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19XL 50/60 Hz Hermetic Centrifugal Liquid Chillers with HCFC­22 and HFC­134a

Installation Instructions

For Units Produced After 11/1/92 (Linear Float Design)

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 531-944 9-94 Form 19XL-3SI Replaces: 19XL-2SI

Copyright © Carrier Corporation 1994

Safety Considerations

Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design specifications. When operating this equipment, use good judgement 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.

DANGER

!

DANGER

DO NOT VENT refrigerant relief devices within a building. Outlet from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ANSI/ASHRAE 15 (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.

WARNING

!

WARNING

DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all refrigerant ((liquid and vapor) has been removed from chiller. Traces of vapor should be displaced with dry air or nitrogen and the work area should be well ventilated. Refrigerant in contact with an open flame produces toxic gases. DO NOT USE eyebolts or eyebolt holes to rig machine sections or the entire assembly. DO NOT work on high-voltage equipment unless you are a qualified electrician. DO NOT WORK ON electrical components including control panels, switches, starters, or oil heater until you are sure ALL POWER IS OFF and no residual voltage can leak from capacitors or solid-state components. LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTERRUPTED, confirm that all circuits are generalized before resuming work. DO NOT siphon refrigerant. AVOID SPILLING liquid refrigerant on skin or getting it into the eyes. USE SAFETY GOGGLES. Wash any spills from the skin with soap and water. If liquid refrigerant enters the eyes, IMMEDIATELY FLUSH EYES with water and consult a physician. NEVER APPLY an open flame or live steam to a refrigerant cylinder. Dangerous over pressure can result. When it is necessary to heat refrigerant, use only warm (110 F [43 C]) water.

WARNING

!

WARNING

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/ASHRAE-15 (latest edition). Contact Carrier for further information on use of this machine with other refrigerants. DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while machine is under pressure or while machine is running. Be sure 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.

CAUTION

!

CAUTION

DO NOT STEP on refrigerant lines. Broken lines can whip about and release refrigerant, causing personal injury. DO NOT climb over a machine. Use platform, catwalk, or staging. 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.

CAUTION

!

CAUTION

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.

Contents List of Tables List of Figures Safety Considerations Introduction

General Job Data Equipment Required

Installation

Receiving the Machine

Inspect Shipment Identify Machine Provide Machine Protection

Rigging the Machine

Rig Machine Assembly

Contents

Rig Machine Components

Install Machine Supports

Install Standard Isolation Install Optional Isolation Install Spring Isolation

Connect Piping

Install Water Piping to Heat Exchangers Install Vent Piping to Relief Devices

Make Electrical Connections

Connect Control Inputs Connect Control Outputs Connect Starter Carrier Comfort Network Interface

Install Field Insulation

Installation Start-Up Request Checklist

Contents List of Tables

Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 -- 19XL Compressor/Motor Weights -- 19XL Component Weights -- 19XL Heat Exchanger Weights -- Additional Heat Exchanger Weight for Marine Waterboxes -- 19XL Waterbox Cover Weights -- Relief Device Locations

Contents List of Figures

Figure 1 -- Model Number Identification Figure 2 -- Typical 19XL Installation (300 to 600 Tons [1055 to 2110 kW]) Figure 3 -- Machine Rigging Guide Figure 4 -- 19XL Dimensions Figure 5 -- 19XL Condenser Drain Figure 6 -- 19XL Motor End View Figure 7 -- 19XL Machine Top View Figure 8 -- 19XL Refrigerant Return Figure 9 -- 19XL Oil Reclaim System Figure 10 -- 19XL Machine Footprint Figure 11 -- Standard Isolation Figure 12 -- Accessory Isolation Figure 13 -- 19XL Accessory Spring Isolation (Shown with Accessory Soleplates)

Contents

Figure 14 -- Typical 19XL Low Profile Isolation Assembly Figure 15 -- Typical Nozzle Piping Figure 16 -- Piping Flow Data Figure 17 -- Optional Pumpout System and/or Storage Tank Figure 18 -- Optional Pumpout System Piping Schematic with Storage Tank Figure 19 -- Optional Pumpout System Piping Schematic without Storage Tank Figure 20 -- Pumpout Unit Figure 21 -- Relief Valve Locations Figure 22 -- Carrier Comfort Network Communication Bus Wiring Figure 23 -- COMM1 CCN Communication Wiring for Multiple Chillers (Typical) Figure 24 -- 19XL with Optional Unit-Mounted Starter Figure 25 -- 19XL with Freestanding Starter

