Carrier 17, 19EX User Manual

Page 1
Installation Instructions
SAFETY CONSIDERATIONS
Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design specifications. Whenoperatingthisequipment, usegood judgmentand safety precautions to avoid damage to equipment and property or injury to personnel.
Be sure you understand and follow the procedures andsafety 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 ASHRAE (American Society of Heating, Refrig­eration and Air Conditioning Engineers) 15. The accumulation of re­frigerant in an enclosed space can displace oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ASHRAE 15, es­pecially for enclosed and low overhead spaces. Inhalation of high concentrations of vapor is harmful and may cause heart irregularities, unconsciousness, or death. Intentional misuse can be fatal. Vapor is heavier than air and reduces the amount of oxygen available for breath­ing. Product causes eye and skin irritation. Decomposition products are hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a machine for any purpose. Oxygen gas reacts violently with oil, grease, and other common substances.
DO NOT USE air to leak test. Use only refrigerant or dry nitrogen. NEVER EXCEED specified test pressures. VERIFY the allowable test
pressure by checking the instruction literature and the design pressures on the equipment nameplate.
DO NOT VALVE OFF any safety device. BE SURE that all pressure relief devices are properly installed and func-
tioning before operating any machine.
DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all refrigerant (liquid and vapor) has been removed from chiller. Traces of vapor should be displaced with dry air or nitrogen and the work area should be well ventilated. Refrigerant in contact with an open flame
produces toxic gases.
DO NOT USE eyebolts or eyebolt holes to rig machine sections or the entire assembly.
DO NOT work on high-voltage equipment unless you are a qualified electrician.
DO NOT WORK ON electrical components, including control panels, switches, starters, or oil heater until you are sure ALL POWER IS OFF and no residual voltage can leak from capacitors or solid-state components.
LOCK OPEN AND TAGelectrical circuits during servicing. IF WORK IS INTERRUPTED, confirm that all circuits are deenergized before resuming work.
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, IMMEDIATELYFLUSH 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.
17/19EX
50/60 Hz
Centrifugal Liquid Chillers
with HFC-134a
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 ASHRAE-15 (latest edition). Contact Carrier for further information on use of this machine with other refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while machine is under pressure or while machine is running. Be sure pres­sure is at 0 psig (0 kPa) before breaking any refrigerant connection.
CAREFULLY INSPECT all relief valves, rupture discs, and other re­lief devices AT LEAST ONCE A YEAR. If machine operates in a cor­rosive atmosphere, inspect the devices at more frequent intervals.
DO NOT ATTEMPTTOREP AIROR 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.
DO NOT STEP on refrigerant lines. Broken lines can whip about, and release refrigerant, causing personal injury.
DO NOT climb over a machine. Use platform, catwalk, or staging. Fol­low safe practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move inspection covers or other heavy components. Even if components are light, use mechanical equipment when there is a risk of slipping or losing your balance.
BE AWARE that certain automatic start arrangements CAN ENGAGE THE STAR TER,TOWERFANOR PUMPS. Open the disconnectahead of the starter, tower fan, and pumps. Shut off the machine or pump before servicing equipment.
USE only repaired or replacement parts that meet the code require­ments of the original equipment.
DO NOT VENT OR DRAIN waterboxes containing industrial brines, liquid, gases, or semisolids without the permission of your process con­trol group.
DO NOT LOOSEN waterbox cover bolts until the waterbox has been completely drained.
DOUBLE-CHECK that coupling nut wrenches, dial indicators, or other items have been removed before rotating any shafts.
DO NOT LOOSEN a packing gland nut before checking that the nut has a positive thread engagement.
PERIODICALLY INSPECT all valves, fittings, and piping for corro­sion, rust, leaks, or damage.
PROVIDE A DRAIN connection in the vent line near each pressure relief device to prevent a build-up of condensate or rain water.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2 2 Tab 5a 5d
PC 211 Catalog No. 531-749 Printed in U.S.A. Form 17/19EX-2SI Pg 1 3-96 Replaces: 17/19EX-1SI
Page 2
CONTENTS
Page
SAFETY CONSIDERATIONS ...................1
INTRODUCTION ..............................2
General ......................................2
Job Data ....................................2
Equipment Required .........................2
INSTALLATION .............................2-30
Receiving the Machine .......................2
• INSPECT SHIPMENT
• IDENTIFY MACHINE
• PROVIDE MACHINE PROTECTION
Rigging the Machine .........................2
• RIG MACHINE ASSEMBLY
• RIG MACHINE COMPONENTS
• COMPONENT DISASSEMBLY
Install Machine Supports ....................14
• INSTALL STANDARD ISOLATION
• INSTALL OPTIONAL ISOLATION
• INSTALL SPRING ISOLATION
Connect Piping .............................17
• INSTALL WATER PIPING TO HEAT EXCHANGERS
• INSTALL WATER TO OIL COOLER ON FA COMPRESSORS
• INSTALL VENT PIPING TO RELIEF DEVICES
Make Electrical Connections .................20
• CONNECT CONTROL INPUTS
• CONNECT CONTROL OUTPUTS
• CARRIER COMFORT NETWORK INTERFACE
Install Field Insulation .......................28
• FACTORY INSULATION (OPTIONAL)
INSTALLATION START-UP REQUEST
CHECKLIST .............................CL-1
INSTALLATION
Receiving the Machine
INSPECT SHIPMENT
Do not open any valves or loosen any connections. The standard 17/19EX machine may be shipped with a ni­trogen holding charge or with the refrigerant charge iso­lated within the utility vessel.
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. Toprevent 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 the machine’s components during shipping. A full operating oil charge is placed in the oil sump of the com­pressor before shipment.
IDENTIFY MACHINE — The machine model number, serial number, and heat exchanger sizes are stamped on machine identification nameplate (Fig. 1). 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.
INTRODUCTION
General —
wired, and leak tested. Installation consists primarily of es­tablishing water and electrical services to the machine. The rigging, installation, field wiring, field piping and insulation are the responsibility of the contractor and/or customer. See Fig. 1 for model number information.
The 17/19EX machine is factory assembled,
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 drawings
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
Rigging the Machine — The 17/19EX machine can
be rigged as an entire assembly. It also has flanged connec­tions that allow the compressor, utility vessel, cooler, and condenser sections to be separated for ease of installation. Figures 2 and 3 show 17/19EX components.
RIG MACHINEASSEMBLY— See rigging instructions on label attached to machine. Also refer to the rigging infor­mation found in Fig. 4-9 and Tables 1-12. Lift machine only fromthe 4 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 damage to the unit and personal injury. Rigging equipment and procedures must be ad­equate for machine weight. See Table 1 for machine weights.
NOTE: These weights are broken down into compo­nent sections for use when installing the unit in sections. For the complete machine weight, add all com­ponent sections and refrigerant charge together. Total machine weight is also stenciled on the cooler and con­denser sections.
2
Page 3
NIH — Nozzle-In-Head *Motors beginning with ‘‘E’’ and open drive motors (FA-JD) cannot be used with size 51-89 or 421-469 compressors.
†Open-drive motor codes:
ASME
‘U’ STAMP
UNDERWRITERS’
LABORATORIES
Fig. 1 — Model Number Identification
3
ARI (Air Conditioning
and Refrigeration
Institute)
PERFORMANCE
CERTIFIED
(60 Hz Only)
Page 4
RIG MACHINE COMPONENTS — Refer to instructions on page 5, Fig. 6-8, and Carrier certified drawings for ma­chine component disassembly.
IMPORTANT: Onlya qualified servicetechnician should disassemble and reassemble the machine. After reas­sembly,the machine must be dehydrated and leak tested.
When rigging components separately, the open drive (17EX) motor must be removed to avoid overturning.
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.
Before rigging the compressor, disconnect the wires leading from the power panel to the control center at the power panel.
NOTE: Wiring for sensors must be disconnected. Label each wire before removal (see Carrier certified drawings).
Detach all transducer and sensor wires at the sensor, then clip all wire ties necessary to remove the wires from the heat exchangers.
1—Refrigerant Liquid Line to Economizer/
Storage Vessel
2—Cooler Suction Pipe 3—Compressor Suction Elbow 4—Condenser 5—Condenser Discharge Pipe 6—Compressor Discharge Elbow 7—Guide Vane Actuator 8—Economizer Gas Line to Compressor
9—Gear Inspection Cover 10 — 2-Stage Hermetic Compressor 11 — Condenser Waterbox Vent (Not Shown) 12 — Condenser Marine Waterbox 13 — Hermetic Compressor Motor 14 — Compressor Motor Terminal Box
(Not Shown)
19EX
LEGEND
15 — Motor Sight Glass (Not Shown) 16 — Oil Filter 17 — Oil Level Sight Glasses (2) 18 — Cooler Relief Valves (Not Shown) 19 — Oil Heater (Not Shown) 20 — Auxiliary Power Panel
(Field Wiring Terminals)
21 — Pumpdown Unit (Not Shown) 22 — Low-Side Float Box Cover 23 — Refrigerant Liquid Line to Cooler 24 — Oil Drain and Charging Valve 25 — Oil Pump 26 — Refrigerant Charging/Service
Valve 10 (Not Shown)
Fig.2—Typical 19EX Installation
4
27 — Oil Cooler 28 — Isolation Valves (Not Shown) 29 — Refrigerant Filter Drier 30 — Local Interface Display Control Panel 31 — Economizer/Storage Vessel 32 — Rigging Guide (Not Shown) 33 — Economizer/Storage Vessel
Relief Valves
34 — Cooler 35 — High-Side Float Box Cover 36 — Take-Apart Connections 37 — Cooler Waterbox Vent 38 — Cooler Marine Waterbox 39 — Cooler Waterbox Drain 40 — Condenser Waterbox Drain
Page 5
COMPONENT DISASSEMBLY To Separate Compressor from the Machine
1. Make sure to check that the machine is at atmospheric pressure before disassembly.
2. Since the center of gravity is high on 17EX machines, the motor MUST be removed before rigging the machine.
3. Suction elbow should be rigged separately (Fig. 6, Item 2). Place slings around the elbow and attach to the hoist. Remove bolting at flanges, (Fig. 6, Items 1 and 3). Detach the elbow.
