Carrier 17 Refrigerator User Manual
Contents
1. D S E 310N 336 I CWNOT1d0 391A30 MOLY LONANNY ALOWSY Q3l ddns 3401502 WWS OJ SHIM 1 3 NOILYOINNWWOO T SC T Sede ong NYO one Y EI o o aay CDA HN HOLIAS oh t re OLIP ez zz jiz 807 ONnou9 EZ ee ie BOWL TOA c t 9 H 0 BR S BRL Lan 9 E 310N 33S o o 1 i YOLIVINOI mim eI ds 4 did 110 aen olog gi Wavy Sud Qo on 13189 9 L E Ste CUTS 45 Dame A6 Gal ME pi tm ETE b wav sud l os osh v 4s J HNVd U3HOd 3NIHOVH El L SS ver wel E LE 310N 338 ci ol S301A30 Al3JVS 3WVdS WNO11d0 SCHER SL ne d Tue LE 310N 338 LE 210N 33S CO tau tee Ba Aids 7 djel i n HOLINS MOT W3lVM d3T11H2 HOLIMS MOTH N3lYM YASNIGNCO 15 uL ur e er Sep MEO e dA ec E J 9 NG H ds de DE aD o wD mu won 8013 So Se YOU ROU LEI ee Go 3 dra s e cu l eyd 335 95 4 86 ve ve LE 310N 33S oe Jl ds L 301430 LYWIS 310W3H VNOIldO e ec I 2 310N 335 CWNOILdO 939208 LINOYII dand 110 CYJIYYYI A8 LOND YOLOW NYJ W3MO0i 9NI1000 DIR Ag LOND HOO dWnd YJLYM YASNIONOD fu3IuuvO AB LOND YOLOW dnd u3iva 0INIHI dau Een O zsol O ZHOS 0S Hd A an Ho wo 9L LD J 8 7HO9 0S Hd ASLL ong m NO11235 39V1 OA MO Kee Se gal Al 3LON 33S STIVI3G TWNIWYAL HOLOW HOGG HAM2. EE ILON 336 EE 310N 335 EE ZION 336 COWNOT Lo S oly id ECH Weiten Deeg LOANNODSIO YO 72290 LINII EC aLON 338 SNOISNANIG XO8 1VNINH3 L HOS 2 Old 338 SLIOA MOD WNIMWHJi YOLOW SOSS3udWO2 193NNO 510 HONVYE 24 NOTES GENERAL 1 0 1 1 1 2 13 14 1 5 1 6 Starters shall be designed and manufactured in accordance with Carrier Engineering requirement Z 375 All field supplied conductors devices and the field installation wiring termination of conductors and devices must be in compliance with all applicable 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 of the reading adjusting or servicing of any component Equipment installation and all starting and control devices must comply 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 I POWER WIRING TO STARTER 2 0 2 1 2 2 Power conductor rating must meet minimum unit nameplate voltage and compressor motor RLA rated load amps When 3 conductors are used Minimum ampacity per conductor 21 25 x compressor R
3. NIH 300 2068 872 396 Maine 2 150 wa 42i 191 138 136 516 516 Marine 300 1032 1032 Maine 2 300 2068 1098 498 138 136 516 516 18 15 104 834 toe 13 30 28 162 79 CONDENSER 2 3 28 ez sis Marine 1842 1542 2 15 1034 6 4 306 1700 204 771 771 Marine 1542 1542 8 300 2068 1630 739 1700 204 771 77i 35 19 t t 300 2068 1588 720 le ame poem sii Marine 150 1034 25 11 1734 208 787 787 NIH Nozzle In Head When using a machine configuration other than 2 pass NIH waterboxes with 150 psig 1034 kPa covers add the weights listed in this table to the appropriate weights in Table 1 to obtain the correct condenser weight TSubtract 228 Ib 103 kg from the weight shown in Table 1 Table 5 Auxiliary Connection Sizes SIZE AND STYLE USAGE Pumpout Condenser Refrigerant Vapor Connection Rupture Disc Pumpout Water Inlet Connection Pumpout Water Outlet Connection Power Panel Oil Pump Power Connection Waterbox Vent Connection Waterbox Drain Connection Cooler Relief Valve Connection Economizer Storage Vessel Connection 9 in Male Flare Ve in FPT Ve in NPT Conduit 1 in NPT 14 in FPT 11 Table 6 Total 19EX Motor Weights 60 Hz Table 7 Total 19EX Motor Weights 50 Hz enee OW VOUT HIGH VOLTAGE soror sae E98 HIGH VOLTAGE 4
4. EN EE EN EN li p RED 4 CHASSIS CHASSIS GROUND GROUND 3 REAR 3 REAR UPPER UPPER NETWORK NETWORK cee DEER T 1 H 4 n H e L L ss S D 4 d Lal LJ i2 KH Gi q G zl 7 ot 19EX CHILLERS LEGEND Factory Wiring Field Wiring Field supplied terminal strip must be located in the control center TSwitches S1 and S2 are factory set on PSIO modules Do not alter the switches Fig 23 COMM1 CCN Communication Wiring for Multiple 17 19EX Chillers Typical 29 COMPRESSOR FRONT VIEW DRIVE DRIVE PLAN VIEW COMPRESSOR END END IT Area must be factory or field insulated IMPORTANT 17EX insulation is identical to the 19EX insulation shown above 17EX motors do not require insulation EZ Area to be field insulated if ambient conditions require NOTE Waterbox covers are to be insulated by the contractor Fig 24 Typical Insulation Area 19EX Shown Copyright 1996 Carrier Corporation Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 2 2 PC 211 Catalog No 531 749 Printed in U S A Form 17 19EX 28SI Pg 30 3 96 Replaces 17 19EX 1Sl Tab 5a 5d INSTALLATION START UP REQUEST CHECKLIST Machine Model Number 17 19EX Serial Number To Date Project Name Attn Carrier Job Number The following information provides the st
5. NOTE Wiring for sensors must be disconnected Label each wire before removal see Carrier certified drawings Detach all transducer and sensor wires at the sensor then clip all wire ties necessary to remove the wires from the heat A WARNING When rigging components separately the open drive exchangers 17EX motor must be removed to avoid overturning A WARNING Do not attempt to disconnect flanges while the machine is under pressure Failure to relieve pressure can result in personal injury or damage to the unit 9 9 99 o9 9oooQ9 e 9 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 19EX LEGEND 1 Refrigerant Liquid Line to Economizer 15 Motor Sight Glass Not Shown 27 Oil Cooler Storage Vessel 16 Oil Filter 28 Isolation Valves Not Shown 2 Cooler Suction Pipe 17 Oil Level Sight Glasses 2 29 Refrigerant Filter Drier 3 Compressor Suction Elbow 18 Cooler Relief Valves Not Shown 30 Local Interface Display Control Panel 4 Condenser 19 Oil Heater Not Shown 31 Economizer Storage Vessel 5 Condenser Discharge Pipe 20 Auxiliary Power Panel 32 Rigging Guide Not Shown 6 Compressor Discharge Elbow Field Wiring Terminals 33 Economizer Storage Vessel 7 Guide Vane Actuator 21 Pumpdown Unit Not Shown Relief Valves 8 Economize
6. 1 Each chain must be capable of supporting the maximum weight of the machine 2 Oe the approximate center of gravity 3 Maximum possible weight is 78 700 Ib 35 698 kg which includes a maxi mum of 6 000 Ib 2 268 kg of HFC 134a in the storage tank 19EX FRONT VIEW mn oo e Ts s 6 55 000 24 948 3 10 1168 6 1 1854 4 6 LIFTING VESSEL MAXIMUM CHAIN LENGTH HEIGHT CENTER OF GRAVITY COOLER LENGTH WEIGHT LIFTING EE APPROXIMATE LOCATION SIZE ANGLE wes qn mte duc Ov uus ee 5 89 12 3 3734 2567 T 2597 5 325 fers 125 3765 1 amp o 466 30 67 2007 69 2057 13 0 3962 122 3708 151 4597 123 3734 EE 4547 14 3 4945 CS ps ee nm eo em e 0 ma s454 71 6 3505 18 7 5664 180 5486 217 6579 3o 94 2769 96 2096 17 0 5182 78 700 35 698 3505 1 5283 19 8 5994 3 10 1168 8 3 2515 4 8 Fig 5 19EX Machine Rigging Guide 6 NOTE Item numbers are referenced in Rigging the Machine Component Disassembly section Fig 6 Typical Top View 19EX Shown A E M a Ge Ettel S mM Mime umi RE T 5 4 3 NOTE Item numbers are referenced in Rigging the Machine Component Disassembly section Fig 7 Typical Side View 19EX Shown NOTE Item numbers are referenced in Rigging the Machine Component Disassembly section Fig 8 Typical Motor End View 19EX Shown To Separate Cooler
