hermetic centrifugal liquid chillers 50 hz - acareacare.eu/carriercd/litt/11997_iom_06_2004.pdf2 the...

19XR (PIC II)

Hermetic CentrifugalLiquid Chillers

50 Hz

Installation, Operation and Maintenance Instructions

2

The cover illustrations, as well as the diagrams, in this document are for illustrative purposes only and not part of anyoffer for sale or contract.

TABLE OF CONTENTS

INITIAL START-UP CHECKLIST FOR 19XR HERMETIC CENTRIFUGAL LIQUID CHILLERS ................................. 5

1 - SAFETY CONSIDERATIONS ................................................................................................................................................... 91.1 - Installation safety considerations ................................................................................................................................................ 91.2 - Maintenance safety considerations ............................................................................................................................................. 91.3 - Operating checks ......................................................................................................................................................................... 91.4 - Equipment and components under pressure ............................................................................................................................. 101.5 - Repair safety considerations ..................................................................................................................................................... 10

2 - INTRODUCTION AND CHILLER FAMILIARIZATION ................................................................................................... 112.1 - C.E. Mark .................................................................................................................................................................................. 112.2 - Abbreviations and explanations ................................................................................................................................................ 112.3 - Chiller familiarization ............................................................................................................................................................... 12

2.3.1 - Chiller information plate .................................................................................................................................................. 122.3.2 - System components .......................................................................................................................................................... 122.3.3 - Cooler ............................................................................................................................................................................... 122.3.4 - Condenser ......................................................................................................................................................................... 122.3.5 - Motor-compressor ............................................................................................................................................................ 122.3.6 - Control centre ................................................................................................................................................................... 122.3.7 - Factory-mounted starter (optional) ................................................................................................................................... 132.3.8 - Storage vessel (optional) .................................................................................................................................................. 13

2.4 - Refrigeration cycle .................................................................................................................................................................... 132.5 - Motor/oil refrigeration cooling cycle ........................................................................................................................................ 142.6 - Lubrication cycle ....................................................................................................................................................................... 14

2.6.1 - Summary .......................................................................................................................................................................... 142.6.2 - Details ............................................................................................................................................................................... 14

2.7 - Power equipment ....................................................................................................................................................................... 15

3 - INSTALLATION ........................................................................................................................................................................ 173.1 - Introduction ............................................................................................................................................................................... 173.2 - Receiving the machine .............................................................................................................................................................. 17

3.2.1 - Inspect shipment ............................................................................................................................................................... 173.2.2 - Provide machine protection .............................................................................................................................................. 17

3.3 - Rigging the machine ................................................................................................................................................................. 173.3.1 - Rigging the complete machine ......................................................................................................................................... 173.3.2 - Rig machine components ................................................................................................................................................. 183.3.3 - Physical data ..................................................................................................................................................................... 19

3.4 - Install machine supports ............................................................................................................................................................ 253.4.1 - Install standard isolation ................................................................................................................................................... 253.4.2 - Installation of a levelling accessory (if necessary) ........................................................................................................... 253.4.3 - Install spring isolation ...................................................................................................................................................... 26

3.5 - Connection of water piping ....................................................................................................................................................... 263.5.1 - Install water piping to heat exchanger .............................................................................................................................. 263.5.2 - Install vent piping to relief devices .................................................................................................................................. 30

3.6 - Make electrical connections ...................................................................................................................................................... 303.6.1 - Installation standards and precautions .............................................................................................................................. 303.6.2 - Electrical characteristics of the motors ............................................................................................................................ 313.6.3 - Recommended wire section ............................................................................................................................................. 343.6.4 - Communication wiring ..................................................................................................................................................... 363.6.5 - Make the necessary connections for the outgoing control signals ................................................................................... 373.6.6 - Connect the starting cabinet ............................................................................................................................................. 373.6.7 - Connect the starting cabinet to the control box ................................................................................................................ 393.6.8 - Carrier Comfort Network interface (CCN) ...................................................................................................................... 40

3.7 - Special characteristics of the control box (wired) ..................................................................................................................... 403.7.1 - Characteristics .................................................................................................................................................................. 413.7.2 - Factory starter control ...................................................................................................................................................... 41

3.8 - Install field insulation ................................................................................................................................................................ 42

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TABLE OF CONTENTS (cont'd)

4 - BEFORE INITIAL START-UP ................................................................................................................................................ 434.1 - Necessary checks ...................................................................................................................................................................... 43

4.1.1 - Job data required .............................................................................................................................................................. 434.1.2 - Equipment required .......................................................................................................................................................... 434.1.3 - Using the optional storage tank and pumpout system ...................................................................................................... 434.1.4 - Remove shipping packaging ............................................................................................................................................ 434.1.5 - Open oil circuit valves ...................................................................................................................................................... 434.1.6 - Tighten all gasketed joints and guide vane shaft packing (torque depends on screw diameter) ...................................... 434.1.7 - Inspect water piping ......................................................................................................................................................... 434.1.8 - Check relief devices ......................................................................................................................................................... 44

4.2 - Chiller tightness ........................................................................................................................................................................ 444.2.1 - Check chiller tightness ..................................................................................................................................................... 444.2.2 - Refrigerant tracer .............................................................................................................................................................. 444.2.3 - Leak test chiller ................................................................................................................................................................ 44

4.3 - Standing vacuum test ................................................................................................................................................................ 454.4 - Chiller dehydration ................................................................................................................................................................... 454.5 - Inspect wiring ............................................................................................................................................................................ 474.6 - Carrier Comfort Network interface (see Fig. 22) ...................................................................................................................... 474.7 - Check starter ............................................................................................................................................................................. 474.8 - Oil charge .................................................................................................................................................................................. 484.9 - Power up the controls and check the oil heater ......................................................................................................................... 484.10 - Check optional pumpout system controls and compressor ..................................................................................................... 484.11 - High altitude locations ............................................................................................................................................................ 484.12 - Charge refrigerant into chiller ................................................................................................................................................. 484.13 - Chiller equalization without pumpout unit ............................................................................................................................. 484.14 - Chiller equalization with pumpout unit .................................................................................................................................. 494.15 - Trimming refrigerant charge ................................................................................................................................................... 49

5 - INITIAL START-UP .................................................................................................................................................................. 505.1 - Preparation ................................................................................................................................................................................ 505.2 - Dry run to test start-up sequence .............................................................................................................................................. 505.3 - Check rotation ........................................................................................................................................................................... 505.4 - Check oil pressure and compressor stop ................................................................................................................................... 505.5 - To prevent accidental start-up ................................................................................................................................................... 505.6 - Check chiller operating condition ............................................................................................................................................. 515.7 - Instruct the customer operator .................................................................................................................................................. 51

6 - OPERATING INSTRUCTIONS ............................................................................................................................................... 516.1 - Operator duties .......................................................................................................................................................................... 516.2 - To start the chiller ...................................................................................................................................................................... 516.3 - Check the running system ......................................................................................................................................................... 516.4 - To stop the chiller ...................................................................................................................................................................... 526.5 - After limited shutdown .............................................................................................................................................................. 526.6 - Extended shutdown ................................................................................................................................................................... 526.7 - After extended shutdown........................................................................................................................................................... 526.8 - Cold-weather operation ............................................................................................................................................................. 526.9 - Manual guide vane operation .................................................................................................................................................... 526.10 - Refrigeration log ..................................................................................................................................................................... 52

7 - MAINTENANCE ....................................................................................................................................................................... 547.1 - General maintenance ................................................................................................................................................................. 54

7.1.1 - Soldering and welding ...................................................................................................................................................... 547.1.2 - Refrigerant properties ....................................................................................................................................................... 547.1.3 - Adding refrigerant ............................................................................................................................................................ 547.1.4 - Removing refrigerant ....................................................................................................................................................... 547.1.5 - Adjusting the refrigerant charge ....................................................................................................................................... 547.1.6 - Refrigerant leak testing .................................................................................................................................................... 547.1.7 - Checking guide vane linkage ........................................................................................................................................... 557.1.8 - Trim refrigerant charge ..................................................................................................................................................... 55

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TABLE OF CONTENTS (cont'd)