4. Unbolt discharge flange to the condenser at flange (Fig. 8, Item 3). Cut copper lines (Fig. 6, Items 7, 8, and 9).
5. Disconnect and detach the economizer vent line (Fig. 8, Item 4). Unbolt the line at flange (Fig. 8, Item 2).
6. On 19EX machines, disconnect the motor cooling drain line at flange (Fig. 8, Item 5).
7. Disconnect wiring to the control center and power panel.
8. Connect rigging to the compressor.
9. Unbolt compressor from the utility vessel (Fig. 7, Items 2, 4, and 5).
10. Hoist the compressor off of the unit.
11. If the compressor is to be transported or set down, the base should be bolted to sections of 4 in.x6in. lumber.
To Separate Condenser from the Machine
1. Unbolt flange (Fig. 6, Item 3).
2. Unbolt flange (Fig. 6, Item 4).
3. Cut copper pipe (Fig. 6, Item 7).
4. Unbolt hot flange (Fig. 7, Item 1).
5. Connect rigging to all corners of the condenser.
6. Unbolt condenser feet (Fig. 8, Items 1 and 6).
1—Condenser 2—Cooler Suction Pipe 3—Compressor Suction Elbow 4—Guide Vane Actuator 5—Condenser Discharge Pipe 6—Oil Filter (Hidden) 7—Two-Stage Compressor 8—Compressor Discharge Elbow
9—Gear Inspection Cover 10 — Economizer Gas Line to Compressor 11 — Open Drive Compressor Motor 12 — Compressor Motor Terminal Box 13 — Coupling Guard 14 — Low-Side Float Box Cover
LEGEND
15 — Refrigerant Liquid Line to Cooler 16 — Power Panel (Field Wiring Terminals) 17 — Oil Level Sight Glasses 18 — Oil Drain and Charging Valve 19 — Oil Heater (Hidden) 20 — Oil Pump 21 — Refrigerant Charging/Service Valve
10 (Not Shown)
22 — Cooler Relief Valves (Not Shown) 23 — Economizer/Storage Vessel 24 — Oil Cooler 25 — Control Center 26 — Economizer/Storage Vessel
Relief Valves
Fig.3—Typical 17EX Installation
5
27 — Pumpout Unit 28 — High Side Float Box Cover 29 — Cooler 30 — Cooler Waterbox Drain 31 — Take-Apart Connections (Typical) 32 — Cooler Marine Waterbox Cover 33 — Cooler Waterbox 34 — Cooler Waterbox Vent 35 — Condenser Waterbox Drain 36 — Refrigerant Liquid Line to
Economizer/Storage Vessel
37 — Condenser Waterbox Vent
Page 6
NOTES:
1. Each chain must be capable of supporting the maximum weight of the machine.
2. = the approximate center of gravity.
3. Maximum possible weight is 88,500 lb (40 166 kg) which includes a maxi­mum of 6,000 lb (2 721 kg) of HFC-134a refrigerant in the storage tank.
17EX FRONT VIEW
VESSEL
COOLER
SIZE
45-48 17-0 5182 88,550 40 166
LENGTH
ft-in. mm lb kg
MAXIMUM
WEIGHT
LIFTING
LIFTING
ANGLE
30° 10- 3 3124 9-0 2743 16-1 4902 13-6 4115 16-11 5156
60° 17-10 5436 17-1 5207 24-9 7544 22-8 6909 27- 3 8306
‘‘A’’ ‘‘B’’ ‘‘C’’ ‘‘D’’
ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm
CHAIN LENGTH
HEIGHT
FROM FLOOR
‘‘E’’
ft-in. mm
Fig. 4 — 17EX Machine Rigging Guide
NOTES:
1. Each chain must be capable of supporting the maximum weight of the machine.
2. = the approximate center of gravity.
3. Maximum possible weight is 78,700 lb (35,698 kg) which includes a maxi­mum of 6,000 lb (2,268 kg) of HFC-134a in the storage tank.
19EX FRONT VIEW
CENTER OF GRAVITY
APPROXIMATE LOCATION
‘‘F’’ ‘‘G’’ ‘‘H’’
4-1 1245 9-1 2769 4-9 144845° 12- 7 3835 11-7 3531 19-1 5817 16-9 5105 20- 8 6299
VESSEL
COOLER
SIZE
31-33 12-3 3734 55,000 24 948
41-44 12-3 3734 70,000 31 752
45-48 17-0 5182 78,700 35 698
LENGTH
ft-in. mm lb kg
MAXIMUM
WEIGHT
LIFTING
LIFTING
ANGLE
30° 7-2 1880 7-2 1880 11-11 3632 11-1 3378 13-7 4140
60° 12-5 3785 12-5 3785 18- 0 5486 17-6 5334 20-9 6325 30° 6-7 2007 6-9 2057 13- 0 3962 12-2 3708 15-1 4597
60° 11-4 3454 11-6 3505 18- 7 5664 18-0 5486 21-7 6579 30° 9-1 2769 9-6 2896 15- 1 4597 14-7 4445 16-4 4978
60° 15-9 4800 16-0 4877 22-10 6960 22-6 6858 25-5 7747
‘‘A’’ ‘‘B’’ ‘‘C’’ ‘‘D’’
ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm
CHAIN LENGTH
HEIGHT
FROM FLOOR
‘‘E’’
ft-in. mm
Fig. 5 — 19EX Machine Rigging Guide
6
CENTER OF GRAVITY
APPROXIMATE LOCATION
‘‘F’’ ‘‘G’’ ‘‘H’’
3-10 1168 6-1 1854 4-6 137245° 8-9 2667 8-9 2667 14- 0 4267 13-4 4064 16-2 4928
4- 0 1219 6-0 1829 4-8 142245° 8-0 2438 8-3 2515 14-11 4547 14-3 4343 17-5 5309
3-10 1168 8-3 2515 4-8 142245° 11-1 3378 11-6 3505 17- 9 5410 17-4 5283 19-8 5994
Page 7
NOTE: Item numbers are referenced in Rigging the Machine, Component Disassembly section.
Fig.6—Typical Top View (19EX Shown)
NOTE: Item numbers are referenced in Rigging the Machine, Component Disassembly section.
Fig.7—Typical Side View (19EX Shown)
7
Page 8
NOTE: Item numbers are referenced in Rigging the Machine, Component Disassembly section.
Fig.8—Typical Motor End View (19EX Shown)
To Separate Cooler From Utility Vessel
1. Remove condenser (see previous section).
2. Cut copper lines (Fig. 6, Items 6 and 8).
3. Unbolt liquid refrigerant line at flange (Fig. 7, Item 3).
4. Connect rigging to all four corners of the cooler before lifting the unit.
5. Unbolt connections to the utility vessel (Fig. 6, Items 5 and 10).
To Assemble the Machine
1. Follow disassembly instructions (in reverse order) and bolt all flanges back together using a gasket sealant. The fol­lowing torque requirements are specified:
FIG. ITEM NO.
6
7
8
N-m — Newton Meters
*This torque is used to rig the entire machine. Once the machine
is in place, if no further rigging is anticipated, the bolt torque can be reduced to 280 ft-lb (380 N-m).
3 580 786
1 or 4 170 230
5 and 10 840* 1139*
1 380 515 4 and 5 250 340 1 and 6 280 380
2 170 230
3 380 515
57196
TORQUE
ft-lb N-m
2. All gasketed or O-ring joints which have been disas­sembled must be assembled using new gaskets and O-rings. These new gaskets and O-rings (along with gasket seal­ant, O-ring lubricant, and copper line couplings) are avail­able through your Carrier representative.
3. Braze all copper lines back together using a suitable braz­ing material for copper. Carrier recommends an AWS (American Welding Society) Classification BCuP-2.
Do not tilt the compressor; oil is contained in the oil sump.
Additional Notes
1. Use silicon grease on new O-rings when refitting.
2. Use gasket sealant on new gaskets when refitting.
3. Cooler, utility, and condenser vessels may be rigged ver­tically, as separate components. Rigging should be fixed to all four corners of the tube sheet.
4. New gaskets, grease for O-rings, and gasket sealant for a complete take-apart operation are available in a kit. Con­tact your Carrier representative.
8
Page 9
NOTES:
1. Certified drawings available upon request.
2. Service accessshould be provided perAmerican Society of Heating,Refrigeration, and Air Con­ditioning Engineers (ASHRAE) 15, latest edition, National Fire Protection Association (NFPA) 70, and local safety codes.
