Carrier 19XR User's Manual
Contents
1. 4 3 1 Guide Vane Actuator Cable 3 Compressor Discharge Elbow Joints 2 Power Panel to Starter Cables Oil Pump Power 4 Condenser Transducer Cable Control Power and Communication Fig 7 19XR Chiller Top View 0 M 0 0 0 6 5 1 Motor Temperature Sensor Cable 4 Compressor Oil Sump Temperature 2 Bearing Temperature Sensor Cable Sensor Cable Connection Inside Box 5 Compressor Oil Discharge Pressure Cable 3 Compressor Oil Sump Pressure Cable 6 Discharge Temperature Sensor Cable Fig 8 Compressor Deiail 15 1 Guide Vane ator 2 Diffuser Actuator 3 Water Temperature Sensor Cables Fig 9 Chiller End View To Rig Compressor NOTE The motor end of the 19XR compressor is heavy and will tip backwards unless these directions are followed 1 Cut two 4 in x 6 in wooden beams to the same length as the compressor 2 Drill holes into the beams and bolt them to the base of the compressor Additional Notes 1 Use silicon grease on new O rings when refitting 2 Use gasket sealant on new gaskets when refitting 3 Cooler and condenser vessels may be rigged vertically Rigging should be fixed2. 0 9 0 5 1 4 0 7 1 8 229 133 181 e _ 1 VAPOR 1 D 0 0 1 8 J 3 PG E LEVEL GAGE RELIEF VALVES m 5 pA Ad 1 NPT FEMALE ELECTRICAL SERVICE 203 55 5 CONDENSER WATER B 2 1 2 FEMALE VAPOR CONN SEE NOTE 5 1 2 FLARE ELECTRICAL SERVICE FEMALE ACCESS SPACE SAFETY HEAD 0 5 7 8 149 3 8 ENS R MALE 0 1 7 8 48 1 1 1 4 M 02 51 337 i C J L H F P 4 QUID LIQUID CONN f NPT FEMALE 0 10 0 3 3 4 0 9 254 95 229 DIMENSIONS ENGLISH ft in TANK L E EE 0426 50 0452 50 SI mm 0428 3175 2997 1448 730 365 945 1499 1121 1118 849 965 89 1442 505 491 1111 1530 oas2_ 4553 4982 1546 826 418 1027 2191 1219 1216 86 2172 528 497 1118 1537 NOTES Denotes center of gravity Dimensions in millimeters The weights and center of gravity values given are for an empty storage tank For additional information on the pumpout unit see certified drawings The available conduit knockout sizes are QTY TRADE SIZE LOCATION top bottom middle middle Ovi CO TO c ao Fig 19
3. A 2 2 61 8 MIN B 610 mm SERVICE AREA Fig 5 19XR Dimensions Refer to Tables 1 Through 3 Table 1 19XR Dimensions Nozzle In Head Waterbox A Length with Nozzle in Head Waterbox HEAT EXCHANGER Leng B Width C Height SIZE 2 tor3Passt mm mm mm ftin mm 10 to 12 11 3 3451 11 10 3626 4 11 1518 6 1 1861 15 to 17 13 7 4150 14 2 4324 4 11 1518 6 1 1861 20 22 11 5 3483 12 0 3670 5 5 1670 6 3 1911 30 32 13 8 4172 14 34 4350 5 5 1670 6 956 2073 35 to 37 15 4 4693 15 1194 4870 5 5 1670 6 956 2073 40 to 42 13 11 4242 14 6 4426 6 2 1880 7 0 2153 45 to 47 15 4763 16 294 4947 6 2 1880 7 0 2153 50 52 13 11 4248 14 6 4439 6 6 1994 7 2 2207 55 to 57 15 7 4769 16 3 4959 6 6 1994 7 27 2207 60 to 62 13 11 4261 14 7 4451 6 10 2096 7 47 2257 65 67 15 8 4782 16 3 4972 6 10 2096 7 4 2257 70 to 72 4978 17 0 5194 7 11 2426 9 9 2985 75 77 5588 19 0 5804 7 11 2426 9 9 2985 80 to 82 16 4 4997 17 1 5220 8 10 2711 9 11 3029 85 to 87 18 4 5607 19 1 5829 8 10 2711 9 114 3029 Assumes both cooler and condenser nozzles on same end of chiller T1 or 3 pass length applies if either or both cooler or condenser is a 1 or 3 pass design NOTES 1 Service access should be provided per American Society of Hea
4. DRIVE END COMPRESSOR END FRAMES 7 AND 8 NOZZLE ARRANGEMENT CODES COOLER WATERBOXES CONDENSER WATERBOXES Code Code 5 A 7 9 c w R e E a EES S EAR Fig 18 Piping Flow Data MWB Frames 4 Through 8 23 Table 9 19 Waterbox Nozzle Sizes FRAME PRESSURE NOMINAL PIPE SIZE in ACTUAL PIPE ID in SIZE psig kPa Condenser 8 8 7 981 7 981 1 150 300 6 6 6 065 6 065 1034 2068 6 6 6 065 6 065 1 1 10 020 10 020 150 300 7 981 7 981 1034 2068 6 065 6 065 1 1 10 020 10 020 150 300 7 981 7 981 1034 2068 6 065 6 065 N Ea 1 10 10 10 020 10 020 1 1034 2068 2 8 8 7 981 7 981 3 6 6 6 065 6 065 1 10 10 10 020 10 020 5 034 2068 2 8 10 7 981 10 020 3 6 8 6 065 7 981 1 10 10 10 020 10 020 6 1 190 200 2 10 10 10 020 10 020 3 8 8 7 981 7 981 150 1 14 14 13 250 13 250 1034 2 12 12 12 000 12 000 3 10 12 10 020 12 000 300 1 14 14 12 500 12 500 2068 2 12 12 11 376 11 750 3 10 12 9 750 11 750 150 1 14 14 13 250 13 250 1034 2 13 250 13 250 B 3 12 000 12 000 300 1 12 500 12 500 2068 2 12 500 12 500 3 11 376 11 376 24 PRESSURE GAGE
5. DRIVE END COMPRESSOR END FRAMES 7 AND 8 NOZZLE ARRANGEMENT CODES FOR ALL 19XR NOZZLE IN HEAD WATERBOXES COOLER WATERBOXES CONDENSER WATERBOXES PASS Arrangement PASS Arrangement Code Code 2 5 2 5 Refer to certified drawings Fig 16 Piping Flow Data NIH Frames 7 and 8 21 MARINE WATERBOXES NOTE NOTE COOLER PASS NOZZLE 45 COOLER 3 PASS NOZZLE 45 NOT SHOWN SIMILIAR TO NOT SHOWN SIMILIAR TO CONDENSER 2 PASS CONDENSER 2 55 DRIVE END COMPRESSOR END FRAMES 2 AND 3 There is no Frame 1 marine waterbox NOZZLE ARRANGEMENT CODES COOLER WATERBOXES CONDENSER WATERBOXES PASS Arrangement Code 1 R 2 5 3 Fig 17 Piping Flow Data MWB Frames 2 and 3 22 MARINE WATERBOXES cont OO oL DRIVE END COMPRESSOR END FRAMES 4 5 AND 6 NOZZLE ARRANGEMENT CODES COOLER WATERBOXES CONDENSER WATERBOXES Arrangement Code
6. a 1 12 El Table 4 19XR Compressor Weights s CODE Ib kg eT 50 Ha BD 1703 3 805 3 805 1726 1726 BG 1792 BH 1792 2153 2165 GL 2167 cu 2209 CN 2215 2212 2212 6 112 6 158 2772 2793 DD 2840 288 DF 6 274 6 412 2846 2908 DH 3115 DJ 3155 5051 EJ 510 5118 EL 5187 5187 5278 5264 Compressor weight is comprised of compressor stator rotor end bell suction elbow and dis charge elbow NOTE For medium voltage motors over 600 v add 490 Ib 222 kg Table 5 19XR Component Weights FRAME 2 FRAME 3 FRAME 4 COMPRESSOR COMPRESSOR COMPRESSOR kg FRAME 5 COMPRESSOR Suction Elbow Discharge Elbow Control Cabinet Included total cooler weight TWeight of optional factory mounted starter is not included and must be added to the heat exchanger weight Table 6 19XR Heat Exchanger Data ENGLISH SI Dry gie Weight Machine Charge Dry Weight Machine Charge CORE Refrigerant Water Volume Refrigerant Water Cooler Condenser Cooler Condenser Weight gal Onl Onl Weight Volume 4 d d Condenser 10 2742 2 704 1244 1227 158 11 2 812 2 772 310 200 37 45 1276 1257 141 91 140 170 15 183 16 198 17 216 20 181 21 210 22 239 30 210 31 246 32 282 35 4 409 4 606 400 310 61 62 2000 2089 181 141 232 233 37 4835
7. 9 The motor starter has not been supplied by Carrier and it has been checked for proper operation COMMENTS CL 1 DATE TO BE TESTING YES NO COMPLETED 1 The cooling tower fan has been checked for blade pitch and proper operation 2 The chilled water and condenser water lines have been a Filled b Tested c Flushed d Vented e Strainers cleaned 3 The chilled water and condenser water pumps have been checked for proper rotation and flow 4 The following cooling load will be available for start up a 25 b 5096 c 75 d 10096 5 The refrigerant charge is at the machine 6 Services such as electrical power and control air will be avail able at start up 7 electrical and mechanical representatives will be available to assist in commissioning the machine 8 The customer s operators will be available to receive instruc tions for proper operation of the chiller after start up Concerns about the installation request for additional assistance I am aware that the start up time for a Carrier chiller can take between 2 and 6 days depending on the model of the machine and the options and accessories used with it Your contact at the jobsite will be Phone number Beeper number Fax number In accordance with our contract we hereby request the services of your technician to render start up services per contract terms for this job on Date I underst
8. Optional Pumpout Unit and Storage Tank 25 RATED DRY WEIGHT AND REFRIGERANT CAPACITY ENGLISH lb TANK SIZE DRY MAXIMUM REFRIGERANT CAPACITY Ib TANK OD WEIGHT Ib in Ib ANSI ASHRAE 15 UL 1963 24 00 2380 1860 27 25 3460 3563 SI kg TANK OD mo MN MAXIMUM REFRIGERANT CAPACITY kg mm ANSI ASHRAE 15 UL 1963 1080 1569 1616 LEGEND ASHRAE American Society of Heating Refrigeration and Air Conditioning Engineers OD Outside Diameter UL Underwriters Laboratories above dry weight includes the pumpout condensing unit weight of 210 16 95 kg Fig 19 Optional Pumpout Unit and Storage Tank cont 26 ERVICE ISOLATION HOT GAS C VALVE REFRIGERANT CONDENSER OPTIONAL COOLING VALVE VALVE VALVE 1 LINEAR OPTIONAL Gas CONDENSER ISOLATION A ait VALVE 7 SERVICE VALVE x STORAGE REFRIGERANT l ISOLATION TANK VALVE TEE FOR COMPRESSOR REFRIGERANT CHILLER CHARGING DISCHARGE 7 CHARGING CHARGER VALUE VALVE VALVE COMPRESSOR SEPARATOR SUCTION CONDENSER PUMPOUT WATER SUPPLY COMPRESSOR AND RETURN PUMPOUT SERVICE VALVEON 7 SERVICE VALVE CONDENSER PUMPOUT UNIT MACHINE C9 STORAGE TANK VENT AT LEAST 2 FT 610 mm CLEARANCE AROUND TORAGE
