Carrier 19XR User's Manual

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Carrier 19XR User's Manual | Manualzz

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 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.

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 accumulation 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. 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 breathing. 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 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 functioning 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 disconnect before touching motor leads or terminals.

NEVER APPLY an open flame or live steam to a refrigerant cylinder.

Dangerous over pressure can result. When it is necessary to heat refrigerant, 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 emptied, 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/ASHRAE15 (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 pressure 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 operates in a corrosive 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 with a compressed spring.

Sudden release of the spring can cause it and objects in its path to act as projectiles.

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.

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. Follow 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 requirements of the original equipment.

DO NOT VENT OR DRAIN waterboxes containing industrial brines, liquid, gases, or semisolids without the permission of your process control 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 corrosion, 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.

Book 2

Tab 5a

PC 211 Catalog No. 531-940 Printed in U.S.A.

Form 19XR-2SI Pg 1 10-97 Replaces: 19XR-1SI

CONTENTS

Page

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . 1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Supports . . . . . . . . . . . . . . . . . . . . 17

• INSTALL STANDARD ISOLATION

• INSTALL ACCESSORY ISOLATION

• INSTALL SPRING ISOLATION

Connect Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

• INSTALL WATER PIPING TO HEAT

EXCHANGERS

• INSTALL VENT PIPING TO

RELIEF VALVES

Make Electrical Connections . . . . . . . . . . . . . . . . 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 piping, 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

Do not open any valves or loosen any connections. The standard 19XR machine is shipped with a full refrigerant charge. Some machines may be shipped with a nitrogen holding charge as an option.

1. Inspect for shipping damage while machine is still on shipping 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 notify the nearest Carrier representative if any item is missing.

3. To prevent loss or damage, leave all parts in original packages until beginning installation. All openings are closed with covers or plugs to prevent dirt and debris from entering machine components during shipping. A full operating 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 protective 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 remove 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 Tables 1-8B. Lift

machine only from the points indicated in rigging guide. Each lifting cable or chain must be capable of supporting the entire weight of the machine.

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 adequate for machine weight. See Fig. 3 and 4 for machine weights.

NOTE: These weights are broken down into component sections for use when installing the unit in sections. For the complete machine weight, add all component 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 before lifting if cooler size is 10 through 67.

2

Fig. 1 — Model Number Identification

3

FRONT TOP VIEW

BOTTOM REAR 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 — Refrigerant Charging Valve

15 — Guide Vane Actuator

16 — Compressor/Transmission

17 — Oil Drain/Charging Valve

18 — Oil Pump

19 — Auxillary Power Panel

20 — Oil Filter Isolation Valve

21 — Oil Filter

22 — Motor

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

4

COMPRESSOR

FRAME SIZE*

COOLER

SIZE

15-17

20-22

30-32

35-37

40-42

45-47

50-52

55-57

50-52

55-57

60-62

MAXIMUM

WEIGHT (lb)

19,000

19,500

21,000

22,500

29,700

31,800

32,200

33,200

32,530

34,230

39,950

VESSEL

LENGTH

12 8

14

8

12 8

14

8

12 8

14

8

10

8

12

8

10

8

12

8

14

8

12

8

14

8

DIM. ‘‘A’’

CHAIN LENGTH

‘‘B’’ ‘‘C’’

2

2 or 3

3

4

10-12

65-67

18,500

36,950

4

8

- 7

9

5

8

- 9

9

4

8

- 7

9

5

8

- 9

9

7

8

- 4

9

5

8

- 9

9

6

8

-10

9

5 8 - 9 9

6

8

-10

9

5 8 - 9 9

6

8

- 2

9

5 8 - 9 9

6

8

- 2

9

*The first digit of the 3-digit compressor code indicates the frame size of the compressor.

‘‘D’’

12

8

-7

9

13

8

-0

9

13

8

-0

9

13

8

-6

9

13

8

-2

9

13

8

-3

9

12

8

-7

9

13

8

-0

9

13

8

-0

9

13

8

-6

9

13

8

-2

9

13

8

-3

9

14

8

-2

9

13

8

-4

9

13

8

-4

9

12

8

-8

9

12

8

-8

9

13

8

-4

9

13

8

-1

9

13

8

-2

9

13

8

-8

9

12 8 -7 9 12 8 -9 9 13 8 -5 9

13

8

-1

9

18

8

-3

9

15

8

-9

9

13 8 -1 9 12 8 -9 9 13 8 -4 9

13

8

-7

9

13

8

-1

9

14

8

-4

9

13 8 -1 9 12 8 -9 9 13 8 -4 9

13

8

-7

9

13

8

-1

9

14

8

-4

9

DIM. ‘‘E’’ DIM. ‘‘F’’

2

3

3

3

3

8

8

8

8

8

-3

-1

-6

-2

-4

9

9

9

9

9

2

2

2

2

2

8

8

8

8

8

-6

-4

-6

-7

-8

9

9

9

9

9

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

8 lifting height. Some minor adjustments may be required.

Fig. 3 — Machine Rigging Guide (Cooler Size 10 Through 67)

5

COMPRESSOR

FRAME SIZE*

4

5

COOLER

SIZE

70-72

75-77

70-72

75-77

80-82

85-87

MAXIMUM

WEIGHT (lb)

40,410

44,210

45,600

49,400

54,900

58,300

VESSEL

LENGTH

14

16

8

14

8

16

8

14

8

16

8

8

DIM. ‘‘A’’

6

8

- 6

9

7

8

- 5

9

6

8

- 2

9

6

8

-11

9

6

8

- 2

9

6 8 -11 9

DIM. ‘‘B’’

3

8

-4

3

8

-5

9

3

8

-6

9

3

8

-6

9

3

8

-6

9

3 8 -6

9

9

DIM. ‘‘C’’

3

8

-5

9

3

8

-5

9

3

8

-7

9

3

8

-6

9

3

8

-7

9

3 8 -6 9

*The first digit of the 3-digit compressor code indicates the frame size of the compressor.