Contents

Figure 26 -- 19XL Typical Field Wiring with Optional Unit-Mounted Starter Figure 27 -- 19XL Typical Field Wiring with Free-Standing Starter Figure 28 -- Oil Pump Wiring Figure 29 -- Oil Heater and Control Power Wiring Figure 30 -- 19XL Insulation Area

Introduction

General

The 19XL 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 mechanic's tools (refrigeration) volt-ohmmeter and clamp-on ammeter leak detector (halide or electronic) absolute pressure manometer or wet-bulb vacuum indicator portable vacuum pumps

Equipment Required

Installation

Receiving the Machine

Inspect Shipment

CAUTION

!

CAUTION

Do not open any valves or loosen any connections. The standard 19XL 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 (Figure 1, Figure 2 (Front View) (Rear View). Check this information against shipping papers and job data.

Click here for Figure 1 -- Model Number Identification 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.

Click here for Figure 2 (Front and Rear Views) -- Typical 19XL Installation (300 to 600 Tons [1055 to 2110 kW])

Rigging the Machine

The 19XL 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 Figure 3, physical data in Figure 4, and Table 1, Table 2, Table 3, Table 4, Table 5A and Table 5B. Lift machine only from the 3 points indicated in rigging guide. Each lifting cable or chain must be capable of supporting the entire weight of the machine.

WARNING

!

WARNING

Lifting machine from points other than those specified may result in serious damage to the unit and personal injury. Rigging equipment and procedures must be adequate for machine weight. See Table 1, Table 2, Table 3, Table 4, Table 5A, and Table 5B 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 Table 1, Table 2, Table 3, Table 4, Table 5A, and Table 5B for machine component weights.

IMPORTANT: Make sure that rigging cable is over the rigging bar before lifting.

Rig Machine Components

Refer to instructions below, Figure 5, Figure 6, Figure 7, Figure 8, Figure 9, and Carrier Certified Prints for machine component disassembly. IMPORTANT: Only a qualified service technician should perform this operation.

WARNING

!

WARNING

Do not attempt to disconnect flanges while the machine is under pressure. Failure to relieve pressure can result in personal injury or damage to the unit.

CAUTION

!

CAUTION

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

Note: If the cooler and condenser vessels must be separated, the heat exchanger separation feet can be unbolted, slipped down, and re-bolted in order to keep each heat exchanger level. See Figure 3.

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.

Click here for Figure 3 -- Machine Rigging Guide

Click here for Figure 4 -- 19XL Dimensions

Click here for Table 1 -- 19XL Compressor/Motor Weights

Click here for Table 2 -- 19XL Component Weights

Click here for Table 3 -- 19XL Heat Exchanger Weights

Click here for Table 4 -- Additional Heat Exchanger Weight for Marine Waterboxes*

Click here for Table 5A -- 19XL Waterbox Cover Weights* (English, lb.)

Click here for Table 5B -- 19XL Waterbox Cover Weights* (SI, kg)

To Separate Cooler and Condenser 1. Turn vessel separation feet into lowered position (Figure 5, Item 1). 2. Disconnect the flared fitting on the refrigerant motor cooling line at the isolation valve (Figure 6, Item 3). 3. Disconnect the condenser discharge line at the compressor (Figure 6, Item 1). 4. Cut the hot gas bypass line on the cooler side of the isolation valve (not shown). 5. Cut cooler liquid feed line at location indicated (Figure 5, Item 2). 6. Cover all openings. 7. Disconnect the wires and cable housings which cross from the starter to the power panel at the power panel (Figure 7, Item 8).