DIMENSIONS
CONDENSER
SIZE
31-33 15-6 4724 N/A N/A 8-10 2692 10-8 41-43 15-6 4724 N/A N/A 45-47 20-3 6172 12-2 3708 17- 6 5334 51-53 15-6 4724 N/A N/A 55-57 20-3 6172 12-2 3708 17- 6 5334
A (LENGTH)† B (WIDTH) C (HEIGHT) H (TUBE PULL)
ft-in. mm
17EX** 19EX
ft-in. mm ft-in. mm
1
⁄22858
9-4
ft-in. mm ft-in. mm
1
⁄23264 12-10 3912
12-2 3708
12-5 3785
12-10 3912
12-10 3912
SERVICE CLEARANCES
COMPONENT
Motor DB - DQ 1-11 Motor EA - ED Motor EE 4- 1 Low-Side Float 2-6
D (DIAMETER)†† E (LENGTH)†† F (DIAMETER) G (LENGTH)
ft-in. mm ft-in. mm ft-in. mm ft-in. mm
1
2- 2
4
3
4
591 3- 71⁄ 679
3-10
2
1 1
1105
4
1175
4
1251
1
2
775 1-0 305
NOZZLE SIZES
HEAT
EXCHANGER
31-33
41-48
51-57
NOZZLE TYPE
Cooler Passes Condenser Passes
123 1 2 3
Marine 12 10 10 12 10 10
NIH 12 10 10 10 10
Marine 20 14 12 20 14 12
NIH 18 14 10 18 12 10
Marine 16
NIH 20 16
NOZZLE SIZES (in.)|
LEGEND
NIH — Nozzle-In-Head
*Distance required for tube removal may be either end.
†Based on 2-pass, nozzle-in-head (NIH) waterboxes with 150 psi (1038 kPa)
covers.
**Overall width of units with 17 Series compressors will vary greatly depend-
ing upon the application. See the appropriate certified drawings.
††For hermetic motors (19 Series) only.
\The table at right provides additional information on nozzle sizes. Victaulic
grooves are standard for these nozzles. Optional 150 psi (1034 kPa) and 300 psi (2068 kPa) flanges are available.
¶In conformance with ASA B36.10 (American Standards Association).
Fig.9—Typical Dimensions
NOMINAL PIPE SIZE (in.) SCHEDULE¶
10 40 .365 9.27 12 Std .375 9.53 14 30 .375 9.53 16 30 .375 9.53 18 Std .375 9.53 20 20 .375 9.53
9
WALL THICKNESS
in. mm
Page 10
Table 1 — 17/19EX Heat Exchanger, Economizer/Storage Vessel, Piping, and Pumpout Unit Weights*
COOLER
COOLER
SIZE†
31 14,173 6 429 17,518 7 946 1,540 699 1,810 217 821 821 32 14,538 6 594 18,117 8 218 1,640 744 1,944 233 882 882 33 14,904 6 760 18,722 8 492 1,740 789 2,078 249 943 943 41 21,674 9 831 26,120 11 848 1,900 862 2,441 293 1 107 1 107 42 22,019 9 988 26,736 12 127 2,000 907 2,575 309 1 168 1 168 43 22,364 10 144 27,322 12393 2,100 953 2,709 325 1 229 1 229 44 23,841 10 814 29,836 13533 2,190 993 3,285 394 1 490 1 490 45 25,032 11 354 30,790 13966 2,260 1 025 3,006 361 1363 1 363 46 25,529 11 580 31,658 14360 2,360 1 070 3,192 383 1448 1 448 47 26,025 11 805 32,496 14740 2,460 1116 3,378 405 1 532 1 532 48 28,153 12 770 36,053 16353 2,540 1 152 4,173 500 1893 1 893
lb kg lb kg lb kg lb gal kg L
TOTAL
WEIGHT
Dry Operating†† Refrigerant Water
COOLER CHARGE
ECONOMIZER/
STORAGE
VESSEL**
lb kg lb kg lb kg lb kg
7,169 3252 610 277 820 372
7,169 3 252 610 277 1,095 497
7,900 3 583 840 381 1,149 521
ECONOMIZER
REFRIGERANT
MISCELLANEOUS
PIPING
PUMPOUT
UNIT
210 95
CONDENSER
SIZE†
31 10,454 4 742 13,022 5 907 950 431 1,613 193 732 732 32 10,809 4 903 13,514 6 130 950 431 1,750 210 794 794 33 11,164 5 064 14,000 6 350 950 431 1,886 226 855 855 41 13,768 6 245 16,999 7711 1,090 494 2,146 257 973 973 42 14,118 6 404 17,498 7 937 1,090 494 2,282 274 1 035 1 035 43 14,468 6 563 17,978 8 155 1,090 494 2,419 290 1 097 1 097 45 16,676 7 564 20,800 9 435 1,400 635 2,720 326 1 234 1 234 46 17,172 7 789 21,489 9 747 1,400 635 2,908 348 1 319 1 319 47 17,669 8 015 22,178 10 060 1,400 635 3,096 371 1 404 1 404 51 17,188 7 796 20,993 9 522 1,100 499 2,707 325 1 228 1 228 52 17,848 8 096 21,923 9 944 1,100 499 2,964 355 1 344 1 344 53 18,400 8 346 22,682 10 288 1,100 499 3,178 381 1 442 1 442 55 20,725 9 401 25,598 11 611 1,420 644 3,453 412 1 566 1 566 56 21,663 9 826 26,896 12 199 1,420 644 3,808 457 1 727 1 727 57 22,446 10 181 27,980 12 691 1,420 644 4,105 492 1 862 1 862
*If a machine configuration other than 2-pass, 150 psig (1034 kPa), NIH waterbox configuration is used, refer to Tables 3
and 4 to obtain the additional dry and water weights that must be added to the values shown in this table.
†Cooler and condenser weights shown are based upon 2-pass, nozzle-in-head (NIH) waterboxes with 150 psig (1034 kPa)
covers. Includes components attached to cooler, but does not include suction/discharge, elbow, or other interconnecting piping.
**Dry weight includes all components attached to economizer: Covers, float valves, brackets, control center (31 lb [14 kg]),
and power panel (20 lb [9 kg]). Dry weight does not include compressor weight, motor weight, or pumpout condensing unit weight. The pumpout condensing unit weight is 210 lb (95 kg). For compressor and motor weights, refer to Tables 6, 7, 8, 10A, and 10B.
††Operating weight includes the sum of the dry weight, refrigerant weight, and water weight.
CONDENSER TOTAL WEIGHT CONDENSER CHARGE
Dry Operating†† Refrigerant Water
lb kg lb kg lb kg lb gal kg L
Table 2 — Refrigerant Charge
HEAT EXCHANGER SIZE COOLER CHARGE CONDENSER CHARGE ECONOMIZER CHARGE Cooler Condenser lb kg lb kg lb kg lb kg
31 31 1540 699 950 431 32 32 1640 744 950 431 3200 1 452 33 33 1740 789 950 431 3300 1 497 41 41 1900 862 1090 494 3600 1 633 42 42 2000 907 1090 494 3700 1 678 43 43 2100 953 1090 494 3800 1 724 44 51 2190 993 1100 499 3900 1 769 44 52 2190 993 1100 499 3900 1 769 44 53 2190 993 1100 499 3900 1 769 45 45 2260 1 025 1400 635 46 46 2360 1 070 1400 635 4600 2 087 47 47 2460 1 116 1400 635 4700 2 132 48 55 2540 1 152 1420 644 4800 2 177 48 56 2540 1 152 1420 644 4800 2 177 48 57 2540 1 152 1420 644 4800 2 177
*Total machine refrigerant charge includes the cooler, condenser, and economizer. NOTE: Regulations mandate that machine shipping charge is limited to 7500 lb (3402 kg).
610 277
844 381
TOTAL REFRIGERANT
CHARGE*
3100 1 406
4500 2 041
10
Page 11
Table 3 — Additional Cooler Weights*
COOLER
FRAME
3
4
NIH — Nozzle-In-Head
*When using a machine configuration other than 2-pass, NIH waterboxes with 150 psig (1038 kPa) covers, add the weights listed in this table to the appropriate weights
in Table 1 to obtain the correct cooler weight.
WATERBOX
TYPE
NIH 1, 3 150 1034 655 297 — NIH 1, 3 300 2068 2226 1010
NIH 2 300 2068 1406 638 — Marine 1, 3 150 1034 780 354 3192 383 1448 1448 Marine 2 150 1034 390 177 1596 191 724 724 Marine 1, 3 300 2068 3412 1548 3192 383 1448 1448 Marine 2 300 2068 1706 774 1596 191 724 724
NIH 1, 3 150 1034 515 234
NIH 1, 3 300 2068 2941 1334
NIH 2 300 2068 2085 946 — Marine 1, 3 150 1034 2100 953 5102 612 2314 2314 Marine 2 150 1034 792 359 2551 306 1157 1157 Marine 1, 3 300 2068 3844 1744 5102 612 2314 2314 Marine 2 300 2068 2536 1150 2551 306 1157 1157
NUMBER
OF PASSES
DESIGN MAXIMUM
WATER PRESSURE
psig kPa lb kg lb gal kg L
ADDITIONAL DRY WEIGHT
ADDITIONAL
WATER WEIGHT
Table 4 — Additional Condenser Weights*
COMPONENT
CONDENSER
NIH — Nozzle-In-Head
*When using a machine configuration other than 2-pass, NIH waterboxes with 150 psig (1034 kPa) covers, add the weights listed in this table to the appropriate weights
in Table 1 to obtain the correct condenser weight.
†Subtract 228 lb (103 kg) from the weight shown in Table 1.