7.2 - Weekly maintenance ................................................................................................................................................................. 557.3 - Scheduled maintenance ............................................................................................................................................................. 56

7.3.1 - Service ontime .................................................................................................................................................................. 567.3.2 - Inspect the control centre ................................................................................................................................................. 567.3.3 - Changing oil filter ............................................................................................................................................................ 567.3.4 - Oil specification ................................................................................................................................................................ 567.3.5 - Refrigerant filter ............................................................................................................................................................... 567.3.6 - Oil reclaim filter ............................................................................................................................................................... 577.3.7 - Inspect refrigerant float system ........................................................................................................................................ 577.3.8 - Inspect relief valves and piping (see chapter 'Safety considerations') ............................................................................. 577.3.9 - Verification of the pressure switch calibration ................................................................................................................. 577.3.10 - Compressor bearing and gear maintenance .................................................................................................................... 577.3.11 - Useful compressor maintenance diagrams ..................................................................................................................... 587.3.12 - Inspect the heat exchanger tubes .................................................................................................................................... 597.3.13 - Water leaks ..................................................................................................................................................................... 597.3.14 - Inspect the starting equipment ........................................................................................................................................ 597.3.15 - Check pressure transducers ............................................................................................................................................ 597.3.16 - Corrosion control ............................................................................................................................................................ 59

LIST OF FIGURESFig. 1 - Model number nomenclature ................................................................................................................................................ 12Fig. 2 - 19XR machine components .................................................................................................................................................. 12Fig. 3 - Refrigerant motor cooling and oil cooling cycles ................................................................................................................ 13Fig. 4 - Lubrication system................................................................................................................................................................ 15Fig. 5A - Starter cabinet - internal view with internal door closed ................................................................................................... 16Fig. 5B - Starter cabinet - internal view with internal door open ...................................................................................................... 16Fig. 6 - Machine rigging guide .......................................................................................................................................................... 18Fig. 7 - Dimensional drawing ............................................................................................................................................................ 22Fig. 8 - Dimensional drawing - cooler, side view.............................................................................................................................. 23Fig. 9 - 19XR chiller top view ........................................................................................................................................................... 23Fig. 10 - Compressor detail ............................................................................................................................................................... 24Fig. 11 - Unit rear view ..................................................................................................................................................................... 24Fig. 12 - Chiller footprint .................................................................................................................................................................. 25Fig. 13 - Standard isolation ............................................................................................................................................................... 26Fig. 14 - Accessory isolation ............................................................................................................................................................. 26Fig. 15 - 19XR Accessory spring isolation ........................................................................................................................................ 26Fig. 16 - Typical nozzle piping .......................................................................................................................................................... 27Fig. 17 - Nozzle arrangements - nozzle-in-head waterboxes ............................................................................................................ 28Fig. 18 - Optional pumpout system piping schematic with storage tank .......................................................................................... 29Fig. 19 - Pumpout system piping schematic with storage tank ......................................................................................................... 29Fig. 20 - Relief device locations ........................................................................................................................................................ 30Fig. 21 - COMM1 CCN communication wiring for multiple chillers (typical) ................................................................................ 36Fig. 22 - 19XR with optional unit-mounted starter ........................................................................................................................... 37Fig. 23 - 19XR with freestanding starter ........................................................................................................................................... 38Fig. 24 - Machine isolation ................................................................................................................................................................ 42Fig. 25 - 19XR leak detection procedure .......................................................................................................................................... 46Fig. 26 - Dehydration cold trap ......................................................................................................................................................... 47Fig. 27 - Rotation diagram ................................................................................................................................................................ 50Fig. 28 - Refrigeration log ................................................................................................................................................................. 53Fig. 29 - Guide vane actuator linkage ............................................................................................................................................... 55Fig. 30 - 19XR float valve design ..................................................................................................................................................... 57Fig. 31 - Compressor fits and clearances .......................................................................................................................................... 58

5

INITIAL START-UP CHECKLIST FOR 19XR HERMETIC CENTRIFUGAL LIQUID CHILLERS

Name: _____________________________________________________________________________________________Address: ____________________________________________________________________________________________Town: ______________________________________________________________________________________________Country: ____________________________________________________________________________________________Post code: ___________________________________________________________________________________________Job No.: _____________________________________________________________________________________________Model: ______________________________________________________________________________________________Serial No.: ____________________________________________________________________________________________

Design conditions:

Cooling Brine Flow Temperature Temperature Pressure Pass Suction Condensingcapacity rate in out drop temperature temperature

Evaporator

Condenser

Compressor: Volts _______________________ RLA: _______________________ OLTA: __________________Starter: Mfg ________________________ Type: _______________________Oil pump: Volts _______________________ RLA: _______________________ OLTA: __________________

Control/oil heater: 115 Volts ___________ 230 Volts ___________Refrigerant: Type _______________ Charge (kg) __________

Carrier obligations:Assemble: Yes ________ No ________Leak test: Yes ________ No ________Dehydrate: Yes ________ No ________Charging: Yes ________ No ________Operating instructions: ____________ Hours

START-UP TO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UP INSTRUCTIONS

Job data required:1. Machine installation instructions 19XR Yes ________ No ________2. Machine assembly, wiring and piping diagrams Yes ________ No ________3. Starting equipment details and wiring diagrams Yes ________ No ________4. Applicable design data (see above) Yes ________ No ________5. Diagrams and instructions for special controls Yes ________ No ________

Initial machine pressure: __________________

Was machine tight? Yes ________ No ________If not, were leaks corrected? Yes ________ No ________Was machine dehydrated after repairs? Yes ________ No ________

Check oil level and record:Add oil: Yes ________ No ________Amount: ___________________________

_______ 3/4 _______ 3/4_______ 1/2 Top sight glass _______ 1/2 Bottom sight glass_______ 1/4 _______ 1/4

Record pressure drops:Evaporator ________________ Condenser ________________

Refrigerant charge:Initial charge _______________ Final charge after trim ______________

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INSPECT WIRING AND RECORD ELECTRICAL DATA:

Ratings:Motor voltage: ________ Motor(s) amps: ________ Oil pump voltage: ________ Starter amps: ________Line voltages: Motor: _____________ Oil pump: _____________ Controls/oil heater: ____________

Field-installed starters only:Check continuity T1 to T1, etc (motor to starter power wiring).Megger starter: Do not megger a motor connected to a solid-state starter, unless the leads to the motor are disconnected andmeggered.

Megger motor Phase to phase Phase to ground

T1-T2 T1-T3 T2-T3 T1-G T2-G T3-G

10-second readings

60-second readings

Polarization ratio

Starter:Electro-mechanical __________ Electronic __________

Motor load current transformer ratio _____ : _____ Signal resistor size ________ OhmsTransition timer time __________ seconds

Check magnetic overloads: Add dash pot oil Yes _______ No _______Solid-state overloadsYes _______ No _______

Solid-state starter: Initial voltage __________ Volts Ramp setting __________ seconds

Controls: safety, operating, etcPerform controls test Yes _______ No _______

CAUTION: Compressor motor and control centre must be properly and individually connected back to the earth ground in thestarter (in accordance with certified drawings). Yes _______

Run machine:Do these safeties shut down the machine?Condenser water flow switch: Yes ________ No ________Chilled water flow switch: Yes ________ No ________Pump interlocks: Yes ________ No ________

Initial start:Line up all valves in accordance with instruction manual: _______ Start water pumps and establish water flow: ________Oil level and temperature correct: ________ Check oil pump rotation pressure ________Check compressor motor rotation (motor end sight glass) and record: Clockwise ________Restart compressor. Bring up to speed. Shut down. Any abnormal coastdown noise?: Yes* ________ No ________* If yes, determine cause

Start machine and operate. Complete the following:A. Trim charge and record.B. Complete any remaining control calibration and record.C. Take at least 2 sets of operational log readings and record.D. After machine has been successfully run and set up, shut down and mark shutdown oil and refrigerant levels.E. Give operating instructions to owner's operating personnel. Hours given: ________ hrsF. Call your Carrier factory representative to report chiller start-up.

