Carrier 19XL series User manual

19XL
50/60 Hz
Hermetic Centrifugal Liquid Chillers
with HCFC–22 and HFC–134a
Installation Instructions
For Units Produced After 11/1/92 (Linear Float Design)
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and
without incurring obligations.
Catalog No. 531-944 9-94 Form 19XL-3SI Replaces: 19XL-2SI
Copyright © Carrier Corporation 1994
Safety Considerations
Centrifugal liquid chillers are designed to provide safe and reliable service when
operated within design specifications. When operating this equipment, use good
judgement and safety precautions to avoid damage to equipment and property or injury
to personnel.
Be sure you understand and follow the procedures and safety precautions contained
in the machine instructions, as well as those listed in this guide.
®

DO NOT VENT refrigerant relief devices within a building. Outlet from rupture disc
or relief valve must be vented outdoors in accordance with the latest edition of
ANSI/ASHRAE 15 (Safety Code for Mechanical Refrigeration). The accumulation
of refrigerant in an enclosed space can displace oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/ASHRAE 15, especially
for enclosed and low overhead spaces. Inhalation of high concentrations of vapor
is harmful and may cause heart irregularities, unconsciousness, or death. Inten-
tional misuse can be fatal. Vapor is heavier than air and reduces the amount of
oxygen available for breathing. Product causes eye and skin irritation. Decompo-
sition products are hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a machine for any purpose.
Oxygen gas reacts violently with oil, grease, and other common substances.
DO NOT USE air to leak test. Use only refrigerant or dry nitrogen.
NEVER EXCEED specified test pressures. VERIFY the allowable test pressure by
checking the instruction literature and the design pressures on the equipment
nameplate.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed and functioning
before operating any machine.
DANGER !DANGER

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
.
DO NOT USE eyebolts or eyebolt holes to rig machine sections or the entire
assembly.
DO NOT work on high-voltage equipment unless you are a qualified electrician.
DO NOT WORK ON electrical components including control panels, switches,
starters, or oil heater until you are sure ALL POWER IS OFF and no residual volt-
age can leak from capacitors or solid-state components.
LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTER-
RUPTED, confirm that all circuits are generalized before resuming work.
DO NOT siphon refrigerant.
AVOID SPILLING liquid refrigerant on skin or getting it into the eyes. USE SAFETY
GOGGLES. Wash any spills from the skin with soap and water. If liquid refrigerant
enters the eyes, IMMEDIATELY FLUSH EYES with water and consult a physician.
NEVER APPLY an open flame or live steam to a refrigerant cylinder. Dangerous
over pressure can result. When it is necessary to heat refrigerant, use only warm
(110 F [43 C]) water.
WARNING !WARNING

DO NOT REUSE disposable (nonreturnable) cylinders or attempt to refill them. It
is DANGEROUS AND ILLEGAL. When cylinder is emptied, evacuate remaining
gas pressure, loosen the collar, and unscrew and discard the valve stem. DO NOT
INCINERATE.
CHECK THE REFRIGERANT TYPE before adding refrigerant to the machine. The
introduction of the wrong refrigerant can cause machine damage or malfunction.
Operation of this equipment with refrigerants other than those cited herein should
comply with ANSI/ASHRAE-15 (latest edition). Contact Carrier for further informa-
tion on use of this machine with other refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while machine is under
pressure or while machine is running. Be sure pressure is at 0 psig (0 kPa) before
breaking any refrigerant connection.
CAREFULLY INSPECT all relief valves, rupture discs, and other relief devices AT
LEAST ONCE A YEAR. If machine operates in a corrosive atmosphere, inspect the
devices at more frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief valve when corrosion
or build-up of foreign material (rust, dirt, scale, etc.) is found within the valve
body or mechanism. Replace the valve.
DO NOT install relief devices in series or backwards.
USE CARE when working near or in line with a compressed spring. Sudden
release of the spring can cause it and objects in its path to act as projectiles.
WARNING !WARNING

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. Even if components are light, use mechanical
equipment when there is a risk of slipping or losing your balance.
BE AWARE that certain automatic start arrangements CAN ENGAGE THE
STARTER, TOWER FAN, OR PUMPS. Open the disconnect ahead of the starter,
tower fan, and pumps. Shut off the machine or pump before servicing equip-
ment.
USE only repaired or replacement parts that meet the code requirements of the
original equipment.
DO NOT VENT OR DRAIN waterboxes containing industrial brines, liquid, gases,
or semisolids without the permission of your process control group.
DO NOT LOOSEN waterbox cover bolts until the waterbox has been completely
drained.
DOUBLE-CHECK that coupling nut wrenches, dial indicators, or other items have
been removed before rotating any shafts.

CAUTION CAUTION
!
DO NOT LOOSEN a packing gland nut before checking thatthe nut has a positive
thread engagement.
PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks,
or damage.
PROVIDE A DRAIN connection in the vent line near each pressure relief device to
prevent a build-up of condensate or rain water.