HEAT EXCHANGER
SIZE
31-33
41-43 45-47
51-53 55-57
WATERBOX TYPE
NIH 3 150 1034 262 119 — NIH 3 300 2068 1328 602
NIH 2 300 2068 872 396 — Marine 3 150 1034 842 382 2276 273 1032 1032 Marine 2 150 1034 421 191 1138 136 516 516 Marine 3 300 2068 1520 689 2276 273 1032 1032 Marine 2 300 2068 1099 498 1138 136 516 516
NIH 1, 3 150 1034 344 156
NIH 1, 3 300 2068 1652 749
NIH 2 300 2068 1132 513 — Marine 1, 3 150 1034 1692 767 3400 408 1542 1542 Marine 2 150 1034 674 306 1700 204 771 771 Marine 1, 3 300 2068 2651 1202 3400 408 1542 1542 Marine 2 300 2068 1630 739 1700 204 771 771
NIH 1 150 1034
NIH 1 300 2068 1588 720
NIH 2 300 2068 1591 721 — Marine 2 150 1034 25 11 1734 208 787 787 Marine 2 300 2068 1225 555 1734 208 787 787
NUMBER OF
PASSES
DESIGN MAXIMUM
WATER PRESSURE
psig kPa lb kg lb gal kg L
ADDITIONAL
DRY WEIGHT
ADDITIONAL
WATER WEIGHT
Table 5 — Auxiliary Connection Sizes
SIZE AND STYLE USAGE
3
⁄8in. Male Flare
1
⁄2in. FPT
1
⁄2in. NPT Conduit Power Panel Oil Pump Power Connection 1 in. NPT
1
⁄4in. FPT
1
Pumpout Condenser Refrigerant Vapor Connection
(Rupture Disc) Pumpout Water Inlet Connection Pumpout Water Outlet Connection
Waterbox Vent Connection Waterbox Drain Connection Cooler Relief Valve Connection Economizer/Storage Vessel Connection
11
Page 12
Table6—Total 19EX Motor Weights (60 Hz)
MOTOR SIZE
DB 1484 673 1420 644 NA NA DC 1496 678 1478 670 NA NA DD 1514 687 1503 682 2097 951 DE 1620 728 1536 696 2152 976 DF 1657 752 1635 742 2656 1205 DG 1662 754 1677 761 2741 1243 DH 1749 793 1715 778 2806 1273 DJ 1790 812 1758 797 2876 1305 DK 1823 827 2267 1028 3054 1385 DL 2262 1026 2374 1077 3162 1434 DM 2337 1060 2501 1134 3222 1461 DN 2415 1095 2558 1160 3277 1486 DP 2456 1114 2688 1219 3402 1543 DQ NA NA 2721 1234 3467 1573 EA 1968 893 2031 921 2377 1078 EB 2128 965 2233 1013 2427 1101 EC 2241 1017 2358 1070 2602 1180 ED 2366 1073 2514 1140 2827 1282 EE 2664 1208 2989 1356 3258 1478
NA — Not Available
NOTE:Low-voltage motors are ratedbelow 600 v,medium-voltage motors range from 600 v to 6,000 v, and high-voltage motors are rated above 6,000 v.
LOW VOLTAGE MEDIUM VOLTAGE HIGH VOLTAGE
lb kg lb kg lb kg
Table7—Total 19EX Motor Weights (50 Hz)
MOTOR SIZE
DB 1662 754 1568 711 NA NA DC 1677 760 1628 740 NA NA DD 1696 769 1662 754 2312 1049 DE 1710 776 1707 775 2332 1058
DF 1792 813 1807 820 2386 1082 DG 1863 845 2212 1003 2947 1337 DH 1921 871 2283 1036 3022 1371
DJ 2222 1008 2340 1061 3097 1405 DK 2331 1057 2472 1121 3187 1446
DL 2373 1076 2624 1190 3257 1477 DM 2481 1125 2692 1221 3317 1505 DN 2555 1159 2864 1299 3407 1545 DP 2597 1178 2924 1326 3502 1588 DQ NA NA 3014 1367 3612 1638 EA 2232 1012 2392 1085 2682 1217 EB 2443 1108 2380 1080 2887 1310 EC 2646 1200 2747 1246 3257 1477 ED 2760 1252 2952 1339 3442 1561
EE 3009 1365 3161 1434 3533 1603
NA — Not Available
NOTE:Low-voltage motors are ratedbelow 600 v,medium-voltage motors range from 600 v to 6,000 v, and high-voltage motors are rated above 6,000 v.
LOW VOLTAGE MEDIUM VOLTAGE HIGH VOLTAGE
lb kg lb kg lb kg
Table 8 — Compressor Weights
COMPONENT
Compressor
Weight*
Suction
Elbow
*Weight does not include motor. NOTES:
1. 19EX compressors include sizes −51 through −89.
2. 17/19FA5 compressors include sizes 531 through 599.
3. 19FA4 compressors include sizes 421 through 469.
19EX COMPRESSOR 17/19FA5 COMPRESSOR 19FA4
lb kg lb kg lbs kg
4886 2216 5150 2336 2625 1191
500 227 500 227 325 147
Table9—Total 17EX Drive Component Weights
MOTOR
HORSEPOWER (kW)
CODE
A 1200 544 75 34 25 11 B 1200 544 75 34 25 11 C 1200 544 75 34 25 11 D 1100 499 75 34 25 11
BASE WEIGHT COUPLING WEIGHT GUARD WEIGHT
lb kg lb kg lb kg
12
Page 13
ENCLOSURE
TYPE
Open-Drip Proof
(ODP)
Weather Protected
Type I (WPI)
Weater Protected
Type II (WPII)
Totally Enclosed
Water-To-Air Cooled
(TEWAC)
Table 10A — 17EX Motors — Total Weight, Lbs (English)
HERTZ VOLTAGE SIZE (HP)
FA (1250) FB (1500) FC (1750) FD (2000)
GA (1350) GB (1500) GC (1750) GD (2000)
HA (1250) HB (1500) HC (1750) HD (2000)
JA (1250) JB (1500) JC (1750) JD (2000)
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
50Hz
60 Hz
50 Hz
2400 4836 5721 5900 7160 3300 4824 5832 5832 7127 4160 4836 5721 5900 7160 6900 5596 6577 8776 8990
3000 5518 5878 7148 9048 3300 5518 5878 7148 9073 6300 5596 6577 8875 8976
2400 5046 5871 6050 7270 3300 5034 5982 5982 7237 4160 5046 5871 6050 7270 6900 5806 6727 8926 9100
3000 5728 6028 7298 9158 3300 5728 6028 7298 9183 6300 5806 6727 9025 9086
2400 5146 6151 6330 7600 3300 5134 6262 6262 7567 4160 5146 6151 6330 7600 6900 5906 7007 9206 9430
3000 5828 6308 7578 9488 3300 5828 6308 7578 9513 6300 5906 7007 9305 9416
2400 5707 6746 6925 8290 3300 5694 6857 6857 8257 4160 5707 6746 6925 8290 6900 6466 7602 9801 10,120
3000 6388 6903 8173 10,178 3300 6388 6903 8173 10,203 6300 6466 7602 9900 10,106
ENCLOSURE
TYPE
Open-Drip Proof
(ODP)
Weather Protected
Type I (WPI)
Weather Protected
Type II (WPII)
Totally Enclosed
Water-To-Air Cooled
(TEWAC)
Table 10B — 17EX Motors — Total Weight, Kg (SI)
FREQ VOLTAGE SIZE (kW)
FA (932) FB (1119) FC (1305) FD (1492)
GA (932) GB (1119) GC (1305) GD (1492)
HA (932) HB (1119) HC (1305) HD (1492)
JA (932) JB (1119) JC (1305) JD (1492)
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
50 Hz
2400 2194 2595 2676 3248 3300 2188 2645 2645 3233 4160 2194 2595 2676 3248 6900 2538 2983 3981 4033
3000 2503 2666 3242 4104 3300 2503 2666 3242 4116 6300 2538 2983 4026 4072
2400 2289 2663 2744 3298 3300 2283 2713 2713 3283 4160 2289 2663 2744 3298 6900 2634 3051 4049 4128
3000 2598 2734 3310 4154 3300 2598 2734 3310 4165 6300 2634 3051 4094 4121
2400 2334 2790 2871 3447 3300 2329 2840 2840 3432 4160 2334 2790 2871 3447 6900 2679 3178 4126 4277
3000 2644 2861 3437 4304 3300 2644 2861 3437 4315 6300 2679 3178 4221 4271
2400 2587 3060 3141 3760 3300 2583 3110 3110 3745 4160 2587 3060 3141 3760 6900 2933 3448 4446 4590
3000 2898 3131 3707 4617 3300 2898 3131 3707 4628 6300 2933 3448 4490 4584
13
Page 14
Table 11 — Marine Waterbox Cover Weights*
HEAT EXCHANGER
SIZE
31-33
41-48
51-57
*Heat exchangers with marine waterboxes have heavier dry and operating weights than heat exchangers with nozzle-
in-head waterboxes.
DESIGN MAXIMUM WATER PRESSURE COOLER CONDENSER
psi kPa lb kg lb kg
150 1034 1667 756 1092 495 300 2068 2280 1034 1436 651 150 1034 2236 1015 1275 579 300 2068 3060 1389 1660 754 150 1034 1643 746 300 2068 2243 1018
Table 12 — NIH Waterbox Cover Weights*
HEAT EXCHANGER
SIZE
31-33
41-48
51-57
NIH — Nozzle-in-Head
*The 150 psig (1034 kPa) 2-pass waterbox cover weights are included in the dry weight shown in Table 1. †Twodifferent waterbox covers are present on 2-pass machines. The weight shown in this table represents the weight
of the waterbox cover that contains the nozzles. A blank waterbox cover is also present on 2-pass units. The weight of the blank waterbox cover is identical to the weight of the same size marine waterbox cover. Refer to Table 11.
