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17EX
Externally Geared Centrifugal Liquid Chillers
50/60 Hz
1500 to 2250 Nominal Tons (5280 to 7910 kW)
Start-Up,Operation,andMaintenanceInstructions
SAFETY CONSIDERATIONS
Centrifugal liquid chillers are designed to provide safe DO NOT REUSE disposable (nonreturnable) cylinders or
and reliable service when operated within design speci- attempttorefillthem.ItisDANGEROUSANDILLEGAL.When
fications.Whenoperatingthisequipment,usegoodjudg- cylinder is emptied, evacuate remaining gas pressure, loosen
ment
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CONTENTS Page Page SAFETY CONSIDERATIONS ......................1 Default Screen Freeze .........................33 Auxiliary Compressor Oil Pump Control ..........33 INTRODUCTION ................................5 Auxiliary Gear Oil Pump Control ................33 ABBREVIATIONS ...............................5 Shaft Seal Oil Control..........................33 17EX CHILLER FAMILIARIZATION.................5 Ramp Loading Control.........................33 Chiller Identification Label ...............
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CONTENTS Page Page Inspect Water Piping ..........................50 Prepare the Chiller for Start-Up .................62 Check Optional Pumpout Compressor Water Starting the Chiller ........................... 62 Piping ....................................50 Check the Running System.....................62 Check Relief Devices ..........................50 Stopping the Chiller ...........................62 Inspect Wiring ................................50 After Limited Shutdown...................
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CONTENTS (cont) Page Page Motor Handling/Rigging........................81 Checking Pressure Transducers ................84 Motor Storage ................................81 • OIL DIFFERENTIAL PRESSURE/POWER SUPPLY External Gear Storage .........................81 MODULE CALIBRATION • TROUBLESHOOTING TRANSDUCERS • SHORT-TERM STORAGE (Indoors) • TRANSDUCER REPLACEMENT • LONG-TERM STORAGE (Indoors) Control Algorithms Checkout Procedure .........85 • EXTENDED DOWNTIME Control Test ..................
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INTRODUCTION 17EX CHILLER FAMILIARIZATION Chiller Identification Label (Fig. 1) — The iden- Beforeinitialstart-upofthe17EXunit,thoseinvolvedin tificationlabelislocatedontherightsideofthechillercon- the start-up, operation, and maintenance should be thor- trol center panel. The label contains information on model oughly familiar with these instructions and other necessary number, refrigerant charge, rated voltage, etc. job data.This book is outlined so that you may become fa- miliarwiththecontrolsy
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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 ARI (Air Conditioning ‘U’STAMP 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 13 14 40 39 38 37 36 35 15 34 33 31 30 28 27 25 22 21 20 17 32 29 26 24 23 19 18 16 LEGEND 1— Condenser 22 — Oil Drain and Charging Valve 2— Cooler Suction Pipe 23 — Oil Heater (Hidden) 3— Compressor Suction Elbow 24 — Compressor Oil Pump 4— Guide VaneActuator 25 — Compressor Oil Cooler/Filter 5— Condenser Discharge Pipe 26 — Local Interface Display Control Panel 6— Com
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The chiller compressor continuously draws large quanti- ExternalGearOilCooling— The external gear oil tiesofrefrigerantvaporfromthecoolerataratedetermined is also water cooled.Water flow through the gear oil cooler bytheamountofguidevaneopening.Thiscompressorsuc- is manually adjusted by a plug valve to maintain an oper- tionreducesthepressurewithinthecooler,allowingtheliq- atingtemperatureofapproximately130F(54C).Ifsoequipped, uidrefrigeranttoboilvigorouslyatafairlylowtemperature an oil heater in
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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 Uponleavingthecoolersection(Item13)oftheoilcooler/ ExternalGearLubricationCycle(RefertoItem filter,theoilisfiltered(Item11)andisdirectedtothepres- numbers shown in Fig. 5) — Oil reservoir is con- surecontrolvalve(Item7).Beforeenteringthepressurecontrol tainedinthegearbase.Theexternalgearoilpumpismounted valve, the oil pressure (Item 16) a
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SHAFT DISPLACEMENT & BRG TEMP. CUTOUT 1 CONNECTIONS SEAL-END COAST DOWN BEARING RESERVOIRS 13 COMPRESSOR OIL PRESSURE LEAVING FILTER LINE 2 12 SHAFT JOURNAL SEAL BEARING 14 THRUST BEARING CHECK VALVE 15 OIL FILTER 16 OIL COOLER/ FILTER TO PIC CONTROLLER 17 3 PLUG VALVE 8 OIL CHARGING MAIN OIL ELBOW RESERVOIR 4 11 PUMP, SEAL SIGHT OIL RETURN GLASSES TO POWER 10 7 6 5 9 PANEL OIL PUMP OIL OIL DRAIN & COMPRESSOR OIL & PRESS. REGULATOR THERMISTOR HEATER CHARGING VALVE SUCTION PRESSURE Fig. 4 — 17E
