Carrier 19EX Series Manuals

Manuals and User Guides for Carrier 19EX Series. We have 3 Carrier 19EX Series manuals available for free PDF download: Start-Up, Operation And Maintenance Instructions Manual, Start Up & Operation Manual, Product Data

Carrier 19EX Series Start-Up, Operation And Maintenance Instructions Manual (437 pages)

50/60 Hz Centrifugal Liquid Chillers with HFC-134a

Brand: Carrier | Category: Chiller | Size: 6 MB

Safety Considerations
1
Table of Contents
7
Motor-Compressor
18
17/19EX Machine Familiarization
39
- Machine Identification Label
  39
- System Components
  39
- Control Center
  40
- Motor Starter
  41
  - Utility Vessel
    41
  - Refrigeration Cycle
    41
  - Motor/Oil Refrigeration Cooling Cycle
    43
  - Pic System Components
    52
  - Pic System Functions
    74
  - Control Point
    75
  - Safety Controls
    79
  - Default Screen Freeze
    81
  - Motor Cooling Control (Hermetic Motors Only)
    81
  - Auxiliary Oil Pump Control (Open Drive Machines Only)
    81
  - Ramp Loading Control
    82
  - Capacity Override
    83
  - High Discharge Temperature Control
    84
  - Oil Sump Temperature Control
    85
  - Oil Cooler
    86
  - Remote Start/Stop Controls
    86
  - Spare Safety Inputs
    87
  - Spare Alarm Contacts
    87
  - Condenser Freeze Prevention
    88
  - Condenser Pump Control
    88
  - Tower-Fan Relay
    89
  - Auto. Restart after Power Failure
    90
  - Water/Brine Reset
    91
  - Surge Prevention Algorithm
    93
  - Demand Limit Control, Option (Requires Optional 8-Input Module)
    93
  - Surge Protection
    95
  - Lead/Lag Control
    96
  - Ice Build Control
    104
  - Attach to Network Device Control
    109
  - Service Operation
    111
  - Local Start-Up
    118
  - Shutdown Sequence
    120
  - Automatic Soft Stop Amps Threshold
    121
  - Chilled Water Recycle Mode
    122
  - Safety Shutdown
    124
  - Before Initial Start-Up
    125
  - Job Data Required
    125
  - Using the Utility Vessel and Pumpout System
    125
  - Remove Shipping Packaging
    126
  - Open-Drive Motor Electrical Connection
    127
  - Open-Drive Motor Auxiliary Devices
    128
  - Open Oil Circuit Valves
    129
  - Torque All Gasketed Joints
    129
  - Check Machine Tightness
    129
  - Refrigerant Tracer
    130
  - Leak Test Machine
    130
  - Standing Vacuum Test
    134
  - Machine Dehydration
    135
  - Inspect Water Piping
    137
  - Check Optional Pumpout Compressor Water Piping
    138
  - Check Relief Devices
    138
  - Inspect Wiring
    139
  - Carrier Comfort Network Interface
    145
  - Check Starter
    147
  - Oil Charge
    150
  - Power up the Controls and Check the Oil Heater
    150
  - Input the Design Set Points
    152
  - Input the Local Occupied Schedule (OCCPC01S)
    152
  - Input Service Configurations
    153
  - High Altitude Locations
    163
  - Charge Refrigerant into Machine
    164
  - Initial Start-Up
    166
  - Manual Operation of the Guide Vanes
    167
  - Dry Run to Test Start-Up Sequence
    168
  - Check Rotation (Open-Drive Motor)
    169
  - Check Rotation (Hermetic Motor)
    174
  - Check Oil Pressure and Compressor Stop
    175
  - Calibrate Motor Current Demand Setting
    175
  - To Prevent Accidental Start-Up
    176
  - Hot Alignment Check for Open-Drive Machines
    177
  - Doweling for Open-Drive Machines
    177
  - Check Machine Operating Condition
    178
  - Instruct the Customer Operator
    178
  - Operating Instructions
    180
  - Operator Duties
    180
  - Check the Running System
    181
  - Prepare the Machine for Start-Up
    181
  - To Start the Machine
    181
  - To Stop the Machine
    183
  - After Extended Shutdown
    184
  - After Limited Shutdown
    184
  - Extended Shutdown
    184
  - Manual Guide Vane Operation
    185
  - Cold Weather Operation
    185
  - Refrigeration Log
    186
  - Pumpout and Refrigerant Transfer Procedures
    187
  - General Maintenance
    195
  - Refrigerant Properties
    195
  - Adding Refrigerant
    196
  - Removing Refrigerant
    196
  - Adjusting the Refrigerant Charge
    196
  - Refrigerant Leak Testing
    197
  - Leak Rate
    197
  - Test after Service, Repair, or Major Leak
    197
  - Repair the Leak, Retest, and Apply Standing Vacuum Test
    199
  - Checking Guide Vane Linkage
    199
  - Machine Alignment (Open-Drive Machines)
    205
  - Check the Lubrication System
    221
  - Weekly Maintenance
    221
  - Scheduled Maintenance
    223
  - Service Ontime
    223
  - Inspect the Control Center
    223
  - Changing Oil Filter
    224
  - Check Safety and Operating Controls Monthly
    224
  - Oil Specification
    226
  - Oil Changes
    226
  - Refrigerant Filter
    227
  - Inspect Refrigerant Float System
    228
  - Inspect Relief Valves and Piping
    228
  - Oil Reclaim Filter
    228
  - Coupling Maintenance (Open-Drive Machines)
    229
  - Motor Maintenance (Open-Drive Machines)
    230
  - Open-Drive Motor Handling/Rigging
    243
  - Open-Drive Motor Storage
    244
  - Inspect the Heat Exchanger Tubes
    246
  - Water Leaks
    248
  - Water Treatment
    248
  - Inspect the Starting Equipment
    249
  - Check Pressure Transducers
    251
  - Pumpout System Maintenance
    251
  - Ordering Replacement Chiller Parts
    253
  - Troubleshooting Guide
    254
  - Checking the Display Messages
    255
  - Checking Temperature Sensors
    255
  - Checking Pressure Transducers
    258
  - Control Algorithms Checkout Procedure
    263
  - Control Modules
    267
  - Notes on Module Operation
    270
  - Processor Module (PSIO)
    272
  - Starter Management Module (SMM)
    273
  - Options Modules (8-Input)
    274
  - Replacing Defective Processor Modules
    275
  - 17/19EX Physical Data and Wiring Schematics
    279
  - Start-Up Failures
    315
  - Troubleshooting
    328