9. Fig 3 Machine Rigging Guide Cooler Size 10 Through 67 FRAME SIZE SIZE WEIGHT Ib LENGTH D E SS ue us pue SS 80 82 54 900 14 6 2 3 6 3 7 11 6 12 5 12 9 85 87 58 300 16 6 11 3 6 3 6 12 0 13 3 13 6 first digit of the 3 digit compressor code indicates the frame size of the compressor CHAIN F SEE NOTE 2 CHAIN D SEE NOTE 2 CHAIN E SEE NOTE 2 15 O MIN 21 0 MAX HEIGHT ABOVE FLOOR CG Center of Gravity MACHINE RIGGING GUIDE NOTES 1 Each chain must be capable of supporting the entire weight of the machine See chart for maximum weights 2 Chain lengths shown are typical for 15 lifting height Some minor adjustments may be required 3 Dimensions A and B define distance from machine center of gravity to tube sheet outermost surfaces Dimension C defines distance from machine center of gravity to floor Fig 4 Machine Rigging Guide Cooler Size 70 Through 87 TUBE REMOVAL SPACE FOR EITHER END 10 0 3048 mm SIZES 10 12 20 22 12 3 1 2 3747 mm SIZES 15 17 12 3 1 2 3747 mm SIZES 30 32 40 42 50 52 60 62 MOTOR SERVICE CLEARANCE 4 0 1219 mm SS 30 915 mm RECOMMENDED OVERHEAD SERVICE CLEARANCE 14 3 4343 mm SIZES 35 37 45 47 55 57 65 67 14 0 4267 mm 512 5 70 72 80 82 16 0 4877 SIZES 75 77 85 87
10. FIELD e FIELD SUPPLIED 1 e GE EE pr v c Bk ee 25 RED 4 REp 4 1 x 1 CHASSIS CHASSIS CHASSIS GROUND GROUND GROUND 2 lt REAR aj REAR 5 REAR UPPER UPPER F UPPER NETWORK NETWORK NETWORK E CONNECTION CONNECTION CONNECTION E COMM 1 COMM 1 COMM 1 PSIO 51 PSIO 51 i ADDRESS ADDRESS 2 SWITCHES SWITCHES SWITCHES t A 19XR CHILLERS LEGEND Factory Wiring Field supplied terminal strip must be located in control panel Field Wiring Fig 25 COMM1 CCN Communication Wiring For Multiple Chillers Typical 29 CONNECT CONTROL OUTPUTS Connect auxiliary equipment chilled and condenser water pumps and spare alarms as required and indicated on job wiring drawings CONNECT STARTER The 19XR is available with either a unit mounted factory installed starter or a free standing field installed starter Fig 28 and 29 Unit Mounted Factory Installed Starter Attach power leads by connecting them from inside the starter cabinet to the line side circuit breaker terminals See Fig 26 and 28 Machines with electro mechanical starters wye
11. Refrigerant Charging Valve 15 Guide Vane Actuator 16 Compressor Transmission 17 Oil Drain Charging Valve 18 Oil Pump 19 Auxillary Power Panel e 20 Oil Filter Isolation Valve e gt 21 Oil Filter 13 12 Gg 22 Motor BOTTOM REAR VIEW 27 23 Waterbox Vents 24 Oil Reclaim Filter 25 Float Chamber 26 Unit Mounted Starter 27 Refrigerant Filter Drier Isolation Valves 28 Sight Glass Moisture Indicator 29 Refrigerant Filter Drier 30 Cooler Liquid Line Isolation Valve 31 Hot Gas Bypass Valve Option 32 Hot Gas Bypass Isolation Valve Option 33 Oil Reclaim Filter Isolation Valve 34 Waterbox Vents Fig 2 Typical 19XR Installation FRAME SIZE SIZE WEIGHT Ib LENGTH c Dp me 2 24 m 35 37 22 500 14 7 4 14 2 13 4 13 4 40 42 29 700 12 5 9 12 8 12 8 13 4 m E The first digit of the 3 digit compressor code indicates the frame size of the compressor HAIN D CORE NOTE 42 CHAIN SEE NOTE 2 CHAIN SEE NOTE 2 OPTIONAL MOUNTED STARTER CHAIN MUST RUN OVER TO MOTOR SIDE OF BOLT HEIGHT ABOVE FLOOR MACHINE RIGGING GUIDE NOTES 1 Each cable must be capable of supporting the entire weight of the machine See chart for maximum weights 2 Chain lengths shown are typical for 15 lifting height Some minor adjustments may be required
12. f compressor oil sump pressure cable Fig 8 Item 3 g compressor oil discharge pressure cable Fig 8 Item 5 h guide vane actuator cable Fig 7 Item 1 i diffuser actuator cable Frame 5 compressor only not shown Disconnect the flared fitting for the oil reclaim line Fig 6 Item 3 vessels aput 6 Unbolt the compressor discharge elbow Fig 7 Item 3 To Separate the Compressor from the Cooler 7 Cover all openings 1 Unbolt the compressor suction elbow at the cooler flange Fig 6 Item 2 2 Cutthe refrigerant motor cooling line at the location shown Fig 6 Item 7 10 Disconnect motor power cables at the starter lugs Fig 6 Item 4 Unbolt the compressor mounting from the cooler Fig 6 Item 9 Rig the compressor COMPRESSOR 4 SEE FIG 8 a gi ETN 08 VSNT EN d KH CY Ay ot ee OX C 6 5 10 9 8 7 5 6 Tube Sheet Refrigerant Motor Cooling Line Cut Motor Drain Unbolt Compressor Mounting Unbolt Cooler Liquid Feed Line Unbolt Optional Hot Gas Bypass Cut Compressor Suction Elbow Unbolt Oil Reclaim Line Unbolt Starter Connector Unbolt Vessel Connectors Unbolt aawons LIII Owvo o Fig 6 Cooler Side View 14
13. 5069 550 2310 80 2193 29 29 301 314 40 5 898 6 054 560 20 89 96 2675 246 254 127 338 365 41 6 080 6 259 630 280 97 106 2757 2839 286 127 368 400 45 6 353 6617 640 50 98 106 2881 3001 290 150 372 403 46 442 47 481 50 483 51 518 52 7417 7 683 900 40 133 136 3364 3484 408 11 502 552 55 536 56 575 57 613 60 8 270 8 286 940 420 144 159 3751 3758 426 190 546 601 62 669 65 668 66 707 67 745 70 791 71 867 72 937 75 885 76 971 77 1052 50 1000 81 1075 82 1150 85 17 296 17 001 1690 860 313 295 7845 7712 767 390 1183 1118 86 17 723 17 492 1820 860 331 318 8039 7934 826 390 1254 1205 18469 17284 Lag 8241 E 1329 1291 Rigging weights are for standard tubes of standard wall thickness Turbo B3 and Spikefin 2 0 025 in 0 635 mm wall NOTES 1 Cooler includes the control panel LID suction elbow 1 2 the distribution piping weight 2 Condenser includes float valve and sump discharge elbow and the distribution piping weight 3 For special tubes refer to the 19XR Computer Selection Program 4 All weights for standard 2 pass NIH nozzle in head design 10 HEAT EXCHANGER FRAME PASS Table 7 19XR Additional Data for Marine Waterboxes Rigging etant Rigging Water Volume gal L FRAMEZ TANDPASS 9 gti FRAME 2 2 PASS E FRAME 3 1 AND 2 PASS 150 730 84 1034 3
14. 2 3 2 3 3 Required Control Wiring Options Wiring fan motors must be provided to assure machine protection If primary pump and tower fan motor are controlled by other means also provide a parallel means for control by Carrier Do not use starter control transformer as the power source for pilot relay loads Do not route control wiring carrying 30 v or less within a conduit which has wires carrying 50 v or higher or alongside wires carrying 50 v or higher Voltage selector switch in machine power panel is factory set for 115 v control power source When 230 v control power source is used set switch to 230 v position Control wiring cables between starter and power panel must be shielded with minimum rating of 600 v 80 C Ground shield at starter If optional oil pump circuit breaker is not supplied within the starter enclo sure as shown it must be located within sight of the machine with wiring routed to suit 3 4 3 5 3 6 3 7 POWER WIRING BETWEEN STARTER AND COMPRESSOR MOTOR 4 0 Low voltage 600 v or less compressor motors have 6 in terminal studs lead connectors not supplied by Carrier Either 3 or 6 leads must be run between compressor motor and starter depending on type of motor starter employed If only 3 leads are required jumper motor terminals as follows 1 to 6 2 to 4 3 to 5 Center to center distance between terminals is 21 inches Compressor motor starter must have nameplate stamped as conformi