CHAIN LENGTH

‘‘D’’ ‘‘E’’ ‘‘F’’

11

8

-6

9

12

8

-5

9

12

8

-9

9

12

8

-0

9

13

8

-3

9

13

8

-6

9

11

8

-6

9

12

8

-5

9

12

8

-9

9

12

8

-0

9

13

8

-3

9

13

8

-6

9

11

8

-6

9

12

8

-5

9

12

8

-9

9

12 8 -0 9 13 8 -3 9 13 8 -6 9

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

8 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)

6

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)

14'-3" (4343 mm)

(SIZES 35-37, 45-47,

55-57, 65-67)

14'-0" (4267 mm)

(SIZES 70-72,

80-82)

16'-0" (4877 mm)

(SIZES 75-77,

85-87)

MOTOR SERVICE

CLEARANCE

4'0"- (1219 mm)

3'0" (915 mm)

RECOMMENDED OVERHEAD

SERVICE CLEARANCE

C

A

2' MIN

(610 mm)

SERVICE AREA

Fig. 5 — 19XR Dimensions (Refer to Tables 1 Through 3)

B

2'-6 1 /

8

" MIN

(362 mm)

Table 1 — 19XR Dimensions (Nozzle-In-Head Waterbox)

HEAT EXCHANGER

SIZE

10 to 12

15 to 17

20 to 22

30 to 32

35 to 37

40 to 42

45 to 47

50 to 52

55 to 57

60 to 62

65 to 67

70 to 72

75 to 77

80 to 82

85 to 87

13-11

15- 7 1 ⁄

2

13-11 1 ⁄

4

15- 7 3 ⁄

4

13-11 3 ⁄

4

15- 8 1 ⁄

4

16- 4

18- 4

16- 4 3 ⁄

4

18- 4 3 ⁄

4

A (Length, with Nozzle-in-Head Waterbox)

2-Pass* 1 or 3 Pass† ft-in.

11- 3 7 ⁄

8 mm

3451 ft-in.

11-10 3 ⁄

4 mm

3626

13- 7 3 ⁄

8

11- 5 1 ⁄

8

13- 8 1 ⁄

4

15- 4 3 ⁄

4

4150

3483

4172

4693

14- 2

12- 0

14- 3

15-11

1

1

1

3

4

2

4

4

4324

3670

4350

4870

4242

4763

4248

4769

4261

4782

4978

5588

4997

5607

14- 6

16- 2

14- 6

16- 3

14- 7

16- 3

17- 0

19- 0

17- 1

19- 1

1

3

3

1

1

3

1

1

1

1

4

4

4

4

4

4

2

2

2

2

5804

5220

5829

4426

4947

4439

4959

4451

4972

5194

B (Width)

6- 6 1 ⁄

2

6- 6 1 ⁄

2

6-10 1 ⁄

2

6-10 1 ⁄

2

7-11 1 ⁄

2

7-11 1 ⁄

2

8-10 3 ⁄

4

8-10 3 ⁄

4 ft-in.

4-11 3 ⁄

4

4-11 3 ⁄

4

5- 5 3 ⁄

4

5- 5 3 ⁄

4

5- 5 3 ⁄

4

6- 2

6- 2

1994

1994

2096

2096

2426

2426

2711

2711 mm

1518

1518

1670

1670

1670

1880

1880

C (Height)

7- 2 7 ⁄

8

7- 2 7 ⁄

8

7- 4 7 ⁄

8

7- 4 7 ⁄

8

9- 9 1 ⁄

2

9- 9 1 ⁄

2

9-11 1 ⁄

4

9-11 1 ⁄

4 ft-in.

6- 1 1 ⁄

4

6- 1 1 ⁄

4

6- 3 1 ⁄

4

6- 9 5 ⁄

8

6- 9 5 ⁄

8

7- 0 3 ⁄

4

7- 0 3 ⁄

4

2207

2207

2257

2257

2985

2985

3029

3029 mm

1861

1861

1911

2073

2073

2153

2153

*Assumes both cooler and condenser nozzles on same end of chiller.

†1 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 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.

7

Table 2 — 19XR Dimensions (Marine Waterbox)

A (Length, Marine Waterbox — not shown)

HEAT EXCHANGER

SIZE 2-Pass* 1 or 3 Pass†

10 to 12

15 to 17

20 to 22

30 to 32

35 to 37

40 to 42

45 to 47

50 to 52

55 to 57

60 to 62

65 to 67

70 to 72

75 to 77

80 to 82

85 to 87 ft-in.

NA

NA

12- 6 5 ⁄

8

14- 9

16- 5 1 ⁄

2

15- 0 1 ⁄

4

16- 8 3 ⁄

4

15- 0 1 ⁄

4

16- 8 3 ⁄

4

15- 0 3 ⁄

4

16- 9 1 ⁄

4

17- 8

19- 8

17- 8 1 ⁄

2

19- 8 1 ⁄

2 mm

NA

NA

3826

4496

5017

4591

5099

4591

5099

4591

5112

5385

5994

5398

6007 ft-in.

NA

NA

14- 3

16- 4 3 ⁄

4

18- 1 1 ⁄

4

16- 8 3 ⁄

4

18- 5 1 ⁄

4

16- 8 3 ⁄

4

18- 5 1 ⁄

4

16- 9 1 ⁄

4

18- 5 3 ⁄

4

19-10 1 ⁄

2

21-10 1 ⁄

2

20- 1

22- 1 mm

NA

NA

4343

4997

5518

5099

5620

5099

5620

5111

5632

6058

6668

6121

6731

*Assumes both cooler and condenser nozzles on same end of chiller.

†1 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.

FRAME

SIZE

6

7

4

5

8

1

2

3

1-Pass

8

10

10

10

10

10

14

14

Table 3 — 19XR Nozzle Size

NOZZLE SIZE (in.)

(Nominal Pipe Size)

Cooler

2-Pass

6

8

8

8

8

10

12

14

3-Pass

6

6

6

8

10

6

6

12

1-Pass

8

10

10

10

10

10

14

14

Condenser

2-Pass

6

8

10

8

8

10

12

14

3-Pass

6

6

6

8

12

6

8

12

8

Table 4 — 19XR Compressor Weights

MOTOR

CODE

CQ

DB

DC

DD

CL

CM

CN

CP

DE

DF

DG

BD

BE

BF

BG

BH

CD

CE

EK

EL

EM

EN

EP

DH

DJ

EH

EJ

6,412

6,466

8,025

11,085

11,160

11,181

11,271

11,335

11,434

4,710

4,737

4,751

4,806

4,874

6,112

6,138

6,216

6,224

6,274

6,364

ENGLISH

Total Compressor Weight*

(lb)

60 Hz 50 Hz

3,755

3,805

3,870

3,950

3,950

4,659

4,685

3,755

3,805

3,870

3,950

3,950

4,756

4,771

6,868

6,977

11,135

11,265

11,282

11,435

11,435

11,635

11,605

4,842

4,868

4,883

4,898

4,898

6,158

6,224

6,262

6,351

6,412

6,466

*Compressor weight is comprised of compressor, stator, rotor, end bell, suction elbow, and discharge elbow.

NOTE: For medium voltage motors (over 600 v), add 490 lb (222 kg).