Signature: ______________________________________ Date: _________(Carrier technician)

Signature: ______________________________________ Date: _________(Customer representative)

7

19XR HERMETIC CENTRIFUGAL LIQUID CHILLER CONFIGURATION SETTINGS LOG(Remove and use for job file)

Controller name: Bus No.:Element No.Table description: Table name: SETPOINT

Setpoint table configuration sheet 19XR

Description Range Units Default Value

Base demand limit 40 to 100 % 100

LCW setpoint 12.2 to 48.9 °C 50

ECW setpoint 12.2 to 48.9 °C 60

Controller name: Bus No.:Element No.Table description: Table name: OCCP01S

Local mode time schedule configuration sheet - 19XR PIC II control - OCCP01S

Day Occupied time Unoccupied time

M T W T F Sa Su H

Period 1

Period 2

Period 3

Period 4

Period 5

Period 6

Period 7

Period 8

Note: Default setting is occupied 24 hours/day

Local mode time schedule configuration sheet - 19XR PIC II control - OCCP01S

Day Occupied time Unoccupied time

M T W T F Sa Su H

Period 1

Period 2

Period 3

Period 4

Period 5

Period 6

Period 7

Period 8

Note: Default setting is occupied 24 hours/day

Controller name: Bus No.:Element No.Table description: Table name: HOLIDEFS

Holiday configuration sheet

Description Range Units Value

Holiday start month 1-12

Holiday start day 1-31

Duration 0-99 Days

8

Table description: Table name: HOLIDEFS





Duration 0-99 Days

Table description: Table name: HOLIDEFS





Duration 0-99 Days

9

1 - SAFETY CONSIDERATIONS

19XR liquid chillers are designed to provide safe and reliableservice when operated within design specifications. Whenoperating this equipment, use good judgment and safetyprecautions to avoid damage to equipment and property orinjury to personnel.

Be sure you understand and follow the procedures and safetyprecautions contained in the machine instructions as well asthose listed in this guide.

1.1 - Installation safety considerations

In certain cases the safety stops are installed on ball valves.These valves are factory-supplied lead-sealed in the openposition. This system permits isolating and removing thesafety stop for checking and replacing. The safety stops aredesigned and installed to ensure protection against fire risk.Removing the safety stops is only permitted if the fire risk isfully controlled and the responsibility of the user.

All factory-installed safety valves are lead-sealed to preventany calibration change. If a safety stop is removed forchecking or replacement please ensure that there is always anactive safety stop on each of the reversing valves installed inthe unit.

The safety valves must be connected to discharge pipes. Thesepipes must be installed in a way that ensures that people andproperty are not exposed to refrigerant leaks. These fluidsmay be diffused in the air, but far away from any building airintake, or they must be discharged in a quantity that isappropriate for a suitably absorbing environment.

Periodic check of the safety valves: See paragraph“Maintenance safety considerations”.

DANGER:DO NOT VENT refrigerant relief valves within a building.Outlet from relief valve must be vented outdoors. The accumu-lation of refrigerant in an enclosed space can displace oxygenand cause asphyxiation.

PROVIDE adequate ventilation, especially for enclosed andlow overhead spaces. Inhalation of high concentrations ofvapour is harmful and may cause heart irregularities, uncon-sciousness, or death. Misuse can be fatal. Vapour is heavierthan air and reduces the amount of oxygen available forbreathing. Product causes eye and skin irritation.Decomposition products are hazardous.

DO NOT USE OXYGEN to purge lines or to pressurize amachine for any purpose. Oxygen gas reacts violently with oil,grease, and other common substances.

NEVER EXCEED specified test pressures, VERIFY the allow-able test pressure by checking the instruction literature andthe design pressures on the equipment nameplate.

DO NOT USE air for leak testing. Use only refrigerant or drynitrogen.

DO NOT VALVE OFF any safety device.

BE SURE that all pressure relief devices are properlyinstalled before operating any machine.

1.2 - Maintenance safety considerations

Engineers working on the electric or refrigeration componentsmust be authorized, trained and fully qualified to do so.

All refrigerant circuit repairs must be carried out by a trainedperson, fully qualified to work on these units. He must havebeen trained and be familiar with the equipment and theinstallation. All welding operations must be carried out byqualified specialists.

Any manipulation (opening or closing) of a shut-off valvemust be carried out by a qualified and authorised engineer.These procedures must be carried out with the unit shut-down.

NOTE: The unit must never be left shut down with the liquidline valve closed.

During any handling, maintenance and service operations theengineers working on the unit must be equipped with safetygloves, glasses, shoes and protective clothing.

WARNING:DO NOT WELD OR FLAMECUT any refrigerant line orvessel until all refrigerant (liquid and vapour) has beenremoved from chiller. Traces of vapour should be displacedwith dry air nitrogen and the work area should be wellventilated. Refrigerant in contact with an open flame producestoxic gases.

DO NOT work on high-voltage equipment unless you are aqualified electrician.

DO NOT WORK ON electrical components, including controlpanels, switches, relays etc, until you are sure ALL POWERIS OFF; residual voltage can leak from capacitors or solidstate components.

LOCK OPEN AND TAG electrical circuits during servicing.

IF WORK IS INTERRUPTED, confirm that all circuits arede-energized before resuming work.

1.3 - Operating checks

During the life-time of the system, inspection and tests mustbe carried out in accordance with national regulations.

The information on operating inspections given in annex C ofstandard EN378-2 can be used if no similar criteria exist inthe national regulations.

Safety device checks (annex C6 – EN378-2): The safetydevices must be checked on site once a year for safety devices(high-pressure switches), and every five years for externaloverpressure devices (safety globe valves).

If the machine operates in a corrosive environment, inspectthe protection devices more frequently.

10

Any use of these chillers with a different refigerant must be inaccordance with applicable national standards.

DO NOT ATTEMPT TO REMOVE connections, componentsetc., while the machine is under pressure or operating. Makesure that the pressure is 0 kPa, before disconnecting therefrigerant connections.

ATTENTION: No part of the unit must use feet, racks orsupports during operation. Periodically monitor and repair orif necessary replace any component or piping that showssigns of damage.

DO NOT climb over a machine. Use platform, or staging.

USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to liftor move heavy components. Even if components are light, usemechanical equipment when there is a risk of slipping or losingyour balance.

DO NOT USE eyelets to lift any part of the machine or thecomplete machine.

BE AWARE that certain automatic start arrangements CANENGAGE COOLING TOWER FAN, OR PUMPS. Open thedisconnect ahead of the tower fans, or pumps.

USE only repair or replacement parts that meet the coderequirements of the original equipment.

DO NOT VENT OR DRAIN water boxes containing industrialbrines, without the permission of your process control group.

DO NOT LOOSEN water box bolts until the water box hasbeen completely drained.

DO NOT LOOSEN a packing gland nut before checking thatthe nut has a positive thread engagement.

PERIODICALLY INSPECT all valves, fittings, and pipingfor corrosion, rust, leaks, or damage.

During refrigerant removal and storage operations follow applic-able regulations. These regulations, permitting conditioning andrecovery of halogenated hydrocarbons under optimum qualityconditions for the products and optimum safety conditions forpeople, property and the environment are described in standardNFE 29795.

Any refrigerant transfer and recovery operations must be carriedout using a transfer unit. A 3/8” SAE connector on the manualliquid line valve is supplied with all units for connection to thetransfer station. The units must never be modified to add refri-gerant and oil charging, removal and purging devices. All thesedevices are provided with the units. Please refer to the certifieddimensional drawings for the units.

DO NOT ATTEMPT TO REPAIR OR RECONDITION anysafety devices when corrosion or build-up of foreign material(rust, dirt, scale, etc.) is found within the valve body ormechanism. If necessary, replace the device.

DO NOT install safety valves in series or backwards.

PROVIDE A DRAIN connection in the vent line near eachpressure relief device to prevent a build-up of condensate orrain water.

1.4 - Equipment and components under pressure

These products incorporate equipment or components underpressure, manufactured by Carrier or other manufacturers. Werecommend that you consult your appropriate national tradeassociation or the owner of the equipment or components underpressure (declaration, re-qualification, retesting, etc.). Thecharacteristics of this equipment/these components are givenon the nameplate or in the required documentation, suppliedwith the products.

