118)  
150-200 (66-93)  
–6.7-420 (–42-2896)  
90-245 (621-1689)  
–40-245 (–40-118)  
2-45 (1-7.2)  
–40-245 (–40-118)  
125-200 (52-93)  
–40-245 (–40-118)  
175-185 (79-85)  
DEG F (DEG C)  
DEG F (DEG C)  
PSI (kPa)  
MTRW  
mt over  
CRP  
CONDENSER PRESSURE  
Override Threshold  
PSI (kPa)  
cp over  
ERT  
EVAPORATOR REFRIG TEMP  
Override Threshold  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
rt over  
CMPD  
DISCHARGE TEMPERATURE  
Alert Threshold  
cd alert  
MTRB  
BEARING TEMPERATURE  
Alert Threshold  
tb alert  
†Information is applicable to hermetic machines (19EX) only.  
NOTE: Overriding is not supported on this maintenance screen. Active overrides show the associated point in alert (*). Reference point names with  
capital letters can be read by CCN and Building Supervisor software.  
30  
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Table 2 — LID Display Data (cont)  
EXAMPLE 13 — MAINTENANCE (MAINT03) 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 MAINT03.  
6. Press SELECT .  
DESCRIPTION  
RANGE/STATUS  
UNITS  
PSI (kPa)  
DEG F (DEG C)  
DEG F (DEG C)  
REFERENCE POINT NAME  
SURGE/HGBP ACTIVE ?  
NO/YES  
Active Delta P  
Active Delta T  
Calculated Delta T  
0-200 (0-1379)  
0-200 (0-111)  
0-200 (0-111)  
dp  
dt  
a
a
dt  
c
Surge Protection Counts  
0-12  
spc  
NOTE: Override is not supported on this maintenance screen. Only values with capital letter reference point names are variables available for read  
operation.  
EXAMPLE 14 — MAINTENANCE (MAINT04) 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 MAINT04.  
6. Press SELECT .  
DESCRIPTION  
RANGE/STATUS  
UNITS  
REFERENCE POINT NAME  
LEAD/LAG: Configuration  
Current Mode  
DISABLE,LEAD,LAG,STANDBY, INVALID  
leadlag  
llmode  
loadbal  
lagstart  
lagstop  
preflt  
pull dt  
pull sat  
leadctrl  
lagmode  
lagstat  
DISABLE,LEAD,LAG,STANDBY, CONFIG  
Load Balance Option  
LAG Start Time  
DISABLE/ENABLE  
0-60  
MIN  
MIN  
MIN  
LAG Stop Time  
0-60  
Prestart Fault Time  
Pulldown: Delta T/Min  
Satisfied?  
0-30  
x.xx  
⌬ DEG F (⌬ DEG C)  
No/Yes  
LEAD CHILLER in Control  
LAG CHILLER: Mode  
Run Status  
No/Yes  
Reset,Off,Local,CCN  
Timeout,Recycle,Startup,Ramping,Running  
Demand,Override,Shutdown,Abnormal,Pumpdown  
Stop,Start,Retain  
Start/Stop  
lag  
s
s
s
Recovery Start Request  
STANDBY CHILLER: Mode  
Run Status  
No/Yes  
lag rec  
stdmode  
Reset,Off,Local,CCN  
Timeout,Recycle,Startup,Ramping,Running  
Demand,Override,Shutdown,Abnormal,Pumpdown  
Stop,Start,Retain  
stdstat  
Start/Stop  
Recovery Start Request  
std  
s
No/Yes  
std rec  
NOTES:  
1. Values on this screen cannot be ‘‘forced’’ (that is, changed by an operator, from the LID or from any other device [such as a CCN terminal]).  
2. ⌬ = delta degrees.  
31  
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The PROPORTIONAL ECW GAIN can be adjusted at the LID  
display from a setting of 1.0 to 3.0, with a default setting of  
2.0. Increase this setting to increase guide vane response to  
a change in entering chilled water temperature.  
DEMAND LIMITING — The PIC responds to the ACTIVE  
DEMAND LIMIT set point by limiting the opening of the  
guide vanes. It compares the set point to either COMPRES-  
SOR MOTOR LOAD or COMPRESSOR MOTOR LOAD CUR-  
RENT (percentage), depending on how the control is con-  
figured for the DEMAND LIMIT SOURCE which is accessed  
on the SERVICE1 screen. The default setting is current  
limiting. The ACTIVE DEMAND LIMIT may be viewed on  
the STATUS01 screen.  
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.).  
Words printed both in capital letters and italics can also be  
viewed on the LID and are parameters (CONTROL MODE,  
COOLING SETPOINT, OVERRIDE THRESHOLD, etc.) with  
associated values (e.g., modes, temperatures, pressures, per-  
centages, on, off, etc.). Words printed in all capital letters  
and in a box represent softkeys on the LID control panel  
(e.g., ENTER and EXIT ). See Table 2 for examples of  
the information that can appear on the LID screens.  
Figures 11-17 give an overview of LID operation and menus.  
CHILLER 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 to  
500,000 hours before the clock turns back to zero. The SERV-  
ICE ONTIME is a resettable timer that can be used to indi-  
cate the hours since the last service visit or any other event.  
The time can be changed from the LID to whatever value is  
desired. This timer can register up to 32,767 hours before it  
rolls over to zero.  
The chiller also maintains a start-to-start timer and a stop-  
to-start timer. These timers limit how soon the chiller can be  
started. See the Start-Up/Shutdown/Recycle Sequence sec-  
tion, page 43, for operational information.  
CAPACITY CONTROL — The PIC controls the chiller ca-  
pacity by modulating the inlet guide vanes in response to  
chilled water temperature changes away from the WATER/  
BRINE CONTROL POINT. The WATER/BRINE CONTROL  
POINT may be changed by a CCN network device or is de-  
termined when the PIC adds any active chilled water reset to  
the chilled water SET POINT. The PIC uses the PROPOR-  
TIONAL INC (Increase) BAND, PROPORTIONAL DEC  
(Decrease) BAND, and the PROPORTIONAL ECW (Enter-  
ing Chilled Water) GAIN to determine how quickly or slowly  
to respond. WATER/BRINE CONTROL POINT may be viewed/  
overridden from the STATUS menu, STATUS01 screen.  
ENTERING CHILLED WATER CONTROL — If this op-  
tion is enabled, the PIC uses the ENTERING CHILLED WA-  
TER temperature to modulate the vanes instead of the LEAVING  
CHILLED WATER temperature. The ENTERING CHILLED  
WATER control option may be viewed/modified from the  
CONFIG screen, accessed from the EQUIPMENT CON-  
FIGURATION table.  
OCCUPANCY SCHEDULE — The chiller schedule, de-  
scribed in the Time Schedule Operation section, page 18,  
determines when the chiller can run. Each schedule consists  
of 1 to 8 occupied/unoccupied time periods, set by the op-  
erator. These time periods can be enabled (or not enabled)  
on each day of the week and for holidays. The day begins  
with 0000 hours and ends with 2400 hours. The chiller is in  
an occupied state unless an unoccupied time period is in  
effect.  
DEADBAND — This is the tolerance on the chilled water/  
brine temperature WATER/BRINE CONTROL POINT. If the  
water temperature goes outside the WATER/BRINE DEAD-  
BAND, the PIC opens or closes the guide vanes in response  
until it is within tolerance. The PIC may be configured with  
a 0.5° to 2° F (0.3° to 1.1° C) deadband. WATER/BRINE  
DEADBAND may be viewed or modified from the  
SERVICE1 screen, accessed from the EQUIPMENT  
SERVICE table.  
For example, a 1° F (0.6° C) deadband setting controls  
the water temperature within ±0.5° F (0.3° C) of the control  
point. This may cause frequent guide vane movement if the  
chilled water load fluctuates frequently. A value of  
1° F (0.6° C) is the default setting.  
NOTE: To determine whether or not the chiller is in an oc-  
cupied state and can be started, access the STATUS01 screen  
and scroll to the OCCUPIED? parameter. If the value in the  
right column is YES, the chiller is in an occupied state and  
can turn on or can be started. If the value is NO, the chiller  
is in an unoccupied state; that is, it can shut down or cannot  
be started without performing an override.  
The schedules can be set to follow the building schedule  
or to be in an occupied state 100% of the time. The sched-  
ules also can be bypassed by forcing the CHILLER START/  
STOP parameter on the STATUS01 screen to START. For  
more information on forced starts, see Local Start-Up,  
page 43. The schedules also can be overridden to keep the  
chiller in an occupied state for up to 4 hours, on a one-time  
basis.  
PROPORTIONAL BANDSAND GAIN — Proportional band  
is the rate at which the guide vane position is corrected in  
proportion to how far the chilled water/brine temperature is  
from the control point. Proportional gain determines how  
quickly the guide vanes react to how quickly the tempera-  
ture is moving from WATER/BRINE CONTROL POINT. Pro-  
portional bands and gain values can be viewed/modified from  
the SERVICE3 screen (accessed from the EQUIPMENT CON-  
FIGURATION table) and the MAINT01 screen (accessed from  
the CONTROL ALGORITHM STATUS table).  
NOTE: A parameter value can be ЉforcedЉ (changed by an  
operator) from the LID screen or from another control de-  
vice such as a CCN terminal. For example, if the CHILLER  
START/STOP parameter is set to START, the operator can  
go to the LID and change the value to STOP to ЉforceЉ the  
chiller to stop.  
Figure 14 shows a schedule for a typical office building  
time schedule, with a 3-hour, off-peak cool down period from  
midnight to 3 a.m., following a weekend shutdown. For ex-  
ample, holiday periods are set to be unoccupied 24 hours per  
day. The building operates Monday through Friday, 7:00 a.m.  
to 6:00 p.m., with a Saturday schedule of 6:00 a.m. to  
1:00 p.m., and includes the Monday midnight to 3:00 a.m.  
weekend cool-down schedule.  
The Proportional Band — There are two response modes,  
one for temperature response above the control point, the  
other for response below the control point.  
The first type is called PROPORTIONAL INC BAND, and  
it can slow or quicken vane response to chilled water/brine  
temperature above the WATER/BRINE DEADBAND. It can  
be adjusted from a setting of 2 to 10; the default setting is  
6.5. PROPORTIONAL DEC BAND can slow or quicken vane  
response to chilled water temperature below deadband plus  
the control point. It can be adjusted on the LID from a set-  
ting of 2 to 10, and the default setting is 6.0. Increasing ei-  
ther of these settings causes the vanes to respond more slowly  
than at a lower setting.  
32  
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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:  
Default Screen Freeze — When the chiller is in an  
alarm state, the default LID display freezes; that is, it stops  
updating. The first line of the LID default screen displays a  
primary alarm message; the second line displays a second-  
ary alarm message. The LID default screen freezes to allow  
the operator to see the condition of the chiller at the time of  
the alarm. Knowledge of the operating state of the chiller at  
the time an alarm occurs is useful when troubleshooting. Cur-  
rent chiller information can be viewed on the STATUS screens  
(see Table 2, Examples 1-4). Once all existing alarms are  
• LOCAL mode — Occupancy Schedule 01(OCCPC01 on  
the SCHEDULE screen).  
• ICE BUILD mode — Occupancy Schedule 02 (OC-  
CPC02 on the SCHEDULE screen).  
• CCN mode — Occupancy Schedule 03-99 (OCCPC02-  
OCCPC99 on the SCHEDULE screen).  
cleared by pressing the RESET softkey, the default LID  
screen returns to normal operation.  
The CCN schedule number is specified on the CONFIG  
screen, which is accessed from the EQUIPMENT CON-  
FIGURATION table. The schedule number can be any value  
from 03 to 99. If this schedule number is changed on the  
CONFIG screen, the operator must use theATTACH TO NET-  
WORK DEVICE screen to upload the new number into the  
schedule screen. See Fig. 12.  
Auxiliary Compressor Oil Pump Control — The  
compressor oil pump (optional) is controlled by the PIC. If,  
during start-up, the main oil pump cannot raise pressure to  
18 psi (124 kPa), the auxiliary oil pump (optional) is ener-  
gized. During compressor operation, the auxiliary oil pump  
is energized if the oil pressure falls below the alert threshold  
(18 psi [124 kPa]). Once the auxiliary compressor oil pump  
is running, it stays on until the compressor is turned off and  
is deenergized along with the main oil pump after the post-  
lubrication period.  
Safety Controls — The PIC monitors all safety control  
inputs, and if required, shuts down the chiller or limits the  
guide vanes to protect the chiller from possible damage from  
several conditions, including:  
• high bearing temperature  
• high motor winding temperature  
• high discharge temperature  
• low compressor oil pressure  
• low gear oil pressure  
• high gear oil temperature  
Auxiliary Gear Oil Pump Control — The optional  
auxiliary gear oil pump is controlled by the PIC. During start-  
up, if the main gear oil pump cannot raise the oil pressure at  
least 20 psi (139 kPa), the auxiliary gear oil pump is ener-  
gized. If, after 30 seconds, the required oil pressure has not  
been established, the PIC initiates an alarm and does not al-  
low the chiller to start. During operation, the auxiliary gear  
oil pump is energized if the oil pressure falls below the alert  
threshold (15 to 20 psi [103 to 139 kPa]). Once the auxiliary  
gear oil pump is running, it stays on until the compressor is  
turned off and is deenergized with the main gear oil pump  
after the post-lubrication period.  
• low cooler refrigerant temperature/pressure  
• condenser high pressure or low pressure  
• inadequate water/brine cooler and condenser flow  
• high, low, or loss of voltage  
• excessive motor acceleration time  
• excessive starter transition time  
• lack of motor current signal  
• excessive motor amps  
Shaft Seal Oil Control — For all open-drive chillers,  
the shaft seal must be bathed in oil at all times, especially  
when the chiller is not running. This ensures that refrigerant  
will not leak past the seal. The PIC energizes the compressor  
oil pump for one minute if the oil pump has not operated  
during the past 12 hours.  
• excessive compressor surge  
• temperature and transducer faults  
Starter faults or optional protective devices within the starter  
can shut down the chiller. These devices depend on what  
options have been purchased.  
IMPORTANT: If control power is turned off for more  
than 12 hours, the refrigerant charge must be pumped  
into the economizer/storage vessel. Because the oil heater  
is also turned off during this time, storing the refrig-  
erant prevents refrigerant from migrating into the oil.  
If a compressor motor overload or ground fault occurs,  
check the motor for grounded or open phases before at-  
tempting a restart.  
If the PIC control initiates a safety shutdown, the control  
displays a primary and secondary alarm message on the LID,  
energizes an alarm relay in the starter, and blinks the alarm  
light on the control panel. The alarm information is stored in  
memory and can be viewed on the LID by accessing the  
ALARM HISTORY table along with a troubleshooting  
message.  
To give a more specific operating condition warning, the  
operator can also define alert limits on various monitored  
inputs. Safety contact and alert limits are defined in Table 3.  
Alarm and alert messages are listed in the Troubleshooting  
Guide section, page 83.  
Ramp Loading Control — Ramp loading control slows  
down the rate at which the compressor loads up. It prevents  
the compressor from loading up during the short time be-  
tween chiller start-up and the time the chilled water loop has  
to be brought down to normal design conditions. Ramp load-  
ing helps to reduce electrical demand by slowly bringing the  
chilled water temperature to the control point temperature.  
The total power draw during this period stays almost  
unchanged.  
The PIC bases ramp loading on either the chilled water  
temperature or on motor load. See the Table 2, Example 6  
(CONFIG screen).  
SHUNT TRIP — The PIC can include an optional shunt trip  
function that acts as a safety trip. The shunt trip is wired  
from an output on the SMM to the motor circuit breaker. If  
the PIC tries to shut down the compressor using normal shut-  
down procedures but is unsuccessful for 30 seconds, the shunt  
trip output is energized and trips off the circuit breaker. If  
ground fault protection has been applied to the starter, the  
ground fault trip also energizes the shunt trip to trip the cir-  
cuit breaker.  
1. The temperature ramp loading rate is an operator-  
configured value that limits the rate at which either the  
leaving chilled water or entering chilled water tempera-  
ture decreases (TEMP PULLDOWN DEG/MIN param-  
eter on the CONFIG screen). The lowest temperature ramp  
rate is used the first time the chiller is started (at com-  
missioning). The lowest temperature ramp rate is also used  
if chiller power has been off for 3 hours or more (even if  
the motor ramp load control method has been selected).  
33  
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Table 3 — Protective Safety Limits and Control Settings  
MONITORED PARAMETER  
LIMIT  
APPLICABLE COMMENTS  
TEMPERATURE SENSORS  
–40 to 245 F (–40 to 118.3 C)  
0.08 to 0.98 Voltage Ratio  
Must be outside range for 2 seconds  
OUT OF RANGE  
PRESSURE TRANSDUCERS  
OUT OF RANGE  
Must be outside range for 2 seconds.  
Ratio = Input Voltage ÷ Voltage Reference  
COMPRESSOR DISCHARGE  
TEMPERATURE  
Ͼ220 F (104.4 C)  
Preset, alert setting configurable  
BEARING TEMPERATURE  
Ͼ220 F (104.4 C)  
Preset, alert setting configurable  
Preset, configure chilled medium for water  
(Service1 table)  
Ͻ33 F (for water chilling) (0.6° C)  
EVAPORATOR REFRIGERANT  
TEMPERATURE  
(Temp converted from Pressure  
Reading)  
Configure chilled medium for brine (Service1  
table). Adjust brine refrigerant trippoint for  
proper cutout  
ϽBrine Refrigerant Trippoint (set point adjustable  
from 0 to 40 F [–18 to 4 C] for brine chilling)  
Preset (Read voltage at terminals 34 and 35  
on PSIO module)  
TRANSDUCER VOLTAGE  
Ͻ4.5 vdc Ͼ 5.5 vdc  
Ͼ218 ± 7 psig (1503 ± 48 kPa),  
CONDENSER PRESSURE — SWITCH  
— CONTROL  
Preset  
reset at 120 ± 10 (827 ± 69 kPa)  
215 psig (1482 kPa)  
Preset  
COMPRESSOR OIL PRESSURE — SWITCH Cutout Ͻ11 psid (76 kPad) ± 1.5 psid (10.3 kPad)  
Cut-in Ͼ16.5 psid (114 kPad) ± 4 psid (27.5 kPad)  
Preset, no calibration needed  
Cutout Ͻ15 psid (103 kPad)  
— CONTROL  
Preset  
Alert Ͻ18 psid (124 kPad)  
LINE VOLTAGE — HIGH  
— LOW  
Ͼ110% for one minute  
Preset, based on transformed line voltage to  
24 vac rated-input to the Starter Management  
Module. Also monitored at PSIO power input.  
Ͻ90% for one minute or р85% for 3 seconds  
Ͻ50% for one cycle  
— SINGLE-CYCLE  
Ͼ110% for 30 seconds  
Preset  
Preset  
Preset  
COMPRESSOR MOTOR LOAD  
(% Compressor Amps)  
Ͻ10% with compressor running  
Ͼ10% with compressor off  
For chillers with reduced voltage mechanical  
and solid-state starters  
STARTER ACCELERATION TIME  
(Determined by inrush current  
going below 100% compressor  
motor load)  
Ͼ45 seconds  
Ͼ10 seconds  
For chillers with full voltage starters  
(Configured on Service1 table)  
STARTER TRANSITION  
Ͼ75 seconds  
Reduced voltage starters only  
Energizes condenser pump relay if condenser refrigerant tem-  
perature or condenser entering water temperature is below the CONDENSER FREEZE POINT configured in  
CONDENSER FREEZE  
PROTECTION  
configured condenser freeze point temperature. Deenergizes  
Service01 table with a default setting of  
when the temperature is 5 F (3 C) above condenser freeze point 34 F (1 C).  
temperature.  
IMPELLER CLEARANCE  
Displacement switch open  
Thrust movement excessive  
Water sensors are installed only on open-drive  
motors that use water cooling. (Totally enclosed,  
water-to-air cooled [TEWAC] motors)  
MOTOR LEAK DETECTOR (TEWAC  
MOTORS ONLY)  
Water from motor cooling is leaking  
GEAR OIL TEMPERATURE  
— CONTROL  
Cut-Out > 150 F (66 C)  
Alert > 130-145 (54 - 63 C)  
Preset  
Adjustable  
GEAR OIL PRESSURE  
—CONTROL  
Cut-out < 12 psi (83 kPa)  
Alert < 15-20 psi (103 - 139 kPa)  
Preset  
Adjustable  
FLOW SWITCHES (Field Supplied)  
Operate water pumps with chiller off. Manually reduce water flow and observe  
switch for proper cutout. Safety shutdown occurs when cutout time exceeds  
3 seconds.  
CUT-OFF  
SETTING  
ADJUSTMENT  
SCREW  
Carrier Part No. HK06ZC001  
NOTE: Dimensions in parentheses are in  
millimeters.  
Carrier Part No. HK06ZC033  
34  
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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).  
To select the ramp type, highlight the SELECT RAMP  
TYPE parameter on the CONFIG screen and select either  
0 (TEMP) or 1 (LOAD). Motor load (1) is the default ramp  
loading control type.  
High Discharge Temperature Control — If the dis-  
charge temperature increases above 200 F (93 C), the guide  
vanes are proportionally opened to increase gas flow through  
the compressor. If the leaving chilled water temperature drops  
5° F (2.8° C) below the control point temperature, chiller  
enters the RECYCLE mode.  
Oil Sump Temperature Control — The oil sump tem-  
perature control is regulated by the PIC which uses the oil  
heater relay when the chiller is shut down.  
As part of the pre-start checks executed by the controls,  
the PIC compares the oil sump temperature to the evapora-  
tor refrigerant temperature. If the difference between these 2  
temperatures is 50 F (27.8 C) or less, the start-up is delayed  
until the oil temperature difference is 50 F (27.8 C) or more.  
Once this temperature is confirmed, the start-up continues.  
The oil heater relay is energized whenever the chiller com-  
pressor is off and the oil sump temperature is less than  
150 F (65.6 C) or the oil sump temperature is less than the  
cooler refrigerant temperature plus 70° F (39° C). The oil  
heater is turned off when the oil sump temperature is either  
Capacity Override (See Table 4) — Capacity over-  
rides can prevent some safety shutdowns caused by exceed-  
ing the motor amperage limit, refrigerant low temperature  
safety limit, motor high temperature safety limit, and con-  
denser high pressure limit. In all of these cases, there are  
2 stages of compressor vane control.  
1. The guide vanes are kept from opening further, and the  
status line on the LID displays the reason for the  
override.  
2. The guide vanes are closed until the condition decreases  
below the first step set point. Then, the vanes are released  
to normal capacity control.  
• more than 160 F (71.1 C)  
Whenever the motor current demand limit set point is reached,  
it activates a capacity override, again using the 2-step pro-  
cess. Exceeding 110% of the rated load amps for more than  
30 seconds initiates a safety shutdown.  
• or the oil sump temperature is more than 155 F (68.3 C)  
and more than the cooler refrigerant temperature plus  
75° F (41.6° C).  
The oil heater is always off during start-up or when the  
compressor is running.  
The compressor high lift (surge prevention) set point causes  
a capacity override as well. When the surge prevention set  
point is reached, the PIC normally prevents the guide vanes  
from opening. See the Surge Prevention Algorithm section,  
page 37. If the chiller is equipped with the hot gas bypass  
option, the PIC opens the hot gas bypass valve instead of  
holding the guide vanes.  
When a power failure to the PSIO module has occurred  
for more than 3 hours (i.e., initial start-up), the compressor  
guide vane opening is slowed down to prevent excessive oil  
foaming that may result from refrigerant migration into the  
oil sump during the power failure. The vane opening is slowed  
via temperature ramp loading to a value of 2° F (1.1° C) per  
minute.  
Table 4 — Capacity Overrides  
SECOND STAGE  
SETPOINT  
OVERRIDE  
FIRST STAGE SETPOINT  
Default Value  
OVERRIDE  
CAPACITY  
CONTROL  
TERMINATION  
View/Modify  
on LID Screen  
Configurable Range  
Value  
Value  
ϾOverride  
Set Point  
+ 4 psid (28 kPad)  
HIGH CONDENSER  
PRESSURE  
Equipment  
Service1  
125 psig  
(862 kPa)  
90 to 200 psig  
(620 to 1379 kPa)  
ϽOverride  
Set Point  
LOW REFRIGERANT  
TEMPERATURE  
(Refrigerant Override  
Delta Temperature)  
рTrippoint  
+ Override  
⌬T –1° F  
(0.56° C)  
ϾTrippoint  
+ Override  
⌬T +2° F  
(1.2° C)  
Equipment  
Service1  
Ͻ3° F (1.6° C)  
(Above Trippoint)  
2° to 5° F  
(1° to 3° C)  
Min: T1 — 1.5° F  
(0.8° C)  
0.5° to 15° F  
(0.3° to 8.3° C)  
30 to 170 psid  
(207 to1172 kPad)  
0.5° to 15° F  
(0.3° to 8.3° C)  
30 to 170 psid  
(207 to 1172 kPad)  
Within  
Lift Limits  
Plus Surge/  
HGBP  
Deadband  
Setting  
P1 — 50 psid  
(345 kPad)  
HIGH COMPRESSOR  
LIFT  
(Surge Prevention)  
Equipment  
Service1  
None  
Max: T2 — 10° F  
(5.6° C)  
P2 — 85 psid  
(586 kPad)  
MANUAL  
GUIDE VANE  
TARGET  
Control  
Algorithm  
Maint01  
Release of  
Manual  
Automatic  
100%  
0 to 100%  
None  
Control  
MOTOR LOAD —  
ACTIVE  
DEMAND LIMIT  
2% Lower  
Than  
Set Point  
у5% of  
Set Point  
Status01  
40 to 100%  
LEGEND  
HGBP  
P1  
—
—
—
—
—
High Gas Bypass  
Minimum Pressure Load  
Maximum Pressure Load  
Minimum Temperature Load  
Maximum Temperature Load  
P2  
T1  
T2  
35  
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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 is  
running.  
The gear oil cooler is a water-cooled, helical tube-in-shell  
type heat exchanger. A plug valve is manually set to main-  
tain proper temperatures. Set the valve to maintain the oil  
temperature leaving the cooler at 130 F (54 C) while the com-  
pressor is running.  
Condenser Freeze Prevention — This control al-  
gorithm helps prevent condenser tube freeze-up by energiz-  
ing the condenser pump relay. If the pump is controlled by  
the PIC, starting the pump helps prevent the water in the  
condenser from freezing. Condenser freeze prevention can  
occur whenever the chiller is not running except when it is  
either actively in pumpdown or in pumpdown lockout with  
the freeze prevention disabled.  
When the condenser refrigerant temperature is less than  
or equal to the condenser freeze point (CONDENSER FREEZE  
POINT on the SERVICE1 screen), or the entering condenser  
water temperature is less than or equal to the condenser freeze  
point, then the condenser water pump (CONDENSER WA-  
TER PUMP on the STATUS02 screen) is energized until the  
condenser refrigerant temperature is greater than the con-  
denser freeze point plus 5° F (2.7° C). If the chiller is in  
PUMPDOWN mode and the pump is energized, the PIC ac-  
tivates an alarm. If the chiller is not in PUMPDOWN mode  
and the pump is energized, the PIC activates an alert. If the  
chiller is in RECYCLE shutdown mode, the mode transi-  
tions to SHUTDOWN (non-recycle shutdown).  
Remote Start/Stop Controls — A remote device, such  
as a time clock with a set of contacts, may be used to start  
and stop the chiller. However, the device should not be pro-  
grammed to start and stop the chiller more than 2 or 3 times  
every 12 hours. If more than 8 starts in 12 hours occur, the  
Excessive Starts alarm is displayed, and the chiller is pre-  
vented from starting. The operator must reset the alarm at  
the LID in order to override the starts counter and start the  
chiller. If the automatic restart after a power failure (AUTO  
RESTART OPTION ) is not activated (disabled) when a power  
failure occurs and the remote contact is closed, the PIC con-  
trol activates an alarm because of the loss of voltage.  
Tower-Fan Relay — This control can be used to assist  
the condenser water temperature control system (field sup-  
plied). Low condenser water temperature can cause the chiller  
to shut down on low refrigerant temperature. The tower fan  
relay, located in the starter, is controlled by the PIC to en-  
ergize and deenergize as the pressure differential between  
cooler and condenser vessels changes. This function pre-  
vents low condenser water temperature and maximizes chiller  
efficiency. The tower-fan relay can only accomplish this if  
the relay has been added to the cooling tower temperature  
controller. The tower-fan relay (TOWER FAN RELAY on the  
STATUS02 screen) is turned on whenever the condenser wa-  
ter pump is running, flow is verified, and the difference be-  
tween cooler and condenser pressure is more than 30 psid  
(207 kPad) or entering condenser water temperature is greater  
than 85 F (29 C). The tower-fan relay is deenergized when-  
ever the condenser pump is off, flow is lost, the evaporator  
refrigerant temperature is less than the override temperature,  
or the differential pressure is less than 28 psid (193 kPad)  
and entering condensing water is less than 80 F (27 C).  
The contacts for remote starting are wired into the starter  
at terminal strip TB5, terminals 8A and 8B. See the certified  
drawings for further details on contact ratings. The contacts  
must be dry (no power).  
Spare Safety Inputs — Normally closed (NC) digital  
inputs for additional field-supplied safeties may be wired to  
the spare protective limits input channel in place of the factory-  
installed jumper. (Wire multiple inputs in series.) Opening  
any contact results in a safety shutdown and LID display.  
Refer to the certified drawings for safety contact ratings.  
Analog temperature sensors may also be added to the op-  
tions modules, if installed. These may be programmed to ac-  
tivate an alert on the CCN network, but not shut down the  
chiller.  
Spare Alarm Contacts — Two spare sets of alarm con-  
tacts are provided in the starter. The contact ratings are pro-  
vided in the certified drawings. The contacts are located on  
terminal strip TB6, terminals 5A and 5B, and terminals 5C  
and 5D.  
IMPORTANT: A field-supplied water temperature con-  
trol system for condenser water should be installed.  
The system should maintain the leaving condenser wa-  
ter temperature at 20° F (11° C) above the leaving chilled  
water temperature.  
Condenser Pump Control — The chiller monitors  
the condenser pressure (CONDENSER PRESSURE param-  
eter on the STATUS01 screen) and may turn on the con-  
denser pump if the pressure becomes too high whenever the  
compressor is shut down. The condenser pressure override  
(COND PRESSURE OVERRIDE parameter on the  
SERVICE1 screen) is the value that determines this pressure  
point. Its default value is 125 psi (862 kPa). If the condenser  
pressure is greater than or equal to the condenser pressure  
override, and the entering condenser water temperature (EN-  
TERING CONDENSER WATER parameter on the  
STATUS01 screen) is less than 115 F (46 C), then the con-  
denser pump energizes to try to decrease the pressure. The  
pump turns off when the condenser pressure is 5psi (34 kPa)  
less than the pressure override, or when the condenser re-  
frigerant temperature (CONDENSER REFRIG TEMP on the  
STATUS01 screen) is within 3° F (2° C) of the entering con-  
denser water temperature.  
The tower-fan relay control is not a substitute for a con-  
denser water temperature control. When used with a wa-  
ter temperature control system, the tower-fan relay con-  
trol can be used to help prevent low condenser water  
temperatures and associated problems.  
Auto. Restart After Power Failure — This option,  
which may be viewed or modified on the CONFIG screen  
(the AUTO RESTART OPTION parameter), can be enabled  
or disabled. If this option is enabled, the chiller starts up au-  
tomatically after a single cycle dropout; low, high, or no volt-  
age; and the power is within ±10% of normal. The  
15-minute start-to-start timer and the stop-to-start timer are  
ignored during this type of start-up.  
When power is restored after a power failure, and if the  
compressor had been running, the oil pump is energized for  
one minute before the evaporator pump is energized. The  
Auto. Restart function then continues like a normal start-up.  
36  
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Water/Brine Reset — Three types of chilled water/  
brine reset are available, Reset Type 1, Reset Type 2, and  
Reset Type 3. They can be viewed or modified on the CON-  
FIG screen (accessed from the EQUIPMENT CONFIGU-  
RATION table). See Table 2, Example 6.  
The LID default screen status message indicates when a  
reset is active. The WATER/BRINE CONTROL POINT tem-  
perature on the STATUS01 table indicates the chiller’s cur-  
rent reset temperature.  
Demand Limit Control Option (Requires  
Optional 8-Input Module) — The demand limit may  
be externally controlled with a 4 to 20 mA signal from an  
Energy Management System (EMS). The option (20 mA DE-  
MAND LIMIT OPTION) is enabled or disabled on the CON-  
FIG screen (Table 2, Example 6). When enabled, the control  
is set for 100% demand with 4 mA and an operator config-  
ured minimum demand set point at 20 mA (DEMAND LIMIT  
AT 20 mA) .  
The EMS demand reset input is hardwired into the No. 1  
8-input module. The signal may be internally powered by  
the module or externally powered. If the signal is externally  
powered, the signal is wired to terminals J1-1(+) and  
J1-2(–). If the signal is internally powered, the signal is wired  
to terminals J1-3(+) and J1-2(–). When enabled, the control  
is set for 100% demand with 4 mA and an operator config-  
ured minimum demand set point at 20 mA(DEMAND LIMIT  
AT 20 mA).  
To configure a reset type, input all configuration informa-  
tion for that reset type on the CONFIG screen. Then activate  
the reset type by entering the reset type number in the SELECT/  
ENABLE RESET TYPE input line.  
RESET TYPE 1 (Requires an optional 8-input module) —  
Reset Type 1 is an automatic chilled water temperature reset  
based on a 4 to 20 mA input signal. The value for Rest Type  
1 is user configurable (DEGREES RESET AT 20 mA). It is  
a temperature that corresponds to a 20 mA signal. (4 mA  
corresponds to 0° F [0° C]; 20 mA corresponds to the tem-  
perature entered by the operator.)  
This reset type permits up to ±30° F (±16° C) of auto-  
matic reset to the chilled water/brine temperature set point,  
based on the input from a 4 to 20 mA signal. The signal is  
hardwired into the No. 1 eight-input module.  
If the 4 to 20 mA signal is externally powered from the  
8-input module, the signal is wired to terminals J1-5(+) and  
J1-6(–). If the signal is powered internally by the 8-input  
module (for example, when using variable resistance), the  
signal is wired to J1-7(+) and J1-6(–). The PIC must be  
configured on the SERVICE2 screen to ensure that the  
appropriate power source is identified. See Table 2,  
Example 9, 20 mA POWER CONFIGURATION.  
Surge Prevention Algorithm — Surge occurs when  
lift conditions become so high that the gas flow across the  
impeller reverses. This condition can eventually cause chiller  
damage. Lift is defined as the difference between the pres-  
sure at the impeller eye and the impeller discharge. The maxi-  
mum lift that a particular impeller wheel can produce varies  
with the gas flow across the impeller and the size of the  
wheel.  
The surge prevention algorithm is operator configurable  
and can determine if lift conditions are too high for the com-  
pressor. If they are, the PIC takes corrective action. The al-  
gorithm also notifies the operator, via the LID, that chiller  
operating conditions are marginal.  
The surge prevention algorithm first determines if correc-  
tive action is necessary. This is done by checking 2 sets of  
operator configured data points: the minimum load points  
(MIN. LOAD POINTS [T1/P1]) and the maximum load  
points (FULL LOAD POINTS [T2/P2]). See the SERVICE1  
screen or Table 2, Example 8. These points have default set-  
tings. Information on how to modifiy the default minimum  
and maximum load points can be found in the Input Service  
Configurations section on page 54.  
RESET TYPE 2 (Requires an optional 8-input module) —  
Reset Type 2 is an automatic chilled water temperature reset  
based on a remote temperature sensor input.  
This reset type permits ±30° F (±16° C) of automatic re-  
set to the set point based on a temperature sensor wired to  
the No. 1 eight-input module (see wiring diagrams or cer-  
tified drawings). The temperature sensor must be wired to  
terminal J1-19 and J1-20.  
Figures 18 and 19 graphically display these settings and  
the algorithm function. The 2 sets of load points (default set-  
tings) describe a line that the algorithm uses to determine  
the maximum lift of the compressor. Whenever the actual  
differential pressure between the cooler and condenser and  
the temperature difference between the entering and leaving  
chilled water are above the line on the graph (as defined by  
the minimum and maximum load points) the algorithm goes  
into a corrective action mode. If the actual values are below  
the line, the algorithm takes no action.  
Corrective action can be taken by making one of 2 choices.  
If the optional hot gas bypass line is present, and the op-  
erator selects the hot gas bypass option on the SERVICE1  
screen (selects 1 for the SURGE LIMIT/HGBP OPTION),  
then the hot gas bypass valve can be energized. If the hot gas  
bypass option is not present, then the SURGE LIMIT/HGBP  
OPTION is on the default setting (0), and the guide vanes  
are held. (Also see Table 4, Capacity Overrides.) Both cor-  
rective actions reduce the lift experienced by the compressor  
and help to prevent a surge condition.  
Configure Reset Type 2 on the CONFIG screen (Table 2,  
Example 6). Enter the temperature of the remote sensor at  
the point where no temperature reset will occur (REMOTE  
TEMP [NO RESET]). Next, enter the temperature at which  
the full amount of reset will occur (REMOTE TEMP [FULL  
RESET]). Then, enter the maximum amount of reset re-  
quired to operate the chiller (DEGREES RESET). Reset  
Type 2 can now be activated.  
RESET TYPE 3 — Reset Type 3 is an automatic chilled wa-  
ter temperature reset based on cooler temperature differ-  
ence. This reset adds ±30° F (±16° C) based on the tempera-  
ture difference between entering and leaving chilled water.  
Reset Type 3 is the only reset available without the need for  
a No. 1 eight-input module. No wiring is required for Reset  
Type 3, because it already uses the cooler water sensors.  
Configure Reset Type 3 on the CONFIG screen (Table 2,  
Example 6). Enter the chilled water temperature difference  
(the difference between entering and leaving chilled water)  
at which no temperature reset occurs (CHW DELTA T [NO  
RESET]). This chilled water temperature difference is usu-  
ally the full design load temperature difference. Enter the  
difference in chilled water temperature at which the full  
amount of reset occurs (CHW DELTA T [FULL RESET]).  
Next, enter the amount of reset (DEGREES RESET). Reset  
Type 3 can now be activated.  
37  
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parameter, Table 2, Example 13) can be monitored on the  
MAINT03 screen. The SURGE TIME PERIOD parameter is  
displayed and configured on the SERVICE1 screen. See  
Table 2, Example 8. It has a default of 2 minutes.  
Lead/Lag Control — Lead/lag is a control system pro-  
cess that automatically starts and stops a lag or second chiller  
in a 2-chiller system. Refer to Fig. 15 and 16 for menu, table,  
and screen selection information. On chillers that have PSIO  
software with lead/lag capability, it is possible to use the PIC  
controls to perform the lead/lag function on 2 chillers. A third  
chiller can be added to the lead/lag system as a standby chiller  
to start up if the lead or lag chiller in the system has shut  
down during an alarm condition and additional cooling is  
required.  
NOTE: Lead/lag parameters can be viewed and modified on  
the LEAD/LAG CONFIGURATION screen, accessed from  
the EQUIPMENT CONFIGURATION table. See Table 2,  
Example 7. Lead/lag status during chiller operation is viewed  
on the MAINT04 screen, accessed from the CONTROL  
ALGORITHM STATUS table. See Table 2, Example 14.  
LEGEND  
⌬P = (Condenser psi) − (Cooler psi)  
⌬T = (ECW) − (LCW)  
Lead/Lag System Requirements:  
ECW  
HGBP  
LCW  
—
—
—
Entering Chilled Water  
Hot Gas Bypass  
Leaving Chilled Water  
• all chillers must have PSIO software capable of perform-  
ing the lead/lag function  
• water pumps MUST be energized from the PIC controls  
• water flows should be constant  
Fig. 18 — 17EX Hot Gas Bypass/Surge  
Prevention With Default Settings (English)  
• CCN Time Schedules for all chillers must be identical  
Operation Features:  
• 2 chiller lead/lag  
• addition of a third chiller for backup  
• manual rotation of lead chiller  
• load balancing if configured  
• staggered restart of the chillers after a power failure  
• chillers may be piped in parallel or in series chilled water  
flow  
COMMON POINT SENSOR INSTALLATION — Lead/  
lag operation does not require a common chilled water point  
sensor. Common point sensors can be added to the 8-input  
option module, if desired. Refer to the certified drawings for  
termination of sensor leads.  
NOTE: If the common point sensor option is chosen on a  
chilled water system, each chiller should have its own 8-input  
option module and common point sensor installed. A chiller  
uses its own common point sensor for control when that chiller  
is designated as the lead chiller. The PIC cannot read the  
value of common point sensors installed on other chillers in  
the chilled water system.  
When installing chillers in series, use a common point sen-  
sor. If a common point sensor is not used, the leaving chilled  
water sensor of the upstream chiller must be moved into the  
leaving chilled water pipe of the downstream chiller.  
If return chilled water control is required on chillers piped  
in series, the common point return chilled water sensor should  
be installed. If this sensor is not installed, the return chilled  
water sensor of the downstream chiller must be relocated to  
the return chilled water pipe of the upstream chiller.  
LEGEND  
⌬P = (Condenser kPa) − (Cooler kPa)  
⌬T = (ECW) − (LCW)  
ECW  
HGBP  
LCW  
—
—
—
Entering Chilled Water  
Hot Gas Bypass  
Leaving Chilled Water  
Fig. 19 — 17EX Hot Gas Bypass/Surge Prevention  
With Default Settings (SI)  
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 DELTA  
PERCENT AMPS) in one second, then one surge event has  
occurred. The setting is displayed and configured on the  
SERVICE1 screen. Its default setting is 25% amps.  
A surge protection chiller shutdown occurs when the surge  
protection counter reaches 12 within an operator specified  
time period, known as the surge time period. The  
surge protection count (SURGE PROTECTION COUNTS  
To properly control the common supply point temperature  
sensor when chillers are piped in parallel, the water flow through  
the shutdown chiller(s) must be isolated so there is no water  
bypass around the operating chiller. The common point sen-  
sor option must not be used if water bypass around the op-  
erating chiller is occurring.  
CHILLER COMMUNICATION WIRING — Refer to the  
chiller Installation Instructions and the Carrier Comfort Net-  
work Interface section on page 53 of this manual for infor-  
mation on chiller communication wiring.  
38  
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LEAD/LAG OPERATION — 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 con-  
figured for lead/lag is set to the LOCAL or OFF modes, it  
will be unavailable for lead/lag operation.  
NOTE: Lead/lag configuration is viewed and edited on the  
LEAD/LAG screen, accessed from the EQUIPMENT CON-  
FIGURATION table of the SERVICE menu. See Table 2,  
Example 7. Lead/lag status during chiller operation is viewed  
on the MAINT04 screen, accessed from the CONTROL AL-  
GORITHM STATUS table. See Table 2, Example 14.  
Standby Chiller Configuration and Operation — The con-  
figured standby chiller is identified as such by having its LEAD/  
LAG SELECT parameter assigned a value of 3. The standby  
chiller can only operate as a replacement for the lag chiller  
if one of the other two chillers is in an alarm (*) condition  
(as indicated on the LID panel). If both lead and lag chillers  
are in an alarm (*) condition, the standby chiller defaults to  
operate in CCN mode based on its configured occupancy sched-  
ule and remote contacts input.  
Lag Chiller Start-Up Requirements — Before the lag chiller  
can be started, the following conditions must be met.  
1. Lead chiller ramp loading must be completed.  
2. Lead chiller’s chilled water temperature must be  
greater than the WATER/BRINE CONTROL POINT (STA-  
TUS01 screen) plus half the WATER/BRINE DEAD-  
BAND (SERVICE1 screen).  
Lead/Lag Chiller Configuration and Operation — A chiller  
is designated the lead chiller when the LEAD/LAG  
SELECT parameter for that chiller is set to 1 on the LEAD/  
LAG CONFIGURATION screen. A chiller is designated the  
lag chiller when the LEAD/LAD SELECT parameter for that  
chiller is set to 2. A chiller is designated the standby chiller  
when the LEAD/LAG SELECT parameter for that chiller is  
set to 3. Setting the LEAD/LAG SELECT parameter to 0 dis-  
ables the lead/lag function in that chiller.  
To configure the LAG ADDRESS parameter on the LEAD/  
LAG CONFIGURATION screen, always use the address of  
the other chiller on the system. Using this address makes it  
easier to rotate the lead and lag chillers.  
NOTE: The chilled water temperature sensor may be the  
leaving chilled water sensor, the return water sensor, the  
common supply water sensor, or the common return wa-  
ter sensor, depending on which options are configured and  
enabled.  
3. Lead chiller ACTIVE DEMAND LIMIT (STATUS01  
screen) value must be greater than 95% of full load amps.  
4. Lead chiller temperature pulldown rate (TEMP PULL-  
DOWN DEG/MIN on the CONFIG screen) of the chilled  
water temperature is less than 0.5° F (0.27° C) per minute.  
5. The lag chiller status indicates it is in CCN mode and is  
not faulted. If the current lag chiller is in an alarm con-  
dition, then the standby chiller becomes the active lag chiller,  
if it is configured and available.  
6. The configured time for the LAG START TIMER param-  
eter has elapsed. The lag start timer starts when the lead  
chiller ramp loading is completed. The LAG START TIMER  
parameter is on the LEAD/LAG screen, which is ac-  
cessed from the EQUIPMENT CONFIGURATION table.  
See Table 2, Example 7.  