2908

2933

3640

5028

5062

5072

5113

5142

5186

2137

2149

2156

2181

2211

2772

2822

2819

2823

2846

2886

SI

Total Compressor Weight*

(kg)

60 Hz 50 Hz

1703

1726

1755

1792

1792

2134

2155

1703

1726

1755

1792

1792

2153

2165

3115

3165

5051

5110

5118

5187

5187

5278

5264

2167

2209

2215

2212

2212

2793

2823

2840

2881

2908

2933

Table 5 — 19XR Component Weights

COMPONENT

Suction Elbow

Discharge Elbow

Control Cabinet*

Optional Unit-Mounted Starter†

Optional Isolation Valves

FRAME 2

COMPRESSOR lb

50 kg

23

60

30

800

115

27

14

363

52

FRAME 3

COMPRESSOR lb

54

46

30

800

115 kg

24

21

14

363

52

*Included in total cooler weight.

†Weight of optional factory-mounted starter is not included and must be added to the heat exchanger weight.

FRAME 4

COMPRESSOR lb

175 kg

79

157

30

800

115

71

14

363

52

FRAME 5

COMPRESSOR lb

210 kg

95

140

30

800

115

63

14

363

52

9

Table 6 — 19XR Heat Exchanger Data

46

47

50

51

40

41

42

45

52

55

56

57

60

22

30

31

32

35

36

37

16

17

20

21

10

11

12

15

81

82

85

86

87

75

76

77

80

67

70

71

72

61

62

65

66

5,898

6,080

6,244

6,353

6,561

6,748

7,015

7,262

7,417

7,559

7,839

8,016

8,270

3,746

4,137

4,319

4,511

4,409

4,617

4,835

2,742

2,812

2,883

3,003

3,089

3,176

3,442

3,590

13,293

13,780

14,159

16,156

16,530

16,919

17,296

17,723

18,169

8,462

8,617

8,943

9,161

9,338

12,395

12,821

13,153

6,054

6,259

6,465

6,617

6,851

7,085

7,285

7,490

7,683

7,990

8,214

8,434

8,286

3,854

3,694

3,899

4,100

4,606

4,840

5,069

2,704

2,772

2,857

2,984

3,068

3,173

3,523

3,690

14,211

14,702

15,160

15,746

16,176

16,606

17,001

17,492

17,984

8,483

8,676

9,204

9,428

9,648

13,139

13,568

13,969

CODE

Dry Rigging Weight

(lb)

Cooler

Only

Condenser

Only

ENGLISH

Machine Charge

Dry Rigging Weight

(kg)

1365

1505

1625

1500

1620

1730

1690

1820

1940

980

1020

1020

1060

1090

1220

1340

1440

560

630

690

640

720

790

750

840

900

870

940

980

940

Refrigerant

Weight

Water Volume

(gal)

Cooler Condenser Cooler Condenser

290 200 34 42

310 200 37 45

330

320

340

370

345

385

435

350

420

490

400

480

550

200

250

250

250

225

225

225

260

260

260

310

310

310

40

39

43

47

48

55

62

55

64

72

61

70

80

65

74

62

72

83

48

55

63

55

49

48

52

57

280

280

280

330

330

330

400

400

400

490

490

490

420

89

97

105

98

108

116

115

126

133

127

139

147

144

96

106

114

106

117

127

128

137

136

142

152

162

159

925

925

925

720

720

720

860

860

860

420

420

510

510

510

780

780

780

245

266

283

285

302

319

313

331

351

153

160

160

169

177

224

243

257

234

257

278

264

284

304

295

318

341

168

177

176

187

197

209

229

248

Cooler

Only

2675

2757

2832

2881

2976

3060

3181

3293

3364

3428

3555

3635

3751

1699

1877

1959

2046

2000

2094

2193

1244

1276

1308

1362

1401

1441

1561

1628

6030

6251

6423

7328

7498

7674

7845

8039

8241

3838

3908

4056

4155

4235

5622

5816

5966

Condenser

Only

2746

2839

2933

3001

3108

3214

3304

3397

3484

3624

3725

3825

3758

1748

1676

1769

1860

2089

2195

2299

1227

1257

1296

1354

1392

1439

1598

1674

6446

6669

6877

7142

7337

7532

7712

7934

8158

3847

3935

4174

4276

4376

5960

6154

6336

SI

Machine Charge

619

683

737

680

735

785

767

826

880

445

463

463

481

494

553

608

653

254

286

313

290

327

358

340

381

408

395

426

445

426

Refrigerant

Weight

Water

Volume

Cooler Condenser Cooler Condenser

132 91 129 158

141 91 140 170

150

145

154

168

156

175

197

159

190

222

181

218

249

91

113

113

113

102

102

102

118

118

118

141

141

141

152

149

163

178

183

207

234

208

242

271

232

266

301

185

183

198

216

181

210

239

210

246

282

233

273

314

127

127

127

150

150

150

181

181

181

222

222

222

190

338

368

396

372

407

438

435

477

502

481

527

557

546

365

400

433

403

442

481

483

518

552

536

575

613

601

420

420

420

327

327

327

390

390

390

190

190

231

231

231

354

354

354

927

1009

1072

1080

1143

1208

1183

1254

1329

578

604

605

641

671

848

919

974

885

971

1052

1000

1075

1150

1118

1205

1291

636

669

668

707

745

791

867

937

*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, and 1 ⁄

2 the distribution piping weight.

2. Condenser includes float valve and sump, discharge elbow, and 1 ⁄

2 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

Table 7 — 19XR Additional Data for Marine Waterboxes*

HEAT EXCHANGER

FRAME, PASS

FRAME 2, 1 AND 2 PASS

FRAME 2, 2 PASS

FRAME 3, 1 AND 2 PASS

FRAME 3, 2 PASS

FRAME 4, 1 AND 3 PASS

FRAME 4, 2 PASS

FRAME 5, 1 AND 3 PASS

FRAME 5, 2 PASS

FRAME 6, 1 AND 3 PASS

FRAME 6, 2 PASS

FRAME 7, 1 AND 3 PASS

FRAME 7, 2 PASS

FRAME 8, 1 AND 3 PASS

FRAME 8, 2 PASS

FRAME 2, 1 AND 3 PASS

FRAME 2, 2 PASS

FRAME 3, 1 AND 3 PASS

FRAME 3, 2 PASS

FRAME 4, 1 AND 3 PASS

FRAME 4, 2 PASS

FRAME 5, 1 AND 3 PASS

FRAME 5, 2 PASS

FRAME 6, 1 AND 3 PASS

FRAME 6, 2 PASS

FRAME 7, 1 AND 3 PASS

FRAME 7, 2 PASS

FRAME 8, 1 AND 3 PASS

FRAME 8, 2 PASS

Psig

300

300

300

300

300

300

300

300

300

150

150

300

300

300

300

300

150

150

150

150

150

150

150

150

150

150

150

150

ENGLISH

Rigging Weight

(lb)

