Carrier 19XL series Installation Instructions Manual
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Carrier 19XL series Installation Instructions Manual

Carrier 19XL series Installation Instructions Manual

50/60 hz hermetic centrifugal liquid chillers with hcfc–22 and hfc–134a
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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
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.
Hermetic Centrifugal Liquid Chillers
®
Installation Instructions
9-94
Form 19XL-3SI
Copyright © Carrier Corporation 1994
Safety Considerations
with HCFC–22 and HFC–134a
Replaces: 19XL-2SI
19XL
50/60 Hz

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  • Page 1 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.
  • Page 2 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.
  • Page 3 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 dis- placed with dry air or nitrogen and the work area should be well ventilated. Refrig- erant in contact with an open flame produces toxic gases .
  • Page 4 Operation of this equipment with refrigerants other than those cited herein should comply with ANSI/ASHRAE-15 (latest edition). Contact Carrier for further informa- tion on use of this machine with other refrigerants.
  • Page 5 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 cov- ers or other heavy components.
  • Page 6 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.

  • Page 7: Table Of Contents

    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...
  • Page 8 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...
  • Page 9 Contents List of Tables Table 1 — 19XL Compressor/Motor Weights Table 2 — 19XL Component Weights Table 3 — 19XL Heat Exchanger Weights Table 4 — Additional Heat Exchanger Weight for Marine Waterboxes Table 5 — 19XL Waterbox Cover Weights Table 6 —...
  • Page 10 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 —...
  • Page 11 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...
  • Page 12 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...

  • Page 13: Introduction

    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.

  • Page 14: Installation

    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.

  • Page 15: Identify Machine

    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.

  • Page 16: Rig Machine Assembly

    Rig Machine Assembly See rigging instructions on label attached to machine. Also refer to rigging guide Figure 5B. Lift physical data in Figure 4, and Table Table Table Table Table 5A Table 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.

  • Page 17: Rig Machine Components

    Refer to instructions below, Figure Figure Figure Figure 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.
  • Page 18 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.
  • Page 19 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.
  • Page 20 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).
  • Page 21 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 —...
  • Page 22 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.

  • Page 23: Install Machine Supports

    (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.

  • Page 24: Install Spring Isolation

    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.

  • Page 25: Connect Piping

    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 CAUTION...
  • Page 26 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.
  • Page 27 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 Figure Figure...

  • Page 28: Install Vent Piping To Relief Devices

    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 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.

  • Page 29: Make Electrical Connections

    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.

  • Page 30: Connect Control Inputs

    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...

  • Page 31: Connect Control Outputs

    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 Figure...
  • Page 32 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.
  • Page 33 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.
  • Page 34 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 —...

  • Page 35: Carrier Comfort Network Interface

    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.
  • Page 36 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.
  • Page 37 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.