If improper address assignments are entered for the LAG  
ADDRESS and STANDBY ADDRESS parameters, the  
lead/lag is disabled and an alert (!) message displays on the  
LID. For example, if the lag chiller’s address matches the  
lead chiller’s address, the lead/lag function is disabled and  
an alert (!) message displays. The lead/lag maintenance screen  
(MAINT04) displays the message INVALID CONFIG in the  
LEAD/LAG CONFIGURATION and CURRENT MODE fields.  
The lead chiller responds to normal start/stop controls such  
as occupancy schedule, forced start/stop, and remote start  
contact inputs. After completing start-up and ramp loading,  
the PIC evaluates the need for additional capacity. If addi-  
tional capacity is needed, the PIC initiates the start-up of the  
chiller configured at the lag address. If the lag chiller is faulted  
(in alarm) or is in the OFF or LOCAL modes, then the chiller  
at the standby address (if configured) is requested to start.  
After the second chiller is started and is running, the lead  
chiller monitors conditions and evaluates whether the ca-  
pacity has been reduced enough for the lead chiller to sus-  
tain the system alone. If the capacity is reduced enough for  
the lead chiller to sustain the control point temperatures alone,  
then the operating lag chiller is stopped.  
If the lead chiller is stopped in CCN mode for any reason  
other than an alarm (*) condition, then the lag and standby  
chillers are stopped. If the configured lead chiller stops for  
an alarm condition, then the configured lag chiller takes the  
lead chiller’s place as the lead chiller and the standby chiller  
serves as the lag chiller.  
If the configured lead chiller does not complete the start-up  
before the PRESTART FAULT TIMER (a user configured pa-  
rameter on the LEAD/LAG screen) elapses, then the lag chiller  
is started and the lead chiller shuts down. The lead chiller  
then monitors the request to start from the acting lead chiller.  
The pre-start fault timer is initiated at the time of a start re-  
quest. This timer’s function is to provide a time-out if there  
is a pre-start alert condition that prevents the chiller from  
starting in a timely manner.  
When all the above requirements have been met, the lag  
chiller is forced to a STARTUP mode. The PIC control then  
monitors the lag chiller for a successful start. If the lag chiller  
fails to start, the standby chiller, if configured, is started.  
Lag Chiller Shutdown Requirements — The following con-  
ditions must be met in order for the lag chiller to be stopped.  
1. Lead chiller COMPRESSOR MOTOR LOAD (STA-  
TUS01 screen) value is less than the lead chiller percent  
capacity plus 15%. See STATUS01 screen or Table 2,  
Example 1.  
NOTE: Lead chiller percent capacity = 100 – LAG PER-  
CENT CAPACITY.  
The LAG PERCENT CAPACITY value is configured on  
the LEAD/LAG CONFIGURATION screen.  
2. The lead chiller chilled water temperature is less than  
the WATER/BRINE CONTROL POINT plus 1/2 of the  
WATER/BRINE DEADBAND. The WATER/BRINE DEAD-  
BAND parameter is on the SERVICE1 screen. See  
Table 2, Example 8.  
3. The configured lag stop time (LAG STOP TIMER param-  
eter on the LEAD/LAG CONFIGURATION screen) has  
elapsed. The lag start time starts when the LEAVING  
CHILLED WATER temperature is less than the WATER/  
BRINE CONTROL POINT plus 1/2 of the WATER/  
BRINE DEADBAND, and the lead chiller COMPRESSOR  
MOTOR LOAD is less than the lead chiller percent ca-  
pacity plus 15%. The lag stop timer is ignored if the chilled  
water temperature reaches 3° F (1.67° C) below the WATER/  
BRINE CONTROL POINT and the lead chiller COM-  
PRESSOR MOTOR LOAD value is less than the lead chiller  
percent capacity plus 15%.  
If the lag chiller does not achieve start-up before the  
pre-start fault time elapses, then the lag chiller is stopped  
and the standby chiller is requested to start, if configured  
and ready.  
39  
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FAULTED CHILLER OPERATION — 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,  
the standby chiller reverts to a stand-alone CCN mode of  
operation.  
build period, the WATER/BRINE CONTROL POINT is set to  
the ICE BUILD SETPOINT (SETPOINT screen) for tem-  
perature control.  
The ICE BUILD RECYCLE OPTION and ICE BUILD  
TERMINATION parameters are on the CONFIG screen. The  
ice build recycle option can be enabled or disabled from this  
screen; the ice build termination value can be set to 0, 1, or  
2, depending on the factor that determines termination (tem-  
perature, contacts, or both). Ice build termination can occur  
when:  
• the ENTERING CHILLED WATER temperature is less than  
the ICE BUILD SETPOINT  
• the REMOTE CONTACTS INPUT (STATUS01 screen) is  
opened based on input from an ice level indicator  
• the end of the ice build time schedule has been reached.  
If the lead chiller is in an alarm (*) condition (indicated  
on the LID ), the RESET softkey is pressed to clear the  
alarm, and the lead chiller is placed in CCN mode, the lead  
chiller communicates and monitors the run status of the lag  
and standby chillers. If both the lag and standby chillers are  
running, the lead chiller does not attempt to start and does  
not assume the role of lead chiller until either the lag or standby  
chiller shuts down. If only one chiller is running, the lead  
chiller waits for a start request from the operating chiller.  
When the configured lead chiller starts, it assumes its role of  
lead chiller.  
LOAD BALANCING — When the LOAD BALANCE OP-  
TION (LEAD/LAG screen) is enabled, the lead chiller sets  
the ACTIVE DEMAND LIMIT in the lag chiller to the lead  
chiller’s COMPRESSOR MOTOR LOAD value. This value  
has limits of 40% to 100%. When setting the lag chiller AC-  
TIVE DEMAND LIMIT, the WATER/BRINE CONTROL POINT  
is modified to a value of 3° F (1.67° C) less than the lead  
chiller’s WATER/BRINE CONTROL POINT value. If the LOAD  
BALANCE OPTION is disabled, the ACTIVE DEMAND LIMIT  
and the WATER/BRINE CONTROL POINT are forced to the  
same value as the lead chiller.  
ICE BUILD INITIATION — The ice build option is acti-  
vated via the ice build time schedule on the OCCPC02S screen.  
If the current time is set as an ice build time on the OCCPC02S  
screen and the ICE BUILD OPTION on the CONFIG screen  
is enabled, then the ice build option is active and the fol-  
lowing events automatically take place (unless overridden  
by a higher authority CCN device):  
1. CHILLER START/STOP is forced to START.  
2. The WATER/BRINE CONTROL POINT is forced to the  
ICE BUILD SETPOINT.  
3. Any force (Auto) on the ACTIVE DEMAND LIMIT is  
removed.  
NOTE: Items 1-3 (shown above) do not occur if the chiller  
is configured and operating as a lag or standby chiller for  
lead/lag operation and is actively controlled by a lead chiller.  
The lead chiller communicates the ICE BUILD SETPOINT,  
desired CHILLER START/STOP state, and ACTIVE DE-  
MAND LIMIT to the lag or standby chiller as required for  
ice build, if configured to do so.  
AUTO. RESTART AFTER POWER FAILURE — When an  
auto. restart condition occurs, each chiller may have a delay  
added to the start-up sequence, depending on its lead/lag con-  
figuration. The lead chiller does not have a delay. The lag  
chiller has a 45-second delay. The standby chiller has a  
90-second delay. The delay time is added after the chiller  
water flow verification. The PIC controls ensure that the guide  
vanes are closed. After the guide vane position is confirmed,  
the delay for lag and standby chillers occurs before ener-  
gizing the oil pump. The normal start-up sequence then con-  
tinues. The auto. restart delay sequence occurs whether the  
chiller is in CCN or LOCAL mode and is intended to stag-  
ger the compressor motor start-up times. This helps reduce  
the in-rush of demand on the building power system.  
START-UP/RECYCLE OPERATION — If the chiller is not  
running when ice build activates, then the PIC checks the  
following parameters, based on the ICE BUILD  
TERMINATION value, to avoid starting the compressor  
unnecessarily:  
• if the ICE BUILD TERMINATION parameter is set to 0  
(temperature only), and the ENTERING CHILLED WA-  
TER temperature is less than or equal to the ICE BUILD  
SETPOINT;  
Ice Build Control — Ice build control automatically sets  
the chilled WATER/BRINE CONTROL POINT of the chiller  
from a normal operation set point temperature to a tempera-  
ture that allows an ice building operation for thermal  
storage.  
NOTE: For ice build control to operate properly, the PIC  
controls must be placed in CCN mode.  
• if the ICE BUILD TERMINATION parameter is set to 1  
(contacts only) and the remote contacts are open;  
• if the ICE BUILD TERMINATION parameter is set to 3  
(both temperature and contacts), the ENTERING CHILLED  
WATER temperature is less than or equal to the ICE BUILD  
SETPOINT, and the remote contacts are open.  
The ICE BUILD RECYCLE OPTION determines whether  
or not the PIC goes into a RECYCLE mode. If the ICE BUILD  
RECYCLE OPTION is set to DSABLE (disable) when the  
ice build terminates, the PIC reverts to normal temperature  
control duty. If the ICE BUILD RECYCLE OPTION is set to  
ENABLE, when ice build terminates, the PIC goes into an  
ice build recycle mode and the chilled water pump relay re-  
mains energized to keep the chilled water flowing. If the EN-  
TERING CHILLED WATER (brine) temperature increases above  
the ICE BUILD SETPOINT plus the RECYCLE RESTART  
DELTA T value, the compressor restarts and controls the chilled  
water/brine temperature to the ICE BUILD SETPOINT.  
The PIC can be configured for ice build operation by chang-  
ing entries on the:  
• CONFIG screen, accessed from the SERVICE menu  
• OCCPC02S screen (ice build time schedule), accessed from  
the SCHEDULE menu  
• SETPOINT screen, accessed from the SETPOINT menu.  
Figures 15 and 16 show how to access each screen.  
The ice build time schedule defines the periods during which  
the ice build option can be activated, if the ice build option  
is enabled. If the ice build time schedule overlaps other sched-  
ules, the ice build time schedule takes priority. During an ice  
40  
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TEMPERATURE CONTROL DURING ICE BUILD  
—During ice build, the capacity control algorithm uses the  
WATER/BRINE CONTROL POINT minus 5 F (2.7 C) to con-  
trol the LEAVING CHILLED WATER temperature. The ECW  
CONTROL OPTION (see CONFIG screen), the 20 mA  
DEMAND LIMIT, and any temperature reset option are ig-  
nored during ice build.  
Figure 20 shows the ATTACH TO NETWORK DEVICE  
table as it appears on the LID. The LOCAL entry is always  
the PSIO module address of the chiller the LID is mounted  
on. Whenever the controller identification of the PSIO is  
changed, this change is reflected on the bus and address for  
the LOCAL DEVICE of the ATTACH TO DEVICE screen  
automatically.  
TERMINATION OF ICE BUILD — Ice build termination  
occurs under the following conditions:  
NAME DESCRIPTOR  
1. Ice Build Time Schedule — The ice build function ter-  
minates when the current time is not designated as an ice  
build time period.  
2. Entering Chilled Water Temperature — Compressor op-  
eration terminates based on temperature if the ICE BUILD  
TERMINATION parameter on the CONFIG screen is set  
to 0 (temperature only) and the ENTERING CHILLED  
WATER temperature is less than the ICE BUILD SET-  
POINT. If the ICE BUILD RECYCLE OPTION is set to  
ENABLE, a recycle shutdown occurs and recycle start-  
up is based on a LEAVING CHILLED WATER tempera-  
ture greater than the WATER/BRINE CONTROL POINT  
plus RECYCLE RESTART DELTA T (see SERVICE1  
screen).  
3. Remote Contacts/Ice Level Input — Compressor opera-  
tion terminates when the ICE BUILD TERMINATION pa-  
rameter is set to 1 (contacts only) and the remote contacts  
are open. In this case, the contacts are used for ice level  
termination control. The remote contacts can still be opened  
and closed to start and stop the chiller if the current time  
is not a time designated as an ice build period. If the cur-  
rent time is designated as an ice build period, the contacts  
are used to stop the ice build function.  
Fig. 20 — Example of Attach to Network  
Device Screen  
Whenever the ATTACH TO NETWORK DEVICE table  
is accessed, no information can be read from the LID on any  
device until you attach one of the devices listed on the dis-  
play. As soon as this screen appears, the LID erases infor-  
mation about the module to which it was attached to make  
room for information on another device. Therefore, a CCN  
module must be attached when this screen is entered.  
To attach to a device listed on this screen, highlight it us-  
ing the SELECT softkey. Then press the ATTACH soft-  
key. The message, UPLOADING TABLES, PLEASE WAIT,  
flashes. The LID then uploads the highlighted device or mod-  
ule. If the device address cannot be found, the message, COM-  
MUNICATION FAILURE, appears. The LID then reverts to  
the ATTACH TO NETWORK DEVICE screen. Try another  
device or check the address of the device that did not attach.  
The upload process time for each CCN module is different.  
In general, the uploading process takes 3 to 5 minutes.  
4. Entering Chilled Water Temperature and Remote Con-  
tacts — Compressor operation terminates when the ICE  
BUILD TERMINATION parameter is set to 2 (both tem-  
perature and contacts) and the previously described con-  
ditions for ENTERING CHILLED WATER temperature and  
remote contacts have occurred.  
NOTE: Before leaving the ATTACH TO NETWORK DE-  
VICE screen, select the LOCAL device. Otherwise, the LID  
will be unable to display information on the local chiller.  
NOTE: Overriding the CHILLER START/STOP, WATER/  
BRINE CONTROL POINT, and ACTIVE DEMAND LIMIT  
values by CCN devices (with a priority less than 4) during  
the ice build period is not possible. However, overriding can  
be accomplished with CCN during two-chiller lead/lag  
operation.  
ATTACHING TO OTHER CCN MODULES — If the chiller  
PSIO has been connected to a CCN network or other PIC  
controlled chillers through CCN wiring, the LID can be used  
to view or change parameters on the other controllers. Other  
PIC chillers can be viewed and set points changed (if the  
other unit is in CCN control) if desired from this particular  
LID module.  
To view the other devices, access the ATTACH TO  
NETWORK DEVICE table. Move the highlight bar to any  
device number. Press the SELECT softkey to change to the  
bus number and address of the module to be viewed. Press  
the ENTER softkey. Press the EXIT softkey to return to  
RETURN TO NON-ICE BUILD OPERATIONS — When  
the ice build function terminates, the chiller returns to nor-  
mal temperature control and start/stop schedule operation. If  
the CHILLER START/STOP or WATER/BRINE CONTROL  
POINT has been forced (with a priority less than 4), before  
the start of ice build operation, then CHILLER START/STOP  
and WATER/BRINE CONTROL POINT forces are removed;  
that is, under these circumstances, the ice build operation  
takes precedence over the force.  
the ATTACH TO NETWORK DEVICE table. If the device  
number is not valid, the message, COMMUNICATION FAIL-  
URE, displays. Enter a new address number or check the  
wiring. If the device is communicating properly, the mes-  
sage, UPLOAD IN PROGRESS, displays and the new de-  
vice can now be viewed.  
Whenever there is a question regarding which CCN de-  
vice the LID is currently showing, check the device name  
descriptor on the upper left hand corner of the LID screen.  
See Fig. 20.When the CCN device has been viewed, use the  
ATTACH TO NETWORK DEVICE table to attach to the  
PSIO that is on the chiller. From the ATTACH TO NET-  
WORK DEVICE table , highlight LOCAL, and press the  
Attach to Network Device Control — One of the  
selections on the SERVICE menu is ATTACH TO NET-  
WORK DEVICE. See Fig. 12. This table serves the follow-  
ing purposes:  
• uploads the occupancy schedule number (OCCPC03S), if  
changed, as defined in the CONFIG screen (SCHEDULE  
NUMBER).  
• attaches the LID to any CCN device, if the chiller has been  
connected to a CCN network. This may include other PIC  
controlled chillers.  
• uploads changes from a new PSIO or LID module or up-  
graded software.  
SELECT softkey. Then, press the ATTACH softkey to up-  
load the LOCAL device. The PSIO will upload.  
41  
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NOTE: The LID does not automatically re-attach to the PSIO  
module on the chiller. Access the ATTACH TO NETWORK  
DEVICE table, scroll to LOCAL, and press the  
EF, EX, FA CHLR HOLDY01S CONF IGURATION SELECT  
ATTACH 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 SERVICE SCREENS  
1. On the MENU screen, press the SERVICE softkey. The  
softkeys now correspond to the numerals 1, 2, 3, and 4.  
NOTE: The factory-set password is 1 - 1 - 1 - 1. See the  
Input Service Configurations section, page 54, for informa-  
tion on how to change a password.  
2. Press the four digits of your password, one at a time. An  
asterisk (*) appears as you enter each digit.  
Fig. 21 — Example of Holiday Period Screen  
If the password is incorrect, an error message is dis-  
played. If this occurs, return to Step 1 and try to access  
the SERVICE tables again. If the password is correct, the  
To view or change the holiday periods for up to 18 dif-  
ferent holidays, perform the following operation:  
softkey labels change to NEXT  
,
PREVIOUS  
,
1. At the Menu screen, press SERVICE to access the  
SERVICE menu.  
SELECT , and EXIT , and the LID screen displays the  
following SERVICE tables:  
• Alarm History  
• Control Test  
• Control Algorithm Status  
• Equipment Configuration  
• Equipment Service  
2. If not logged on, follow the instructions for entering your  
password. See the section, To Access the Service Screens,  
page 42. Once logged on, press NEXT until  
• Time and Date  
• Attach to Network Device  
• Log Out of Device  
• Controller Identification  
• LID Configuration  
EQUIPMENT CONFIGURATION is highlighted.  
See Fig. 16 for additional screens and tables available form  
the SERVICE tables listed above. Use the EXIT softkey to  
return to the MENU screen.  
3. Press the SELECT softkey to access the EQUIP-  
MENT CONFIGURATION tables.  
TO LOG OFF — Access the LOG OUT OF DEVICE table  
from the SERVICE menu. The LID exits the SERVICE menu.  
To re-enter the SERVICE menu, you must re-enter your pass-  
word as described above.  
NOTE: To prevent unauthorized persons from accessing the  
LID service screens, the LID automatically signs off and  
password-protects itself if a key has not been pressed for  
15 minutes. The sequence is as follows. Fifteen minutes af-  
ter the last key is pressed, the default screen displays, the  
LID screen light goes out (analogous to a screen saver), and  
the LID logs out of the password-protected SERVICE menu.  
Other screens and menus, such as the STATUS screen can  
be accessed without the password by pressing the appropri-  
ate softkeys.  
4. Press NEXT until HOLIDEF is highlighted. This is  
the holiday definition table.  
5. Press SELECT to access the HOLIDEF screen.  
This screen lists 18 holiday tables.  
HOLIDAY SCHEDULING (Fig. 21) — The time schedules  
may be configured for special operation during holiday pe-  
riods. When modifying a time period, an ‘‘H’’ at the end of  
the days of the week field signifies that the period is appli-  
cable to a holiday. (See Fig. 14.)  
The broadcast function must be activated for the holidays  
configured on the HOLIDEF screen to work properly. Ac-  
cess the BRODEF screen from the EQUIPMENT CON-  
FIGURATION table and set the parameter that activates the  
BRODEF function to YES. Note that, when the chiller is  
connected to a CCN network, only one chiller or CCN de-  
vice can be configured to be the broadcast device. The con-  
troller that is configured to be the broadcaster is the device  
responsible for transmitting holiday, time, and daylight-  
savings dates throughout the network.  
6. Press NEXT to highlight the holiday table that you  
wish to view or change. Each table is one holiday pe-  
riod, starting on a specific date, and lasting up to 99 days.  
42  
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If the checks are successful, the chilled water/brine pump  
relay is energized. Five seconds later, the condenser pump  
relay is energized. One minute later the PIC monitors the  
chilled water and condenser water flow switches, and waits  
until the WATER FLOW VERIFY TIME (operator config-  
ured, default 5 minutes) to confirm flow. See the SERVICE1  
screen or Table 2, Example 8. After flow is verified, the chilled  
water/brine temperature is compared to WATER/BRINE CON-  
TROL POINT plus DEADBAND. If the temperature is less  
than or equal to this value, the PIC turns off the condenser  
pump relay and goes into a RECYCLE mode.  
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 HOLIDAY  
START MONTH, START DAY, or DURATION.  
If the water/brine temperature is high enough, the start-up  
sequence continues and checks 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 3 psid (21 kPad), the oil  
pump relay is then energized. The PIC then waits a mini-  
mum of 15 seconds (maximum 5 minutes) to verify that the  
compressor oil pressure (OIL PRESSURE on the STA-  
TUS01 screen) has reached 15 psid (103 kPad). At the same  
time, the PIC waits up to 30 seconds to verify that the gear  
oil pressure (GEAR OIL PRESSURE on the STATUS04  
screen) has reached 24 psi (166 kPa). After the oil pressures  
are verified, the PIC waits 10 seconds, and then the  
compressor start relay (1CR) is energized to start the  
compressor.  
9. Press SELECT to modify the month, day, or  
duration.  
10. Press INCREASE or DECREASE to change the se-  
lected value.  
11. Press ENTER to save the changes.  
12. Press EXIT to return to the previous menu.  
LEGEND  
START-UP/SHUTDOWN/  
RECYCLE SEQUENCE (Fig. 22)  
A
—
START INITIATED — Prestart checks made; chilled water  
pump started.  
Condenser water pump started (5 seconds after A).  
Water flows verified (one minute to 5 minutes maximum  
afterA). Chilled water temperature checked against control point.  
Guide vanes checked for closure. Oil pumps started; tower fan  
control enabled.  
Oil pressure verified (for compressor, 15 seconds minimum,  
300 seconds maximum, after C; for gear, within 30 seconds  
after C).  
Compressor motor starts, compressor ontime and service  
ontime starts, 15-minute inhibit timer starts (10 seconds  
after D). Start-in-12 hours counter advances by one.  
SHUTDOWN INITIATED — Compressor motor stops, guide  
vanes close, compressor ontime and service ontime stops, stop-  
to-start inhibit timer starts.  
B
C
—
—
Local Start-Up — Local start-up (or a manual start-up)  
is initiated by pressing the LOCAL menu softkey which is  
on the default LID screen. Local start-up can proceed if the  
OCCUPIED ? parameter on the STATUS01 table is set to  
YES and after the internal 15-minute start-to-start timer and  
the stop-to-start inhibit timer have expired.  
The CHILLER START/STOP parameter on the STA-  
TUS01 screen may be overridden to start, regardless of the  
time schedule, in order to start the chiller locally. Also, the  
remote contacts may be enabled through the LID and closed  
to initiate a start-up.  
Whenever the chiller is in LOCAL control mode, the PIC  
waits for the current time to coincide with an occupied time  
period as configured in the local time schedule (OCCPC01S)  
and for the remote contacts to close, if enabled. The PIC  
then performs a series of pre-start checks to verify that all  
pre-start alerts and safeties are within the limits shown in  
Table 3. The RUN STATUS line on the STATUS01 screen  
now reads STARTUP.  
D
—
—
—
—
—
E
F
G
After the post-lube period, oil and evaporator pumps deener-  
gized. Post-lube configurable to between one and 5 minutes  
after Step F.  
Restart permitted (both inhibit timers expired) (minimum of  
15 minutes after E; minimum of 1 minute after F).  
O/A  
Fig. 22 — Control Sequence  
43  
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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 STARTS IN 12 HOURS counter (STATUS01 screen).  
Any failure after the 1CR relay has energized causes a safety  
shutdown, advances the STARTS IN 12 HOURS counter by  
one, and displays the applicable shutdown status on the LID  
display.  
When the automatic soft stop amps threshold is being ap-  
plied, a status message, SHUTDOWN IN PROGRESS, COM-  
PRESSOR UNLOADING, displays.  
Chilled Water Recycle Mode — When the compres-  
sor is running under light load conditions, the chiller  
may cycle off and wait until the load increases to restart  
again. This cycling is normal and is known as recycle. A  
recycle shutdown is initiated when any of the following  
occurs:  
• when the chiller is operating under the control of the leav-  
ing chilled water temperature (that is, when the ECW CON-  
TROL OPTION on the CONFIG screen is disabled), the  
difference between the LEAVING CHILLED WATER tem-  
perature and ENTERING CHILLED WATER temperature  
is less than the RECYCLE SHUTDOWN DELTA T (found  
in the SERVICE1 table) and the LEAVING CHILLED WA-  
TER TEMP is below the WATER/BRINE CONTROL POINT,  
and the WATER/BRINE CONTROL POINT has not in-  
creased in the last 5 minutes  
• when the chiller is operating under the control of the en-  
tering chilled water temperature (that is, the ECW CON-  
TROL OPTION is enabled), the difference between the  
ENTERING CHILLED WATER temperature and the LEAV-  
ING CHILLED WATER temperature is less than the  
RECYCLE SHUTDOWN DELTA T (found in the SERV-  
ICE1 table) and the ENTERING CHILLED WATER tem-  
perature is below the WATER/BRINE CONTROL POINT,  
and the WATER/BRINE CONTROL POINT has not in-  
creased in the last 5 minutes  
Shutdown Sequence — The chiller shuts down if any  
of the following occurs:  
• the STOP button on the control panel is pressed for at least  
one second. The alarm light blinks once to confirm the  
stop command.  
• a recycle condition is present (see Chilled Water Recycle  
Mode section).  
• the OCCUPIED ? parameter on the STATUS01 screen reads  
NO; that is, the chiller is not scheduled to run at the cur-  
rent time and date.  
• the remote contact opens.  
• the CHILLER START/STOP status is overridden to STOP  
from the CCN network or the LID.  
When a stop signal occurs, the shutdown sequence first  
stops the compressor by deactivating the start relay. A status  
message, SHUTDOWN IN PROGRESS, COMPRESSOR  
DEENERGIZED, displays. The guide vanes are then brought  
to the closed position. The oil pump relay and the chilled  
water/brine pump relay are shut down 60 seconds after the  
compressor stops. The condenser water pump shuts down  
when the condenser refrigerant temperature is less than the  
condenser pressure override minus 5 psi (34 kPa) or is less  
than or equal to the entering condenser water temperature  
plus 3° F (2° C). The stop-to-start timer now begins to count  
down. If the value of the start-to-start timer is still greater  
than the value of the start-to-stop timer, then the start-to-  
start time is displayed on the LID.  
There are certain conditions during shutdown that can change  
this sequence:  
• if the COMPRESSOR MOTOR LOAD (STATUS01 screen)  
is greater than 10% after shutdown or the starter contacts  
remain energized, the oil pump and chilled water pump  
remain energized and the alarm is displayed  
• when the LEAVING CHILLED WATER temperature is within  
3° F (2° C) of the BRINE REFRIG TRIPPOINT.  
(See the SERVICE1 screen.)  
When the chiller is in RECYCLE mode, the chilled water  
pump relay remains energized so that the chilled water tem-  
perature can be monitored for increasing load. The recycle  
control uses the RECYCLE RESTART DELTA T value  
to check when the compressor should be restarted. This is an  
operator-configured value that defaults to 5° F (3° C). The  
value can be viewed/modified on the SERVICE1 screen. The  
compressor restarts when:  
• the chiller is operating under leaving chilled water tem-  
perature control and the LEAVING CHILLED WATER  
temperature is greater than the WATER/BRINE CON-  
TROL POINT plus the RECYCLE RESTART DELTA T; or  
• the chiller is operating under entering chilled water tem-  
perature control and the ENTERING CHILLED WATER  
temperature is greater than the WATER/BRINE CON-  
TROL POINT plus the RECYCLE RESTART DELTA T.  
Once these conditions are met, the compressor initiates a  
start-up, with a normal start-up sequence.  
An alert condition may be generated if 5 or more recycles  
occur in less than 4 hours. Because excessive recycling can  
reduce chiller life, compressor recycling caused by ex-  
tremely low loads should be reduced. To accomplish this,  
use the time schedule to shut the chiller down during periods  
of known low load operation or increase the chiller load by  
running the fan systems. If the hot gas bypass is installed,  
adjust the values to ensure that hot gas is energized during  
light load conditions. Increase the RECYCLE RESTART DELTA  
T value on the SERVICE1 screen to lengthen the time be-  
tween restarts.  
• if the ENTERING CONDENSER WATER (STATUS01 screen)  
temperature is greater than 115 F (46 C) at shutdown, the  
condenser pump is deenergized after the 1CR compressor  
start relay  
• if the chiller shuts down due to low refrigerant tempera-  
ture, the chilled water pump keeps running until the LEAV-  
ING CHILLED WATER temperature is greater than the  
WATER/BRINE CONTROL POINT plus 5° F (3° C).  
Automatic Soft Stop Amps Threshold — The au-  
tomatic soft stop amps threshold is an operator configured  
value that closes the guide vanes of the compressor auto-  
matically when a non-recycle, non-alarm stop signal occurs  
before the compressor motor is deenergized.  
If the STOP button on the control panel is pressed, the  
guide vanes close to a preset amperage percent or until the  
guide vane is less than 2% open. The compressor then shuts  
off.  
If the chiller enters an alarm state or if the compressor  
enters a RECYCLE mode, the compressor is deenergized  
immediately.  
To activate the automatic soft stop amps threshold, access  
the SERVICE1 screen. Set the SOFT STOP AMPS THRESH-  
OLD parameter value to the percent of amps at which the  
motor will shut down. The default setting is 100% amps (no  
soft stop).  
The chiller should not be operated below design mini-  
mum load without a hot gas bypass installed on the  
chiller.  
44  
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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  
Remove Shipping Packaging — Remove any pack-  
aging material from the control center, power panel, guide  
vane actuator, motor and bearing temperature sensor covers,  
and the factory-mounted starter.  
shutdown requires that the RESET softkey be pressed in  
order to clear the alarm. If the alarm continues, the alarm  
light continues to blink. Once the alarm is cleared, the op-  
MOTOR  
erator must press the CCN or LOCAL softkeys to restart  
the chiller.  
The motor may be provided with a shipping brace or  
shipping bolt (normally painted yellow) to prevent shaft  
movement during transit. It must be removed prior to  
operation. See Fig. 24.  
Do not reset starter loads or any other starter safety for  
30 seconds after the compressor has stopped. Voltage  
output to the compressor start signal is maintained for  
10 seconds to determine starter fault.  
BEFORE INITIAL START-UP  
Job Data Required  
• list of applicable design temperatures and pressures (prod-  
uct data submittal)  
• certified drawings of the chiller  
• starting equipment details and wiring diagrams  
• diagrams and instructions for special controls or options  
• installation instructions  
• pumpout unit instructions  
Equipment Required  
Fig. 24 — Shipping Bolt on Open Drive Motor  
• mechanic’s tools (refrigeration)  
• digital volt-ohmmeter (DVM)  
The motor should be inspected for any temporary, yellow  
caution tags with legends that convey information concern-  
ing actions necessary before the motor can be safely oper-  
ated. Any slushing compound on the shaft or other parts must  
be removed using a petroleum type solvent. Observe proper  
safety precautions.  
• clamp-on ammeter  
• electronic leak detector  
• absolute pressure manometer or wet-bulb vacuum indica-  
tor (Fig. 23)  
• 500 v insulation tester (megohmmeter) for compressor mo-  
tors with nameplate voltage of 600 v or less, or a  
5000 v insulation tester for compressor motor rated above  
600 v  
NOTE: If a shipping bolt was used to restrain the rotor, the  
Westinghouse logo must be installed over the hole in the end-  
cover. The logo, the gasket, and hardware can be found with  
the parts that have been shipped loose. (Usually these are  
packed inside the main power lead box.)  
EXTERNAL GEAR — Remove any packaging material that  
may be on the external gear. Be sure that the breather is in  
place and free of any obstructions.  
Motor Electrical Connection — All interconnect-  
ing wiring for controls and grounding should be in strict com-  
pliance with both the (NEC) National Electrical Code and  
any local requirements.  
The main lead box furnished with the motor has been sized  
to provide adequate space for making up connections be-  
tween the motor lead cables and the incoming power cables.  
The bolted joints between the motor lead and the power cables  
must be made and insulated in a workman-like manner fol-  
lowing the best trade practices.  
Fabricated motors are provided with 2 stainless steel ground-  
ing pads drilled and tapped with the NEMA (National Elec-  
trical Manufacturers Association) 2-hole pattern (two 1⁄2-13  
tapped holes on 13⁄4 in. centers). Fan cooled cast frames are  
provided with a special grounding bolt. The motor should be  
grounded by a proper connection to the electrical system ground.  
Fig. 23 — Typical Wet-Bulb Type  
Vacuum Indicator  
Using the Economizer/Storage Vessel and Pump-  
out System — Refer to the Pumpout and Refrigerant Trans-  
fer Procedures section, page 63 for: pumpout system prepa-  
ration, refrigerant transfer, and chiller evacuation.  
45  
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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, start  
the motor and observe the direction of rotation. Allow the  
motor to achieve full speed before disconnecting it from the  
power source. Refer to Motor Pre-Start Checks (page 51)  
for information concerning initial start-up. If the resulting  
rotation is incorrect, it can be reversed by interchanging any  
2 incoming cables.  
Do not use air or oxygen as a means of pressurizing the  
chiller. Some mixtures of HFC-134a and air can un-  
dergo combustion.  
Leak Test the Chiller — Due to regulations regarding  
refrigerant emissions and the difficulties associated with sepa-  
rating contaminants from refrigerant, Carrier recommends  
the following leak test procedures. See Fig. 25 for an outline  
of the leak test procedures. Refer to Tables 5A and 5B for  
refrigerant pressure/temperature values and to the Pumpout  
and Refrigerant Transfer Procedures section, page 63.  
Motor Auxiliary Devices — Auxiliary devices such  
as resistance temperature detectors, thermocouples, thermo-  
guards, etc., generally terminate on terminal blocks located  
in the auxiliary terminal box on the motor. Other devices  
may terminate on their own enclosures elsewhere on the mo-  
tor. Such information can be obtained by referring to the cer-  
tified drawing. Information regarding terminal designations  
and the connection of auxiliary devices can be obtained from  
the auxiliary drawings referenced by the outline drawing.  
If the motor is provided with internal space heaters, to  
ensure proper heater operation, the incoming voltage sup-  
plied to them must be exactly as shown by either the name-  
plate on the motor or the outline drawing. Exercise caution  
any time contact is made with the incoming space heater cir-  
cuit, because space heater voltage is often automatically ap-  
plied when the motor is shut down.  
1. If the pressure readings are normal for the chiller  
condition:  
a. Evacuate the nitrogen holding charge from the ves-  
sels, if present.  
b. Raise the chiller pressure, if necessary, by adding re-  
frigerant until the pressure is at an equivalent satu-  
rated pressure for the surrounding temperature. Follow  
the pumpout procedures in the Pumpout and Refrig-  
erant Transfer Procedures section, page 63.  
Never charge liquid refrigerant into the chiller if the pres-  
sure in the chiller is less than 35 psig (241 kPa). Charge  
as a gas only, with the cooler and condenser pumps run-  
ning, until this pressure is reached, using PUMPDOWN/  
LOCKOUT and TERMINATE LOCKOUT mode on the  
PIC. Flashing of liquid refrigerant at low pressures can  
cause tube freeze-up and considerable damage.  
Open Oil Circuit Valves — Check that the oil filter  
isolation valves for both the compressor and external gear  
are open by removing the valve cap and checking the valve  
stem. (See Scheduled Maintenance, Changing the Oil Fil-  
ters, page 76.)  
Tighten All Gasketed Joints and Guide Vane  
Run the chiller water pumps whenever transferring, re-  
moving, or charging refrigerant.  
Shaft Packing — Gaskets and packings normally relax  
by the time the chiller arrives at the jobsite. Tighten all gas-  
keted joints and the guide vane shaft packing to ensure a  
leak-tight chiller.  
NOTE: Check the chiller cold alignment. Refer to Chiller  
Alignment in the General Maintenance section, page 71.  
c. Leak test chiller as outlined in Steps 3 - 9.  
2. If the pressure readings are abnormal for chiller  
conditions:  
a. Prepare to leak test chillers shipped with refrigerant  
(Step 2h).  
b. Check for large leaks by connecting a nitrogen bottle  
and raising the pressure to 30 psig (207 kPa). Soap  
test all joints. If the test pressure holds for 30 minutes,  
prepare to test for small leaks (Steps 2g - h).  
c. Plainly mark any leaks that are found.  
d. Release the pressure in the system.  
e. Repair all leaks.  
Check Chiller Tightness — Figure 25 outlines the  
proper sequence and procedures for leak testing.  
17EX chillers may be shipped with the refrigerant con-  
tained in the economizer/storage vessel and the oil charge  
shipped in the compressor. The cooler/condenser vessels have  
a 15 psig (103 kPa) refrigerant charge. Units may also be  
ordered with the refrigerant shipped separately, along with a  
15 psig (103 kPa) nitrogen-holding charge in each vessel.  
To determine if there are any leaks, the chiller should be  
charged with refrigerant. Use an electronic leak detector to  
check all flanges and solder joints after the chiller is pres-  
surized. If any leaks are detected, follow the leak test  
procedure.  
If the chiller is spring isolated, keep all springs blocked in  
both directions in order to prevent possible piping stress and  
damage during the transfer of refrigerant from vessel to ves-  
sel during the leak test process or any time refrigerant is trans-  
ferred. Adjust the springs when the refrigerant is in operat-  
ing condition and when the water circuits are full.  
f. Retest the joints that were repaired.  
g. After successfully completing the test for large leaks,  
remove as much nitrogen, air, and moisture as pos-  
sible, given the fact that small leaks may be present in  
the system. This can be accomplished by following  
the dehydration procedure, outlined in the Chiller  
Dehydration section, page 49.  
h. Slowly raise the system pressure to the equivalent satu-  
rated pressure for the surrounding temperature but no  
less than 35 psig (241 kPa) by adding HFC-134a  
refrigerant. Proceed with the test for small leaks  
(Steps 3-9).  
Refrigerant Tracer — Carrier recommends using an en-  
vironmentally acceptable refrigerant tracer for leak testing  
with an electronic detector.  
3. Check the chiller carefully with an electronic leak detec-  
tor, or soap bubble solution.  
Ultrasonic leak detectors also can be used if the chiller is  
under pressure.  
46  
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Fig. 25 — 17EX Leak Test Procedures  
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Table 5A — HFC-134a Pressure — Temperature (F)  
Table 5B — HFC-134a Pressure — Temperature (C)  
TEMPERATURE (F)  
PRESSURE (psi)  
TEMPERATURE (C)  
PRESSURE (kPa)  
0
2
4
6
8
6.50  
7.52  
-18.0  
-16.7  
-15.6  
-14.4  
-13.3  
44.8  
51.9  
59.3  
66.6  
74.4  
8.60  
9.66  
10.79  
10  
12  
14  
16  
18  
11.96  
13.17  
14.42  
15.72  
17.06  
-12.2  
-11.1  
-10.0  
-8.9  
82.5  
90.8  
99.4  
108.0  
118.0  
-7.8  
20  
22  
24  
26  
28  
18.45  
19.88  
21.37  
22.90  
24.48  
-6.7  
-5.6  
-4.4  
-3.3  
-2.2  
127.0  
137.0  
147.0  
158.0  
169.0  
30  
32  
34  
36  
38  
26.11  
27.80  
29.53  
31.32  
33.17  
-1.1  
0.0  
1.1  
2.2  
3.3  
180.0  
192.0  
204.0  
216.0  
229.0  
40  
42  
44  
46  
48  
35.08  
37.04  
39.06  
41.14  
43.28  
4.4  
5.0  
5.6  
6.1  
6.7  
242.0  
248.0  
255.0  
261.0  
269.0  
50  
52  
54  
56  
58  
45.48  
47.74  
50.07  
52.47  
54.93  
7.2  
7.8  
8.3  
8.9  
9.4  
276.0  
284.0  
290.0  
298.0  
305.0  
60  
62  
64  
66  
68  
57.46  
60.06  
62.73  
65.47  
68.29  
10.0  
11.1  
12.2  
13.3  
14.4  
314.0  
329.0  
345.0  
362.0  
379.0  
70  
72  
74  
76  
78  
71.18  
74.14  
77.18  
80.30  
83.49  
15.6  
16.7  
17.8  
18.9  
20.0  
396.0  
414.0  
433.0  
451.0  
471.0  
80  
82  
84  
86  
88  
86.17  
90.13  
93.57  
97.09  
100.70  
21.1  
22.2  
23.3  
24.4  
25.6  
491.0  
511.0  
532.0  
554.0  
576.0  
90  
92  
94  
96  
98  
104.40  
108.18  
112.06  
116.02  
120.08  
26.7  
27.8  
28.9  
30.0  
31.1  
598.0  
621.0  
645.0  
669.0  
694.0  
100  
102  
104  
106  
108  
124.23  
128.47  
132.81  
137.25  
141.79  
32.2  
33.3  
34.4  
35.6  
36.7  
720.0  
746.0  
773.0  
800.0  
828.0  
110  
112  
114  
116  
118  
146.43  
151.17  
156.01  
160.96  
166.01  
37.8  
38.9  
40.0  
41.1  
42.2  
857.0  
886.0  
916.0  
946.0  
978.0  
120  
122  
124  
126  
128  
171.17  
176.45  
181.83  
187.32  
192.93  
43.3  
44.4  
45.6  
46.7  
47.8  
1010.0  
1042.0  
1076.0  
1110.0  
1145.0  
130  
132  
134  
136  
138  
140  
198.66  
204.50  
210.47  
216.55  
222.76  
229.09  
48.9  
50.0  
51.1  
52.2  
53.3  
54.4  
55.6  
56.7  
57.8  
58.9  
60.0  
1180.0  
1217.0  
1254.0  
1292.0  
1330.0  
1370.0  
1410.0  
1451.0  
1493.0  
1536.0  
1580.0  
48  
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4. Leak Determination — If an electronic leak detector in-  
dicates a leak, use a soap bubble solution, if possible, to  
confirm it. Total all leak rates for the entire chiller. Leak-  
age for the entire chiller at rates greater than the EPA (En-  
vironmental Protection Agency) guidelines or local codes  
must be repaired. Note the total chiller leak rate on the  
start-up report. This leak rate repair is only for new start-  
ups. See page 67 in General Maintenance section for rec-  
ommendations on checking leak rates and leak repairs for  
operating chillers.  
Do not start or megohm-test the compressor motor or  
oil pump motor, even for a rotation check, if the chiller  
is under dehydration vacuum. Insulation breakdown and  
severe damage may result.  
Dehydration is readily accomplished at room tempera-  
tures. Using a cold trap (Fig. 26) may substantially reduce  
the time required to complete the dehydration. The higher  
the room temperature, the faster dehydration takes place. At  
low room temperatures, a very deep vacuum is required for  
boiling off any moisture. If low ambient temperatures are  
involved, contact a qualified service representative for the  
dehydration techniques required.  
5. If no leak is found during the initial start-up procedures,  
complete the transfer of refrigerant gas (see Pumpout and  
Refrigerant Transfer Procedures section, page 63.)  
6. If no leak is found after a retest:  
a. Transfer the refrigerant to the economizer/storage ves-  
sel or other storage tank and perform a standing vacuum  
test as outlined in the Standing Vacuum Test section,  
this page.  
b. If the chiller fails this test, check for large leaks  
(Step 2b).  
c. Dehydrate the chiller if it passes the standing vacuum  
test. Follow the procedure in the Chiller Dehydration  
section, below. Charge chiller with refrigerant (see  
Pumpout and Refrigerant Transfer Procedures section,  
page 63).  
Perform dehydration as follows:  
1. Connect a high capacity vacuum pump (5 cfm  
[0.002 m3/s] or larger is recommended) to the refrigerant  
charging valve (Fig. 6). Tubing from the pump to the chiller  
should be as short and as large in diameter as possible to  
provide the least resistance to gas flow.  
2. Use an absolute pressure manometer or a wet bulb vacuum  
indicator to measure the vacuum. Open the shutoff valve  
to the vacuum indicator only when taking a reading. Leave  
the valve open for 3 minutes to allow the indicator vacuum  
to equalize with the chiller vacuum.  
3. Open all isolation valves (if present), if the entire chiller  
is to be dehydrated.  
4. With the chiller ambient temperature at 60 F (15.6 C) or  
higher, operate the vacuum pump until the manometer reads  
29.8 in. Hg vac, ref 30 in. bar. (0.1 psia)(–100.61 kPa) or  
a vacuum indicator reads 35 F (1.7 C). Operate the pump  
an additional 2 hours.  
7. If a leak is found, pump the refrigerant back into the  
economizer/storage vessel or other storage tank.  
8. Transfer the refrigerant until the chiller pressure is  
18 in. Hg (41 kPa absolute).  
9. Repair the leak and repeat the procedure, beginning from  
Step 2g to ensure a leak-tight repair. (If chiller is opened  
to the atmosphere for an extended period, evacuate it be-  
fore repeating the leak test.)  
Do not apply a greater vacuum than 29.82 in. Hg vac  
(757.4 mm Hg) or go below 33 F (0.56 C) on the wet  
bulb vacuum indicator. At this temperature/pressure, iso-  
lated pockets of moisture can turn into ice. The slow rate  
of evaporation (sublimation) of ice at these low temperatures/  
pressures greatly increases dehydration time.  
Standing Vacuum Test — When performing the stand-  
ing vacuum test or chiller dehydration, use a manometer or  
a wet bulb indicator. Dial gages cannot indicate the small  
amount of acceptable leakage during a short period of time.  
1. Attach an absolute pressure manometer or wet bulb in-  
dicator to the chiller.  
2. Evacuate the vessel (see Pumpout and Refrigerant Trans-  
fer Procedures section, page 63) to at least 18 in. Hg vac,  
ref 30-in. bar (41 kPa), using a vacuum pump or the pump-  
out unit.  
