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)