15. 235 212 FRAME 6 FRAME4 maus WATERBOX 380 382 381 COOLER 265 CONDENSER 434 451 432 ss HEAT WATERBOX FRAME 7 COOLER FRAME 7 CONDENSER 1 Pass Cover 150 psig 631 666 547 582 580 581 COOLER 417 CONDENSER NIH 1 Pass Cover 300 psig 900 975 767 840 845 831 E HE WITEHEGE FRANE i COOLER Y 8 COOLER TAANE 0 CONDENSER EXCHANGER DESCRIPTION Flanged Flanged 1 Pass Cover 150 psig 831 866 763 798 791 3 Pass 1500 50 86 72 799 COOLER NIHIMWB End Cover 150 psig 6 671 57 557 CONDENSER NIH 1 Pass Cover 300 psig 1220 1295 1156 1147 802 LEGEND NIH Nozzle in Head MWB Marine Waterbox NOTE Weight for NIH 2 Pass Cover 150 psig is included in the heat exchanger weights shown in Table 6 NOTE If the cooler and condenser vessels must be sepa Remove all transducer and sensor wires at the sensor Clip rated the heat exchangers should be kept level by placing a all wire ties necessary to pull heat exchangers apart support plate under the tube sheets The support plate will also help to keep the vessels level and aligned when the ves To Separate Cooler and Condenser sels are bolted back together 1 Place a support plate under each tube sheet to keep each NOTE Wiring must also be disconnected Label each wire vessel level Fig 6 Item 6 before removal see Carrier Certified Prints In
16. 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 Lug adapters may be required if installation conditions dictate that con ductors be sized beyond the minimum ampacity required Contact starter supplier for lug information Compressor motor and controls must be grounded by using equip ment grounding lugs provided inside starter enclosure CONTROL WIRING 3 0 Field supplied control conductors to be at least 18 AWG or larger 3 1 Chilled water and condenser water flow switch contacts optional re mote start device contacts and optional spare safety device contacts must have 24 vdc rating Max current is 60 mA nominal current is 10 mA Switches with gold plated bifurcated contacts are recommended Remove jumper wire between 12A and 12B before connecting auxil iary safeties between these terminals Pilot relays can control cooler and condenser pump and tower fan mo tor contactor coil loads rated 10 amps at 115 vac up to 3 amps at 600 vac Control wiring required for Carrier to start pumps and tower fan motors must be provided to assure machine protection If primary pump and tower fan motor are controlled by other means also provide a parallel means for control by Carrier Do not use starter control trans former as the power source for pilot relay loads 2 1 2 2 3 2 3 3 L an Lee CONDE
17. TANK FOR SERVICE AND OPERATION WORK Fig 20 Optional Pumpout System Piping Schematic with Storage Tank REFRIGERANT CONDENSER OPTIONAL BEIGE COOLING ISOLATION GAS ANE VALVE VALVE VALVE TA dr LINEAR ba FLOAT OPTIONAL CONDENSER HOT GAS ISOLATION VALVE COOLER ee Compressor ISOLATION MACHINE DISCHARGE VALVE CHARGING VALVE _ SEPARATOR COMPRESSOR SUCTION VALVE ES Iess CONDENSER PUMPOUT 14 WATER SUPPLY COMPRESSOR AND RETURN PUMPOUT SERVICE VALVE ON _ SERVICE VALVE ON CONDENSER PUMPOUT UNIT MACHINE Fig 21 Optional Pumpout System Piping Schematic without Storage Tank 27 OIL DISCHARGE RETURN LINE CONNECTION VENT VALVE SUCTION SERVICE OIL SIGHT GLASS VALVE COMPRESSOR CONDENSER REFRIGERANT MOUNTING WATER CONNECTIONS INLET VALVE SPRINGS Fig 22 Pumpout Unit INSTALL VENT PIPING TO RELIEF VALVES The 19XR chiller is factory equipped with relief devices on the cooler and condenser shells Refer to Fig 23 and Table 10 for size and location of relief devices Vent relief devices to the outdoors in accordance with ANSI ASHRAE 15 latest edition Safety Code for Mechanical Refrigeration and all other applicable codes A DANGER Refrigerant discharged into confined spaces can dis place oxygen
18. delta will have a top hat shipped with the machine if the RLA rated load amps is greater than 935 amps If the machine is equipped with a solid state starter a top hat is provided if the RLA exceeds 740 amps The top hat is shipped in the knocked down po sition and must be assembled and installed on top of the starter cabinet over the line side circuit breaker During assembly remove the access plate and use it as the cover piece of the top hat The top hat provides additional wire bending space to attach line side power leads to the circuit breaker within the starter IMPORTANT Be sure to ground the power circuit in accordance with the National Electrical Code NEC applicable local codes and job wiring diagrams Also make sure correct phasing is observed for proper rotation MAIN COMPRESSOR MOTOR POWER TO CHILLED WATER PUMP TO CONDENSER WATER PUMP TO COOLING TOWER FAN Piping Control Wiring Power Wiring LEGEND Disconnect Unit Mounted Starter Control Cabinet Power Panel Vents Pressure Gages Chilled Water Pump Condenser Water Pump Chilled Water Pump Starter Condensing Water Pump Starter Cooling Tower Fan Starter C0ONOURWN sch IMPORTANT Wiring and piping shown for general point of connection only and are not intended to show details for a specific installation Certified field wiring and dimensional
19. order to dis 2 Cut the refrigerant motor cooling line at the location shown connect the starter from the machine remove wiring for the Fig 6 Item 7 oil pump oil heater control wiring at the power panel and the main motor leads at the starter lugs 13 8 Disconnect the compressor discharge elbow at the com pressor Fig 7 Item 3 Cut the hot gas bypass line at the location shown Fig 6 Item 1 Unbolt the cooler liquid feed line at the location shown Fig 6 Item 10 Cover all openings Disconnect all wires and cables that cross from the cooler side of the machine to the condenser side including a temperature sensor cable at the waterbox Fig 9 Item 1 b condenser transducer cable at the transducer Fig 7 Item 4 motor power wires at the starter Fig 6 Item 4 d wires and cable housings at the power panel that cross from the starter to the power panel Fig 7 Item 2 Disconnect the rabbet fit connectors on the tube sheets Fig 6 Item 5 e Disconnect the motor refrigerant return line Fig 6 Item 8 Disconnect the following a compressor oil sump temperature sensor cable Fig 8 Item 4 b bearing temperature sensor cable Fig 8 Item 2 motor temperature sensor cable Fig 8 Item 1 d wires and cable housings that cross from the power panel to the starter and control panel Fig 7 Item 2 e discharge temperature sensor cable Fig 8 Item 6
20. shut down WARNING Do not use aluminum conductors Installer is responsible for any damage caused by improper wiring be tween starter and machine POWER WIRING TO STARTER 2 0 Power conductor rating must meet minimum unit nameplate voltage and compressor motor RLA 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 Lug adapters may be required if installation conditions dictate that con ductors be sized beyond the minimum ampacity required Contact starter supplier for lug information Compressor motor and controls must be grounded by using equip ment grounding lugs provided inside starter enclosure CONTROL WIRING 3 0 Field supplied control conductors to be at least 18 AWG or larger 3 1 Chilled water and condenser water flow switch contacts optional re mote start device contacts and optional spare safety device contacts must have 24 vdc rating Max current is 60 mA nominal current is 10 mA Switches with gold plated bifurcated contacts are recommended Remove jumper wire between 12A and 12B before connecting auxil iary safeties between these terminals Pilot relays can control cooler and condenser pump and tower fan mo tor contactor coil loads rated 10 amps at 115 vac up to 3 amps at 600 vac Control wiring required for Carrier to start pumps and tower 1 2 1 3 1 4 1 5 1 6 2 1 2
21. 177 81 SEE NOTE 2 1 THK 25 5 ACCESSORY SOLEPLATE DETAIL TUBE SHEET JACKING SCREW SEE NOTE SUPPORT PLATE LEVEL BASE LINE SEE NOTE 4 FLOOR LINE ZEE LEVELING PAD 3 Jacking screws to be removed after grout has set 4 Thickness of grout will vary depending on the amount necessary to level chiller Use only pre mixed non shrinking grout Ceilcote 648CP 0 11 38 1 to 0 214 57 thick Fig 12 Accessory Isolation SUPPORT PLATE ATTACH SECURELY TO SOLEPLATE FOUNDATION ACCESSORY ACCESSORY RESILIENT SHEAR SPRING ATTACHES SECURELY FLEX PAD BONDED TO ISOLATOR TO ISOLATOR TOP AND BOTTOM OF SPRING MOUNT NOTE The accessory spring isolators are supplied by Carrier for installation in the field Fig 13 19XR Accessory Spring Isolation Shown with Accessory Soleplates 18 Connect Piping INSTALL WATER PIPING TO HEAT EXCHANGERS Install piping using job data piping drawings and proce dures outlined below A typical piping installation is shown in Fig 14 CAUTION Factory supplied insulation is not flammable but can be damaged by welding sparks and open flame Protect in sulation with a wet canvas cover CAUTION Remove chilled and condenser water sensors before welding connecting piping to water nozzles Refer to Fig 9 Replace sensors after welding is complete 1 Offset pipe flanges to permit removal