5. Valve off the vacuum pump, stop the pump, and record  
the instrument reading.  
6. After a 2-hour wait, take another instrument reading. If  
the reading has not changed, dehydration is complete. If  
the reading indicates a vacuum loss, repeat Steps 4 and 5.  
7. If the reading continues to change after several attempts,  
perform a leak test up to the maximum 180 psig  
(1241 kPa) pressure. Locate and repair the leak, and re-  
peat dehydration.  
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 (0.17 kPa)  
in 24 hours, the chiller is sufficiently tight.  
b. If the leakage rate exceeds 0.05 in. Hg (0.17 kPa) in  
24 hours, repressurize the vessel and test for leaks. If  
refrigerant is available in the other vessel, pressurize  
by following Steps 2-10 of Return Chiller To Normal  
Operating Conditions section, page 67. If not, use ni-  
trogen and a refrigerant tracer. Raise the vessel pres-  
sure in increments until the leak is detected. If refrig-  
erant is used, the maximum gas pressure is approximately  
70 psig (483 kPa) at normal ambient temperature.  
5. Repair the leak, retest, and proceed with dehydration.  
Chiller Dehydration — Dehydration is recommended  
if the chiller has been open for a considerable period of time,  
if the chiller is known to contain moisture, or if there has  
been a complete loss of chiller holding charge or refrigerant  
pressure.  
Fig. 26 — Dehydration Cold Trap  
49  
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6. Check that all electrical equipment and controls are prop-  
erly grounded in accordance with job drawings, certi-  
fied drawings, and all applicable electrical codes.  
7. Make sure that the customer’s contractor has verified  
the proper operation of the pumps, cooling tower fans,  
and associated auxiliary equipment. This includes en-  
suring that motors are properly lubricated, have proper  
electrical supply, and have proper rotation.  
Inspect Water 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, with no stress on  
the waterbox nozzles and covers. Water flows through the  
cooler and condenser must meet job requirements. Measure  
the pressure drop across the cooler and condenser.  
8. Tighten all wiring connections to the plugs on the SMM,  
8-input, and PSIO modules.  
9. Ensure that the voltage selector switch inside the power  
panel is switched to the incoming voltage rating, 115 v.  
The 230 v alternative is not used.  
10. On chillers with free-standing starters, inspect the power  
panel to ensure that the contractor has fed the wires into  
the bottom of the panel. Wiring into the top of the panel  
can cause debris to fall into the contactors. Clean and  
inspect the contactors if this has occurred.  
Water must be within design limits, clean, and treated  
to ensure proper chiller performance and reduce the po-  
tential of tube damage due to corrosion, scaling, or ero-  
sion. Carrier assumes no responsibility for chiller dam-  
age resulting from untreated or improperly treated  
water.  
Check Optional Pumpout Compressor Water Pip-  
ing — If the optional pumpout system is installed, check  
to ensure that the pumpout condenser water has been piped  
in. Check for field-supplied shutoff valves and controls as  
specified in the job data. Check for refrigerant leaks on field-  
installed piping.  
Voltage to terminals LL1 and LL2 comes from a con-  
trol transformer in a starter built to Carrier specifica-  
tions. Do not connect an outside source of control power  
to the compressor motor starter (terminals LL1 and LL2).  
An outside power source will produce dangerous volt-  
age at the line side of the starter, because supplying volt-  
age at the transformer secondary terminals produces in-  
put level voltage at the transformer primary terminals.  
Check Relief Devices — Be sure that relief devices  
have been piped to the outdoors in compliance with the lat-  
est edition of ANSI/ASHRAE (American National Stan-  
dards Institute/American Society of Heating, Refrigeration,  
and Air Conditioning Engineers) Standard 15 and applicable  
local safety codes. Piping connections must allow for access  
to the valve mechanism for periodic inspection and leak  
testing.  
CHECK INSULATION RESISTANCE — Before applying  
operating voltage to the motor, whether for checking rota-  
tion direction or for actual operation, measure the resistance  
of the stator winding insulation.  
The test voltage, based on the motor operating voltage, is  
as follows:  
Relief valves are set to relieve at the 225 psig (1551 kPa)  
chiller design pressure.  
Operating Voltage  
DC Test Voltage  
Inspect Wiring  
0- 900  
901- 7000  
7001-14500  
500  
1000  
2500  
Do not check voltage supply without proper equipment  
and precautions. Serious injury may result. Follow power  
company recommendations.  
This is particularly important if the motor may have been  
exposed to excessive dampness either during transit or while  
in storage. A ‘‘megger’’ type instrument can be used to mea-  
sure the insulation resistance. The test voltage should be ap-  
plied between the entire winding (all winding leads connected  
together) and ground for approximately one minute with the  
winding at ambient temperature. The recommended mini-  
mum insulation resistance is determined as follows:  
Do not apply any kind of test voltage, including to check  
compressor oil pump even for a rotation check, if the  
chiller is under a dehydration vacuum. Insulation break-  
down and serious damage may result.  
RM =  
Where  
RM =  
KV + 1  
1. Examine wiring for conformance to job wiring dia-  
grams and to all applicable electrical codes.  
2. Compare the ampere rating on the starter nameplate with  
the compressor nameplate. The overload trip amps must  
be 108% to 120% of the rated load amps.  
3. The starter for a centrifugal compressor motor must con-  
tain the components and terminals required for PIC re-  
frigeration control. Check the certified drawings.  
4. Check the voltage to the following components and com-  
pare to the nameplate values: compressor and gear oil  
pump contactors, pumpout compressor starter, and power  
panel.  
Recommended minimum insulation resis-  
tance in megohms at 104° F (40° C) of the  
entire winding.  
KV =  
Rated motor terminal to terminal voltage in  
kilovolts (1000 volts = 1 KV).  
On a new winding, where the contaminant-causing low  
insulation resistance is generally moisture, drying the wind-  
ing through the proper application of heat normally in-  
creases the insulation resistance to an acceptable level.  
The following methods are acceptable for applying heat to  
a winding:  
5. Be sure that fused disconnects or circuit breakers have  
been supplied for the compressor and gear oil pumps,  
power panel, and pumpout unit.  
1. If the motor is equipped with space heaters, energize the  
heaters to heat the winding.  
50  
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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 half of the applied current. If the motor has 6 leads  
(3 mains and 3 neutrals), the 3 phases should be con-  
nected into one series circuit.  
3. Heated air can be blown either directly into the motor or  
into a temporary enclosure surrounding the motor. The  
source of heated air should preferably be electrical vs.  
fueled (such as kerosene), since a malfunction of the fuel  
burner could result in carbon entering the motor. Exer-  
cise caution when heating the motor with any source of  
heat other than self-contained space heaters. Raise the wind-  
ing temperature at a gradual rate to allow any entrapped  
moisture to vaporize and escape without rupturing the in-  
sulation. The entire heating cycle should extend over 15  
to 20 hours.  
External Gear Pre-Start Checks  
There are 2 service valves on the external gear oil lines.  
See Fig. 27. Open both valves before starting the chiller.  
External gears are shipped without oil. Before start-up,  
the gear must be filled with the proper type and amount  
of oil.  
Before starting the external gear, check for any signs of  
mechanical damage, such as damaged piping or accessories.  
Then, follow the procedures listed below.  
1. Fill the gear and auxiliary sump (if applicable) with oil  
to the level indicated next to the sight glass. Fill the gear  
to the proper level as follows. Make sure all external pip-  
ing, gear oil cooler, and pumps are filled before confirm-  
ing the final oil level. Fill to the oil level indicated next  
to the glass sight gage.  
Insulation resistance measurements can be made while the  
winding is being heated. However, they must be corrected to  
104 F (40 C) for evaluation since the actual insulation re-  
sistance decreases with increasing temperature. For a new  
winding, the insulation resistance approximately halves for  
each 18° F (10° C) increase in insulation temperature above  
the dew point.  
Add oil through the gear inspection cover. The inspection  
cover must be removed in order to add oil. Take care to  
seal the cover when it is replaced.  
Never attempt to add or replace oil while the ex-  
ternal gear is running unless a vertical sight glass is  
in use and the running oil level has been established  
and marked on the sight glass. Do not fill beyond  
the indicated oil level. Excess lubrication increases  
the churning effect and may result in overheating and  
subsequent thinning of oil and possible damage to  
the rotating components.  
Motor Pre-Start Checks — To prevent damage to the  
motor, the following steps must be taken before 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. Use a rust and oxidation in-  
hibited, turbine grade oil. The viscosity of the oil must be  
32 ISO (150 SSU) at 100 F (37.7 C). Oil capacity in each  
of the two bearings is 0.6 gal. (2.3 L) per bearing. Use of  
Carrier Oil Specification PP16-0 is approved, Carrier Part  
No. PP23BZ091 (Mobil DTE Light or Texaco Regal  
R+O32).  
3. If possible, the shaft should be turned over by hand to  
ensure that there is free rotation. On sleeve bearing mo-  
tors, the shaft should be moved to both extremes of its  
end play while it is being rotated, and the oil rings should  
be viewed through the viewing ports in the top of the bear-  
ing housing to verify free ring rotation.  
2. The viscosity of the oil must be 68 ISO. Use of Carrier  
oil, specification PP16-2 is approved (Mobil DTE Heavy  
Medium or Texaco Regal UR & 068; Carrier Part No.  
PP23BB005).  
3. Check that all electrical connections have been made and  
are in working order. Check that all accessories are prop-  
erly mounted.  
4. Turn the gear shafts by hand with a spanner wrench to  
confirm that there are no obstructions to rotation.  
5. Check that all couplings are properly aligned, mounted,  
and keyed on the shaft extension.  
4. On fan-cooled motors, the area around the external fan  
inlet should be checked for loose debris that could be drawn  
into the fan during operation.  
6. Check that the inspection cover is securely fastened. See  
Table 7 for recommended torque values.  
5. All external, factory-made, bolted joints should be checked  
for any looseness that may have occurred in transit. Refer  
to Table 6 for recommended bolt torques.  
7. For units operating in cold ambient temperatures, op-  
tional heaters must be turned on and the oil temperature  
must be allowed to rise to at least 60 F (16 C) before  
start-up.  
8. Start the chiller under as light a load as possible. Check  
for oil leaks, unusual sounds, excessive vibration, and ex-  
cessive heat. If an operating problem develops, shut down  
immediately and correct the problem before restarting.  
Table 6 — Recommended Motor Fastener  
Tightening Torques  
1
3
1
5
3
7
Bolt size  
Grade  
⁄
4
؆
5⁄16؆  
⁄
8؆  
⁄
2؆  
⁄
8؆  
⁄4؆  
⁄8  
؆
1؆ 11⁄3  
؆
11⁄2  
؆
SAE GR 5  
12 31 63 115 180 275 550  
Ft-lbs  
3.5  
7
960  
Torque*  
.
N m  
4.7 9.5 16 42 85 156 244 373 746 1302  
Bolt size M4 M6 M8 M10 M12 M10 M12 M16  
Grade  
Ft-lbs  
DIN 8.8  
15  
DIN 12.9  
92  
2
8
35  
47  
65  
88  
45  
61  
225  
305  
Torque*  
.
N m  
2.7 11  
20  
125  
*Torque values based upon dry friction.  
51  
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Fig. 27 — External Gear Lubrication System  
52  
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Table 7 — Recommended Compressor and  
External Gear Fastener Tightening Torques  
Check Starter  
FASTENER  
DIAMETER (in.)  
TORQUE*  
•
Lb.-Ft. (N m)  
BE AWARE that certain automatic start arrangements  
can engage the starter. Open the disconnect ahead of  
the starter in addition to shutting off the chiller and pump.  
UNC  
Minimum  
Maximum  
1
⁄
4
7
14  
(9.5)  
(19.0)  
9
17  
(12.2)  
(23.1)  
5⁄16  
3
⁄
8
25  
(33.9)  
31  
(42.0)  
7⁄16  
1
40  
(54.2)  
(81.4)  
50  
75  
108  
150  
266  
429  
643  
(67.8)  
Use the instruction and service manual supplied by the  
starter manufacturer to verify that the starter has been in-  
stalled correctly.  
⁄
2
60  
(101.7)  
(137.0)  
(203.4)  
(360.7)  
(581.7)  
(871.9)  
9⁄16  
5
87  
(118.0)  
(162.7)  
(288.8)  
(465.1)  
(698.3)  
(861.1)  
⁄
⁄
⁄
8
4
8
120  
213  
343  
515  
635  
3
7
1
11⁄8  
11⁄4  
13⁄8  
11⁄2  
13⁄4  
2
793 (1075.3)  
1120 (1518.7)  
1468 (1990.6)  
1950 (2644.2)  
2286 (3099.8)  
3437 (4660.6)  
5027 (6816.6)  
6875 (9322.5)  
9323 (12,642.0)  
The main disconnect on the starter front panel may not  
deenergize all internal circuits. Open all internal and re-  
mote disconnects before servicing the starter.  
896 (1215.0)  
1175 (1593.3)  
1560 (2115.4)  
1828 (2478.8)  
2750 (3729.0)  
4022 (5453.8)  
5500 (7458.6)  
7456 (10,110.3)  
Whenever a starter safety trip device activates, wait at least  
30 seconds before resetting the safety. The microprocessor  
maintains its output to the 1CR relay for 10 seconds after  
starter safety shutdown to determine the fault mode of  
failure.  
21⁄4  
21⁄2  
23⁄4  
*Dry fastener.  
NOTE: The torque values listed are to be used for end covers, seal  
cages, shaft guards, inspection covers, and housing split line bolts,  
unless otherwise specified on the drawing or assembly instructions.  
MECHANICAL STARTERS  
1. Check all field wiring connections for tightness, clear-  
ance from moving parts, and correct connection.  
Carrier Comfort Network Interface — The Carrier  
Comfort Network (CCN) communication bus wiring is sup-  
plied and installed by the electrical contractor. It consists of  
shielded, 3-conductor cable with drain wire.  
The system elements are connected to the communication  
bus in a daisy chain arrangement. The positive pin of each  
system element communication connector must be wired to  
the positive pins of the system element on either side of it;  
the negative pins must be wired to the negative pins; the sig-  
nal ground pins must be wired to signal ground pins.  
To attach the CCN communication bus wiring, refer to  
the certified drawings and wiring diagrams. The wire is in-  
serted into the CCN communications plug (COMM1) on the  
PSIO module. This plug also is referred to as J5.  
NOTE: Conductors and drain wire must be 20 AWG (Ameri-  
can Wire Gage) minimum stranded, tinned copper. Indi-  
vidual conductors must be insulated with PVC, PVC/nylon,  
vinyl, Teflon, or polyethylene. An aluminum/polyester 100%  
foil shield and an outer jacket of PVC, PVC/nylon, chrome  
vinyl, or Teflon with a minimum operating temperature range  
of –20 C to 60 C is required. See table below for cables that  
meet the requirements.  
2. Check the contactor(s) to be sure they move freely. Check  
the mechanical interlock between contactors to ensure that  
the 1S and 2M contactors cannot be closed at the same  
time. Check all other electro-mechanical devices, such as  
relays and timers, for free movement. If the devices do  
not move freely, contact the starter manufacturer for re-  
placement components.  
3. Some dashpot-type magnetic overload relays must be filled  
with oil at the jobsite. If the starter is equipped with de-  
vices of this type, remove the fluid cups from these mag-  
netic overload relays. Add dashpot oil to the cups per in-  
structions supplied with the starter. The oil is usually shipped  
in a small container attached to the starter frame near the  
relays. Use only dashpot oil supplied with the starter. Do  
not substitute.  
Factory-filled dashpot overload relays need no oil at start-  
up, and solid-state overload relays do not have oil.  
4. Reapply starter control power (not main chiller power) to  
check the electrical functions. When using a reduced-  
voltage starter (such as a wye-delta starter) check the tran-  
sition timer for proper setting. The factory setting is  
30 seconds (±5 seconds), timed closing. The timer is ad-  
justable in a range between 0 and 60 seconds, and set-  
tings other than the nominal 30 seconds may be chosen  
as needed (typically 20 to 30 seconds).  
MANUFACTURER  
Alpha  
CABLE NO.  
2413 or 5463  
A22503  
American  
Belden  
When the timer has been set, check that the starter (with  
relay 1CR closed) goes through a complete and proper  
8772  
Columbia  
02525  
start cycle.  
When connecting the CCN communication bus to a sys-  
tem element, a color code system for the entire network is  
recommended to simplify installation and checkout. The fol-  
lowing color code is recommended:  
SOLID-STATE STARTERS  
The solid-state starter is at line voltage when AC power  
is connected. Pressing the Stop button does not remove  
voltage. Use caution when adjusting the potentiometers  
on the equipment.  
SIGNAL CCN BUS CONDUCTOR  
PSIO MODULE  
TYPE  
INSULATION COLOR COMM 1 PLUG (J5) PIN NO.  
+
Ground  
–
RED  
WHITE  
BLACK  
1
2
3
53  
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1. Check that all wiring connections are properly termi-  
nated to the starter.  
2. Verify that the ground wire to the starter is installed prop-  
erly and is of sufficient size.  
3. Verify that the motors are properly grounded to the starter.  
4. Check that all the relays are properly seated in their  
sockets.  
5. Verify that the proper AC input voltage is brought into  
the starter per the certified drawings.  
6. Verify that the initial factory settings (i.e., starting torque,  
ramp potentiometers, etc.) are set per the manufacturer’s  
instructions.  
Input the Design Set Points — To modify the set  
points, access the SETPOINT menu. (Press the MENU and  
SETPOINT softkeys.) From this menu, you can modify the  
base demand limit and the leaving chilled water, entering  
chilled water, and ice build set points. See Fig. 15 for the  
SETPOINT menu structure.  
The PIC can control a set point according to ether the leav-  
ing or entering chilled water temperature. To change the type  
of control, access the CONFIG screen. Scroll down to high-  
light ECW CONTROL OPTION. To control the set point ac-  
cording to the leaving chilled water, press the DISABLE  
softkey; to control the set point according to the entering  
chilled water, press the ENABLE softkey.  
Compressor Oil Charge — If oil is added, it must  
meet Carrier’s specification for centrifugal compressor use  
as described in the Scheduled Maintenance, Oil Specifica-  
tions section (page 77).  
Oil may be added through the compressor oil drain and  
charging valve (Fig. 2, Item 22) using a pump. The pump  
must be able to lift from 0 to 150 psig (0 to 1034 kPa), or  
above chiller pressure. However, an oil charging elbow on  
the seal-oil return chamber (Fig. 4, Item 3) allows oil to be  
added without pumping. The seal oil return pump automati-  
cally transfers the oil to the main oil reservoir.  
Input the Local Occupied Schedule (OCCPC01S)  
— To set up the occupied time schedule according to the  
site requirements, access the SCHEDULE screen on the LID.  
(Press the MENU and SCHEDULE softkeys.) The de-  
fault, factory-set schedule is 24 hours, occupied 7 days per  
week including holidays. For more information about how  
to set up a time schedule, see the Controls section, page 11.  
If the ice build option is being used, configure the ice build  
schedule (OCCPC02S).  
If a CCN system is being installed or if a secondary time  
schedule is required, configure the CCN occupancy sched-  
ule (OCCPC03S to OCCPC99S). This task is normally done  
using a CCN Building Supervisor terminal, but it can also  
be done at the LID. For more information on CCN func-  
tions, see 17EX CCN supplement. Also, in this manual, see  
the section on Occupancy Schedule, page 32.  
Oil should only be charged or removed when the chiller  
is shut down. Maximum oil level is the middle of the upper  
sight glass.  
Power Up the Controls and Check the Com-  
pressor Oil Heater — Be sure that an oil level is vis-  
ible in the compressor before energizing the controls. Aseparate  
disconnect energizes the oil heater and the control circuit.  
When first powered, the LID should display the default screen  
within a short period of time.  
Input Service Configurations — The following con-  
figurations are done from the SERVICE menu:  
• password  
• input time and date  
• LID configuration  
• controller identification  
• service parameters  
• equipment configuration  
• automated control test  
PASSWORD — You must enter a password whenever you  
access the SERVICE screens. The default, factory-set pass-  
word is 1 - 1 - 1 - 1. The password may be changed from the  
LID CONFIGURATION screen. To change the password:  
The oil heater is energized by powering the control cir-  
cuit. This should be done several hours before start-up to  
minimize oil-refrigerant dilution. The oil heater is con-  
trolled by the PIC and is powered through a contactor in the  
power panel. Starters contain a separate circuit breaker to  
power the heater and the control circuit. This arrangement  
allows the heater to energize when the main motor circuit  
breaker is off for service work or extended shutdowns. The  
oil heater relay status can be viewed on the STATUS02 screen  
on the LID. Oil sump temperature can be viewed on the LID  
default screen.  
1. Press the MENU and SERVICE softkeys. Enter your  
password and highlight LID CONFIGURATION. Press  
the SELECT softkey. Only the last 5 entries on the LID  
SOFTWARE VERSION — The software version is always  
labeled on the PSIO module and on the back side  
of the LID module. The software number also appears on  
both the CONTROLLER IDENTIFICATION and LID CON-  
FIGURATION tables. See Fig. 15.  
CONFIGURATION screen can be changed: BUS #,  
ADDRESS #, BAUD RATE, US IMP/METRIC, and  
PASSWORD.  
2. Use the ENTER softkey to scroll to PASSWORD. The  
Set Up Chiller Control Configuration  
first digit of the password is highlighted on the LID screen.  
3. To change the digit, press the INCREASE or  
DECREASE softkey. When you see the digit you want,  
Do not operate the chiller before the control configu-  
rations have been checked and a Control Test has been  
satisfactorily completed. Protection by safety controls  
cannot be assumed until all control configurations have  
been confirmed.  
press the ENTER softkey.  
4. The next digit is highlighted. Change it and the third and  
fourth digits in the same way you changed the first.  
As you configure the 17EX chiller, write down all con-  
figuration settings. A log, such as the one shown on pages  
CL-1 to CL-12, is a convenient way to list configuration  
values.  
54  
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5. After the last digit is changed, the LID goes to the  
Modify Minimum and Maximum Load Points (⌬T1/P1;  
⌬ T2/P2) If Necessary —These pairs of chiller load points,  
located on the SERVICE1 table, determine when to limit guide  
vane travel or to open the hot gas bypass valve when surge  
prevention is needed. These points should be set based on  
individual chiller operating conditions.  
BUS # parameter. Press the EXIT softkey to leave the  
screen, record your password change, and return to the  
SERVICE menu.  
If, after configuring a value for these points, surge pre-  
vention is operating too soon or too late for conditions, these  
parameters should be changed by the operator.  
Example of configuration:  
Chiller operating parameters:  
Refrigerant used: HFC-134a  
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 you install and  
download a new PSIO module.  
Estimated Minimum Load Conditions:  
44 F (6.7 C) LCW  
45.5 F (7.5 C) ECW  
43 F (6.1 C) Suction Temperature  
70 F (21.1 C) Condensing Temperature  
Estimated Maximum Load Conditions:  
44 F (6.7 C) LCW  
54 F (12.2 C) ECW  
42 F (5.6 C) Suction Temperature  
98 F (36.7 C) Condensing Temperature  
INPUT TIME AND DATE — Access the Time and Date  
table on the SERVICE menu. Input the present time of day,  
date, and day of the week. HOLIDAY TODAY should only  
be configured to YES if the present day is a holiday.  
CHANGE THE LID CONFIGURATION IF NECESSARY  
— From the LID CONFIGURATION screen, the LID CCN  
address, units (English or SI), and password can be changed.  
If there is more than one chiller at the jobsite, change the  
LID address on each chiller so that each chiller has its own  
address. Note and record the new address. Change the screen  
to SI units as required, and change the password if desired.  
To Change the LID Display From English to Metric Units  
— By default, the LID displays information in English units.  
To change to metric units:  
1. Press the MENU and SERVICE softkeys. Enter your pass-  
word and highlight LID CONFIGURATION. Press the  
SELECT softkey.  
Calculate Maximum Load — To calculate the maximum load  
points, use the design load condition data. If the chiller full  
load cooler temperature difference is more than 15° F  
(8.3° C), estimate the refrigerant suction and condensing tem-  
peratures at this difference. Use the proper saturated pres-  
sure and temperature for the particular refrigerant used.  
Suction Temperature:  
2. Use the ENTER softkey to scroll to US IMP/METRIC.  
3. Press the softkeys that correspond to the units you want  
displayed on the LID (e.g., US or METRIC ).  
42 F (5.6 C) = 37 psig (255 kPa) saturated  
refrigerant pressure (HFC-134a)  
Condensing Temperature:  
98 F (36.7 C) = 120 psig (1827 kPa) saturated  
MODIFY CONTROLLER IDENTIFICATION IF NECES-  
SARY — The PSIO module address can be changed from  
the CONTROLLER IDENTIFICATION screen. If there is  
more than one chiller at the site, change the controller ad-  
dress for each chiller. Write the new address on the PSIO  
module for future reference.  
refrigerant pressure (HFC-134a)  
Maximum Load ⌬T2:  
54 – 44 = 10° F (12.2 – 6.7 = 5.5° C)  
Maximum Load ⌬P2:  
120 – 37 = 83 psid (827 – 255 = 572 kPad)  
To avoid unnecessary surge prevention, add about 10 psid  
INPUT EQUIPMENT SERVICE PARAMETERS IF NEC-  
ESSARY — The EQUIPMENT SERVICE table has 3 screens:  
SERVICE1, SERVICE2, and SERVICE3.  
(70 kPad) to ⌬P2 from these conditions:  
⌬T2 = 10° F (5.5° C)  
⌬P2 = 93 psid (642 kPad)  
Configure SERVICE1 Table — Access the SERVICE1 table  
to modify or view the following:  
Calculate Minimum Load — To calculate the minimum load  
conditions, estimate the temperature difference that the cooler  
will have at 20% load, then estimate what the suction and  
condensing temperatures will be at this point. Use the proper  
saturated pressure and temperature for the particular refrig-  
erant used.  
Chilled Medium  
Water or Brine?  
Brine Refrigerant Trippoint Usually 3° F (1.7° C) below design  
refrigerant temperature  
Is HGBP installed?  
Surge Limiting or  
Hot Gas Bypass Option  
Minimum Load Points  
(T1/P1)  
Per job data — See Modify Load  
Points section  
Suction Temperature:  
43 F (6.1 C) = 38 psig (262 kPa) saturated  
Full Load Points  
(T2/P2)  
Per job data — See Modify Load  
Points section  
refrigerant pressure (HFC-134a)  
Motor Rated Load Amps  
Per job data  
Condensing Temperature:  
Motor Rated Line Voltage Per job data  
70 F (21.1 C) = 71 psig (490 kPa) saturated  
Motor Rated Line kW  
Line Frequency  
Per job data (if kW meter installed)  
50 or 60 Hz  
refrigerant pressure (HFC-134a)  
Compressor Starter Type  
Stop-to-Start Timer  
Reduced voltage or full?  
Minimum Load ⌬T1 (at 20% Load):  
2° F (1.1° C)  
Follow motor vendor recommenda-  
tion for time between starts. See  
certified prints for correct value.  
Minimum Load ⌬P1:  
71 – 38 = 33 psid (490 – 262 = 228 kPad)  
NOTE: Other values are left at the default values. These may be changed  
by the operator as required. SERVICE2 and SERVICE3 tables can  
be modified by the owner/operator as required.  
Again, to avoid unnecessary surge prevention, add 20 psid  
(140 kPad) at ⌬P1 from these conditions:  
⌬T1 = 2° F (1.1° C)  
⌬P1 = 53 psid (368 kPad)  
55  
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If surge prevention occurs too soon or too late, make the  
following adjustments:  
PERFORM AN AUTOMATED CONTROL TEST — Check  
the safety controls status by performing an automated con-  
trols test. Access the CONTROL TEST table from the SERV-  
ICE menu. This table has the following screens:  
SURGE PREVENTION SURGE PREVENTION  
LOAD  
OCCURS TOO SOON OCCURS TOO LATE  
At low loads  
Increase P1 by  
Decrease P1 by  
Automated Test  
As described above, a complete  
control test.  
Checks all PSIO thermistors only.  
Checks all options board thermistors.  
Checks all transducers.  
Checks the guide vane operation.  
Checks operation of pump output;  
either all pumps can be  
activated or individual pumps.  
Also tests the associated input  
such as flow or pressure.  
Activates all on/off outputs, all  
at once or individually.  
Pumpdown prevents the low  
refrigerant alarm during  
evacuation so refrigerant  
can be removed from the unit,  
locks the compressor off. and  
starts the water pumps.  
(Ͻ50%)  
10 psid (70 kPad)  
10 psid (70 kPad)  
At high loads  
Increase P2 by  
10 psid (70 kPad)  
Decrease P2 by  
10 psid (70 kPad)  
PSIO Thermistors  
Options Thermistors  
Transducers  
Guide Vane Actuator  
Pumps  
(Ͼ50%)  
MODIFY EQUIPMENT CONFIGURATION IF NECES-  
SARY — The EQUIPMENT CONFIGURATION table has  
a number of screens to select, view, and/or modify. See  
Fig. 16 for the menu structure of this table. Carrier provides  
certified drawings that have the configuration values re-  
quired for specific jobsites. Modify these values only if  
requested.  
Discrete Outputs  
CONFIG Screen Modifications — Change the values on this  
screen according to your job data. See certified drawings for  
the correct values. Modifications can include:  
Pumpdown/Lockout  
• chilled water reset  
• entering chilled water control (Enable/Disable)  
• 4 to 20 mA demand limit  
Terminate Lockout  
Charges refrigerant and enables  
the chiller to run after pumpdown  
lockout.  
• auto. restart option (Enable/Disable)  
• remote contact option (Enable/Disable)  
FX Gear Oil Pump I/O Activates external gear main oil pump  
LEAD/LAG Screen Modifications — Change the values on  
this screen according to your job data. See certified draw-  
ings for specific values. Modifications can include:  
and auxiliary oil pump (if supplied).  
Automated Test — Before running this test, be sure that the  
compressor is in the OFF mode and the 24-v input to the  
SMM is in range (per line voltage percent on STATUS01  
screen). Put the compressor in OFF mode by pressing the  
STOP pushbutton on the LID.  
The automated test starts with a check of the PSIO ther-  
mistors and proceeds through the rest of the tests listed in  
the table below. The test not only checks readings, such as  
temperature and pressure readings, but also lets the operator  
know if certain devices, such as pumps or relays, are on or  
off and if all outputs and inputs are functioning. It also sets  
the refrigerant type.  
As each test is executed, the LID display shows which  
test is running as well as other pertinent data. At the end of  
each test, the LID displays, OK TO CONTINUE? If a test  
indicates a problem, error, or device malfunction, the op-  
erator can choose to address the problem as the test is being  
done or note the problem and proceed to the next test.  
• lead/lag selection  
• load balance option  
• common sensor option  
• lag start/stop timers  
• standby chiller option  
Owner-Modified CCN Tables— The following tables are de-  
scribed for reference only. For detailed information on CCN  
operations, consult the CCN supplement for your chiller.  
• OCCDEFCS Screen Modifications — This table contains  
the local and CCN time schedules, which can be modified  
here, or on the SCHEDULE screen as described  
previously.  
• HOLIDEF Screen Modifications — This table configures  
the days of the year that holidays are in effect. See the  
holiday paragraphs in the Controls section for more  
details.  
• BRODEF Screen Modifications — This table defines the  
outside-air temperature sensor and humidity sensor if one  
is to be installed. It also defines the start and end of day-  
light savings time. Enter the dates for the start and end of  
daylight savings, if required for your location. BRODEF  
also activates the Broadcast function, which enables the  
holiday periods defined on the LID to take effect.  
• Other Tables — The ALARMDEF, CONS-DEF, RUNT-  
DEF, and WSMALMDF screens contain information for  
use with a CCN system. See the applicable CCN manual  
for more information on these screens. These screens can  
only be changed from a CCN Building Supervisor  
terminal.  
NOTE: If during the control test the guide vanes do not open,  
check to see that the low pressure alarm is not active. (This  
causes the guide vanes to close.)  
NOTE: The oil pump test will not energize the oil pump if  
cooler pressure is below –5 psig (–35 kPa).  
When the test is finished, or the EXIT softkey is pressed,  
the test stops and the CONTROL TEST menu is displayed.  
If a specific automated test procedure is not completed, ac-  
cess that test by scrolling to it and selecting it to test the  
function when ready. The CONTROL TEST menu is de-  
scribed in more detail in Table 8.  
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 the LINE VOLTAGE: ACTUAL parameter and then  
increasing or decreasing the value so that the value appear-  
ing on the LID is calibrated to match the incoming power  
voltage reading. Voltage can be calibrated only between 90  
and 100% of the rated line voltage.  
Check Pumpout System Controls and Optional  
Pumpout Compressor — The pumpout system con-  
trols include an on/off switch, a 3-amp fuse, the compressor  
overloads, an internal thermostat, a compressor contactor, and  
a refrigerant high pressure cutout. The high pressure cutout  
is factory set to open at 161 psig (1110 kPa) and reset at  
130 psig (896 kPa). Check that the water-cooled condenser  
has been connected. Loosen the compressor holddown bolts  
to allow free spring travel. Open the compressor suction and  
discharge service valves. Check that oil is visible in the com-  
pressor sight glass. Add oil if necessary.  
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Table 8 — Control Test Menu Functions  
See the Pumpout and Refrigerant Transfer Procedures  
(page 63) and Pumpout System Maintenance sections  
(page 83) for details on transferring refrigerant, oil specifi-  
cations, etc.  
TESTS TO BE  
PERFORMED  
DEVICES TESTED  
1. Automated Tests*  
Operates the second through seventh  
tests  
High Altitude Locations — Because the chiller is ini-  
tially calibrated at sea level, it is necessary to recalibrate the  
pressure transducers if the chiller is to be operated at a high  
altitude location. Please see the calibration procedure in the  
Troubleshooting Guide section.  
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  
Charge Refrigerant into Chiller  
3. Options Thermistors Common chilled water supply sensor  
Common chilled water return sensor  
Remote reset sensor  
Temperature sensor — Spare 1  
The 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  
directions.  
Spare 2  
Spare 3  
Spare 4  
Spare 5  
Spare 6  
Spare 7  
Spare 8  
Spare 9  
The 17EX chiller may have the refrigerant already charged  
in the economizer/storage vessels. If chiller is not shipped  
fully charged, refrigerant is shipped separately to conform  
with transportation regulations. The 17EX may be ordered  
with a nitrogen holding charge of 15 psig (103 kPa). Evacu-  
ate the entire chiller, and charge chiller from refrigerant  
cylinders.  
The full refrigerant charge on the 17EX will vary with  
chiller components and design conditions as indicated on the  
job data specifications. An approximate charge may be found  
in Physical Data and Wiring Schematics section, page 99.  
The full chiller charge is printed on the chiller identification  
label.  
4. Transducers  
Evaporator pressure  
Condenser pressure  
Oil pressure differential†  
5. Guide Vane Actuator Open  
Close  
6. Pumps  
All pumps or individual pumps may be  
activated:  
Oil pump — Confirm pressure  
Chilled water pump — Confirm flow  
Condenser water pump — Confirm flow  
Auxiliary oil pump — confirm  
pressure†  
7. Discrete Outputs  
All outputs or individual outputs may  
be energized:  
Always operate the condenser and chilled water pumps  
during charging operations to prevent water in heat ex-  
changer tubes from freezing.  
Hot gas bypass relay  
Oil heater relay  
Motor cooling relay  
Tower fan relay  
Alarm relay  
Shunt trip relay  
Use the CONTROLS TEST terminate lockout function to  
monitor conditions and start the pumps.  
8. Pumpdown/Lockout When using pumpdown/lockout,  
observe freeze up precautions when  
removing charge.  
If the chiller has been shipped with a holding charge, add  
refrigerant through the refrigerant charging valve (Fig. 6) or  
to the pumpout charging connection. First evacuate the ni-  
trogen holding charge from the vessels. Charge the refrig-  
erant as a gas until the system pressure exceeds 35 psig  
(141 kPa). After the chiller is beyond this pressure, the re-  
frigerant should be charged as a liquid until all the recom-  
mended refrigerant charge has been added.  
Instructs operator as to which valves  
to close and when.  
Starts chilled water and condenser wa-  
ter pumps and confirms flows.  
Monitors — Evaporator pressure  
Condenser pressure  
Evaporator temperature  
during pumpout  
TRIMMING REFRIGERANT CHARGE — The 17EX is  
shipped with the correct charge for the design duty of the  
chiller. Trimming the charge can best be accomplished when  
the chiller is operating at design load. To trim, check the  
temperature difference between the leaving chilled water tem-  
perature and the cooler refrigerant temperature at full load  
design conditions. If necessary, add or remove refrigerant to  
bring the temperature difference to design conditions or a  
minimum differential.  
procedures  
Turns pumps off after pumpdown.  
Locks out compressor.  
9. Terminate Lockout  
Starts pumps and monitors flows.  
Instructs operator as to which valves  
to open and when.  
Monitors — Evaporator pressure  
Condenser pressure  
Evaporator temperature  
during charging process  
Terminates compressor lockout.  
10. FX Gear Oil  
Pump I/O  
Activates gear main oil pump; con-  
firms pressure.  
INITIAL START-UP  
Activates optional gear auxiliary pump;  
confirms pressure.  
Preparation — Before starting the chiller, check that the:  
1. Power is on to the main starter, oil pump relay (which  
energizes both the compressor and gear oil pumps), tower  
fan starter, oil heater relay, and the chiller control  
center.  
*During any of the tests that are not automated, an out-of-range read-  
ing will have an asterisk (*) next to the reading and a message will  
be displayed.  
†On open-drive chillers, differential pressure is the only oil pressure  
displayed.  
2. Cooling tower water is at proper level and at or below  
design entering temperature.  
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3. Chiller is charged with refrigerant and all refrigerant and  
all oil valves are in their proper operating position.  
5. Check the main contactor for proper operation.  
6. The PIC will activate an alarm for motor amps not sensed.  
Reset this alarm and continue with the initial start-up.  
4. Gear oil, compressor oil, and motor bearing oil are at the  
proper levels in the reservoir sight glasses.  
Check Motor Rotation  
INITIAL MOTOR START-UP  
5. Compressor oil reservoir temperature is above 140 F  
(60 C) or refrigerant temperature plus 50° F (28° C).  
Initial Uncoupled Start-Up — The initial start-up of the mo-  
tor should be made with the motor uncoupled. Verify that oil  
has been added to each bearing housing to the correct level.  
6. Valves in the evaporator and condenser water circuits are  
open.  
NOTE: If the water pumps are not automatic, make sure  
water is circulating properly.  
1. If the motor is equipped with unidirectional fans (refer to  
the certified drawing) and verification of rotation direc-  
tion is required, do the following:  
7. Check the starter to be sure it is ready to start and that all  
safety circuits have been reset. Be sure to keep the starter  
door closed.  
a. Start the motor and observe the rotation direction. See  
Fig. 28.  
b. Allow the motor to achieve full speed before discon-  
necting it from the power source.  
c. If the rotation direction must be changed, refer to the  
Before Initial Start-Up, Motor Electrical Connection  
section, page 45. Otherwise, the motor can be re-  
started immediately after it has coasted to a stop.  
Do not permit water or brine that is warmer than 110 F  
(43 C) to flow through the cooler or condenser. Refrig-  
erant overpressure may discharge through the relief de-  
vices and result in the loss of refrigerant charge.  
8. To prevent accidental start-ups, the CHILLER START/  
STOP parameter is set to STOP at the factory. Access the  
STATUS01 screen and scroll to the CHILLER START/  
STOP parameter. Press the RELEASE softkey to enable  
the chiller to start.  
Manual Operation of the Guide Vanes — Manual  
operation of the guide vanes helps to establish a steady mo-  
tor current when calibrating the motor amps value.  
To manually operate the guide vanes, override the target  
guide vane position (TARGET GUIDE VANE POS param-  
eter on the STATUS01 screen). Manual control is also in-  
dicated on the default screen on the run status line.  
1. Access the STATUS01 screen and look at the TARGET  
GUIDE VANE POS parameter. (Refer to Fig. 13). If the  
compressor is off, the value reads zero.  
2. Move the highlight bar to the TARGET GUIDE VANE  
POS parameter and press the SELECT softkey.  
Fig. 28 — Correct Motor Rotation  
3. Press ENTER to override the automatic target. The screen  
2. After the initial start-up, monitor the bearing tempera-  
tures closely. Verify the free rotation of the oil rings on  
the sleeve bearings by observing them through the view-  
ing port in the top of the housing. The rate of rise in bear-  
ing temperature is more indicative of impending trouble  
than the actual temperature. If the rate of rise in tempera-  
ture is excessive or if the motor exhibits excessive vi-  
bration or noise, shut it down immediately and conduct a  
thorough investigation to find the cause before operating  
the motor again. If the bearing temperatures rise and mo-  
tor operation appears to be normal, continue operating  
the motor until the bearing temperatures stabilize.  
reads a value of zero. The word SUPVSR! flashes to in-  
dicate that manual control is in effect. The default screen  
also indicates that the guide vanes are in manual control.  
4. To return the guide vanes to automatic mode, press the  
SELECT softkey; then press the RELEASE softkey.  
After a few seconds, the word SUPVSR! disappears.  
Dry Run to Test Start-Up Sequence  
1. Disengage the main motor disconnect on the starter front  
panel. This should only disconnect the motor power. Power  
to the controls, oil pumps, 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 corner should read, MANUALLY  
The recommended limits on bearing temperature rise over  
ambient temperature are listed below:  
Temperature Rise  
Sleeve Bearing Temperature  
Over Ambient  
STOPPED. Press the CCN or LOCAL softkey to start.  
As Measured By  
Temperature  
If MANUALLY STOPPED is not on the default screen  
access the SCHEDULE screen and override the schedule  
or change the occupied time. Then, press the LOCAL  
A permanently installed  
72° F (40° C)  
detector  
A temporary detector on top  
of the bearing sleeve near the  
oil ring  
softkey to begin the start-up sequence.  
63° F (35° C)  
3. Check that the chilled water and condenser water pumps  
have energized.  
4. Check that the oil pumps have started and have pressur-  
ized the lubrication system. After the oil pumps have run  
about 15 seconds, the starter energizes and goes through  
its start-up sequence.  
NOTE: When operating flood-lubricated sleeve bearings,  
the bearing temperature must not be allowed to exceed  
185 F (85 C) total temperature.  
58  
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Note that each start time an induction motor starts, it is  
subjected to the full inrush of current along with heating of  
the stator and rotor windings. Each acceleration and re-  
peated start can produce more heat than is produced and dis-  
sipated by the motor under full load. The starting duty for  
which the motor is designed is shown on a nameplate mounted  
on the motor. Do not exceed this amount if long motor life  
is expected.  
Abnormally low terminal voltage, excessive load torque,  
and/or excessive load inertia during motor start-up can cause  
lengthened acceleration times during which rotor ventilation  
is reduced. This can cause rotor damage or can lead to short-  
ened rotor life.  
The temperature rating of the motor is shown on the main  
nameplate as a temperature rise above an ambient tempera-  
ture. If there is a service factor, it is also shown. If the motor  
temperature switch opens, investigate the situation before at-  
tempting to continue operation.  
If the motor is a TEWAC (Totally Enclosed Water-to-Air  
Cooled) design, the maximum inlet water temperature and  
the water flow rate or gpm (gallons per minute) at the air  
cooler must be as shown on the certified drawing. Other-  
wise, the discharge air temperature from the cooler (actually  
the ambient air for the motor as shown by the main name-  
plate) could be too high for the motor to properly cool.  
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 rate of bearing temperature rise is less than  
2° F (1.1° C) per half-hour, the bearing temperature  
is considered to be stabilized.  
If the total bearing temperature exceeds 195 F  
(91 C), the motor should be shut down immediately.  
3. Any abnormal noise or vibration should be immediately  
investigated and corrected. Increased vibration (with the  
motor uncoupled from its load) can indicate a change in  
balance due to a mechanical failure or loose rotor part, a  
stator winding problem, a foundation problem, or a change  
in motor alignment.  
Disc Coupling Installation and Alignment — Be-  
fore installing the disc coupling, inspect it for any signs of  
damage during shipment. Check that all parts are available,  
as ordered. Cradle or support the coupling components dur-  
ing handling to avoid damage. Wrap the components for pro-  
tection. Keep flanges free of nicks and burrs. Read all the  
instructions and review this procedure before beginning the  
actual installation. Some steps apply only to certain types of  
couplings (e.g., high speed coupling).  
4. Verify that the magnetic center indicator aligns with the  
shaft.  
Initial Coupled Start-Up — After initial uncoupled start-up,  
take the following steps to ensure safe coupled operation:  
1. Follow the procedure stated in the General Maintenance,  
Chiller Alignment section to align the motor to the driven  
chiller.  
2. Prepare the coupling for operation according to the Disc  
Coupling Installation andAlignment instructions, this page.  
Note any match marks on the couplings and assemble ac-  
cordingly. For sleeve bearing motors, verify that the cor-  
rect limited end float coupling has been installed. The end  
float limits can be found on the certified drawing.  
Use only the bolts and nuts supplied by the coupling  
manufacturer.  
3. Ensure that all personnel are at a safe distance from ro-  
tating parts. Start the motor in accordance with instruc-  
tions supplied with the motor control.  
1. Installing the Coupling Hubs (Keyed Mounting).  
a. Check the hub bore and shaft for nicks and burrs; dress  
if necessary.  