8. Disconnect the rabbet-fit connectors on the tube sheets (Figure 7, Item 7). 9. Rig vessels apart. To Separate the Compressor from the Cooler 1. Unbolt suction elbow at the cooler flange (Figure 7, Item 11). 2. Disconnect the flared fitting on the refrigerant motor cooling line at the isolation valve (Figure 6, Item 3). 3. Cut the refrigerant return line from the oil cooler (Figure 6, Item 2). 4. Disconnect the motor refrigerant return line (Figure 8, Item 1). 5. Disconnect the following (Figure 7): a. Oil sump sensor cable (Item 5). b. Bearing sensor cable (Item 4). c. Motor sensor cable (Item 3). d. Wires and cable housing which cross to the starter and control panel from the power panel (Items 8 and 9). e. Discharge sensor cable (Item 6). f. Oil pressure transducer cable (Item 2). g. Guide vane actuator cable (Item 10). 6. Disconnect the flared fittings for the oil reclaim lines (Figure 9, Item 1).

7. Unbolt the compressor discharge line (Figure 6, Item 1). 8. Cover all openings. 9. Disconnect motor power cables at the starter lugs (Figure 7, Item 1). 10. Rig compressor.

CAUTION

!

CAUTION

Do not tilt the compressor; oil charge is still contained in the oil sump.

Click here for Figure 5 -- 19XL Condenser Drain

Click here for Figure 6 -- 19XL Motor End View

Click here for Figure 7 -- 19XL Machine Top View

Click here for Figure 8 -- 19XL Refrigerant Return

Click here for Figure 9 -- 19XL Oil Reclaim System

To Rig Compressor Note: The motor end of the 19XL compressor is heavy and will tip backwards unless these directions are followed: 1. Remove rigging bar (Figure 6, Item 4) and the bolts securing it. 2. Place the rigging bar vertically over the compressor end bell (Figure 6, Item 5). Attach the rigging bar to the compressor end bell using the 2 bolts removed in Step 1. 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

Figure 10 and Figure 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 Figure 10 and Figure 12. Level machine by using jacking screws in isolation sole-plates. Use a level at least 24-in. (600 mm) long. For adequate and long lasting machine support, proper grout selection and placement is essential. Carrier recommends that only premixed, 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.

Click here for Figure 10 -- 19XL Machine Footprint

Click here for Figure 11 -- Standard Isolation 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 Figure 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 (Figure 14). 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.

Click here for Figure 12 -- Accessory Isolation

Click here for Figure 13 -- 19XL Accessory Spring Isolation (Shown with Accessory Soleplates) Click here for Figure 14 -- Typical 19XL Low Profile Isolation Assembly

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 Figure 15.

CAUTION

!

CAUTION

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

CAUTION

!

CAUTION

Remove chilled and condenser water sensors before welding connecting piping to water nozzles. Refer to Figure 2. 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 Figure 16. 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 Figure 17, Figure 18, Figure 19, and Figure 20.

Figure 15 -- Typical Nozzle Piping

Figure 16 -- Piping Flow Data

Figure 17 -- Optional Pumpout System and/or Storage Tank

Figure 18 -- Optional Pumpout System Piping Schematic with Storage Tank

Figure 19 -- Optional Pumpout System Piping Schematic without Storage Tank

Figure 20 -- Pumpout Unit Install Vent Piping to Relief Devices

The 19XL chiller is factory equipped with relief devices on the cooler and condenser shells. Refer to Figure 21 and Table 6 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.

DANGER

!

DANGER

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 spring-isolated 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.

Make Electrical Connections

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

CAUTION

!

CAUTION

Do not run 120-v wiring into the control cabinet. The control cabinet should only be used for additional extra low-voltage wiring (50 v maximum). Wiring diagrams in this publication (Figure 22, Figure 23, Figure 24, Figure 25, Figure 26, Figure 27, Figure 28, and Figure 29) are for reference only and are not intended for use during actual installation; follow job specific wiring diagrams.

WARNING

!

WARNING

Do not attempt to start compressor or oil pump (even for a rotation check) or apply test voltage of any kind while machine is under dehydration vacuum. Motor 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 Figure 22 and Figure 23.

Click here for Figure 21 -- Relief Valve Locations

Click here for Figure 22 -- Carrier Comfort Network Communication Bus Wiring

Click here for Figure 23 -- COMM1 CCN Communication Wiring for Multiple Chillers (Typical) 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 19XL is available with either a unit-mounted, factory-installed starter or a free-standing, field-installed starter (Figure 24 and Figure 25). Unit Mounted, Factory-Installed Starter Attach power leads by connecting them from inside the starter cabinet to the line side circuit breaker terminals. See Figure 24 and Figure 26. Machines with electro-mechanical starters (wye-delta) will have a top hat shipped with the machine if the RLA is greater than 432 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. The solid-state starter does not require a top hat.

