advertisement
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
advertisement
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project