4. If the motor rotor fails to start turning in a second or two,  
shut off the power supply immediately. This can result  
from:  
b. For taper bores, check the fit of the bore to the shaft.  
c. Fit keys precisely to the keyways in the shaft and hub.  
Each key should have a tight fit on the sides with a  
slight clearance on top. To maintain dynamic balance,  
the keys should fill the keyways exactly and not be too  
short or too long.  
a. too low a voltage at the motor terminals  
b. the load is too much for the rotor to accelerate  
c. the load is frozen up mechanically  
d. all required electrical connections are not made  
e. single-phase power has been applied  
f. any combination of the above.  
d. Clean the hub bore and shaft.  
e. Heat the hub to expand the bore. DO NOT allow the  
hub temperature to exceed 600 F (300 C). DO NOT  
apply an open flame to any part of the coupling. Car-  
rier recommends using an oven to heat the hub.  
Investigate thoroughly and take corrective action before  
attempting a restart.  
5. Carefully observe the vibration of the bearing housing and  
any abnormal noise generator. Note that coupled motor  
vibration may not be the same as uncoupled vibration  
amounts. If coupled vibration is excessive, recheck the  
mounting and alignment.  
6. Carefully observe the bearing temperature rise and the  
movement of the oil ring.  
To avoid the risk of explosion, fire, or damage to  
the coupling and equipment and/or injury to per-  
sonnel, do not use an open flame or oil bath to ex-  
pand the hub. If heat is used at anytime for instal-  
lation, DO NOT ALLOW the hub temperature to  
exceed 600 F (300 C).  
If the bearing temperatures rise and motor operation ap-  
pears normal, operation should continue until the bearing  
temperatures stabilize.  
f. Place the hub in the proper position on the shaft. Hold  
the hub in place as it cools. For tapered bores, verify  
the hub advance and install the shaft retaining nut.  
7. If possible, check the motor line currents for balance.  
59  
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2. Offset 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 the reference diameter.  
3. Final Assembly — The terminology used to identify parts  
and the order of assembly may differ from one coupling  
style to another. Follow the instructions that apply to the  
coupling you are installing.  
e. Place the disc pack nuts on the bolts. Tighten all nuts  
evenly and in an alternating fashion to the torque speci-  
fied in Table 9.  
Low Speed Coupling (Close-Coupled Style):  
a. Place the disc pack and adapter in position over the  
hub body diameter. The reamed holes in the adapter  
should be aligned with the large clearance holes in the  
hub as in the upper portion of Fig. 30. The large clear-  
ance holes in the adapter should be aligned with the  
reamed holes in the hub as shown in the lower portion  
of Fig. 30.  
High Speed Coupling (Spacer Style):  
DISK  
PACK  
ADAPTERS  
a. Place the spacer in position between the hub flanges.  
Place the disc packs between the flanges on both ends  
of the coupling.  
SPACING  
WASHER  
DISC  
PACK  
BOLT  
b. Insert the disc pack bolt into the reamed hole of the  
hub and through the disc pack bushing. See Fig. 29  
(compressor side). The flat of the bolt head acts as a  
bolt lock with the hub body. Make sure the spacer is  
properly indexed for the large flange holes to receive  
the bolt ends. Tap the bolts lightly for full engagement  
until the heads rest on the hub flange surface. Repeat  
for the other bolts.  
DISC  
PACK  
NUT  
HUB  
MOTOR  
SIDE  
GEAR  
SIDE  
c. Place the spacing washers and disc pack nuts on the  
bolts. Tighten all nuts evenly and in an alternating fash-  
ion to the torque specified in Table 9.  
SHAFT  
PREPARATION  
(0.19 IN.  
[4.83 mm]  
d. Place a spacing washer over a disc pack bolt. Insert  
the bolt through the large hub flange hole and the disc  
pack bushing. See Fig. 29 (gear side). Tap the bolts  
lightly for full engagement. Repeat for the other bolts.  
FLANGE BOLT  
FLANGE NUT  
NOTE: Motor rotor should be positioned on the mechanical center  
and gear shaft should be on geometric center when coupling is po-  
sitioned as shown.  
Fig. 30 — Typical Low Speed Coupling for 17FX  
Compressor/External Gear (Close Coupled)  
b. Loosely assemble the disc pack bolts, nuts, and spac-  
ing washers. Half of the bolts attach the adapter to the  
disc pack. Refer to Fig. 30. These bolts are inter-  
spersed by bolts that attach the disc pack to the hub.  
c. Tighten all nuts evenly and in an alternating fashion to  
the torque specified in Table 9.  
d. Bring the driving and driven equipment together until  
the flanges of the adapters just begin to touch. If there  
is a gap between the flanges at any point, adjust the  
axial position of the equipment until the amount of  
gap is cut in half to minimize the amount of axial mis-  
alignment.  
e. Rotate the equipment shafts until the flange holes are  
aligned.  
f. Bolt the flanges together using the flange bolts and nuts.  
See Fig. 30. Tighten all flange nuts evenly and in a  
alternating fashion to the torque specified in Table 10.  
NOTES:  
1. Compressor shaft should be in the thrust position and gear shaft  
should be on geometric center when coupling is positioned as shown.  
2. The taper is 1 inch per side for the driven unit bore (compressor  
side).  
Fig. 29 — Typical High Speed Coupling for 17FX  
Compressor/External Gear (Spacer Style)  
Table 10 — Flange Nut Tightening Torques  
(Low Speed Couplings Only)  
Table 9 — Disc Pack Nut Tightening Torques  
Torque  
(dry)  
Torque  
(lubed)*  
N-M  
Coupling  
Size  
Nut  
Tightening  
ft-lb  
Tightening  
ft-lb  
Torque  
(dry)  
Torque  
(lubed)*  
N-M  
Coupling  
Size  
Nut  
Tightening  
ft-lb  
Tightening  
ft-lb  
Size  
N-m  
Size  
N-m  
204  
304  
1/2-20  
5/8-18  
55  
75  
45  
90  
60  
304  
5/16-24  
20  
27  
18  
24  
115  
155  
120  
*Light machine oil.  
*Light machine oil.  
60  
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4. General Recommendations  
3. When a steady motor current value in the desired range  
is reached, compare the MOTOR RATED LOAD AMPS  
value on the STATUS01 screen to the actual amps shown  
on the ammeter on the starter. Adjust the amps value on  
the STATUS01 screen to match the actual value on the  
a. Both disc couplings are designed to operate for ex-  
tended periods without the need for lubrication or main-  
tenance. Visual inspection of the disc packs is enough  
to assess the operational condition of the coupling.  
starter ammeter, if there is a difference. Highlight the amps  
value; then, press the SELECT softkey. Press the  
INCREASE or DECREASE softkey to bring the value  
b. All machinery should be monitored to detect unusual  
or changing vibration levels. Both couplings, under nor-  
mal operating conditions, have no wearing parts and  
retain their original balance quality. Any change in vi-  
bration levels should be investigated, and remedial ac-  
tion should be taken immediately.  
to that indicated on the ammeter. Press ENTER when  
the values are equal.  
4. Release the target guide vane position to automatic mode.  
See the section on Manual Operation of the Guide Vanes,  
page 58, for instructions on how to do this.  
5. Removal  
a. Disassemble the coupling in the reverse order of the  
applicable assembly procedure.  
To Prevent Accidental Start-Up — The PIC can be  
configured so that starting the unit is more difficult than just  
b. Keyed couplings — Install a puller on the hub using  
the tapped holes provided in the hub face. Pull the hub  
off the shaft.  
pressing the LOCAL or CCN softkeys during chiller serv-  
ice or whenever necessary. Access the STATUS01  
screen, and highlight the CHILLER START/STOP param-  
IMPORTANT INFORMATION:  
eter. Override the value by pressing SELECT and then the  
STOP and ENTER softkeys. The word SUPVSR ap-  
pears. When attempting to restart the chiller, remember to  
release the override. Access the STATUS01 screen and high-  
light CHILLER START/STOP. The 3 softkeys represent 3  
choices:  
• START - forces the chiller ON.  
• STOP - forces the chiller OFF  
• RELEASE - puts the chiller under remote or schedule  
control.  
To return the chiller to normal control, press the  
RELEASE softkey; then, press the ENTER softkey. For  
Coupling guards protect personnel. ALL COUPLINGS  
MUST BE COVERED WITH A GUARD ACCORD-  
ING TO OSHA (Occupational Safety and Health  
Administration) REQUIREMENTS. Safety guards are  
included with this product and must be installed at all  
times.  
1. Recheck alignment after all foundation bolts and me-  
chanical connections are tightened.  
2. Make sure all fasteners are properly installed and  
tightened.  
3. Take the time to double check your work.  
additional information, see Local Start-Up, page 43.  
The default LID screen message indicates which com-  
mand is in effect.  
4. Only authorized disc coupling manufacturer replacement  
parts are to be used.  
5. Call the disc coupling manufacturer for any clarifications  
or questions.  
Hot Alignment Check — The operating temperatures  
of various chiller components can affect the alignment of the  
compressor with the heat exchangers, gear, and driver. When  
all the chiller components have reached operating tempera-  
ture (after running at nearly full load for 4 to 8 hours), make  
a hot alignment check.  
The self-locking nuts on the disc pack bolts should  
be replaced after they have been assembled and re-  
moved from the bolts 5 times.  
Using proper equipment and procedures, make the hot align-  
ment check with either assembled or disassembled cou-  
plings. The procedures are detailed in the General Mainte-  
nance section, page 67.  
A clamping tool, Part No. TS-170, is available for check-  
ing alignment without disassembling the couplings. Check  
with your local Carrier representative.  
Check Oil Pressure and Compressor Stop  
1. When the motor is up to full speed, note the differential  
compressor oil pressure reading on the LID default screen.  
It should be between 18 and 30 psid (124 to 206 kPad).  
2. Press the Stop button and listen for any unusual sounds  
from the compressor as it coasts to a stop.  
Calibrate Motor Current Demand Setting  
1. Make sure that the MOTOR RATED LOAD AMPS pa-  
rameter on the SERVICE1 screen has been configured.  
Place an ammeter on the line that passes through the mo-  
tor load current transfer on the motor side of the power  
factor correction capacitors (if provided).  
2. Start the compressor and establish a steady motor current  
value between 70% and 100% RLA by manually over-  
riding the guide vane target value (TARGET GUIDE VANE  
POS parameter on the STATUS01 screen) and setting the  
chilled water set point (WATER/BRINE SETPOINT on the  
STATUS01 screen) to a low value. Do not exceed 105%  
of the nameplate RLA (rated load amps).  
Never operate the compressor or drive with the cou-  
pling guards removed. Serious injury can result from  
contact with rotating equipment.  
Doweling — The size, quantity, and location of dowels  
vary considerably with type and arrangement of gear and  
drive. Check your job data for specific doweling instruc-  
tions. Typical doweling practices are described in the Gen-  
eral Maintenance section.  
Check Chiller Operating Condition — Check to  
be sure that chiller temperatures, pressures, water flows, and  
oil and refrigerant levels indicate that the system is func-  
tioning properly.  
61  
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2. On the LID default screen, press the LOCAL or  
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 and tubes, and vents and drains.  
CCN softkey to start the system. If the schedule indi-  
cates that the current time and date have been established  
as a run time and date (a condition referred to as ‘‘oc-  
cupied’’) and the 3- and 15-minute start timers have ex-  
pired, the start sequence will start. Follow the procedure  
described in the Start-Up/Shutdown/Recycle Sequence  
section, page 43.  
ECONOMIZER/STORAGE VESSEL — Float chambers, re-  
lief valves, charging valve.  
Check the Running System — After the compres-  
sor starts, monitor the LID display and observe the param-  
eters for normal operating conditions:  
1. The oil reservoir temperature should be above 150 F  
(66 C) or refrigerant temperature plus 70° F (38° C) dur-  
ing shutdown and above 125 F (52 C) during compressor  
operation.  
2. The bearing oil temperature (BEARING TEMPERA-  
TURE on the STATUS01 screen) should be 150 to 200 F  
(65 to 93 C). If the bearing oil temperature reads more  
than 210 F (99 C) with the oil pump running, stop the  
chiller and determine the cause of the high temperature.  
Do not restart the chiller until corrected.  
3. The oil level should be visible in the lower sight glass  
when the compressor is running. At shutdown, oil level  
should be halfway in the lower sight glass.  
PUMPOUT SYSTEM — Transfer valves and pumpout sys-  
tem, refrigerant charging and pumpdown procedure, lubri-  
cation, and relief devices.  
COMPRESSOR ASSEMBLY — Guide vane actuator, trans-  
mission, oil cooling system, temperature and pressure sen-  
sors, oil sight glasses, integral oil pump, isolatable oil filter,  
extra oil and motor temperature sensors, synthetic oil, and  
compressor serviceability.  
COMPRESSOR LUBRICATION SYSTEM — Oil pump,  
cooler filter, oil heater, oil charge and specification, operat-  
ing and shutdown oil level, temperature and pressure, oil charg-  
ing connections, and seal oil chambers.  
EXTERNAL GEAR LUBRICATION SYSTEM — Oil pump,  
cooler/filter, oil charge and specification, operating and shut-  
down oil level, temperature and pressure, and oil charging  
procedures.  
4. The oil pressure should be between 18 and 30 psid (124  
to 207 kPad) differential, as seen on the LID default  
screen. Typically the reading will be 18 to 25 psid (124  
to 172 kPad) at initial start-up.  
CONTROL SYSTEM — CCN and local start, reset, menu,  
softkey functions, LID operation, occupancy schedule, set  
points, safety controls, and auxiliary and optional controls.  
5. The condenser pressure and temperature vary with the chiller  
design conditions. Typically the pressure ranges between  
57 and 135 psig (393 and 930 kPa) with a corresponding  
temperature range of 60 to 105 F (15 to 41 C) for R-134a.  
The condenser entering water temperature should be con-  
trolled to remain below the specified design entering wa-  
ter 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.  
6. Cooler pressure and temperature also vary with the de-  
sign conditions. Typical cooler pressure ranges between  
30 and 40 psig (206 and 275 kPa); temperature ranges  
between 34 and 45 F (1 and 8 C) for R-134a).  
AUXILIARY EQUIPMENT — Starters and disconnects, sepa-  
rate electrical sources, pumps, and cooling tower.  
CHILLER CYCLES — Refrigerant, motor cooling, lubri-  
cation, and oil reclaim cycles.  
MAINTENANCE — Scheduled, routine, and extended shut-  
downs; importance of a log sheet, water treatment, tube clean-  
ing, and maintaining a leak-free chiller.  
SAFETY DEVICES AND PROCEDURES — Electrical dis-  
connects, relief device inspection, and handling refrigerant.  
CHECK OPERATOR KNOWLEDGE — Start, stop, and shut-  
down procedures, safety and operating controls, refrigerant  
and oil charging, and job safety.  
7. The compressor may operate at full capacity for a short  
time after the pulldown ramping has ended, even though  
the building load is small. The active electrical demand  
setting can be overridden to limit the compressor IkW, or  
the pulldown rate can be decreased to avoid a high de-  
mand charge for the short period of high demand  
operation. Pulldown rate can be based on kW rate (LOAD  
PULLDOWN %/MIN) or temperature rate (TEMP PULL-  
DOWN DEG/MIN) These parameters may be accessed  
on the CONFIG screen (see Table 2, Example 6).  
THIS MANUAL — Be sure that the operator is familiar with  
the contents of this manual.  
OPERATING INSTRUCTIONS  
Operator Duties  
1. Become familiar with chiller refrigeration and related equip-  
ment before operating the chiller.  
2. Prepare the system for start-up, start and stop the chiller,  
and place the system in a shutdown condition.  
3. Maintain a log of operating conditions and document any  
abnormal readings.  
8. The oil pump is energized once every 12 hours during  
shutdown periods to ensure that the shaft seal is filled  
with oil.  
4. Inspect the equipment, make routine adjustments, and per-  
form a controls test. Maintain the proper oil and refrig-  
erant levels.  
5. Protect the system from damage during shutdown  
periods.  
Stopping the Chiller  
1. The occupancy schedule starts and stops the chiller au-  
tomatically once the time schedule is set up.  
2. Pressing the Stop button on the control panel for one sec-  
ond causes the alarm light to blink once to confirm that  
the button has been pressed. Then, the compressor fol-  
lows the normal shutdown sequence as described in the  
Controls section. The chiller is now in the OFF mode.  
6. Maintain the set point, time schedules, and other PIC  
functions.  
Prepare the Chiller for Start-Up — Follow the steps  
described in the Initial Start-Up section, page 57.  
The chiller will not restart until the CCN or  
LOCAL softkey is pressed.  
Starting the Chiller  
1. Start the water pumps if they are not automatic.  
62  
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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 restart the chiller  
until the problem is diagnosed and corrected.  
guide vane control and close the guide vanes, if necessary.  
For descriptions of capacity overrides and set points, see the  
Controls section.  
Refrigeration Log — A refrigeration log, such as the  
one shown in Fig. 31, is a convenient way to track routine  
inspection and maintenance and provides a continuous record  
of chiller performance. It is an aid in scheduling routine main-  
tenance and in diagnosing chiller problems.  
Keep a record of the chiller pressures, temperatures, and  
liquid levels on a log similar to Fig. 31. It is possible to au-  
tomatically record PIC data by using CCN devices such as  
the Data Collection module and a Building Supervisor ter-  
minal. Contact your Carrier representative for more  
information.  
After Limited Shutdown — No special preparations  
should be necessary. Follow the regular preliminary checks  
and starting procedures. Control power must be maintained  
in order to keep the oil temperature hot and all control safe-  
ties operational. The oil pump operates occasionally to keep  
the contact seal filled with oil to prevent refrigerant loss.  
Extended Shutdown — The refrigerant should be trans-  
ferred into the economizer/storage vessel (see Pumpout and  
Refrigerant Transfer Procedures, this page) in order to re-  
duce chiller pressure and the possibility of leaks. Maintain  
a holding charge of 5 to 10 lbs (2.27 to 4.5 kg) of refrigerant  
within the cooler/condenser/compressor sections, to prevent  
air from leaking into the chiller.  
If freezing temperatures are likely to occur in the chiller  
area, drain the chilled water, condenser water, and the pump-  
out condenser water circuits to avoid freeze-up. Keep the  
waterbox drains open.  
PUMPOUT AND REFRIGERANT TRANSFER  
PROCEDURES  
Preparation — The 17EX may come equipped with  
an optional pumpout compressor. The refrigerant can be pumped  
for service work to either the cooler/condenser/compressor  
sections or the economizer/storage vessel by using the pump-  
out system. The following procedures describe how to trans-  
fer refrigerant from vessel to vessel and perform chiller  
evacuations.  
Leave the oil charge in the chiller with the oil heater and  
controls energized to maintain the minimum oil reservoir  
temperature.  
To prevent tube freeze-up, always be sure that the con-  
denser and cooler water pumps are operating whenever  
charging, transferring, or removing refrigerant from the  
chiller.  
After Extended Shutdown — Be sure that the water  
system drains are closed. It may be advisable to flush the  
water circuits to remove any soft rust which may have formed.  
This is a good time to brush the tubes if necessary.  
Check the cooler pressure on the LID default screen, and  
compare it to the original holding charge that was left in the  
chiller. If (after adjusting for ambient temperature changes)  
any loss in pressure is indicated, check for refrigerant leaks.  
See the Check Chiller Tightness section, page 46.  
If the chiller water pumps are controlled by the PIC, ac-  
cess the CONTROL TEST table on the LID and use the  
PUMPDOWN/LOCKOUT screen or TERMINATE LOCK-  
OUT screen to perform the functions described below. If the  
chiller water pumps are not controlled by the PIC, they must  
be turned on and off manually.  
Recharge the chiller by transferring refrigerant from  
the economizer/storage vessel. Follow the Pumpout and Re-  
frigerant Transfer Procedures section, this page. Observe  
freeze-up precautions.  
Carefully make all regular preliminary and running sys-  
tem checks. Perform a controls test before start-up. If the  
compressor oil level appears abnormally high, the oil may  
have absorbed refrigerant. Make sure that the oil tempera-  
ture is above 150 F (66 C) or above the cooler refrigerant  
temperature plus 70° F (39° C).  
When performing pumpout, do not leave the compres-  
sor unattended for long periods of time or loss of com-  
pressor oil may result. Periodically check oil level.  
Operating the Optional Pumpout Compressor  
1. Be sure that the suction and the discharge service valves  
on the optional pumpout compressor are open (back seated)  
during operation. Figure 32 shows the location of these  
valves (valves 2, 3, 4, 5, and 8). Rotate the valve stem  
fully counterclockwise to open. Front seating the valve  
closes the refrigerant line and opens the gage port to com-  
pressor pressure.  
2. Make sure that the compressor holddown bolts have been  
loosened to allow free spring travel.  
3. Open the refrigerant inlet valve on the pumpout compressor.  
Cold Weather Operation — When the entering con-  
denser water temperature is very low, the PIC can automati-  
cally cycle the cooling tower fans off to keep the tempera-  
ture up. Provide a way to control the condenser water  
temperature to the chiller either by arranging a tower bypass  
piping system and/or adding a tower water temperature con-  
trol system.  
4. Oil should be visible in the compressor sight glass under  
all operating conditions and during shutdown. If oil is  
low, add oil as described under Pumpout System Main-  
tenance section, page 83. The pumpout unit control wir-  
ing schematic is detailed in Fig. 33. The Optional Pump-  
out System is detailed in Fig. 34.  
Manual Guide Vane Operation — It is possible to  
operate the guide vane manually in order to check control  
operations or control the guide vanes in an emergency. This  
is done by overriding the target guide vane position. Access  
the STATUS01 screen on the LID and highlight TARGET  
GUIDE VANE POS. To control the position, enter the de-  
sired percentage of guide vane opening. Zero percent is fully  
READING REFRIGERANT PRESSURES during pumpout  
or leak testing:  
closed; 100% is fully open. To release the guide vanes to  
automatic operation, press the RELEASE softkey.  
1. The LID display on the chiller control center is suitable  
for determining refrigerant-side pressures and low (soft)  
vacuum. To measure evacuation or dehydration pres-  
sures, use a quality vacuum indicator or manometer to  
ensure the desired range and accuracy. This can be placed  
on the Schrader connections on each vessel by removing  
the pressure transducer.  
NOTE: Manual guide vane control allows the operator to  
manipulate the guide vane position and override the pull-  
down rate during start-up. However, motor current above the  
electrical demand setting, capacity overrides, and chilled wa-  
ter temperature below the control point will override manual  
63  
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REFRIGERATION LOG CARRIER 17EX EXTERNALLY GEARED CENTRIFUGAL CHILLER  
Chiller Serial No.  
Plant  
Chiller Model No.  
Refrigerant Type  
REC. 1  
REC. 2  
REC. 3  
REC. 4  
REC. 5  
REC. 6  
REC. 7  
REC. 8  
REC. 9  
TIME  
DATE  
OPERATOR INITIALS  
COOLER  
Refrigerant  
Pressure  
Temperature  
Water  
Pressure In  
Pressure Out  
Pressure GPM  
Temperature In  
Temperature Out  
CONDENSER  
Refrigerant  
Pressure  
Temperature  
Water  
Pressure In  
Pressure Out  
Pressure GPM  
Temperature In  
Temperature Out  
COMPRESSOR  
Bearing Temperature  
Oil  
Pressure Differential  
Temperature (Reservoir)  
Level  
Motor  
FLA  
Amps (or Vane Position)  
EXTERNAL GEAR  
Bearing Temperature  
Oil  
Pressure Differential  
Temperature (Reservoir)  
Level  
Motor  
FLA  
Aps (or Vane Position  
REMARKS: On an attached sheet, Indicate shutdowns on safety controls, repairs made, and oil or refrigerant added or removed. Include amounts.  
Include time, date, operator initials for each remark.  
Fig. 31 — Refrigeration Log  
64  
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NOTE: Location of pumpout compressor may vary depending on ma-  
chine arrangement.  
9
10  
CHILLER  
CHARGER VALVE  
COOLER  
ISOLATION  
VALVE  
11  
7
DRIVE END  
COMPRESSOR END  
REAR VIEW  
Fig. 32 — Pumpout Unit Location and Valve Number Locations  
65  
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COMPRESSOR MOTOR  
LEGEND  
Hz  
50  
Ph  
3
Volts  
400  
298  
230  
460  
375  
Max. RLA  
4.7  
1
2
—
Compressor Motor  
Circuit Disconnect  
Control Circuit  
3
10.9  
9.5  
—
3
Disconnect  
Contactor  
60  
3
4.7  
C
OL  
RLA  
T’stat  
—
—
—
—
Compressor Overload  
Rated Load Amps  
Internal Thermostat  
3
3.8  
Compressor Terminal  
Contactor Terminal  
Overload Terminal  
Pumpout Unit Terminal  
Fig. 33 — Pumpout Unit Wiring Schematic  
1. Isolate and push refrigerant into the economizer/storage  
vessel with the pumpout compressor.  
VENT VALVE  
a. Valve positions: (Blank spaces indicate open valves).  
VALVE  
1
2
3
4
5
6
7
8
9
10 11  
CONDITION  
C
C
C
C
C
C
VALVES  
b. Turn off the chiller water pumps and pumpout con-  
denser water.  
c. Turn on pumpout compressor to push liquid out of the  
cooler/condenser/compressor section.  
d. When all liquid has been pushed into the economizer/  
storage vessel, close the cooler isolation valve 7.  
e. Access the CONTROL TEST table on the LID. Select  
the PUMPDOWN/LOCKOUT screen. From this screen,  
turn on the chiller water pumps and view the chiller  
pressures.  
CONTROL BOX  
(WIRING BY  
VALVES  
CONTRACTOR)  
COMPRESSOR  
f. Turn off pumpout compressor.  
CONDENSER  
WATER  
CONNECTIONS  
(FIELD PIPING)  
2. Evacuate refrigerant gas from the cooler/condenser/  
compressor vessel.  
CONDENSER  
DISCHARGE VALVE  
a. Valve positions: close valves 2 and 5, open valves 3  
and 4.  
Fig. 34 — Optional Pumpout Compressor  
VALVE  
1
2
3
4
5
6
7
8
9
10 11  
CONDITION  
C
C
C
C
C
C
C
2. To 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.  
b. Turn on the pumpout condenser water.  
c. Run the pumpout compressor until the suction reaches  
15 in. Hg (50 kPa abs). Monitor pressures on the LID  
and on the refrigerant gages.  
d. Close valve 1.  
e. Turn off pumpout compressor.  
f. Close valves 3, 4, and 6. (All valves are now closed.)  
g. Turn off pumpout condenser water.  
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  
directions.  
h. Use the PUMPDOWN LOCKOUT screen on the LID  
to turn off the chiller water pumps and to lock out the  
chiller compressor from operation.  
Transferring Refrigerant into the Economizer/  
Storage Vessel — These steps describe the method of  
moving refrigerant from the cooler/condenser/compressor sec-  
tions into the economizer/storage vessel. This is normally  
done to prepare for service work on the cooler, condenser, or  
the compressor components or for long-term chiller  
shutdown.  
66  
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10. Continue to use the TERMINATE/LOCKOUT function  
on the LID to turn off water pumps and enable the com-  
pressor to operate.  
Transferring 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/  
compressor section:  
GENERAL MAINTENANCE  
Refrigerant Properties — Refrigerant HFC-134a is  
the standard refrigerant in the 17EX. At normal atmospheric  
pressure, HFC-134a boils at −14 F (−25 C) and must, there-  
fore, be kept in pressurized containers or storage tanks. The  
refrigerant is practically odorless when mixed with air. This  
refrigerant is non-combustible at atmospheric pressure. Read  
the Material Safety Data Sheet (MSDS) and the latest ASHRAE  
Safety Guide for Mechanical Refrigeration to learn more about  
safe handling of this refrigerant.  
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 chiller water pumps and pumpout condenser  
water.  
c. Turn on the pumpout compressor to push refrigerant  
out of the economizer/storage vessel.  
Refrigerant HFC-134a will dissolve oil and some non-  
metallic materials, dry the skin, and, in heavy concen-  
trations, may displace enough oxygen to cause asphyxi-  
ation. When handling this refrigerant, protect the hands  
and eyes and avoid breathing fumes.  
d. When all liquid refrigerant is out of the economizer/  
storage vessel, close the cooler isolation valve 7.  
e. Turn off the pumpout compressor.  
2. Evacuate refrigerant from the economizer/storage vessel.  
a. Access the CONTROL TEST table on the LID. Select  
the PUMPDOWN LOCKOUT screen. From this screen,  
turn on the chiller water pumps and monitor vessel  
pressures.  
Adding Refrigerant — Follow the procedures de-  
scribed in Charge Refrigerant into Chiller section, page 57.  
b. Valve positions: Close valves 3 and 4, open valves 2  
and 5.  
Use the PUMPDOWN LOCKOUT function on the CON-  
TROL TEST table to turn on the chiller water pumps  
and lock out the compressor when transferring refrig-  
erant. Liquid refrigerant may flash into a gas and cause  
possible freeze-up when the chiller pressure is below  
30 psig (207 kPa) for HFC-134a. If the water pumps are  
not controlled by the PIC, they must be controlled  
manually.  
VALVE  
1
2
3
4
5
6
7
8
9
10 11  
CONDITION  
C
C
C
C
C
C
C
c. Turn on the pumpout condenser water.  
d. Run the pumpout compressor until the suction reaches  
15 in. Hg (50 kPa abs). Monitor pressures on the LID  
and on refrigerant gages.  
e. Close valve 6.  
f. Turn off the pumpout compressor.  
Removing Refrigerant — When the optional pump-  
out system is used, the 17EX refrigerant charge may be trans-  
ferred into the economizer/storage vessel or another storage  
vessel. Follow procedures in the Pumpout and Refrigerant  
Transfer Procedures section when removing or transferring  
refrigerant.  
g. Close valves 1, 2, and 5 (all valves are now closed).  
h. Turn off the pumpout condenser water.  
i. From the CONTROL TEST table on the LID, turn off  
the chiller water pumps and lock out the chiller com-  
pressor from operation.  
Return Chiller to Normal Operating Conditions  
1. Be sure that the vessel that was opened has been evacu-  
ated and dehydrated.  
2. Access the CONTROL TEST table. From this table, se-  
lect the TERMINATE LOCKOUT function to view the  
vessel pressures and to turn on chiller water pumps.  
3. Open valves 1, 3, and 6.  
Adjusting the Refrigerant Charge — If it is nec-  
essary to add or remove refrigerant to improve chiller per-  
formance, follow the procedures under the Trimming Refrigerant  
Charge section.  
Refrigerant Leak Testing — Because HFC-134a is  
above atmospheric pressure at room temperature, leak test-  
ing can be performed with refrigerant in the chiller. Use an  
electronic detector, soap bubble solution, or ultra-sonic leak  
detector. To keep false readings to a minimum, be sure that  
the room is well ventilated and free from concentration of  
refrigerant. Before making any necessary repairs to a leak,  
transfer all refrigerant from the leaking vessel.  
VALVE  
1
2
3
4
5
6
7
8
9
10 11  
CONDITION  
C
C
C
C
C
C
C
C
4. Slowly open valve 5, gradually increasing pressure  
in the evacuated vessel to 35 psig (141 kPa)  
for HFC-134a. Feed refrigerant slowly to prevent  
freeze-up.  
5. Perform a leak test at 35 psig (141 kPa).  
6. Open valve 5 fully. Let the vessel pressures equalize.  
Leak Rate — The ASHRAE recommendation is that chill-  
ers should be immediately taken off line and repaired if the  
refrigerant leak rate for the entire chiller is more than 10%  
of the operating refrigerant charge per year.  
VALVE  
1
2
3
4
5
6
7
8
9
10 11  
Additionally, Carrier recommends that leaks totalling less  
than the above rate but more than a rate of 1 lb (0.5 kg) per  
year should be repaired during annual maintenance or when-  
ever the refrigerant is pumped over for other service work.  
CONDITION  
C
C
C
C
C
C
C
7. Open valves 9 and 10.  
8. Open valve 7 to equalize liquid refrigerant levels.  
9. Close valves 1, 3, 5, and 6.  
Test After Service, Repair, or Major Leak — If  
all refrigerant has been lost or if the chiller has been opened  
for service, the chiller or the affected vessels must be pres-  
sure and leak tested. Refer to the Leak Test Chiller section  
(page 46) to perform a leak test.  
VALVE  
1
2
3
4
5
6
7
8
9
10 11  
CONDITION  
C
C
C
C
C
C
C
C
67  
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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 tracer for leak test procedures.  
TO PRESSURIZE WITH DRY NITROGEN — Another  
method of leak testing is to pressurize with nitrogen only  
and use a soap bubble solution or an ultrasonic leak detector  
to determine if leaks are present. This should only be done  
if all refrigerant has been evacuated from the vessel.  
1. Connect a copper tube from the pressure regulator on the  
cylinder to the refrigerant charging valve. Never apply  
full cylinder pressure to the pressurizing line. Follow the  
listed sequence.  
2. Open the charging valve fully.  
3. Slowly open the cylinder regulating valve.  
Fig. 35 — Electronic Vane Actuator Linkage  
4. Observe the pressure gage on the chiller and close the  
regulating valve when the pressure reaches test level. Do  
not exceed 140 psi (965 kPa).  
5. Close the charging valve on the chiller. Remove the cop-  
per tube if no longer required.  
During shutdown, no refrigerant should be detected ex-  
cept for minute outgassing from residual oil in the seal area.  
There should be no oil seepage. If oil flow or the presence  
of refrigerant is noted while the chiller is shut down, a seal  
defect is indicated. Arrange for a seal assembly inspection  
by a qualified serviceman to determine the cause of the leak-  
age and make the necessary repairs.  
Repair the Leak, Retest, and Apply Standing  
Vacuum Test — After pressurizing the chiller, test for  
leaks with an electronic leak detector, soap bubble solution,  
or an ultrasonic leak detector. Bring the chiller back to at-  
mospheric pressure, repair any leaks found, and retest.  
After retesting and finding no leaks, apply a standing vacuum  
test, and then dehydrate the chiller. Refer to the Standing  
Vacuum Test and Chiller Dehydration in the Before Initial  
Start-Up section, page 49.  
SEAL DISASSEMBLY (Fig. 36) — Contact seal disassem-  
bly and repair should be performed only by well qualified  
compressor maintenance personnel. These disassembly in-  
structions are included only as a convenient reference for  
the authorized serviceman.  
For ease of disassembly, refer to Fig. 36 while following  
these instructions.  
1. Remove refrigerant.  
Checking Guide Vane Linkage — Refer to Fig. 35.  
2. Remove compressor shaft coupling hub and coupling spacer  
(if any).  
If slack develops in the drive chain, eliminate backlash as  
follows:  
3. The snap ring (Item 16) used for seal assembly/disassembly  
is clipped over three screws (Item 41) on the windage  
baffle (Item 7). Remove the snap ring and put it aside  
for now.  
4. Remove the screws holding the windage baffle and the  
shaft end labyrinth (Item 8).  
1. With the chiller shut down (guide vanes closed), remove  
the chain guard, loosen the actuator holddown bolts, and  
remove the chain.  
2. Loosen the vane sprocket set screw and rotate the sprocket  
wheel until the set screw clears the existing spotting hole.  
3. With the set screw still loose, replace the chain, and move  
the vane actuator to the left until all the chain slack is  
taken up.  
4. Tighten the actuator holddown bolts and retighten the set  
screw in the new position.  
5. Remove the contact sleeve key (Item 11).  
6. Using a snap ring tool, install the snap ring (Item 16) in  
the groove on the end of the contact sleeve (Item 18), as  
shown in Fig. 36.  
7. Remove the tubing between the coupling (Item 20) and  
the atmospheric oil chamber. Loosen the bolts (Item 6)  
holding the coupling guard mounting ring (Item 4) and  
the seal housing (Item 3). The spring contact sleeve  
(Item 17) will push the housing out until the snap ring  
(Item 16) contacts the seal housing (Item 3). To avoid  
binding, loosen the bolts in a circular pattern until the  
spring stops pushing out on the housing. Then, remove  
2 bolts that are 180 degrees apart. Replace them with a  
1/2-13 all-thread rod to support the housing while the  
rest of the bolts are removed.  
5. Realign the chain guard as required to clear the chain.  
Contact Seal Maintenance (Refer to Fig. 36) —  
During chiller operation, oil that lubricates the seal seeps through  
the space between the contact sleeve (Item 18) and the lock  
nut (Item 15). This oil slowly accumulates in an atmo-  
spheric oil chamber and is automatically returned to the sys-  
tem by a seal oil return pump.  
Oil should never leak around the outer diameter of the  
contact sleeve (Item 18). If oil is found in this area, O-ring  
(Item 12) should be checked and replaced.  
The oil passing through the shaft seal carries with it some  
absorbed refrigerant. As the oil reaches the atmosphere, the  
absorbed refrigerant is released from the oil as a vapor. For  
this reason, a detector will indicate the presence of a slight  
amount of refrigerant around the compressor shaft when-  
ever the chiller is running.  
8. Remove the rest of the bolts, and remove the seal  
housing.  
68  
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NOTE: Adjust shims (Item 33) to main-  
tain .525 ± .01 in. (13.3 ± .3 mm) dimen-  
sion with shaft thrust toward drive and check  
carbon for +.06 minimum travel.  
LEGEND  
1
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Lubricating Tube  
O-Ring  
2A  
2B  
3
O-Ring  
Seal Housing  
4
Coupling Guard Mounting Ring  
1
5
Plain ⁄2-in. Washer (8 Required)  
1
6
Hex Head Bolt,  
Windage Baffle  
⁄2-13 × 4 lg (8 Required)  
7
8
Shaft End Labyrinth  
1
3
9
Screw  
⁄4  
- 20 ×  
⁄
4
lg (4 Required)  
lg  
1
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
Screw, 10-24 ×  
⁄
2
Key, Contact Sleeve  
O-Ring  
Compressor Shaft  
O-Ring  
Lock Nut  
Snap Ring (Service tool only; must be removed for operation)  
Spring Contact Sleeve  
Contact Sleeve  
Outer Carbon Ring  
Coupling (Connection to atmospheric oil chamber)  
Rotating Contact Ring  
Diaphragm Retainer  
Inner Seal Retaining Screw, 10-24 × 1 lg (14 Required)  
Gasket  
Diaphragm  
Inner Carbon Ring  
Inner Seal Spring  
Inner Seal Retainer  
Seal Gland Sleeve  
Spacer  
Journal Bearing Housing  
Journal Bearing  
Inner Seal Shim  
Inner Carbon Guide Ring  
O-Ring  
Inner Carbon Key  
Screw, 10-24 × 11⁄4 lg (2 Required)  
Retaining Ring  
Seal Shoulder  
Compressor End Wall  
1
Thread Cut Screw, 8-32 ×  
⁄
4
lg (3 Required)  
Screw, 5⁄16-18 × 13⁄4 lg (2 Required)  
Fig. 36 — Contact Seal  
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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 extended.  
10. Remove Items 2B and 12 (O-rings).  
11. Slide the outer carbon ring (Item 19) off the shaft.  
12. Remove the lubricating tube (Item 1) and gasket  
(Item 24).  
13. Remove the inner carbon key (Item 36).  
3. Place the diaphragm (Item 25) over the inner seal re-  
tainer (Item 28). With the best lapped sealing face of the  
carbon away from the diaphragm and the notch for the  
key centered between two of the bolt holes in the dia-  
phragm, gently push the inner carbon ring (Item 26) into  
the inner carbon guide ring until it is tight against the  
diaphragm. Make sure that the diaphragm is not wrinkled  
or folded between the carbon and the retainer. Place the  
spring (Item 27) over the back of the guide ring. Place  
this assembly into the seal, and make sure that the car-  
bon face can travel a minimum of 0.06 inches (1.5 mm)  
in each direction from the outside edge of the seal gland  
sleeve (Item 29).  
4. Install the O-ring (Item 14). Slide the rotating contact  
ring (Item 21) into position against the seal gland sleeve.  
Install the lock nut (Item 15) and tighten it with a  
spanner.  
5. Gently rotate the inner seal assembly to line up the bolt  
holes in the diaphragm with the bolt holes in the inner  
seal retainer (Item 28). Place the diaphragm retainer over  
the diaphragm with the beveled side toward the dia-  
phragm. Install the 14 one-inch long screws (Item 23),  
leaving the top 2 holes on either side of the notch in the  
carbon open. Tighten to 2 ft-lb.  
6. Install the inner carbon key (Item 36) using the 1-1/4-in.  
screws (Item 37). Tighten to 2 ft-lb.  
7. Install the lubricating tube (Item 1) and gasket (Item 24).  
8. Lightly coat the outer carbon ring with compressor oil.  
Then, slide the outer carbon ring (Item 19) into position  
against the rotating contact ring.  
14. Remove the inner seal retaining screws (Item 23) and  
the diaphragm retainer (Item 22).  
15. Using a spanner wrench, loosen the lock nut (Item 15).  
The lock nut has a right-hand thread. Remove the lock  
nut. The inner seal spring (Item 27) may push the con-  
tact ring part way out as the lock nut is loosened.  
16. Carefully slide the rotating contact ring (Item 21) off  
the shaft. The ring slips onto the shaft with a very close  
tolerance and is prone to sticking. Slide it slowly to avoid  
a tight jam. To release, tap gently with a SOFT hammer.  
17. Remove O-ring (Item 14). This O-ring will be crushed  
into a triangular shape. Since it is not an ordinary O-ring  
gland, this is normal. Always replace with a new O-ring.  
18. The seal gland sleeve (Item 29) can be removed, but it  
is generally not necessary to do so. If the seal gland is  
removed, make sure it is reinstalled with the bevel (that  
contains the O-ring) facing outward.  
9. Install O-ring (Item 12).  
19. The inner carbon ring (Item 26), the diaphragm  
(Item 25), the inner carbon guide ring (Item 34), and the  
inner seal spring (Item 27) can be removed as an as-  
sembly. The carbon ring is held to the guide ring by raised  
barbs on the guide ring. Carefully pull the carbon ring  
from the guide ring. The diaphragm can now be re-  
moved from the guide ring. Inspect the diaphragm for  
wear.  
20. To remove the inner seal retainer (Item 28) and O-ring  
(Item 35), use 4 screws (Item 23) in the 4 threaded holes  
spaced evenly around the seal retainer to jack the part  
out of position.  
If the inner seal shims are damaged, carefully measure them  
so that a shim package of the same thickness can be in-  
stalled. The thickness of the shim package should not be changed  
unless the compressor shaft and/or thrust bearing are re-  
placed. Replacing either of these items could affect the float  
of the inner seal. This float is adjusted by varying the thick-  
ness of the shim pack.  
10. Place the contact sleeve (Item 18) face down on a clean,  
lint-free cloth on a smooth, hard, work surface, and place  
the contact sleeve spring over the sleeve. Lightly coat  
the outside surface of the contact sleeve with compres-  
sor oil. While one person places the seal housing  
(Item 3) over the contact sleeve and presses the spring  
down, another person must install the snap ring  
(Item 16) in the groove around the small end of the con-  
tact sleeve. Once the snap ring is firmly seated in the  
groove, slowly let the seal housing rise until the snap  
ring rests against the housing. Rotate the sleeve in the  
seal housing until the key slot in the sleeve is in line  
with the bolt hole for the contact sleeve key (Item 11).  
11. Install the O-ring (Item 2B) into its groove, and place  
the seal housing into position on the compressor. Guide  
rods can help accomplish this task. Place the coupling  
guard mounting ring (Item 4) over the seal housing, and  
fasten both in place with 8 hex-head bolts (Item 6). Draw  
in the housing against the seal spring by tightening the  
bolts in steps in a crisscross pattern to draw the housing  
evenly.  
12. Once the bolts have been tightened, remove the snap  
ring from the contact sleeve, and set it aside.  
13. Install the contact sleeve key (Item 11).  
14. Install the shaft end labyrinth (Item 8) and the windage  
baffle using screws (Item 9). The split lines of the laby-  
rinth and windage baffle should be located 90 degrees  
apart.  
15. Mount the snap ring (Item 16) on the screws (Item 41)  
near the inside surface of the windage baffle.  
This completes the disassembly of the seal.  
Clean all parts to be reused with solvent, coat with oil and  
place in a protected area until needed.  
SEAL REASSEMBLY (Fig. 36) — Be sure that all gasket  
surfaces are clean and that all holes, including oil holes, are  
properly aligned between the gasket and mating flange. Coat  
the gasket with oil-graphite mixture to prevent sticking.  
1. Install the inner seal retainer (Item 28) and O-ring  
(Item 35). Then, remove the bolts to allow installation  
of the inner seal assembly.  
2. Replace the seal gland sleeve (Item 29) if it has been  
removed. Make sure that the plain side is against the  
shaft shoulder and that the beveled side is facing  
outward.  
16. Reconnect the tubing from the atmospheric oil chamber  
to the coupling (Item 20).  
The reassembly of the seal is complete.  
Run the oil pump to fill the seal, and rotate the shaft sev-  
eral times by hand before leak testing.  
NOTE: If the seal gland sleeve is oriented improperly,  
refrigerant will leak under the contact ring.  
70  
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Low Speed Coupling Alignment  
Chiller Alignment  
1. Move the motor with the coupling attached into align-  
ment with the gear coupling. The motor must be in its  
mechanical center and the gear must be centered between  
the thrust collars when determining the motor position  
relative to the gear. Adjust the jackscrews to reach close  
alignment. Follow the procedure outlined in the Correct-  
ing Angular Misalignment and Correcting Parallel Mis-  
alignment sections.  
2. Maintain the exact hub-to-hub distance as specified in  
Fig. 30.  
3. Where the shaft ends are very close, a taper gage may be  
used in place of the dial indicator.  