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.

Click here for Figure 24 -- 19XL with Optional Unit-Mounted Starter

Freestanding, Field-Installed Starter Assemble and install compressor terminal box in desired orientation, and cut necessary conduit openings in conduit support plates. See Figure 25 and Figure 27. 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. The vinyl tape is not acceptable, a high voltage terminal methods must be used. Connect Power Wires to Oil Pump Starter See Figure 28. 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 Figure 27. Check that power supply voltage agrees with oil pump voltage. Follow correct phasing for proper motor rotation.

CAUTION

!

CAUTION

Do not punch holes or drill into the top surface of the power panel. Knockouts are provided in the bottom of the power panel for wiring connections.

Click here for Figure 25 -- 19XL with Freestanding Starter

Click here for Figure 26 -- 19XL Typical Field Wiring with Optional Unit-Mounted Starter Click here for Figure 27 -- 19XL Typical Field Wiring with Free-Standing Starter

Connect Power Wires to Oil Heater Contactor Connect power wiring to oil heater contactor using a separate power source and fused disconnect. Refer to Figure 29 and wiring label on the machine power panel.

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.

Click here for Figure 28 -- Oil Pump Wiring

Click here for Figure 29 -- 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. The negative pins must be wired to the negative pins. The signal ground pins must be wired to the signal ground pins. See Figure 22 for location of the CCN network connector (COMM1) on the processor module.

Note: Conductors and drain wire must be 20 AWG (American Wire Gauge) 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 Figure 23. 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 19XL chiller to the network, proceed as follows (Figure 23): 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 CAUTION

!

CAUTION

Protect insulation from weld heat damage and weld splatter. Cover with wet canvas cover during water piping installation. When installing insulation at the job site, 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 (Figure 30).

Click here for Figure 30 -- 19XL Insulation Area

Click here for 19XL Installation Start-up Request Checklist CL-1, CL-2 (Print and use for job file)

Table 1 -- 19XL Compressor/Motor Weights

English Motor Size Compressor Weight (lb)

2660 2660 2660 2660 2660 2660 2660 2660 2660 2660

SI Stator Weight (lb) 60 Hz

1135 1143 1153 1162 1202 1225 1276 1289 1306 1335

Rotor Weight (lb) 60 Hz

171 197 234 237 246 254 263 266 273 282

50 Hz

1147 1150 1213 1227 1283 1308 1341 1356 1363 1384

50 Hz

233 239 252 255 270 275 279 284 287 294

End Bell Cover (lb)

250 250 250 250 250 250 250 250 250 250

Compressor Weight (kg)

1208 1208 1208 1208 1208 1208 1208 1208 1208 1208

Stator Weight (kg) 60 Hz

515 218 523 528 546 556 579 585 593 606

Rotor Weight (kg) 60 Hz

78 90 106 108 112 115 119 121 124 128

50 Hz

520 522 551 557 582 594 609 616 619 628

50 Hz

106 109 114 116 123 125 127 129 130 133

End Bell Cover (kg)

114 114 114 114 114 114 114 114 114 114

CB CC CD CE CL CM CN CP CQ CR

Note: For medium voltage motors add 85 lbs (39 kg) to above for 60-Hz motors and 145 lbs (66 kg) for 50-Hz motors. Total compressor/motor weight is the sum of the compressor, stator, rotor, and end bell cover weight. Compressor weight includes suction and discharge elbow weights.

Table 2 -- 19XL Component Weights

Component

Suction Elbow* Discharge Elbow* Control Cabinet Optional Mounted Starter**

lb

554 546 530 500

kg

225 221 214 227

Legend *Included in total compressor weight. Included in total cooler weight. **Weight of optional factory-mounted starter is not included and must be added to heat exchanger weights.