PASSES
DESIGN MAXIMUM WATER PRESSURE COOLER CONDENSER
psi kPa lb kg lb kg
1
2
3
1
2†
3
1
2†
3
150 1034 1880 853 — 300 2068 2748 1247 — 150 1034 2168 983 1356 615 300 2068 3107 1409 1959 889 150 1034 2105 955 1283 582 300 2068 2991 1357 1828 829 150 1034 2997 1361 1735 788 300 2068 4225 1918 2510 1140 150 1034 2984 1355 1885 856 300 2068 4188 1901 2590 1176 150 1034 3035 1378 1777 807 300 2068 4244 1927 2539 1153 150 1034 2032 923 300 2068 2940 1335 150 1034 2649 1203 300 2068 3640 1653 150 1034 — 300 2068
Install Machine Supports
INSTALL STANDARD ISOLATION — Figures 10 and 11 show the position of support plates and shear flex pads, which together form the standard machine support system.
INSTALL OPTIONAL ISOLATION (if required) — Un­even floors or other considerations may dictate the use of soleplates and leveling pads. Refer to Fig. 10 and 11.
Level machine by using jacking screws in isolation sole-
plates. Use a level at least 24 in. (600 mm) long.
For adequate and long lasting machine support, proper grout selection and placement is essential. Carrier recommends that only pre-mixed, epoxy-type, non-shrinking grout be used for machine installation. Follow manufacturer’s instructions in applying grout.
1. Check machine location prints for required grout
thickness.
2. Carefully wax jacking screws for easy removal from grout.
3. Grout must extend above the base of the soleplate and there must be no voids in grout beneath the plates.
4. Allow grout to set and harden, per manufacturer’s in­structions, before starting machine.
5. Remove jacking screws from leveling pads after grout has hardened.
INSTALL SPRING ISOLATION — Field-supplied spring isolators may be placed directly under machine support plates or be located under machine soleplates. Consult job data for specific arrangement. Low profile spring isolation assem­blies are recommended so that the machine is kept at a con­venient working height inside of the tube sheet.
Obtain specific details on spring mounting and machine weight distribution from job data. Also, check job data for methods for supporting and isolating pipes that are attached to the spring-isolated machines.
14
Page 15
COOLER SIZES 31-33 AND 41-44
COOLER SIZES
AB C
ft-in. mm ft-in. mm ft-in. mm
31-33 8-8
2
2654 8-10 2692 4- 8 1422
1
41-44 9-3 2819 9- 4
COOLER SIZES 45-48
DIMENSIONS
1
2
2858 4-111⁄
4
1505
NOTES:
1. Dimensions in ( ) are in mm.
2. 1 inch = 25.4 mm.
3. All dimensions approximately ±
1
⁄2inch.
Fig. 10 — Machine Contact Surfaces
15
Page 16
SOLEPLATE ISOLATION TYPICAL ISOLATION
ACCESSORY ISOLATION
SOLEPLATE DETAIL
SECTION A-A
NOTES:
1. Dimensions in ( ) are in millimeters.
2. Accessory soleplate package includes 4 soleplates, 16 jacking screws and leveling pads. Requires isolation package.
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 Master Builders 636, 08-1
1
⁄29 (38.1) to 08-21⁄49 (57) thick.
STANDARD ISOLATION
VIEW B-B
ISOLATION WITH ISOLATION PACKAGE ONLY
(STANDARD)
NOTE: Isolation package includes 4 shear flex pads.
Fig. 11 — Machine Vibration Isolation
16
Page 17
Connect Piping
INSTALL WATER PIPING TO HEAT EXCHANGERS — Install piping using job data, piping drawings, and proce­dure outlined below. A typical piping installation is shown in Fig. 12.
Factory-supplied insulation is not flammable but can be damaged by welding sparks and open flame. Protect in­sulation with a wet canvas cover.
Remove chilled and condenser water sensors before welding connecting piping to water nozzles. Refer to Fig. 2 and 3. Replace sensors after welding is complete.
1. If the machine is a nozzle-in-head (NIH) arrangement, offset pipe flanges to permit removal of waterbox cover for maintenance and to provide clearance for pipe clean­ing. See Tables 11 and 12 for waterbox cover weights. No flanges are necessary with marine waterboxes; how­ever, water piping should not cross in front of the water­box or access will be blocked off.
2. Provide openings in water piping for required pressure gages and thermometers. Openings should be at least 6 to
10 pipe diameters from the waterbox nozzle. For thor­ough mixing and temperature stabilization, wells in the leaving water pipe should extend inside pipe at least 2 in. (50 mm).
3. Install air vents at all high points in piping to remove air and prevent water hammer.
4. Install pipe hangers where needed. Make sure no weight or stress is placed on waterbox nozzles or flanges.
5. Water flow direction must be as specified in Fig. 13. NOTE: Entering water is always the lower of the 2 nozzles.
Leaving water is always the upper nozzle for cooler or condenser.
6. Water flow switches must be of vapor-tight construction and must be installed on top of pipe in a horizontal run and at least 5 pipe diameters from any bend.
Differential pressure type flow switches may be con­nected at the nozzle of the waterbox.
7. Install waterbox vent and drain piping in accordance with individual job data. All connections are3⁄4-in. FPT.
8. Install waterbox drain plugs in the unused waterbox drains and vent openings.
9. Install water piping to the optional pumpout system con­denser storage tank as shown in Fig. 14.
LEGEND
COM — Common N.O. — Normally Open
*Donot locate pressure connections past the machineisolation valve.
Fig. 12 — Typical Nozzle Piping
17
Page 18
NOZZLE-IN-HEAD WATERBOXES
FRAME 3 AND 5 MARINE WATERBOXES
COOLER WATERBOX
Pass In Out
1
2
3
Pass In Out
1
2
3
NOTES:
1. Frame 5 condenser available in 1 and 2 pass only. Frame 3 in 2 and 3 pass only.
2. The vents for these waterboxes, located in the covers are 1 in. FPT at the top of each box, and the drains are 1 in. FPT,at the bottom.
3. Victaulic connections are standard.
4. Flanged waterbox connections are optional.
85 A 58 B 79 C 46 D 76 E 49 F
CONDENSER WATERBOX
11 2 P
211 Q
10 12 R
13 S
10 3 T
112 U
Arr.
Code
Arr.
Code
Fig. 13 — Nozzle Arrangements
COOLER WATERBOX
Pass In Out
1
2
3
Pass In Out
2
3
NOTES:
1. Frame 3 condenser available in 2 and 3 pass only.Frame 5 condenser available in 2 pass only.
2. The vents for these waterboxes are 1 in. FPT at the top of each box, and the drains are 1 in. FPT, at the bottom.
3. Victaulic connections are standard.
4. Flanged waterbox connections are optional.
85 A 58 B 79 C 46 D
16 17 G
76 E 49 F
CONDENSER WATERBOX
10 12 R
13 S 13 15 Y 10 3 T
112 U
Arr.
Code
Arr.
Code
18
Page 19
FRAME 4 MARINE WATERBOXES
NOTES:
1. The vents for these waterboxes are 1 in. FPT at the top of each box. The drains are 1 in. FPT, at the bottom.
2. Victaulic connections are standard.
3. Flanged connections are optional.
COOLER WATERBOX
Pass In Out
1
2
3
Pass In Out
1
2
3
85 A 58 B 79 C 46 D
16 17 G
76 E 49 F
CONDENSER WATERBOX
11 2 P
211 Q
10 12 R
13 S 13 15 Y 10 3 T
112 U
Arr.
Code
Arr.
Code
Fig. 13 — Nozzle Arrangements (cont)
Fig. 14 — Pumpout Unit
INSTALL WATER TO OIL COOLER ON FA COMPRE­SORS — On FAcompressors, water must be piped to the oil cooler heat exchanger (located under the suction pipe to the compressor). The water supply may be either city water or chilled water. Pipe city water to an open sight drain. Chilled water enters via the cooling entering water intake (Fig. 15).
City water must be clean and noncorrosive. Water side erosion or corrosion of the oil cooler coil may lead to extensive machine damage not covered by the standard warranty.
If water from the machine chilled water circuit is used for oil cooling, it should enter the oil cooler from the entering water line of the machine cooler. Water leaving the oil cooler should connect to the leaving water line of the machine cooler at a point downstream from the chilled water sensor, so that oil cooler leaving water temperature does not affect the sen­sor readings.
Locate the oil cooler leaving water connection at some distance from any water temperature indicators. On single­pass machines, water leaving the oil cooler should be con­nected into the suction side of the chilled water pump so that adequate pressure drop is assured for oil cooling.
The nominal conditions for oil cooler water flow are:
Flow rate .......................30gpm(1.9 L/s)
Leaving temperature ........85to100F(29to38C)
Pressure drop at oil cooler .......7.25 psid (50 kPad)
Max differential pressure across closed
solenoid valve ..............150psid (1034 kPad)
1
The oil cooler connections are 1
⁄4in. FPT.
19
Page 20
Fig. 15 — Water Piping, Oil Cooler to
Chilled Water Circuit (Typical)
INSTALL VENT PIPING TO RELIEF DEVICES — The 17/19EX chiller is factory equipped with relief devices on the cooler and utility vessels. Refer to Fig. 2 and 3, and Table 13 for size and location of relief devices, as well as information that will help determine pipe size. Vent relief devices to the outdoors in accordance with ASHRAE 15 (latest edition) Safety Code for Mechanical Refrigeration and all other applicable codes. Toensure relief valve serviceabil­ity, and as required in ASHRAE 15, latest edition, 3-way dual shutoff valves and redundant relief valves are installed on the economizer/storage vessel, refer to Fig. 16.
NOTE: The 3-way dual shutoff valve should be either front seated or back seated. Running the refrigeration system with the valve stem in the center position can reduce total relief capacity and cause valve chattering.
Refrigerant discharged into confined spaces can dis­place oxygen and cause asphyxiation.
1. If relief device piping is manifolded, the cross-sectional area of the relief pipe must at least equal the sum of the areas required for individual relief pipes.