730

365

730

365

1060

530

1240

620

600

1380

690

1650

825

3100

2295

2745

1630

1500

750

2010

740

1855

585

860

430

860

430

1210

61

139

69

162

81

326

163

405

203

406

203

84

42

84

42

123

Water Volume

(gal)

84

42

84

42

123

61

139

69

162

81

326

163

*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).

kPa

2068

2068

2068

2068

2068

2068

2068

2068

2068

1034

1034

2068

2068

2068

2068

2068

1034

1034

1034

1034

1034

1034

1034

1034

1034

1034

1034

1034

SI

Rigging Weight

(kg)

331

166

331

166

481

240

562

281

272

626

313

748

374

1406

1041

1245

739

680

340

912

336

841

265

390

195

390

195

549

231

526

263

612

306

1234

617

1533

768

1537

768

318

159

317

159

465

Water Volume

(L)

318

159

317

159

465

231

526

263

612

306

1234

617

11

HEAT

EXCHANGER

COOLER/

CONDENSER

HEAT

EXCHANGER

COOLER/

CONDENSER

HEAT

EXCHANGER

COOLER/

CONDENSER

Table 8A — 19XR Waterbox Cover Weights

ENGLISH (lb)

WATERBOX

DESCRIPTION

NIH, 1 Pass Cover, 150 psig

NIH, 2 Pass Cover, 150 psig

NIH, 3 Pass Cover, 150 psig

NIH/MWB End Cover, 150 psig

NIH, 1 Pass Cover, 300 psig

NIH, 2 Pass Cover, 300 psig

NIH, 3 Pass Cover, 300 psig

NIH/MWB End Cover, 300 psig

FRAME 1

Standard

Nozzles

Flanged

177

185

180

204

218

196

136

248

255

253

175

136

301

324

288

175

FRAME 2

Standard

Nozzles

Flanged

320

320

300

350

350

340

300

411

411

433

400

300

486

518

468

400

WATERBOX

DESCRIPTION

NIH, 1 Pass Cover, 150 psig

NIH, 2 Pass Cover, 150 psig

NIH, 3 Pass Cover, 150 psig

NIH/MWB End Cover, 150 psig

NIH, 1 Pass Cover, 300 psig

NIH, 2 Pass Cover, 300 psig

NIH, 3 Pass Cover, 300 psig

NIH/MWB End Cover, 300 psig

WATERBOX

DESCRIPTION

NIH, 1 Pass Cover, 150 psig

NIH, 2 Pass Cover, 150 psig

NIH, 3 Pass Cover, 150 psig

NIH/MWB End Cover, 150 psig

NIH, 1 Pass Cover, 300 psig

NIH, 2 Pass Cover, 300 psig

NIH, 3 Pass Cover, 300 psig

NIH/MWB End Cover, 300 psig

FRAME 4

Standard

Nozzles

Flanged

485

487

521

540

504

379

593

594

621

569

520

379

668

700

656

569

FRAME 7 COOLER

Standard

Nozzles

1392

1345

1434

1022

1985

1934

2009

1567

Flanged

1469

1461

1471

1022

2150

2174

2090

1567

FRAME 5

Standard

Nozzles

Flanged

616

590

652

663

629

428

764

761

795

713

655

428

655

839

838

713

FRAME 7 CONDENSER

Standard

Nozzles

Flanged

1205

1163

1222

920

1282

1279

1280

920

1690

1628

1714

1923

1851

1862

1831

1923

FRAME 3

Standard

Nozzles

Flanged

320

320

300

350

350

340

300

411

411

433

400

300

486

518

468

400

FRAME 6

Standard

Nozzles

Flanged

802

770

838

843

817

583

880

844

901

833

843

583

956

995

952

833

HEAT

EXCHANGER

WATERBOX

DESCRIPTION

COOLER/

CONDENSER

NIH, 1 Pass Cover, 150 psig

NIH, 2 Pass Cover, 150 psig

NIH, 3 Pass Cover, 150 psig

NIH/MWB End Cover, 150 psig

NIH, 1 Pass Cover, 300 psig

NIH, 2 Pass Cover, 300 psig

NIH, 3 Pass Cover, 300 psig

NIH/MWB End Cover, 300 psig

LEGEND

NIH Nozzle-in-Head

MWB — Marine Waterbox

FRAME 8 COOLER

Standard

Nozzles

Flanged

1831

1739

1851

1480

2690

2595

2698

1440

1909

1893

1909

1480

2854

2924

2861

1440

FRAME 8 CONDENSER

Standard

Nozzles

1682

1589

1702

1228

2394

2269

2417

1767

Flanged

1760

1744

1761

1228

2549

2578

2529

1767

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 component disassembly.

IMPORTANT: Only a qualified service technician should perform this operation.

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.

Before rigging the compressor, disconnect all wires entering the power panel.

12

HEAT

EXCHANGER

COOLER/

CONDENSER

HEAT

EXCHANGER

COOLER/

CONDENSER

HEAT

EXCHANGER

COOLER/

CONDENSER

Table 8B — 19XR Waterbox Cover Weights

SI (kg)