22. 19XR 50 60 Hz Hermetic Centrifugal Liquid Chillers with HFC 134a Installation 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 Be sure you understand and follow the procedures and safety precautions contained in the machine instruc tions as well as those listed in this guide DANGER DO NOT VENT refrigerant relief devices within a building Outlet from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ANSI ASHRAE 15 American National Standards Institute American Society of Heating Refrigeration and Air Conditioning Engineers Safety Code for Mechanical Refrigeration The accumu lation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation PROVIDE adequate ventilation in accordance with ANSI ASHRAE 15 especially for enclosed and low overhead spaces Inha lation of high concentrations of vapor is harmful and may cause heart irregularities unconsciousness or death Intentional misuse can be fa tal Vapor is heavier than air and reduces the amount of oxygen avail able for breathing Product causes eye and skin irritation Decompo sition products are hazardous DO NOT USE OXYGEN to purge lines or to p
23. 31 317 FRAME 4 1 AND 3 PASS 465 FRAME 4 2 PASS so 00 12 FRAME 5 LAND PASS 150 12 EE FRAME 5 2 PASS o 19 28 28 FRAMES LAND SPASS 19 1800 5 FRAME 6 2 PASS 15 758 8 1 i0 34 ae FRAMET iAND3PASS i50 a0 56 32 FRAME 7 2 PASS i5 74 15 m 87 FRAMES SPAS 150 1855 98 FRAME 8 2 PASS 150 1034 768 FRAME 2 2 PASS FRAMES SPASS ER 3 2 55 2068 185 159 FRAME 4 2 PASS gt FRAME 5 1 AND 5 300 139 19 266 66 5 FRAME 5 2 PASS 30 89 3 FRAMES PASS 300 168 16 26 8 52 FRAME 6 2 PASS Ca 8 34 06 FRAMET 1 AND SPASS 5100 6 eoe 1 12 FRAME 7 2 PASS 30 265 15 l 268 o FRAME 8 1 AND 3 PASS 1533 FRAME 8 2 PASS 768 Add to heat exchanger data for total weights or volumes NOTES 1 Weight adder shown is the same for cooler and condenser of equal frame size 2 For the total weight of a vessel with a marine waterbox add these values to the heat exchanger weights or volumes 11 Table 8A 19XR Waterbox Cover Weights ENGLISH Ib FRAME1 FRAME2 HEAT WATERBOX Standard Standard sm T 320 350 NIH 2 Pas
24. 5 4 35 37 5 4 40 42 6 0 45 57 14 7 6 0 50 52 12 10 6 55 57 6 5 60 62 6 9 65 67 6 9 70 72 710 75 77 710 80 82 8 9 85 87 8 9 Fig 10 19XR Machine Footprint 17 INSTALL SPRING ISOLATION Spring isolation may be purchased as an accessory from Carrier for field instal lation It may also be field supplied and installed Spring iso lators may be placed directly under machine support plates or located under machine soleplates See Fig 13 Consult job data for specific arrangement Low profile spring isola tion assemblies can be field supplied to keep the machine at a convenient working height SUPPORT PLATE EE e SE eg ENSE NOTES 1 Dimensions in are in millimeters 2 Isolation package includes 4 shear flex pads Obtain specific details on spring mounting and machine weight distribution from job data Also check job data for methods to support and isolate pipes that are attached to spring isolated machines TUBE SHEET 03 8 10 LEVEL BASE LINE SHEAR FLEX PAD 3 8 10 THK VIEW Y Y Fig 11 Standard Isolation 0 10 9 1 1 2 38 7 8 9UNC 4 HOLES FOR JACKING SCREWS 1 9 1 4 11 6 1 4 539 8 463 6 SOLEPLATE 0 1 1 2 38 LEGEND HRS Hot Rolled Steel NOTES 1 Dimensions in are in millimeters 2 Accessory Carrier supplied field installed soleplate package includes 4 soleplates 16 jacking screws and leveling pads 1
25. CK wire to the matching location on the terminal strip Install Field Insulation CAUTION Protect insulation from weld heat damage and weld splatter Cover with wet canvas cover during water piping installation When installing insulation at the jobsite insulate the fol lowing components compressor motor cooler shell WHEN DISCH ISOLATION VALVE IS USED ORIENTATE HANDLE AS SHOWN TOP VIEW DRIVE END FRONT VIEW COMPRESSOR END FACTORY INSTALLED FIELD SUPPLIED AND INSTALLED INSULATION INSULATION IF REQUIRED cooler tube sheets suction piping motor cooling drain oil reclaim piping oil cooler refrigerant side tubing refrigerant liquid line to cooler NOTE Insulation of the waterbox covers is applied only at the jobsite by the contractor When insulating the covers make sure there is access for removal of waterbox covers for ser vicing Fig 32 END VIEW Fig 32 19XR Insulation Area 35 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 531 940 Printed in U S A Form 19 251 Pg 38 10 97 Replaces 19XR 1SI Tab INSTALLATION START UP R
26. EQUEST CHECKLIST Machine Model Number 19XR Serial Number To Date Project Name Attn Carrier Job Number The following information provides the status of the chiller installation YES NO DATE TO BE N A COMPLETED 1 The machine is level 2 The machine components are installed and connected in accordance with the installation instructions 3 The isolation package and grouting if necessary are installed 4 The relief valves are piped to the atmosphere 5 All piping is installed and supported Direction of flow is indicated in accordance with the installation instructions and job prints Chilled water piping a b Condenser water piping c Waterbox drain piping d Pumpout unit condenser piping if installed e Other 6 Gages are installed as called for on the job prints required to establish design flow for the cooler and condenser a Water pressure gages IN and OUT b Water temperature gages IN and OUT 7 The machine s starter wiring is complete The wiring is installed per installation instructions and certified prints a Power wiring to compressor motor Motor leads will not be taped until the Carrier technician megger tests the motor b Oil pump wiring c Oil heater control wiring d Other 8 The motor starter has not been supplied by Carrier It has been installed according to the manufacturer s instructions
27. NS CARI F T d CUSTOMER SUPPLIED REMOTE I ANNUNCIATOR DEVICE pet OPTIONAL 1 NOTE 3 3 NOT BY CARRIER Jw eee e CUSTOMER SUPPLIED REMOTE ALARM OPTIONAL SEE NOTE 3 3 NOT BY CARRIER IMPORTANT Wiring shown is typical and not intended to show detail for a specific installation Refer to certified field wiring diagrams NOTES GENERAL 1 0 Starters shall be designed and manufactured in accordance with Carrier Engineering Requirement Z 375 1 1 All field supplied conductors devices field installation wiring and ter mination of conductors and devices must be in compliance with all ap plicable codes and job specifications The routing of field installed conduit and conductors and the location of field installed devices must not interfere with equipment access or the reading adjusting or servicing of any component Equipment installation and all starting and control devices must com ply with details in equipment submittal drawings and literature Contacts and switches are shown in the position they would assume with the circuit deenergized and the chiller shut down WARNING Do not use aluminum conductors Installer is responsible for any damage caused by improper wiring be tween starter and machine 1 2 13 14 1 5 1 6 POWER WIRING TO STARTER 2 0 Power conductor rating must meet minimum unit nameplate voltage and compressor motor RLA When
28. NSER WATER FLOW SWITCH INO CHILLEO WATER FLOW SWITCH INO SEE NOTE 3 1 BY CARRIER NOT BY CARRIER D MACHINE POWER PANEL 1 SUPPLIED BY CARRIER vi Ou MATER OIL PU CONTACTOR CONTACTOR dd SE T i qp m T Puce E s stem xs LEGEND AWG American Wire Gage SMM Starter Management Normally Closed Module Normally Open Terminal Block PR Pilot Relay emm Required Power Wiring RLA Rated Load Amps Required Control Wiring Options Wiring 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 carrying 50 v or higher 3 5 Voltage selector switch in machine power panel is factory set for 115 v control power source When 230 v control power source is used Set switch to 230 v position 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 3 7 If optional oil pump circuit breaker is not supplied within the starter en closure as shown it must be located within sight of the machine with wiring routed to suit 3 8 For 19XR chillers with free standing starts voltage to terminals LL1 and LL2 comes from a control transformer in a starter built to Carrier Specifications Do not connect an outside source of control power to the compressor motor s