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’s guidelines when  
using the laser technique.  
Where job conditions such as close-spaced shafts prohibit  
the use of dial indicators for coupling face readings, other  
instruments such as a taper gage may be used. The same pro-  
cedures described for the dial indicator may be used with the  
taper gage.  
Shafts placed in perfect alignment in the non-operating  
(cold) condition will always move out of alignment to some  
extent as the chiller warms to operating temperature. In most  
cases, this shaft misalignment is acceptable for the initial run-in  
period before hot check and alignment can be made (see Hot  
Alignment Check section, page 61).  
4. Get the motor alignment as close as possible by using the  
jackscrew adjustment.  
NOTE: The drive shaft end-float at final drive position must  
not allow the coupling hub faces to make contact or the cou-  
pling shroud to bind.  
PRELIMINARY ALIGNMENT — To get within dial indi-  
cator range, roughly align the equipment as shown in Fig. 37  
and as described below.  
Place a straight edge across the OD of one coupling to the  
OD of the other. Measure the gap between the straight edge  
and the OD of the second coupling with a feeler gage. Then,  
by adding or removing shims at each corner, raise or lower  
the equipment by the measured amount.  
NOTE: The physical configuration of the 17FX compressor  
makes the oil sump temperature a more significant factor in  
alignment than the suction and discharge temperatures. There-  
fore, warm the sump oil to operating temperature (approxi-  
mately 140 F [60 C]), if possible, before beginning align-  
ment procedures.  
General  
1. Final shaft alignment must be within .002-in. (.05-mm)  
TIR (Total Indicated Runout) in parallel. Angular align-  
ment must be within 0.00033 inches per inch of traverse  
(0.00033 mm per mm of traverse) across the coupling face  
(or inch of indicator swing diameter) at operating tem-  
peratures. For example, if a bracket-mounted indicator  
moves through a 10-in. diameter circle when measuring  
angular misalignment, the allowable dial movement will  
be 10 times 0.00033 for a total of 0.0033 in. (0.0033 mm).  
In a similar manner, measure the shaft offset from side to  
side and jack the equipment over as required to correct.  
2. Follow the alignment sequence specified in the Near  
Final Alignment section.  
3. All alignment work is performed on gear and drive equip-  
ment. Once the compressor is bolted in a perfectly level  
position and is piped to the cooler and condenser, it must  
not be moved prior to hot check.  
4. All alignment checks must be made with the equipment  
hold-down bolts tightened.  
5. In setting dial indicators on zero and when taking read-  
ings, both shafts should be tight against their respective  
thrust bearings.  
6. The space between coupling hub faces must be held to  
the dimensions in Fig. 29 and 30.  
Fig. 37 — Checking Preliminary Alignment  
7. Accept only repeatable readings.  
High Speed Coupling Alignment  
NEAR FINAL ALIGNMENT — Once the chiller compo-  
nents are within dial indicator range, the adjustments for mis-  
alignment should be made in a specific sequence. The four  
positions of alignment described below are arranged in the  
recommended order.  
1. Move the gear with the coupling attached into alignment  
with the compressor coupling. The compressor must be  
in the thrust position and the gear must be centered be-  
tween the thrust collars when determining gear position  
relative to the compressor. Adjust the jackscrews to reach  
close alignment. Follow the procedures outlined in the  
Correcting Angular Misalignment and Correcting Paral-  
lel Misalignment sections.  
1. Angular in elevation — This alignment is adjusted  
with shims and is not readily lost in making the other  
adjustments.  
2. A 5-in. long spacer hub is supplied between the gear and  
compressor. Maintain the exact hub-to-hub distance speci-  
fied in Fig. 29.  
3. Where the shaft ends are very close, a taper gage may be  
used in place of the dial indicator.  
4. Get the gear alignment as close as possible by using the  
jackscrew adjustment.  
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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 in plan and can easily be  
lost if elevation adjustments are made.  
Fig. 38 — Measuring Angular Misalignment  
in Elevation  
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 opposite  
hub. Position the indicator so that the plunger is at approxi-  
mately mid-position when the dial is set to zero. Both shafts  
should be held tightly against their thrust bearings when the  
dial is set and when readings are taken.  
Fig. 39 — Measuring Angular Misalignment  
in Elevation Using Brackets  
Measurement — Occasionally, coupling faces may not be per-  
fectly true or may have been damaged in handling. To com-  
pensate for any such runout, determine the actual or ‘‘net’’  
shaft misalignment as follows:  
To be sure that the indicator linkage is tight and the button  
is on securely, rotate the coupling exactly 360 degrees. The  
dial reading should return to zero. Accept only repeatable  
readings.  
Check the opening at the top and at the bottom of the cou-  
pling faces (or at each side when making plan adjustment).  
Rotate both shafts exactly 180 degrees and recheck the open-  
ings. Record the difference. (Example below is in inches.)  
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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.  
Obtain:  
D — coupling face diameter in inches (or indicator but-  
ton circle)  
L — distance between front and rear holddown bolts  
(inches)  
M — net misalignment in inches  
And:  
Divide L, the bolt distance, by D, the coupling diameter.  
Multiply the result by M, the net misalignment.  
L
D
S =  
× M  
Example: Face diameter 5 in. (D). Distance between front  
and rear holddown bolts 30 in. (L). Net misalign-  
ment in elevation .012 in. (M).  
30 divided by 5 is 6  
6 multiplied by .012 is .072 in.  
S = .072 in.  
If the larger opening between coupling faces is at the top,  
place .072 in. of shim under each rear foot or remove  
.072 in. from the front footings to bring the couplings into  
angular alignment in elevation.  
Tighten the holddown bolts and recheck the net  
misalignment.  
If the larger opening remains the same, and remains  
on the same side, the amount is entirely shaft (net)  
misalignment.  
The height of the shaft above the footings and the dis-  
tance the shaft extends beyond the equipment will not affect  
the calculations.  
Determine the angular adjustment in plan by the same method  
of calculation. At this point, however, the procedure should  
include a correction for the change in coupling gap which  
always occurs in adjusting angular alignment (Fig. 40). By  
selecting the proper pivot point (see Fig. 41), the coupling  
gap can be kept at the dimension specified in the job data.  
1. Pivot on the front bolt at the closed side of the couplings  
to shorten the gap; pivot on the front bolt at the open side  
to lengthen it. It may sometimes be advantageous to pivot  
half the required amount on one front footing and half on  
the other.  
2. Place a dial indicator against the rear foot as indicated in  
Fig. 41.  
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.  
3. Place a screw jack on the other rear foot to move the equip-  
ment towards the indicator.  
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.  
Adjustment — Having obtained the net misalignment, the  
amount by which the equipment must be moved can now be  
calculated.  
S
L
—
—
Thickness of Shim Required  
Distance Between Front and  
Rear Holddown Bolt in Inches  
Diameter of Coupling in Inches  
Net Misalignment in Inches  
To determine:  
D
M
—
—
S — amount of movement (in plan) or the thickness of  
shim (in elevation) required.  
Fig. 40 — Alignment Formula  
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4. Loosen all holddown bolts except the pivot bolt. Turn the  
screw jack until the rear end of the equipment moves against  
the 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.  
Measurement — With dial set at zero in the top position,  
rotate the shaft to which the indicator is attached 180 de-  
grees. If the dial reading is plus, the shaft on which the but-  
ton rests is low. If the reading is minus, the shaft on which  
the button rests is high.  
Never accept a single reading. Look for repeatability. Ro-  
tate the shaft several times to see if the reading remains the  
same. It is good practice to reverse the procedure and read  
from zero at the bottom.  
Always rotate the shafts in the same direction when tak-  
ing readings. Backlash in the coupling teeth could cause some  
differences.  
Adjustment — Divide the total indicator reading by two to  
obtain the exact amount of shaft offset. As illustrated in  
Fig. 42, the indicator will read the total of A plus B but the  
required shaft adjustment is only half of this as indicated  
by C.  
Add or remove identical amounts of shims at all footings  
to bring the shaft to the proper elevation. Tighten all the hold-  
down bolts and recheck the readings. Parallel alignment must  
be within .002 TIR.  
To correct parallel misalignment in plan, use a screw jack  
and dial indicator as shown in Fig. 42. With a front hold-  
down bolt as the pivot, move the rear of the equipment 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 chiller hot check. All  
piping, including water and steam, must be completed, but  
the water and refrigerant charges need not be in place.  
HOT ALIGNMENT CHECK  
General — When all chiller components have reached op-  
erating temperature (after running near full load for from 4  
to 8 hours), a hot alignment check must be made. Hot align-  
ment check may be made with couplings assembled or  
disassembled.  
Disassembled Couplings  
1. Shut down chiller.  
Fig. 41 — Adjusting Angular Misalignment in Plan  
Correcting Parallel Misalignment  
Preparation — Attach the dial indicator to one shaft or cou-  
pling hub and place the indicator button on the outside di-  
ameter of the other hub. The reach of the dial from one hub  
to the other should be parallel to the shafts, and the dial but-  
ton shaft should point directly through the center of the shaft  
on which it rests. Compress the plunger to about mid-  
position and set the dial at zero.  
Check the tightness of the dial button and the indicator  
linkage by rotating the shaft to which the indicator is at-  
tached 360 degrees. The dial should return to zero. Check  
for repeatability.  
2. With chiller hot, quickly disassemble couplings.  
3. Check angular and parallel alignment in plan and eleva-  
tion as described in the Near Final Adjustment section.  
Record the indicator readings (see page CL-12) and make  
necessary adjustments to bring alignment within .002 in.  
TIR and .00033 inches per in. of coupling face traverse  
(or in. of indicator swing). Follow procedures described  
in the Near Final Alignment section.  
4. Reinstall couplings and run chiller until it again reaches  
operating temperature.  
5. Repeat steps 1 through 4 until alignment remains within  
specified tolerances.  
Check for runout by rotating the hub on which the dial  
button rests 180 degrees. If the runout exceeds .001 total in-  
dicator reading, the hub should be removed and the shaft  
checked. Shaft runout must not exceed .001 TIR.  
The effect of hub runout can be eliminated by locating a  
position on the half coupling where two readings 180 de-  
grees apart read zero. Rotate the coupling so that one zero  
point is at the top and the other at the bottom when checking  
for misalignment in elevation. Place the zero points side to  
side in a similar manner when checking for misalignment in  
plan.  
Assembled Couplings — If there is room on the shaft be-  
tween coupling and component to clamp a sturdy bracket,  
the arrangement illustrated in Fig. 43 may be used. The clamps  
must have room to rotate with the shaft.  
This method is quicker because the couplings do not have  
to be disassembled. In addition, eccentricity or coupling face  
runout are not problems since both shafts rotate together.  
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Fig. 43 — Alignment Check — Assembled Coupling  
5. Recheck the alignment per steps 1 through 4 until it re-  
mains within the specified tolerances.  
Be sure that coupling guards are replaced after these checks.  
DOWELING  
Techniques — After a hot alignment check has been com-  
pleted, the compressor, gear and drive must be doweled to  
their sole plates. Doweling permits exact repositioning of com-  
ponents if they have to be moved.  
1. Doweling must be completed with equipment at maxi-  
mum operating temperature (full load).  
2. Use No. 8 taper dowels to dowel the compressor, gear,  
and drive to the base. Use a 13⁄32-in. drill and No. 8 taper  
reamer with straight flutes. Drill pilot hole and then ex-  
pand the pilot hole to final dimension.  
3. Fit dowel so that 1⁄16-in. of taper is left above the equip-  
ment foot. If dowel holes are re-reamed as a result of re-  
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  
accordance with the drive manufacturer’s instructions. The  
number of dowels used in the drive is usually four, but some  
manufacturers require more.  
Fig. 42 — Correcting Parallel Misalignment  
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. With chiller at operating temperature, quickly install  
brackets.  
3. Check that alignment is within .002 in. TIR and  
.00033 in. per in. of traverse (0.00033 mm per mm of  
traverse) across the diameter of measurement. Adjust align-  
ment as required. (Refer to Near Final Alignment  
section.)  
4. Remove brackets and run chiller until operating tempera-  
ture is again reached.  
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Check the oil level in the motor bearings and observe the  
level each week. If additional oil is required, add oil as de-  
scribed in the Oil Changes section on page 77. The added oil  
must meet Carrier specifications. (See Table 11.) Any addi-  
tional oil added or removed should be logged by noting the  
amount and date.  
WEEKLY 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:  
SCHEDULED MAINTENANCE  
Establish a regular maintenance schedule based on the ac-  
tual chiller requirements such as chiller load, run hours, and  
water quality. The time intervals listed in this section are of-  
fered as guides to service only.  
Oil may be added through the oil drain and charging valve  
(Fig. 2, Item 22) using a pump. However, an oil charging  
elbow on the seal-oil return chamber (Fig. 4) allows oil to be  
added without pumping. The seal oil return pump automati-  
cally transfers the oil to the main oil reservoir. A pump is  
required for adding oil against refrigerant pressure. The oil  
charge is approximately 20 gallons (76 L) for FX (size 531-  
599) style compressors. The added oil must meet Carrier’s  
specifications. Refer to Changing the Oil Filters and Oil Changes  
sections. Any additional oil that is added should be logged  
by noting the amount and date. Any oil that is added due to  
oil loss that is not related to service will eventually return to  
the sump, and must be removed when the level is high.  
An oil heater is controlled by the PIC to maintain oil tem-  
perature above 150 F (65.5 C) or refrigerant temperature plus  
70° F (38.9° C) (see the Controls section) when the com-  
pressor is off. The LID STATUS02 screen displays whether  
the heater is energized or not (OIL HEATER RELAY). If the  
PIC shows that the heater is ON, but the sump is not heating  
up, the power to the oil heater may be off or the oil level  
may be too low. Check the oil level, the oil heater contactor  
voltage, and oil heater resistance.  
The PIC does not permit compressor start-up if the oil tem-  
perature is too low. The PIC continues with start-up only  
after the temperature is within limits.  
After the initial start or a 3-hour power failure, the PIC  
allows the chiller to start once the oil is up to proper tem-  
perature, but uses a slow ramp load rate of 2° F (1.6° C) per  
minute.  
Be sure that the isolation valves on the oil line near the  
filter(s) (Fig. 44) are fully open before operating the com-  
pressor.  
There are no lubrication requirements for the FX disc  
coupling.  
Service Ontime — The LID displays a SERVICE ON-  
TIME value on the STATUS01 screen. This value should  
be reset to zero by the service person or the operator each  
time major service work is completed so that time span be-  
tween service can be tracked and viewed.  
Inspect the Control Center — Maintenance is lim-  
ited to general cleaning and tightening of connections. Vacuum  
the cabinet to eliminate dust build-up. If the chiller controls  
malfunction, 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 chiller protection, the automated control test  
should be done at least once per month. See Table 3 for safety  
control settings.  
Changing the Oil Filters  
COMPRESSOR OIL FILTER — Change this oil filter an-  
nually or whenever the chiller is open for repairs. The 17FX  
compressor has an isolatable filter so that the filter may be  
changed without removing refrigerant from the chiller. Use  
the following procedure.  
1. Make sure the compressor is off and that the compressor  
disconnect is open.  
Check the oil level in the gear reservoir and observe the  
level each week. If additional oil is required, add oil as de-  
scribed in the Oil Changes section on page 77. The added oil  
must meet Carrier specifications. (See Table 11.) Do not over-  
fill the reservoir. Any additional oil added or removed should  
be logged by noting the amount and date.  
2. Disconnect the power to the oil heater and oil pump.  
3. Close the valves to the filter.  
4. Relieve the pressure from within the filter by using the  
pressure connection on the oil feed line valve to the com-  
pressor. Run a hose from the connection to a bucket to  
catch the oil.  
*Water out line is hidden behind oil out line.  
Fig. 44 — Typical Compressor or Gear Oil Cooler/Filter  
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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.  
7. Replace the drain fitting, using standard practices to en-  
sure a leak-tight joint.  
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 (filters, spacer,  
and stopper assembly), and make sure that the spring is  
centered against the filter assembly as shown in Fig. 44.  
7. Replace the drain fitting, using standard practices to en-  
sure a leak-tight joint. Evacuate the air from the cooler/  
filter assembly.  
8. Open the isolation valves.  
9. Connect power to the oil heater, if equipped, and oil pump.  
Operate the oil pump for 2 minutes. Add oil, if required,  
to keep the level up in the sight glass.  
Oil should be visible in the reservoir sight glass during all  
operating and shutdown conditions.  
Oil Specifications — If oil is to be added, it must meet  
the Carrier specifications shown in Table 11.  
8. Once the assembly has been evacuated, open the isola-  
tion valves.  
9. Connect power to the oil heater and oil pump. The oil  
heater should turn on and warm the oil to 140 to 150 F  
(60 to 66 C). Operate the oil pump for 2 minutes. Add oil,  
if required, to keep the level up in the lower sight glass.  
Oil Changes — Carrier recommends changing the oil  
after the first year of operation and every three to five years  
thereafter as a minimum. Carrier also recommends a yearly  
oil analysis. However, if a continuous oil monitoring system  
is functioning and a yearly oil analysis is performed, the time  
between oil changes can be extended.  
Oil should be visible in the reservoir sight glass during all  
operating and shutdown conditions.  
COMPRESSOR OIL  
1. Open the control and oil heater circuit breaker.  
2. Drain the oil reservoir by opening the oil charging valve,  
(Fig. 2, Item 22). Slowly open the valve against refrig-  
erant pressure.  
3. Change the oil filter at this time. See the Changing the  
Oil Filters section, page 76.  
EXTERNAL GEAR OIL FILTER — Change the oil filter  
annually or whenever the chiller is open for repairs. The 17EX  
external gear lubrication system has an isolatable filter. Use  
the following procedure.  
1. Make sure that the compressor is off and the compressor  
disconnect is open.  
2. Disconnect the power to the oil heater, if equipped, and  
to the oil pump.  
3. Close the line valves to the filter.  
4. Relieve any pressure from within the filter by using the  
pressure connection on the oil feed line valve to the com-  
pressor. Run a hose from the connection to a bucket to  
catch the oil.  
4. Charge the chiller with approximately 20 gallons (76 L)  
of oil for FX (size 531-599) style compressors in order to  
bring the level to the middle of the upper sight glass  
(Fig. 2, Item 21). Turn on the power to the oil heater and  
let the PIC warm it up to at least 140 F (60 C). Operate  
the oil pump manually, through the control test, for 2 min-  
utes. The oil level should be between the lower sight glass  
and one-half full in the upper sight glass for shutdown  
conditions.  
EXTERNAL GEAR OIL — Proper lubrication is vital to  
maintain gear drive performance. After 500 hours or 4 weeks  
of initial operation, whichever is first, the external gear drive  
should be thoroughly drained, flushed, and refilled with the  
proper lubricant. Under normal operating conditions, the lu-  
bricant should be changed every 2500 hours or 6 months,  
whichever comes first. This change frequency can be ex-  
tended if an oil sample analysis indicates a very limited deg-  
radation or contamination.  
5. Open the drain located on the shell of the cooler/filter.  
Run a hose from the connection to a bucket to catch the  
oil.  
6. Once the pressure has been removed and the oil drained,  
loosen the bolts that hold the cover on the filter body.  
Remove the oil filter cartridges and replace with new car-  
tridges. Assemble the filter assembly (filters, spacer, and  
stopper assembly), and make sure that the spring is cen-  
tered against the filter assembly, as shown in Fig. 44.  
Table 11 — 17EX Chiller Oil Specifications  
PUMPOUT  
COMPRESSOR  
AND OIL  
MOTOR SLEEVE  
BEARINGS  
EXTERNAL  
GEAR  
SPECIFICATION  
Oil Type*  
COMPRESSOR  
SEPARATOR  
Inhitited Polyolester-Based Mineral-Based, Rust and  
Rust and Oxidation  
Inhibited Oil  
Reciprocating  
Compressor Oil  
Synthetic Compressor Oil  
Oxidation Inhibited Turbine  
Grade Oil  
Viscosity at  
100 F (37 C)  
ISO 68  
(300 SSU)  
ISO 32  
(150 SSU)  
ISO 68  
(300 SSU)  
ISO 68  
(300 SSU)  
Carrier Part Number PP23BZ107  
Carrier Specification PP47-12  
PP23BZ091  
PP16-0  
PP23BB005  
PP16-2  
PP23BZ103  
PP47-31  
Recommended  
Manufacturer  
ICI, Emkarate RL68H  
Mobil, DTE Light  
Mobil Oil, DTE Heavy Medium Castrol Icematic SW68  
Texaco, Regal R & 0432  
Sun Oil, Sunvis 932  
Chevron, GST ISO 32  
Texaco, Regal UR & 068  
Chevron, OC #68  
ICI Emkarate RL68HP  
NOCO, Turbine T-68  
Capacity  
20 gal (76 L)  
0.6 gal (2.3 L) per bearing  
17 gal (41.6L)  
Compressor:  
4.5 pints (2.6 L)  
Oil Separator:  
1 pint (0.6 L)  
LEGEND  
Saybolt Universal Seconds  
*Oil type specified for chillers using HFC-134a refrigerant.  
SSU  
—
77  
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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.  
Inspect Relief Valves and Piping — The relief valves  
on this chiller protect the system against the potentially dan-  
gerous effects of overpressure. To ensure against damage to  
the equipment and possible injury to personnel, these de-  
vices must be kept in peak operating condition.  
To change the oil in the external gear:  
As a minimum, the following maintenance is required.  
1. Make sure that the compressor is off and the disconnect  
for the compressor is open.  
2. Disconnect the power to the oil heater, if equipped, and  
the oil pump.  
1. At least once a year, disconnect the vent piping at the  
valve outlet and carefully inspect the valve body and mecha-  
nism for any evidence of internal corrosion or rust, dirt,  
scale, leakage, etc.  
2. If corrosion or foreign material is found, do not attempt  
3. Open the drain located on the shell of the cooler/filter.  
Run a hose from the drain to a bucket to catch the oil.  
to repair or recondition. Replace the valve.  
3. If the chiller is installed in a corrosive atmosphere or the  
relief valves are vented into a corrosive atmosphere, make  
valve inspections at more frequent intervals.  
4. Once the pressure has been removed and the oil drained,  
loosen the bolts that hold the cover on the filter body.  
Remove the old filter cartridges. Assemble the filter as-  
sembly (filters, spacer, and stopper assembly), and make  
sure that the spring is centered against the filter assembly  
as shown in Fig. 44.  
5. Replace the drain fitting, using standard practices to en-  
sure a leak-tight joint.  
6. Open the isolation valves and add new oil. Refer to  
Table 11 for oil specifications.  
Coupling Maintenance — Proper coupling mainte-  
nance is important since the coupling supports the outboard  
end of the compressor high speed shaft. Clean and inspect  
both couplings for wear yearly. Misalignment causes undue  
noise and wear. Check alignment yearly, or more often if  
vibration or heating occur. Refer to Chiller Alignment sec-  
tion, page 71.  
7. Connect power to the oil heater, if equipped, and the oil  
pump. Operate the oil pump for 2 minutes. Add oil, if  
required, to keep the level up in the sight glass.  
Never operate the drive without the coupling guards in  
place. Contact with a rotating shaft or coupling can cause  
serious injury.  
MOTOR SLEEVE BEARING AND PUMPOUT COM-  
PRESSOR OIL — For instructions on changing the motor  
sleeve bearing oil, refer to the section on Motor Mainte-  
nance, this page.  
For instructions on changing the optional pumpout com-  
pressor and oil separator oil, refer to the section on Pumpout  
System Maintenance, page 83.  
Motor Maintenance — A carefully planned and ex-  
ecuted program of inspection and maintenance will do much  
to ensure maximum motor availability and minimum main-  
tenance cost. If it becomes necessary to repair, recondition,  
or rebuild the motor, it is recommended that the nearest West-  
inghouse repair facility be consulted.  
In addition to a daily observation of the appearance and  
operation of the motor, it is recommended that a general in-  
spection procedure be established to periodically check the  
following items:  
Inspect Refrigerant Float System — Inspect the  
refrigerant float system once every 5 years or when the  
economizer/storage vessel is opened for service. Transfer the  
refrigerant into the cooler vessel or into a storage tank. There  
are two floats on the 17EX, one on each side of the economizer/  
storage vessel. Remove the float access covers. Clean the  
chambers and valve assembly thoroughly. Be sure that the  
valves move freely. Make sure that all openings are free of  
obstructions. Examine the cover gaskets and replace if nec-  
essary. See Fig. 45 for a view of both floats.  
• cleanliness, both external and internal  
• stator and rotor (squirrel-cage) windings  
• bearings  
Fig. 45 — Typical Float Valve Arrangement  
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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 into the motor.  
If the motor is equipped with air filters, they should be  
replaced (disposable type) or cleaned and reconditioned (per-  
manent type) at a frequency that is dictated by conditions. It  
is better to replace or recondition filters too often than not  
often enough.  
Adequate ventilation must always be provided in any  
area where solvents are being used to avoid the danger  
of fire, explosion, or health hazards. In confined areas  
(such as pits) each operator should be provided with an  
air line respirator, a hose mask, or a self-contained breath-  
ing apparatus. Operators should wear goggles, aprons,  
and suitable gloves. Solvents and their vapors should  
never be exposed to open flames or sparks and should  
always be stored in approved safety containers.  
SLEEVE BEARINGS  
Oil Changing — The oil reservoirs of the self lubricated bear-  
ings should be drained and refilled every 6 months. More  
frequent changes may be needed if severe oil discoloration  
or contamination occurs. In conditions where contamination  
does occur, it may be advisable to flush the reservoir with  
kerosene to remove any sediment before new oil is added.  
Proper care must be taken to thoroughly drain the reservoir  
of the flushing material before refilling it with the new oil.  
Washing motors using a water spray is not recom-  
mended. Manual or compressed air cleaning is pre-  
ferred. If it becomes necessary to spray-wash a motor,  
it should be done with extreme care. Do not aim high  
pressure sprays directly at air inlet openings, conduit con-  
nections, shaft seals, or gasketed surfaces to prevent the  
possibility of forcing water inside the chiller.  
Refill the reservoir to the center of the oil sight glass with  
a rust and oxidation inhibited, turbine grade oil. The viscos-  
ity of the oil must be 32 ISO (150 SSU) at 100 F (37.7 C).  
Oil capacity in each of the 2 bearings is 0.6 gal. (2 l) per  
bearing. Use of Carrier Oil Specification PP16-0 is ap-  
proved (refer to Table 11).  
The stator windings of motors with open ventilation sys-  
tems can become contaminated with dirt and other sub-  
stances brought into the motor by the ventilating air. Such  
contaminants can impair cooling of the winding by clogging  
the air passages in the winding end-turns and vent ducts through  
the stator core and by reducing heat transfer from the wind-  
ing insulation surfaces to the cooling air. Conducting con-  
taminants can change or increase electrical stresses on the  
insulation, and corrosive contaminants can chemically at-  
tack and degrade the insulation. This may lead to shortened  
insulation life and stator failure.  
Disassembly — The bearing sleeve is spherically seated and  
self-aligning. The opposite drive end bearing is normally in-  
sulated for larger motors (or when specified). On some mo-  
tors, the insulation is bonded to the spherical seat of the bearing  
housing. Use extreme care when removing the sleeve from  
the insulated support to avoid damaging this insulation.  
Several satisfactory methods of cleaning stator windings  
and stator cores are offered below:  
Note that some bolts and tapped holes associated with the  
bearing housings, bearing sleeves, and seals are metric.  
Compressed Air — Low pressure (30 psi maximum), clean  
(no oil) dry air can be used to dislodge loose dust and par-  
ticles in inaccessible areas such as air vent ducts in the stator  
core and vent passages in the winding end-turns. Excessive  
air pressure can damage insulation and drive contaminants  
into inaccessible cracks and crevices.  
The following procedure is recommended for removing  
the bearing sleeve.  
1. Remove the oil drain plug in the housing bottom and  
drain the oil sump.  
2. Remove all instrumentation sensors that are in contact  
with the bearing sleeve. These include resistance tem-  
perature detectors, thermocouples, temperature relay bulbs,  
thermometers, etc.  
Vacuum — Vacuum cleaning can be used, both before and  
after other methods of cleaning, to remove loose dirt and  
debris. It is a very effective way to remove loose surface  
contamination from the winding without scattering it. Vacuum  
cleaning tools should be nonmetallic to avoid any damage to  
the winding insulation.  
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 front  
bearing is being disassembled. Remove the bearing cap  
and top half of the inner air seal by lifting straight up to  
avoid damaging the labyrinth seals. Place them on a clean,  
dry surface to avoid damage to the parting surfaces.  
5. Remove any split bolts that may be holding the two bear-  
ing halves together. Remove the top half of the bearing  
sleeve using suitable eyebolts in the tapped holes pro-  
vided. Lift the bearing top straight up and avoid any con-  
tact with the shoulders of the shaft journals that might  
damage the thrust faces of the bearing. Place on a clean,  
dry surface, taking care to prevent damage to either the  
parting surfaces or the locating pins that are captive in  
the top bearing half.  
Wiping — Surface contamination on the winding can be re-  
moved by wiping, using a soft, lint-free wiping material. If  
the contamination is oily, the wiping material can be moist-  
ened (not dripping wet) with a safety-type petroleum sol-  
vent, such as Stoddard solvent. In hazardous locations, a solvent  
such as inhibited methyl chloroform may be used, but must  
be used sparingly and immediately removed. While this sol-  
vent is non-flammable under ordinary conditions, it is toxic.  
Proper health and safety precautions should be followed while  
using it.  
Solvents of any type should never be used on windings  
provided with abrasion protection. Abrasion protection is a  
grey, rubber-like coating applied to the winding end-turns.  
6. Remove the 4 screws at the partings in the oil ring and  
dismantle the ring by gently tapping the dowel pin ends  
with a soft-faced mallet. Remove the ring halves and  
immediately reassemble them to avoid any mixup in parts  
or damage to the surfaces at the partings.  
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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.  
Twist counterclockwise to disengage the lock, remove  
the garter spring, then rotate the lower half of the seal  
out of the groove in the bearing housing while noting  
the orientation of the oil drain holes. Note the condition  
of these floating labyrinth seals. If they are cracked or  
chipped, they must be replaced. Do not attempt to reuse  
a damaged seal.  
1. The interior of the bearing housing should be cleaned  
and then flushed with clean oil or kerosene.  
2. The bearing halves and the shaft journal should be wiped  
clean using lint-free cloth soaked with clean oil.  
3. All parts should be carefully inspected for nicks, scratches,  
etc., in any contact surfaces. Such imperfections should  
be removed by an appropriate method such as stoning,  
scraping, filing, etc., followed by thorough cleaning.  
4. Apply a few drops of oil to the journal and bearing saddles.  
5. Roll the bottom half of the bearing into place and lower  
the shaft.  
8. To remove the bottom bearing half, the shaft must be  
raised a slight amount to relieve pressure on the bear-  
ing. On the rear end, this can be done by jacking or lift-  
ing on the shaft extension. (Care must be taken to pro-  
tect the shaft from damage.) On the front end, jacking  
or lifting can be done using bolts threaded into the tapped  
holes provided in the shaft end.  
6. Before installing the floating labyrinth seal halves, ob-  
serve their condition. Do not attempt to use a cracked or  
chipped seal. The bottom half seal has a set of drilled  
holes in its side face. These must be placed at the bot-  
tom toward the inside of the bearing so that accumu-  
lating oil may drain back into the housing.  
7. Put a small bead of Curil-T around the bottom seal half  
outside diameters on both sides adjacent to the garter  
spring groove. This prevents oil from bypassing the seal  
around its outside.  
NOTE: Lift only enough to free the bearing; over-  
lifting the shaft can cause difficulty in removing the  
bearing.  
9. Roll the bottom bearing half to the top of the shaft jour-  
nal and then lift it using suitable eyebolts threaded into  
the holes provided. Again, avoid any contact with the  
shaft shoulders that could damage the bearing thrust faces.  
Place the lower bearing half on a clean, dry surface to  
protect the parting surfaces.  
8. Place the bottom seal half on top of the shaft (ensuring  
that the proper orientation of the drain holes is pro-  
vided) 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 around  
the outside diameters on both sides adjacent to the gar-  
ter spring groove on this half also.  
9. Carefully reassemble the two oil ring halves. Inspect the  
dowel pins for burrs and straightness and make any cor-  
rections required. Do not force the ring halves together.  
Excessive force may alter the roundness or flatness of  
the ring which can change its oil delivery performance.  
Apply locking compound to the oil ring screws prior to  
reassembly.  
Use extreme care when rolling out the lower bear-  
ing half. Keep the hands and fingers well clear of  
any position where they might be caught by the bear-  
ing half if it were accidentally released and rotated  
back to its bottom position. Serious personal injury  
could result.  
10. Protect the shaft journal by wrapping it with clean, heavy  
paper or cardboard.  
10. Assemble the top half of the bearing liner making sure  
that the match marks on the liner halves align with one  
another. Failure to ensure alignment of match marks can  
cause misalignment and possible damage to bearings and  
journal surfaces. Reinstall any split bolts, if supplied,  
between the bearing halves.  
Reassembly — Bearing reassembly is basically a reversal of  
the disassembly procedures outlined above, with the follow-  
ing additional steps.  
11. Some of the pipe plugs in the housing are metric thread  
type and have a copper, lead, or similar material washer.  
If these plugs are removed, be careful not to lose the  
washers. Before reassembly, inspect the washers and re-  
place them if required.  
Curil-T is the only approved compound for use in the  
assembly of the bearings on this motor. Other products  
may harden and impede the operation.  
12. Before installing the bearing cap, observe the position  
of the floating labyrinth seal. The ‘‘tab’’ must be on top  
to engage the pocket. Failure to position the seal prop-  
erly will result in damage when the cap is assembled.  
13. Carefully lower the bearing housing cap over the float-  
ing seals. Keep the bearing cap level to avoid binding  
and possibly damaging the seals. The bearing cap should  
seat evenly on the bearing housing base.  
During the reassembly of the bearing parts, a thin layer  
of Curil-T should be applied to all gasketed and ma-  
chined interface surfaces. This suggestion does not ap-  
ply to the machined surfaces of the bearing liner halves.  
When seating the bearing shell, apply a thin layer of  
lubricating oil at the spherical surface of the liner. Slowly  
roll the lower bearing liner into the bearing housing mak-  
ing sure that the split surfaces of the liner and the hous-  
ing are flush. Gradually lower the shaft onto the bear-  
ing. The weight of the shaft will help rotate the bearing  
liner so that the babbitt surface of the liner will match  
the slope of the journal. Sometimes it is necessary to  
use a rubber mallet to tap lightly on the bearing housing  
while slowly rolling the shaft to help this seating  
operation.  
Do not force the bearing cap down. Damage could  
occur to the labyrinth seals.  
If the bearing cap does not seat completely, remove and  
reset the floating labyrinth seal position. When install-  
ing upper bearing cap, the floating labyrinth seals some-  
times rotate and the anti-rotation ‘‘tab’’ does not seat in  
its holder, thus preventing the bearing housing from seat-  
ing properly. This procedure should be repeated until  
the bearing cap seats properly.  
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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. Torque the bearing housing cap bolts by following the  
torque values as provided in Table 6 on page 51.  
provide proper protection while the motor is being stored.  
The motor should be stored under cover in a clean, dry lo-  
cation and should be protected from rapid temperature changes.  
Since moisture can be very detrimental to electrical com-  
ponents, the motor temperature should be maintained at ap-  
proximately 5° F (3° C) above the dew point temperature by  
providing either external or internal heat. If the motor is  
equipped with space heaters, they should be energized at the  
voltage shown by the space heater nameplate attached to the  
motor. Incandescent light bulbs can be placed within the mo-  
tor to provide heat. However, if used, they must not be al-  
lowed to come in contact with any parts of the motor because  
of the concentrated hot spot that could result.  
Motor Handling/Rigging — Each motor is provided  
with lifting lugs, welded to the four corners of the motor  
frame, for lifting the assembled chiller. The motor should  
always be lifted by using the lifting lugs located on all four  
corners of the motor frame. (See Fig. 46.)  
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 45). It is very important that this  
brace be reinstalled exactly as it was originally, before the  
motor is moved from storage or any time when the motor is  
being transported. This prevents axial rotor movement that  
might damage the bearings.  
Spreader bars of adequate capacity and number must be  
used to avoid applying any pressure against the top air  
housing with the lifting plugs.  
Motors equipped with sleeve bearings are shipped from  
the factory with the bearing oil reservoirs drained. In stor-  
age, the oil reservoirs should be properly filled to the center  
of the oil level gage with a good grade of rust inhibiting oil  
(refer to the certified drawing for oil viscosity and any spe-  
cial requirements). To keep the bearing journals well oiled  
and to prevent rusting, the motor shaft should be rotated sev-  
eral revolutions every 2 weeks. While the shaft is rotating it  
should be pushed to both extremes of the endplay to allow  
for oil flow over the entire length of the journals.  
External Gear Storage — All internal and unpainted  
external surfaces of the gear drives have been treated with a  
rust preventative at the factory before shipment. The pro-  
tective life of the rust preventative varies with temperature  
fluctuations, atmospheric moisture content, degree of expo-  
sure to the elements during storage, and degree of contact  
with other objects.  
Inspect all machined surfaces, and spray or add rust in-  
hibitor to exposed metal surfaces that may have had the pro-  
tective coating removed during shipping and handling.  
To be sure that the gear drive operates satisfactorily at start-  
up, take certain precautions when you receive it. The ex-  
pected length of storage and the storage atmosphere dictate  
the maintenance schedule to be followed. The gear must al-  
ways be stored in its operating position, level on its mount-  
ing feet, and free of loads or weights on input and output  
shafts.  
Fig. 46 — Motor Riggings  
If the motor is lifted with the top air housing removed, the  
angle of the lifting slings with the horizontal should never  
be less than 45 degrees.  
With the exclusion of the TEWAC cooler, the top air hous-  
ing is provided with 3⁄4-10 tapped holes for lifting devices to  
be installed in order to remove the air housing from the mo-  
tor. The top air housing can be detached by removing the  
enclosure holddown bolts, located in the inside corners of  
the enclosure. These enclosure holddown bolts are accessed  
through the louver/screens located on the front and rear end  
of the chiller or through access panels bolted to the sides of  
the enclosure.  
SHORT-TERM STORAGE (Indoors) — If the units are to  
be stored for 30 days or less, observe the following precau-  
tions.  
• Store the unit in a clean, dry location with the factory pack-  
ing intact and with as nearly a constant temperature as  
possible.  
• Elevate the unit a minimum of 6 in. above the floor level.  
• Avoid areas that are subject to extremes in temperature,  
vibration, and humidity.  
Uneven lifting must always be avoided. When single  
point lifting is to be used, slings of equal lengths must  
always be used to avoid uneven lifting.  
LONG-TERM STORAGE (Indoors) — If the unit is to be  
stored for more than 30 days, observe the following precau-  
tions. Store in a clean, dry location. Elevate the unit at a  
minimum of 6 in. above the ground floor level. Avoid areas  
that are subject to extremes in temperature, vibration, and  
humidity. In addition, do one of the following:  
• Remove the breather and replace it with pipe plugs. Pack  
the entire seal area with grease to form a vapor barrier and  
seal with tape.  
Under no circumstances should the motor be lifted us-  
ing the shaft as an attachment point.  
NOTE: Refer to weights specified on certified drawing to  
determine proper lifting equipment required for specific com-  
ponents or assemblies.  
Motor Storage — If the chiller is to be placed in ex-  
tended shutdown, certain precautions must be taken to  
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Fill the gear drive to the recommended oil level with heated  
Shell VSI grade 68 oil or its equivalent, heated between  
110 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  
required.  
Drain and replace the oil with the recommended oil type  
prior to start-up.  
• Remove the breather and replace it with a pipe plug. Pack  
the entire seal area with grease to form a vapor barrier and  
seal it with tape.  
A vapor-phase rust inhibitor, such as Daubert Chemical,  
Non-Rust Motorstor VCi-10 or its equivalent, may be added  
to the recommended oil type in the amount of 2% of the  
total sump capacity. Fill the unit to the recommended level.  
Do not overfill.  
Inspect the unit every 30 days and spray or add rust in-  
hibitor suitable for anticipated storage conditions, as  
required.  
Annually  
• Check the heat exchanger for corrosion and clogged tubes.  
• Check the bearing clearance and end play.  
Disassembly and Assembly Instructions — The following in-  
structions apply to standard high speed gear units.  
• Required Equipment: In addition to standard mechanic’s  
tools, have the following equipment on hand: hoist, sling,  
torque wrench, feeler gages, and dial indicator.  
• General Instructions: Clean external surfaces of the gear  
unit before removing the cover to prevent contaminants  
from falling into it. Record the mounting dimensions and  
the location of accessories for reference when reassem-  
bling. To remove the gear from its operating area, discon-  
nect all connected equipment and lift the gear from its  
foundation using 4 lifting lugs.  
Inspect the Heat Exchanger Tubes  
COOLER — Inspect and clean the cooler tubes at the end of  
the first operating season. Because these tubes have internal  
ridges, a rotary-type tube cleaning system is necessary to fully  
clean the tubes. Upon inspection, the tube condition deter-  
mines the scheduled frequency for cleaning and indicates  
whether water treatment is adequate in the chilled water/  
brine circuit. Inspect the entering and leaving chilled water  
temperature sensors for signs of slime, corrosion, or scale.  
Replace the sensor if corroded or remove any scale if found.  
The unit may run without changing this oil mixture.  
EXTENDED DOWNTIME — Consider the length of down-  
time the unit will undergo. The lubricating oil used in the  
unit should protect the interior parts for up to 30 days of  
shutdown. If the unit will be shut down longer than 30 days,  
it must be operated a minimum of 30 minutes every 30 days  
to distribute the lubricant to all interior parts.  
If it is impractical to operate the unit every 30 days, the  
long-term storage instructions described above must be fol-  
lowed. All seals applied for this storage condition must be  
removed before operating the unit.  
CONDENSER — Since this water circuit is usually an open-  
type system, the tubes may be subject to contamination and  
scale. Clean the condenser tubes with a rotary tube cleaning  
system at least once per year and more often if the water is  
contaminated. Inspect the entering and leaving condenser wa-  
ter sensors for signs of slime, corrosion, or scale. Replace  
the sensor if corroded or remove any scale if found.  
Higher than normal condenser pressures, together with the  
inability to reach full refrigeration load, usually indicate dirty  
tubes or air in the chiller. If the refrigeration log indicates a  
rise above normal condenser pressures, check the condenser  
refrigerant temperature against the leaving condenser water  
temperature. If this reading is more than what the design dif-  
ference is supposed to be, then the condenser tubes may be  
dirty, or water flow may be incorrect. Because HFC 134a is  
a high-pressure refrigerant, air usually does not enter the chiller;  
rather, the refrigerant leaks out.  
Compressor Bearing Maintenance — The key to  
good bearing maintenance is proper lubrication. Use the proper  
grade of oil, maintained at recommended level, temperature,  
and pressure. Inspect the lubrication system regularly and  
thoroughly.  
Only a trained service technician should remove and  
examine the bearings. The bearings should be examined on  
a scheduled basis for signs of wear. The frequency of ex-  
amination is determined by the hours of chiller operation,  
load conditions during operation, and the condition of the  
oil and the lubrication system. Excessive bearing wear can  
sometimes be detected through increased vibration or in-  
creased bearing temperature. If either symptom appears, con-  
tact an experienced and responsible service organization for  
assistance.  
During the tube cleaning process, use brushes especially  
designed to avoid scraping and scratching the tube wall. Con-  
tact your Carrier representative to obtain these brushes. Do  
not use wire brushes.  
External Gear Maintenance — Perform the re-  
quired maintenance and recommended intervals. Good pre-  
ventive maintenance prolongs the life of the unit.  
Hard scale may require chemical treatment for its pre-  
vention or removal. Consult a water treatment specialist  
for proper treatment.  
Daily  
• Inspect for leaks and loose connections.  
• Check the oil level.  
• Check the oil temperature and pressure.  
• Check for unusual noise and/or vibration.  
Water Leaks — Water in the refrigerant is indicated dur-  
ing chiller operation by the refrigerant moisture indicator on  
the refrigerant motor cooling line. Water leaks should be re-  
paired immediately.  
Weekly — Check the oil filter.  
Monthly  
• Obtain oil sample analysis.  
• Clean or replace oil filters.  
• Check the foundation mounting bolts for tightness.  
• Clean the air filter.  
• Check the operation of all auxiliary equipment.  
The chiller must be dehydrated after repair of water leaks.  
See Chiller Dehydration section, page 49.  
Water Treatment — Untreated or improperly treated wa-  
ter may result in corrosion, scaling, erosion, or algae. The  
services of a qualified water treatment specialist should be  
obtained to develop and monitor a treatment program.  
Semi-Annually  
• Check gear tooth wear.  
• Check the oil and replace it if necessary.  
• Check the coupling alignment.  
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4. Stop the compressor and isolate the system by closing  
the discharge service valve.  
5. Slowly remove the oil return line connection. Add oil as  
required.  
6. Replace the connection and reopen the compressor serv-  
ice valves.  
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.  
PUMPOUT SAFETY CONTROL SETTINGS (Fig. 47) —  
The pumpout system high-pressure switch should open at  
161 psig (1110 kPa) and close at 130 psig (896 kPa). Check  
the switch setting by operating the pumpout compressor and  
slowly throttling the pumpout condenser water.  
Inspect the Starting Equipment — Before work-  
ing on any starter, shut off the chiller, and open all discon-  
nects supplying power to the starter.  
The disconnect on the starter front panel does not de-  
energize all 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 the 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, lubrication, spare parts  
ordering, and other maintenance requirements.  