Carrier 19EX Series Start Up & Operation Manual (116 pages)

Centrifugal Liquid Chillers 50/60 Hz with HFC-134a

Brand: Carrier | Category: Chiller | Size: 2 MB

Safety Considerations
1
Table of Contents
2
Cooler
8
Condenser
8
Motor-Compressor
8
Control Center
8
Motor Starter
8
Utility Vessel
8
Refrigeration Cycle
8
Motor/Oil Refrigeration Cooling Cycle (19Ex Chillers)
8
Cycle
10
Details
10
Open-Drive Machines (17 Series Lubrication Cycle
12
Cycle
12
Summary
12
Details
12
Starters
12
Controls
12
Deﬁnitions
12
General
12
PIC System Components
14
Processor Module (Psio)
14
Starter Management Module (Smm)
14
Local Interface Device (Lid)
14
6-Pack Relay Board
14
8-Input Modules
14
Oil Heater Contactor (1C)
14
Oil Pump Contactor (2C)
14
HOT GAS BYPASS CONTACTOR RELAY (3C) (Optional)
14
Oil Auxiliary Relay (4C)
14
Oil Auxiliary Relay (4C
20
LID Operation and Menus
21
General
21
Alarms and Alerts
21
Lid Default Screen Menu Items
22
Menu Structure
22
To View or Change Point Status
22
Menu Structure
23
Override Operations
25
To View or Change Time Schedule Operation
25
To View and Change Set Points
26
Service Operation
26
PIC System Functions
35
Capacity Control
35
Entering Chilled Water Control
35
Proportional Bands and Gain
35
Demand Limiting
35
Machine Timers
35
Occupancy Schedule
35
Safety Controls
35
Shunt Trip
36
Default Screen Freeze
36
Motor Cooling Control (Hermetic Motors Only)
36
Auxiliary Oil Pump Control (Open-Drive Machines Only)
36
Shaft Seal Oil (Open Drive Machines Only)
36
Ramp Loading Control
36
Capacity Override
36
High Discharge Temperature Control
36
Oil Sump Temperature Control
38
Oil Cooler
38
Remote Start/Stop Controls
38
Spare Safety Inputs
38
Spare Alarm Contacts
38
Condenser Pump Control
39
Condenser Freeze Prevention
39
Tower-Fan Relay
39
Auto. Restart after Power Failure
39
Water/Brine Reset
39
Demand Limit Control Option
40
Surge Prevention Algorithm
40
Surge Protection
40
Lead/Lag Control
40
Common Point Sensor Installation
41
Machine Communication Wiring
41
Lead/Lag Operation
41
Load Balancing
41
Faulted Chiller Operation
42
Load Balancing
42
Auto. Restart after Power Failure
42
Ice Build Control
42
Ice Build Initiation
42
Termination of Ice Build
42
Start-Up/Recycle Operation
43
Temperature Control During Ice Build
43
Termination of Ice Build
43
Return to Non-Ice Build Operations
43
Attach to Network Device Control
43
Attaching to Other Ccn Modules
43
Service Operation
44
To Log on
44
To Log off
44
Holiday Scheduling
44
Start-Up/Shutdown/Recycle Sequence
45
Local Start-Up
45
Shutdown Sequence
46
Automatic Soft Stop Amps Threshold
46
Chilled Water Recycle Mode
46
Safety Shutdown
46
Before Initial Start-Up
47
Job Data Required
47
Equipment Required
47
Using the Utility Vessel and Pumpout System
47
Remove Shipping Packaging
47
Open-Drive Motor Electrical Connection
47
Open-Drive Motor Auxiliary Devices
48
Open Oil Circuit Valves
48
Tighten All Gasketed Joints and Guide Vane Shaft Packing
48
Check Machine Tightness
48
Refrigerant Tracer
48
Leak Test Machine
48
Standing Vacuum Test
49
Machine Dehydration
51
Inspect Water Piping
52
Check Optional Pumpout Compressor Water Piping
52
Check Relief Devices
52
Inspect Wiring
52
Check Insulation Resistance
52
Carrier Comfort Network Interface
53
Check Starter
54
Oil Charge
54
Power up the Controls and Check the Oil Heater
54
Software Version
54
Set up Machine Control Conﬁguration
55
Input the Design Set Points
55
Input Service Conﬁgurations
55
Password
55
Input Time and Date
55
Change Lid Configuration if Necessary
55
Modify Controller Identification if
55
Input Equipment Service Parameters if
55
Necessary
56