29. T BY CARRIER wet Lage ee Pe elle e zm e e x Te e CONDENSER WATER FLOW SWITCH 01 CHILLED WATER FLOW SWITCH OI Io sas NOT EY CARRER NOT BY CARRIE IMPORTANT Wiring shown is typical and not intended to show detail for a specific installation Refer to certified field wiring 2 diagrams LEGEND AWG American Wire Gage N C Normally Closed Normally Open ru PR Pilot Relay RLA Rated Load Amps pr ST Z ShuntTrip TB Terminal Block i Required Power Wiring a a spe tw i CUSTOMER SUPPLIED REMOTE ALARM OPTIONAL SEE NOTE 3 3 NOT BY CARRIER NOTES GENERAL 1 0 Starters shall be designed and manufactured in accordance with Carrier Engineering Requirement Z 375 1 1 All field supplied conductors devices field installation wiring and ter mination of conductors and devices must be in compliance with all ap plicable codes and job specifications The routing of field installed conduit and conductors and the location of field installed devices must not interfere with equipment access or the reading adjusting or servicing of any component Equipment installation and all starting and control devices must com ply with details in equipment submittal drawings and literature Contacts and switches are shown in the position they would assume with the circuit deenergized and the chiller
30. Water Pump Condenser Water Pump Chilled Water Pump Starter Condensing Water Pump Starter Cooling Tower Fan Starter Disconnect Oil Pump Disconnect see Note 4 A amp ON O OQO0 Ioo0 RON DRAIN IMPORTANT Wiring and piping shown are for general point of connection only and are not intended to show details for a specific installation Certified field wiring and dimensional dia grams are available on request NOTES 1 All wiring must comply with applicable codes 2 Refer to Carrier System Design Manual for details regarding pip ing techniques 3 Wiring not shown for optional devices such as remote start stop remote alarm optional safety device 4to 20 mA resets optional remote sensors 4 Oil pump disconnect may be located within the enclosure of Item 2 Free Standing Compressor Motor Starter Fig 27 19XR with Free Standing Starter 31 COMPRESSOR MOTOR STARTER BRANCH DISCONNECT NOT BY CARRIER LUG ADAPTERS NOTE 21 BY CARRIER MAIN DISCONNECT COMPRESSOR MOTOR STARTER OPTIONAL WO OFF AUTO SW SEE NOIE 3 3 HAND OF SEE CHILLED WATER CONDENSER WATER PUMP MOTOR PUMP HOTOR NOT BY CARRIER COOLING TOWER FAN MOTOR BY CARRIER NOT BY CARRIERY OPTIONAL REMOTE START DEVICE 0 SEE NOTE 31 NOT BY CARRIER OPTIONAL SPARE SAFETY DEVICE SEE NOTE 31 NO
31. ables 1 8B Lift machine only from the points indicated in rigging guide Each lifting cable or chain must be capable of supporting the en tire weight of the machine WARNING Lifting machine from points other than those specified may result in serious damage to the unit and personal injury Rigging equipment and procedures must be ad equate for machine weight See Fig 3 and 4 for ma chine weights NOTE These weights are broken down into compo nent sections for use when installing the unit in sections For the complete machine weight add all com ponent sections and refrigerant charge together See Tables 4 8B for machine component weights IMPORTANT Ensure that rigging cable is over the guide bolt or cable hook on the motor end cover be fore lifting if cooler size is 10 through 67 19XR 52 51 4 3 DG H 62 Description 19XR High Efficiency Hermetic Centrifugal Liquid Chiller Special Order Indicator Cooler Size Standard 10 12 Frame 1 Length 10 ft S Special Order 15 17 Frame 1 Length 12 ft 20 22 Frame 2 Lenght 10 ft Motor Voltage Code 30 32 Frame 3 Length 12 ft Code Volts Phase Hertz 35 37 Frame 3 Length 14 ft 60 200 3 60 40 42 Frame 4 Length 12 ft 61 230 3 60 45 47 Frame 4 Length 14 ft 62 380 3 60 50 52 Frame 5 Length 12 ft 63 416 3 60 55 57 Frame 5 Length 14 ft 64 460 3 60 60 62 Frame 6 Length 12 ft 65 575 3 60 65 67 Fra
32. and cause asphyxiation 1 If relief devices are manifolded the cross sectional area of the relief pipe must at least equal the sum of the areas required for individual relief pipes 2 Provide a pipe plug near outlet side of each relief device for leak testing Provide pipe fittings that allow vent pip ing to be disconnected periodically for inspection of valve mechanism 3 Piping to relief devices must not apply stress to the device Adequately support piping A length of flexible tubing or piping near the device is essential on spring isolated machines Cover the outdoor vent with a rain cap and place a con densation drain at the low point in the vent piping to pre vent water build up on the atmospheric side of the relief device Table 10 Relief Device Locations QUANTITY RELIEF VALVE Frame 5 OUTLET SIZE LOCATION Compressor With Frame 7 or 8 Others Heat Exchanger 1 in NPT FEMALE 1 in NPT FEMALE 1 in NPT FEMALE Optional 2 2 CONNECTOR Storage Tank NOTE All valves relieve at 185 psi 1275 kPa Make Electrical Connections Field wiring must be installed in accordance with job wiring diagrams and all applicable electrical codes CAUTION Do not run 120 v wiring into the control cabinet The control cabinet should only be used for additional extra low voltage wiring 50 v maximum Wiring diagrams in this publication Fig 24 31 are for reference only and are not intended for u
33. and that the technician s time will be charged as extra services due to correcting items in this checklist that are incomplete Signature of Purchaser Signature of Jobsite Supervisor 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 531 940 Printed in U S A Form 19 2 1 Pg CL 2 10 97 Replaces 19XR 1SI Tab CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE
34. been completely drained DOUBLE CHECK that coupling nut wrenches dial indicators or other items have been removed before rotating any shafts 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 corro sion rust leaks or damage PROVIDE A DRAIN connection in the vent line near each pressure 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 Catalog No 531 940 Book 2 PC 211 Tab 5a Printed in U S A Form 19 2 1 Pg 1 10 97 Replaces 19 1 1 CONTENTS Page SAFETY CONSIDERATIONS 1 INTRODUCTION 2 General sor ob eee ned Bees 2 Job Data 2 INSTALLATION 2 35 Receiving the Machine 2 INSPECT SHIPMENT IDENTIFY MACHINE PROVIDE MACHINE PROTECTION Rigging the Machine 2 RIG MACHINE ASSEMBLY RIG MACHINE COMPONENTS Install Machine 17 INSTALL STANDARD ISOLATION INSTALL ACCESSORY ISOLATION INSTALL SPRING ISOLATION Connect bing 19 INSTALL WATER PIPING TO HEAT EXCHANGERS INSTALL VENT PIPING TO RELIEF VALVES Make Electrical Connecti
35. ces in put level voltage at the transformer primary terminals Connect Wiring from Starter to Power Panel Connect con trol wiring from main motor starter to the machine power panel control wiring must use shielded cable Also con nect the communications cable Refer to the job wiring dia grams for cable type and cable number Make sure the con trol circuit is grounded in accordance with applicable electrical codes and instructions on machine control wiring label u D s 0 4 YEL VOLTAGE 2 22 2 O 4 DRAWINGS 23 2 43 PED RED RED LEGEND Factory Wiring Field Wiring A Oil Pump Terminal Power Panel Component Terminal Fig 30 Oil Pump Wiring 11 E SV EET 1 WO It i 15 o 16 250 WIRING 21 It NEE Eh 230V 2 40 SEE WRING MODIFICATIONS 22 1C 12 BLK BLK 9 8LK 115V 23 ic 15 E OIL HEATER COM o wn WHT 1 115V WIRING LEGEND Field Wiring Power Panel Terminal NOTE voltage selector switch the machine power panel is factory set for 115 v control power source When a 230 v control power Source is used set the voltage selector switch at 230 v Fig 31 Oil Heater and Control Power Wiring CARRIER COMFORT NETWORK INTERFACE The Carrier Comfort Network CCN communication bus wiring i