WATERBOX

DESCRIPTION

NIH, 1 Pass Cover, 150 psig

NIH, 2 Pass Cover, 150 psig

NIH, 3 Pass Cover, 150 psig

NIH/MWB End Cover, 150 psig

NIH, 1 Pass Cover, 300 psig

NIH, 2 Pass Cover, 300 psig

NIH, 3 Pass Cover, 300 psig

NIH/MWB End Cover, 300 psig

FRAME 1

Standard

Nozzles

Flanged

80

84

82

93

99

89

62

112

116

115

79

62

137

147

131

79

FRAME 2

Standard

Nozzles

Flanged

145

145

136

159

159

154

136

186

186

196

181

136

220

235

212

181

WATERBOX

DESCRIPTION

NIH, 1 Pass Cover, 150 psig

NIH, 2 Pass Cover, 150 psig

NIH, 3 Pass Cover, 150 psig

NIH/MWB End Cover, 150 psig

NIH, 1 Pass Cover, 300 psig

NIH, 2 Pass Cover, 300 psig

NIH, 3 Pass Cover, 300 psig

NIH/MWB End Cover, 300 psig

WATERBOX

DESCRIPTION

NIH, 1 Pass Cover, 150 psig

NIH, 2 Pass Cover, 150 psig

NIH, 3 Pass Cover, 150 psig

NIH/MWB End Cover, 150 psig

NIH, 1 Pass Cover, 300 psig

NIH, 2 Pass Cover, 300 psig

NIH, 3 Pass Cover, 300 psig

NIH/MWB End Cover, 300 psig

FRAME 4

Standard

Nozzles

Flanged

220

221

236

245

229

172

269

269

282

258

236

172

303

318

298

258

FRAME 7 COOLER

Standard

Nozzles

631

610

650

464

900

877

911

711

Flanged

666

663

667

464

975

986

948

711

FRAME 5

Standard

Nozzles

Flanged

279

268

296

301

285

194

347

345

361

323

297

194

381

398

380

323

FRAME 7 CONDENSER

Standard

Nozzles

Flanged

547

528

554

417

582

580

581

417

767

738

777

872

840

845

831

872

FRAME 3

Standard

Nozzles

Flanged

145

145

140

159

159

154

136

186

186

196

181

136

220

235

212

181

FRAME 6

Standard

Nozzles

Flanged

364

349

380

382

371

265

399

383

409

378

381

265

434

451

432

378

HEAT

EXCHANGER

WATERBOX

DESCRIPTION

COOLER/

CONDENSER

NIH, 1 Pass Cover, 150 psig

NIH, 2 Pass Cover, 150 psig

NIH, 3 Pass Cover, 150 psig

NIH/MWB End Cover, 150 psig

NIH, 1 Pass Cover, 300 psig

NIH, 2 Pass Cover, 300 psig

NIH, 3 Pass Cover, 300 psig

NIH/MWB End Cover, 300 psig

LEGEND

NIH Nozzle-in-Head

MWB — Marine Waterbox

FRAME 8 COOLER

Standard

Nozzles

Flanged

831

789

840

671

1220

1177

1224

653

866

859

866

671

1295

1326

1298

653

FRAME 8 CONDENSER

Standard

Nozzles

763

721

772

557

1086

1029

1096

802

Flanged

798

791

799

557

1156

1169

1147

802

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 separated, the heat exchangers should be kept level by placing a support plate under the tube sheets. The support plate will also help to keep the vessels level and aligned when the vessels are bolted back together.

NOTE: Wiring must also be disconnected. Label each wire before removal (see Carrier Certified Prints). In order to disconnect the starter from the machine, remove wiring for the oil pump, oil heater, control wiring at the power panel, and the main motor leads at the starter lugs.

Remove all transducer and sensor wires at the sensor. Clip all wire ties necessary to pull heat exchangers apart.

To Separate Cooler and Condenser:

1. Place a support plate under each tube sheet to keep each vessel level (Fig. 6, Item 6).

2. Cut the refrigerant motor cooling line at the location shown

(Fig. 6, Item 7).

13

3. Disconnect the compressor discharge elbow at the compressor (Fig. 7, Item 3).

4. Cut the hot gas bypass line at the location shown (Fig. 6,

Item 1).

5. Unbolt the cooler liquid feed line at the location shown

(Fig. 6, Item 10).

6. Cover all openings.

7. 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) c. 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).

8. Disconnect the rabbet-fit connectors on the tube sheets

(Fig. 6, Item 5).

9. Rig the vessels apart.

To Separate the Compressor from the Cooler:

1. Unbolt the compressor suction elbow at the cooler flange

(Fig. 6, Item 2).

2. Cut the refrigerant motor cooling line at the location shown

(Fig. 6, Item 7).

3. Disconnect the motor refrigerant return line (Fig. 6,

Item 8).

4. Disconnect the following: a. compressor oil sump temperature sensor cable

(Fig. 8, Item 4) b. bearing temperature sensor cable (Fig. 8, Item 2).

c. 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) 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)

5. Disconnect the flared fitting for the oil reclaim line

(Fig. 6, Item 3).

6. Unbolt the compressor discharge elbow (Fig. 7, Item 3).

7. Cover all openings.

8. Disconnect motor power cables at the starter lugs

(Fig. 6, Item 4).

9. Unbolt the compressor mounting from the cooler

(Fig. 6, Item 9).

10. Rig the compressor.

1 — Optional Hot Gas Bypass (Cut)

2 — Compressor Suction Elbow (Unbolt)

3 — Oil Reclaim Line (Unbolt)

4 — Starter Connector (Unbolt)

5 — Vessel Connectors (Unbolt)

6 — Tube Sheet

7 — Refrigerant Motor Cooling Line (Cut)

8 — Motor Drain (Unbolt)

9 — Compressor Mounting (Unbolt)

10 — Cooler Liquid Feed Line (Unbolt)

Fig. 6 — Cooler, Side View

14

1 — Guide Vane Actuator Cable

2 — Power Panel to Starter Cables (Oil Pump Power,

Control Power, and Communication)

3 — Compressor Discharge Elbow Joints

4 — Condenser Transducer Cable

Fig. 7 — 19XR Chiller Top View

1 — Motor Temperature Sensor Cable

2 — Bearing Temperature Sensor Cable

Connection (Inside Box)

3 — Compressor Oil Sump Pressure Cable

4 — Compressor Oil Sump Temperature

Sensor Cable

5 — Compressor Oil Discharge Pressure Cable

6 — Discharge Temperature Sensor Cable

Fig. 8 — Compressor Detail

15

1 — Guide Vane Actuator

2 — Diffuser Actuator

3 — Water Temperature Sensor Cables

Fig. 9 — Chiller End View

16

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. × 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 fixed 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.

INSTALL ACCESSORY ISOLATION (if required) — Uneven floors or other considerations may dictate the use of accessory soleplates (supplied by Carrier for field installation) and leveling pads. Refer to Fig. 10 and 12.

Level machine by using jacking screws in isolation soleplates. 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 instructions, before starting machine.

5. Remove jacking screws from leveling pads after grout has hardened.

HEAT EXCHANGER

SIZE

10-12

15-17

20-22

30-32

35-37

40-42

45-57

50-52

55-57

60-62

65-67

70-72

75-77

80-82

85-87

A

DIMENSIONS (ft-in.)

B

10- 7 1 ⁄

4

12-10 3 ⁄

4

4-11

4-11

1

1

4

4

10- 7 1 ⁄

4

12-10 3 ⁄

4

14- 7 1 ⁄

4

12-10 3 ⁄

4

5- 5

5- 4

5- 4

6- 0

1

1

1

4

4

4

14- 7 1 ⁄

4

12-10 3 ⁄

4

14- 7 1 ⁄

4

12-10 3 ⁄

4

14- 7 1 ⁄

4

15- 1 7 ⁄

8

17- 1 7 ⁄

8

15- 1 7 ⁄

8

17- 1 7 ⁄

8

6- 0

6- 5 1 ⁄

2

6- 5 1 ⁄

2

6- 9 1 ⁄

2

6- 9 1 ⁄

2

7-10 1 ⁄

2

7-10 1 ⁄

2

8- 9 3 ⁄

4

8- 9 3 ⁄

4

Fig. 10 — 19XR Machine Footprint

17

INSTALL SPRING ISOLATION — Spring isolation may be purchased as an accessory from Carrier for field installation. It may also be field supplied and installed. Spring isolators 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 isolation assemblies can be field supplied to keep the machine at a convenient working height.