7. 46 46 230 1070 i40 65 a7 a IS 2594 1162 1420 94 m 48 56 250 112 1420 94 48 Total machine refrigerant charge includes the cooler condenser and economizer NOTE Regulations mandate that machine shipping charge is limited to 7500 Ib 3402 kg 10 CHARGE T406 T 452 3300 1497 3600 1 633 1678 1724 1769 1769 1769 z041 2087 2192 2177 2177 2177 Table 3 Additional Cooler Weights DESIGN MAXIMUM ADDITIONAL ADDITIONAL EDOLER NUMBER WATER PRESSURE WATER WEIGHT Ge OF PASSES psig ka b Cb oa w L 150 1034 655 297 300 2068 2226 1010 NH 2 30 2x8 14 638 3 383 1448 1448 190 724 724 883 1448 1448 190 724 724 NH 13 o 19 S55 2 13 30 208 29 ea NH 2 so 2x8 29 96 4 e2 2814 2314 ae mer e 612 2814 2814 ae nsz 1157 NIH Nozzle In Head When using a machine configuration other than 2 pass NIH waterboxes with 150 psig 1038 kPa covers add the weights listed in this table to the appropriate weights in Table 1 to obtain the correct cooler weight Table 4 Additional Condenser Weights COMPONENT HEAT EEN WATERBOX TYPE NUMBER OF WATER PRESSURE DRY WEIGHT WATER WEIGHT kPa b kg b gal ky t 150 10M 28 19 300 2068 1328 602
8. 2400 3 60 54 3300 3 50 Compressor Size 51 through 89 421 through 469 531 through 599 65 3300 3 60 55 6300 3 50 Motor Size Gear Code Hermetic Drive Open Drive t 2 Digit Compressor Sizes 3 Digit Compressor Sizes DB DG DM EA FA GA HA JA 5 A DC DH DN EB FB GB HB JB 6 B DD DJ DP EC FC GC HC JC C DE DK DQ ED FD GD HD JD D DF DL EE NIH Nozzle In Head Motors beginning with E and open drive motors FA JD cannot be used with size 51 89 or 421 469 compressors TOpen drive motor codes FA Open Drive Motor Horsepower kW Motor Type hp kW ODP Open Drip Proof 1250 932 WPI Weather Protected Type l 1500 1119 WPII Weather Protected Type II 1750 1305 Con com TEWAC Totally Enclosed Water to Air Cooled 2000 UL U UL ASME UNDERWRITERS ARI Air Conditioning U STAMP LABORATORIES and Refrigeration Institute PERFORMANCE CERTIFIED 60 Hz Only Fig 1 Model Number Identification RIG MACHINE COMPONENTS Refer to instructions on page 5 Fig 6 8 and Carrier certified drawings for ma chine component disassembly A CAUTION Before rigging the compressor disconnect the wires leading from the power panel to the control center at the IMPORTANT Only a qualified service technician should power panel disassemble and reassemble the machine After reas sembly the machine must be dehydrated and leak tested
9. 348 1319 1319 47 1 404 5 825 1228 1228 52 1 344 53 381 1442 1442 55 1 566 56 644 3 808 457 1727 1727 57 644 4105 492 1862 1 862 H a machine configuration other than 2 pass 150 psig 1034 kPa NIH waterbox configuration is used refer to Tables 3 and 4 to obtain the additional dry and water weights that must be added to the values shown in this table tCooler and condenser weights shown are based upon 2 pass nozzle in head NIH waterboxes with 150 psig 1034 kPa covers Includes components attached to cooler but does not include suction discharge elbow or other interconnecting piping Dry weight includes all components attached to economizer Covers float valves brackets control center 31 Ib 14 kg and power panel 20 Ib 9 kg Dry weight does not include compressor weight motor weight or pumpout condensing unit weight The pumpout condensing unit weight is 210 Ib 95 kg For compressor and motor weights refer to Tables 6 7 8 10A and 10B ttOperating weight includes the sum of the dry weight refrigerant weight and water weight Table 2 Refrigerant Charge TOTAL REFRIGERANT Coder Condenser w w w b J w SI a2 32 eo 74 90 4 33 1740 789 950 431 a a 200 97 i90 44 60 277 a a ao 95 190 494 a 51 29 98 1100 49 4 52 2i Se Mo 49 a s 219 Se Ho 49 a 45 220 105 1400 635
10. SEE NOTE 3 5 CONDENSER WATER FLOW SWITCH N O SEE NOTE 3 1 CHILLED WATER FLOW SWITCH INO SEE NOTE 3 1 NOT BY CARRIER POWER WIRING BETWEEN STARTER AND COMPRESSOR MOTOR SEE NOTE 3 5 LEGEND Required Power Wiring Required Control Wiring Options Wiring SMM Starter Management Module 3 4 Do not route control wiring carrying 30 v or less within a conduit which has wires carrying 50 v or higher or along side wires carrying 50 v or higher 3 5 Voltage selector switch in machine power panel is factory set for 115 v control power Source Do not use the 230 v position If this switch is set to 230 v position the oil heater will not operate 3 6 Control wiring cables between starter and power panel must be shielded with mini mum rating of 600 v 80 C ground shield at starter Wires A B and C are commu nication wires and must be run in a separate cable 3 7 If optional oil pump circuit breaker is not supplied within the starter enclosure as shown it must be located within sight of the machine with wiring routed to suit 3 8 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 starter 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 termi
11. e s pig b s b s ps L r 0 4 Dg 6 754 1558 7i NA DC NA DC NA T NA DD e DD 1049 pE 1620_ 728 1536 696 2152 976 DE 1058 DF 1205 DF 1082 DG 1243 DG 1997 DH 1273 DH n Dj 1305 Dj 1405 DK 1385 DK 1446 DL 1494 DL 1477 DM ve DM 1505 DN 2415 1095 2558 1160 3277 1486 DN 2555 1159 2864 1299 3407 1545 D 1573 DG 1638 EA 1078 EA 1217 EB Hoi EB 1310 EC SE EC 1477 ED 1262 ED 1561 EE Ge EE 1803 NA Not Available NA Not Available NOTE Low voltage motors are rated below 600 v medium voltage motors range NOTE Low voltage motors are rated below 600 v medium voltage motors range from 600 v to 6 000 v and high voltage motors are rated above 6 000 v from 600 v to 6 000 v and high voltage motors are rated above 6 000 v Table 8 Compressor Weights COMPONENT Compressor Weight Suction Elbow Weight does not include motor NOTES 1 19EX compressors include sizes 51 through 89 2 17 19FA5 compressors include sizes 531 through 599 3 19FA4 compressors include sizes 421 through 469 Table 9 Total 17EX Drive Component Weights MOTOR GC COUPLING WEIGHT GUARD WEIGHT HORSEPOWER kW DE 12 Table 10A 17EX Motors Total Weight Lbs English ENCLOSURE TYPE HERTZ vom SIZE HP FA 1250 FB 1500 FC 1750 FD 2000 5721 5900 7160 60 Hz 5832 5832 7127 Open Drip Proof 5721 5900 7160 ODP 6577 8776 8990 5878
12. Cooler utility and condenser vessels may be rigged ver tically as separate components Rigging should be fixed to all four corners of the tube sheet New gaskets grease for O rings and gasket sealant for a complete take apart operation are available in a kit Con tact your Carrier representative 0 L 0 O O 2 Qj OI 0 QJ 3 f B E 9 em 0 y D DIAM LS P g gt oN e fa y A Ell o 50 5 0 S ND C i 9 I S 0 9 0 I Sp S 9 o o 7 o M JI _ F DIAN o UI o 5 Y i G e 2 0 610 mm iom MINIMUM B SERVICE i oe H NOTES 1 Certified drawings available upon request 2 Service access should be provided per American Society of Heating Refrigeration and Air Con SERVICE AREA ditioning Engineers ASHRAE 15 latest edition National Fire Protection Association NFPA 70 and local safety codes DIMENSIONS A LENGTH t B WIDTH C HEIGHT H TUBE PULL CONDENSER SIZE tm mm E um mm 31 33 JE 41 43 NODE Sieg ERN USE T 45 17 TRIES BIEN 51 53 ves 2210 3812 5334 SERVICE CLEARANCES aor COMPONENT 2 S E La e Cum mm fm a EE ET em Ta EE Motor EE em EE lug Low Side Float HA E a a NOZZLE SIZES NOZZLE SIZES in EXCHANGER NOZZLE TYPE pcc Passes LEGEND NIH Nozzle In Head NOMINAL PIPE SIZE in SCHEDULE
