Troubleshooting; Compressor Will Not Start; Compressor Surge; Chilled Water Temperature Too High - Carrier 17DA Start-Up, Operation And Maintenance Instructions Manual

During shutdown all pressures equalize and refrigerant will
not separate from air in the purge. Do not vent the purge when
the machine is not running.

TROUBLESHOOTING

When troubleshooting the 17DA machine, check the PLC
display on the control panel first. Messages on the main screen
will indicate the fault or faults, plus further information can be
found on the screens applicable to that function or functions re-
lated to the fault.

Compressor Will Not Start

SAFETY SWITCH MALFUNCTION — There are standard
mechanical switches on the chiller along with sensors that pro-
vide information to the PLC. Two standard sensors that are al-
ways provided are the seal movement safety switch and the
shaft movement safety switch. If either switch or its wiring is
open circuited, then the PLC will show an alarm.
Mechanical switches for various temperatures and pressures
may be provided in addition to the sensors of the PLC, if speci-
fied by the customer. These mechanical switches are also con-
nected to PLC inputs and the switch or circuit that is open will
be reported by the PLC.
DRIVE MALFUNCTION — Safety switches and sensors on
the motor, speed increaser or turbine normally are connected to
and identified by the PLC. Variable frequency (speed) drives
(VFD) will have their own display panel. Starters of the size
used for the 17DA chillers generally have monitoring instru-
ments that will provide information on internal problems, prob-
lems with incoming power, etc.
Compressor Surge —
covery of the compressors aerodynamic lift. This loss of lift is
characterized by a reversal of flow back through the compres-
sor. During surge there will be an intermittent high pitched
whistle signifying the reversal of the flow through the com-
pressor. The pressure gages and the motor amps will rise and
fall.
Intermittent operation in surge is not normally detrimental
to the machine. Prolonged operation in surge can cause damage
related to heat build-up.
The ability of a centrifugal compressor to produce pressure
is directly related to the amount of gas passing through it, and
the lift characteristics on the compressor at these load points.
All of the possible causes are related to this fact. Computer
modeling of the 17DA compressor for each application can
provide guidance on how to adjust the characteristics of the op-
eration to minimize the occurrence of surge.
The amount of required condenser water temperature reduc-
tion versus load reduction varies widely among centrifugal
compressors based on design and duty. The 17DA chiller is
able to handle deep load reductions without a major drop in
condenser water temperature. This does not imply that con-
denser water temperature should be held near design tempera-
ture at all times. It is an advantage to power consumption to
keep the condenser water temperature as low as possible down
to a minimum temperature. The minimum and maximum tem-
peratures vary with machine and duty. They may be obtained
through your Carrier Service Office.
The following sections are some of the causes of surge and
corrections associated with them.
INSUFFICIENT LOAD TO MAINTAIN STABILITY —
Increase load on the machine. Open the optional hot gas
bypass. Reduce condenser water temperature. If none of these
Surge is a repeated loss and re-
can be done, stop the machine until load on the system
increases.
CONDENSER WATER
HIGH — As machine cooling load drops below design, enter-
ing condenser water temperature must also drop. The ability of
a centrifugal compressor to produce pressure is directly related
to the amount of gas passing through it. Lower the condenser
water pressure or temporarily raise the chilled water set point.
FOULED TUBES IN EITHER HEAT EXCHANGER —
Clean the tubes.
LOW WATER
EXCHANGER — Condenser water should remain at design
flow. Cooler water flow can be varied to meet system needs.
The allowable minimum must be determined for each machine.
If surge occurs the load on the machine may seem sufficient
when it is not unless flow rate and delta T are both checked.
VARIABLE SPEED
SLOWLY. — When leaving chiller water temperature is con-
trolled by varying the compressor speed, it is possible that dur-
ing low load conditions the rpm required for the capacity may
be too low to maintain the required lift. In this case, the speed
must be temporarily increased and the guide vanes used to con-
trol the water temperature. Conditions allowing return to speed
control are indicated by the full opening of the guide vanes.
Chilled Water Temperature Too High —
ing are some of the causes of a high chilled water temperature
and corrections associated with them.
CHILLED WATER SET POINT TOO HIGH — Lower set
point.
MOTOR IS LOAD LIMITED BELOW THE REQUIRED
POWER TO MAINTAIN CHILLED WATER TEMPERA-
TURE — Reset limit.
CHILLED WATER SET POINT HAS BEEN OVERRID-
DEN BY THE BUILDING CONTROL SYSTEM —
Check settings of building control system.
GUIDE VANES NOT FULLY OPENING (for reasons other
than the above)
• Check supply air pressure to the actuator
• Check the instrument air signal
• Guide vane travel limited in the PLC
• Defective electronic-to-air signal transducer
• Guide vanes mechanically stuck
• Actuator or positioner malfunctioning
• "Quick dump" solenoid operated valve on the positioner is
leaking
HIGH CONDENSER PRESSURE — See section entitled
Condenser Pressure Too High.
COOLER WATERBOX DIVISION PLATE GASKET OUT
OF PLACE — Fix gasket.
LEAVING CHILLED WATER SENSOR DEFECTIVE —
Replace sensor.
EXCESSIVE WATER
COOLER — Check chiller configuration.
EXCESSIVE DIFFERENCE
WATER TEMPERATURE AND REFRIGERANT TEM-
PERATURE
• Low refrigerant charge
• Fouled cooler tubes
• Debris in waterbox blocking tubes
The temperature difference will increase at low flow.
Check refrigerant-leaving chilled water difference at design
flow.
20
TEMPERATURE
FLOW IN EITHER
DRIVE OPERATING
FLOW THROUGH
BETWEEN CHILLED
IS TOO
HEAT
TOO
Follow-
THE