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.

NOTES:

1. Dimensions in ( ) are in millimeters.

2. Isolation package includes 4 shear flex pads.

VIEW Y-Y

Fig. 11 — Standard Isolation

ACCESSORY SOLEPLATE DETAIL

VIEW X-X

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.

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 8 -1 1 ⁄

2

9 (38.1) to 0 8 -2 1 ⁄

4

9 (57) thick.

Fig. 12 — Accessory Isolation

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 procedures outlined below. A typical piping installation is shown in Fig. 14.

Factory-supplied insulation is not flammable but can be damaged by welding sparks and open flame. Protect insulation with a wet canvas cover.

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 of waterbox cover for maintenance and to provide clearance for pipe cleaning. No flanges are necessary with marine waterbox option; however, water piping should not cross in front of the waterbox or access will be blocked.

2. Provide openings in water piping for required pressure gages and thermometers. For thorough mixing and temperature 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 any bend.

7. Install waterbox vent and drain piping in accordance with individual job data. All connections are 3 ⁄

4

-in. FPT.

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.

*

LEGEND

COM — Common

N.O.

Normally Open

*Do not tap connections after shutoff valve.

Fig. 14 — Typical Nozzle Piping

*

19

NOZZLE-IN HEAD WATERBOXES

FRAMES 1, 2, AND 3

FRAMES 4, 5, AND 6

PASS

1

2

3

In

8

5

7

4

7

4

*Refer to certified drawings.

NOZZLE ARRANGEMENT CODES FOR ALL 19XR NOZZLE-IN-HEAD WATERBOXES

COOLER WATERBOXES

Out

5

8

9

6

6

9

Arrangement

Code*

A

B

C

D

E

F

PASS

1

2

3

In

11

2

10

1

10

1

CONDENSER WATERBOXES

Out

Arrangement

Code*

2

11

12

3

3

12

P

Q

R

S

T

U

Fig. 15 — Piping Flow Data (NIH, Frames 1 Through 6)

20

NOZZLE-IN-HEAD WATERBOXES

FRAMES 7 AND 8

NOZZLE ARRANGEMENT CODES FOR ALL 19XR NOZZLE-IN-HEAD WATERBOXES

PASS

1

2

3

In

4

7

4

8

5

7

*Refer to certified drawings.

COOLER WATERBOXES

Out

Arrangement

Code*

A 5

8

9

6

6

9

B

C

D

E

F

PASS

1

2

3

In

1

10

1

11

2

10

CONDENSER WATERBOXES

Out

Arrangement

Code*

P 2

11

12

3

3

12

Q

R

S

T

U

Fig. 16 — Piping Flow Data (NIH, Frames 7 and 8)

21

MARINE WATERBOXES

FRAMES 2 AND 3*

*There is no Frame 1 marine waterbox.

PASS

1

2

3

NOZZLE ARRANGEMENT CODES

In

4

7

4

8

5

7

COOLER WATERBOXES

Out

Arrangement

Code

A 5

8

9

6

6

9

B

C

D

E

F

In

1

10

CONDENSER WATERBOXES

Out

Arrangement

Code

— —

12

3

R

S

Fig. 17 — Piping Flow Data (MWB, Frames 2 and 3)

22

MARINE WATERBOXES (cont)

FRAMES 4, 5, AND 6

PASS

1

2

3

In

7

4

9

6

7

4

NOZZLE ARRANGEMENT CODES

COOLER WATERBOXES

Out

9

6

6

9

6

9

Arrangement

Code

A

B

C

D

E

F

In

CONDENSER WATERBOXES

Out

Arrangement

Code

10

1

12

3

R

S

FRAMES 7 AND 8

PASS

1

2

3

NOZZLE ARRANGEMENT CODES

In

4

7

4

8

5

7

COOLER WATERBOXES

Out

Arrangement

Code

A 5

8

9

6

6

9

B

C

D

E

F

In

10

1

CONDENSER WATERBOXES

Out

Arrangement

Code

— —

12

3

R

S

Fig. 18 — Piping Flow Data (MWB, Frames 4 Through 8)

23

FRAME

SIZE

1

2

3

4

5

6

7

8

PRESSURE psig (kPa)

150/300

(1034/2068)

150/300

(1034/2068)

150/300

(1034/2068)

150/300

(1034/2068)

150/300

(1034/2068)

150/300

(1034/2068)

150

(1034)

300

(2068)

150

(1034)

300

(2068)

PASS

1

2

3

1

2

3

1

2

3

1

2

3

1

2

3

1

2

3

1

2

3

1

2

3

1

2

3

1

2

3

Table 9 — 19XR Waterbox Nozzle Sizes

14

12

10

14

12

10

14

14

12

14

14

12

10

8

6

10

10

8

10

8

6

10

8

6

NOMINAL PIPE SIZE (in.)

Cooler

8

6

6

10

8

6

Condenser

8

6

6

10

8

6

10

10

8

10

10

8

10

8

6

10

8

6

14

12

12

14

12

12

14

14

12

14

14

12

13.250

12.000

10.020

12.500

11.376

9.750

13.250

13.250

12.000

12.500

12.500

11.376

ACTUAL PIPE ID (in.)

Cooler

7.981

6.065

6.065

10.020

7.981

6.065

Condenser

7.981

6.065

6.065

10.020

7.981

6.065

10.020

7.981

6.065

10.020

7.981

6.065

10.020

7.981

6.065

10.020

10.020

7.981

10.020

7.981

6.065

10.020

7.981

6.065

10.020

10.020

7.981

10.020

10.020

7.981

13.250

12.000

12.000

12.500

11.750

11.750

13.250

13.250

12.000

12.500

12.500

11.376

24

DIMENSIONS

ENGLISH (ft-in.)

TANK

SIZE

A B C D E F G H J K L M N P R S T

0428 10- 5 9-10 4-9 2-4 3 ⁄

4

1-2 3 ⁄

8

3-1 3 ⁄

16

4-11 3-8 1 ⁄

8

3- 8

0452 14-11 1 ⁄

4

14- 4 1 ⁄

2

5-0 7 ⁄

8

2-8 1 ⁄

2

1-4 1 ⁄

4

3-4 7 ⁄

16

7- 2 1 ⁄

4

4-0 3-11 7 ⁄

8

2-9

3-1

7

5

16

16

3-2

3-5 7 ⁄

8

0-3

0-3

1

3

2

8

4-8

7-1

3

1

4

2

1-7

1-8

7

3

8

4

1-7

1-7

5

9

16

16

3-7

3-8

3 ⁄

4

5-0

5-0

1

1 ⁄

4

2

SI (mm)

TANK

SIZE

0428

0452

A B C D E F G H J K L M N P R S T

3175 2997 1448 730 365 945 1499 1121 1118 849 965 89 1442 505 491 1111 1530

4553 4382 1546 826 413 1027 2191 1219 1216 948 1064 86 2172 528 497 1118 1537

NOTES:

1.