13. From Utility Vessel l 5 Remove condenser see previous section 2 Cut copper lines Fig 6 Items 6 and 8 2 4 Connect rigging to all four corners of the cooler before Unbolt liquid refrigerant line at flange Fig 7 Item 3 lifting the unit Unbolt connections to the utility vessel Fig 6 Items 5 and 10 To Assemble the Machine 1 Follow disassembly instructions in reverse order and bolt all flanges back together using a gasket sealant The fol lowing torque requirements are specified FIG ITEM NO TORQUE b 786 6 230 DE 515 4 and 5 250 340 230 k 515 N m Newton Meters This torque is used to rig the entire machine Once the machine is in place if no further rigging is anticipated the bolt torque can be reduced to 280 ft lb 380 N m 2 All gasketed or O ring joints which have been disas sembled must be assembled using new gaskets and O rings These new gaskets and O rings along with gasket seal ant O ring lubricant and copper line couplings are avail able through your Carrier representative Braze all copper lines back together using a suitable braz ing material for copper Carrier recommends an AWS American Welding Society Classification BCuP 2 CAUTION Do not tilt the compressor oil is contained in the oil sump Additional Notes Use silicon grease on new O rings when refitting Use gasket sealant on new gaskets when refitting
14. Item 5 37 1 2 3 4 9 9 6 Low Side Float Box Cover Relief Valves e 10 11 To Disconnect wiring to the control center and power panel Connect rigging to the compressor Unbolt compressor from the utility vessel Fig 7 Items 2 4 and 5 Hoist the compressor off of the unit If the compressor is to be transported or set down the base should be bolted to sections of 4 in x 6 in lumber DEE H E e Separate Condenser from the Machine Unbolt flange Fig 6 Item 3 Unbolt flange Fig 6 Item 4 Cut copper pipe Fig 6 Item 7 Unbolt hot flange Fig 7 Item 1 Connect rigging to all corners of the condenser Unbolt condenser feet Fig 8 Items 1 and 6 et 11 26 25 24 23 22 21 20 19 17 16 15 LEGEND Condenser 15 Refrigerant Liquid Line to Cooler 27 Pumpout Unit Cooler Suction Pipe 16 Power Panel Field Wiring Terminals 28 High Side Float Box Cover Compressor Suction Elbow 17 Oil Level Sight Glasses 29 Cooler Guide Vane Actuator 18 Oil Drain and Charging Valve 30 Cooler Waterbox Drain Condenser Discharge Pipe 19 Oil Heater Hidden 31 Take Apart Connections Typical Oil Filter Hidden 20 Oil Pump 32 Cooler Marine Waterbox Cove
15. box using holes cut by contractor to suit conduit Flex ible 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 special motor terminal box not supplied by Carrier Lead connec tions 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 National Electrical Code NFPA 70 and applicable codes Means for grounding compressor motor is a pressure connector for 4 to 500 MCM wire supplied and located in the back lower left side corner of the compressor 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 Fig 17 Typical Field Wiring Low Voltage Motors with Free Standing Starter 23 1euejs Buipuejs ea14 jeuondo YUM eio10ouw eDeyoA uf Bum Diet 84 Du Bumm suongdo Buum Jo04u05 pasinbey EE 310N 33S O DUUUM Jewog p nboy m npoy Juswebeueyy IAS N 04002 pereJbeiu jonpojd LS EE aed Buiwojo uo S JON QN3931 d CTVNO1LdO Wuvv SLOWSY O3l dd S YAWOLSNI EE 310N 335 a
16. compressor motor Connect Power Wires to Oil Pump Contactor Connect power wires to oil pump contactor mounted in machine power panel See Fig 19 Use the electrical disconnect located in the machine starter if supplied or a separate fused disconnect as shown on job wiring diagrams Check that power supply voltage agrees with oil pump voltage Follow correct phas ing for proper motor rotation A CAUTION Do not wire into the top surface of the power panel Knock outs are provided on the underside of the panel Connect Power Wires to Oil Heater Contactor Connect control power wiring between the oil heater contactor ter minals Fig 17 and 18 and terminals LL1 and LL2 on the field wiring strip in the compressor motor starter Refer to Fig 21 and wiring label on the chiller power panel A WARNING Voltage to terminals LL1 and LL2 comes from a con trol transformer in a starter built to Carrier specifica tions Do not connect an outside source of control power to the compressor motor starter terminals LL1 and LL2 An outside power source will produce dangerous volt age at the line side of the starter because supplying volt age at the transformer secondary terminals produces in put level voltage at the transformer primary terminals Connect Communication and Control Wiring from Starter to Power Panel Connect control wiring from main motor starter to the chiller power panel All control wiring mus
17. conductors must be insulated with PVC PVC nylon vinyl Teflon or polyethylene An aluminum poly ester 100 foil shield and an outer jacket of PVC PVC nylon chrome vinyl or Teflon with a minimum operating 27 temperature range of 4 F 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 COMM1 PLUG SIGNAL TYPE INSULATION COLOR PIN NO s Red 1 Ground White 2 Black 3 If a cable with a different color scheme is selected a similar 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 23 If the communication bus cable exits from one build ing and enters another the shields must be connected to ground at the lightning suppressor in each building where the cable enters or exits the building one point only To connect the 17 19EX chiller to the network proceed as follows Fig 23 1 Cut power to the PIC Product Inte
18. 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 531 749 Printed in U S A Book 2 12 PC 211 Tab 5a 5d Form 17 19EX 2S1 Pg 1 3 96 Replaces 17 19EX 1SI CONTENTS Page SAFETY CONSIDERATIONS 1 INTRODUCTION 000s 2 General ENEE EN EEN ee 2 Job Data 1 EE Sk ees s 2 Equipment Required 2 INSTALLATION 2 30 Receiving the Machine 2 INSPECT SHIPMENT IDENTIFY MACHINE PROVIDE MACHINE PROTECTION Rigging the Machine 2 RIG MACHINE ASSEMBLY RIG MACHINE COMPONENTS COMPONENT DISASSEMBLY Install Machine Supports 14 INSTALL STANDARD ISOLATION INSTALL OPTIONAL ISOLATION INSTALL SPRING ISOLATION Connect Piping 17 INSTALL WATER PIPING TO HEAT EXCHANGERS INSTALL WATER TO OIL COOLER ON FA COMPRESSORS INSTALL VENT PIPING TO RELIEF DEVICES Make Electrical Connections 20 CONNECT CONTROL INPUTS CONNECT CONTROL OUTPUTS CARRIER COMFORT NETWORK INTERFACE Install Field Insulation 28 FACTORY INSULATION OPTIONAL INSTALLATION START UP REQUEST CHECKLIST erch ha ete Rees CL 1 INTRODUCTION General The 17 19EX mac
19. is factory equipped with relief devices on the cooler and utility vessels Refer to Fig 2 and 3 and Table 13 for size and location of relief devices as well as information that will help determine pipe size Vent relief devices to the outdoors in accordance with ASHRAE 15 latest edition Safety Code for Mechanical Refrigeration and all other applicable codes To ensure relief valve serviceabil ity and as required in ASHRAE 15 latest edition 3 way dual shutoff valves and redundant relief valves are installed on the economizer storage vessel refer to Fig 16 NOTE The 3 way dual shutoff valve should be either front seated or back seated Running the refrigeration system with the valve stem in the center position can reduce total relief capacity and cause valve chattering A DANGER Refrigerant discharged into confined spaces can dis place oxygen and cause asphyxiation 1 If relief device piping is 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 4 Cover the outd