1.5 - Repair safety considerations

All installation parts must be maintained by the personnel incharge, in order to avoid material deterioration and injuries topeople. Faults and leaks must be repaired immediately. Theauthorized technician must have the responsibility to repair thefault immediately. Each time repairs have been carried out tothe unit, the operation of the safety devices must be re-checked.

If a leak occurs or if the refrigerant becomes polluted (e.g. by ashort circuit in a motor) remove the complete charge using arecovery unit and store the refrigerant in mobile containers.Repair the leak detected and recharge the circuit with the totalR134a charge, as indicated on the unit name plate.

DO NOT siphon refrigerant.

AVOID SPILLING liquid refrigerant on skin or getting itinto the eyes. USE SAFETY GOGGLES AND SAFETYGLOVES. Wash any spills from the skin with soap and water.If liquid refrigerant enters the eyes, IMMEDIATELY FLUSHEYES with water and consult a physician.

NEVER APPLY an open flame or live steam to refrigerantcylinder. Dangerous overpressure can result. If it is necessaryto heat refrigerant, use only warm water.

DO NOT REUSE disposable (non-returnable) cylinders orattempt to refill them. It is DANGEROUS AND ILLEGAL.When cylinders are emptied, evacuate remaining gas pressure,loosen the collar and unscrew and discard the valve stem. DONOT INCINERATE.

After refrigerant draining operations, CHECK THE REFRI-GERANT TYPE before adding refrigerant to the machine.The introduction of the wrong refrigerant can cause damageor malfunction to this machine.

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2 - INTRODUCTION AND CHILLER FAMILIARIZATION

Prior to initial start-up of the 19XR unit, those involved in thestart-up, operation, and maintenance should be thoroughlyfamiliar with these instructions and other necessary job data. Thisbook is outlined so that you may become familiar with the con-trol system before performing start-up procedures. Proceduresin this manual are arranged in the sequence required for properchiller start-up and operation.

Maximum outside temperature:For transport and storage of the 19XR units the minimum andmaximum allowable temperatures are –20°C and +48°C.

Unit operating range

Evaporator 19XR Minimum Maximum

Evaporator entering water temperature* °C 6 17Evaporator leaving water temperature* °C 3.3 10

Condenser (water-cooled) 19XR Minimum Maximum

Condenser entering water temperature* °C 16 35Condenser leaving water temperature* °C 13.3 44

* For application requiring brine operation, contact Carrier SA for unit selectionusing the Carrier electronic catalog.

WARNING: This unit uses a microprocessor control system.Do not short or jumper between terminations on circuitboards or modules; control or board failure may result.

Be aware of electrostatic discharge (static electricity) whenhandling or making contact with circuit boards or moduleconnections. Always touch a chassis (grounded) part todissipate body electrostatic charge before working inside controlcentre.

Use extreme care when handling tools near boards and whenconnecting or disconnecting terminal plugs. Circuit boardscan easily be damaged. Always hold boards by the edges andavoid touching components and connections.

This equipment uses, and can radiate, radio frequency energy.If not installed and used in accordance with the instructionmanual, it may cause interference to radio communications. Ithas been tested and found to comply with European Directive89/336/EEC, on Electromagnetic Compatibility. Operation ofthis equipment in a residential area is likely to cause inter-ference, in which case the user, at his own expense, will berequired to take whatever measures may be required to correctthe interference. Always store and transport replacement ordefective boards in anti-static shipping bag.

2.1 - C.E. Marking

The machines that carry the CE mark must comply with thefollowing European directives:- Pressure equipment directive (PED) 97/23/EC- Machinery directive 98/37/EC, modified- Low voltage directive 73/23/EEC, modified- Electromagnetic compatibility 89/336/EEC, modified, and

with the recommendations of the appluicable Europeanstandards:- Machinery safety, electrical equipment for machines,

general regulations: EN 60204-1- Electromagnetic emission: EN 50081-2- Electromagbnetic immunity: EN 50082-2

2.2 - Abbreviations and explanations

Frequently used abbreviations in this manual include:CCM - Chiller Control ModuleCCN - Carrier Comfort NetworkCCW - CounterclockwiseCVC - Chiller Visual ControlCW - ClockwiseECW - Entering Chilled WaterECDW - Entering Condenser WaterEMS - Energy Management SystemHGBP - Hot Gas BypassI/O - Input/OutputISM - Integrated Starter ModuleLCD - Liquid Crystal DisplayLCDW - Leaving Condenser WaterLCW - Leaving Chilled WaterLED - Light-Emitting DiodeOLTA - Overload Trip AmpsPIC II - Product Integrated Control IIRLA - Rated Load AmpsSI - International System of Units of MeasurementTXV - Thermostatic Expansion Valve

The CVC software version number of your 19XR unit will belocated on the CVC module.

Information on the unit control is not included in this manual.Refer to separate control manual.

All information given on unit-mounted starters refers to star-delta connected starters. Electronic starters have separatedocumentation.

12

2.3 - Chiller familiarization

2.3.1 - Chiller information plateThe information plate is located below the control box.

Chronological number

19XR 52 51 CQ 475 I S P EE

Fig. 1 - Model number nomenclature

2.3.2 - System componentsThe components include the cooler and condenser heat exchan-gers in separate vessels, motor-compressor, lubrication package,control centre, and motor starter. All connections from pressurevessels have external threads to enable each component to bepressure tested with a threaded pipe cap during factory assembly.

2.3.3 - CoolerThis vessel (also known as the evaporator) is located underneaththe compressor. The cooler is maintained at lower temperature/pressure so that evaporating refrigerant can remove heat fromwater flowing through its internal tubes.

2.3.4 - CondenserThe condenser operates at a higher temperature/pressure thanthe cooler and has water flowing through its internal tubes inorder to remove heat from the refrigerant.

2.3.5 - Motor-compressorThis component maintains system temperature/pressuredifferences and moves the heat carrying refrigerant from thecooler to the condenser.

2.3.6 - Control centreThe control centre is the user interface for controlling thechiller. It regulates the chiller’s capacity as required to maintainproper leaving chilled water temperature.

Fig. 2 - 19XR machine components

1. Guide vane actuator2. Suction elbow3. Compressor4. Cooler, auto reset relief valve*5. Cooler pressure transducer6. Condenser in/out temperature thermistors7. Cooler in/out temperature thermistors8. Machine identification nameplate (situated on the starter cabinet side) - see

right-hand figure 'Rear view'9. Refrigerant charging valve10. Typical flange connections11. Oil drain valve12. Oil level sight glass13. Refrigerant oil cooler (hidden)14. Branch circuit control box

* One relief valve is standard. The optional dual relief valves include change-over for each heat exchanger.

��

15. Condenser auto reset relief valves*16. Circuit breaker/disconnect switch17. CVC18. Unit-mounted starter (optional)19. Motor sight glass20. Cooler return-end waterbox cover21. Cooler nameplate22. Condenser nameplate23. Typical waterbox drain port24. Condenser return-end waterbox cover25. Refrigerant moisture/flow indicator26. Refrigerant filter/drier27. Liquid line isolation valve (optional)28. Linear float valve chamber29. Vessel take-apart connector30. Discharge isolation valve (optional)31. Pumpout valve32. Condenser pressure transducer

9

1011

14

13 12

7

1 23

4

5

6

32

15

29 28 27 26 25 2230

31

1819

20

21

2324

1617

8 33

Internal codes

Model descriptionHigh-efficiency hermeticcentrifugal liquid chiller

Cooler size- 6 sizes- 3 lengths

Condenser size- 6 sizes- 3 lengths

Compressor code

Motor code- 4 sizes- 27 models

European pressurevessel codeP - PED

Motor efficiency codeH: high efficiencyS: standard efficiency

Chronology

13

The control centre:• registers cooler, condenser, and lubricating system pressures• shows chiller operating condition and alarm shutdown

conditions• records the total chiller operating hours• sequences chiller start, stop, and recycle under micro-

processor control• provides access to other CCN (Carrier Comfort Network)

devices

2.3.7 - Factory-mounted starter (Optional)The starter allows for the proper start and disconnect of elec-trical energy for the compressor-motor, oil pump, oil heater,and control panels.

2.3.8 Storage vessel (optional)There are 2 sizes of storage vessels available. The vessels haverelief valves, a drain valve and a male flare vapour connectionfor the pumpout unit.