Table 3 -- 19XL Heat Exchanger Weights

English Rigging Wt (lb)* Code Cooler Only Condenser Only 4643 4771 4909 5064 6413 6584 6780 7005 8008 8260 8560 8900 Machine Charge Refrigerant (lb) Cooler 1920 1990 1050 1100 1300 1350 1430 1500 1840 1910 2020 2120 Condenser 350 350 350 350 350 350 350 350 490 490 490 490 Water (gal.) Cooler 153 158 164 171 179 187 196 104 104 115 128 140 Condenser 156 162 168 175 184 192 101 110 112 123 135 119 Cooler Only SI Rigging Wt (kg)* Condenser Only 2108 2166 2229 2299 2912 2989 3078 3180 3632 3746 3882 4037 Machine Charge Refrigerant (kg) Cooler 417 449 476 499 590 612 649 681 835 866 916 961 Condenser 159 159 159 159 159 159 159 159 222 222 222 222 Water (L) Cooler 200 219 242 269 299 329 363 394 394 435 485 530 Condenser 212 235 257 284 318 348 382 416 424 466 511 564

40 41 42 43 50 51 52 53 55 56 57 58

5154 5275 5418 5577 6730 6927 7140 7359 8220 8517 8836 9164

2340 2395 2460 2532 3055 3145 3242 3341 3728 3863 4007 4156

* Rigging weights are for standard tubes of standard wall thickness. For special tubes refer to the 19XL Computer Selection Program. Refrigerant charge listed is the same for both HCFC-22 and HFC-134a.

Table 4 -- Additional Heat Exchanger Weight for Marine Waterboxes*

English Heat Exchanger Frame, Pass Rigging Wt (lb) Condenser

1660

SI Water Volume (gal.) Cooler

169

Rigging Wt (kg) Condenser

300 527 424 771

Water Volume (gal.) Cooler

261 524 331 663

Cooler Frame 4, 2 Pass Frame 4,1 & 3 Pass Frame 5, 2 Pass Frame 5,1 & 3 Pass

1115 2030 1220 2240

Condenser

151

Cooler

1506 1922 1554

Condenser

193 384 243 486

1160

1935

138

188

101

164

1705

175

128

1017

*Add to heat exchanger weights for total weight.

Table 5A -- 19XL Waterbox Cover Weights (English)*

English (Lb) Frame 4, Std Nozzles 150 psig

284 285 292 243 CS CS 306 288 319 226 CS CS

Frame 4, Flanged 150 psig

324 341 309 243 CS CS 346 344 336 226 CS CS

Heat Exchanger

Waterbox Description

Frame 5, Std Nozzles 150 psig

412 410 423 304 CS CS 373 368 407 271 CS CS

Frame 5, Flanged 150 psig

452 466 440 3044 CS CS 413 428 419 271 CS CS

300 psig

414 411 433 292 621 482 446 435 466 271 474 359

300 psig

491 523 469 292 621 482 523 547 502 271 474 359

300 psig

579 573 602 426 766 471 472 469 493 379 590 428

300 psig

655 685 638 426 766 471 549 541 549 379 590 428

NIH, 1 Pass Cover NIH, 2 Pass Cover NIH, 3 Pass Cover

Coolers

NIH, Plain End Cover MWB Cover Plain End Cover NIH, 1 Pass Cover NIH, 2 Pass Cover

Condensers

NIH, 3 Pass Cover NIH, Plain End Cover MWB Cover Plain End Cover

Legend CS NIH -- Contact Syracuse -- Nozzle-In-Head MWB -- Marine Waterbox

* These weights are for reference only. The 150 psig (1034 kPa) standard waterbox cover weights have been included in the heat exchanger weights shown in Table 3 and Table 4.

Table 5B -- 19XL Waterbox Cover Weights (SI)*

SI (kg) Frame 4, Std Nozzles 1034 kPa

129 129 133 110 CS CS 139 131 145 103 CS CS

Heat Exchanger

Waterbox Description

Frame 4, Flanged 1034 kPa

148 155 140 110 CS CS 157 156 153 103 CS CS

Frame 5, Std Nozzles 2068 kPa

223 237 213 133 282 219 237 248 228 123 215 163

Frame 5, Flanged 1034 kPa

205 212 200 138 CS CS 188 194 190 123 CS CS

2068 kPa

188 187 197 133 282 219 202 197 212 123 215 163

1034 kPa

187 186 192 138 CS CS 169 167 185 123 CS CS

2068 kPa

262 260 273 193 348 214 214 213 224 172 268 194

2068 kPa

297 311 290 193 348 214 249 246 249 172 268 194

NIH, 1 Pass Cover NIH, 2 Pass Cover NIH, 3 Pass Cover

Coolers

NIH, Plain End Cover MWB Cover Plain End Cover NIH, 1 Pass Cover NIH, 2 Pass Cover