20. to the machine control center as indicated in Fig 22 and 23 CONNECT CONTROL OUTPUTS Connect auxiliary equipment chilled and condenser water pumps and spare alarms as required and indicated on job wiring drawings Connect Starter Assemble and install compressor termi nal box in desired orientation and cut necessary conduit open ings in conduit support plates Attach power leads to com pressor terminals in accordance with job wiring drawings observing caution label in terminal box Use only copper con ductors The motor must be grounded in accordance with NEC National Electrical Code applicable local codes and job wiring diagrams 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 insulate the elec trical terminals as follows 1 Insulate each terminal by wrapping with one layer of insulation putty 2 Overwrap putty with 4 layers of vinyl tape High voltage units require special terminal preparation The vinyl tape is not acceptable a high voltage tape must be used Installer is responsible for any damage caused by improper wiring between starter and
21. 17 19EX 50 60 Hz 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 specifications When operating this equipment use good judgment and safety precautions to avoid damage to equipment and property or injury to personnel Be sure you understand and follow the procedures and safety precautions contained in the machine instructions as well as those listed in this guide A 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 ASHRAE American Society of Heating Refrig eration and Air Conditioning Engineers 15 The accumulation of re frigerant in an enclosed space can displace oxygen and cause asphyxiation PROVIDE adequate ventilation in accordance with ASHRAE 15 es pecially for enclosed and low overhead spaces Inhalation of high concentrations of vapor is harmful and may cause heart irregularities unconsciousness or death Intentional misuse can be fatal Vapor is heavier than air and reduces the amount of oxygen available for breath ing Product causes eye and skin irritation Decomposition products are hazardous DO NOT USE OXYGEN to purge lines or to pressurize a machine for any purpose Oxygen gas reacts violently with oil grease and other common substanc
22. 7148 9048 50 Hz 5878 7148 9073 6577 8875 8976 GA 1350 GB 1500 GC 1750 GD 2000 5871 6050 7270 60 Hz 5982 5982 7237 Weather Protected 5871 6050 7270 Type WPI 6727 8926 9100 5728 6028 7298 9158 50 Hz 5728 6028 7298 9183 5806 6727 9025 9086 HA 1250 HB 1500 HC 1750 HD 2000 6151 6330 7600 60 Hz 6262 6262 7567 Weater Protected 6151 6330 7600 Type Il WPI 7007 9206 9430 5828 6308 7578 9488 50Hz 5828 6308 7578 9513 5906 7007 9305 9416 JA 1250 JB 1500 JC 1750 JD 2000 60 Hz 6746 6925 8290 Totally Enclosed 6857 6857 8257 Water To Air Cooled erde Se n TEWAC 6903 8173 10 178 50 Hz 6903 8173 10 203 7602 9900 10 106 Table 10B 17EX Motors Total Weight Kg SI ENCLOSURE TYPE FREQ vouTace SIZE kW FA 932 FB 1119 FC 1305 FD 1492 2676 3248 60 Hz 2645 3233 Open Drip Proof 2676 3248 ODP 3981 4033 2503 2666 3242 4104 50 Hz 3300 2503 2666 3242 4116 2538 2983 4026 4072 GA 932 GB 1119 GC 1305 GD 1492 2744 3298 60 Hz 2713 3283 Weather Protected 2744 3298 Type WPI 4049 4128 3310 4154 50 Hz 3310 4165 4094 4121 HA 932 HB 1119 HC 1305 HD 1492 2871 3447 60 Hz 2840 3432 Weather Protected 2871 3447 Type II WPII 4126 4277 2644 2861 3437 4304 50 Hz 2644 2861 3437 4315 2679 3178 4221 4271 JA 932 JB 1119 JC 1305 JD 1492 EUH 3141 3760 wu A SEM a f Ea a ater To Air Coole TEWAC 4446 4590 3000 2898 3131 3707 4617 50 Hz 3300 2898 3131 3707 4628 6300 2933 3448 44
23. 90 4584 HEAT EXCHANGER SIZE 31 33 41 48 51 57 Table 11 Marine Waterbox Cover Weights COOLER ssi e b 18 304 388 o 2 22 CONDENSER kg 495 651 579 754 746 1018 Heat exchangers with marine waterboxes have heavier dry and operating weights than heat exchangers with nozzle in head waterboxes Table 12 NIH Waterbox Cover Weights HEAT EXCHANGER SIZE PASSES psi 150 31 33 150 150 150 41 48 DESIGN MAXIMUM WATER PRESSURE COOLER CONDENSER ka kg b kg 104 eo 8 amp 3 800 2058 2748 tear 615 300 389 582 800 829 788 800 656 150 51 57 159 150 NIH Nozzle in Head 2068 4188 1901 2590 1034 3035 1378 1777 2068 4244 1927 2539 134 2052 ses sp 2040 134 294 s 208 940 EE EH mei 8e as 1 1 The 150 psig 1034 kPa 2 pass waterbox cover weights are included in the dry weight shown in Table 1 TTwo different waterbox covers are present on 2 pass machines The weight shown in this table represents the weight of the waterbox cover that contains the nozzles A blank waterbox cover is also present on 2 pass units The weight of the blank waterbox cover is identical to the weight of the same size marine waterbox cover R
24. IER Indicates chilled water pump control contacts or run status contacts TIndicates condenser water pump control contacts Indicates tower fan relay contacts TtIndicates circuit breaker shunt trip contacts Indicates remote alarm contacts NOTES GENERAL 1 0 14 1 2 1 8 1 4 1 5 1 6 Starters shall be designed and manufactured in accordance with Carrier Engineer ing Requirement Z 375 All field supplied conductors devices field installation wiring and termination of con R and devices must be in compliance with all applicable codes and job speci ications 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 comply with de tails 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 between starter and machine POWER WIRING TO STARTER 2 0 2 1 22 Power conductor rating must meet minimum unit nameplate voltage and compres sor motor RLA When 3 conductors are used Minimum ampacity per conductor 1 25 x compressor RLA When 6 conductors are used for W
25. LA When 6 conductors are used Minimum ampacity per conductor 20 721 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 Ill CONTROL WIRING 3 0 3 1 3 2 3 3 Field supplied control conductors to be at least 18 AWG American Wire Gage or larger 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 Maximum 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 auxiliary safeties between these terminals Maximum load on pilot relays is 10 amps Pilot relays can control cooler and condenser pump and tower fan motor contactor coil loads rated up to 10 amps at 115 vac or up to 3 amps at 600 vac Control wiring re quired for Carrier to start pumps and tower fan motors must be pro vided to assure machine protection If primary pump and tower motor control is 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 IV 3 4 Do not route control wiring carrying 30 v or l
26. NOTE Carrier does not provide waterbox insulation Insu lation of the waterbox covers must be field supplied at the jobsite When insulating the waterbox covers allow enough room for removal of the waterbox covers during servicing FACTORY INSULATION OPTIONAL Optional factory insulation is available for the evaporator shell and tube sheets suction pipe compressor motors and refriger ant drain line s Insulation applied at the factory is 20 in 19 0 mm thick and has a thermal conductivity K value of Btu e in 0 28 Ee with UL Standard 94 Classification 94 HBF W sp 0 0404 tr C Insulation conforms 28 Table 15 Insulation Requirements Sheet Foam Insulation COMPONENT t2 m2 Cooler Shell Sizes 31 33 254 23 6 Cooler Shell Sizes 41 44 28 4 Cooler Shell Sizes 45 48 374 34 7 Economizer Low Side Float Chamber 4 5 Economizer Main Shell with cooler sizes 31 44 7 9 Economizer Main Shell with cooler sizes 45 48 10 1 Suction Line 2 3 Cooler Marine Waterbox 1 or 3 pass with 126 117 frame 3 coolers Cooler Marine Waterbox 2 pass with 100 93 frame 3 coolers Cooler Marine Waterbox 1 or 3 pass with 158 14 7 frame 4 coolers Cooler Marine Waterbox 2 pass with 123 11 4 frame 4 coolers Cooler NIH Waterbox with frame 3 coolers 6 9 Cooler NIH Waterbox with frame 4 coolers 8 2 Main Motor Shell with 51 through 89 25 compressors Main Motor Shell with 421 through 469 compressors 2 5 Mai