NOTE: If a storage vessel is not used at the jobsite, factory-installed isolation valves on the chiller may be used to isolatethe chiller charge in either the cooler or condenser. An optionalpump-out system is used to transfer refrigerant from vessel tovessel.

2.4 - Refrigeration cycle

The compressor continuously draws refrigerant vapour fromthe cooler at a rate set by the amount of guide vane opening.As the compressor suction reduces the pressure in the cooler,the remain-ing refrigerant boils at a fairly low temperature(typically 3 to 6°C). The energy required for boiling is obtainedfrom the water flowing through the cooler tubes. With heatenergy removed, the water becomes cold enough for use in anair conditioning circuit or process liquid cooling.

After taking heat from the water, the refrigerant vapour is com-pressed. Compression adds still more heat energy, and the refri-gerant is quite warm (typically 37 to 40°C) when it is dischargedfrom the compressor into the condenser.

Relatively cool (typically 18 to 32°C) water flowing into thecondenser tubes removes heat from the refrigerant and thevapour condenses to liquid.

The liquid refrigerant passes through orifices into the FLASC(Flash Subcooler) chamber (Fig. 3). Since the FLASC chamberis at a lower pressure, part of the liquid refrigerant flashes tovapour, thereby cooling the remaining liquid. The FLASC vapour

Fig. 3 - Refrigerant motor cooling and oil cooling cycles

1. FLASC chamber2. Condenser water3. Condenser4. Condenser isolation valve5. Transmission6. Diffuser7. Guide vane motor8. Motor9. Guide vanes10. Impeller

11. Compressor12. Back pressure orifice13. Oil cooling14. Oil filter15. Oil pump16. Stator17. Rotor18. Refrigerant cooling isolation valve19. Float valve chamber20. Filter drier

21. Orificed fitting22. Moisture/flow indicator23. Orificed fitting24. Thermostatic expansion valves (TXV)25. Distribution pipe26. Cooler isolation valve27. Evaporator28. Chilled water29. Refrigerant liquid30. Refrigerant vapour31. Refrigerant liquid/vapour

14

is recondensed on the tubes which are cooled by entering con-denser water. The liquid drains into a float chamber between theFLASC chamber and cooler. Here a float valve forms a liquidseal to keep FLASC chamber vapour from entering the cooler.When liquid refrigerant passes through the valve, some of it flashesto vapour in the reduced pressure on the cooler side. In flashing,it removes heat from the remaining liquid. The refrigerant isnow at a temperature and pressure at which the cycle began.

2.5 - Motor/oil refrigeration cooling cycle

The motor and the lubricating oil are cooled by liquid refrigeranttaken from the bottom of the condenser vessel (Fig. 3). Flow ofrefrigerant is maintained by the pressure differential that existsdue to compressor operation. After the refrigerant flows past anisolation valve, an in-line filter, and a sight glass/moisture indi-cator, the flow is split between motor cooling and oil coolingsystems.

Flow to the motor flows through an orifice and into the motor.Once past the orifice, the refrigerant is directed over the motorby a spray nozzle. The refrigerant collects in the bottom of themotor casing and then is drained back into the cooler throughthe motor refrigerant drain line. A back pressure valve or anorifice in this line maintains a higher pressure in the motorshell than in the cooler/oil sump. The motor is protected by atemperature sensor imbedded in the stator windings. A furtherincrease in motor winding temperature past the motor overrideset point will override the temperature capacity control to hold,and if the motor temperature rises 5.5 K above this set point,will close the inlet guide vanes. If the temperature rises abovethe safety limit, the compressor will shut down.

Refrigerant that flows to the oil cooling system is regulated bythermostatic expansion valves (TXVs). The TXVs regulate flowinto the oil/refrigerant plate and frame-type heat exchanger. Theexpansion valve bulbs control oil temperature to the bearings.The refrigerant leaving the heat exchanger then returns to thecooler.

2.6 - Lubrication cycle

2.6.1 - SummaryThe oil pump, oil filter, and oil cooler make up a package locatedpartially in the transmission casting of the compressor-motorassembly. The oil is pumped into a filter assembly to removeforeign particles and is then forced into an oil cooler heat exchan-ger where the oil is cooled to proper operational temperatures.After the oil cooler, part of the flow is directed to the gears andthe high speed shaft bearings; the remaining flow is directed tothe motor shaft bearings. Oil drains into the transmission oilsump to com-plete the cycle (Fig. 4).

2.6.2 - DetailsOil is charged into the lubrication system through a hand valve.Two sight glasses in the oil reservoir permit oil level observation.Normal oil level is between the middle of the upper sight glassand the top of the lower sight glass when the compressor isshut down. The oil level should be visible in at least one of the2 sight glasses during operation.

Oil sump temperature is displayed on the CVC default screen.Oil sump temperature ranges during compressor operationbetween 52 to 66°C.

The oil pump suction is fed from the oil reservoir. An oil pressurerelief valve maintains 124 to 172 kPa differential pressure inthe system at the pump discharge. This differential pressurecan be read directly from the CVC default screen.

The oil pump discharges oil to the oil filter assembly. This filtercan be closed to permit removal of the filter without drainingthe entire oil system. The oil is then piped to the oil cooler.This heat exchanger uses refrigerant from the condenser as thecoolant. The refrigerant cools the oil to a temperature between49°C and 60°C.

As the oil leaves the oil cooler, it passes the oil pressure transducerand the thermal bulb for the refrigerant expansion valve on theoil cooler. The oil is then divided, with a portion flowing to thethrust bearing, forward pinion bearing, and gear spray. Thebalance then lubricates the motor shaft bearings and the rearpinion bearing. The oil temperature is measured as the oil leavesthe thrust and forward journal bearings within the bearinghousing. The oil then drains into the oil reservoir at the base ofthe compressor. The PIC II (Product Integrated Control)measures the temperature of the oil in the sump and maintainsthe temperature during shut-down. This temperature is read onthe CVC default screen.

During the chiller start-up, the PIC II will energize the oil pumpand provide 15 seconds of prelubrication to the bearings afterpressure is verified before starting the compressor. During shutdown, the oil pump will run for 60 seconds to post-lubricateafter the compressor shuts down. The oil pump can also beenergized for testing purposes in the Control Test.

Ramp loading can slow the rate of guide vane opening tominimize oil foaming at start-up. If the guide vanes open quickly,the sudden drop in suction pressure can cause any refrigerantin the oil to flash. The resulting oil foam cannot be pumpedefficiently; therefore, oil pressure falls off and lubrication ispoor. If oil pressure falls below 103 kPa differential, the PIC IIwill shut down the compressor.

If the controls are subject to a power failure that lasts more than 3hours, the oil pump will be energized periodically when thepower is restored. This helps to eliminate refrigerant that hasmigrated to the oil sump during the power failure. The controlswill energize the pump for 60 seconds every 30 minutes untilthe chiller is started.

Oil reclaim systemThe oil reclaim system returns oil lost from the compressorhousing back to the oil reservoir by recovering the oil from 2areas on the chiller. The guide vane housing is the primary areaof recovery. Oil is also recovered by skimming it from theoperating refrigerant level in the cooler vessel.

Primary oil recovery modeOil is normally recovered through the guide vane housing onthe chiller. This is possible because oil is normally entrainedwith the refrigerant in the chiller. As the compressor pulls therefrigerant up from the cooler into the guide vane housing tobe compressed, the oil normally drops out at this point and fallsto the bottom of the guide vane housing where it accumulates.Using discharge gas pressure to power an eductor, the oil isdrawn from the housing and is discharged into the oil reservoir.

15

Secondary oil recovery methodThe secondary method of oil recovery is significant under lightload conditions, when the refrigerant going up to the compressorsuction does not have enough velocity to bring oil along with it.

Under these conditions, oil normally collects in a greater con-centration at the top level of the refrigerant in the cooler. Thisoil and refrigerant mixture is skimmed from the side of thecooler and is then drawn up to the guide vane housing. There isa filter in this line. Because the guide vane housing pressure ismuch lower than the cooler pressure, the refrigerant boils off,leaving the oil behind to be collected by the primary oil recoverymethod.