36. cheme is selected a simi lar color code should be adopted for the entire network At each system element the shields of its communication bus cables must be tied together If the communication bus is entirely within one building the resulting continuous shield must be connected to ground at only one single point See Fig 25 If the communication bus cable exits from one build ing and enters another the shields must be connected to ground at the lightening suppressor in each building where the cable enters or exits the building one point only To connect the 19XR chiller to the network proceed as follows Fig 24 and 25 1 Cut power to the PIC control panel 2 Remove the COMMI plug from the processor module 3 Cuta CCN wire and strip the ends of the RED WHITE and BLACK conductors 4 Using a wirenut connect the drain wires together 5 Insert and secure the RED wire to Terminal 1 of the COMMI plug 6 Insert and secure the WHITE wire to Terminal 2 of the COMMI plug 7 Insert and secure the BLACK wire to Terminal 3 of the COMMI plug 8 Mount a terminal strip in a convenient location 9 Connect the opposite ends of each conductor to separate terminals on the terminal strip 10 Cut another CCN wire and strip the ends of the conductors 11 Connect the RED wire to the matching location on the terminal strip 12 Connect the WHITE wire to the matching location on the terminal strip 13 Connect the BLA
37. dia grams are available on request NOTES 1 All wiring must comply with applicable codes 2 Refer to Carrier System Design Manual for details regarding pip ing techniques 3 Wiring not shown for optional devices such as remote start stop remote alarm optional safety device 4to 20 mA resets optional remote sensors Fig 26 19XR with Optional Unit Mounted Starter 30 Free Standing Field Installed Starter Assemble and in stall compressor terminal box in desired orientation and cut necessary conduit openings in conduit support plates See Fig 27 and 29 Attach power leads to compressor terminals in accordance with job wiring drawings observing caution label in terminal box Use only copper conductors The mo tor must be grounded in accordance with NEC National Elec trical Code applicable local codes and job wiring diagrams Installer is responsible for any damage caused by improper wiring between starter and compressor motor IMPORTANT Do not insulate terminals until wiring arrangement has been checked and approved by Carrier start up personnel Also make sure correct phas ing is followed for proper motor rotation Insulate Motor Terminals and Lead Wire Ends Insulate compressor motor terminals lead wire ends and electrical wires to prevent moisture condensation and electrical arc ing For low voltage units up to 600 v obtain insulation material from machine shipping package consi
38. ectrical circuits during servicing IF WORK IS INTERRUPTED confirm that all circuits are deenergized before 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 liquid refrigerant enters the eyes IMMEDIATELY FLUSH EYES with water and consult a physician NEVER APPLY an open flame or live steam to a refrigerant cylinder Dangerous over pressure can result When it is necessary to heat re frigerant use only warm 110 F 43 C water DO NOT REUSE disposable nonreturnable cylinders or attempt to refill them Itis DANGEROUS AND ILLEGAL When cylinder is emp tied evacuate remaining gas pressure loosen the collar and unscrew and discard the valve stem DO NOT INCINERATE CHECK THE REFRIGERANT TYPE before adding refrigerant to the machine The introduction of the wrong refrigerant can cause machine damage or malfunction Operation of this equipment with refrigerants other than those cited herein should comply with ANSI ASHRAEIS latest edition Contact Carrier for further information on use of this machine with other refrigerants DO NOT ATTEMPT TO REMOVE fittings covers etc while machine is under pressure or while machine is running Be sure pres sure is at 0 psig 0 kPa before breaking any refrigerant connection CAREFULLY INSPECT all relief valves rupture discs and other relief devices AT LEAST ONCE A YEAR If machine operat
39. es in a corrosive atmosphere inspect the devices at more frequent intervals DO NOT ATTEMPT TO REPAIR OR RECONDITION relief valve when corrosion or build up of foreign material rust dirt scale etc is found within the valve body or mechanism Replace the valve DO NOT install relief devices in series or backwards 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 A CAUTION DO NOT STEP on refrigerant lines Broken lines can whip about and release refrigerant causing personal injury DO NOT climb over a machine Use platform catwalk or staging Fol low safe practices when using ladders USE MECHANICAL EQUIPMENT crane hoist etc to lift or move inspection covers or other heavy components Even if components are light use mechanical equipment when there is a risk of slipping or losing your balance BE AWARE that certain automatic start arrangements CAN ENGAGE THE STARTER TOWER FAN OR PUMPS Open the disconnect ahead of the starter tower fan and pumps Shut off the machine or pump before servicing equipment USE only repaired 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 the permission of your process con trol group DO NOT LOOSEN waterbox cover bolts until the waterbox has
40. ied by Carrier Lead connections between 3 phase motors and their starters must not be insulated until Carrier personnel have checked compressor and oil pump rotations Compressor motor frame to be grounded in accordance with the Na tional Electrical Code NFPA 70 and applicable codes Means for ground ing compressor motor is a pressure connector for No 4 to 500 MCM wire supplied and located in the back lower left side corner of the com pressor motor terminal box Do not allow motor terminals to support weight of wire cables Use cable supports and strain reliefs as required Use backup wrench when tightening lead connectors to motor terminal studs Torque to 45 lb ft max 4 4 2 4 3 4 4 4 5 Fig 29 19XR Typical Field Wiring with Free Standing Starter 33 Connect Power Wires to Heater Contactor Connect control power wiring between the oil heater contactor ter minals and terminals LL1 and LL2 on the field wiring strip in the compressor motor starter Refer to Fig 31 and wiring label on the machine power panel WARNING Voltage to terminals LL1 and LL2 comes from 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 transfomer secondary terminals produ
41. ith Optional Unit Mounted Starter 32 COMPRESSOR MOTOR STARTER BRANCH DISCONNECT NOT BY CARRIER 00 75 COMPRESSOR MOTOR TERMINAL BOX 19 9 16 SQ X 12 7716 DEEP APPROX INSIDE DIMENSIONS 2 GROUNDING LUGS PROVIDED LUG ADAPTERS WIRE RANGE 350 BOO NOTE 21 NOT BY CARRIER CIRCUIT BREAKER OR DISCONNECT OPTIONAL OPTIONAL HAND CFF AUTO SM SEE NOTE 3 3 CHILLED WATER CONDENSER WATER COOLING TOWER PUMP MOTOR PUMP MOTOR FAN MOTOR NOT BY CARRIER INOT BY CARRIER NOT BY CARRIER SEE NOTE 3 5 m Rus Y COMPRESSOR MOTOR TERMINAL DETAILS D LERN SEE NOTE iv MEM ILL EC K OR 50 2 Ie 230v HD 4 TB E SEE et ere NOTE Tipe oe Tap Y sen so tonz el ar ESI ed RED Uu OIL PUMP CIRCUIT BREAKER COPTIONAL LS gt 2 OPTIONAL REMOTE START DEVICE NO S Lal SEE NOTE 3 al en BY CARRIER 38 id bag dog gt gt tole 78 BREAKER am omm Mi x aes ae PRA SHUNT TRIP e Cf m 2 ke Sens ES mm OPTIONAL SPARE SAFETY DEVICES T e p eoo SEE NOTE 3 1 gt BY CARRIER E RW X SMM COMMUNICATIO
42. me 6 Length 14 ft 66 2400 3 60 70 72 Frame 7 Length 14 ft 67 3300 3 60 75 77 Frame 7 Length 16 ft 68 4160 3 60 80 82 Frame 8 Length 14 ft 69 6900 3 60 85 87 Frame 8 Length 16 ft 50 230 3 50 51 346 3 50 Condenser Size 52 400 3 50 10 12 Frame 1 Length 10 ft 53 3000 3 50 15 17 Frame 1 Length 12 ft 54 3300 3 50 20 22 Frame 2 Lenght 10 ft 55 6300 3 50 30 32 Frame 3 Length 12 ft 35 37 Frame 3 Length 14 ft Motor Efficiency Code 40 42 Frame 4 Length 12 ft H High Efficiency 45 47 Frame 4 Length 14 ft S Standard Efficiency 50 52 Frame 5 Length 12 ft 55 57 Frame 5 Length 14 ft 60 62 Frame 6 Length 12 ft Motor Code 65 67 Frame 6 Length 14 ft BD CD DB EH 70 72 Frame 7 Length 14 ft BE CE DC EJ 75 77 Frame 7 Length 16 ft BF CL DD EK 80 82 Frame 8 Length 14 ft BG CM DE EL 85 87 Frame 8 Length 16 ft BH DF Compressor Code DJ Fig 1 Model Number Identification FRONT VIEW 1 Oil Level Sight Glass 2 Diffuser Actuator Hidden 19XR5 Only 3 Discharge Isolation Valve 4 Condenser Pumpout Connection 5 Condenser Safety Relief Valves 6 Three Way Condenser Relief Valve 7 Hot Gas Bypass Line 8 Condenser Waterbox Nozzles 9 Cooler Waterbox Nozzles 10 Cooler Safety Relief Valves 11 Cooler Pumpout Connection 12 Machine Identification Nameplate 13 Control Panel 14