27. NTS 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 50 c 75 d 100 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 The 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 job site 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 understand that the technician s time will be charged as extra services due to correcting items in this checklist that are inc
28. R 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 It is 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 ASHRAE 15 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 re lief devices AT LEAST ONCE A YEAR If machine operates in a cor rosive atmosphere inspect the devices at more frequent intervals DO NOT ATTEMPT TO REPAIR OR RECONDITION any 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
29. SOLATION 0 1 1 2 38 SUPPORT PLATE STANDARD ISOLATION ELASTOMERIC 7 8 9UNC 4 HOLES PAD ads FOR JACKING SCREWS 19 ZE JACKING 635 pos OPTIONAL SOLEPLATE L SOLEPLATE PACKAGE c LEVELING pie UP 0 1 1 2 38 356 ACCESSORY ISOLATION SOLEPLATE DETAIL SECTION A A TUBE SHEET SUPPORT PLATE JACKING SCREW SEE NOTE 3 TEENS LEVEL BASE LINE 1 THK 25 H R S P 0 1 3 8 35 SOLE PLATE E SEE NOTE 4 Ze K Se DEC E Zi LEVELING PAD NOTES 1 Dimensions in are in millimeters 2 Accessory soleplate package includes 4 soleplates 16 jacking screws and leveling pads Requires isolation package Jacking screws to be removed after grout has set Thickness of grout will vary depending on the amount necessary to level chiller Use only pre mixed non shrinking grout Celcote HT 648 or Master Builders 636 0 112 38 1 to 0 24 57 thick PO STANDARD ISOLATION VIEW B B TUBE SHEET 0 3 8 10 LEVEL BASE LINE EE e SE e HERB GB SHEAR FLEX PAD 3 8 10 THK ISOLATION WITH ISOLATION PACKAGE ONLY STANDARD SUPPORT PLATE NOTE Isolation package includes 4 shear flex pads Fig 11 Machine Vibration Isolation 16 Connect Piping INSTALL WATER PIPING TO HEAT EXCHANGERS Install piping using job data piping drawings and proce dure outlined below A typical piping installation is shown in Fig 12 CAUTION Factory supplied insula
30. T Distance required for tube removal may be either end 40 TBased on 2 pass nozzle in head NIH waterboxes with 150 psi 1038 kPa 10 365 covers 12 Sd 37 Overall width of units with 17 Series compressors will vary greatly depend 14 ing upon the application See the appropriate certified drawings ttFor hermetic motors 19 Series only 16 The table at right provides additional information on nozzle sizes Victaulic 18 sad 375 grooves are standard for these nozzles Optional 150 psi 1034 kPa and 20 20 35 300 psi 2068 kPa flanges are available din conformance with ASA B36 10 American Standards Association Fig 9 Typical Dimensions 9 Table 1 17 19EX Heat Exchanger Economizer Storage Vessel Piping and Pumpout Unit Weights COOLER COOLER TOTAL WEIGHT COOL CHAR STORAGE VESSEL ECONOMIZER ECONOMIZER MISCELLANEOUS PUMPOUT REFRIGERANT PIPING UNIT ER GE gal b b k ko foal ks t 5 32 7169 3252 eo 277 s2 372 33 14 904 6 760 18 722 8 492 1 740 789 2 078 249 943 943 2 22 2 000 SAA ce ETH EE ten E a3 210 95 aa 2 190 as 46 2 360 Es hene DK roam vee a7 2 460 a8 2540 CONDENSER TOTAL WEIGHT CONDENSER CHARGE COEUR Dry Operatingtt Refrigerant Water Ib kg Ib kg Ib kg Ib gal kg L 5 732 32 210 794 794 33 855 41 257 973 973 42 1 035 a3 290 1097 1097 a5 1 234 46 635 2908
31. atus 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 a Chilled water piping b Condenser water piping c Waterbox drain piping d Pumpout unit condenser piping if installed e Oil cooler water piping FA compressors only f 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 9 The motor starter has not been supplied by Carrier and it has been checked for proper operation COMME
32. de Each lifting cable or chain must be capable of supporting the entire weight of the machine A 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 Table 1 for machine 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 Total machine weight is also stenciled on the cooler and con denser sections 19EX 43 43 85 6 DP 62 1 Model Description 17EX Open Drive Centrifugal Special Order Code Standard Liquid Chiller S Special Order 19EX Hermetic Centrifugal Liquid Chiller Waterbox Code 1 Marine Waterbox Cooler Marine Waterbox Condenser Cooler S ke e 2 Marine Waterbox Cooler 31 33 Frame 3 41 44 Frame 4 45 48 Frame 4 Stretched NIH Waterbox Condenser 3 NIH Waterbox Cooler Marine Waterbox Condenser 4 NIH Waterbox Cooler Condenser Size NIH Waterbox Condenser 31 33 Frame 3 41 43 Frame 4 51 53 Frame 5 Motor Voltage 45 47 Frame 4 Stretched 55 57 Frame 5 Stretched 06 200 3 60 67 6900 3 60 60 230 3 60 50 230 3 50 61 380 3 60 51 346 3 50 62 460 3 60 52 400 3 50 63 575 3 60 53 3000 3 50 64
33. efer to Table 11 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 INSTALL OPTIONAL ISOLATION if required Un even floors or other considerations may dictate the use of soleplates and leveling pads Refer to Fig 10 and 11 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 14 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 INSTALL SPRING ISOLATION Field supplied spring isolators may be placed directly under machine support plates or be located under machine soleplates Consult job data for specific arrangement Low profile spring isolation assem blies are recommended so that the machine is kept at a con venient working he
34. es 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 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 electrical 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 NEVE
35. ess within a conduit which has wires carrying 50 v or higher or along side wires carrying 50 v or higher 3 5 Voltage selector switch in machine power panel is factory set for 115 v control and oil heater power source The 230 v position is not used If switch is set to 230 v position oil heater will not operate 3 6 Control wiring cables between starter and power panel must be shielded with minimum rating of 600 v 80 C Ground shield at starter Wires A B and C are communication wires and must be run in a separate cable 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 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 starter 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 produces input level voltage at the transformer pri mary terminals POWER WIRING BETWEEN STARTER AND COMPRESSOR MOTOR 4 0 Medium voltage over 600 volts hermetic compressor motors have 3 terminals Use no 4 AWG strand wires for all medium and high volt age hermetic motors Distance between terminal is Z ie inches Use suitable splice connectors and insulation for high voltage alter