Modify Equipment Configuration if
56
Check Voltage Supply
56
Perform an Automated Control Test
56
Check Pumpout System Controls and Optional Pumpout Compressor
57
High Altitude Locations
57
Charge Refrigerant into Machine
57
Initial Start-Up
58
Manual Operation of the Guide Vanes
58
Dry Run to Test Start-Up Sequence
58
Check Rotation (Open-Drive Motor)
58
Open Drive Motor Initial Start-Up
58
Check Rotation (Hermetic Motor)
59
Check Oil Pressure and Compressor Stop
59
Calibrate Motor Current Demand Setting
60
To Prevent Accidental Start-Up
60
Hot Alignment Check for Open-Drive Machines
60
Doweling for Open-Drive Machines
60
Check Machine Operating Condition
60
Instruct the Customer Operator
60
Cooler-Condenser
60
Utility Vessel
60
Pumpout System
60
Motor Compressor Assembly
60
Operating Instructions
61
Initial Start-Up
61
Prepare the Machine for Start-Up
61
To Start the Machine
61
Check the Running System
61
To Stop the Machine
61
After Limited Shutdown
61
Extended Shutdown
62
After Extended Shutdown
62
Cold Weather Operation
62
Manual Guide Vane Operation
62
Refrigeration Log
62
Procedures
64
Operating the Optional Pumpout Compressor
64
To Read Refrigerant Pressures
64
Transferring Refrigerant from Normal Operation into the Utility Vessel
66
Transferring Refrigerant from Normal Operation into the Cooler/Condenser/Compressor Section
66
Return Refrigerant to Normal Operating Conditions
66
General Maintenance
67
Procedures
67
Refrigerant Properties
67
Adding Refrigerant
67
Removing Refrigerant
67
Refrigerant Leak Testing
67
Leak Rate
67
Test after Service, Repair, or Major Leak
67
Repair the Leak, Retest, and Apply Standing Vacuum Test
67
Checking Guide Vane Linkage
67
Contact Seal Maintenance (Open-Drive Machines)
68
Seal Disassembly
68
Seal Reassembly
68
Machine Alignment (Open-Drive Machines)
70
Alignment Methods
70
Preliminary Alignment
70
Near Final Alignment
70
Hot Alignment Check
70
Preliminary Alignment
71
Near Final Alignment
71
Near Final Alignment
74
Hot Alignment Check
74
Scheduled Maintenance
76
Service Ontime
76
Inspect the Control Center
76
Check Safety and Operating Controls Monthly
76
Changing Oil Filter
76
19Ex Compressors
76
Fa Style Compressors
76
Oil Speciﬁcation
77
Oil Changes
77
Refrigerant Filter
77
Oil Reclaim Filter
77
Inspect Refrigerant Float System
77
Inspect Relief Valves and Piping
77
Coupling Maintenance (Open-Drive Machines)
77
Procedure
77
Motor Maintenance (Open-Drive Machines)
78
Cleanliness
78
Sleeve Bearings
79
Open-Drive Motor Handling/Rigging
81
Open-Drive Motor Storage
81
Compressor Bearing and Gear Maintenance
81
Inspect the Heat Exchanger Tubes
81
Cooler
81
Water Leaks
82
Water Treatment
82
Inspect the Starting Equipment
82
Check Pressure Transducers
82
Pumpout System Maintenance
82
Optional Pumpout Compressor Oil Charge
82
Pumpout Safety Control Settings
83
Ordering Replacement Chiller Parts
83
Open-Drive Motor Renewal Parts
83
Troubleshooting Guide
83
Overview
83
Checking the Display Messages
83
Checking Temperature Sensors
83
Resistance Check
83
Voltage Drop
83
Check Sensor Accuracy
84
Dual Temperature Sensors
84
Checking Pressure Transducers
84
Oil Differential Pressure/Power Supply
84
Troubleshooting Transducers
85
Transducer Replacement
85
Control Algorithms Checkout Procedure
85
Control Test
85
Troubleshooting Guide
86
Control Modules
95
Notes on Module Operation
95
Processor Module (PSIO)
95
Inputs
95
Outputs
95
Starter Management Module (SMM)
96
Options Modules (8-Input)
96
Replacing Defective Processor Modules
96
Installation of New Psio Module
97
17/19Ex Physical Data and Wiring Schematics
97
Compressor Fits and Clearances
102
Index
115