Condensers

NIH, 3 Pass Cover NIH, Plain End Cover MWB Cover Plain End Cover

Legend CS NIH -- Contact Syracuse -- Nozzle-In-Head MWB -- Marine Waterbox

* These weights are for reference only. The 150 psig (1034 kPa) standard waterbox cover weights have been included in the heat exchanger weights shown in Table 3 and Table 4.

Table 6 -- Relief Device Locations

Relief Valve Outlet Size 1-in. NPT Female Connector 1-in. NPT Female Connector 1-in. NPT Female Connector Location

Cooler

Quantity

1

Condenser

2

Optional Storage Tank

2

Figure 1 -- Model Number Identification

Figure 2 (Front View) -- Typical 19XL Installation (300 to 600 Tons [1055 to 2110 kW]) (See next page for Rear View)

Figure 2 (Rear View) -- Typical 19XL Installation (300 to 600 Tons [1055 to 2110 kW])

Center of Gravity -- Approximate Dimensions Heat Exchanger (Cooler and Condenser) Size

40 to 43 (Frame 4) 50 to 53 (Frame 5) 55 to 58 (Frame 5)

A (Length) Ft-in.

5-5 5-5 7-9

B (Width) Ft-in.

2-8 2-8 2-8

C (Height) Ft-in.

3-5 3-5 3-5

Maximum Rigging Weight (Without Refrigerant Charge) lb

21,200 26,400 30,850

mm

1689 1689 2362

mm

813 813 813

mm

1040 1040 1040

kg

19,616 11,975 14,000

Chain Length Vessel Length "B" ft-in.

12-3 12-3 17-0

"C" mm

3658 3658 4166

"D" mm

3912 3912 4521

mm

3734 3734 5182

ft-in.

12-0 12-0 13-9

ft-in.

12-10 12-10 14-10

ft-in.

12-10 12-10 14-10

mm

3912 3912 4521

Figure 3 -- Machine Rigging Guide

Heat Exchanger Code (Cooler and Condenser)

40-43 50-53 55-58

A (Length) 2 Pass* ft-in.

13-7 3/4 13-8 18-4 1/2

1 or 3 Pass mm

4159 4166 5601

B (Width) ft-in.

5-5 3/4 6-0 1/4 6-0 1/4

C (Height) ft-in.

6-8 5/8 7-2 1/8 7-2 1/8

Nozzle Size (in.) (Nominal Pipe Size) 1-Pass 2-Pass 3-Pass

10 10 10 8 8 8 6 6 6

ft-in.

mm

mm

1670 1835 1835

mm

2048 2188 2188

14-3 1/4 4350 14-3 3/4 4362 19-0 1/4 5798

Heat Exchanger Code (Cooler and Condenser)

40-53 55-58

A (Length with Marine Waterbox -- Not Shown) 2 Pass* ft-in.

14-9 5/8 19-6 1/8

1 or 3 Pass mm

4512 5947

ft-in.

16-5 1/2 21-5 1/2

mm

5017 6541

Motor Service Clearance D ft-in.

4-0

mm

1219

Figure 4 -- 19XL Dimensions

Figure 5 -- 19XL Condenser Drain

Figure 6 -- 19XL Motor End View

Figure 7 -- 19XL Machine Top View

Figure 8 -- 19XL Refrigerant Return

Figure 9 -- 19XL Oil Reclaim System

Heat Exchanger (Cooler/ Condenser)

40-43 50-53 55-58

A ft-in.

5-5 3/4 6-0 1/4 6-0 1/4

B mm

1670 1835 1835

ft-in.