1. Rear motor bearing2. Forward motor bearing3. Labyrinth gas line4. Oil supply to forward high speed bearing5. Isolation valve6. Filter

13. Oil pump14. Oil motor15. Oil cooler16. Isolation valve17. Pressure transducer18. TXV bulb19. Motor cooling line

Fig. 4 - Lubrication system

2.7 - Power equipment

The 19XR requires a starter cabinet to control a hermeticturbo-compressor motor, the oil pump and various auxiliaryunits. This cabinet serves as a user interface. Only one type ofcabinet is currently available from Carrier SA: electronic starting(see specification Z375 and EE038 for specific requirementsfor the starter cabinet). All cabinets must comply with thesespecifications with the aim of achieving correct compressorstarting and satisfying the mechanical safety requirements.

The cabinets may be supplied separately from the units, andeither function on a remote basis or are mounted directly on theunit (optional for low voltages only).

7. Sight glass8. Isolation valve9. Check valve10. Filter11. Eductor12. Oil heater

16

Fig. 5A - Starter cabinet - internal view with internaldoor closed

Fig. 5B - Starter cabinet - internal view with internaldoor open

1. ISM module2. Circuit breaker3. CCM module4. CVC module5. Electronic starter6. Contactor7. Door closed (Fig. 5A above) or open (Fig. 5B opposite)8. Conductor for field connection

Factory-mounted electronic starter (optional) - see Figures5A and 5B

NOTE: The main circuit breaker QF101* on the left of thestarter disconnects all circuits.

Circuit breaker QF66* supplies power to the control centre, theoil heater and the compressor starter control circuit. Circuitbreaker QF4* supplies power to the oil pump. Circuit breakerQF11* supplies power to the control circuit. All three circuitbreakers are connected downstream of QF101* so that they donot remain energized if the QF101* disconnect is in the “off”position.

The starter cabinet includes:The electronic starter that provides on/off phase control as itsprimary function, also reduces starting torque and motor inrushcurrent, thus reducing mechanical stress and increasing theuseful life of the motor.

The ISM module controls the motor start-up, the controlsection and the PIC II control.

* For more details refer to the wiring diagram supplied withthe unit.

17

3 - INSTALLATION

3.1 - Introduction

The 19XR machine is factory assembled, wired, leak testedand electrically tested. Installation (not by Carrier) consistsprimarily of establishing water and electrical services to themachine. The rigging, installation, field wiring, field piping,and insulation of waterbox covers are the responsibilty of thecontractor and/or customer.

3.2 - Receiving the machine

3.2.1 - Inspect shipment

CAUTION: Do not open any valves or loosen any connections.The standard 19XR machine is shipped with a full refrigerantcharge. Some machines may be shipped with a nitrogen holdingcharge as an option.

Inspect for shipping damage while machine is still onshipping conveyance. If machine appears to be damaged or hasbeen torn loose from its anchorage, have it examined bytransportation inspectors before removal. Forward claimpapers directly to transportation company. Manufacturer isnot responsible for any damage incurred in transit.

• Confirm that the unit received is the one ordered. Comparethe name plate data with the order.

• The unit name plate must include the followinginformation:- Version number- Model number- CE marking- Serial number- Year of manufacture and test date- Refrigerant used and refrigerant class- Refrigerant charge per circuit- Containment fluid to be used- PS: Min./max. allowable pressure (high and low

pressure side)- TS: Min./max. allowable temperature (high and low

pressure side)- Globe valve cut-out pressure- Pressure switch cut-out pressure- Unit leak test pressure- Voltage, frequency, number of phases- Maximum current drawn- Maximum power input- Unit net weight

High pressure Low pressureMin. Max. Min. Max.

PS (bar) -0.9 12.5 -0.9 12.5TS (°C) -20 48 -20 48Pressure switch cut-out pressure (bar) 11 -Valve cut-out pressure (bar) 12.5 12.5Test pressure, unit leak test (bar) 10

Check all items against shipping list. Immediately notify thenearest Carrier representative if any item is missing.

To prevent loss or damage (standard EN 378-2 11.22 k, annexA and B), leave all parts in original packages until beginninginstallation. All openings are closed with covers or plugs toprevent dirt and debris from entering machine componentsduring shipping. A full operating oil charge is placed in theoil sump before shipment.

3.2.2 - Provide machine protectionProtect machine and starter from construction dirt and moisture.Keep protective shipping covers in place until machine is readyfor installation.

Do not keep the 19XR units outside where they are exposed tothe weather, as the sensitive control mechanism and theelectronic modules may be damaged.

The unit must be checked periodically during its wholeoperating life to ensure that no shocks (handling accessories,tools etc.) have damaged it. If necessary, the damaged partsmust be repaired or replaced. See also chapter “Maintenance”.

If machine is exposed to freezing temperatures after watercircuits have been installed, open waterbox drains and removeall water from cooler and condenser. Leave drains open untilsystem is filled.

3.3 - Rigging the machine

The 19XR machine can be rigged as an entire assembly. It alsohas flanged connections that allow the compressor, cooler, andcondenser sections to be separated and rigged individually.

3.3.1 - Rigging the complete machineSee rigging instructions on label attached to machine. Also referto physical data and Tables 1 to 7 (chapter 3.3.3). Lift machineonly from the points indicated in the instructions supplied andin the machine rigging drawings. Each lifting cable or chainmust be capable of supporting the entire weight of the machine.

WARNING: Lifting machine from points other than thosespecified may result in serious damage to the unit and personalinjury. Rigging equipment and procedures must be adequatefor machine weight. See Tables 1 to 7 (chapter 3.3.3) formachine weights.

NOTE: These weights are broken down into componentsections for use when installing the unit in sections. For thecomplete machine weight, add all component sections andrefrigerant charge together. See Tables 1 to 7 (chapter 3.3.3)for machine component weights.

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

18

Fig. 6 - Machine rigging guide

1. Optional mounted starter2. Chain must run over to motor side of bolt3. Chain B (see note 2)4. Chain C (see note 2)5. Chain D (see note 2)6. Minimum height above floor

Notes:1. Each chain must be capable of supporting the entire weight of the chiller. The

maximum weight of each chiller is listed in the table below.2. Chain lengths shown are typical for 4570 mm lifting height. Some minor

adjustment may be required.

Machine Compressor Machine Length Dim. A Chain length, mmcode size weight, kg m mm B C D

30-32 2 9526 3.66 1766 4115 4013 403835-37 2 10206 4.27 2236 4318 4064 4064

3.3.2 - Rig machine componentsRefer to instructions below, Fig. 8 to 11, and Carrier CertifiedPrints for machine component disassembly.

IMPORTANT: Only a qualified service technician shouldperform this operation.

WARNING: Do not attempt to disconnect flanges while themachine is under pressure. Failure to relieve pressure canresult in personal injury or damage to the unit.

CAUTION: Before rigging the compressor, disconnect all wiresentering the control box.

NOTE: If the cooler and condenser vessels must beseparated, the heat exchangers should be kept level byplacing a support plate under the tube sheets. The supportplate will also help to keep the vessels level and aligned whenthe vessels are bolted back together.

NOTE: Wiring must also be disconnected. Label each wirebefore removal (see Carrier Certified Prints). In order to dis-connect the starter from the machine, remove wiring for theoil pump, oil heater, control wiring at the control box, and themain motor leads at the starter lugs.

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

1

2

3

4

5

6

762 "A"

1066

4570

19

3.3.3 - Physical data

Table 1Motor weight (standard and high efficiency motors)

Motor size Stator weight*, kg Motor weight, kg Casing, kg50 Hz 50 Hz

Compressor 19XR2*, low voltage motor

BD 467 109 84BE 485 113 84BF 508 120 84BG 533 132 84BH 533 132 84

Compressor 19XR3*, low and medium voltage motor

CD 616 142 125CE 624 145 125CL 651 151 125CM 660 154 125CN 665 155 125CP 671 156 125CQ 671 156 125

Compressor 19XR4*, low and medium voltage motor**

DB 762 177 107DC 786 183 107DD 800 186 107DE 832 195 107DF 854 201 107DG 872 207 107DH 1001 261 107DJ 1045 266 107

Compressor 19XR5*, low and medium voltage motor***

EH 1415 341 188EJ 1415 341 188EK 1474 341 188EL 1529 363 188EM 1529 363 188EN 1597 386 188EP 1597 386 188

* Stator weight includes stator and shell.** The rotor weight includes the weights of the rotor, the shaft and the lubrication

systems.