Denotes center of gravity.

2. Dimensions in ( ) are in millimeters.

3. The weights and center of gravity values given are for an empty storage tank.

4. For additional information on the pumpout unit, see certified drawings.

5. The available conduit knockout sizes are:

QTY

1

1

1

1

TRADE SIZE

1 ⁄

2

9

3 ⁄

4

9

1

9

1 1 ⁄

4

9

LOCATION top bottom middle middle

Fig. 19 — Optional Pumpout Unit and Storage Tank

25

TANK

SIZE

0428

0452

TANK OD

(in.)

24.00

27.25

RATED DRY WEIGHT AND REFRIGERANT CAPACITY

ENGLISH (lb)

DRY

WEIGHT*

(lb)

2380

3460

MAXIMUM REFRIGERANT CAPACITY (lb)

ANSI/ASHRAE 15

1860

3563

UL 1963

1716

3286

SI (kg)

TANK

SIZE

0428

0452

TANK OD

(mm)

610

592

DRY

WEIGHT*

(kg)

1080

1569

LEGEND

ASHRAE — American Society of Heating, Refrigeration, and Air Conditioning Engineers

OD

UL

Outside Diameter

Underwriters’ Laboratories

MAXIMUM REFRIGERANT CAPACITY (kg)

ANSI/ASHRAE 15

*The above dry weight includes the pumpout condensing unit weight of 210 lbs (95 kg).

844

1616

UL 1963

778

1491

Fig. 19 — Optional Pumpout Unit and Storage Tank (cont)

26

Fig. 20 — Optional Pumpout System Piping Schematic with Storage Tank

Fig. 21 — Optional Pumpout System Piping Schematic without Storage Tank

27

OIL

RETURN LINE

CONNECTION

SERVICE

VALVES

CONDENSER

WATER CONNECTIONS

REFRIGERANT

INLET VALVE

COMPRESSOR

MOUNTING

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.

Refrigerant discharged into confined spaces can displace oxygen 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 piping 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 springisolated machines.

4. Cover the outdoor vent with a rain cap and place a condensation drain at the low point in the vent piping to prevent water build-up on the atmospheric side of the relief device.

Table 10 — Relief Device Locations

RELIEF VALVE

OUTLET SIZE

LOCATION

QUANTITY

Frame 5

Compressor With

Frame 7 or 8

Heat Exchanger

All

Others

1-in. NPT FEMALE

CONNECTOR

1-in.NPT FEMALE

CONNECTOR

1-in. NPT FEMALE

CONNECTOR

Cooler

Condenser

Optional

Storage Tank

NOTE: All valves relieve at 185 psi (1275 kPa).

4

4

2

2

2

2

Make Electrical Connections —

Field wiring must be installed in accordance with job wiring diagrams and all applicable electrical codes.

Do not run 120-v wiring into the control cabinet. The control cabinet should only be used for additional extralow voltage wiring (50 v maximum).

Wiring diagrams in this publication (Fig. 24-31) are for reference only and are not intended for use during actual installation; follow job specific wiring diagrams.

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 insulation breakdown and serious damage may result.

CONNECT CONTROL INPUTS — Connect the control input 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 indicated in Fig. 24 and 25.

Fig. 23 — Relief Valve Locations

28

Fig. 24 — Carrier Comfort Network Communication Bus Wiring

LEGEND

Factory Wiring

Field Wiring

*Field supplied terminal strip must be located in control panel.

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-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 position 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.

3

8

7

Piping

Control Wiring

Power Wiring

LEGEND

1 — Disconnect

2 — Unit Mounted Starter

3 — Control Cabinet

4 — Power Panel

5 — Vents

6 — Pressure Gages

7 — Chilled Water Pump

8 — Condenser Water Pump

9 — Chilled Water Pump Starter

10 — Condensing Water Pump Starter

11 — Cooling Tower Fan Starter

IMPORTANT: Wiring and piping shown are for general pointof-connection only and are not intended to show details for a specific installation. Certified field wiring and dimensional diagrams are available on request.

NOTES:

1. All wiring must comply with applicable codes.

2. Refer to Carrier System Design Manual for details regarding piping techniques.

3. Wiring not shown for optional devices such as:

• remote start-stop

• remote alarm

• optional safety device

• 4 to 20 mA resets

• optional remote sensors

Fig. 26 — 19XR with Optional Unit-Mounted Starter

30

Free-Standing, Field-Installed Starter — Assemble and install 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 motor must be grounded in accordance with NEC (National Electrical 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 phasing 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 arcing. For low-voltage units (up to 600 v), obtain insulation material from machine shipping package consisting of 3 rolls of insulation putty and one roll of vinyl tape.

1. Insulate each terminal by wrapping with one layer of insulation putty.

2. Overwrap putty with 4 layers of vinyl tape.

High Voltage Units — High-voltage units require special terminal preparation. Follow local electrical codes for highvoltage 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 machine 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. Follow correct phasing for proper motor rotation.

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.

Piping

Control Wiring

Power Wiring

LEGEND

1 — Disconnect

2 — Free-Standing Compressor Motor Starter

3 — Compressor Motor Terminal Box

4 — Chiller Power Panel

5 — Control Cabinet

6 — Vents

7 — Pressure Gages

8 — Chilled Water Pump

9 — Condenser Water Pump

10 — Chilled Water Pump Starter

11 — Condensing Water Pump Starter

12 — Cooling Tower Fan Starter

13 — Disconnect

14 — Oil Pump Disconnect (see Note 4)

IMPORTANT: Wiring and piping shown are for general pointof-connection only and are not intended to show details for a specific installation. Certified field wiring and dimensional diagrams are available on request.

NOTES:

1. All wiring must comply with applicable codes.

2. Refer to Carrier System Design Manual for details regarding piping techniques.

3. Wiring not shown for optional devices such as:

• remote start-stop

• remote alarm

• optional safety device

• 4 to 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

IMPORTANT: Wiring shown is typical and not intended to show detail for a specific installation. Refer to certified field wiring diagrams.

LEGEND

AWG — American Wire Gage

N.C.

Normally Closed

N.O.

Normally Open

PR Pilot Relay

RLA Rated Load Amps

ST Shunt Trip

TB Terminal Block

Required Power Wiring

Required Control Wiring

Options Wiring

NOTES:

I. 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 termination of conductors and devices must be in compliance with all applicable codes and job specifications.