36. grated 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 Attach the COMMI plug back onto the processor module 9 Mount a terminal strip in a convenient location 10 Connect the opposite ends of each conductor to separate terminals on the terminal strip 11 Attach the CCN Network wiring a Connect the RED wire to the matching location on the terminal strip b Connect the WHITE wire to the matching location on the terminal strip c Connect the BLACK wire to the matching location on the terminal strip Install Field Insulation A CAUTION Protect insulation from weld heat damage and weld splat ter Cover with wet canvas cover during water piping installation When installing insulation at the job site insulate the fol lowing components see Fig 24 and Table 15 compressor motor cooler shell cooler tube sheets suction piping motor cooling drain oil cooler refrigerant side tubing utility vessel low side Additional insulation of condenser and compressor com ponents and lines may be necessary to prevent condensation on these components
37. hine is factory assembled wired and leak tested Installation consists primarily of es tablishing water and electrical services to the machine The rigging installation field wiring field piping and insulation are the responsibility of the contractor and or customer See Fig 1 for model number information 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 drawings Equipment Required mechanic s tools refrigeration volt ohmmeter and clamp on ammeter leak detector halide or electronic absolute pressure manometer or wet bulb vacuum indicator portable vacuum pumps INSTALLATION Receiving the Machine INSPECT SHIPMENT CAUTION Do not open any valves or loosen any connections The standard 17 19EX machine may be shipped with a ni trogen holding charge or with the refrigerant charge iso lated within the utility vessel 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 transportation company Manufacturer is not responsible for any damage incurred in transit 2 Check all items against shipping list Immediately notif
38. ight inside of the tube sheet Obtain specific details on spring mounting and machine weight distribution from job data Also check job data for methods for supporting and isolating pipes that are attached to the spring isolated machines COOLER S IZES 31 33 AND 41 44 13 3 3 4 0 6 1 8 156 TYP T 10 559 TYP ME L 1 4 406 TYP ACCESSORY SOLEPLATE f b p 0 3 76 TYP al 0 0 1 2 13 TYP COMPRESSOR END COOLER SIZES 4058 6 1 3 4 1873 Midi g COOLER oe eer S E OUTSIDE EDGE OF COOLER TUBESHEET TYPICAL BOTH ENDS A VESSELS L OUTSIDE EDGE OF ECONOMIZER END PLATE ECONOMIZER TYPICAL BOTH ENDS Lovo 3 4 19 TYP B B DRIVE END DIMENSIONS EE E al c 2654 2692 2819 zs 1 COOLER SIZES 45 48 18 0 1 4 6493 0 6 1 8 156 TYP 1 10 559 TYP 1 4 406 TYP c COOLER REENEN t OUTSIDE EDGE OF COOLER TUBESHEET TYPICAL BOTH ENDS 9 4 12 2858 9 3 4 11 1 4 VESSELS 2819 1505 r ACCESSORY SOLEPLATE OUTSIDE EDGE OF ECONOMIZER END PLATE t I e ECONOMIZER TYPICAL BOTH ENDS TI 0 3 76 TYP l A A L 0 0 3 4 19 TYP 0 0 1 2 13 TYP S te i B B COMPRESSOR END DRIVE END NOTES 1 Dimensions in are in mm 2 1 inch 25 4 mm 3 All dimensions approximately 1 2 inch Fig 10 Machine Contact Surfaces 15 SOLEPLATE ISOLATION TYPICAL I
39. ion or corrosion of the oil cooler coil may lead to extensive machine damage not covered by the standard warranty If water from the machine chilled water circuit is used for oil cooling it should enter the oil cooler from the entering water line of the machine cooler Water leaving the oil cooler should connect to the leaving water line of the machine cooler at a point downstream from the chilled water sensor so that oil cooler leaving water temperature does not affect the sen sor readings Locate the oil cooler leaving water connection at some distance from any water temperature indicators On single pass machines water leaving the oil cooler should be con nected into the suction side of the chilled water pump so that adequate pressure drop is assured for oil cooling The nominal conditions for oil cooler water flow are low fate e eA 30 gpm 1 9 L s Leaving temperature 85 to 100 F 29 to 38 C Pressure drop at oil cooler 7 25 psid 50 kPad Max differential pressure across closed solenoid valve 150 psid 1034 kPad The oil cooler connections are 11 4 in FPT PLUG COCK SOLENOID VALVE CHILLED COOLER ENTERING WATER x COOLER LEAVING WATER UTILITY VESSEL ON SINGLE PASS OIL COOLER MACHINES CONNECT TO SUCTION SIDE OF WATER PUMP Fig 15 Water Piping Oil Cooler to Chilled Water Circuit Typical INSTALL VENT PIPING TO RELIEF DEVICES The 17 19EX chiller
40. m the requirement to vent outside However Carrier recommends that the pumpout con denser be connected to the rest of the vent system Table 14 Individual Component Ratings DESIGN CENTER SUPPLY POWER SOURCE ITEM AVERAGE kW VOLTAGE V PH HZ LRA x Seal EP 115 1 50 60 4 78 21 7 17EX Onl Ge Molor Space 115 1 50 60 4 35 Control Module 115 1 60 a tt and Actuator 115 1 50 Oil Sump Heater Ween 200 240 3 60 24 5 380 480 3 60 12 2 2 Oil Pump 507 619 3 60 25 0 3 Pumpout Optional Compressor LEGEND FLA Full Load Amps LRA Locked Rotor Amps Available for 17EX machines only tAvailable for 17 19EX machines Available as an option on 17 19EX machines 1 49 230 220 240 3 50 7 83 28 0 1 49 393 346 440 3 50 2 59 12 2 xx Hot Gas 1 Bypass 112060 T9 200 208 3 60 63 5 220 240 3 60 57 5 440 480 3 60 28 8 550 600 3 60 23 0 340p 3804153 50 288 22 NOTE The oil pump is powered through a field wiring terminal into the power panel Power to the controls and oil heater via the power panel must be on circuits that can provide continuous service when the compressor starter is disconnected VOLTS MOTOR TERNINAL BOX 3 PHASE 19 8 16 50 X 12 2 15 DEEP CAPPROX INSIDE DIMENSIONS SEE NOTE Ir OIL PUMP CIRCUIT BREAKER OPTIONAL SEE MOTE 3 7 SEE WOTE 3 1 NOT BY CARRIER COMMUNICATION WIRE TO SMM CUSTOMER SUPPLIED REMOTE ALARM COPTIONAL SEE NOTE 3 9 NOT BY CARR
41. n Motor Shell with 531 through 599 compressors 3 8 Foam Tubing Insulation TYPE m 11 Foam Tubing 2 7 15 Foam Tubing 0 6 2 Foam Tubing 2 7 5 Foam Tubing 4 3 NOTES 1 Cooler value includes marine waterbox on one end even pass arrangement 2 Values are approximate 3 Thermal insulation is available as a factory installed option Waterbox in sulation must be field supplied GROUND DRAIN WIRE DRAIN WIRE DRAIN WIRE DRAIN WIRE CCN BLACK BACK IL SS NETWORK Se Z CK SCH B BLACK K BLACK WIRING WHITE Ee WHITE P WHITE pce DES rM Ni RED SEN RED man c RED M Eesen TERMINAL STRIP Ag 9 9 2 TERMINAL STRIP Pe gee FIELD SUPPLIED FIELD SUPPLIED 7 p 1 ied immi Sege E E Ifc i lj g 95
42. nals produces input level voltage at the trans former primary terminals 4 0 4 1 4 2 4 3 4 4 4 5 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 com pressor 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 21346 inches Compressor motor starter must have nameplate stamped as to conforming with Carrier requirement Z 375 Medium voltage over 600 v compressor motors have 3 terminals Connections out of ter minals are 3 in long stranded wire pigtails 4 AWG strand wire for all medium voltage motor sizes Distance between terminal is 7 4e inches Use suitable splice connectors and insulation for high voltage alternating current cable terminations these items are not supplied by Carrier Compressor motor starter must have nameplate stamped as to 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 and 3 in one conduit and those to 4 5 and 6 in another Compressor motor power connections can be made through top top rear or sides of compressor motor terminal