Periodically vacuum or blow off accumulated debris on  
the internal parts with a high-velocity, low-pressure blower.  
Power connections on newly installed starters may relax  
and loosen after a month of operation. Turn power off and  
retighten. Recheck annually thereafter.  
Fig. 47 — Controls for Optional Pumpout  
Compressor  
Loose power connections can cause voltage spikes, over-  
heating, malfunctioning, or failures.  
Ordering Replacement Chiller Parts — When or-  
dering Carrier specified parts, the following information must  
accompany an order:  
• chiller model number and serial number  
• name, quantity, and part number of the part required  
• delivery address and method of shipment  
Check Pressure Transducers — Prior to start-up  
and once a year, the pressure transducers should be checked  
against a pressure gage reading. Check all three transducers:  
oil pressure, condenser pressure, and cooler pressure.  
Note the evaporator and condenser pressure readings on  
the STATUS01 screen on the LID. Attach an accurate set of  
refrigeration gages to the cooler and condenser Schrader fit-  
tings. Compare the two readings. If there is a difference in  
readings, the transducer can be calibrated, as described in  
the Troubleshooting Guide section.  
MOTOR REPLACEMENT PARTS — Replacement or re-  
newal parts information for the motor and any auxiliary de-  
vices can be obtained from the nearest Westinghouse Motor  
Company sales office. A complete description of the needed  
part(s) is necessary, together with the complete motor name-  
plate reading for positive motor identification.  
Pumpout System Maintenance — For compres-  
sor maintenance details, refer to the 06D, 07D Installation,  
Start-Up, and Service Instructions.  
EXTERNAL GEAR REPLACEMENT PARTS — Replace-  
ment or renewal parts information for the external gear and  
any auxiliary devices can be obtained from the nearest Nut-  
tall or Lufkin sales office. Acomplete description of the needed  
part(s) is necessary, together with the complete gear name-  
plate reading for positive identification.  
OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE —  
Use oil conforming to Carrier specifications for reciprocat-  
ing compressor usage. See Table 11.  
Oil should be visible in the compressor sight glass both  
during operation and at shutdown. Always check the oil  
level before operating the compressor. Before adding or chang-  
ing oil, relieve the refrigerant pressure as follows:  
1. Attach a pressure gage to the gage port of either com-  
pressor service valve (Fig. 34).  
2. Close the suction service valve and open the discharge  
line to the storage tank or the chiller.  
TROUBLESHOOTING GUIDE  
Overview — The PIC has many features to help the op-  
erator and the technician troubleshoot a 17EX chiller.  
• By using the LID display, the actual operating conditions  
of the chiller can be viewed while the unit is running.  
• The CONTROL ALGORITHM STATUS table includes  
screens with information that can be used to diagnose prob-  
lems with chilled water temperature control, chilled water  
3. Operate the compressor until the crankcase pressure drops  
to 2 psig (13 kPa).  
83  
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temperature control overrides, hot gas bypass, surge al-  
gorithm status, and time schedule operation. Refer to  
Fig. 14 and Table 2, Examples 11-14.  
See Fig. 6 for sensor locations. The sensors are immersed  
directly in the refrigerant or water circuits. The wiring at each  
sensor is easily disconnected by unlatching the connector.  
These connectors allow only one-way connection to the sen-  
sor. When installing a new sensor, apply a pipe sealant or  
thread sealant to the sensor threads.  
DUAL TEMPERATURE SENSORS — There are 2 sensing  
elements on each of the bearing temperature sensors for ser-  
vicing convenience. In case one of the dual sensors is dam-  
aged, the other one can be used by moving a wire.  
• 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/off outputs while the compressor is stopped. It  
also has the ability to lock off the compressor and turn on  
water pumps for pumpout operation. The LID display shows  
the required temperatures and pressures during these op-  
erations. Refer to Fig. 16 for the CONTROL TEST menu  
structure and to the Control Test section, page 85, for more  
information on this feature.  
• Other SERVICE menu tables can access configured items,  
such as chilled water resets, override set points, etc.  
• If an operating fault is detected, an alarm message is gen-  
erated and displayed on the LID default screen. A more  
detailed message, along with a diagnostic message, is also  
stored in the ALARM HISTORY table in the PIC.  
The number 1 terminal in the sensor terminal box is the  
common line. To use the second sensor, move the wire from  
the number 2 position to the number 3 position.  
Checking Pressure Transducers — The 17EX chiller  
has 5 transducers. These transducers sense cooler pressure,  
condenser pressure, compressor oil supply pressure, oil sump,  
and gear oil supply pressure. The compressor oil supply pres-  
sure and the oil transmission sump pressure difference is cal-  
culated by a differential pressure power supply module. The  
PSIO then reads this differential. In effect, then, the  
PSIO reads 3 pressure inputs. The cooler and condenser  
transducers are used by the PIC to determine refrigerant  
temperatures.  
All pressure inputs can be calibrated, if necessary. It is not  
usually necessary to calibrate at initial start-up. However, at  
high altitude locations, calibration of the transducer will be  
necessary to ensure the proper refrigerant temperature/  
pressure relationship. Each transducer is supplied with 5 vdc  
power from a power supply. If the power supply fails, a trans-  
ducer voltage reference alarm occurs. If the transducer read-  
ing is suspected of being faulty, check the supply voltage. It  
should be 5 vdc ± .5 v. If the supply voltage is correct, the  
transducer should be re-calibrated or replaced.  
Checking the Display Messages — The first area  
to check when troubleshooting the 17EX is the LID display.  
If the alarm light is flashing, check the primary and second-  
ary message lines on the LID default screen (Fig. 11). These  
messages indicate where the fault is occurring. The ALARM  
HISTORY table on the SERVICE menu also carries an alarm  
message to further expand on this alarm. For a complete list  
of alarm messages, see Table 12. If the alarm light starts to  
flash while accessing a menu screen, depress the EXIT soft-  
key to return to the default LID screen to read the failure  
message. The compressor does not run while an alarm con-  
dition exists unless the alarm type is an unauthorized start or  
a failure to shut down.  
To calibrate oil pressure differential, refer to Oil Pressure  
Differential Calibration at the end of this section.  
Checking Temperature Sensors — All tempera-  
ture sensors are thermistors. This means that the resistance  
of the sensor varies with temperature. All sensors have the  
same resistance characteristics. Determine sensor tempera-  
ture by measuring voltage drop if the controls are powered,  
or resistance if the controls are powered off. Compare the  
readings to the values listed in Table 14A or 14B.  
Calibration can be checked by comparing the pressure read-  
ings from the transducer against an accurate refrigeration gage.  
These readings are all viewed or calibrated from the  
STATUS01 screen on the LID. The transducer can be checked  
and calibrated at 2 pressure points. These calibration points  
are 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.  
RESISTANCE CHECK — Turn off the control power and  
disconnect the terminal plug of the sensor in question from  
the module. With a digital ohmmeter, measure the sensor re-  
sistance between the receptacles designated by the wiring  
diagram. The resistance and corresponding temperature are  
listed in Table 14A or 14B. Check the resistance of both wires  
to ground. This resistance should be infinite.  
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.  
VOLTAGE DROP — Using a digital voltmeter, the voltage  
drop across any energized sensor can be measured while the  
control is energized. Table 14A or 14B lists the relationship  
between temperature and sensor voltage drop (volts dc mea-  
sured across the energized sensor). Exercise care when mea-  
suring voltage to prevent damage to the sensor leads, con-  
nector plugs, and modules. The sensor wire should also be  
checked at the sensor plug connection. Check the sensor wire  
by removing the condenser at the sensor and measure for  
5 vdc back to the module, if the control is powered.  
3. Access the STATUS01 screen, and view the particular trans-  
ducer reading; it should read 0 psi (0 kPa). If the reading  
is not 0 psi (0 kPa), but within ± 5 psi (35 kPa), the  
value may be zeroed by pressing the SELECT softkey  
while the parameter for the transducer is highlighted.  
Then, press the ENTER softkey. The value will now go  
to zero.  
If the transducer value is not within the calibration range,  
the transducer returns to the original reading. If the LID  
pressure value is within the allowed range (noted above),  
check the voltage ratio of the transducer. To obtain the  
voltage ratio, divide the voltage (dc) input from the trans-  
ducer by the supply voltage signal, measured at the PSIO  
terminals J7-J34 and J7-J35. For example, the condenser  
transducer voltage input is measured at PSIO terminals  
J7-1 and J7-2. The voltage ratio must be between  
0.80 vdc and 0.11 vdc for the software to allow calibra-  
tion. Pressurize the transducer until the ratio is within range.  
Then attempt calibration again.  
Relieve all refrigerant pressure or drain the water prior  
to replacing the temperature sensors.  
CHECK SENSOR ACCURACY — Place the sensor in a  
medium of a known temperature and compare that tempera-  
ture to the measured reading. The thermometer used to de-  
termine the temperature of the medium should be of labo-  
ratory quality with 0.5° F (.25° C) graduations. The sensor  
in question should be accurate to within 2° F (1.2° C).  
84  
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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  
TROUBLESHOOTING TRANSDUCERS — When trouble-  
shooting transducers, keep the negative lead of your volt-  
ohmmeter on terminal U4 of the power supply (or terminal  
4 on power supplies without the comparator circuit).  
Voltage VO1 = (VH1-VL1) + .467 ± .1 V  
For all PIC transducers:  
STATUS01 screen, highlighting the transducer, pressing  
the SELECT softkey, and then increasing or decreasing  
the value to the exact pressure on the refrigerant gage.  
Press ENTER to finish. High altitude locations must com-  
pensate the pressure so that the temperature/pressure re-  
lationship is correct.  
Measured pressure = (507.97 × (V /V )) − 47.33  
out in  
V
V
= transducer output ref. to neg. terminal  
(4 or U4) i.e., VH1 to U4 or VL1 to U4  
= power supply output, i.e., U3 to U4  
out  
in  
If the transducer reading returns to the previous value and  
the pressure is within the allowed range, check the volt-  
age ratio of the transducer. Refer to Step 3 above. The  
voltage ratio for this high pressure calibration must be  
between 0.585 and 0.634 vdc to allow calibration. Change  
the pressure at the transducer until the ratio is within the  
acceptable range. Then attempt to calibrate to the new  
pressure input.  
TRANSDUCER REPLACEMENT — Since the transduc-  
ers are mounted on Schrader-type fittings, there is no need  
to remove refrigerant from the vessel. Disconnect the trans-  
ducer wiring by pulling up on the locking tab while pulling  
up on the weather-tight connecting plug from the end of the  
transducer. Do not pull on the transducer wires. Unscrew  
the transducer from the Schrader fitting. When installing a  
new transducer, do not use pipe sealer, which can plug the  
sensor. Put the plug connector back on the sensor and snap  
into place. Check for refrigerant leaks.  
The PIC will not allow calibration if the transducer is too  
far out of calibration. A new transducer must be installed  
and re-calibrated.  
OIL DIFFERENTIAL PRESSURE/POWER SUPPLY MOD-  
ULE CALIBRATION — (See Fig. 48.) The oil reservoir in  
the 17EX chiller is not common to cooler pressure. There-  
fore, a comparison of pump output to cooler pressure can  
not be used to provide differential oil pressure information.  
A different method has been developed.  
Oil transmission sump pressure and oil supply pressure  
are fed to a comparator circuit on a 5V power supply board.  
The output of this circuit, which represents differential oil  
pressure, is fed to the PSIO. The oil differential pressure is  
calibrated to 0 psid (0 kPad) by selecting the oil pressure  
input on the STATUS01 screen. Then, with the oil pump turned  
Make sure to use a backup wrench on the Schrader fit-  
ting whenever removing a transducer.  
Control Algorithms Checkout Procedure — One  
of the tables in the SERVICE menu is the CONTROL AL-  
GORITHM STATUS table. This table has 6 screens that may  
be viewed to see how a particular control algorithm is  
operating, that is, to see what parameters and values the PIC  
is using to control the chiller.  
OFF and the transducers connected, press the ENTER soft-  
MAINT01  
MAINT02  
MAINT03  
Capacity  
Control  
The values used to calculate the chilled  
water/brine control point.  
key to zero the point. No high end calibration is needed or  
possible.  
Override  
Status  
Details of all chilled water control over-  
ride values  
17EX OIL PRESSURE INPUT  
Surge/  
HGBP  
Status  
The surge and hot gas bypass control  
algorithm status as well as the values  
dealing with this control.  
MAINT04  
LEAD/LAG LEAD/LAG operation status.  
Status  
OCCDEFM  
Time  
The Local and CCN occupied sched-  
Schedules ules, displayed in a way that allows the  
Status  
operator to quickly determine whether  
the schedule is in an occupied period  
or not.  
WSMDEFME Water  
System  
The status of the WSM (water system  
manager), a CCN module that can turn  
on the chiller and change the chilled  
water control point.  
Manager  
Status  
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 — The control test feature can check all  
the thermistor temperature sensors, including those on the  
Options modules, pressure transducers, pumps and their as-  
sociated flow switches, the guide vane actuator, and other  
control outputs, such as hot gas bypass. The tests can help  
to determine whether a switch is defective, or a pump relay  
is not operating, among other useful troubleshooting tests.  
During pumpdown operations, the pumps are energized  
to prevent freeze-up, and the vessel pressures and tempera-  
tures are displayed. The pumpdown/lockout feature pre-  
vents the compressor from starting up when there is no re-  
frigerant in the chiller or when the vessels are isolated. The  
operator then uses the terminate lockout screen to end the  
pumpdown lockout after the pumpdown procedure is re-  
versed and refrigerant is added.  
Fig. 48 — Oil Differential Pressure/Power  
Supply Module  
85  
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LEGEND FOR TABLE 12, A - N  
1CR AUX  
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Compressor Start Contact  
Compressor Current  
Carrier Comfort Network  
Condenser Water Flow  
Chiller Start/Stop  
OILPD  
OILT  
PIC  
PRS TRIP  
PSIO  
RLA  
RUN AUX  
SMM  
SPR PL  
STR FLT  
TXV  
—
—
—
—
—
—
—
—
—
—
—
—
—
Oil Pressure  
CA  
P
Oil Sump Temperature  
Product Integrated Control  
Pressure Trip Contact  
Processor Sensor Input/Output Module  
Rated Load Amps  
Compressor Run Contact  
Starter Management Module  
Spare Protective Limit Input  
Starter Fault  
CCN  
CDFL  
CHIL  
CHW  
CMPD  
CRP  
S
S
Chilled Water  
Discharge Temperature  
Condenser Pressure  
Evaporator Refrigerant Temperature  
Chilled Water Flow  
Target Guide Vane Position  
Light-Emitting Diode  
Local Interface Device  
Bearing Temperature  
Motor Winding Temperature  
ERT  
EVFL  
GV TRG  
LED  
LID  
Thermostatic Expansion Valve  
Line Voltage: Percent  
Voltage Reference  
V
V
P
REF  
MTRB  
MTRW  
Table 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages  
with Troubleshooting Guides  
A. SHUTDOWN WITH ON/OFF/RESET-OFF  
PRIMARY MESSAGE  
SECONDARY MESSAGE  
PROBABLE CAUSE/REMEDY  
PIC in OFF mode, press the CCN or local softkey to  
start unit.  
MANUALLY STOPPED — PRESS  
CCN OR LOCAL TO START  
Enter the CONTROL TEST table and select TERMINATE LOCKOUT  
to unlock compressor.  
TERMINATE PUMPDOWN MODE  
SHUTDOWN IN PROGRESS  
SHUTDOWN IN PROGRESS  
ICE BUILD  
TO SELECT CCN OR LOCAL  
COMPRESSOR UNLOADING  
COMPRESSOR DEENERGIZED  
OPERATION COMPLETE  
Chiller unloading before shutdown due to soft/stop feature.  
Chiller compressor is being commanded to stop. Water pumps are deen-  
ergized within one minute.  
Chiller shutdown from Ice Build operation.  
B. TIMING OUT OR TIMED OUT  
PRIMARY MESSAGE  
SECONDARY MESSAGE  
UNOCCUPIED MODE  
PROBABLE CAUSE/REMEDY  
Time schedule for PIC is unoccupied.  
Chillers will start only when occupied.  
READY TO START IN XX MIN  
READY TO START IN XX MIN  
READY TO START IN XX MIN  
READY TO START IN XX MIN  
REMOTE CONTACTS OPEN  
STOP COMMAND IN EFFECT  
RECYCLE RESTART PENDING  
Remote contacts have stopped chiller. Close contacts to start.  
Chiller START/STOP on STATUS01 manually forced to stop. Re-  
lease value to start.  
Chiller in recycle mode.  
Time schedule for PIC is unoccupied. Chiller will start when occu-  
pied. Make sure the time and date have been set on the  
SERVICE menu.  
READY TO START  
UNOCCUPIED MODE  
READY TO START  
READY TO START  
REMOTE CONTACTS OPEN  
STOP COMMAND IN EFFECT  
Remote contacts have stopped chiller. Close contacts to start.  
Chiller START/STOP on STATUS01 manually forced to stop. Re-  
lease value to start.  
READY TO START IN XX MIN  
READY TO START IN XX MIN  
READY TO START  
REMOTE CONTACTS CLOSED  
OCCUPIED MODE  
Chiller timer counting down unit. Ready for start.  
Chiller timer counting down unit. Ready for start.  
Chiller timers complete, unit start will commence.  
Chiller timers complete, unit start will commence.  
CCN loadshed module commanding chiller to stop.  
REMOTE CONTACTS CLOSED  
OCCUPIED MODE  
READY TO START  
STARTUP INHIBITED  
LOADSHED IN EFFECT  
Chiller START/STOP on STATUS01 has been manually forced to  
start. Chiller will start regardless of time schedule or remote contact  
status.  
READY TO START IN XX MIN  
START COMMAND IN EFFECT  
C. IN RECYCLE SHUTDOWN  
PRIMARY MESSAGE  
SECONDARY MESSAGE  
PROBABLE CAUSE/REMEDY  
Unit in recycle mode, chilled water temperature is not high enough  
to start.  
RECYCLE RESTART PENDING  
OCCUPIED MODE  
Unit in recycle mode, chilled water temperature is not high enough  
to start.  
RECYCLE RESTART PENDING  
RECYCLE RESTART PENDING  
RECYCLE RESTART PENDING  
REMOTE CONTACT CLOSED  
START COMMAND IN EFFECT  
ICE BUILD MODE  
Chiller START/STOP on STATUS01 manually forced to start, chilled  
water temperature is not high enough to start.  
Chiller in ICE BUILD mode. Chilled water/brine temperature is satis-  
fied for ICE BUILD SETPOINT temperature.  
86  
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Table 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages  
with Troubleshooting Guides (cont)  
D. PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary.  
PRIMARY MESSAGE  
PRESTART ALERT  
SECONDARY MESSAGE  
ALARM MESSAGE/PRIMARY CAUSE  
ADDITIONAL CAUSE/REMEDY  
STARTS LIMIT EXCEEDED  
STARTS EXCESSIVE Compressor Starts (8 in  
12 hours)  
Depress the RESET softkey if additional start is  
required. Reassess start-up requirements.  
PRESTART ALERT  
PRESTART ALERT  
HIGH MOTOR TEMPERATURE  
HIGH BEARING TEMPERATURE  
MTRW [VALUE] exceeded limit of [LIMIT]*.  
Check motor temperature.  
Check motor cooling line for proper operation.  
Check for excessive starts within a short time  
span.  
MTRB [VALUE] exceeded limit of [LIMIT]*.  
Check thrust bearing temperature.  
Check oil heater for proper operation, check for  
low oil level, partially closed oil supply valves,  
etc. Check sensor accuracy.  
PRESTART ALERT  
PRESTART ALERT  
PRESTART ALERT  
PRESTART ALERT  
HIGH DISCHARGE TEMP  
LOW REFRIGERANT TEMP  
LOW OIL TEMPERATURE  
LOW LINE VOLTAGE  
CMPD [VALUE] exceeded limit of [LIMIT]*.  
Check discharge temperature.  
Check sensor accuracy. Allow discharge tem-  
perature to cool. Check for excessive starts.  
ERT [VALUE] exceeded limit of [LIMIT]*. Check  
refrigerant temperature.  
Check transducer accuracy. Check for low chilled  
water/brine supply temperature.  
OILT [VALUE] exceeded limit of [LIMIT]*.  
Check oil temperature.  
Check oil heater power, oil heater relay. Check  
oil level.  
V
P [VALUE] exceeded limit of [LIMIT]*.  
Check voltage supply. Check voltage transform-  
ers. Consult power utility if voltage is low. Cali-  
brate voltage reading on STATUS01 Table.  
Check voltage supply.  
PRESTART ALERT  
HIGH LINE VOLTAGE  
V
P [VALUE] exceeded limit of [LIMIT]*.  
Check voltage supply. Check voltage transform-  
ers. Consult power utility if voltage is low. Cali-  
brate voltage reading on STATUS01 table.  
Check voltage supply.  
PRESTART ALERT  
PRESTART ALERT  
HIGH CONDENSER PRESSURE  
HIGH GEAR OIL TEMP  
CRP [VALUE] exceeded limit of [LIMIT]*. Check  
condenser water and transducer.  
Check for high condenser water temperature.  
Check transducer accuracy.  
GEAOILT [VALUE] exceeded limit of [LIMIT].*  
Check gear oil cooler flow.  
Check for cooler water flow. Check sensor for  
accuracy.  
*[LIMIT] is shown on the LID as 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 the control tripped.  
E. NORMAL OR AUTO.-RESTART  
PRIMARY MESSAGE  
STARTUP IN PROGRESS  
STARTUP IN PROGRESS  
SECONDARY MESSAGE  
OCCUPIED MODE  
PROBABLE CAUSE/REMEDY  
Chiller starting. Time schedule is occupied.  
Chiller starting. Remote contacts are closed.  
REMOTE CONTACT CLOSED  
Chiller starting. Chiller START/STOP on STATUS01 manually forced  
to start.  
STARTUP IN PROGRESS  
START COMMAND IN EFFECT  
AUTORESTART IN PROGRESS  
AUTORESTART IN PROGRESS  
OCCUPIED MODE  
Chiller starting. Time schedule is occupied.  
Chiller starting. Remote contacts are closed.  
REMOTE CONTACT CLOSED  
Chiller starting. Chiller START/STOP on STATUS01 manually forced  
to start.  
AUTORESTART IN PROGRESS  
START COMMAND IN EFFECT  
F. SPARE SENSOR ALERT MESSAGES  
PRIMARY MESSAGE  
SPARE SENSOR ALERT  
SPARE SENSOR ALERT  
SECONDARY MESSAGE  
COMMON CHWS SENSOR  
ALARM MESSAGE/PRIMARY CAUSE  
ADDITIONAL CAUSE/REMEDY  
Sensor Fault: Check common CHWS sensor.  
COMMON CHWR SENSOR  
REMOTE RESET SENSOR  
TEMP SENSOR — SPARE 1  
TEMP SENSOR — SPARE 2  
TEMP SENSOR — SPARE 3  
TEMP SENSOR — SPARE 4  
TEMP SENSOR — SPARE 5  
TEMP SENSOR — SPARE 6  
TEMP SENSOR — SPARE 7  
TEMP SENSOR — SPARE 8  
TEMP SENSOR — SPARE 9  
Sensor Fault: Check common CHWR  
sensor.  
SPARE SENSOR ALERT  
SPARE SENSOR ALERT  
SPARE SENSOR ALERT  
SPARE SENSOR ALERT  
SPARE SENSOR ALERT  
SPARE SENSOR ALERT  
SPARE SENSOR ALERT  
SPARE SENSOR ALERT  
SPARE SENSOR ALERT  
SPARE SENSOR ALERT  
Sensor Fault: Check remote reset tempera-  
ture sensor.  
Sensor Fault: Check temperature sensor —  
Spare 1.  
Sensor Fault: Check temperature sensor —  
Spare 2.  
Sensor Fault: Check temperature sensor —  
Spare 3.  
Check alert temperature set points on EQUIP-  
MENT SERVICE table, SERVICE2 screen.  
Check sensor for accuracy if reading is not  
accurate.  
Sensor Fault: Check temperature sensor —  
Spare 4.  
Sensor Fault: Check temperature sensor —  
Spare 5.  
Sensor Fault: Check temperature sensor —  
Spare 6.  
Sensor Fault: Check temperature sensor —  
Spare 7.  
Sensor Fault: Check temperature sensor —  
Spare 8.  
Sensor Fault: Check temperature sensor —  
Spare 9.  
87  
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Table 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages  
with Troubleshooting Guides (cont)  
G. START-UP FAILURES: This is an alarm condition. A manual reset is required to clear.  
PRIMARY MESSAGE  
SECONDARY MESSAGE  
ALARM MESSAGE/PRIMARY CAUSE  
ADDITIONAL CAUSE/REMEDY  
FAILURE TO START LOW OIL PRESSURE  
OILPD [VALUE] exceeded limit of [LIMIT]*. Check Check for closed oil supply valves. Check oil filter.  
oil pump system.  
Check for low oil temperature. Check transducer  
accuracy.  
FAILURE TO START OIL PRESS SENSOR FAULT  
OILPD [VALUE] exceeded limit of [LIMIT]*. Check Check for excessive refrigerant in oil sump. Run oil  
oil pressure sensor.  
pump manually for 5 minutes. Check calibration of  
oil pressure differential amplifier modules. Check wir-  
ing. Replace transducers if necessary.  
FAILURE TO START LOW CHILLED WATER FLOW  
EVFL Evap Flow Fault: Check water pump/flow Check wiring to flow switch. Check through CON-  
switch. TROL TEST for proper switch operation.  
FAILURE TO START LOW CONDENSER  
CDFL Cond. Flow Fault: Check water pump/flow Check wiring to flow switch. Check through CON-  
switch. TROL TEST for proper switch operation.  
WATER FLOW  
FAILURE TO START STARTER FAULT  
STR FLT Starter Fault: Check Starter for Fault A starter protective device has faulted. Check starter  
Source. for ground fault, voltage trip, temperature trip, etc.  
FAILURE TO START STARTER OVERLOAD TRIP  
FAILURE TO START LINE VOLTAGE DROPOUT  
STR FLT Starter Overload Trip: Check amps Reset overloads, check ICR relay before restarting  
calibration/reset overload. chiller.  
V
P Single-Cycle Dropout Detected: Check volt- Check voltage supply. Check transformers for sup-  
age supply.  
ply. Check with utility if voltage supply is erratic. Moni-  
tor must be installed to confirm consistent, single-  
cycle dropouts. Check low oil pressure switch.  
FAILURE TO START HIGH CONDENSER  
High Condenser Pressure [LIMIT]:* Check switch Check for proper design condenser flow and tem-  
PRESSURE  
2C aux, and water temperature/flow.  
perature. Check condenser approach. Check 2C aux-  
iliary contacts on oil sump starter. Check high pres-  
sure switch.  
FAILURE TO START EXCESS ACCELERATION  
CA P Excess Acceleration: Check guide vane clo- Check that guide vanes are closed at start-up. Check  
TIME  
sure at start-up.  
starter for proper operation. Reduce unit pressure  
if possible.  
FAILURE TO START STARTER TRANSITION  
RUN AUX Starter Transition Fault: Check 1CR/ Check starter for proper operation.  
1M/Interlock mechanism. Run contact failed to close.  
FAULT  
FAILURE TO START 1CR AUX CONTACT FAULT  
1CR AUX Starter Contact Fault: Check 1CR/1M Check starter for proper operation.  
aux. contacts. Start contact failed to close.  
FAILURE TO START MOTOR AMPS NOT SENSED  
CA P Motor Amps Not Sensed: Check motor load Check for proper motor amps signal to SMM. Check  
signal.  
wiring from SMM to current transformer. Check main  
motor circuit breaker for trip.  
FAILURE TO START CHECK REFRIGERANT TYPE  
FAILURE TO START LOW OIL PRESSURE  
Current Refrigerant Properties Abnormal — Check Pressures at transducers indicate another refriger-  
Selection of refrigerant type.  
ant type in control test. Make sure to access the AT-  
TACH TO NETWORK DEVICE screen after speci-  
fying HFC-134a refrigerant type.  
Low Oil Pressure [LIMIT]:* Check oil pressure switch/ The oil pressure differential switch is open when the  
pump and 2C aux.  
compressor tried to start. Check the switch for proper  
operation. Also, check the oil pump interlock (2C aux)  
in the power panel and the high condenser pres-  
sure switch.  
FAILURE TO START LOW GEAR OIL PRESSURE  
GEAROILP [VALUE] exceeded limit of [LIMIT].*  
Check gear oil pump/filter.  
Check for closed oil supply valves. Check oil filter.  
Check transducer accuracy.  
FAILURE TO START GEAR OIL PRESSURE SENSOR Gear Oil Pressure Transducer Out of Range [VALUE]. Check calibration of transducer. Replace if  
necessary.  
*[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 the control tripped.  
H. COMPRESSOR JUMPSTART AND REFRIGERANT PROTECTION  
PRIMARY MESSAGE  
SECONDARY MESSAGE  
ALARM MESSAGE/PRIMARY CAUSE  
ADDITIONAL CAUSE/REMEDY  
UNAUTHORIZED  
OPERATION  
UNIT SHOULD BE  
STOPPED  
CA P Emergency: Compressor  
running without control authorization.  
Compressor is running with more than 10% RLA  
and control is trying to shut it down. Turn power  
off to compressor if unable to stop. Determine cause  
before re-powering.  
POTENTIAL FREEZE-UP  
FAILURE TO STOP  
EVAP PRESS/TEMP  
TOO LOW  
ERT Emergency: Freeze-up  
prevention.  
Determine cause. If pumping refrigerant out of  
chiller, stop operation and go over pumpout  
procedures.  
DISCONNECT POWER  
WITH STARTER  
RUN AUX Emergency: DISCONNECT  
POWER.  
Starter run and start contacts are energized while  
control tried to shut down. Disconnect power to  
starter.  
LOSS OF  
COMMUNICATION  
Loss of Communication with Starter: Check  
chiller.  
Check wiring from PSIO to SMM. Check SMM mod-  
ule troubleshooting procedures.  
STARTER CONTACT  
FAULT  
ABNORMAL 1CR OR  
RUN AUX  
1CR AUX Starter Contact Fault: Check  
1CR/1M aux. contacts.  
Starter run and start contacts energized while chiller  
was off. Disconnect power.  
POTENTIAL FREEZE UP  
COND PRESS/TEMP  
TOO LOW  
CRT [VALUE] exceeded limit of [LIMIT]*  
Emergency: Freeze-up prevention.  
The condenser pressure transducer is reading a  
pressure that could freeze the water in the con-  
denser tubes. Check for condenser refrigerant leaks,  
bad transducers, or transferred refrigerant. Place  
the unit in PUMPDOWN mode to eliminate the  
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 the control tripped.  
88  
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Table 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages  
with Troubleshooting Guides (cont)  
I. NORMAL RUN WITH RESET, TEMPERATURE, OR DEMAND  
PRIMARY MESSAGE  
SECONDARY MESSAGE  
4-20MA SIGNAL  
PROBABLE CAUSE/REMEDY  
RUNNING — RESET ACTIVE  
RUNNING — RESET ACTIVE  
RUNNING — RESET ACTIVE  
RUNNING — TEMP CONTROL  
RUNNING — TEMP CONTROL  
RUNNING — TEMP CONTROL  
RUNNING — DEMAND LIMITED  
RUNNING — DEMAND LIMITED  
RUNNING — DEMAND LIMITED  
RUNNING — DEMAND LIMITED  
RUNNING — DEMAND LIMITED  
REMOTE SENSOR CONTROL  
CHW TEMP DIFFERENCE  
LEAVING CHILLED WATER  
ENTERING CHILLED WATER  
TEMPERATURE RAMP LOADING  
BY DEMAND RAMP LOADING  
BY LOCAL DEMAND SETPOINT  
BY 4-20MA SIGNAL  
Reset program active based on CONFIG screen setup.  
Default method of temperature control.  
ECW control activated on CONFIG screen.  
Ramp loading in effect. Use SERVICE1 screen to modify.  
Ramp loading in effect. Use SERVICE1 screen to modify.  
Demand limit set point is Ͻ actual demand.  
BY CCN SIGNAL  
Demand limit is active based on CONFIG screen setup.  
BY LOADSHED/REDLINE  
Hot gas bypass option is energized. See surge prevention in the  
control section.  
RUNNING — TEMP CONTROL  
HOT GAS BYPASS  
RUNNING — DEMAND LIMITED  
RUNNING — TEMP CONTROL  
BY LOCAL SIGNAL  
ICE BUILD MODE  
Active demand limit manually overridden on STATUS01 table.  
Chiller is running under Ice Build temperature control.  
J. NORMAL RUN OVERRIDES ACTIVE (ALERTS)  
PRIMARY MESSAGE  
SECONDARY MESSAGE  
ALARM MESSAGE/PRIMARY CAUSE  
ADDITIONAL CAUSE/REMEDY  
RUN CAPACITY LIMITED  
HIGH CONDENSER PRESSURE  
CRP [VALUE] exceeded limit of [LIMIT]*.  
Condenser pressure override.  
RUN CAPACITY LIMITED  
RUN CAPACITY LIMITED  
RUN CAPACITY LIMITED  
RUN CAPACITY LIMITED  
HIGH MOTOR TEMPERATURE  
LOW EVAP REFRIG TEMP  
HIGH COMPRESSOR LIFT  
MANUAL GUIDE VANE TARGET  
MTRW [VALUE] exceeded limit of [LIMIT]*.  
Motor temperature override.  
See Capacity Overrides, Table 4.  
Correct operating condition, modify set-  
point, or release override.  
ERT [VALUE] exceeded limit of [LIMIT]*. Check  
refrigerant charge level.  
Surge Prevention Override; lift too high for  
compressor.  
GV TRG Run Capacity Limited: Manual guide  
vane target.  
*[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 temperature, pressure, voltage, etc., at which the control tripped.  
K. OUT-OF-RANGE SENSOR FAILURES  
PRIMARY MESSAGE  
SENSOR FAULT  
SECONDARY MESSAGE  
ALARM MESSAGE/PRIMARY CAUSE  
ADDITIONAL CAUSE/REMEDY  
LEAVING CHW TEMPERATURE  
Sensor Fault: Check leaving CHW  
sensor.  
SENSOR FAULT  
SENSOR FAULT  
SENSOR FAULT  
SENSOR FAULT  
SENSOR FAULT  
SENSOR FAULT  
SENSOR FAULT  
SENSOR FAULT  
ENTERING CHW TEMPERATURE  
CONDENSER PRESSURE  
EVAPORATOR PRESSURE  
BEARING TEMPERATURE  
MOTOR WINDING TEMP  
Sensor Fault: Check entering CHW  
sensor.  
Sensor Fault: Check condenser pressure  
transducer.  
Sensor Fault: Check evaporator pressure  
transducer.  
See sensor test procedure and check  
sensors for proper operation and  
wiring.  
Sensor Fault: Check bearing temperature  
sensor.  
Sensor Fault: Check motor temperature  
sensor.  
DISCHARGE TEMPERATURE  
OIL SUMP TEMPERATURE  
OIL PRESSURE TRANSDUCER  
Sensor Fault: Check discharge temperature  
sensor.  
Sensor Fault: Check oil sump temperature  
sensor.  
Sensor Fault: Check oil pressure  
transducer.  
89  
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Table 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages  
with Troubleshooting Guides (cont)  
L. CHILLER PROTECT LIMIT FAULTS  
Excessive numbers of the same fault can lead to severe chiller  
damage. Seek service expertise.  
PRIMARY MESSAGE  
PROTECTIVE LIMIT  
SECONDARY MESSAGE  
ALARM MESSAGE/PRIMARY CAUSE  
ADDITIONAL CAUSE/REMEDY  
HIGH DISCHARGE TEMP  
CMPD [VALUE] exceeded limit of [LIMIT]*. Check discharge temperature immediately. Check sen-  
Check discharge temperature.  
sor for accuracy; check for proper condenser flow and  
temperature; check oil reservoir temperature. Check  
condenser for fouled tubes or air in chiller. Check for  
proper guide vane actuator operation.  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
LOW REFRIGERANT TEMP  
ERT [VALUE] exceeded limit of [LIMIT]*. Check for proper amount of refrigerant charge; check  
Check evap pump and flow switch.  
for proper water flow and temperatures. Check for  
proper guide vane actuator operation.  
HIGH MOTOR TEMPERATURE  
MTRW [VALUE] exceeded limit of [LIMIT]*. Check motor temperature immediately. Check sen-  
Check motor cooling and solenoid.  
sor for accuracy. Check for proper condenser flow and  
temperature. Check motor cooling system for restric-  
tions. Check motor cooling solenoid for proper opera-  
tion. Check refrigerant filter.  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
HIGH BEARING TEMPERATURE  
LOW OIL PRESSURE  
MTRB [VALUE] exceeded limit of [LIMIT]*. Check for throttled oil supply isolation valves. Valves  
Check oil cooling control.  
should be wide open. Check oil cooler thermal ex-  
pansion valve. Check sensor accuracy. Check jour-  
nal and thrust bearings. Check refrigerant filter. Check  
for excessive oil sump level.  
OILPD [VALUE] exceeded limit of [LIMIT]*. Check power to oil pump and oil level. Check for dirty  
Check oil pump and transducer.  
filters or oil foaming at start-up. Check for thermal over-  
load cutout. Reduce ramp load rate if foaming noted.  
NOTE: This alarm is not related to pressure switch  
problems.  
Low Oil Pressure [OPEN]*. Check oil  
pressure switch/pump and 2C aux.  
Check the oil pressure switch for proper operation.  
Check oil pump for proper pressure. Check for ex-  
cessive refrigerant in oil system.  
PROTECTIVE LIMIT  
NO MOTOR CURRENT  
CA  
P
Loss of Motor Current: Check Check wiring: Check torque setting on solid-state starter.  
sensor.  
Check for main circuit breaker trip. Check power sup-  
ply to PSIO module.  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
POWER LOSS  
V
P Power Loss: Check voltage  
supply.  
Check 24-vac input on the SMM (terminals 23 and  
LOW LINE VOLTAGE  
HIGH LINE VOLTAGE  
LOW CHILLED WATER FLOW  
V
P [VALUE] exceeded limit of [LIMIT]*. 24). Check transformers to SMM. Check power to PSIO  
Check voltage supply.  
module. Check distribution bus. Consult power  
company.  
V
P [VALUE] exceeded limit of [LIMIT]*.  
Check voltage supply.  
EVFL Flow Fault: Check evap pump/flow  
switch.  
Perform pumps control test (from CONTROL TEST  
table) and verify proper switch operation. Check all  
water valves and pump operation.  
LOW CONDENSER WATER FLOW CDFL Flow Fault: Check condenser pump/  
flow switch.  
HIGH CONDENSER PRESSURE  
High Cond Pressure [OPEN]*: Check switch, Check the high-pressure switch. Check for proper con-  
oil pressure contact, and water temp/flow.  
denser pressures and condenser water flow. Check  
for fouled tubes. Check the 2C aux. contact and the  
oil pressure switch in the power panel. This alarm is  
not caused by the transducer.  
High Cond Pressure [VALUE]*: Check switch, Check water flow in condenser. Check for fouled tubes.  
water flow, and transducer.  
Transducer should be checked for accuracy. This alarm  
is not caused by the high pressure switch.  
PROTECTIVE LIMIT  
HIGH CONDENSER PRESSURE  
High Cond Pressure [VALUE]*: Check switch, Check water flow in condenser. Check for fouled tubes.  
water flow, and transducer.  
Transducer should be checked for accuracy. This alarm  
is not caused by the high pressure switch.  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
1CR AUX CONTACT FAULT  
RUN AUX CONTACT FAULT  
CCN OVERRIDE STOP  
CR AUX Starter Contact Fault: Check 1CR auxiliary contact opened while chiller was run-  
1CR/1M aux contacts. ning. Check starter for proper operation.  
RUN AUX Starter Contact Fault: Check Run auxiliary contact opened while chiller was run-  
1CR/1M aux contacts. ning. Check starter for proper operation.  
CHIL  
S
S CCN Override Stop while in CCN has signaled chiller to stop. Reset and restart  
LOCAL run mode.  
when ready. If the signal was sent by the LID, release  
the Stop signal on STATUS01 table.  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
SPARE SAFETY DEVICE  
EXCESSIVE MOTOR AMPS  
EXCESSIVE COMPR SURGE  
STARTER FAULT  
SRP PL Spare Safety Fault: Check  
contacts.  
Spare safety input has tripped or factory-installed jumper  
not present.  
CA P [VALUE] exceeded limit of [LIMIT]*. Check motor current for proper calibration. Check guide  
High Amps; Check guide vane drive. vane drive and actuator for proper operation.  
Compressor Surge: Check condenser wa- Check condenser flow and temperatures. Check con-  
ter temp and flow. figuration of surge protection.  
STR FLT Starter Fault: Check starter for Check starter for possible ground fault, reverse rota-  
tion, voltage trip, etc.  
fault source.  
STARTER OVERLOAD TRIP  
STR FLT Starter Overload Trip: Check Reset overloads and reset alarm. Check motor cur-  
amps calibration/reset overload.  
rent calibration or overload calibration (do not field-  
calibrate overloads).  
*[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 temperature, pressure, voltage, etc., at  
which the control tripped. [OPEN] indicates that an input circuit is open.  
90  
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Table 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages  
with Troubleshooting Guides (cont)  
L. CHILLER PROTECT LIMIT FAULTS (cont)  
Excessive numbers of the same fault can lead to severe chiller  
damage. Seek service expertise.  
PRIMARY MESSAGE  
PROTECTIVE LIMIT  
SECONDARY MESSAGE  
ALARM MESSAGE/PRIMARY CAUSE  
ADDITIONAL CAUSE/REMEDY  
TRANSDUCER VOLTAGE FAULT  
V
REF [VALUE] exceeded limit of [LIMIT]*.  
Check transformer power (5 vdc) supply to  
transducers. Power must be 4.5 to 5.5 vdc.  
Check transducer power supply.  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
LOW GEAR OIL PRESSURE  
HIGH GEAR OIL TEMP  
CCN OVERRIDE STOP  
GEAROILP [VALUE] exceeded imit of  
[LIMIT]*. Check gear oil pump filter.  
Check for closed oil supply valves. Check oil fil-  
ter. Check transducer accuracy.  
GEAOILT [VALUE] exceeded limit of  
[LIMIT]*. Check gear oil cooler filter.  
Check for cooler water flow. Check sensor for  
accuracy.  
CHIL  
S
S CCN. Override stop while in  
Machine received a command from the net-  
work to stop overriding local operating mode.  
local run mode.  
*[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 temperature, pressure, voltage,  
etc., at which the control tripped. [OPEN] indicates that an input circuit is open.  
M. CHILLER ALERTS  
PRIMARY MESSAGE  
RECYCLE ALERT  
SECONDARY MESSAGE  
ALARM MESSAGE/PRIMARY CAUSE  
ADDITIONAL CAUSE/REMEDY  
HIGH AMPS AT SHUTDOWN  
HighAmps at Recycle: Check guide vane  
drive.  
Check that guide vanes are closing. Check  
motor amps correction calibration is cor-  
rect. Check actuator for proper operation.  
SENSOR FAULT ALERT  
SENSOR FAULT ALERT  
LEAVING COND WATER TEMP  
ENTERING COND WATER TEMP  
CHECK OIL FILTER  
Sensor Fault: Check leaving condenser  
water sensor.  
Check sensor. See sensor test procedure.  
Sensor Fault: Check entering condenser  
water sensor.  
LOW OIL PRESSURE  
ALERT  
Low Oil Pressure Alert: Check oil  
Check oil filter. Check for improper oil level  
or temperature.  
AUTORESTART PENDING  
AUTORESTART PENDING  
AUTORESTART PENDING  
SENSOR ALERT  
POWER LOSS  
V
P Power Loss: Check voltage  
Check power supply if there are excessive  
compressor starts occurring.  
supply.  
LOW LINE VOLTAGE  
V
P [VALUE] exceeded limit of [LIMIT]*.  
Check voltage supply.  
HIGH LINE VOLTAGE  
V
P [VALUE] exceeded limit of [LIMIT]*.  
Check voltage supply.  
HIGH DISCHARGE TEMP  
CMPD [VALUE] exceeded limit of  
[LIMIT]*. Check discharge  
temperature.  
Discharge temperature exceeded the alert  
threshold. Check entering condenser water  
temperature.  
SENSOR ALERT  
HIGH BEARING TEMP  
MTRB [VALUE] exceeded limit of  
[LIMIT]*. Check thrust bearing  
temperature.  
Thrust bearing temperature exceeded the  
alert threshold. Check for closed valves, im-  
proper oil level or temperatures.  
CONDENSER PRESSURE  
ALERT  
PUMP RELAY ENERGIZED  
CRP High Condenser Pressure [LIMIT]*.  
Pump energized to reduce pressure.  
Check ambient conditions. Check con-  
denser pressure for accuracy.  
RECYCLE ALERT  
EXCESSIVE RECYCLE STARTS  
Excessive recycle starts.  
The chiller load is too small to keep the chiller  
on line and there have been more than 5  
restarts in 4 hours. Increase chiller load, ad-  
just hot gas bypass, increase RECYCLE RE-  
START DELTA T from SERVICE1 screen.  
SENSOR ALERT  
SENSOR ALERT  
LOW GEAR OIL PRESSURE  
HIGH GEAR OIL TEMP  
GEAROILP [VALUE] exceeded imit of  
[LIMIT]*. Check gear oil pump filter.  
Check for closed oil supply valves. Check  
oil filter. Check transducer accuracy.  