  • Page 38: Install Field Insulation

    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.
  • Page 39 Note: Insulation of the waterbox covers is applied only at the jobsite by the contractor. When insulating the covers, make sure there is access for removal of waterbox covers for ser- vicing (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)
  • Page 40 Table 1 — 19XL Compressor/Motor Weights English Stator Rotor Stator Rotor Com- Com- Motor Weight (lb) Weight (lb) Weight (kg) Weight (kg) pressor Bell pressor Bell Size Weight Cover Weight Cover (lb) (lb) (kg) (kg) 2660 1135 1147 1208 2660 1143 1150 1208...
  • Page 41 Table 2 — 19XL Component Weights Component Suction Elbow* Discharge Elbow* Control Cabinet† Optional Mounted Starter** 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.
  • Page 42 Table 3 — 19XL Heat Exchanger Weights English Rigging Wt (lb)* Machine Charge Rigging Wt (kg)* Machine Charge Code Refrigerant (lb)† Water (gal.) Refrigerant (kg)† Water (L) Con- Con- Cooler Cooler denser denser Only Only Con- Con- Con- Con- Only Cooler Cooler Only...
  • Page 43 Table 4 — Additional Heat Exchanger Weight for Marine Waterboxes* English Water Volume Water Volume Heat Exchanger Rigging Wt (lb) Rigging Wt (kg) (gal.) (gal.) Frame, Pass Con- Con- Con- Con- Cooler Cooler Cooler Cooler denser denser denser denser 1115 Frame 4, 2 Pass 2030 1160...
  • Page 44 Table 5A — 19XL Waterbox Cover Weights (English)* English (Lb) Frame 4, Std Frame 5, Std Frame 5, Frame 4, Flanged Nozzles Nozzles Flanged Heat Waterbox Exchanger Description psig psig psig psig psig psig psig psig NIH, 1 Pass Cover NIH, 2 Pass Cover NIH, 3 Pass Cover Coolers...
  • Page 45 Table 5B — 19XL Waterbox Cover Weights (SI)* SI (kg) Frame 4, Std Frame 4, Frame 5, Std Frame 5, Nozzles Flanged Nozzles Flanged Heat Waterbox Exchanger Description 1034 2068 1034 2068 1034 2068 1034 2068 NIH, 1 Pass Cover NIH, 2 Pass Cover NIH, 3 Pass Cover Coolers...
  • Page 46 Table 6 — Relief Device Locations Relief Valve Outlet Size Location Quantity Cooler 1-in. NPT Female Connector Condenser 1-in. NPT Female Connector Optional Storage Tank 1-in. NPT Female Connector...
  • Page 47 Figure 1 — Model Number Identification...
  • Page 48 Figure 2 (Front View) — Typical 19XL Installation (300 to 600 Tons [1055 to 2110 kW]) (See next page for Rear View)
  • Page 49 Figure 2 (Rear View) — Typical 19XL Installation (300 to 600 Tons [1055 to 2110 kW])
  • Page 50 Center of Gravity — Approximate Dimensions Maximum Rigging Heat Exchanger Weight (Without (Cooler and A (Length) B (Width) C (Height) Refrigerant Charge) Condenser) Size Ft-in. Ft-in. Ft-in. 40 to 43 (Frame 4) 1689 1040 21,200 19,616 50 to 53 (Frame 5) 1689 1040 26,400...
  • Page 51 Heat A (Length) Nozzle Size (in.) B (Width) C (Height) Exchanger (Nominal Pipe Size) 2 Pass* 1 or 3 Pass† Code (Cooler and ft-in. ft-in. ft-in. ft-in. 1-Pass 2-Pass 3-Pass Condenser) 40-43 13-7 3/4 4159 14-3 1/4 4350 5-5 3/4 1670 6-8 5/8 2048...
  • Page 52 Figure 5 — 19XL Condenser Drain...
  • Page 53 Figure 6 — 19XL Motor End View...
  • Page 54 Figure 7 — 19XL Machine Top View...
  • Page 55 Figure 8 — 19XL Refrigerant Return...
  • Page 56 Figure 9 — 19XL Oil Reclaim System...
  • Page 57 Heat Exchanger (Cooler/ Condenser) ft-in. ft-in. 40-43 5-5 3/4 1670 13-0 1/4 3968 50-53 6-0 1/4 1835 13-0 1/4 3968 55-58 6-0 1/4 1835 17-8 3/4 5404 Figure 10 — 19XL Machine Footprint...
  • Page 58 Figure 11 — Standard Isolation...
  • Page 59 Figure 12 — Accessory Isolation...
  • Page 60 Figure 13 — 19XL Accessory Spring Isolation (Shown with Accessory Soleplates)
  • Page 61 Figure 14 — Typical 19XL Low Profile Isolation Assembly...
  • Page 62 Figure 15 — Typical Nozzle Piping...
  • Page 63 Drive End Compressor End Nozzle-in-Head Waterboxes Drive End Compressor End Front View Drive End Compressor End Marine Waterboxes Drive End Compressor End Front View Nozzle Arrangement Codes Cooler Waterboxes Condenser Waterboxes Pass Arrangement Code Arrangement Code Waterbox Nozzle Sizes Nominal Pipe Size (in.) Actual Pipe ID (in.) Actual Pipe OD (in.) Pass...
  • Page 64 Denotes center of gravity Dimensions—English (ft-in.) Tank Size 0428 10-5 9-10 4-11 4 3/4 2 3/8 10 3/4 8 1/8 9 7/16 3 1/2 8 3/4 7 7/8 7 5/16 7 3/4 0452 11 1/4 4 1/2 0 7/8 8 1/2 4 1/4 2 1/4 11 7/8...
  • Page 65 Trade Size Location 1/2” 3/4” bottom 1” middle 1 1/4” middle Rated Dry Weight and Refrigerant Capacity English (lb) Maximum Refrigerant Capacity (lb) Tank Tank OD Weight* ASHRAE 15 ARI 495 Size (in.) (lb) (HCFC-22) (HFC-134a) (HCFC-22) (HFC-134a) 0428 24.00 2200 1840 2025...
  • Page 66 Figure 18 — Optional Pumpout System Piping Schematic with Storage Tank...
  • Page 67 Figure 19 — Optional Pumpout System Piping Schematic without Storage Tank...
  • Page 68 Figure 20 — Pumpout Unit...
  • Page 69 Figure 21 — Relief Valve Locations...
  • Page 70 Figure 22 — Carrier Comfort Network Communication Bus Wiring...
  • Page 71 Figure 23 — COMM1 CCN Communication Wiring For Multiple Chillers (Typical)
  • Page 72 Figure 24 — 19XL With Optional Unit-Mounted Starter...
  • Page 73 Figure 25 — 19XL With Freestanding Starter...
  • Page 74 LEGEND AWG — 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...
  • Page 75 LEGEND — Required Power Wiring — Required Control Wiring — Options Wiring Figure 27 — 19XL Typical Field Wiring with Free-Standing Starter...
  • Page 76 Figure 28 — Oil Pump Wiring...
  • Page 77 Figure 29 — Oil Heater and Control Power Wiring...
  • Page 78 Figure 30 — 19XL Insulation Area...

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