43. ng with Carrier requirement Z 375 When more than one conduit is used to run conductors from starter to compressor motor terminal box one conductor from each phase must be in each conduit to prevent excessive heating e g conductors to motor terminals 1 2 amp 3 in one conduit and those to 4 5 amp 6 in another Compressor motor power connections can be made through top top rear or sides of compressor motor terminal box using holes cut by con tractor 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 or 12 conductors larger than 500 MCM may require an oversize spe cial motor terminal box not supplied by Carrier Lead connections between 3 phase motors and their starters must not be insulated until Carrier personnel have checked compressor and oil pump rotations Compressor motor frame to be grounded in accordance with the Na tional Electrical Code NFPA 70 and applicable codes Means for ground ing compressor motor is a pressure connector for No 4 to 500 MCM wire supplied and located in the back lower left side corner of the com pressor motor terminal box Do not allow motor terminals to support weight of wire cables Use cable supports and strain reliefs as required Use backup wrench when tightening lead connectors to motor terminal studs Torque to 45 Ib ft max 4 1 4 2 4 3 4 4 4 5 Fig 28 19XR Typical Field Wiring w
44. ny bend 7 Install waterbox vent and drain piping in accordance with individual job data All connections are 8 Install waterbox drain plugs in the unused waterbox drains and vent openings 9 Install optional pumpout system or pumpout system and storage tank as shown in Fig 19 22 WIRE BACK TO STARTER PRESSURE DIFFERENTIAL SWITCH BOX MOUNTED TO WALL MACHINE OR COLUMN COM NO PRESSURE CONNECTION LOW HIGH 3 8 IN COPPER OR SUITABLE LINE MACHINE WATERBOX NOZZLES FLARED FITTING FOR EASY DISCONNECT TO FLUSH BLEED AND SERVICE COPPER LINES LOW PRESSURE NEEDLE TYPE VALVE FOR SWITCH MAINTENANCE o PRESSURE we m INLET VIEW ISOLATION VALVES Fig 14 Typical Nozzle Piping 19 NOZZLE IN HEAD WATERBOXES DRIVE END COMPRESSOR END FRAMES 1 2 AND 3 DRIVE END COMPRESSOR END FRAMES 4 5 AND 6 NOZZLE ARRANGEMENT CODES FOR ALL 19XR NOZZLE IN HEAD WATERBOXES COOLER WATERBOXES CONDENSER WATERBOXES PASS Arrangement PASS Arrangement Code 1 C 5 3 T E U 3 F Refer to certified drawings Fig 15 Piping Flow Data NIH Frames 1 Through 6 20 NOZZLE IN HEAD WATERBOXES
45. of waterbox cover for maintenance and to provide clearance for pipe clean ing No flanges are necessary with marine waterbox option however water piping should not cross in front of the waterbox or access will be blocked LEAVING CONDENSER WATER ENTERING DIFFERENTIAL PRESSURE dM CONDENSER SWITCH OR USE 2 VAPOR TIGHT PIPE FLANGES FLOW SWITCH VAPOR TIGHT FLOW SWITCH LOCATED A MINIMUM OF 5 PIPE DIAMETERS FROM ANY BEND OR USE DIFFERENTIAL PRESSURE SWITCH AIR VENT THERMOMETER OPENINGS OPTIONAL PIPE HANGERS ENTERING CHILLED WATER LEAVING CHILLED WATER LEGEND COM Common N O Normally Open Do not tap connections after shutoff valve 2 Provide openings in water piping for required pressure gages and thermometers For thorough mixing and tem perature stabilization wells in the leaving water pipe should extend inside pipe at least 2 in 50 mm 3 Install air vents at all high points in piping to remove air and prevent water hammer 4 Install pipe hangers where needed Make sure no weight or stress is placed on waterbox nozzles or flanges 5 Water flow direction must be as specified in Fig 15 18 NOTE Entering water is always the lower of the 2 nozzles Leaving water is always the upper nozzle for cooler or condenser 6 Water flow switches must be of vapor tight construction and must be installed on top of pipe in a horizontal run and at least 5 pipe diameters from a
46. ons 28 CONNECT CONTROL INPUTS CONNECT CONTROL OUTPUTS CONNECT STARTER CARRIER COMFORT NETWORK INTERFACE Install Field Insulation 35 INSTALLATION START UP REQUEST CHECKLIST CL 1 CL 2 INTRODUCTION General The 19XR machine is factory assembled wired and leak tested Installation not by Carrier consists primarily of establishing water and electrical services to the machine The rigging installation field wiring field pip ing and insulation of waterbox covers are the responsibility of the contractor and or customer Carrier has no installation responsibilities for the equipment Job Data Necessary information consists of job contract or specifications machine location prints rigging information piping prints and details field wiring drawings starter manufacturer s installation details Carrier certified print INSTALLATION Receiving the Machine INSPECT SHIPMENT CAUTION Do not open any valves or loosen any connections The standard 19XR machine is shipped with a full refrig erant charge Some machines may be shipped with a ni trogen holding charge as an option 1 Inspect for shipping damage while machine is still on ship ping conveyance If machine appears to be damaged or has been torn loose from its anchorage have it examined by transportation inspectors before removal Forward claim papers directly to transpo
47. ressurize a machine for any purpose Oxygen gas reacts violently with oil grease and other common substances DO NOT USE air to leak test Use only refrigerant or dry nitrogen NEVER EXCEED specified test pressures VERIFY the allowable test pressure by checking the instruction literature and the design pressures on the equipment nameplate DO NOT VALVE OFF any safety device BE SURE that all pressure relief devices are properly installed and func tioning before operating any machine RISK OF INJURY OR DEATH by electrocution High voltage is present on motor leads even though the motor is not running when a solid state or inside delta mechanical starter is used Open the power supply dis connect before touching motor leads or terminals A WARNING DO NOT WELD OR FLAMECUT 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 machine sections or the entire assembly DO NOT work on high voltage equipment unless you are a qualified electrician DO NOT WORK ON electrical components including control panels 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 LOCK OPEN AND TAG el
48. rtation company Manufacturer is not responsible for any damage incurred in transit 2 Check all items against shipping list Immediately notify the nearest Carrier representative if any item is missing 3 To prevent loss or damage leave all parts in original pack ages until beginning installation All openings are closed with covers or plugs to prevent dirt and debris from en tering machine components during shipping A full op erating oil charge is placed in the oil sump before shipment IDENTIFY MACHINE The machine model number serial number and heat exchanger sizes are stamped on machine identification nameplate Fig 1 and 2 Check this information against shipping papers and job data PROVIDE MACHINE PROTECTION Protect machine and starter from construction dirt and moisture Keep pro tective shipping covers in place until machine is ready for installation If machine is exposed to freezing temperatures after water circuits have been installed open waterbox drains and re move all water from cooler and condenser Leave drains open until system is filled Rigging the Machine The 19XR machine can be rigged as an entire assembly It also has flanged connections that allow the compressor cooler and condenser sections to be separated and rigged individually RIG MACHINE ASSEMBLY See rigging instructions on label attached to machine Also refer to rigging guide Fig 3 and 4 physical data in Fig 5 and T