Contents
List of Tables
List of Figures
Safety Considerations
Introduction
General
Job Data
Equipment Required
Installation
Receiving the Machine
Inspect Shipment
Identify Machine
Provide Machine Protection
Rigging the Machine
Rig Machine Assembly

Contents
Rig Machine Components
Install Machine Supports
Install Standard Isolation
Install Optional Isolation
Install Spring Isolation
Connect Piping
Install Water Piping to Heat Exchangers
Install Vent Piping to Relief Devices
Make Electrical Connections
Connect Control Inputs
Connect Control Outputs
Connect Starter
Carrier Comfort Network Interface
Install Field Insulation
Installation Start-Up Request Checklist

Contents
List of Tables
Table 1 — 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 — Relief Device Locations

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

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

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

Introduction
General
The 19XL machine is factory assembled, wired, and leak tested. Installation (not by Carrier)
consists primarily of establishing water and electrical services to the machine. The rigging,
installation, field wiring, field piping and insulation of waterbox covers are the responsibility of
the contractor and/or customer. Carrier has no installation responsibilities for the equipment.
Job Data
Necessary information consists of:
• job contract or specifications
• machine location prints
• rigging information
• piping prints and details
• field wiring drawings
• starter manufacturer’s installation details
• Carrier certified print
Equipment Required
• mechanic’s tools (refrigeration)
• volt-ohmmeter and clamp-on ammeter
• leak detector (halide or electronic)
• absolute pressure manometer or wet-bulb vacuum indicator
• portable vacuum pumps

Installation
Receiving the Machine
Inspect Shipment
1. Inspect for shipping damage while machine is still on shipping conveyance. If machine
appears to be damaged or has been torn loose from its anchorage, have it examined by
transportation inspectors before removal. Forward claim papers directly to transportation
company.
Manufacturer is not responsible for any damage incurred in transit.
2. Check all items against shipping list. Immediately notify the nearest Carrier representative if
any item is missing.
3. To prevent loss or damage, leave all parts in original packages until beginning installation.
All openings are closed with covers or plugs to prevent dirt and debris from entering
machine components during shipping. A full operating oil charge is placed in the oil sump
before shipment.
CAUTION CAUTION
!
Do not open any valves or loosen any connections. The standard 19XL machine
is shipped with a full refrigerant charge. Some machines may be shipped with a
nitrogen holding charge as an option.

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.
Provide Machine Protection
Protect machine and starter from construction dirt and moisture. Keep protective shipping
covers in place until machine is ready for installation. If machine is exposed to freezing
temperatures after water circuits have been installed, open waterbox drains and remove all
water from cooler and condenser. Leave drains open until system is filled.
Rigging the Machine
The 19XL machine can be rigged as an entire assembly. It also has flanged connections that
allow the compressor, cooler, and condenser sections to be separated and rigged individually.
Click here for Figure 1 — Model Number Identification
Click here for Figure 2 (Front and Rear Views) — Typical 19XL Installation
(300 to 600 Tons [1055 to 2110 kW])

Rig Machine Assembly
See rigging instructions on label attached to machine. Also refer to rigging guide Figure 3,
physical data in Figure 4, and Table 1, Table 2, Table 3, Table 4, Table 5A and Table 5B.
Lift
machine only from the 3 points indicated in rigging guide.
Each lifting cable or chain must be
capable of supporting the entire weight of the machine.
Lifting machine from points other than those specified may result in serious dam-
age to the unit and personal injury. Rigging equipment and procedures must be
adequate for machine weight. See Table 1, Table 2, Table 3, Table 4, Table 5A, and
Table 5B for machine weights.
Note: These weights are broken down into component sections for use when
installing the unit in sections. For the complete machine weight, add all compo-
nent sections and refrigerant charge together. See Table 1, Table 2, Table 3,
Table 4, Table 5A, and Table 5B for machine component weights.
WARNING !WARNING
IMPORTANT: Make sure that rigging cable is over the rigging bar before lifting.

Rig Machine Components
Refer to instructions below, Figure 5, Figure 6, Figure 7, Figure 8, Figure 9, and Carrier
Certified Prints for machine component disassembly.
Note: If the cooler and condenser vessels must be separated, the heat exchanger separation
feet can be unbolted, slipped down, and re-bolted in order to keep each heat exchanger
level. See Figure 3.
IMPORTANT: Only a qualified service technician should perform this operation.
Do not attempt to disconnect flanges while the machine is under pressure. Failure
to relieve pressure can result in personal injury or damage to the unit.
WARNING !WARNING
CAUTION CAUTION
!
Before rigging the compressor, disconnect all wires entering the power panel.

Note: Wiring must also be disconnected. Label each wire before removal (see Carrier Certified
Prints). In order to disconnect the starter from the machine, remove wiring for the oil
pump, oil heater, control wiring at the power panel, and the main motor leads at the
starter lugs.
Remove all transducer and sensor wires at the sensor. Clip all wire ties necessary to pull
heat exchangers apart.
Click here for Figure 3 — Machine Rigging Guide
Click here for Figure 4 — 19XL Dimensions
Click here for Table 1 — 19XL Compressor/Motor Weights
Click here for Table 2 — 19XL Component Weights
Click here for Table 3 — 19XL Heat Exchanger Weights

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

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