2. Provide a pipe plug near outlet side of each relief device for leak testing. Provide pipe fittings that allow vent pip­ing to be disconnected periodically for inspection of valve mechanism.
3. Piping to relief devices must not apply stress to the device. Adequately support piping. A length of flexible tubing or piping near the device is essential on spring­isolated machines.
4. Cover the outdoor vent with a rain cap and place a con­densation drain at the low point in the vent piping to pre­vent water build-up on the atmospheric side of the relief device.
Make Electrical Connections — Field wiring must
be installed in accordance with job wiring diagrams and all applicable electrical codes.
Fig. 16 — Typical 17/19EX Utility Vessel
Relief Valve Tee
Do not run 120-v wiring into the control center. The control center should only be used for additional extra low-voltage wiring (50 v maximum).
Wiring diagrams in this publication (Fig. 17-23) are for reference only and are not intended for use during actual in­stallation; follow job specific wiring diagrams.
Specific electrical ratings for individual components are shown in Table 14.
Do not attempt to start compressor or oil pump — even for a rotation check — or apply test voltage of any kind while machine is under dehydration vacuum. Motor in­sulation breakdown and serious damage may result.
CONNECT CONTROL INPUTS — Connect the control in­put wiring from the chilled and condenser water flow switches to the starter terminal strip. Wiring may also be specified for a spare safety switch, and a remote start/stop contact can be wired to the starter terminal strip, as shown in Fig. 17 and
18. Additional spare sensors and Carrier Comfort Network modules may be specified as well. These are wired to the machine control center as indicated in Fig. 22 and 23.
CONNECT CONTROL OUTPUTS — Connect auxiliary equipment, chilled and condenser water pumps, and spare alarms as required and indicated on job wiring drawings.
Connect Starter — Assemble and install compressor termi­nal box in desired orientation, and cut necessary conduit open­ings in conduit support plates. Attach power leads to com­pressor terminals in accordance with job wiring drawings, observing caution label in terminal box. Use only copper con­ductors. The motor must be grounded in accordance with NEC (National Electrical Code), applicable local codes, and job wiring diagrams.
IMPORTANT: Do not insulate terminals until wiring arrangement has been checked and approved by Carrier start-up personnel.Also, make sure correct phas­ing is followed for proper motor rotation.
20
Page 21
Insulate Motor Terminals and Lead Wire Ends — Insulate compressor motor terminals, lead wire ends, and electrical wires to prevent moisture condensation and electrical arc­ing. For low-voltage units (up to 600 v), insulate the elec­trical terminals as follows:
1. Insulate each terminal by wrapping with one layer of insulation putty.
2. Overwrap putty with 4 layers of vinyl tape.
High-voltage units require special terminal preparation. The vinyl tape is not acceptable; a high voltage tape must be used. Installer is responsible for any damage caused by improper wiring between starter and compressor motor.
Connect Power Wiresto Oil Pump Contactor — Connect power wires to oil pump contactor mounted in machine power panel. (See Fig. 19.) Use the electrical disconnect located in the machine starter (if supplied), or a separate fused disconnect as shown on job wiring diagrams. Check that power supply voltage agrees with oil pump voltage. Follow correct phas­ing for proper motor rotation.
Do notwire into the top surface of the power panel. Knock­outs are provided on the underside of the panel.
Table 13 — Relief Valve Locations and Data
Connect Power Wires to Oil Heater Contactor — Connect control power wiring between the oil heater contactor ter­minals (Fig. 17 and 18) and terminals LL1 and LL2 on the field wiring strip in the compressor motor starter. Refer to Fig. 21 and wiring label on the chiller power panel.
Voltage to terminals LL1 and LL2 comes from a con­trol transformer in a starter built to Carrier specifica­tions. Do not connect an outside source of control power to the compressor motor starter (terminals LL1 and LL2). An outside power source will produce dangerous volt­age at the line side of the starter, because supplying volt­age at the transformer secondary terminals produces in­put level voltage at the transformer primary terminals.
Connect Communication and Control Wiring from Starter to Power Panel — Connect control wiring from main motor starter to the chiller power panel. All control wiring must use shielded cable. Also connect the communications cable. Make sure the control circuit is grounded in accordance with applicable electrical codes and instructions on chiller control wiring label.
RELIEF VALVE
LOCATION
Cooler
Economizer/Storage
Pumpout Unit Condenser ALL ALL 1.5 0.01
*To ensure relief valve serviceability, and as required in ASHRAE 15,
latest edition, three-way valves and redundant relief valves are in­stalled on the storage vessel. Only one half of the ‘‘No. of Valves’’ listed are in service at any time.
NOTES:
1. Thecooler relief C-factor is forboth cooler and condenser vented through the cooler in accordance with ASHRAE (American Society of Heating, Refrigeration, and Air Conditioning Engi­neers) 15, latest edition.
Vessel
HEAT EXCHANGER
SIZE
Cooler Condenser lb air/min. kg air/sec. psig kPa
31-33 31-33 139.7 1.06 1 41-43 41-43 158.8 1.20 1
44 51-53 164.6 1.24 1
45-47 45-47 216.3 1.64 1
48 55-57 228.5 1.73 1 41-44 ALL 64.2 0.49 1 45-48 ALL 84.3 0.64 1
REQUIRED C FACTOR
NOMINAL OUTLET
PIPE SIZE (in.)
1
⁄4FPT 2 225 1551
1
⁄4FPT 2 225 1551
1
⁄4FPT 2 225 1551
1
⁄4FPT 3 225 1551
1
⁄4NPT 3 225 1551
1
⁄4NPT 2* 225 1551
1
3
2. Relief valve discharge pipe sizing is to be calculated per latest version of ASHRAE 15, using the tabulated C-factors and nom­inal pipe size listed above. Cooler and economizer/storage ves­sel rated relief valve pressure is 225 psig (1551 kPa).
3. The pumpout unit condenser contains less than 110lb (50 kg) of HFC-134a,which isa GroupA1 refrigerant.TheASHRAE15 stand­ard exempts small-volume vessels from the requirement to vent outside. However, Carrier recommends that the pumpout con­denser be connected to the rest of the vent system.
⁄4FPT 2* 225 1551
⁄8in. Male Flare MPT 1 385 2655
NUMBER OF
VALVES
RATED RELIEF
PRESSURE
21
Page 22
Table 14 — Individual Component Ratings
POWER SOURCE ITEM AVERAGE kW
Seal Leakage
1*
(17EX Only)
1†
2† Oil Pump
1**
3**
(Optional)
LEGEND
FLA — Full Load Amps LRA — Locked Rotor Amps
*Available for 17EX machines only.
†Available for 17/19EX machines.
**Available as an option on 17/19EX machines.
Pump
Motor Space
Heater
Control Module
and Actuator
Oil Sump Heater 1.00 115
Hot Gas
Bypass
Pumpout
Compressor
0.23 115 115-1-50/60 4.78 21.7
0.50 115 115-1-50/60 4.35 4.35
0.40 115
1.35 220 200/240-3-60 4.32 24.5
1.30 430 380/480-3-60 2.15 12.2
1.37 563 507/619-3-60 2.13 25.0
1.49 230 220/240-3-50 4.83 28.0
1.49 393 346/440-3-50 2.59 12.2
0.20 115 115-1-50/60 2.00 4.75
3.41
DESIGN CENTER
VOLTAGE
204 200/208-3-60 10.90 63.5 230 220/240-3-60 9.50 57.5 460 440/480-3-60 4.70 28.8 575 550/600-3-60 3.80 23.0
400 380/415-3-50 4.70 28.8
NOTE: The oil pump is powered through a field wiring terminal into the power panel. Power to the controls and oil heater via the power panel must be on circuits that can provide continuous service when the compressor starter is disconnected.
SUPPLY V-PH-HZ
115-1-60 115-1-50
115-1-60 115-1-50
FLA LRA
3.50
8.70
22
Page 23
*Indicates chilled water pump control contacts or run status contacts.
†Indicates condenser water pump control contacts.
**Indicates tower fan relay contacts.
††Indicates circuit breaker shunt trip contacts.
\ Indicates remote alarm contacts.
NOTES:
I. GENERAL
1.0 Starters shall be designed and manufactured in accordance with Carrier Engineer­ing Requirement Z-375.
1.1 All field-supplied conductors, devices, field-installation wiring, and termination ofcon­ductors and devices, must be in compliance with all applicable codes and job speci­fications.
1.2 The routing of field-installed conduit and conductors and the location of field­installed devices must not interfere with equipment access or the reading, adjusting, or servicing of any component.
1.3 Equipment, installation, and all starting and control devices must comply with de­tails in equipment submittal drawings and literature.
1.4 Contacts and switches are shown in the position they would assume with the circuit deenergized and the chiller shut down.
1.5 WARNING — Do not use aluminum conductors.
1.6 Installer is responsible for any damage caused by improper wiring between starter and machine.
II. POWER WIRING TO STARTER
2.0 Power conductor rating must meet minimum unit nameplate voltage and compres­sor motor RLA.
When (3) conductors are used: Minimum ampacity per conductor = 1.25 x compressor RLA
When (6) conductors are used for Wye-Delta starting: Minimum ampacity per conductor = 0.721 x compressor RLA
2.1 Lug adapters may be required if installation conditions dictate that conductors be sized beyond the minimum ampacity required. Contact starter supplier for lug information.
2.2 Compressor motor and controls must be grounded by using equipment grounding lugs provided inside starter enclosure.
III. CONTROL WIRING
3.0 Field supplied control conductors to be at least 18 AWG or larger.
3.1 Chilled water and condenser water flow switch contacts, optional remote start de­vice contacts and optional spare safety device contacts must have 24 vdc rating. Max current is 60 ma, nominal current is 10 ma. Switches with gold plated bifur­cated contacts are recommended.