43. nating current cable terminations these items are not supplied by Carrier Compressor motor starter must have nameplate stamped as to con forming with Carrier requirement Z 375 Medium voltage open motors have lug terminations see certified drawings for size 4 1 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 and 3 in one conduit and those to 1 2 and 3 in another 4 2 Compressor motor power connections can be made through top top rear or sides of compressor motor terminal box by using holes cut by contractor to suit conduit Flexible conduit should be used for the last few feet to the terminal box for unit vibration isolation Use of stress cones may require an oversize special motor terminal box not sup plied by Carrier 4 3 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 no 4 AWG 500 MCM pressure connector supplied and located in the lower left side corner of the compressor motor terminal box 4 4 Do not allow motor terminals to support weight of wire cables use cable supports and strain reliefs as required Fig 18 Field Wiring High Voltage Motors with Optional Free Standing Starter cont 25 L1 21 VOLTAGE 22 PER JOB
44. omplete Signature of Purchaser Signature of Job Site Supervisor Copyright 1996 Carrier Corporation Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 2 2 PC 211 Catalog No 531 749 Printed in U S A Form 17 19EX 2Sl Pg CL 2 3 96 Replaces 17 19EX 1Sl Tab 5a 5d CUT ALONG DOTTED LINE
45. oor 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 Make Electrical Connections Field wiring must be installed in accordance with job wiring diagrams and all applicable electrical codes 20 RELIEF VALVES 3 WAY VALVE Fig 16 Typical 17 19EX Utility Vessel Relief Valve Tee CAUTION Do not run 120 v wiring into the control center The control center should only be used for additional extra low voltage wiring 50 v maximum Wiring diagrams in this publication Fig 17 23 are for reference only and are not intended for use during actual in stallation follow job specific wiring diagrams Specific electrical ratings for individual components are shown in Table 14 A 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 as shown in Fig 17 and 18 Additional spare sensors and Carrier Comfort Network modules may be specified as well These are wired
46. ow 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 any bend Differential pressure type flow switches may be con nected at the nozzle of the waterbox Install waterbox vent and drain piping in accordance with individual job data All connections are 3 4 in FPT Install waterbox drain plugs in the unused waterbox drains and vent openings Install water piping to the optional pumpout system con denser storage tank as shown in Fig 14 WIRE BACK TO STARTER PRESSURE DIFFERENTIAL SWITCH BOX MOUNTED TO WALL MACHINE OR COLUMN COM N O PRESSURE CONNECTION LOW _ HIGH 3 8 IN COPPER OR SUITABLE LINE LEAVING HI CHILLED WATER MACHINE LO WATERBOX FLANGES ENTERING NOZZLES 4 CHILLED WATER FLARED FITTING FOR EASY DISCONNECT TO FLUSH BLEED PRESSURE AND SERVICE COPPER LINES THERMOMETERS w NEEDLE TYPE VALVE OPTIONAL FOR SWITCH MAINTENANCE LEGEND COM Common HIGH N o n Normally Open A de Lan Do not locate pressure connections past the machine isolation valve Fig 12 Typical Nozzle Piping 17 MPRE REND NOZZLE IN HEAD WATERBOXES DRIVE END Fig 13 Nozzle Arrangements COOLER WATERBOX NOTES 1 2 Ao Frame 5 condenser available in 1 and 2 pass only Frame 3 in 2 and 3 pass only The vents for these wate
47. r Two Stage Compressor 21 Refrigerant Charging Service Valve 33 Cooler Waterbox Compressor Discharge Elbow 10 Not Shown 34 Cooler Waterbox Vent Gear Inspection Cover 22 Cooler Relief Valves Not Shown 35 Condenser Waterbox Drain Economizer Gas Line to Compressor 23 Economizer Storage Vessel 36 Refrigerant Liquid Line to Open Drive Compressor Motor 24 Oil Cooler Economizer Storage Vessel Compressor Motor Terminal Box 25 Control Center 37 Condenser Waterbox Vent Coupling Guard 26 Economizer Storage Vessel Fig 3 Typical 17EX Installation 5 Pan VESSEL LENGTH NOTES 1 Each chain must be capable of supporting the maximum weight of the machine 2 e the approximate center of gravity 3 Maximum possible weight is 88 500 Ib 40 166 kg which includes a maxi mum of 6 000 Ib 2 721 kg of HFC 134a refrigerant in the storage tank 17EX FRONT VIEW LIFTING VESSEL MAXIMUM HEIGHT CENTER OF GRAVITY LENGTH WEIGHT BIETING CHAIN LENGTH FROM FLOOR APPROXIMATE LOCATION d ANGLE 5182 88 COOLER SIZE Ib kg Dos mm ien es fe mm Dese Fri Umm f mm es 35 19 s se oo eras 161 1902 135 4115 tem 5156 60 40 166 45 12 7 3895 T fesor 19 e17 169 5105 20 8 5299 41 1245 ot 2760 49 0 1730 sae 17 5207 2e9 7544 228 6909 27 3 5909 VESSEL LENGTH NOTES
48. r Gas Line to Compressor 22 Low Side Float Box Cover 34 Cooler 9 Gear Inspection Cover 23 Refrigerant Liquid Line to Cooler 35 High Side Float Box Cover 10 2 Stage Hermetic Compressor 24 Oil Drain and Charging Valve 36 Take Apart Connections 11 Condenser Waterbox Vent Not Shown 25 Oil Pump 37 Cooler Waterbox Vent 12 Condenser Marine Waterbox 26 Refrigerant Charging Service 38 Cooler Marine Waterbox 13 Hermetic Compressor Motor Valve 10 Not Shown 39 Cooler Waterbox Drain 14 Compressor Motor Terminal Box 40 Condenser Waterbox Drain Not Shown Fig 2 Typical 19EX Installation 4 COMPONENT DISASSEMBLY To Separate Compressor from the Machine 1 2 OONODOORUON Make sure to check that the machine is at atmospheric pressure before disassembly Since the center of gravity is high on 17EX machines the motor MUST be removed before rigging the machine Suction elbow should be rigged separately Fig 6 Item 2 Place slings around the elbow and attach to the hoist Remove bolting at flanges Fig 6 Items 1 and 3 Detach the elbow Unbolt discharge flange to the condenser at flange Fig 8 Item 3 Cut copper lines Fig 6 Items 7 8 and 9 Disconnect and detach the economizer vent line Fig 8 Item 4 Unbolt the line at flange Fig 8 Item 2 On 19EX machines disconnect the motor cooling drain line at flange Fig 8
49. rboxes located in the covers are 1 in FPT at the top of each box and the drains are 1 in FPT at the bottom Victaulic connections are standard Flanged waterbox connections are optional COOLER WATERBOX NOTES 1 Ao Frame 3 condenser available in 2 and 3 pass only Frame 5 condenser available in 2 pass only The vents for these waterboxes are 1 in FPT at the top of each box and the drains are 1 in FPT at the bottom Victaulic connections are standard Flanged waterbox connections are optional FRAME A MARINE WATERBOXES COMPRESSOR END NOTES 1 The vents for these waterboxes are 1 in FPT at the top of each box The drains are 1 in FPT at the bottom 2 Victaulic connections are standard 3 Flanged connections are optional COOLER WATERBOX DRIVE END Fig 13 Nozzle Arrangements cont PUMPOUT RELIEF STARTER PANEL VALVE WIRING BY CONTRACTOR CONDENSER WATER CONNECTIONS PIPING BY CONTRACTOR Fig 14 Pumpout Unit INSTALL WATER TO OIL COOLER ON FA COMPRE SORS On FA compressors water must be piped to the oil cooler heat exchanger located under the suction pipe to the compressor The water supply may be either city water or chilled water Pipe city water to an open sight drain Chilled water enters via the cooling entering water intake Fig 15 19 CAUTION City water must be clean and noncorrosive Water side eros