Note: For each motor size the weight given is that of the nearest motor (based onvoltage).

Table 2Compressor weight, kg*

Components Compressor Compressor Compressor CompressorFrame 2** Frame 3** Frame 4** Frame 5**

Suction elbow 23 24 79 95Discharge elbow 27 21 71 63Transmission* 145 331 298 454Suction housing 136 159 202 544Impeller shroud 16 36 57 113Crankcase 571 476 721 1676Diffuser 16 32 59 136Oil pump 57 68 68 84Miscellaneous 45 61 65 100Total weight*** 1043 1207 1684 3107

* The transmission weight does not include the weight of the rotor, nor that ofthe shaft, and that of the lubrication system (see table above).

** The first figure of the 'compressor type' (Fig. 1) is the compressor size.*** ±5% (less motor and elbows)

Table 3Miscellaneous additional weights (kg)

Compressor size 2/3 4/5

Control box 34 34Factory-mounted starter box 275 350Isolation valve (optional) 52 52

Table 419XR Heat exchanger weight

Code No. of tubes Rigging Machine chargeweight Refr. weight Water weightkg kg kg

Evap. Cond. Evap. Cond. Evap. Cond. Evap. Cond.

30 200 218 1876 1675 159 118 210 21031 240 267 1958 1768 190 118 241 24632 280 315 2046 1859 222 118 273 28235 200 218 2000 2089 181 141 232 23336 240 267 2094 2195 218 141 266 27337 280 315 2193 2300 249 141 303 31440 324 370 2675 2745 254 127 338 36241 364 417 2757 2839 286 127 368 39842 400 463 2832 2932 313 127 396 43445 324 370 2881 3001 290 150 372 39946 364 417 2976 3107 327 150 407 44047 400 463 3060 3213 358 150 438 48150 431 509 3181 3304 340 181 435 48251 485 556 3293 3397 381 181 477 51852 519 602 3364 3484 408 181 502 55255 431 509 3428 3619 395 222 481 53456 485 556 3555 3725 426 222 527 57557 519 602 3635 3825 444 222 557 61360 557 648 3751 3758 426 190 546 60161 599 695 3838 3847 444 190 578 63662 633 741 3908 3935 462 190 604 66965 557 648 4056 4174 462 231 605 66866 599 695 4155 4276 481 231 641 70767 633 741 4235 4376 494 231 671 74570 644 781 5621 5959 453 354 846 79071 726 870 5814 6153 531 354 917 86572 790 956 5965 6335 589 334 972 93675 644 781 6028 6445 506 420 926 88376 726 870 6259 6667 592 420 1007 96977 790 956 6421 6875 660 420 1070 105080 829 990 7326 7141 653 327 1078 99881 901 1080 7496 7336 716 327 1141 107382 976 1170 7673 7531 785 327 1205 114885 829 990 7844 7710 730 390 1181 111686 901 1080 8037 7933 798 390 1252 120287 976 1170 8240 8156 880 390 1326 1288

Notes regarding cooler data:Based on a cooler with standard wall tubing (TB3 0.025 in), 2-pass, nozzle-in-headwaterbox with victaulic grooves. Weight includes suction elbow, control panel, anddistribution piping. Weight does not include compressor.

Notes regarding condenser data:Based on a condenser with standard wall tubing (SPK2 0.025 in), 2-pass, nozzle-in-head waterbox with victaulic grooves. Weight includes the float valve, dischargeelbow, and distribution piping. Weight does not include unit-mounted starter,isolation valves, and pumpout unit.

Table 5Marine water box additional weight*

Heat exchanger passes kPa Rigging weight Water volumeand frame kg l

Frame 3, passes 1 and 2 1034 331 317Frame 3, pass 2 1034 166 159Frame 4, passes 1 and 3 1034 481 465Frame 4, pass 2 1034 240 231Frame 5, passes 1 and 3 1034 562 526Frame 5, pass 2 1034 281 263Frame 6, passes 1 and 3 1034 680 612Frame 6, pass 2 1034 340 306Frame 7, passes 1 and 3 1034 912 1234Frame 7, pass 2 1034 336 617Frame 8, passes 1 and 3 1034 841 1537Frame 8, pass 2 1034 265 768

Frame 3, passes 1 and 3 2068 390 317Frame 3, pass 2 2068 195 159Frame 4, passes 1 and 3 2068 549 465Frame 4, pass 2 2068 272 231Frame 5, passes 1 and 3 2068 626 526Frame 5, pass 2 2068 313 263Frame 6, passes 1 and 3 2068 748 612Frame 6, pass 2 2068 374 306Frame 7, passes 1 and 3 2068 1406 1234Frame 7, pass 2 2068 830 617Frame 8, passes 1 and 3 2068 1245 1533Frame 8, pass 2 2068 739 768

* Add to base heat exchanger data for total weights or volumes.Note: The additional weights are the same for coolers and condensers of the sameframe size.

20

Table 619XR water box casing weights, kg

Heat exchanger Water box type Frame 3 Frame 4

Standard Flanged Standard Flangedconnections connections connectiions connections

Evaporator/condenser NIH, perforated end cover, 1 pass, 1034 kPa 145 159 220 236NIH, perforated end cover, 2 passes, 10343 kPa 145 159 221 245NIH, perforated end cover, 3 passes, 1034 kPa 141 154 229 236NIH/MWB, plain end cover, 1034 kPa 136 136 172 172NIH, perforated end cover, 1 pass, 2068 kPa 186 220 269 303NIH, perforated end cover, 2 passes, 2068 kPa 186 235 269 318NIH, perforated end cover, 3 passes, 2068 kPa 196 212 282 298NIH/MWB, plain end cover, 2068 kPa 181 181 258 258

Heat exchanger Water box type Frame 5 Frame 6



Heat exchanger Water box type Frame 7 - evaporator Frame 7 - condenser



Heat exchanger Water box type Frame 8 - evaporator Frame 8 - condenser



Notes:NIH Nozzle-in-head water boxMWB Marine water boxNote: The weight of nozzle-in-head water boxes, 2 passes, 1034 kPa is included in the heat exchanger weights (see table 4).

21

Maximum and minimum heat exchanger flow rates (l/s)*

Evaporator 1 pass 2 passes 3 passes Condenser 1 pass 2 passes 3 passesModel Size Min. Max. Min. Max. Min. Max. Model Size Min. Max. Min. Max. Min. Max.

1 10 27 108 13 54 9 36 1 10 34 135 17 67 11 4511 31 123 15 62 10 41 11 37 149 19 75 12 5012 35 139 17 69 12 46 12 42 168 21 84 14 5615 27 108 13 54 9 36 15 34 135 17 67 11 4516 31 123 15 62 10 41 16 37 149 19 75 12 5017 35 139 17 69 12 46 17 42 168 21 84 14 56

2 20 39 154 19 77 13 51 2 20 41 163 20 81 14 5421 46 185 23 93 15 62 21 50 200 25 100 17 6722 54 217 27 109 18 72 22 59 235 29 118 20 78

3 30 38 154 19 77 13 51 3 30 41 163 20 81 14 5431 46 185 23 92 15 62 31 50 199 25 100 17 6732 54 215 27 108 18 72 32 59 235 29 118 20 7935 38 154 19 77 13 51 35 41 163 20 81 14 5436 46 185 23 92 15 62 36 50 199 25 100 17 6737 54 215 27 108 18 72 37 59 235 29 118 20 79

4 40 62 249 31 125 21 83 4 40 69 277 35 138 23 9241 70 281 35 140 23 93 41 78 312 39 156 26 10442 77 307 38 154 26 112 42 86 346 43 173 29 11545 62 249 31 125 21 93 45 69 277 35 138 23 9246 70 281 35 140 23 93 46 78 312 39 156 26 10447 77 307 38 154 26 112 47 86 346 43 173 29 115