GEAOILT [VALUE] exceeded limit of  
[LIMIT]*. Check gear oil cooler filter.  
Check for cooler water flow. Check sensor  
for accuracy.  
*[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 temperature, pressure, voltage,  
etc., at which the control tripped.  
91  
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Table 12 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages  
with Troubleshooting Guides (cont)  
N. OTHER PROBLEMS/MALFUNCTIONS  
DESCRIPTION/MALFUNCTION  
PROBABLE CAUSE/REMEDY  
Chilled Water/Brine Temperature  
Too High (Chiller Running)  
Chilled water set point set too high. Access set point on LID and verify.  
Capacity override or excessive cooling load (chiller at design capacity). Check  
LID status messages. Check for outside air infiltration into conditioned space.  
Condenser temperature too high. Check for proper flow, examine cooling  
tower operation, check for air or water leaks, check for fouled tubes.  
Refrigerant level low. Check for leaks, add refrigerant, and trim charge.  
Liquid bypass in waterbox. Examine division plates and gaskets for leaks.  
Guide vanes fail to open. Use control test to check operation.  
Chilled water control point too high. Access CONTROL ALGORITHM STA-  
TUS table, MAINT01 screen, and check chilled water control operation.  
Guide vanes fail to open fully. Be sure that the guide vane target is released.  
Check guide vane linkage. Check limit switch in actuator. Check that sensor  
is in the proper terminals.  
Chilled Water/Brine Temperature Too Low (Chiller  
Running)  
Chilled water set point set too low. Access set point on LID and verify.  
Chilled water control point too low. Access CONTROL ALGORITHM STA-  
TUS tables, MAINT01 screen, and check chilled water control for proper  
resets.  
High discharge temperature keeps guide vanes open.  
Guide vanes fail to close. Be sure that guide vane target is released. Check  
chilled water sensor accuracy. Check guide vane linkage. Check actuator  
operation.  
Chilled Water Temperature Fluctuates. Vanes Hunt  
Deadband too narrow. Configure LID for a larger deadband (SERVICE1 screen).  
Proportional bands too narrow. Either PROPORTIONAL INC BAND or PRO-  
PORTIONAL DEC BAND should be increased (MAINT01 screen).  
Loose guide vane drive. Adjust chain drive.  
Defective vane actuator. Check using control test feature.  
Defective temperature sensor. Check sensor accuracy.  
Check for proper oil level (not enough oil).  
Low Oil Sump Temperature While Running  
(Less than 100 F [38 C])  
At Power Up, Default Screen Does Not Appear, ‘‘Tables Load-  
ing’’ Message Continually 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 96.  
High Oil Temperature While Running  
Check for proper oil level (too much oil). Check water supply to oil cooler.  
Blank LID Screen (Minimal Contrast Visible)  
Increase contrast potentiometer. See Fig. 49. Check red LED on LID for  
proper operation, (power supply). If LED is blinking, but green LED’s are  
not, replace LID module, (memory failure). Check light bulb if backlit model.  
‘‘Communications Failure’’ Highlighted Message At  
Bottom of LID Screen  
LID is not properly addressed to the PSIO. Make sure that, on ATTACH TO  
NETWORK DEVICE screen,. LOCAL DEVICE is set to read the PSIO ad-  
dress. Check LEDs on PSIO. Is red LED operating properly? Are green LEDs  
blinking? See Control Module troubleshooting section.  
Control Test Disabled  
Press the Stop pushbutton. The PIC must be in the OFF mode for the con-  
trol test feature to operate. Clear all alarms. Check line voltage percent on  
STATUS01 screen. The percent must be within 90% to 110%. Check volt-  
age input to SMM; calibrate starter voltage potentiometer for accuracy.  
Vanes Will Not Open in Control Test  
Oil Pump Does Not Run  
Low pressure alarm is active. Put chiller into PUMPDOWN mode or equal-  
ize pressure. Check guide vane actuator wiring.  
Check oil pump voltage supply. Cooler vessel pressure under vacuum.  
Pressurize vessel. Check temperature overload cutout switch.  
LID Default Screen Does Not Update  
This is normal operation when an alarm is present. The screen freezes the  
moment the alarm is activated to aid in troubleshooting. The STATUS01 screen  
provides current information.  
Chiller Does Not Stop When the STOP Button is Pressed  
LID Screen Dark  
The STOP button wiring connector on the LID module is not properly con-  
nected or the chiller is in soft stop mode and the guide vanes are  
closing.  
Light bulb burned out. Replace as needed.  
92  
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Table 13 — External Gear Troubleshooting Guide  
PROBLEM  
Excessive Operating Temperature  
Oil Leakage  
POSSIBLE CAUSE — ITEM NO.s*  
1,2,3,4,5,6,7,9,12,18,20,21  
1,2,3,4,5,7,9,12,13,18,19,21  
Gear Wear  
Bearing Failure  
Unusual Noise  
1,2,3,4,6,7,8,9,10,11,12,13,14,15,16,18,19,21,22  
1,6,7,8,9,10,11,12,15,16,19,20,21  
1,2,3,4,6,7,8,9,10,11,12,13,15,16,17,20,21  
*See table below for probable cause and suggested remedy.  
POSSIBLE CAUSE  
1. Unit Overload  
ACTION  
Reduce the loading.  
2. Incorrect Oil Level  
Verify that the oil level is correct. Too little or too much oil can cause high  
temperature.  
3. Wrong Oil Grade  
Use only the AGMA (American Gear Manufacturers Association) grade oil  
as specified for the unit size and ambient temperature.  
4. Contaminated Oil  
5. Clogged Breather  
If oil is oxidized, dirty, or has high sludge content, change the oil.  
Clean breather regularly.  
6. Improper Bearing Clearance  
Too large or too small bearing clearance. Refer to drawing or contact the  
gear manufacturer for correct clearance, checking technique, and toler-  
ance. Shafts should turn freely when disconnected from the load.  
7. Improper Coupling Alignment  
8. Incorrect Coupling  
Disconnect couplings, check spacing between shafts, and check alignment.  
Realign as required.  
Rigid couplings can cause shaft failure. Replace with a coupling that pro-  
vides flexibility and lateral float.  
9. Excessive Operating Speed  
Reduce the speed.  
10. Torsional or Lateral Vibrations  
Vibrations can occur through a particular speed range known as the critical  
speed. Contact the factory for specific recommendations.  
11. Extreme Repetitive Shocks  
Apply couplings capable of absorbing shocks.  
12. Improper Lubrication of Bearings  
13. Improper Storage or Prolonged Shutdown  
Verify that all bearings are receiving adequate amounts of lubricating oil.  
Destructive rusting of bearings and gears will be caused by storage or pro-  
longed shutdown in moist ambient temperatures. If rust is found, unit must  
be disassembled, inspected, and repaired.  
14. Excessive Backlash  
15. Misalignment of Gears  
16. Housing Twisted or Distorted  
17. Gear Tooth Wear  
Contact gear manufacturer.  
Contact pattern to be a minimum of 80% of face.  
Verify proper shimming or stiffness of the foundation.  
Contact gear manufacturer.  
18. Open Drains  
Tighten drain plugs.  
19. Loosely Bolted Covers  
20. Motor Related  
Check all bolted joints and tighten if necessary.  
Verify that actual operating conditions are consistent with motor nameplate.  
21. Excessive Ambient Temperature  
Shield unit from heat source and maintain proper air flow around the gear  
unit.  
93  
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Table 14A — Thermistor Temperature (F) vs Resistance/Voltage Drop  
TEMPERATURE  
(F)  
VOLTAGE  
DROP (V)  
RESISTANCE  
(Ohms)  
TEMPERATURE  
(F)  
VOLTAGE  
DROP (V)  
RESISTANCE  
(Ohms)  
TEMPERATURE  
(F)  
VOLTAGE  
DROP (V)  
RESISTANCE  
(Ohms)  
−25.0  
−24.0  
−23.0  
−22.0  
−21.0  
−20.0  
−19.0  
−18.0  
−17.0  
−16.0  
−15.0  
−14.0  
−13.0  
−12.0  
−11.0  
−10.0  
−9.0  
−8.0  
−7.0  
−6.0  
−5.0  
−4.0  
−3.0  
−2.0  
−1.0  
0.0  
4.821  
4.818  
4.814  
4.806  
4.800  
4.793  
4.786  
4.779  
4.772  
4.764  
4.757  
4.749  
4.740  
4.734  
4.724  
4.715  
4.705  
4.696  
4.688  
4.676  
4.666  
4.657  
4.648  
4.636  
4.624  
4.613  
4.602  
4.592  
4.579  
4.567  
4.554  
4.540  
4.527  
4.514  
4.501  
4.487  
4.472  
4.457  
4.442  
4.427  
4.413  
4.397  
4.381  
4.366  
4.348  
4.330  
4.313  
4.295  
4.278  
4.258  
4.241  
4.223  
4.202  
4.184  
4.165  
4.145  
4.125  
4.103  
4.082  
4.059  
4.037  
4.017  
3.994  
3.968  
3.948  
3.927  
3.902  
3.878  
3.854  
3.828  
3.805  
3.781  
3.757  
3.729  
3.705  
3.679  
3.653  
3.627  
3.600  
3.575  
3.547  
3.520  
3.493  
3.464  
3.437  
3.409  
3.382  
3.353  
3.323  
3.295  
3.267  
3.238  
3.210  
3.181  
3.152  
3.123  
98010  
94707  
91522  
88449  
85486  
82627  
79871  
77212  
74648  
72175  
69790  
67490  
65272  
63133  
61070  
59081  
57162  
55311  
53526  
51804  
50143  
48541  
46996  
45505  
44066  
42679  
41339  
40047  
38800  
37596  
36435  
35313  
34231  
33185  
32176  
31202  
30260  
29351  
28473  
27624  
26804  
26011  
25245  
24505  
23789  
23096  
22427  
21779  
21153  
20547  
19960  
19393  
18843  
18311  
17796  
17297  
16814  
16346  
15892  
15453  
15027  
14614  
14214  
13826  
13449  
13084  
12730  
12387  
12053  
11730  
11416  
11112  
10816  
10529  
10250  
9979  
71  
72  
3.093  
3.064  
3.034  
3.005  
2.977  
2.947  
2.917  
2.884  
2.857  
2.827  
2.797  
2.766  
2.738  
2.708  
2.679  
2.650  
2.622  
2.593  
2.563  
2.533  
2.505  
2.476  
2.447  
2.417  
2.388  
2.360  
2.332  
2.305  
2.277  
2.251  
2.217  
2.189  
2.162  
2.136  
2.107  
2.080  
2.053  
2.028  
2.001  
1.973  
1.946  
1.919  
1.897  
1.870  
1.846  
1.822  
1.792  
1.771  
1.748  
1.724  
1.702  
1.676  
1.653  
1.630  
1.607  
1.585  
1.562  
1.538  
1.517  
1.496  
1.474  
1.453  
1.431  
1.408  
1.389  
1.369  
1.348  
1.327  
1.308  
1.291  
1.289  
1.269  
1.250  
1.230  
1.211  
1.192  
1.173  
1.155  
1.136  
1.118  
1.100  
1.082  
1.064  
1.047  
1.029  
1.012  
0.995  
0.978  
0.962  
0.945  
0.929  
0.914  
0.898  
0.883  
0.868  
0.853  
5781  
5637  
5497  
5361  
5229  
5101  
4976  
4855  
4737  
4622  
4511  
4403  
4298  
4196  
4096  
4000  
3906  
3814  
3726  
3640  
3556  
3474  
3395  
3318  
3243  
3170  
3099  
3031  
2964  
2898  
2835  
2773  
2713  
2655  
2597  
2542  
2488  
2436  
2385  
2335  
2286  
2239  
2192  
2147  
2103  
2060  
2018  
1977  
1937  
1898  
1860  
1822  
1786  
1750  
1715  
1680  
1647  
1614  
1582  
1550  
1519  
1489  
1459  
1430  
1401  
1373  
1345  
1318  
1291  
1265  
1240  
1214  
1190  
1165  
1141  
1118  
1095  
1072  
1050  
1029  
1007  
986  
167  
168  
169  
170  
171  
172  
173  
174  
175  
176  
177  
178  
179  
180  
181  
182  
183  
184  
185  
186  
187  
188  
189  
190  
191  
192  
193  
194  
195  
196  
197  
198  
199  
200  
201  
202  
203  
204  
205  
206  
207  
208  
209  
210  
211  
212  
213  
214  
215  
216  
217  
218  
219  
220  
221  
222  
223  
224  
225  
0.838  
0.824  
0.810  
0.797  
0.783  
0.770  
0.758  
0.745  
0.734  
0.722  
0.710  
0.700  
0.689  
0.678  
0.668  
0.659  
0.649  
0.640  
0.632  
0.623  
0.615  
0.607  
0.600  
0.592  
0.585  
0.579  
0.572  
0.566  
0.560  
0.554  
0.548  
0.542  
0.537  
0.531  
0.526  
0.520  
0.515  
0.510  
0.505  
0.499  
0.494  
0.488  
0.483  
0.477  
0.471  
0.465  
0.459  
0.453  
0.446  
0.439  
0.432  
0.425  
0.417  
0.409  
0.401  
0.393  
0.384  
0.375  
0.366  
719  
705  
690  
677  
663  
650  
638  
626  
614  
602  
591  
581  
570  
561  
551  
542  
533  
524  
516  
508  
501  
494  
487  
480  
473  
467  
461  
456  
450  
445  
439  
434  
429  
424  
419  
415  
410  
405  
401  
396  
391  
386  
382  
377  
372  
367  
361  
356  
350  
344  
338  
332  
325  
318  
311  
304  
297  
289  
282  
73  
74  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
85  
86  
87  
88  
89  
90  
91  
92  
93  
94  
95  
96  
1.0  
97  
2.0  
98  
3.0  
99  
4.0  
100  
101  
102  
103  
104  
105  
106  
107  
108  
109  
110  
111  
112  
113  
114  
115  
116  
117  
118  
119  
120  
121  
122  
123  
124  
125  
126  
127  
128  
129  
130  
131  
132  
133  
134  
135  
136  
137  
138  
139  
140  
141  
142  
143  
144  
145  
146  
147  
148  
149  
150  
151  
152  
153  
154  
155  
156  
157  
158  
159  
160  
161  
162  
163  
164  
165  
166  
5.0  
6.0  
7.0  
8.0  
9.0  
10.0  
11.0  
12.0  
13.0  
14.0  
15.0  
16.0  
17.0  
18.0  
19.0  
20.0  
21.0  
22.0  
23.0  
24.0  
25.0  
26.0  
27.0  
28.0  
29.0  
30.0  
31.0  
32.0  
33.0  
34.0  
35.0  
36.0  
37.0  
38.0  
39.0  
40.0  
41.0  
42.0  
43.0  
44.0  
45.0  
46.0  
47.0  
48.0  
49.0  
50.0  
51.0  
52.0  
53.0  
54.0  
55.0  
56.0  
57.0  
58.0  
59.0  
60.0  
61.0  
62.0  
63.0  
64.0  
65.0  
66.0  
67.0  
68.0  
69.0  
70.0  
9717  
9461  
9213  
8973  
8739  
8511  
8291  
965  
8076  
945  
7868  
925  
7665  
906  
7468  
887  
7277  
868  
7091  
850  
6911  
832  
6735  
815  
6564  
798  
6399  
782  
6238  
765  
6081  
750  
5929  
734  
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Table 14B — Thermistor Temperature (C) vs Resistance/Voltage Drop  
TEMPERATURE  
(C)  
VOLTAGE  
DROP (V)  
RESISTANCE  
(Ohms)  
TEMPERATURE  
(C)  
VOLTAGE  
DROP (V)  
RESISTANCE  
(Ohms)  
−40  
−39  
−38  
−37  
−36  
−35  
−34  
−33  
−32  
−31  
−30  
−29  
−28  
−27  
−26  
−25  
−24  
−23  
−22  
−21  
−20  
−19  
−18  
−17  
−16  
−15  
−14  
−13  
−12  
−11  
−10  
−9  
4.896  
4.889  
4.882  
4.874  
4.866  
4.857  
4.848  
4.838  
4.828  
4.817  
4.806  
4.794  
4.782  
4.769  
4.755  
4.740  
4.725  
4.710  
4.693  
4.676  
4.657  
4.639  
4.619  
4.598  
4.577  
4.554  
4.531  
4.507  
4.482  
4.456  
4.428  
4.400  
4.371  
4.341  
4.310  
4.278  
4.245  
4.211  
4.176  
4.140  
4.103  
4.065  
4.026  
3.986  
3.945  
3.903  
3.860  
3.816  
3.771  
3.726  
3.680  
3.633  
3.585  
3.537  
3.487  
3.438  
3.387  
3.337  
3.285  
3.234  
3.181  
3.129  
3.076  
3.023  
2.970  
2.917  
2.864  
2.810  
2.757  
2.704  
2.651  
2.598  
2.545  
2.493  
2.441  
2.389  
2.337  
2.286  
2.236  
2.186  
2.137  
2.087  
2.039  
1.991  
1.944  
168 230  
157 440  
147 410  
138 090  
129 410  
121 330  
113 810  
106 880  
100 260  
94 165  
88 480  
83 170  
78 125  
73 580  
69 250  
65 205  
61 420  
57 875  
54 555  
51 450  
48 536  
45 807  
43 247  
40 845  
38 592  
38 476  
34 489  
32 621  
30 866  
29 216  
27 633  
26 202  
24 827  
23 532  
22 313  
21 163  
20 079  
19 058  
18 094  
17 184  
16 325  
15 515  
14 749  
14 026  
13 342  
12 696  
12 085  
11 506  
10 959  
10 441  
9 949  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
64  
65  
66  
67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
85  
86  
87  
88  
89  
90  
91  
92  
93  
94  
95  
96  
97  
98  
99  
100  
101  
102  
103  
104  
105  
106  
107  
1.898  
1.852  
1.807  
1.763  
1.719  
1.677  
1.635  
1.594  
1.553  
1.513  
1.474  
1.436  
1.399  
1.363  
1.327  
1.291  
1.258  
1.225  
1.192  
1.160  
1.129  
1.099  
1.069  
1.040  
1.012  
0.984  
0.949  
0.920  
0.892  
0.865  
0.838  
0.813  
0.789  
0.765  
0.743  
0.722  
0.702  
0.683  
0.665  
0.648  
0.632  
0.617  
0.603  
0.590  
0.577  
0.566  
0.555  
0.545  
0.535  
0.525  
0.515  
0.506  
0.496  
0.486  
0.476  
0.466  
0.454  
0.442  
0.429  
0.416  
0.401  
0.386  
0.370  
2 184  
2 101  
2 021  
1 944  
1 871  
1 801  
1 734  
1 670  
1 609  
1 550  
1 493  
1 439  
1 387  
1 337  
1 290  
1 244  
1 200  
1 158  
1 118  
1 079  
1 041  
1 006  
971  
938  
906  
876  
836  
805  
775  
747  
719  
693  
−8  
669  
−7  
645  
−6  
623  
−5  
602  
−4  
583  
−3  
564  
−2  
547  
−1  
531  
0
516  
1
502  
2
489  
3
477  
4
466  
5
456  
6
446  
7
436  
8
427  
9
419  
10  
410  
11  
9 485  
402  
12  
9 044  
393  
13  
8 627  
385  
14  
8 231  
376  
15  
7 855  
367  
16  
7 499  
357  
17  
7 161  
346  
18  
6 840  
335  
19  
6 536  
324  
20  
6 246  
312  
21  
5 971  
299  
22  
5 710  
285  
23  
5 461  
24  
5 225  
25  
5 000  
26  
4 786  
27  
4 583  
28  
4 389  
29  
4 204  
30  
4 028  
31  
3 861  
32  
3 701  
33  
3 549  
34  
3 404  
35  
3 266  
36  
3 134  
37  
3 008  
38  
2 888  
39  
2 773  
40  
2 663  
41  
2 559  
42  
2 459  
43  
2 363  
44  
2 272  
95  
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RED LEDs  
Control Modules  
PSIO Module — If the LED is blinking continuously at a  
2-second rate, it is indicating proper operation. If it is lit con-  
tinuously it indicates a problem requiring replacement of the  
module. Off continuously indicates that the power should be  
checked. If the red LED blinks 3 times per second, a soft-  
ware error has been discovered and the module must be re-  
placed. If there is no input power, check the fuses and the  
circuit breaker. If the fuses are good, check for a shorted  
secondary of transformer, or if power is present to the mod-  
ule, replace the module.  
4-In/2-Out Module — If the LED is blinking, this module is  
operating properly. A steady red light indicates a module fail-  
ure. Replace the 4-In/2-Out module.  
GREEN LEDs — There are 1 or 2 green LEDs on each type  
of module. These LEDs indicate communication status be-  
tween different parts of the controller and the network mod-  
ules as follows:  
Turn the controller power off 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 evaluations of the hard-  
ware to determine its condition. Proper operation of all modules  
is indicated by LEDs (light-emitting diodes) located on the  
side of the LID (Fig. 49); on the top horizontal surface of the  
PSIO (Fig. 50), SMM, and 8-input modules; and on the 4-in/  
2-out module.  
LID Module  
Upper LED — Communication with CCN network, if present;  
blinks when communication occurs.  
Lower LED — Communication with PSIO module; must blink  
every 5 to 8 seconds when the LID default screen is  
displayed.  
PSIO Module  
Green LED Closest to Communications Connection — Com-  
munication with SMM and 8-input module; must blink  
continuously.  
Other Green LED — Communication with LID; must blink  
every 3 to 5 seconds.  
8-Input Modules and SMM — Communication with PSIO  
module; blinks continuously.  
4-In/2-Out Module — Communication with PSIO module;  
blinks continuously.  
Notes on Module Operation  
1. The chiller operator monitors and modifies configura-  
tions in the microprocessor through the 4 softkeys and  
the LID. Communication with the LID and the PSIO is  
accomplished through the CCN bus (COMM1). The com-  
munication between the PSIO, SMM, both 8-input mod-  
ules, and the 4-in/2-out module is accomplished through  
the sensor bus (COMM3), which is a 3-wire cable. On  
the sensor bus terminal strips, Terminal 1 of the PSIO  
module is connected to Terminal 1 of each of the other  
modules. Terminals 2 and 3 are connected in the same  
manner, except for the connection to the 4-in/2-out mod-  
ule. See Fig. 51.  
NOTE: Address switches on this module can be at any position. Ad-  
dresses are only changed through the LID screen for CCN.  
Fig. 49 — LID Module (Rear View) and  
LED Locations  
2. If a green LED is on continuously, check the communi-  
cation wiring. If a green LED is off, check the red LED  
operation. If the red LED is normal, check the module  
address switches (Fig. 52-54). Proper addresses are set as  
shown below:  
ADDRESS  
MODULE  
S1  
S2  
SMM (Starter Management Module)  
8-input Options Module 1  
8-input Options Module 2  
3
6
7
2
4
2
SWITCH  
MODULE  
1
2
3
4
5
6
7
8
4-In/2-Out Module  
O
O
O
O
C
O
C
O
O
C
—
—
Open  
Closed  
Fig. 50 — PSIO Module LED Locations  
96  
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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/2-out  
module indicates a communication failure, check the com-  
munications plug on that module. If a good connection is  
assured and the condition persists, replace the module.  
All system operating intelligence rests in the PSIO mod-  
ule. Some safety shutdown logic resides in the SMM in  
case communications are lost between the 2 modules. The  
PSIO monitors conditions using input ports on the PSIO,  
the SMM, the 8-input modules, and the 4-in/2-out mod-  
ules. Outputs are controlled by the PSIO and SMM as  
well.  
3. Power is supplied to the modules within the control panel.  
The transformers are located within the power panel, with  
the exception of the SMM, which operates from a 24-vac  
power source and has its own 24-vac transformer located  
in the starter.  
In the power panel, T1 supplies power 21-vac to the LID,  
the PSIO, and the 5-vac power supply for the transduc-  
ers. T3 supplies 24-vac power to the 4-in/2-out module.  
T4 is another 21-vac transformer, which supplies power  
to both 8-input modules (if present). T4 is capable of sup-  
plying power to two modules; if additional modules are  
added, another power supply will be required.  
NOTE: Address switches on this module can be at any position. Addresses can  
only be changed through the LID or CCN.  
Fig. 52 — Processor (PSIO) Module  
Power is connected to Terminals 1 and 2 of the power  
input connection on each module.  
Starter Management Module (SMM) (Fig. 53)  
INPUTS — Inputs on strips J2 and J3 are a mix of analog  
and discrete (on/off) inputs. The chiller application deter-  
mines which terminals are used. Always refer to the indi-  
vidual unit wiring diagram for terminal numbers.  
PSIO (J8)  
SMM (J5)  
4-IN/2-OUT (J3)  
8-INPUT (J5)  
8-INPUT (J5)  
+
1
+
1
+
1
+
1
+
1
GRD  
GRD  
GRD  
GRD  
2
-
2
3
2
3
2
3
2
3
OUTPUTS — Outputs are 24 vdc and wired to strip J1. There  
are 2 terminals used per output.  
-
-
-
-
GRD  
3
LEGEND  
GRD  
—
—
—
Ground  
PSIO  
—
Processor/Sensor Input/  
Output Module  
J
Junction  
SMM  
Starter Management  
Module  
Pins  
Fig. 51 — Sensor Input/Output (SIO) Wiring  
Schematic for COMM3 Bus  
Processor/Sensor Input/Output Module (PSIO)  
(Fig. 52)  
INPUTS — Each input channel has 3 terminals; only 2 of  
the terminals are used. The chiller application determines which  
terminals are normally used. Always refer to individual unit  
wiring diagrams for terminal numbers.  
OUTPUTS — Output is 20 vdc. There are 3 terminals per  
output, only 2 of which are used, depending on the appli-  
cation. Refer to the unit wiring diagram.  
NOTE: SMM address switches should be set as follows: S1 set at 3; S2 set  
at 2.  
Fig. 53 — Starter Management Module (SMM)  
97  
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configurations. The inputs monitor the gear oil temperature  
and pressure. InputAI#2 should be factory-set with the jumper  
on (T). Inputs AI#3, and AI#4 should be factory set on (V).  
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 modules  
available include the following:  
OUTPUTS — The two analog outputs are each configurable  
by on-board jumpers as 0 to 10 vdc (maximum current:  
10 mA) or 4 to 20 mA (maximum load: 600 ohms) outputs.  
The outputs control the relay that activates the gear oil pump  
starter. Outputs AO#1 and AO#2 should be factory set with  
the jumper on (V).  
This module has a field-configurable DIP (dual in-line pack-  
age) switch to designate its address. It should be factory set  
with the following switches open: 1, 2, 3, 4, 6, and 8. Switches  
5 and 7 should be closed.  
OPTIONS MODULE 1  
4 to 20 mA Auto. Demand Reset  
4 to 20 mA Auto. Chilled Water Reset  
Common Chilled Water Supply Temperature  
Common Chilled Water Return Temperature  
Remote Temperature Reset Sensor  
Spare Temperature 1  
Spare Temperature 2  
Spare Temperature 3  
Note the SIO bus wiring for this module. Unlike the stand-  
ard PIC modules, Pin 2 is negative and Pin 3 is the ground  
(or common). See Fig. 51.  
OPTIONS MODULE 2  
4 to 20 mA Spare 1  
4 to 20 mA Spare 2  
Spare Temperature 4  
Spare Temperature 5  
Spare Temperature 6  
Spare Temperature 7  
Spare Temperature 8  
Spare Temperature 9  
Replacing Defective Processor Modules — The  
replacement part number is printed on a small label on the  
front of the PSIO module. The model and serial numbers are  
printed on the unit nameplate located on an exterior corner  
post. The proper software is factory-installed by Carrier in  
the replacement module. When ordering a replacement pro-  
cessor module (PSIO), specify complete replacement part num-  
ber, full unit model number, and serial number. This new  
unit requires reconfiguration to the original chiller data by  
the installer. Follow the procedures described in the Set Up  
Chiller Control Configuration section on page 54. Electrical  
shock can cause personal injury. Disconnect all electrical power  
before servicing.  
Terminal block connections are provided 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. 54) and to configure the chiller for each feature being  
used.  
Electrical shock can cause personal injury. Disconnect  
all electrical power before servicing.  
INSTALLATION OF NEW PSIO MODULE  
1. Verify that the existing PSIO module is defective by us-  
ing the procedure described in the Notes on Module Op-  
eration section, page 96, and the Control Modules sec-  
tion, page 96. Do not access theATTACH TO NETWORK  
DEVICE screen if the LID displays a communication  
failure.  
2. Data regarding the PSIO configuration should have been  
recorded and saved. This data must be reconfigured into  
the LID. If this data is not available, follow the proce-  
dures described in the Set Up Chiller Control Configu-  
ration section, page 54. Record the TOTAL COMPRES-  
SOR STARTS and the COMPRESSOR ONTIME from the  
STATUS01 table on the LID.  
If a CCN Building Supervisor or Service Tool is present,  
the module configuration should have already been up-  
loaded into memory; then, when the new module is in-  
stalled, the configuration can be downloaded from the  
computer (if the software version is the same).  
Any communication wires from other chillers or CCN  
modules must be disconnected.  
3. Check that all power to the unit is off. Carefully dis-  
connect all wires from the defective module by unplug-  
ging the 6 connectors. It is not necessary to remove any  
of the individual wires from the connectors.  
SWITCH SETTING  
OPTIONS MODULE 1  
OPTIONS MODULE 2  
S1  
S2  
6
4
7
2
4. Remove the defective PSIO by removing its mounting  
screw with a long-shaft Phillips screwdriver and remov-  
ing the module from the control box. Save the screw for  
later use. The green ground wire is held in place with  
the module mounting screw.  
5. Package the defective module in the carton of the new  
module for return to Carrier.  
Fig. 54 — Options Module  
Four-In/Two-Out Module (Fig. 55)  
INPUTS — The four analog inputs each have 3 terminals  
and are configurable by movable on-board jumpers as ther-  
mistor (T), 4 to 20 mA (C), or 0 to 10 vdc (V)  
98  
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6. Restore control system power (the LID displays, COM-  
MUNICATION FAILURE at the bottom of the screen).  
same as the value from the old module. Press the  
ENTER softkey to save this value.  
15. Move the highlight bar to the COMPRESSOR  
7. Access the SERVICE menu. Highlight and select  
the ATTACH TO NETWORK DEVICE screen. Press  
ONTIME line. Press the SELECT softkey and the, us-  
the ATTACH softkey. (The LID displays, UPLOAD-  
ING TABLES. PLEASE WAIT; then, COMMUNICA-  
TION FAILURE.) Press the EXIT softkey.  
8. Turn off control power.  
9. Mount the new module in the unit control box using a  
long-shaft Phillips screwdriver and the screw saved in  
Step 4 on page 98. 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.  
12. Restore control power and verify that the red and green  
LEDs on the PSIO are functioning properly.  
13. The LID should indicate AVAILABLE MEMORY and  
a value. This value should start to decrease. (If it does  
not, check the LID wiring to the PSIO; ensure connec-  
tion to the proper plug.) The bottom of the screen dis-  
plays, UPLOADING TABLES, PLEASE WAIT.  
14. After the PSIO tables have been uploaded into the LID,  
access the STATUS01 screen. Move the highlight bar to  
the TOTAL COMPRESSOR STARTS line. Press the  
ing the INCREASE or DECREASE softkeys, change  
this value until it matches the old module run hours. Press  
the SELECT softkey to save this value.  
16. Change the address of the PSIO In the CONTROLLER  
IDENTIFICATION table back to its previous value. Write  
the address on the PSIO.  
17. Use the configuration sheets (pages CL-3 to CL-11) to  
input set point, configuration, and schedule information  
into the PSIO. The TIME AND DATE table from the  
SERVICE menu must also be set. A Building Supervi-  
sor terminal can be used to download the old configu-  
ration into the PSIO.  
18. Access the CONTROL TEST table and perform the con-  
trol tests to verify all that all tested functions are work-  
ing properly.  
If the software version has been updated, a CCN down-  
load of the configuration will not be allowed. Configure  
the PSIO by hand, and upload the PSIO into the net-  
work using the ATTACH TO NETWORK DEVICE  
screen.  
19. Restore the chiller to normal operation; calibrate the mo-  
tor amps.  
PHYSICAL DATA AND WIRING  
SCHEMATICS  
Tables 15-26 and Fig. 56-61 provide additional informa-  
tion regarding compressor fits and clearances, physical and  
electrical data, and wiring schematics for operator conve-  
nience during troubleshooting.  
SELECT softkey and then, using the INCREASE or  
DECREASE softkeys, change the value until it is the  
Fig. 55 — 4-In/2-Out Module  
99  
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Fig. 56 — Model Number Nomenclature for Compressor Size (See Fig. 1 Also)  
Table 15 — 17EX Heat Exchanger Economizer/Storage Vessel, Piping, and Pumpout Unit Weights*  
COOLER  
TOTAL  
WEIGHT  
ECONOMIZER/  
STORAGE  
VESSEL  
COOLER  
CHARGE  
ECONOMIZER MISCELLANEOUS PUMPOUT  
REFRIGERANT PIPING UNIT  
COOLER  
SIZE†  
Dry**  
Operating††  
lb kg  
Refrigerant  
lb kg  
Water  
gal kg  
lb  
kg  
lb  
kg  
lb  
kg  
lb  
kg  
lb  
kg  
lb  
L
45  
46  
47  
48  
25,032 11 355 30,098 13 652 2,060  
25,529 11 580 30,881 14 008 2,160  
934 3,006 361 1 364 1366  
980 3,192 383 1 448 1450  
7,900  
3 583  
840  
318  
1,149  
521  
210 95  
26,025 11 805 31,663 14 362 2,260 1 025 3,378 405 1 532 1533  
28,153 12 770 34,866 15 815 2,540 1 152 4,173 500 1 893 1893  
CONDENSER TOTAL WEIGHT  
CONDENSER  
CONDENSER CHARGE  
Refrigerant Water  
Dry**  
Operating††  
SIZE†  
lb  
kg  
lb  
kg  
lb  
kg  
lb  
kg  
45  
46  
47  
55  
56  
57  
16,676  
17,172  
17,669  
20,725  
21,663  
22,446  
7 564  
7 789  
8 015  
9 401  
9 826  
10 182  
20,596  
21,280  
21,965  
25,598  
26,891  
27,971  
9 342  
9 653  
1,200  
1,200  
1,200  
1,420  
1,420  
1,420  
544  
544  
544  
644  
644  
644  
2,720  
2,908  
3,096  
3,453  
3,808  
4,105  
1 234  
1 319  
1 404  
1 566  
1 727  
1 862  
9 963  
11 611  
12 198  
12 688  
**Dry weight includes all components attached to economizer: covers, float valves,  
brackets, control center (31 lb [14 kg]), and power panel (20 lb [9 kg]). Dry  
weight does not include compressor weight, motor weight, or pumpout con-  
densing unit weight. The pumpout condensing unit weight is 210 lb (95 kg).  
For compressor and motor weights, refer to Tables 18 and 20A and 20B.  
††Operating weight includes dry weight, refrigerant weight, and water weight.  
*If a chiller configuration other than 2-pass, 150 psig (1034 kPa), NIH waterbox  
configuration is used, refer to Tables 16 and 17 to obtain the additional dry and  
water weights that must be added to the values shown in this table.  
†Cooler and condenser weights shown are based on 2-pass, nozzle-in-head  
(NIH) waterboxes with 150 psig (1034 kPa) covers. Includes components at-  
tached to cooler, but does not include suction/discharge, elbow, or other  
interconnecting piping.  
Table 16 — Additional Cooler Weights*  
DESIGN MAXIMUM  
WATER PRESSURE  
ADDITIONAL  
DRY WEIGHT  
ADDITIONAL  
COOLER  
FRAME  
WATERBOX  
TYPE  
NUMBER  
WATER WEIGHT  
OF PASSES  
psig  
150  
300  
300  
150  
150  
300  
300  
kPa  
1034  
2068  
2068  
1034  
1034  
2068  
2068  
lb  
kg  
lb  
—
—
gal  
—
kg  
—
L
—
—
—
2314  
1157  
2314  
1157  
NIH  
NIH  
NIH  
Marine  
Marine  
Marine  
Marine  
1, 3  
1, 3  
2
1, 3  
2
515  
234  
2941  
2085  
2100  
792  
1334  
946  
953  
—
—
—
—
—
4
5102  
2551  
5102  
2551  
612  
306  
612  
306  
2314  
1157  
2314  
1157  
359  
1, 3  
2
3844  
2536  
1744  
1150  
*When using a chiller configuration other than 2-pass, NIH waterboxes with 150 psig (1038 kPa) covers, add the weighs listed in this table to the  
appropriate weights in Table 15 to obtain the correct cooler weight.  
100  
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Table 17 — Additional Condenser Weights*  
DESIGN MAXIMUM  
NUMBER OF  
ADDITIONAL  
DRY WEIGHT  
ADDITIONAL  
HEAT EXCHANGER  
SIZE  
WATER PRESSURE  
WATER WEIGHT  
COMPONENT  
WATERBOX TYPE  
PASSES  
psig  
150  
300  
300  
150  
150  
300  
300  
150  
300  
300  
150  
300  
kPa  
lb  
kg  
156  
749  
513  
767  
306  
1 202  
739  
†
lb  
—
kg  
—
NIH  
NIH  
1, 3  
1, 3  
2
1034  
2068  
2068  
1034  
1034  
2068  
2068  
1034  
2068  
2068  
1034  
2068  
344  
1652  
1132  
1692  
674  
—
—
NIH  
—
—
45 - 47  
Marine  
Marine  
Marine  
Marine  
NIH  
1, 3  
2
3 400  
1 700  
3 400  
1 700  
—
1 542  
771  
1 542  
771  
—
1, 3  
2
2651  
1630  
†
CONDENSER  
1
NIH  
1
1588  
1591  
25  
720  
721  
11  
—
—
55 - 57  
NIH  
2
—
—
Marine  
Marine  
2
1 734  
1 734  
787  
787  
2
1225  
555  
NIH  
—
Nozzle-In-Head  
†Subtract 228 lb (103 kg) from the weight shown in Table 15.  
*When using a chiller configuration other than 2-pass, NIH waterboxes with  
150 psig (1034 kPa) covers, add the weights listed in this table to the appro-  
priate weights in Table 15 to obtain the correct condenser weight.  
Table 18 — Compressor Weight and Elbow Weight  
WEIGHT*  
English (lb)  
COMPONENT  
SI (kg)  
2270  
225  
COMPRESSOR  
5000  
500  
SUCTION ELBOW  
*Approximate.  
Table 19 — Drive Component Weights*  
COUPLING  
GEAR  
BASE  
GUARD  
kg  
23  
High  
Low  
lb  
kg  
lb  
kg  
lb  
kg  
lb  
kg  
lb  
2200  
998  
1500  
680  
32  
15  
75  
34  
50  
*See Table 20A or 20B for motor weights.  
101  
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Table 20A — Total Motor Weight, English (lb)  
ENCLOSURE  
TYPE  
HERTZ  
VOLTAGE  
SIZE (HP)  
FH (1600)  
FA, FF (1250)  
FB, FG (1500)  
FC, FJ (1750)  
FD, FK (2000)  
2400  
3300  
4160  
6900  
4836  
4824  
4836  
5596  
5721  
5832  
5721  
6577  
5900  
5832  
5900  
8776  
5900  
5832  
5900  
8776  
7160  
7127  
7160  
8990  
60 Hz  
Open-Drip Proof  
(ODP)  
3000  
3300  
6300  
5518  
5518  
5596  
5878  
5878  
6577  
7148  
7148  
8875  
7148  
7148  
8875  
9048  
9073  
8976  
50 Hz  
60 Hz  
50Hz  
HA, HF (1250)  
HB, HG (1500)  
HH (1600)  
HC, HJ (1750)  
HD, HK (2000)  
2400  
3300  
4160  
6900  
5146  
5134  
5146  
5906  
6151  
6262  
6151  
7007  
6330  
6262  
6330  
9206  
6330  
6262  
6330  
9206  
7600  
7567  
7600  
9430  
Weather Protected  
Type II (WPII)  
3000  
3300  
6300  
5828  
5828  
5906  
6308  
6308  
7007  
7578  
7578  
9305  
7578  
7578  
9305  
9488  
9513  
9416  
JA, JF (1250)  
JB, JG (1500)  
JH (1600)  
JC, JJ (1750)  
JD, JK (2000)  
2400  
3300  
4160  
6900  
5707  
5694  
5707  
6466  
6746  
6857  
6746  
7602  
6925  
6857  
6925  
9801  
6925  
6857  
6925  
9801  
8290  
8257  
60 Hz  
50 Hz  
Totally Enclosed  
Water-To-Air Cooled  
(TEWAC)  
8290  
10,120  
3000  
3300  
6300  
6388  
6388  
6466  
6903  
6903  
7602  
8173  
8173  
9900  
8173  
8173  
9900  
10,178  
10,203  
10,106  
Table 20B — Total Motor Weight, SI (kg)  
ENCLOSURE  
TYPE  
FREQ  
VOLTAGE  
SIZE (kW)  
FA, FF (932)  
FB, FG (1119)  
FH (1194)  
FC, FJ (1305)  
FD, FK (1492)  
2400  
3300  
4160  
6900  
2194  
2188  
2194  
2538  
2595  
2645  
2595  
2983  
2676  
2645  
2676  
3981  
2676  
2645  
2676  
3981  
3248  
3233  
3248  
4033  
60 Hz  
Open-Drip Proof  
(ODP)  
3000  
3300  
6300  
2503  
2503  
2538  
2666  
2666  
2983  
3242  
3242  
4026  
3242  
3242  
4026  
4104  
4116  
4072  
50 Hz  
60 Hz  
50 Hz  
60 Hz  
50 Hz  
HA, HF (932)  
HB, HG (1119)  
HH (1194)  
HC, HJ (1305)  
HD, HK (1492)  
2400  
3300  
4160  
6900  
2334  
2329  
2334  
2679  
2790  
2840  
2790  
3178  
2871  
2840  
2871  
4175  
2871  
2840  
2871  
4126  
3447  
3432  
3447  
4277  
Weather Protected  
Type II (WPII)  
3000  
3300  
6300  
2644  
2644  
2679  
2861  
2861  
3178  
3437  
3437  
4221  
3437  
3437  
4221  
4304  
4315  
4271  
JA, JF (932)  
JB, JG (1119)  
JH (1194)  
JC, JJ (1305)  
JD, JK (1492)  
2400  
3300  
4160  
6900  
2587  
2583  
2587  
2933  
3060  
3110  
3060  
3448  
3141  
3110  
3141  
4446  
3141  
3110  
3141  
4446  
3760  
3745  
3760  
4590  
Totally Enclosed  
Water-To-Air Cooled  
(TEWAC)  
3000  
3300  
6300  
2898  
2898  
2933  
3131  
3131  
3448  
3707  
3707  
4491  
3707  
3707  
4490  
4617  
4628  
4584  
102  
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Table 21 — Marine Waterbox Cover Weights*  
DESIGN MAXIMUM WATER PRESSURE  
COOLER  
CONDENSER  
HEAT EXCHANGER  
SIZE  
psi  
150  
300  
150  
300  
kPa  
1034  
2068  
1034  
2068  
lb  
kg  
1015  
1389  
—
lb  
kg  
579  
754  
746  
1018  
2236  
3060  
—
1275  
1660  
1643  
2243  
45 - 48  
55 - 57  
—
—
*Heat exchangers with marine waterboxes have heavier dry and operating weights than heat exchangers  
with nozzle-in-head waterboxes.  
Table 22 — NIH Waterbox Cover Weights*  
DESIGN MAXIMUM WATER PRESSURE  
COOLER  
lb kg  
CONDENSER  
HEAT EXCHANGER  
SIZE  
PASSES  
psi  
150  
300  
150  
300  
150  
300  
150  
300  
150  
300  
150  
300  
kPa  
lb  
kg  
788  
1140  
856  
1176  
807  
1153  
923  
1335  
1203  
1653  
—
1034  
2068  
1034  
2068  
1034  
2068  
1034  
2068  
1034  
2068  
1034  
2068  
2997 1361 1735  
4225 1918 2510  
2984 1355 1885  
4188 1901 2590  
3035 1378 1777  
4244 1927 2539  
1
45 - 48  
2†  
3
—
—
—
—
—
—
—
—
—
—
—
—
2032  
2940  
2649  
3640  
—
1
55 - 57  
2†  
3
—
—
NIH  
—
Nozzle-in-Head  
*The 150 psig (1034 kPa) waterbox cover weights are included in the dry weight shown in Table 15.  
†Two different waterbox covers are present on 2-pass chillers. The weight shown in this table represents the  
weight of the waterbox cover that contains the nozzles. A blank 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 21.  
Table 23 — Approximate Refrigerant (HCFC-134a) Charge*  
TOTAL CHILLER  
COOLER  
SIZE  
CONDENSER  
SIZE  
CHARGE  
lb  
kg  
45  
46  
47  
55  
56  
57  
45  
46  
47  
55  
56  
57  
45  
46  
47  
55  
56  
57  
45  
46  
47  
55  
56  
57  
4100  
1860  
45  
46  
47  
48  
4320  
4200  
4420  
4300  
4520  
4580  
4800  
1960  
1905  
2005  
1950  
2050  
2077  
2177  
*Total chiller refrigerant charge includes the cooler, condenser, and economizer charges.  
NOTE: Regulations mandate that chiller shipping charge is limited to 7500 lb (3402 kg).  