50. t use shielded cable Also connect the communications cable Make sure the control circuit is grounded in accordance with applicable electrical codes and instructions on chiller control wiring label Table 13 Relief Valve Locations and Data HEAT SE REQUIRED C FACTOR RATED RELIEF RELIEF VALVE NOMINAL OUTLET NUMBER OF PRESSURE LOCATION PIPE SIZE in VALVES kPa 2 1551 1 4 FPT 1551 Cooler 44 51 53 164 6 1 24 1 FPT 1551 1551 Economizer Storage 1551 Vessel 45 48 ALL 84 3 0 64 114 FPT 1551 Pumpout Unit Condenser 3 in Male Flare MPT 2655 To ensure relief valve serviceability and as required in ASHRAE 15 latest edition three way valves and redundant relief valves are in stalled on the storage vessel Only one half of the No of Valves listed are in service at any time NOTES 1 The cooler relief C factor is for both cooler and condenser vented through the cooler in accordance with ASHRAE American Society of Heating Refrigeration and Air Conditioning Engi neers 15 latest edition 21 2 Relief valve discharge pipe sizing is to be calculated per latest version of ASHRAE 15 using the tabulated C factors and nom inal pipe size listed above Cooler and economizer storage ves sel rated relief valve pressure is 225 psig 1551 kPa 3 The pumpout unit condenser contains less than 110 Ib 50 kg of HFC 134a which is a Group A1 refrigerant The ASHRAE 15 stand ard exempts small volume vessels fro
51. tion 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 2 and 3 Replace sensors after welding is complete 1 If the machine is a nozzle in head NIH arrangement offset pipe flanges to permit removal of waterbox cover for maintenance and to provide clearance for pipe clean ing See Tables 11 and 12 for waterbox cover weights No flanges are necessary with marine waterboxes how ever water piping should not cross in front of the water box or access will be blocked off 2 Provide openings in water piping for required pressure gages and thermometers Openings should be at least 6 to PRESSURE GAGES REQUIRED DIFFERENTIAL PRESSURE SWITCH TYPICAL INSTALLATION 10 pipe diameters from the waterbox nozzle For thor ough mixing and temperature stabilization wells in the leaving water pipe should extend inside pipe at least 2 in 50 mm Install air vents at all high points in piping to remove air and prevent water hammer Install pipe hangers where needed Make sure no weight or stress is placed on waterbox nozzles or flanges Water flow direction must be as specified in Fig 13 NOTE Entering water is always the lower of the 2 nozzles Leaving water is always the upper nozzle for cooler or condenser Water fl
52. ud EE RE DRAWINGS L3 23 0 LEGEND Factory Wiring Field Wiring Oil Pump Terminal Power Panel Component Terminal Fig 19 Oil Pump Wiring TO TO CHILLED WATER PUMP TO CONDENSER WATER PUMP TO COOLING TOWER FAN L DIFFERENTIAL PRESSURE JESWITCH FROM COOLING TOWER TO COOLER UN NOZZLE IN FROM COOLING LOAD 4 C OUT COOLING LOAD eJ Fej lel 7 h lt COOLER 1 2 3 NOZZLE 2 E oe 5 eooooooo9 DIFFERENTIAL PRESSURE SWITCH R OOLING FROM TOWER CONDENSER NOZZLE OUT mM TO CONDENSER NOZZLE IN M DRAIN 19EX SHOWN LEGEND NOTES 1 Wiring and piping shown are for general point of connection only 1 En Ge e and are not intended to show details for a specific installation Cer 3 Cooling Tower Fan Starter Cen wiring and dimensional diagrams are available on re S kondensor Water Pump 2 All wiring must comply with applicable codes 6 Disconnect p 3 Refer to Carrier System Design Manual for details regarding pip d ing techniques 7 Oil Pump Disconnect See Note 5 ng 8 Free Standing Compressor Motor Starter 4 Aing nol ee optional devices such as 9 Chiller Auxiliary Power Panel Remote Alarms p gt Piping Optional Safety De
53. vice Control Wiring 4 to 20 mA Resets Power Wiring Optional Remote Sensors Oil pump disconnect may be located within the enclosure of Item 8 Free Standing Compressor Motor Starter Water piping to the oil cooler is required on FA compressors Fig 20 17 19EX with Free Standing Starter 26 11i RED 1 BIK OIL HEATER 1200 W 13 mm LEGEND Field Wiring O Power Panel Component Terminal Fig 21 Oil Heater and Control Power Wiring NETWORK SENSOR BUS CONNECTOR CONNECTOR COMM 1 COMM 3 PROCESSOR MODULE Fig 22 Carrier Comfort Network Communication Bus Wiring CARRIER COMFORT NETWORK INTERFACE The Carrier Comfort Network CCN communication bus wiring is supplied and installed by the electrical contractor if re quired by jobsite prints It consists of shielded 3 conductor cable with drain wire The system elements are connected to the communication bus in a daisy chain arrangement The positive pin of each system element communication connector must be wired to the positive pins of the system element on either side of it The negative pins must be wired to the negative pins The signal ground pins must be wired to the signal ground pins See Fig 23 for location of the CCN network connector COMM1 on the processor module NOTE Conductors and drain wire must be 20 AWG American Wire Gage minimum stranded tinned copper In dividual
54. with a compressed spring Sudden release of the spring can cause it and objects in its path to act as projectiles 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 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
55. y 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 the machine s components during shipping A full operating oil charge is placed in the oil sump of the com pressor before shipment IDENTIFY MACHINE The machine model number serial number and heat exchanger sizes are stamped on machine identification nameplate Fig 1 Check this infor mation 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 17 19EX machine can be rigged as an entire assembly It also has flanged connec tions that allow the compressor utility vessel cooler and condenser sections to be separated for ease of installation Figures 2 and 3 show 17 19EX components RIG MACHINE ASSEMBLY See rigging instructions on label attached to machine Also refer to the rigging infor mation found in Fig 4 9 and Tables 1 12 Lift machine only from the 4 points indicated in rigging gui
56. ye Delta starting Minimum ampacity per conductor 0 721 x compressor RLA Lug adapters may be required if installation conditions dictate that conductors be sized beyond the minimum ampacity required Contact starter supplier for lug information Compressor motor and controls must be grounded by using equipment grounding lugs provided inside starter enclosure CONTROL WIRING 3 0 3 1 32 33 Field supplied control conductors to be at least 18 AWG or larger Chilled water and condenser water flow switch contacts optional remote start de vice 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 bifur cated contacts are recommended Remove jumper wire between 12A and 12B before connecting auxiliary safeties be tween these terminals Pilot relays can control cooler and condenser pump and tower fan motor 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 con trol transformer as the power source for pilot relay loads OPTIONAL REMOTE START DEVICE N O G GROUNDING LUGS PROVIDED COMPRESSOR MOTOR TERMINAL DETAILS 015 Y WIRING en Qv WIRING OUO
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