1.2 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.

1.3 Equipment, installation, and all starting and control devices must comply with details in equipment submittal drawings and literature.

1.4 Contacts and switches are shown in the position they would assume with the circuit deenergized and the chiller shut down.

1.5 WARNING — Do not use aluminum conductors.

1.6 Installer is responsible for any damage caused by improper wiring between starter and machine.

II. 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

2.1 Lug adapters may be required if installation conditions dictate that conductors be sized beyond the minimum ampacity required. Contact starter supplier for lug information.

2.2 Compressor motor and controls must be grounded by using equipment grounding lugs provided inside starter enclosure.

III. 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 remote 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.

3.2 Remove jumper wire between 12A and 12B before connecting auxiliary safeties between these terminals.

3.3 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 control transformer as the power source for pilot relay loads.

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 enclosure as shown, it must be located within sight of the machine with wiring routed to suit.

IV. POWER WIRING BETWEEN STARTER AND COMPRESSOR MOTOR

4.0 Low voltage (600 v or less) compressor motors have (6) 3 ⁄

4 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 2 15 ⁄

16 inches. Compressor motor starter must have nameplate stamped as conforming with Carrier requirement Z-375.

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 & 3 in one conduit, and those to 4, 5 & 6 in another.)

4.2 Compressor motor power connections can be made through top, top rear, or sides of compressor motor terminal box 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 or 12 conductors larger than 500 MCM may require an oversize (special) 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.

4.3 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 No. 4 to 500 MCM wire, supplied and located in the back 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.

4.5 Use backup wrench when tightening lead connectors to motor terminal studs. Torque to 45 lb-ft max.

Fig. 28 — 19XR Typical Field Wiring with Optional Unit-Mounted Starter

32

IMPORTANT: Wiring shown is typical and not intended to show detail for a specific installation. Refer to certified field wiring diagrams.

NOTES:

I. 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 termination of conductors and devices must be in compliance with all applicable codes and job specifications.

1.2 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.

1.3 Equipment, installation, and all starting and control devices must comply with details in equipment submittal drawings and literature.

1.4 Contacts and switches are shown in the position they would assume with the circuit deenergized and the chiller shut down.

1.5 WARNING — Do not use aluminum conductors.

1.6 Installer is responsible for any damage caused by improper wiring between starter and machine.

II. 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

2.1 Lug adapters may be required if installation conditions dictate that conductors be sized beyond the minimum ampacity required. Contact starter supplier for lug information.

2.2 Compressor motor and controls must be grounded by using equipment grounding lugs provided inside starter enclosure.

III. 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 remote 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.

3.2 Remove jumper wire between 12A and 12B before connecting auxiliary safeties between these terminals.

3.3 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 towerfan 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.

AWG — American Wire Gage

N.C.

Normally Closed

N.O.

Normally Open

PR Pilot Relay

RLA Rated Load Amps

LEGEND

SMM — Starter Management

TB

Module

Terminal Block

Required Power Wiring

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 enclosure 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 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 primary terminals.

IV. POWER WIRING BETWEEN STARTER AND COMPRESSOR MOTOR

4.0 Low voltage (600 v or less) compressor motors have (6) 3 ⁄

4 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 2 15 ⁄

16 inches. Compressor motor starter must have nameplate stamped as conforming with Carrier requirement Z-375.

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 & 3 in one conduit, and those to 4, 5 & 6 in another.)

4.2 Compressor motor power connections can be made through top, top rear, or sides of compressor motor terminal box 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 or 12 conductors larger than 500 MCM may require an oversize (special) 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.

4.3 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 No. 4 to 500 MCM wire, supplied and located in the back 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.

4.5 Use backup wrench when tightening lead connectors to motor terminal studs. Torque to 45 lb-ft max.

Fig. 29 — 19XR Typical Field Wiring with Free-Standing Starter

33

Connect Power Wires to Oil Heater Contactor — Connect control power wiring between the oil heater contactor terminals 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.

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 transfomer secondary terminals produces input level voltage at the transformer primary terminals.

Connect Wiring from Starter to Power Panel — Connect control wiring from main motor starter to the machine power panel. All control wiring must use shielded cable. Also, connect the communications cable. Refer to the job wiring diagrams for cable type and cable number. Make sure the control circuit is grounded in accordance with applicable electrical codes and instructions on machine control wiring label.

LEGEND

Factory Wiring

Field Wiring

Oil Pump Terminal

Power Panel Component Terminal

Fig. 30 — Oil Pump Wiring

LEGEND

Field Wiring

Power Panel Component Terminal

NOTE: The voltage selector switch in 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 is supplied and installed by the electrical contractor. 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.

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

(COMM1) on the processor module.

NOTE: Conductors and drain wire must be 20 AWG

(American Wire Gage) minimum stranded, tinned copper. Individual conductors must be insulated with PVC, PVC/ nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester

100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl, or Teflon with a minimum operating 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

Alpha

American

Belden

Columbia

CABLE NO.

2413 or 5463

A22503

8772

02525

When connecting the CCN communication bus to a system element, a color code system for the entire network is recommended to simplify installation and checkout. The following color code is recommended:

SIGNAL TYPE

+

Ground

CCN BUS CONDUCTOR

INSULATION COLOR

Red

White

Black

COMM1 PLUG

PIN NO.

1

2

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. 25. If the communication bus cable exits from one building 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 COMM1 plug from the processor module.

3. Cut a 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

COMM1 plug.

6. Insert and secure the WHITE wire to Terminal 2 of the

COMM1 plug.

7. Insert and secure the BLACK wire to Terminal 3 of the

COMM1 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 BLACK wire to the matching location on the terminal strip.

Install Field Insulation

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 following components:

• compressor motor

• cooler shell

• 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 servicing (Fig. 32).

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

Tab 5a

PC 211 Catalog No. 531-940 Printed in U.S.A.

Form 19XR-2SI Pg 38 10-97 Replaces: 19XR-1SI

Machine Model Number: 19XR

To:

INSTALLATION START-UP REQUEST CHECKLIST

Serial Number:

Date

Project Name

Attn:

Carrier Job Number

The following information provides the status of the chiller installation.

YES/NO

(N/A)

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. 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.

COMMENTS:

DATE TO BE

COMPLETED

CL-1

TESTING

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 available 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 instructions for proper operation of the chiller after start-up.

Concerns about the installation/request for additional assistance:

YES/NO

DATE TO BE

COMPLETED

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 understand 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

Tab 5a

PC 211 Catalog No. 531-940 Printed in U.S.A.

Form 19XR-2SI Pg CL-2 10-97 Replaces: 19XR-1SI

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