49. s Cover 150 psig 185 218 320 350 320 350 COOLER 300 300 CONDENSEH 411 486 411 518 433 468 400 400 FRAME 6 FRAME4 5 HEAT WATERBOX 802 838 770 843 817 843 COOLER 563 583 CONDENSER 880 956 844 995 901 952 ee 20 WATERBOX FRAME 7 COOLER FRAME 7 CONDENSER 1282 1279 1280 920 CONDENSER 1851 1862 1831 1925 Mens Ee ER 8 COOLER FRAME E CONDENSER EXCHANGER DESCRIPTION Flanged Flanged 1760 1744 1761 COOLER 1228 CONDENSER NIH 1 Pass Cover 300 psig 2690 2854 2394 2549 2529 1767 LEGEND Nozzle in Head MWB Marine Waterbox NOTE Weight for NIH 2 Pass Cover 150 psig is included in the heat exchanger weights shown in Table 6 RIG MACHINE COMPONENTS Refer to instructions below Fig 6 9 and Carrier Certified Prints for machine com WARNING ponent disassembly Do not attempt to disconnect flanges while the machine is under pressure Failure to relieve pressure can result IMPORTANT Only a qualified service technician should in personal injury or damage to the unit perform this operation CAUTION Before rigging the compressor disconnect all wires en tering the power panel 12 Table 8B 19 Waterbox Cover Weights SI kg FRAME 3 FRAME1 FRAME2 HEAT WATERBOX 1 Pass Cover 150 psig 80 9 145 159 1 159 2 Pass Cover 150 psig 84 99 145 159 145 159 COOLER 136 CONDENSER 220
50. s supplied and installed by the electrical contractor It con sists 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 34 The negative pins must be wired to the negative pins The signal ground pins must be wired to the signal ground pins See Fig 24 for location of the CCN network connector on the processor module NOTE Conductors and drain wire must be 20 AWG American Wire Gage minimum stranded tinned copper In dividual conductors must be insulated with PVC PVC nylon vinyl Teflon or polyethylene An aluminum polyester 10096 foil shield and an outer jacket of PVC PVC nylon chrome vinyl or Teflon with a minimum operating tempera ture range of 4 to 140 F 20 C to 60 C is required See table below for cables that meet the requirements MANUFACTURER CABLE NO Alpha 2413 or 5463 American A22503 Belden 8772 Columbia 02525 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 CCN BUS CONDUCTOR COMMI PLUG SIGNAL TYPE INSULATION COLOR PIN NO Red 1 Ground White 2 Black 3 If a cable with a different color s
51. se during actual in stallation follow job specific wiring diagrams WARNING Do not attempt to start compressor or oil pump even for a rotation check or apply test voltage of any kind while machine is under dehydration vacuum Motor in sulation breakdown and serious damage may result CONNECT CONTROL INPUTS Connect the control in put wiring from the chilled and condenser water flow switches to the starter terminal strip Wiring may also be specified for a spare safety switch and a remote start stop contact can be wired to the starter terminal strip Additional spare sensors and Carrier Comfort Network modules may be specified as well These are wired to the machine control panel as indi cated in Fig 24 and 25 RELIEF VALVES CONDENSER BE AN COOLER 4 RELIEF VALVES Fig 23 Relief Valve Locations 28 NETWORK SENSOR BUS CONNECTOR CONNECTOR COMM 1 COMM 3 PROCESSOR MODULE Fig 24 Carrier Comfort Network Communication Bus Wiring GROUND DRAIN WIRE DRAIN WIRE DRAIN WIRE DRAIN WIRE BLACK A prts BLACK mid BLACK WHITE PX WHITE rx uoce RED A PX pep EC RED E oo 5 TERMINAL sw 9 95422
52. sting of 3 rolls of insulation putty and one roll of vinyl tape 1 Insulate each terminal by wrapping with one layer of in sulation putty 2 Overwrap putty with 4 layers of vinyl tape High Voltage Units High voltage units require special ter minal preparation Follow local electrical codes for high voltage installation Vinyl tape is not acceptable a high voltage terminal method must be used Connect Power Wires to Oil Pump Starter See Fig 30 Connect power wires to oil pump starter mounted in ma chine power panel Use separate fused disconnect or circuit breaker as shown on job wiring diagrams and Fig 30 Check that power supply voltage agrees with oil pump voltage Fol low correct phasing for proper motor rotation CAUTION Do not punch holes or drill into the top surface of the power panel Knockouts are provided in the bottom of the power panel for wiring connections MAIN POWER 1 13 13 13 a 10 41 12 4 TO CHILLED WATER PUMP lt 5 TO CONDENSER WATER PUMP a 9 TO COOLING TOWER 9 LJ 0 D TO p COOLING TOWER FROM 4 e a TOWER p FROM LOAD 7 9 o 9 LOAD 6 8 7 Piping Control Wiring Power Wiring LEGEND Disconnect Free Standing Compressor Motor Starter Compressor Motor Terminal Box Chiller Power Panel Control Cabinet Vents Pressure Gages Chilled
53. tarter terminals LL1 and LL2 An outside power Source will produce dangerous voltage at the line side of the starter because supplying voltage at the transformer secondary terminals pro duces input level voltage at the transformer primary terminals IV POWER WIRING BETWEEN STARTER AND COMPRESSOR MOTOR 4 0 Low voltage 600 v or less compressor motors have 6 34 in terminal studs lead connectors not supplied by Carrier Either 3 or 6 leads must be run between compressor motor and starter depending on type of motor starter employed If only 3 leads are required jumper motor terminals as follows 1 to 6 2 to 4 3 to 5 Center to center distance between terminals is 21 inches Compressor motor starter must have nameplate stamped as conforming with Carrier requirement Z 375 When more than one conduit is used to run conductors from starter to compressor motor terminal box one conductor from each phase must be in each conduit to prevent excessive heating e g conductors to motor terminals 1 2 amp in one conduit and those to 4 5 amp another Compressor motor power connections can be made through top top rear or sides of compressor motor terminal box using holes cut by con tractor 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 or 12 conductors larger than 500 MCM may require an oversize spe cial motor terminal box not suppl
54. ting Refrigeration and Air Conditioning Engineers ASHRAE 15 latest edition National Fire Protection Association NFPA 70 and local safety code 2 Allow at least 3 ft 915 mm overhead clearance for service rigging 3 Certified drawings available upon request Table 2 19XR Dimensions Marine Waterbox A Length Marine Waterbox HEAT EXCHANGER not shown SIZE 1 or 3 Passt Rim mm i mm 101012 NA 151017 NA 20 to 22 12 6 3826 14 3 4343 35 to 37 5518 40 to 42 5099 45 to 47 16 8 5099 18 5 5620 50 to 52 15 0 16 8 5099 55 to 57 5620 60 to 62 5111 65 to 67 5632 70 to 72 6058 75 to 77 6668 80 to 82 6121 85 to 87 es Assumes both cooler and condenser nozzles on same end of chiller T1 or 3 pass length applies if cooler is a 1 or 3 pass design NOTES 1 Service access should be provided per American Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE 15 latest edition National Fire Protection Association NFPA 70 and local safety code 2 Allow at least 3 ft 915 mm overhead clearance for service rigging 3 Certified drawings available upon request Table 3 19XR Nozzle Size NOZZLE SIZE in FRAME Nominal Pipe Size SIZE Condenser Pass Pass SPass 2Pass 3Pass es 2 8 e 6 e l 6 6 s s
55. to all 4 corners of the tube sheet Install Machine Supports INSTALL STANDARD ISOLATION Figures 10 and 11 show the position of support plates and shear flex pads which together form the standard machine support system 0 3 1 2 88 9 ACCESSORY SOLEPLATE 0 0 1 2 12 7 HEAT EXCHANGER SIZE INSTALL ACCESSORY ISOLATION if required Un even floors or other considerations may dictate the use of accessory soleplates supplied by Carrier for field installa tion and leveling pads Refer to Fig 10 and 12 Level machine by using jacking screws in isolation sole plates Use a level at least 24 in 600 mm long For adequate and long lasting machine support proper grout selection and placement is essential Carrier recommends that only pre mixed epoxy type non shrinking grout be used for machine installation Follow manufacturer s instructions in applying grout 1 Check machine location prints for required grout thickness 2 Carefully wax jacking screws for easy removal from grout 3 Grout must extend above the base of the soleplate and there must be no voids in grout beneath the plates 4 Allow grout to set and harden per manufacturer s in structions before starting machine 5 Remove jacking screws from leveling pads after grout has hardened 17 3 1 4 387 4 TYP 0 0 1 2 12 7 DIMENSIONS ft in EIS CREE B 10 12 1177 15 17 TET 20 22 5 5 30 32
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