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1— Gear Mesh 8— Oil Supply Temperature Thermistor 2— Bearings 9— Oil Pump Motor 3— Gear Mesh Spray 10 — Oil Pump and Pressure Regulator 4— Oil Level Glass 11 — Oil Filter 5— Orifice 12 — Oil Cooler/Filter 6— Oil Supply Pressure 13 — Oil Cooler Transducer 14 — Plug Valve 7— Pressure Control Valve 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 contai
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• power panel PICSystemComponents— TheProductIntegrated — 115 v control voltage Control (PIC) is the control system on the chiller. See — up to 600 v for oil pump power Table1.ThePICcontrolstheoperationofthechillerbymoni- • starter cabinet toringalloperatingconditions.ThePICcandiagnoseaprob- — chiller power wiring (per job requirement) lemandlettheoperatorknowwhattheproblemisandwhat to check. It promptly positions the guide vanes to maintain Table 1 — Major PIC Components and leavingchilledwater
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LEGEND 13 — Condenser Pressure Transducer 17 — Oil Pump Conduit 14 — Condenser Entering Water 18 — Oil Pump Sensor Temperature Sensor 19 — PIC Control Panel 15 — Condenser Entering and Leaving Water 20 — Condenser Leaving Water Temperature Cable Temperature Sensor 16 — Oil Suction Pressure Sensor 21 — Gear Oil Cooler Solenoid Conduit LEGEND 22 — Cooler Temperature Cable 23 — Cooler Leaving Water Temperature Sensor 24 — Cooler Entering Water Temperature Sensor 25 — Cooler Pressure Sensor 26 — Ref
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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 PIC — Product Integrated Controls PSIO — Processor Sensor Input/Output Module 1— Optional 8-Input Module for Spare Inputs to Control Interface (One of TwoAvailable) 2— PSIO 3— LID Input/Output Interface Panel Display 4— Oil Differential Pressure/Power Supply Module (Hidden) 5— LID Light (Hidden) 6— 6-Pack Relay Board
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15 LEGEND EQUIP GND — Equipment Ground GRD — Ground M— Motor TEWAC — Totally Enclosed Water-to- Air Cooled Fig. 10 — 17EX Chiller Power Panel and Controls Connections
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PROCESSOR/SENSORINPUT/OUTPUTMODULE(PSIO) incomingcontrolvoltagetoeither21vacpowerforthePSIO — This module contains all the operating software needed module and options modules, or 24 vac power for 3 power tocontrolthechiller.The17EXuses5pressuretransducers panel contactor relays and a control solenoid valve. and8thermistorstosensepressuresandtemperatures.These CONTROL AND OIL HEATER VOLTAGE SELECTOR inputs are connected to the PSIO module. The PSIO also (S1)—Itisnecessarytouse115vincomingcontrol
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• Press NEXT or PREVIOUS to highlight the desired NOTE: When an alarm is detected, the LID default screen freezes(stopsupdating)atthetimeofalarm.Thefreezeen- entry. 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. • Press SELECT to access the highlighted point. • Press QUIT to leave the selected decisio
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Override Indication — An override value is indicated by 3. Press SELECT to view the desired Point Status table. ‘‘SUPVSR,’’‘‘SERVC,’’or‘‘BEST’’flashingnexttothepoint value on the Status table. TOVIEWORCHANGETIMESCHEDULEOPERATION (Fig. 14) 4. On the Point Status table press NEXT or 1. On the Menu screen, press SCHEDULE . PREVIOUS untildesiredpointisdisplayedonthescreen. 2. Press NEXT or PREVIOUS to highlight one of the For Discrete Points — Press START or STOP , following schedules. YES or NO,ON o
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DEFAULT SCREEN MENU CCN LOCAL RESET (SOFTKEYS) Start Chiller In CCN Control Start Chiller In Local Control Clear Alarms Access Main Menu STATUS SCHEDULE SETPOINT SERVICE (ENTER A 4-DIGIT PASSWORD) 12 3 4 List the Status Tables List the Service Tables Display the Setpoint Table STATUS01 STATUS02 List the Schedules STATUS03 • Base Demand Limit STATUS04 • LCW Setpoint • ECW Setpoint • Ice Build Setpoint NEXT PREVIOUS SELECT EXIT (SELECT A TABLE) (SELECT A POINT NEXT PREVIOUS SELECT EXIT ON THE TABL
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SERVICE TABLE PREVIOUS SELECT EXIT NEXT ALARM HISTORY 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 CONTROL ALGORITHM STATUS • PSIO Thermistors • Options Thermistor • Transducers • Guide Vane Actuator List the Control Algorithm Status Tables • Pumps MAINT01 (Capacity Control) • Discrete Outputs MAINT02 (Override Status) • Pumpdown Lockout MAINT03 (Surge/HGBP Status) • Terminate