103  
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Table 24 — Auxiliary Systems, Electrical Data  
DESIGN CENTER  
AVERAGE kW  
SUPPLY  
V-PH-Hz  
POWER SOURCE  
ITEM  
FLA  
4.78  
4.35  
3.50  
8.70  
2.00  
LRA  
21.7  
4.35  
—
VOLTAGE  
Seal Leakage  
Pump  
0.23  
0.50  
0.40  
1.00  
0.20  
115  
115  
115  
115  
115  
115-1-50/60  
115-1-50/60  
Motor Space  
Heater  
Control Module  
and Actuator  
115-1-60  
115-1-50  
1
115-1-60  
115-1-50  
Oil Sump Heater  
—
Hot Gas*  
Bypass  
115-1-50/60  
4.75  
220  
430  
563  
200/240-3-60  
380/480-3-60  
507/619-3-60  
4.34  
2.15  
2.14  
24.5  
13.1  
25.0  
Compressor  
Oil Pump  
2†  
3†  
0.66  
0.7  
230  
393  
220/240-3-50  
346/440-3-50  
4.84  
2.59  
28.0  
12.2  
204  
220  
460  
575  
200/208-3-60  
208/230-3-60  
440/480-3-60  
518/632-3-60  
5.7  
4.2  
2.1  
1.7  
33.5  
30.6  
15.3  
12.3  
Gear  
Oil Pump  
205  
410  
190/220-3-50  
380/440-3-50  
5.0  
2.5  
28.9  
14.5  
204  
230  
460  
575  
200/208-3-60  
220/240-3-60  
440/480-3-60  
550/600-3-60  
10.90  
9.50  
4.70  
3.80  
63.5  
57.5  
28.8  
23.0  
Pumpout*  
Compressor  
4
3.41  
400  
380/415-3-50  
4.70  
28.8  
LEGEND  
NOTE: The oil pump is powered through a field wiring terminal into  
the power panel. Power to the controls and oil heater via the power  
panel must be on circuits that can provide continuous service when  
the compressor starter is disconnected.  
FLA  
LRA  
—
—
Full Load Amps  
Locked Rotor Amps  
*Available as an option on 17EX chillers.  
†The compressor and gear oil pump contactors are wired together  
on the line side. Their amperage values must be added together  
when sizing conductors.  
Table 25 — Relief Valve Locations and Data  
NOMINAL  
OUTLET  
PIPE SIZE  
(in.)  
HEAT EXCHANGER  
SIZE  
REQUIRED  
C FACTOR  
RATED RELIEF  
PRESSURE  
RELIEF VALVE  
LOCATION  
NUMBER OF  
VALVES  
Cooler  
Condenser  
lb air/min.  
kg air/sec.  
psig  
kPa  
45-47  
48  
45-47  
55-57  
216.3  
228.5  
1.64  
1.73  
11⁄4 FPT  
11⁄4 NPT  
3
3
225  
225  
1551  
1551  
Cooler  
Economizer/Storage  
Vessel  
ALL  
ALL  
ALL  
ALL  
84.3  
1.5  
0.64  
0.01  
11⁄4 FPT  
2*  
1
225  
385  
1551  
2655  
Pumpout Unit  
Condenser  
3
⁄8  
in. Male Flare MPT  
*To ensure relief valve serviceability, and as required in ASHRAE 15,  
latest edition, three-way valves and redundant relief valves are in-  
stalled on the storage vessel. Only one of the ‘‘No. of Valves’’ listed  
are in service at any time.  
2. Relief valve discharge pipe sizing is to be calculated per latest  
version of ASHRAE 15, using the tabulated C-factors and nom-  
inal pipe size listed above. Cooler and economizer/storage vessel  
rated relief valve pressure is 225 psig (1551 kPa).  
3. The pumpout unit condenser contains less than 110 lb (50 kg) of  
HFC-134a, which is a Group A1 refrigerant. The ASHRAE 15 stand-  
ard exempts small-volume vessels from the requirement to vent  
outside. However, Carrier recommends that the pumpout con-  
denser be connected to the rest of the vent system.  
NOTES:  
1. The cooler relief C-factor is for both cooler and condenser vented  
through the cooler in accordance with ASHRAE (American  
Society of Heating, Refrigeration, and Air Conditioning Engi-  
neers) 15, latest edition.  
104  
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NOTE: Refer to Table 26 for item number references.  
Fig. 57 — Compressor Fits and Clearances  
105  
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Table 26 — Compressor Fits and Clearances  
CLEARANCE  
TYPE OF  
MEASURE  
ITEM  
DESCRIPTION  
Minimum  
Maximum  
in.  
mm  
in.  
mm  
1
2
3
4
5
6
7
8
1st Stage Impeller to Diaphragm  
Interstage Labyrinth  
See Tabulation  
Axial  
Diametral  
Axial  
0.012  
0.305  
0.016  
0.406  
2nd Stage Impeller to Discharge Wall  
Thrust End Journal Bearing  
Thrust End Float  
See Tabulation  
0.0035  
0.010  
0.0889  
0.254  
0.0055  
0.015  
0.1397  
0.381  
Diametral  
Axial  
Inner Carbon Ring Travel  
Shaft End Labyrinth  
.06 in. (1.52 mm) minimum in each direction  
Axial  
0.001  
0.092  
0.008  
0.023  
0.006  
0.008  
0.018  
0.008  
0.016  
0.018  
0.0035  
0.025  
2.337  
0.203  
0.584  
0.152  
0.203  
0.457  
0.203  
0.406  
0.457  
0.0889  
0.005  
0.095  
0.010  
0.025  
0.010  
0.012  
0.022  
0.012  
0.020  
0.022  
0.0055  
0.127  
2.413  
0.254  
0.635  
0.254  
0.305  
0.559  
0.305  
0.508  
0.559  
0.1397  
Diametral  
Diametral  
Windage Baffle to Shaft  
Shaft Displacement (Shrouds 3 - 6)  
Detector (Shrouds 8 & 9)  
9
10  
11  
12  
13  
14  
Axial  
Counterthrust Bearing Seal Ring  
Balancing Piston, Labyrinth  
2nd Stage Labyrinth  
Diametral  
Diametral  
Diametral  
Diametral  
Diametral  
(Shrouds 3 - 6)  
(Shrouds 8 & 9)  
1st Stage  
Labyrinth  
Seal End Journal Bearing  
106  
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Tabulation — Impeller Clearances (Open-Drive Compressors)  
DIMENSION*  
IMPELLER DIAMETER  
COMPRESSOR  
SIZE  
DIAM  
CODE  
SHROUD  
Item 1  
Item 3  
in.  
mm  
304.8  
314.5  
323.8  
336.6  
349.2  
304.8  
314.5  
323.8  
336.6  
349.2  
304.8  
314.5  
323.8  
336.6  
349.2  
304.8  
314.5  
323.8  
336.6  
349.2  
349.2†  
342.9**  
349.2†  
342.9**  
in.  
mm  
in.  
mm  
1
3
5
7
9
1
3
5
7
9
1
3
5
7
9
1
3
5
7
9
12.00  
12.38  
12.75  
13.25  
13.75  
12.00  
12.38  
12.75  
13.25  
13.75  
12.00  
12.38  
12.75  
13.25  
13.75  
12.00  
12.38  
12.75  
13.25  
13.75  
13.75†  
13.50**  
13.75†  
13.50**  
.837  
21.26  
20.24  
19.23  
18.21  
17.53  
24.82  
23.80  
22.78  
23.62  
20.57  
29.90  
28.88  
27.36  
25.83  
24.64  
32.94  
31.42  
29.90  
27.86  
26.67  
.638  
.609  
.579  
.541  
.541  
.760  
.726  
.688  
.639  
.632  
.895  
.852  
.809  
.750  
.731  
.972  
.928  
.880  
.817  
.796  
16.21  
15.47  
14.71  
13.74  
13.74  
19.30  
18.44  
17.48  
16.23  
16.05  
25.02  
21.64  
20.55  
19.05  
18.57  
24.69  
23.57  
22.35  
20.75  
20.22  
.797  
3
.757  
.717  
.690  
.977  
.937  
4
5
6
.897  
.837  
.810  
1.177  
1.137  
1.077  
1.017  
.970  
17FX  
1.297  
1.237  
1.177  
1.097  
1.050  
8
9
1-9  
1-9  
4.425  
4.425  
112.39  
112.39  
.876  
22.25  
26.80  
1.055  
*Measured with shaft in thrust position (towards suction end); tolerance = ± .005 in. (± .127 mm).  
†First-stage diameter.  
**Second-stage diameter.  
107  
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LEGEND  
BRG  
C
—
—
—
—
—
—
—
—
Bearing  
DIFF  
—
—
—
—
—
—
—
—
Differential  
INT  
J
—
—
—
—
—
—
—
—
Internal  
Contactor  
DISCH  
ENT  
Discharge  
Entering  
Junction  
CB  
Circuit Breaker  
Channel  
Communications  
Compressor  
Condenser  
Detector  
K
Relay Designation  
Line Terminal  
Leak Detector  
Local Interface Device  
Leaving  
CH  
EVAP  
EXT  
Evaporator  
External  
Guide Vane  
Hot Gas Bypass  
Heater  
L
COM  
COMP’R  
COND  
DETR  
LD  
LID  
LVG  
M
G.V.  
HGBP  
HTR  
Motor  
Fig. 58 — Typical 17EX Power Panel and Control Panel Wiring Schematic  
108  
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LEGEND  
PH  
—
—
—
Phase  
TEMP  
—
—
Temperature  
IMPORTANT: Wiring shown is typical and not intended to  
show detail for a specific installation. Refer to certified field  
wiring diagrams.  
PRESS.  
PSIO  
Pressure  
TEWAC  
Totally Enclosed  
Water-to-Air Cooled  
Terminal Designation  
Terminal Strip  
Processor/Sensor  
Input/Output Module  
Terminal Designation  
Starter Management Module  
Terminal  
Thermistor  
Terminal Block  
TG  
TS  
—
—
R
—
—
—
—
—
SMM  
T
Required Power Wiring  
Required Control Wiring  
Options Wiring  
t*  
TB  
Fig. 58 — Typical 17EX Power Panel and Control Panel Wiring Schematic (cont)  
109  
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LEGEND  
NOTE: Voltage to terminals LL1 and LL2 comes from a control trans-  
former 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.  
CB  
—
—
—
—
—
—
—
—
—
Circuit Breaker  
Communications  
Normally Open  
Normally Closed  
Overload  
COMM  
N.O.  
N.C.  
O.L.  
PR  
Pilot Relay  
RLA  
SMM  
TB  
Rated Load Amps  
Starter Management Module  
Terminal Block  
Starter Vendor Supplied Wiring  
Field Wiring  
Carrier Factory Wiring  
Fig. 59 — Elementary Wiring Diagram for Starter Management Module (SMM) and Control Interface Between  
Starter and Chiller Power Panel (For Low and Medium Voltage Free-Standing Starters)  
110  
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Fig. 59 — Elementary Wiring Diagram for Starter Management Module (SMM) and Control Interface Between  
Starter and Chiller Power Panel (For Low and Medium Voltage Free-Standing Starters) (cont)  
111  
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LEGEND  
⌬P  
—
—
—
—
—
—
Differential Pressure  
PR  
SP  
—
—
Pilot Relay  
IMPORTANT: Wiring shown is typical and not intended to show detail  
for a specific installation. Refer to certified field wiring diagrams.  
C
Contactor  
Open Terminal Designation  
(Open Space)  
Switch  
COMP’R  
Compressor  
Ground  
Line Terminal  
Control Power Line  
Terminal  
Motor  
Overloads  
3-Phase Current Power  
Source  
G
SW  
T
TB  
—
—
—
L
Terminal  
Terminal Board  
Required Power Wiring  
Required Control Wiring  
Options Wiring  
LL  
M
OL’s  
OS  
—
—
—
Fig. 60 — Field Wiring Diagram (Medium Voltage Motor, PIC Controls With Free-Standing Starter)  
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NOTES FOR FIG. 60  
I GENERAL  
3.4 Do not route control wiring carrying 30 v or less within a conduit  
which has wires carrying 50 v or higher or alongside wires car-  
rying 50 v or higher.  
1.0 Starters shall be designed and manufactured in accordance  
with Carrier Engineering requirement Z-375.  
3.5 Voltage selector switch in chiller power panel is factory set for  
115 v control and oil heater power source. The 230 v position is  
not used. If switch is set to 230 v position, oil heater will not  
operate.  
3.6 Control wiring cables between starter and power panel must be  
shielded with minimum rating of 600 v, 80 C. Ground shield at  
starter. Starter Management Module (SMM) communication cable  
must be separate.  
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 field-installed conduit and conductors and the  
location of field-installed devices must not interfere with equip-  
ment access of the reading, adjusting, or servicing of any  
component.  
1.3 Equipment installation and all starting and control devices must  
comply with details in equipment submittal drawings and  
literature.  
1.4 Contacts and switches are shown in the position they would  
assume with the circuit deenergized and the chiller shut down.  
1.5 WARNING: Do not use aluminum conductors.  
1.6 Installer is responsible for any damage caused by improper  
wiring between starter and chiller.  
3.7 If optional oil pump circuit breaker is not supplied within the starter  
enclosure as shown, it must be located within sight of the chiller  
with wiring routed to suit.  
3.8 Voltage to terminals LL1 and LL2 comes from a control trans-  
former in a starter built to Carrier specifications. Do not connect  
an outside source of control power to the compressor motor starter  
(terminals LL1 and LL2). An outside power source will produce  
dangerous voltage at the line side of the starter, because sup-  
plying voltage at the transformer secondary terminals produces  
input level voltage at the transformer primary terminals.  
4.0 Medium voltage (over 600 volts) compressor motors have 3 ter-  
minal connections (lead hooks). Use suitable splice connectors  
and insulation for high voltage alternating current cable termi-  
nations (these items are not supplied by Carrier). Compressor  
motor starter must have nameplate stamped to conform with  
Carrier requirement Z-375.  
II POWER WIRING TO STARTER  
2.0 Provide a means of disconnecting power to the starter.  
2.1 Power conductor rating must meet minimum unit nameplate  
voltage and compressor motor RLA (rated load amps). When  
3 conductors are used:  
Minimum ampacity per conductor = 1.25 x compressor RLA.  
When 6 conductors are used:  
Minimum ampacity per conductor = 0.721 x compressor RLA.  
2.2 Lug adapters may be required if installation conditions dic-  
tate that conductors be sized beyond the minimum ampacity  
required. Contact starter supplier for lug information.  
2.3 Compressor motor and controls must be grounded by using  
equipment grounding lugs provided inside starter enclosure.  
4.1 Power conductor rating must meet minimum unit nameplate volt-  
age and compressor motor RLA. (Conductor as defined below  
may be a single lead or multiple smaller ampacity leads in par-  
allel for the purpose of carrying the equivalent or higher current  
of a single larger lead.)  
III CONTROL WIRING  
When (3) conductors are used:  
3.0 Field supplied control conductors to be at least 18 AWG  
Minimum ampacity per conductor = 1.25 × compressor RLA.  
4.2 When more than one conduit is used to run conductors form starter  
to compressor motor terminal box, an equal number of leads from  
each phase (conductor) must be in each conduit to prevent ex-  
cessive heating (e.g., conductors to motor terminals 1, 2 and 3  
in one conduit, and those to 1, 2 and 3 in another.)  
4.3 Compressor motor power connections can be made through top,  
top rear, or sides of compressor motor terminal box using holes  
cut by contractor to suit conduit. Flexible conduit should be used  
for the last few feet to the terminal box for unit vibration isolation.  
Use of stress cones may require an oversize (special) motor ter-  
minal box (not supplied by Carrier).  
4.4 Compressor motor frame to be grounded in accordance with the  
National Electrical Code (NFPA-70) and applicable codes. Means  
for grounding compressor motor is 2 ground pads, 1 each lo-  
cated near each motor foot opposite the shaft end.  
4.5 Do not allow motor terminals to support weight of wire cables.  
Use cable supports and strain reliefs as required.  
(American Wire Gage) or larger.  
3.1 Chilled water and condenser water flow switch contacts, op-  
tional remote start device contacts, and optional spare safety  
device contacts must have 24 vdc rating. Maximum current is  
60 mA; nominal current is 10 mA. Switches with gold plated  
bifurcated contacts are recommended.  
3.2 Remove jumper wire between 12A and 12B before connect-  
ing auxiliary safeties between these terminals.  
3.3 Pilot relays can control cooler and condenser pump and tower  
fan motor contactor coil loads rated up to 10 amps at 115 vac  
or up to 3 amps at 600 vac. Control wiring required for Carrier  
to start pumps and tower fan motors must be provided to as-  
sure chiller protection. If primary pump and tower motor con-  
trol is by other means, also provide a parallel means for con-  
trol by Carrier. Do not use starter control transformer as the  
power source for pilot relay loads.  
113  
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LEGEND  
EQUIP  
GND  
HGBP  
S
T1-T4  
TS  
—
—
—
—
—
—
Equipment  
Ground  
Hot Gas Bypass  
Switch  
Power Panel Transformers  
Terminal Strip  
Fig. 61 — Oil Pump and Control Power Panel (Interior View)  
114  
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INDEX  
Abbreviations, 5  
Check Pressure Transducers, 83  
Check Pumpout System Controls and Optional  
Pumpout Compressor, 56  
Access the Service Screen, To (Service Operation), 42  
Accidental Start-Up, To Prevent, 61  
Accuracy, Check Sensor (Checking  
Temperature Sensors), 84  
Check Relief Devices, 50  
Check Safety and Operating Controls Monthly, 76  
Check Sensor Accuracy (Checking Temperature Sensors), 84  
Check Starter, 53  
Check the Compressor Oil Heater, Power Up  
the Controls and, 54  
Check the Lubrication System, 76  
Check the Running System, 62  
Check Voltage Supply, 56  
Checking Guide Vane Linkage, 68  
Checking Pressure Transducers, 84  
Checking Temperature Sensors (Troubleshooting Guide), 84  
Checking the Display Messages, 84  
Checklist for 17EX Externally Geared Centrifugal  
Liquid Chiller, Initial Start-Up, CL-1 to CL-12  
Checkout Procedure, Control Algorithms, 85  
Chilled Water Control, Entering, 32  
Chilled Water Recycle Mode, 44  
Chiller Alignment, 71  
Chiller Communication Wiring (Lead/Lag Control), 38  
Chiller Control Configuration, Set Up, 54  
Chiller Cycles (Instruct the Operator), 62  
Chiller Dehydration, 49  
Chiller Familiarization, 17EX, 5  
Chiller Identification Label, 5  
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  
Auto. Restart (Controls), 36  
Alarm Contacts, Spare, 36  
Alarms and Alerts, 16  
Alerts, Alarms and, 16  
Algorithm, Surge Prevention, 37  
Alignment,  
Chiller, 71  
Disc Coupling, and Installation, 59  
Final (Chiller Alignment), 74  
Near Final (Chiller Alignment), 71  
Preliminary (Chiller Alignment), 71  
Alignment Check,  
Hot (Chiller Alignment), 74  
Hot, 61  
Alignment Methods (Chiller Alignment), 71  
Altitude Locations, High, 57  
Analog Signal (Controls), 11  
Attach to Network Device Control, 41  
Attaching to Other CCN Modules  
(Attach to Network Device Control), 41  
Auto. Restart After Power Failure (Controls), 36  
Auto. Restart After Power Failure (Lead/Lag Control), 40  
Automated Control Test, Perform an, 56  
Automatic Soft Stop Amps Threshold, 44  
Auxiliary Compressor Oil Pump Control, 33  
Auxiliary Devices, Motor, 46  
Auxiliary Equipment (Instruct the Operator), 62  
Auxiliary Gear Oil Pump Control, 33  
Balancing, Load (Lead/Lag Control), 40  
Bearing Maintenance, Compressor, 82  
Before Initial Start-Up, 45  
Chiller Operating Condition, Check, 61  
Chiller Parts, Ordering Replacement, 83  
Chiller Tightness, Check, 46  
Chiller Timers, 32  
Chiller, Leak Test the, 46  
Cleanliness (Motor Maintenance), 79  
Cold Weather Operation, 63  
Common Point Sensor Installation (Lead/Lag Control), 38  
Communication Wiring, Chiller (Lead/Lag Control), 38  
Components,  
PIC System, 12  
System, 5  
Compressor, 5  
Compressor Assembly (Instruct the Operator), 62  
Compressor Bearing Maintenance, 82  
Compressor Lubrication Cycle, 8  
Compressor Lubrication System (Instruct the Operator), 62  
Compressor Oil (Oil Changes), 77  
Compressor Oil Charge, 54  
Calibrate Motor Current Demand Setting, 61  
Calibration, Oil Differential Pressure/Power Supply  
Module (Checking Pressure Transducers), 85  
Capacity Control, 32  
Capacity Override, 35  
Carrier Comfort Network Interface (CCN), 53  
CCN Modules, Attaching to Other (Attach to  
Network Device Control), 41  
Compressor Oil Cooling, 8  
Compressor Oil Filter (Changing the Oil Filters), 76  
Compressor Oil Pump Contactor (2C) and Gear  
Oil Pump Contactor (5C), 16  
Change LID Configuration If Necessary, 55  
Change Point Status, To View or, 17  
Change Set Points, To View and, 22  
Change Time Schedule Operation, To View or, 18  
Changing the Oil Filters, 76  
Charge, Compressor Oil, 54  
Charge Refrigerant into Chiller, 57  
Check,  
Hot Alignment (Chiller Alignment), 74  
Hot Alignment, 61  
Resistance (Checking Temperature Sensors), 84  
Check Chiller Operating Condition, 61  
Check Chiller Tightness, 46  
Check Insulation Resistance (Inspect Wiring), 50  
Check Motor Rotation, 58  
Check Oil Pressure and Compressor Stop, 61  
Check Operator Knowledge, 62  
Check Optional Pumpout Compressor Water Piping, 50  
Compressor Oil Pump Control, Auxiliary, 33  
Compressor Stop, Check Oil Pressure and, 61  
Compressor, Operating the Optional Pumpout, 63  
Condenser, 5  
Condenser (Inspect the Heat Exchanger Tubes), 82  
Condenser Freeze Prevention, 36  
Condenser Pump Control, 36  
Configuration,  
Change LID, If Necessary, 55  
Modify Equipment, If Necessary, 56  
Set Up Chiller Control, 54  
Configurations, Input Service, 54  
Contact Seal Maintenance, 68  
Contactor (IC), Oil Heater, 16  
Contactors, Compressor Oil Pump (2C) and  
Gear Oil Pump (5C), 16  
Contacts, Spare Alarm, 36  
115  
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INDEX (cont)  
Eight-Input Modules, 16  
Control,  
Auxiliary Compressor Oil Pump, 33  
Electrical Connection, Motor, 45  
Entering Chilled Water Control, 32  
Equipment Configuration, Modify If Necessary, 56  
Equipment Required (Before Initial Start-Up), 45  
Equipment Service Parameters, Input If Necessary, 55  
Extended Downtime (External Gear Storage), 82  
Extended Shutdown, 63  
Auxiliary Gear Oil Pump, 33  
Capacity, 32  
Condenser Pump, 36  
Entering Chilled Water, 32  
High Discharge Temperature, 35  
Ice Build, 40  
Lead/Lag, 38  
Extended Shutdown, After, 63  
Oil Sump Temperature, 35  
External Gear (Remove Shipping Packaging), 45  
External Gear Lubrication Cycle, 9  
External Gear Lubrication System (Instruct the  
Operator), 62  
Ramp Loading, 33  
Control Algorithms Checkout Procedure, 85  
Control and Oil Heater Voltage Selector (S1), 16  
Control Center, 5  
External Gear Maintenance, 82  
Control Center, Inspect the (Scheduled Maintenance), 76  
Control Configuration, Set Up Chiller, 54  
Control Modules, 96  
External Gear Oil (Oil Changes), 77  
External Gear Oil Cooling, 8  
External Gear Oil Filter (Changing the Oil Filters), 77  
External Gear Pre-Start Checks, 51  
External Gear Replacement Parts, 83  
External Gear Storage, 81  
Familiarization, 17EX Chiller, 5  
Faulted Chiller Operation (Lead/Lag Control), 40  
Filter,  
Control Settings, Pumpout Safety, 83  
Control System (Instruct the Operator), 62  
Control Test (Troubleshooting Guide), 85  
Control Test, Perform and Automated, 56  
Control Transformers (T1-T4), 16  
Controller Identification, Modify If Necessary, 55  
Controls, 11  
Compressor Oil (Changing the Oil Filters), 76  
External Gear Oil (Changing the Oil Filters), 77  
Final Alignment (Chiller Alignment), 74  
Four-In/2-Out Module, 16, 98  
Controls,  
Remote Start/Stop, 36  
Safety, 33  
Cooler, 5  
Freeze, Default Screen, 33  
Freeze Prevention, Condenser, 36  
Functions, PIC System, 32  
Cooler (Inspect the Heat Exchanger Tubes), 82  
Cooler-Condenser (Instruct the Operator), 62  
Cooler/Condenser/Compressor Section, Transferring  
Refrigerant Into the, 67  
Gasketed Joints and Guide Vane Shaft Packing,  
Tighten All, 46  
Coupling, Disc, Installation and Alignment, 59  
Coupling Maintenance, 78  
Gear, External, 45  
Gear Maintenance, External, 82  
Cycle,  
Gear Oil Pump Contactor (5C), and Compressor  
Oil Pump Contactor (2C), 16  
Lubrication, 8  
Oil Cooling, 8  
Gear Oil Pump Control, Auxiliary, 33  
General (Controls), 11  
General (LID Operation and Menus), 16  
General Maintenance, 67  
Refrigeration, 5  
Cycles, Chiller (Instruct the Operator), 62  
Date, Input Time and, 55  
Deadband (PIC System Functions), 32  
Default Screen Freeze, 33  
Green LEDs (Control Modules), 96  
Guide Vane Linkage, Checking, 68  
Guide Vane Operation, Manual (Operating Instructions), 63  
Guide Vane Shaft Packing, Tighten All Gasketed  
Joints and, 46  
Guide Vanes, Manual Operation of the, 58  
Guide, Troubleshooting, 83  
Handling/Rigging, Motor, 81  
Heat Exchanger Tubes, Inspect the (Scheduled  
Maintenance), 82  
High Altitude Locations, 57  
High Discharge Temperature Control, 35  
Holiday Scheduling (Service Operation), 42  
Hot Alignment Check, 61  
Hot Alignment Check (Chiller Alignment), 74  
Hot Gas Bypass Contactor Relay (3C) (Optional), 16  
Ice Build,  
Default Screen Menu Items, LID, 17  
Defective Processor Modules, Replacing, 98  
Definitions, 11  
Dehydration, Chiller, 49  
Demand Limit Control Option (Requires Optional  
8-Input Module), 37  
Demand Limiting, 32  
Design Set Points, Input the, 54  
Device (LID), Local Interface, 16  
Digital Signal (Control), 11  
Disc Coupling Installation and Alignment, 59  
Display Messages, Checking the, 84  
Doweling, (Chiller Alignment), 75  
Doweling, (Initial Start-Up), 61  
Downtime, Extended (External Gear Storage), 82  
Dry Nitrogen, To Pressurize With, 68  
Dry Run to Test Start-Up Sequence, 58  
Dual Temperature Sensors (Checking Temperature  
Sensors), 84  
Temperature Control During (Ice Build Control), 41  
Termination of (Ice Build Control), 41  
Ice Build Control, 40  
Ice Build Initiation (Ice Build Control), 40  
Identification Label, Chiller, 5  
Duties, Operator, 62  
Economizer/Storage Vessel (Instruct the Operator), 62  
Economizer/Storage Vessel and Pumpout System,  
Using the, 45  
Important Information (Disc Coupling Installation  
and Alignment), 61  
Initial Start-Up, 57  
Economizer/Storage Vessel, 5  
Economizer/Storage Vessel, Transferring Refrigerant  
Into the, 66  
Initial Start-Up Checklist for 17EX Externally  
Geared Centrifugal Liquid Chiller, CL-1 to CL-12  
116  
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INDEX (cont)  
Maintenance,  
Initial Start-Up,  
Before, 45  
Compressor Bearing, 82  
Motor, 58  
Contact Seal, 68  
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 Time and Date, 55  
Coupling, 78  
External Gear, 82  
General, 67  
Motor, 78  
Pumpout System, 83  
Scheduled, 76  
Weekly, 76  
Inputs,  
(4-In/2-Out Module), 98  
(Processor/Sensor Input/Output Module), 97  
(Starter Management Module), 97  
Spare Safety, 36  
Inspect Refrigerant Float System (Scheduled  
Maintenance), 78  
Inspect Relief Valves and Piping (Scheduled  
Maintenance), 78  
Major Leak, Test After Service, Repair or, 67  
Manual Guide Vane Operation (Operating Instructions), 63  
Manual Operation of the Guide Vanes, 58  
Mechanical Starters (Check Starter), 53  
Memory, Volatile, 11  
Menu Items, LID Default Screen, 17  
Menu Structure, 17  
Menus, LID Operation and, 16  
Messages, Checking the Display, 84  
Mode, Chilled Water Recycle, 44  
Modify Controller Identification If Necessary, 55  
Modify Equipment Configuration If Necessary, 56  
Module,  
Installation of New PSIO, 98  
Oil Differential Pressure/Power Supply, 16  
Processor/Sensor Input/Output (Troubleshooting  
Guide), 97  
Starter Management (Troubleshooting Guide), 97  
Module (PSIO), Processor/Sensor Input/Output, 16  
Module (PSIO), Processor/Sensor Input/Output  
(Troubleshooting Guide), 97  
Inspect the Control Center (Scheduled Maintenance), 76  
Inspect the Heat Exchanger Tubes (Scheduled  
Maintenance), 82  
Inspect the Starting Equipment (Scheduled Maintenance), 83  
Inspect Water Piping, 50  
Inspect Wiring, 50  
Installation and Alignment, Disc Coupling, 59  
Installation of New PSIO Module, 98  
Installation, Common Point Sensor (Lead/Lag Control), 38  
Instruct the Operator, 62  
Instructions, Operating, 62  
Insulation Resistance, Check (Inspect Wiring), 50  
Interface (CCN), Carrier Comfort Network, 53  
Introduction, 5  
Module (SMM), Starter Management, 16  
Module (SMM), Starter Management (Troubleshooting  
Guide), 97  
Job Data Required (Before Initial Start-Up), 45  
Label, Chiller Identification, 5  
Lead/Lag Control, 38  
Module Calibration, Oil Differential Pressure/Power  
Supply (Checking Pressure Transducers), 85  
Module Operation, Notes on, 96  
Module, 4-In/2-Out, 16, 98  
Lead/Lag Operation (Lead/Lag Control), 39  
Leak,  
Test the Chiller, 46  
Modules,  
Water, 82  
Attaching to Other CCN (Attach to Network Device  
Control), 41  
Leak Rate, 67  
LEDs,  
Control, 96  
Green (Control Modules), 96  
Red (Control Modules), 96  
Eight-Input, 16  
Options (8-Input), 98  
LID Configuration, Change If Necessary, 55  
LID Default Screen Menu Items, 17  
LID, Local Interface Device, 16  
LID Operation and Menus, 16  
Limited Shutdown, After, 63  
Linkage, Checking Guide Vane, 68  
Load Balancing (Lead/Lag Control), 40  
Local Interface Device (LID), 16  
Local Occupied Schedule (OCCPC01S), Input the, 54  
Local Start-Up, 43  
Replacing Defective Processor, 98  
Monthly, Check Safety and Operating Controls, 76  
Motor (Remove Shipping Packaging), 45  
Motor Auxiliary Devices, 46  
Motor Current Demand Setting, Calibrate, 61  
Motor Electrical Connection, 45  
Motor Handling/Rigging, 81  
Motor Initial Start-Up, 58  
Motor Maintenance, 78  
Motor Pre-Start Checks, 51  
Log Off, To (Service Operation), 42  
Log, Refrigeration, 63  
Motor Replacement Parts, 83  
Motor Rotation, Check, 58  
Long-Term Storage (External Gear Storage), 81  
Lubrication Cycle, 8  
Motor Sleeve Bearing and Pumpout Compressor Oil  
(Oil Changes), 78  
Lubrication Cycle,  
Motor Starter, 5  
Motor Storage, 81  
Compressor, 8  
External Gear, 9  
Near Final Alignment (Chiller Alignment), 71  
Network Device Control, Attach to, 41  
Nitrogen, To Pressurizes With Dry, 68  
Non-Ice Build Operations, Return to (Ice Build Control), 41  
Normal Operating Conditions, Return Chiller to, 67  
Notes on Module Operation, 96  
Lubrication System,  
Check the, 76  
Compressor (Instruct the Operator), 62  
External Gear (Instruct the Operator), 62  
Maintenance (Instruct the Operator), 62  
117  
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INDEX (cont)  
Perform an Automated Control Test, 56  
OCCPC01S, Input the Local Occupied Schedule, 54  
Occupancy Schedule, 32  
Physical Data and Wiring Schematics, 99  
PIC System Components, 12  
PIC System Functions, 32  
Occupied Schedule (OCCPC01S), Input the Local, 54  
Oil,  
Compressor, 77  
Piping,  
External Gear, 77  
Check Optional Pumpout Compressor Water, 50  
Inspect Relief Valves and (Scheduled Maintenance), 78  
Inspect Water, 50  
Oil Auxiliary Relay (4C), 16  
Oil Changes (Scheduled Maintenance), 77  
Oil Charge, Compressor, 54  
Point Status, To View or Change, 17  
Power Failure,  
Oil Charge, Optional Pumpout Compressor, 83  
Oil Circuit Valves, Open, 46  
Auto. Restart After (Lead/Lag Control), 40  
Auto. Restart After (Controls), 36  
Power Up the Controls and Check the Compressor  
Oil Heater, 54  
Oil Control, Shaft Seal, 33  
Oil Cooler, 36  
Oil Cooling Cycle, 8  
Oil Differential Pressure/Power Supply Module, 16  
Oil Differential Pressure/Power Supply Module  
Calibration (Checking Pressure Transducers), 85  
Oil Filter,  
Pre-Start Checks,  
External Gear, 51  
Motor, 51  
Preliminary Alignment (Chiller Alignment), 71  
Preparation (Initial Start-Up), 57  
Preparation (Pumpout and Refrigerant Transfer  
Procedures), 63  
Compressor (Changing the Oil Filters), 76  
External Gear (Changing the Oil Filters), 77  
Oil Filters, Changing the, 76  
Oil Heater Contactor (IC), 16  
Oil Heater, Power Up the Controls and Check the  
Compressor, 54  
Prepare the Chiller for Start-Up, 62  
Pressure Transducers,  
Check, 83  
Oil Heater Voltage Selector (SI), Control and, 16  
Oil Pressure and Compressor Stop, Check, 61  
Oil Pump Contactors, Compressor (2C) and Gear (5C), 16  
Oil Specifications, 77  
Checking, 84  
Pressure/Power Supply Module, Oil Differential, 16  
Pressurize With Dry Nitrogen, To, 68  
Prevent Accident Start-Up, To, 61  
Prevention Algorithm, Surge, 37  
Prevention, Condenser Freeze, 36  
Processor/Sensor Input/Output (PSIO) Module  
(Troubleshooting Guide), 97  
Oil Sump Temperature Control, 35  
Ontime, Service, 76  
Open Oil Circuit Valves, 46  
Operating Condition, Check Chiller, 61  
Operating Instructions, 62  
Operating the Optional Pumpout Compressor, 63  
Operation,  
Cold Weather, 63  
Faulted Chiller (Lead/Lag Control), 40  
Lead/Lag (Lead/Lag Control), 39  
Manual Guide Vane (Operating Instructions), 63  
Service, 22, 42  
Processor/Sensor Input/Output Module (PSIO), 16  
Processor Modules, Replacing Defective, 98  
Proportional Bands and Gain, 32  
Protection, Surge, 38  
PSIO Module,  
Installation of New, 98  
Processor/Sensor Input/Output (Troubleshooting  
Guide), 97  
Start-Up Recycle (Ice Build Control), 40  
Operation and Menus, LID, 16  
Operation of the Guide Vanes, Manual, 58  
Operations,  
PSIO, Processor/Sensor Input/Output Module, 16  
Pumpout and Refrigerant Transfer Procedures, 63  
Pumpout Compressor (Optional), Check Pumpout  
System Controls and, 56  
Override, 18  
Pumpout Compressor Oil, Motor Sleeve Bearing  
and (Oil Changes), 78  
Return to Non-Ice Build (Ice Build Control), 41  
Operator Duties, 62  
Operator, Instruct the, 62  
Operator Knowledge, Check, 62  
Option, Demand Limit Control (Requires Optional  
8-Input Module), 37  
Optional Pumpout Compressor,  
Check Pumpout System Controls and, 56  
Operating the, 63  
Pumpout Compressor, Operating the Optional, 63  
Pumpout Compressor Water Piping, Check Optional, 50  
Pumpout Safety Control Settings, 83  
Pumpout System (Instruct the Operator), 62  
Pumpout System Controls and Optional Pumpout  
Compressor, Check, 56  
Pumpout System Maintenance, 83  
Pumpout System, Using the Economizer/Storage  
Vessel and, 45  
Optional Pumpout Compressor Oil Charge, 83  
Options Modules (8-Input), 98  
Ordering Replacement Chiller Parts, 83  
Outputs,  
Ramp Loading Control, 33  
Reading Refrigerant Pressures, 63  
Recycle Mode, Chilled Water, 44  
Red LEDs (Control Modules), 96  
Refrigerant,  
(4-In/2-Out Module), 98  
(Processor/Sensor Input/Output Module), 97  
(Starter Management Module), 97  
Override, Capacity, 35  
Adding, 67  
Charge into Chiller, 57  
Override Operations, 18  
Removing, 67  
Overview (Troubleshooting Guide), 83  
Packaging, Remove Shipping, 45  
Parameters, Input Service Equipment, If Necessary, 55  
Parts, Motor Replacement, 83  
Password, 54  
Transferring Into the Cooler/Condenser/Compressor  
Section, 67  
Transferring Into the Economizer/Storage Vessel, 66  
Refrigerant Charge,  
Adjusting the, 67  
Trimming, 57  
118  
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INDEX (cont)  
Refrigerant Float System, Inspect (Scheduled  
Maintenance), 78  
Shunt Trip (Safety Controls), 33  
Shutdown,  
Refrigerant Leak Testing, 67  
After Extended, 63  
Refrigerant Pressures, Reading, 63  
Refrigerant Properties, 67  
After Limited, 63  
Extended, 63  
Refrigerant Tracer (Test After Service, Repair, or  
Major Leak), 68  
Safety, 45  
Shutdown Sequence, 44  
Six-Pack Relay Board, 16  
Sleeve Bearings (Motor Maintenance), 79  
SMM,  
Refrigerant Tracer, 46  
Refrigerant Transfer Procedures, Pumpout and, 63  
Refrigeration Cycle, 5  
Refrigeration Log, 63  
Starter Management Module (Troubleshooting Guide), 97  
Starter Management Module, 16  
Soft Stop Amps Threshold, Automatic, 44  
Software Version, 54  
Relay (3C) (Optional), Hot Gas Bypass Contactor, 16  
Relay (4C), Oil Auxiliary, 16  
Relay Board, Six-Pack, 16  
Relay, Tower Fan, 36  
Solid-State Starters (Check Starter), 53  
Spare Alarm Contacts, 36  
Spare Safety Inputs, 36  
Relief Devices, Check, 50  
Relief Valves and Piping, Inspect (Schedule  
Maintenance), 78  
Specifications, Oil, 77  
Remote Start/Stop Controls, 36  
Standing Vacuum Test, 49  
Start-Up,  
Remove Shipping Packaging, 45  
Removing Refrigerant, 67  
Before Initial, 45  
Repair, or Major Leak, Test After Service, 67  
Repair the Leak, Retest, and Apply Standing  
Vacuum Test, 68  
Initial, 57  
Local, 43  
Motor Initial, 58  
Replacement Chiller Parts, Ordering, 83  
Replacement Parts, External Gear, 83  
Replacement Parts, Motor, 83  
Prepare the Chiller for, 62  
To Prevent Accidental, 61  
Start-Up Checklist for 17EX Externally Geared  
Centrifugal Liquid Chiller, Initial, CL-1 to CL-12  
Start-Up/Recycle Operation (Ice Build Control), 40  
Start-Up Sequence, Dry Run to Test, 58  
Start-Up/Shutdown/Recycle Sequence, 43  
Start/Stop Controls, Remote, 36  
Starter Management Module (SMM) (Troubleshooting  
Guide), 97  
Replacement, Transducer, 85  
Replacing Defective Processor Modules, 98  
Required, Equipment (Before Initial Start-Up), 45  
Required, Job Data (Before Initial Start-Up), 45  
Reset, Water/Brine, 37  
Resistance Check (Checking Temperature Sensors), 84  
Return Chiller to Normal Operating Conditions, 67  
Return to Non-Ice Build Operations (Ice Build Control), 41  
Rotation, Check Motor, 58  
Starter Management Module (SMM), 16  
Starter,  
Running System, Check the, 62  
Check, 53  
S1, Control and Oil Heater Voltage Selector, 16  
Safety and Operating Controls, Check Monthly, 76  
Safety Considerations, 1  
Motor, 5  
Starters, 9  
Starters,  
Safety Controls, 33  
Mechanical (Check Starter), 53  
Solid-State (Check Starter), 53  
Starting Equipment, Inspect the (Scheduled  
Maintenance), 83  
Safety Devices and Procedures (Instruct the Operator), 62  
Safety Inputs, Spare, 36  
Safety Shutdown, 45  
Schedule (OCCPC01S), Input the Local Occupied, 54  
Schedule, Occupancy, 32  
Starting the Chiller, 62  
Stopping the Chiller, 62  
Storage,  
Schedule Maintenance, 76  
Scheduling, Holiday (Service Operation), 42  
Schematics, Physical Data and Wiring, 99  
Screen Freeze, Default, 33  
External Gear, 81  
Motor, 81  
Structure, Menu, 17  
Seal Disassembly (Contact Seal Maintenance), 68  
Seal Reassembly (Contact Seal Maintenance), 70  
Sensor Installation, Common Point (Lead/Lag Control), 38  
Sensors, Checking Temperature (Troubleshooting Guide), 84  
Service Configurations, Input, 54  
Service Ontime, 76  
Surge Prevention Algorithm, 37  
Surge Protection, 38  
System Components, 5  
T1-T4, Control Transformers, 16  
Temperature Control During Ice Build (Ice Build  
Control), 41  
Service Operation, 22, 42  
Temperature Control,  
Service, Repair, or Major Leak, Test After, 67  
Service Screen, To Access the (Service Operation), 42  
Set Points, Input the Design, 54  
High Discharge, 35  
Oil Sump, 35  
Temperature Sensors,  
Set Points, To View and Change, 22  
Set Up Chiller Control Configuration, 54  
Settings, Pumpout Safety Control, 83  
Shaft Seal Oil Control, 33  
Shipping Packaging, Remove, 45  
Short-Term Storage (External Gear Storage), 81  
Checking (Troubleshooting Guide), 84  
Dual (Checking Temperature Sensors), 84  
Termination of Ice Build (Ice Build Control), 41  
Test After Service, Repair, or Major Leak, 67  
Test Start-Up Sequence, Dry Run to, 58  
119  
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INDEX (cont)  
Test,  
Trimming Refrigerant Charge, 57  
Control (Troubleshooting Guide), 85  
Trip, Shunt (Safety Controls), 33  
Troubleshooting Guide, 83  
Perform and Automated Control, 56  
Standing Vacuum, 49  
Testing, Refrigerant Leak, 67  
This Manual (Instruct the Operator), 62  
Threshold, Automatic Soft Stop Amps, 44  
Tighten All Gasketed Joints and Guide Vane Shaft  
Packing, 46  
Tightness, Check Chiller, 46  
Time and Date, Input, 55  
Time Schedule Operation, To View or Change, 18  
Timers, Chiller, 32  
Troubleshooting Transducers, 85  
Tubes, Inspect the Heat Exchanger (Scheduled  
Maintenance), 82  
Using the Economizer/Storage Vessel and Pumpout  
System, 45  
Vacuum Test, Standing, 49  
Valves, Open Oil Circuit, 46  
Vessel, Economizer/Storage, 5  
View and Change Set Points, To, 22  
View or Change Time Schedule Operation, To, 18  
View or Change Point Status, To, 17  
Volatile Memory, 11  
To Prevent Accidental Start-Up, 61  
To View and Change Set Points, 22  
To View or Change Point Status, 17  
To View or Change Time Schedule Operation, 18  
Tower Fan Relay, 36  
Voltage Drop (Checking Temperature Sensors), 84  
Voltage Selector (SI), Control and Oil Heater, 16  
Voltage Supply, Check, 56  
Tracer, Refrigerant, 46, 68  
Water Leaks, 82  
Water Piping,  
Transducer Replacement, 85  
Transducers,  
Check Optional Pumpout Compressor, 50  
Inspect, 50  
Check Pressure, 83  
Checking Pressure, 84  
Water Treatment, 82  
Troubleshooting, 85  
Water/Brine Reset, 37  
Transferring Refrigerant into the Cooler/Condenser/  
Compressor Section, 67  
Weekly Maintenance, 76  
Wiring, Chiller Communication (Lead/Lag Control), 38  
Wiring, Inspect, 50  
Transferring Refrigerant into the Economizer/Storage  
Vessel, 66  
Wiring Schematics, Physical Data and, 99  
Transformers (T1-T4), Control, 16  
Copyright 1997 Carrier Corporation  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Book 2  
PC 211  
Catalog No. 531-721  
Printed in U.S.A.  
Form 17EX-1SS  
Pg 120  
7-97  
Replaces: New  
Tab 5d  
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