13-0 1/4 13-0 1/4 17-8 3/4

mm

3968 3968 5404

Figure 10 -- 19XL Machine Footprint

Figure 11 -- Standard Isolation

Figure 12 -- Accessory Isolation

Figure 13 -- 19XL Accessory Spring Isolation (Shown with Accessory Soleplates)

Figure 14 -- Typical 19XL Low Profile Isolation Assembly

Figure 15 -- Typical Nozzle Piping

Drive End

Compressor End Drive End Compressor End Front View

Nozzle-in-Head Waterboxes

Drive End

Compressor End Drive End Front View Compressor End

Marine Waterboxes

Nozzle Arrangement Codes

Cooler Waterboxes Pass

1 2 3

Condenser Waterboxes Out

5 8 9 6 6 9

In

8 5 7 4 7 4

Arrangement Code

A B C D E F

In

11 12 10 11 10 11

Out

12 11 12 13 13 12

Arrangement Code

P Q R S T U

Waterbox Nozzle Sizes

Nominal Pipe Size (in.) Pass Cooler

1 2 3 10 18 16

Actual Pipe ID (in.) Condenser

10 18 16

Actual Pipe OD (in.)

Cooler/Condenser

10,020 17,981 16,065 10,750 18,625 16,625

Figure 16 -- Piping Flow Data

Denotes center of gravity

Dimensions--English (ft-in.)

Tank Size

0428 0452

A

10-5 1411 1/4

B

9-10 144 1/2

C

4-9 50 7/8

D

24 3/4 28 1/2

E

12 3/8 14 1/4

F

210 3/4 3-2

G

4-11 72 1/4

H

38 1/8 4-0

J

3-6 311 7/8

K

29 7/16 31 5/16

L

3-2 35 7/8

M

03 1/2 03 3/8

N

48 3/4 71 1/2

P

17 7/8 18 3/4

R

17 5/16 17 9/16

S

37 3/4 3-8

T

5-4 54 1/4

SI (mm)

Tank Size

0428 0452

A

3175 4553

B

2997 4382

C

1448 1546

D

730 826

E

365 413

F

883 965

G

1499 2191

H

1121 1219

J

1067 1216

K

849 948

L

965 1064

M

89 86

N

1442 2172

P

505 528

R

491 497

S

1111 1118

T

1626 1632

Figure 17 -- Optional Pumpout System and/or Storage Tank (Page 1 of 2)

QTY

1 1 1 1

Trade Size

1/2" 3/4" 1" 1 1/4"

Location

top bottom middle middle

Rated Dry Weight and Refrigerant Capacity

English (lb) Tank Size

0428 0452

Dry Tank OD Weight* (in.) (lb)

24.00 27.25 2200 3270

Maximum Refrigerant Capacity (lb) ASHRAE 15 (HCFC-22)

1840 3525 2025 3880

ARI 495 (HFC-134a) (HCFC-22)

1645 3155

(HFC-134a)

1810 3465

SI (kg) Tank Size

0428 0452

Dry Tank OD Weight* (mm) (kg)

610 592 1998 1606

Maximum Refrigerant Capacity (kg) ASHRAE 15 (HCFC-22)

1835 1599 1928 1760

ARI 495 (HFC-134a) (HCFC-22)

1747 1431

(HFC-134a)

1822 1572

Figure 17 -- Optional Pumpout System and/or Storage Tank (Continued)

Figure 18 -- Optional Pumpout System Piping Schematic with Storage Tank

Figure 19 -- Optional Pumpout System Piping Schematic without Storage Tank

Figure 20 -- Pumpout Unit

Figure 21 -- Relief Valve Locations

Figure 22 -- Carrier Comfort Network Communication Bus Wiring

Figure 23 -- COMM1 CCN Communication Wiring For Multiple Chillers (Typical)

Figure 24 -- 19XL With Optional Unit-Mounted Starter

Figure 25 -- 19XL With Freestanding Starter

LEGEND AWG NO NC PR RLA ST TB -- -- -- -- -- -- -- -- -- -- American Wire Gage Normally Open Normally Closed Pilot Relay Rated Load Amps Shunt Trip Terminal Block Required Power Wiring Required Control Wiring Options Wiring

Figure 26 -- 19XL Typical Field Wiring with Optional Unit-Mounted Starter

LEGEND -- Required Power Wiring -- Required Control Wiring -- Options Wiring

Figure 27 -- 19XL Typical Field Wiring with Free-Standing Starter

Figure 28 -- Oil Pump Wiring

Figure 29 -- Oil Heater and Control Power Wiring

Figure 30 -- 19XL Insulation Area

Information

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