3.2 Remove jumper wire between 12A and 12B before connecting auxiliary safeties be­tween these terminals.
3.3 Pilot relays can control cooler and condenser pump and tower fan motor contactor coil loads rated 10 amps at 115vacupto 3 amps at 600 vac. Control wiring required for Carrier to start pumps and tower fan motors must be provided to assure machine protection. If primary pump and tower fan motor are controlled by other means, also provide a parallel means for control by Carrier. Do not use starter con­trol transformer as the power source for pilot relay loads.
Fig. 17 — Typical Field Wiring (Low-Voltage Motors) with Free-Standing Starter
LEGEND Required Power Wiring Required Control Wiring
SMM — Starter Management Module
IV. POWER WIRING BETWEEN STARTERAND COMPRESSOR MOTOR
Options Wiring
3.4 Do not route control wiring carrying 30 v or less within a conduit which has wires carrying 50 v or higher or along side wires carrying 50 v or higher.
3.5 Voltage selector switch in machine power panel isfactorysetfor 115vcontrolpower source. Do not use the 230 v position. If this switch is set to 230 v position, the oil heater will not operate.
3.6 Control wiring cables between starter and power panel must be shielded with mini­mum rating of 600 v, 80 C ground shield at starter. Wires A,B, and C are commu­nication wires and must be run in a separate cable.
3.7 If optional oil pump circuit breaker is not supplied within the starter enclosure as shown, it must be located within sight of the machine with wiring routed to suit.
3.8 Voltage to terminals LL1 and LL2 comes from a control transformer in a starter built to Carrier specifications. Do not connect an outside source of control power to the compressor motor starter (terminals LL1 and LL2). An outside power source will produce dangerous voltage at the line sideof the starter,because supplying voltage at the transformer secondary terminals produces input level voltage at the trans­former primary terminals.
4.0 Low voltage (600 v or less) compressor motors have (6),5⁄8in. terminal studs (lead connectors not supplied by Carrier). Either 3 or 6 leads must be run between com­pressor motor and starter, depending on type of motor starter employed. If only 3 leads are required, jumper motor terminals as follows: 1 to 6, 2 to 4, 3 to 5. Center tocenter distance between terminals is 2 have nameplate stamped as to conforming with Carrier requirement Z-375. Medium voltage (over 600 v) compressor motors have (3) terminals. Connections out of ter­minals are 3 in. long stranded wire pigtails, #4 AWG, strand wire for all medium voltage motor sizes. Distance between terminal is 7 connectorsandinsulationforhighvoltagealternatingcurrentcableterminations(these items are not supplied by Carrier). Compressor motor starter must have nameplate stamped as to conforming with Carrier requirement Z-375.
4.1 When more than one conduit is used to run conductors from starter to compressor motor terminal box, one conductor from each phase must be in each conduit to prevent excessive heating. (e.g., conductors to motor terminals 1, 2 and 3 in one conduit, and those to 4, 5 and 6 in another.)
4.2 Compressor motor power connections can be made through top, top rear or sides of compressor motor terminal box using holes cut bycontractor to suit conduit. Flex­ible conduit should be used for the last few feet to the terminal box for unit vibration isolation. Use of stress cones or 12 conductors larger than 500 MCM may require an oversize (special) motor terminal box (not supplied by Carrier). Lead connec­tions between 3-phase motors and their starters must not be insulated until Carrier personnel have checked compressor and oil pump rotations.
4.3 Compressor motor frame to be grounded in accordance with the National Electrical Code (NFPA-70) and applicable codes. Means for grounding compressor motor is a pressure connector for #4 to 500 MCM wire, supplied and located in the back lower left side corner of the compressor motor terminal box.
4.4 Do not allow motor terminals to support weight of wire cables. Use cable supports and strain reliefs as required.
4.5 Use backup wrench when tightening lead connectors to motorterminalstuds.Torque to 45 lb-ft max.
15
⁄16inches.Compressor motor starter must
9
⁄16inches. Use suitable splice
23
Page 24
Notes on following page.
LEGEND
PIC Product Integrated Control
SMM — Starter Management Module
Required Power Wiring
Required Control Wiring
Options Wiring
Fig. 18 — Field Wiring (High Voltage Motors) with Optional Free-Standing Starter
24
Page 25
NOTES:
I GENERAL
1.0 Starters shall be designed and manufactured in accordance with Carrier Engineering requirement Z-375.
1.1 All field-supplied conductors, devices and the field-installation wiring, termination of conductors and devices, must be in compliance with all applicable codes and job specifications.
1.2 The routing of field-installed conduit and conductors and the location of field-installed devices, must not interfere with equipment access of the reading, adjusting, or servicing of any component.
1.3 Equipment installation and all starting and control devices must comply with details in equipment submittal drawings and literature.
1.4 Contacts and switches are shown in the position they would assume with the circuit deenergized and the chiller shut down.
1.5 WARNING: Do not use aluminum conductors.
1.6 Installer is responsible for any damage caused by improper wiring be­tween starter and machine.
II POWER WIRING TO STARTER
2.0 Power conductor rating must meet minimum unit nameplate voltage and compressor motor RLA (rated load amps). When (3) conductors are used: Minimum ampacity per conductor =1.25 x compressor RLA
When (6) conductors are used: Minimum ampacity per conductor =0.721 x compressor RLA.
2.1 Lug adaptersmay be required if installation conditions dictate thatcon­ductorsbe sized beyond the minimumampacity required. Contact starter supplier for lug information.
2.2 Compressor motor and controls must be grounded by using equip­ment grounding lugs provided inside starter enclosure.
III CONTROL WIRING
3.0 Field supplied control conductors to be at least 18AWG(AmericanWire Gage), or larger.
3.1 Chilled water and condenser water flow switch contacts, optional re­mote start device contacts, and optional spare safety device contacts must have 24 vdc rating. Maximum current is 60 ma, nominal current is 10 ma. Switches with gold plated bifurcated contacts are recommended.
3.2 Remove jumper wire between 12A and 12B before connecting auxiliary safeties between these terminals.
3.3 Maximum loadon pilot relays is 10amps. Pilot relays can control cooler and condenser pump and tower fan motor contactor coil loads rated up to 10 amps at 115 vac or up to 3 amps at 600 vac. Control wiring re­quired for Carrier to start pumps and tower fan motors must be pro­vided to assure machine protection. If primary pump and tower motor control is by other means, also provide a parallel means for control by Carrier. Do not use starter control transformer as the power source for pilot relay loads.
3.4 Do not route control wiring carrying 30 v or less within a conduit which has wires carrying 50 v or higher or along side wires carrying 50 v or higher.
3.5 Voltage selector switch in machine power panel is factory set for 115 v control and oil heater power source. The 230 v position is not used. If switch is set to 230 v position, oil heater will not operate.
3.6 Control wiring cablesbetween starter and powerpanel must be shielded with minimum rating of 600 v, 80 C. Ground shield at starter. Wires A, B, and C arecommunication wires and must be run ina separate cable.
3.7 If optional oil pump circuit breaker is not supplied within the starter en­closure as shown, it must be located within sight of the machine with wiring routed to suit.
3.8 Voltage to terminals LL1 and LL2 comes from a control transformer in astarter built to Carrierspecifications. Do not connectan outside source of control power to the compressor motor starter (terminals LL1 and LL2). An outside power source will produce dangerous voltage at the line side of the starter, because supplying voltage at the transformer secondary terminals produces inputlevel voltage at the transformer pri­mary terminals.
IV POWER WIRING BETWEEN STARTER AND COMPRESSOR MOTOR
4.0 Medium voltage (over 600 volts) hermetic compressor motors have 3 terminals. Use no. 4 AWG strand wires for all medium and high volt­age hermetic motors. Distance between terminal is 7 suitable splice connectors and insulation for high-voltage alternating current cable terminations (these items are not supplied by Carrier). Compressor motor starter must have nameplate stamped as to con­forming with Carrier requirement Z-375. Medium voltage open motors have lug terminations (see certified drawings for size).
4.1 When more than one conduit is used to run conductors from starter to compressor motor terminal box, one conductor from each phase must be in each conduit, to prevent excessive heating, (e.g., conductors to motor terminals 1, 2, and 3 in one conduit, and those to 1, 2, and 3 in another).
4.2 Compressor motor power connections can be made through top, top rear, or sides of compressor motor terminal box by using holes cut by contractor to suit conduit. Flexible conduit should be used for the last few feet to the terminal box for unit vibration isolation. Use of stress cones may require an oversize (special) motor terminal box (not sup­plied by Carrier).
4.3 Compressor motor frame to be grounded in accordance with the Na­tionalElectrical Code (NFPA-70)andapplicablecodes. Means for ground­ing compressor motor is a no. 4 AWG, 500 MCM pressure connector, supplied and located in the lower left side corner of the compressor motor terminal box.