Carrier 19EX Series Product Data (37 pages)

Hermetic Centrifugal 50/60 Hz 800 to 1400 Nominal Tons (2810 to 4920 kW)

Brand: Carrier | Category: Chiller | Size: 2 MB

Features/Benefits
1
Modular Construction
1
Application Flexibility
1
Table of Contents
2
Model Number Nomenclature
2
Lubrication System
2
Variable Inlet Guide Vanes
2
Heat Exchangers
3
Microprocessor Control System
3
2-Stage Hermetic Compressor
4
Single-Piece Modular Construction
4
Typical 19Ex Refrigeration Cycle
6
19EX Refrgeration Cycle
6
Compressor Components
7
Options and Accessories
7
Machine Components
8
Physical Data
9
Rigging and Operating Weights
9
Dimensions
10
Service Clearance
10
Nozzle Sizes
10
Performance Data
11
Electrical Data
11
Auxiliary Ratings
11
Compressor Motor Controllers
11
Low-Voltage Motors
12
Medium and High-Voltage Motors
12
Application Data
14
Range of Application
14
ASME Stamping
14
Design Pressure
14
Pressure Gage Location
15
Auxiliary Connections
15
Refrigerant Temperature Sensors
15
Thermometers
15
Heat Exchanger Minimum
16
Maximum Flow Rates
16
Machine Contact Surfaces
17
Soleplate Isolation
18
Typical Isolation
18
Nozzle Arrangements
19
Nozzle-In-Head Waterboxes
19
Marine Waterboxes
19
Controls
20
Microprocessor Control Panel
21
Control Panel with Options
21
Local Interface Device Typical Display Panels
22
Default Display
22
Status Screens
22
Set Point Screen
22
Service Screens
23
Alarm History File
23
The Service Configuration Screens
23
The Controls Test Screen
23
Control Sequence
24
Once Started
24
Shutdown Sequence
24
Typical C Ontrol Wiring
25
Typical Field Wiring
27
Typical Piping and Wiring
29
Guide Specifications
30
General
30
System Description
30
Equipment
30
Motor
31
Cooler and Condenser
31
Interstage Flash Economiser
31
Insulation
31
Set Point Function
32
Service Function
32
Electrical Requirements
34
Electrical Contractor Shall
34
Field-Installed Accessories
35
Factory Installed Options
35

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