5 50 83 332 42 166 28 111 5 50 95 380 48 190 32 12751 93 374 47 187 31 125 51 104 416 52 208 35 13852 100 400 50 200 33 133 52 112 450 56 225 37 15055 83 332 42 166 28 111 55 95 380 48 190 32 12756 93 374 47 187 31 125 56 104 416 52 208 35 13857 100 400 50 200 33 133 57 112 450 56 225 37 150

6 60 107 429 54 215 36 143 6 60 121 484 61 242 40 16161 115 462 58 231 38 154 61 130 519 65 260 43 17362 122 488 61 244 41 163 62 138 554 69 277 46 18565 107 429 54 215 36 143 65 121 484 61 242 40 16166 115 462 58 231 38 154 66 130 519 65 260 43 17367 122 488 61 244 41 163 67 138 554 69 277 46 185

7 70 124 496 62 248 41 165 7 70 146 583 73 291 49 19471 140 560 70 280 47 187 71 163 650 81 325 54 21772 152 609 76 305 51 203 72 178 713 89 356 59 23875 124 596 62 248 41 165 75 146 583 73 291 49 19476 140 560 70 280 47 187 76 163 650 81 325 54 21777 152 609 76 305 51 203 77 178 713 89 356 69 238

8 80 140 562 70 281 47 187 8 80 185 740 92 370 62 24781 174 695 87 347 58 232 81 202 807 101 404 67 26982 188 752 94 376 63 251 82 219 874 109 437 73 29185 160 639 80 320 53 213 85 185 740 92 370 62 24786 174 695 87 347 58 232 86 202 807 101 404 67 26987 188 752 94 376 63 251 87 219 874 109 437 73 291

* Flow rates based on standard tubes in the cooler and condenser. Minimum flow based on tube velocity of 0,91 m/s (3 ft/s); maximum flow based on tube velocity of3.66 m/s (12 ft/s).

22

Fig. 7 - Dimensional drawing

1. Motor service space (1219 mm)2. Recommended clearance above the machine (915 mm)3. 362 mm4. 610 mm5. Clearances required6. Clearance for float valve, variable depending on the unit height - see chapter 2.3, figure 2 - legend No. 28

Heat exchanger size A - Length with nozzle-in-head B - Width C - Height A - Length, marine waterbox D Ewater box (not shown)

2 pass* 1 or 3 pass** 2 pass* 1 or 3 pass**mm mm mm mm mm mm mm mm

30 to 32 4172 4350 1670 2073 4496 4997 3747 25035 to 37 4693 4870 1670 2073 5017 5518 4343 25040 to 42 4242 4426 1880 2153 4591 5099 3747 25045 to 47 4763 4947 1880 2153 5099 5620 4343 25050 to 52 4248 4439 1994 2207 4591 5099 3747 25055 to 57 4769 4959 1994 2207 5099 5620 4343 25060 to 62 4261 4451 2096 2257 4591 5111 3747 25065 to 67 4782 4972 2096 2257 5112 5632 4343 25070 to 72 4978 5194 2426 2985 5385 6058 4267 46075 to 77 5588 5804 2426 2985 5994 6668 4877 46080 to 82 4997 5220 2711 3029 5398 6121 4267 46085 to 87 5607 5829 2711 3029 6007 6731 4877 460

* Assumes that both cooler and condenser nozzes are on the sme end of the chiller.** 1 or 3 pass length applies, id either (or both) cooler or condenser is a 1 or 3 pass design

D

1 2

3

5

4

A

B

C

E

23

1. Hot gas bypass (cut)2. Compressor suction elbow (unbolt)3. Oil reclaim line4. Starter connector (unbolt)5. Heat exchanger assembly (unbolt)

6. Tube sheet7. Refrigerant motor cooling line (cut)8. Motor drain9. Compressor mounting (unbolt)10. Cooler liquid feed line

Fig. 8 - Dimensional drawing - cooler, side view

1. Guide vane motor2. Branch circuit control box

3. Compressor discharge elbow joints4. Condenser transducer cable

Fig. 9 - 19XR chiller top view

A CondenserB CoolerC Compressor

24

1. Motor temperature sensor cable2. Bearing temperature sensor cable connection (inside box)3. Compressor oil sump pressure cable

4. Compressor oil sump temperature sensor cable5. Compressor oil discharge pressure cable6. Discharge temperature sensor cable7. Connection for high pressurestat (DBK/SDBK)

Fig. 10 - Compressor detail

1. Guide vane motor cable2. Diffuser motor (only XR5 compressor)3. Condenser leaving water pressure cable4. Condenser leaving water temperature cable5. Condenser entering water temperature cable6. Condenser entering water pressure cable

12 1 2

10

9

8

7 6

5

4

3

11

Fig. 11 - Unit rear view

7. Evaporator entering water temperature cable8. Evaporator entering water pressure cable9. Evaporator leaving water temperature cable10. Evaporator leaving water pressure cable11. Chiller Visual Control (CVC)12. Guide vane motor

25

3

2

1

3.4 - Install machine supports

Typical applications of these units are in refrigerationsystems, and they do not require earthquake resistance.Earthquake resistance has not been verified.

3.4.1 - Install standard isolationFigs. 12 and 13 show the position of support plates and shearflex pads which together form the standard machine supportsystem.

3.4.2 - Installation of a levelling accessory (if necessary)Where a floor surface is irregular or uneven, it may provenecessary to use accessory spring isolators (supplied by Carrierfor field installation) and levelling pads (see Figs. 13 and 15).

Place the unit levelly, using the spring isolator jacking screws.Use a level at least 600 mm long.

In order to provide adequate, long-lasting support for the unit,it is essential to choose the right grout and to apply it properly.Carrier advise using an epoxy-type, pre-mixed, non-shrinkinggrout only. Follow the manufacturer’s instructions for applyingthe grout.• Check the unit layout plans to determine the required

grout thickness.• Apply wax to the jacking screws to facilitate subsequent

removal from the grout.• The grout must be applied up to the top of the base of the

spring isolator, and there must be no gap in the groutbelow the spring isolators.

• Allow the grout to dry and set in accordance with themanufacturer’s instructions before starting up the unit.

• Remove the jacking screws from the soleplates once thegrout has set.

1. Soleplate detail2. Condenser3. Evaporator Heat exchanger size

Evaporator/condenser A Bmm mm

30-32 4001 167035-37 4525 167040-42 4001 188045-47 4525 188050-52 4001 199455-57 4525 199460-62 4001 209665-67 4525 209670-72 4620 242675-77 5229 242680-82 4620 271185-87 5229 2711

Fig. 12 - Chiller footprint

26

Note: The isolation package includes 4 shear flex pads.

Fig. 13 - Standard isolation

3.4.3 - Install spring isolationSpring isolation may be purchased as an accessory from Carrierfor field installation. It may also be field supplied and installed.

Spring isolators may be placed directly under machine supportplates or located under machine soleplates. See Fig. 15.

Obtain specific details on spring mounting and machine weightdistribution from job data. Also, check job data for methods tosupport and isolate pipes that are attached to spring isolatedmachines.

Notes:1. Dimensions are in mm.2. Accessory (Carrier supplied, field-installed) soleplate package includes 4

soleplates, 16 jacking screws and levelling 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. Celcote HT-648 or MasterBuilders 636, 38.1 to 57 mm thick.

Fig. 14 - Accessory isolation

3. Level base line4. Shear flex pad

1. Support plate2. Machine foot

1. See notes3. Support plate4. Machine foot5. Jacking screw (see note 3)

6. Level base line7. 35 mm8. Levelling pad

1. Accessory spring isolator2. Soleplate (accessory) attaches securely to isolator3. Level foundation4. Resilient shear flex pad, bonded to top and bottom of spring mount5. Support plate - attach securely to soleplate

Fig. 15 - 19XR Accessory spring isolation

3.5 - Connection of water piping

For size and position of the heat exchanger water inlet andoutlet connections refer to the certified dimensional drawingssupplied with the unit.

The water pipes must not transmit any radial or axial force tothe heat exchangers nor any vibration.

The water supply must

hermetic centrifugal liquid chillers 50 hz - acareacare.eu/carriercd/litt/11997_iom_06_2004.pdf2 the...

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