4.4 Do not allow motor terminals to support weight of wire cables, use cable supports and strain reliefs as required.
9
⁄16inches. Use
Fig. 18 — Field Wiring (High Voltage Motors) with Optional Free-Standing Starter (cont)
25
Page 26
LEGEND
Factory Wiring Field Wiring
Oil Pump Terminal Power Panel Component Terminal
Fig. 19 — Oil Pump Wiring
LEGEND
1—Chilled Water Pump Starter 2—Condenser Water Pump Starter 3—Cooling Tower Fan Starter 4—Condenser Water Pump 5—Chilled Water Pump 6—Disconnect 7—Oil Pump Disconnect (See Note 5) 8—Free-Standing Compressor Motor Starter 9—Chiller Auxiliary Power Panel
Piping Control Wiring Power Wiring
Fig. 20 — 17/19EX with Free-Standing Starter
19EX SHOWN
NOTES:
1. Wiring and piping shown are for general point-of-connection only
2. All wiring must comply with applicable codes.
3. Refer to Carrier System Design Manual for details regarding pip-
4. Wiring not shown for optional devices such as:
5. Oil pump disconnect may be located within the enclosure of Item
6. Water piping to the oil cooler is required on FA compressors.
26
and are not intended to show details fora specific installation. Cer­tified field wiring and dimensional diagrams are available on re­quest.
ing techniques.
• Remote Start-Stop
• Remote Alarms
• Optional Safety Device
• 4 to 20 mA Resets
• Optional Remote Sensors 8 — Free-Standing Compressor Motor Starter.
Page 27
LEGEND
Field Wiring Power Panel Component Terminal
Fig. 21 — Oil Heater and Control Power Wiring
temperature range of −4 F to 140 F (−20 C to 60 C) is required. See table below for cables that meet the requirements.
MANUFACTURER CABLE NO.
Alpha 2413 or 5463
American A22503
Belden 8772
Columbia 02525
When connecting the CCN communication bus to a sys­tem element, a color code system for the entire network is recommended to simplify installation and checkout. The fol­lowing color code is recommended:
Fig. 22 — Carrier Comfort Network
Communication Bus Wiring
CARRIER COMFORT NETWORK INTERFACE — The Carrier Comfort Network (CCN) communication bus wiring is supplied and installed by the electrical contractor (if re­quired by jobsite prints). It consists of shielded, 3-conductor cable with drain wire.
The system elements are connected to the communication bus in a daisy chain arrangement. The positive pin of each system element communication connector must be wired to the positive pins of the system element on either side of it. The negative pins must be wired to the negative pins. The signal ground pins must be wired to the signal ground pins. See Fig. 23 for location of the CCN network connector (COMM1) on the processor module.
NOTE: Conductors and drain wire must be 20 AWG (American WireGage) minimum stranded, tinned copper. In­dividual conductors must be insulated with PVC, PVC/ nylon, vinyl, Teflon, or polyethylene. An aluminum/ poly­ester 100% foil shield and an outer jacket of PVC, PVC/ nylon, chrome vinyl, or Teflon with a minimum operating
SIGNAL TYPE
+ Red 1
Ground White 2
Black 3
CCN BUS CONDUCTOR
INSULATION COLOR
COMM1 PLUG
PIN NO.
If a cable with a different color scheme is selected, a
similar color code should be adopted for the entire network.
At each system element, the shields of its communication bus cables must be tied together. If the communication bus is entirely within one building, the resulting continuous shield must be connected to ground at only one single point. See Fig. 23. If the communication bus cable exits from one build­ing and enters another, the shields must be connected to ground at the lightning suppressor in each building where the cable enters or exits the building (one point only).
To connect the 17/19EX chiller to the network, proceed as follows (Fig. 23):
1. Cut power to the PIC (Product Integrated Control) panel.
2. Remove the COMM1 plug from the processor module.
3. Cut a CCN wire and strip the ends of the RED, WHITE, and BLACK conductors.
4. Using a wirenut, connect the drain wires together.
5. Insert and secure the RED wire to Terminal 1 of the COMM1 plug.
6. Insert and secure the WHITE wire to Terminal 2 of the COMM1 plug.
7. Insert and secure the BLACK wire to Terminal 3 of the COMM1 plug.
8. Attach the COMM1 plug back onto the processor module.
9. Mount a terminal strip in a convenient location.
10. Connect the opposite ends of each conductor to separate terminals on the terminal strip.
11. Attach the CCN Network wiring:
a. Connect the RED wire to the matching location on
the terminal strip.
b. Connect the WHITE wire to the matching location
on the terminal strip.
c. Connect the BLACK wire to the matching location
on the terminal strip.
27
Page 28
Install Field Insulation
Protect insulation from weld heat damage and weld splat­ter. Cover with wet canvas cover during water piping installation.
When installing insulation at the job site, insulate the fol-
lowing components (see Fig. 24 and Table 15):
• compressor motor
• cooler shell
• cooler tube sheets
• suction piping
• motor cooling drain
• oil cooler refrigerant side tubing
• utility vessel (low side) Additional insulation of condenser and compressor com-
ponents and lines may be necessary to prevent condensation on these components.
NOTE: Carrier does not provide waterbox insulation. Insu­lation of the waterbox covers must be field supplied at the jobsite. When insulating the waterbox covers, allow enough room for removal of the waterbox covers during servicing.
FACTORY INSULATION (OPTIONAL) — Optional factory insulation is available for the evaporator shell and tube sheets, suction pipe, compressor motors, and refriger­ant drain line(s). Insulation applied at the factory is (19.0 mm) thick and has a thermal conductivity K value of
in. W
0.28 (0.0404 °C). Insulation conforms
Btu
hr
ft2● °F
m
with UL Standard 94, Classification 94 HBF.
3
⁄4in.
Table 15 — Insulation Requirements
Sheet Foam Insulation
2
COMPONENT
Cooler Shell (Sizes 31-33) 254 23.6 Cooler Shell (Sizes 41-44) 306 28.4 Cooler Shell (Sizes 45-48) 374 34.7 Economizer Low Side Float Chamber 48 4.5 Economizer Main Shell (with cooler sizes 31-44) 85 7.9 Economizer Main Shell (with cooler sizes 45-48) 115 10.1 Suction Line 25 2.3 Cooler Marine Waterbox (1 or 3 pass, with
frame-3 coolers)
Cooler Marine Waterbox (2 pass, with
frame-3 coolers)
Cooler Marine Waterbox (1 or 3 pass, with
frame-4 coolers)
Cooler Marine Waterbox (2 pass, with
frame-4 coolers)
Cooler NIH Waterbox (with frame-3 coolers) 74 6.9 Cooler NIH Waterbox (with frame-4 coolers) 88 8.2 Main Motor Shell (with −51 through −89
compressors)
Main Motor Shell (with 421 through 469 compressors) 27 2.5 Main Motor Shell (with 531 through 599 compressors) 41 3.8
Foam Tubing Insulation
TYPE Ft m
1
⁄8( Foam Tubing 9 2.7
1
5
⁄8( Foam Tubing 2 0.6
1 2( Foam Tubing 9 2.7 5( Foam Tubing 14 4.3
NOTES:
1. Cooler value includes marine waterbox on one end (even-pass arrangement).
2. Values are approximate.
3. Thermal insulation is available as a factory-installed option. Waterbox in­sulation must be field supplied.
ft
m
126 11.7 100 9.3 158 14.7 123 11.4
27 2.5
2
28
Page 29
19EX CHILLERS
LEGEND
Factory Wiring Field Wiring
*Field-supplied terminal strip must be located in the control center. †Switches S1 and S2 are factory set on PSIO modules. Do not alter the switches.
Fig. 23 — COMM1 CCN Communication Wiring for Multiple 17/19EX Chillers (Typical)
29
Page 30
FRONT VIEW
PLAN VIEW
— Area must be factory or field insulated — Area to be field insulated, if ambient conditions require.
NOTE: Waterbox covers are to be insulated by the contractor.
IMPORTANT: 17EX insulation is identical to the 19EX insulation shown above. 17EX motors do not require insulation.
Fig. 24 — Typical Insulation Area (19EX Shown)
Copyright 1996 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2 2 Tab 5a 5d
PC 211 Catalog No. 531-749 Printed in U.S.A. Form 17/19EX-2SI Pg 30 3-96 Replaces: 17/19EX-1SI
Page 31
INSTALLATION START-UP REQUEST CHECKLIST
Machine Model Number: 17/19EX Serial Number: To:
Attn:
The following information provides the status of the chiller installation.
1. The machine is level.
2. The machine components are installed and connected in accordance with the installation instructions.
3. The isolation package and grouting (if necessary) are installed.
4. The relief valves are piped to the atmosphere.
5. All piping is installed and supported. Direction of flow is indicated in accordance with the installation instructions and job prints.
a. Chilled water piping b. Condenser water piping c. Waterbox drain piping d. Pumpout unit condenser piping (if installed) e. Oil cooler water piping (FA compressors only) f. Other
6. Gages are installed as called for on the job prints required to establish design flow for the cooler and condenser.
a. Water pressure gages IN and OUT b. Water temperature gages IN and OUT
7. The machine’s starter wiring is complete. The wiring is installed per installation instructions and certified prints.
a. Power wiring to compressor motor. (Motor leads will
not be taped until the Carrier technician megger tests
the motor.) b. Oil pump wiring c. Oil heater/control wiring d. Other
8. The motor starter has not been supplied by Carrier. It has been installed according to the manufacturer’s instructions.
9. The motor starter has not been supplied by Carrier and it has been checked for proper operation.
COMMENTS:
Date
Project Name
Carrier Job Number
YES/NO
(N/A)
DATE TO BE
COMPLETED
CL-1
Page 32
TESTING YES/NO
1. The cooling tower fan has been checked for blade pitch and proper operation.
2. The chilled water and condenser water lines have been:
a. Filled b. Tested c. Flushed d. Vented e. Strainers cleaned
3. The chilled water and condenser water pumps have been checked for proper rotation and flow.
4. The following cooling load will be available for start-up:
a. 25% b. 50% c. 75% d. 100%
5. The refrigerant charge is at the machine.
6. Services such as electrical power and control air will be avail­able at start-up.
7. The electrical and mechanical representatives will be available to assist in commissioning the machine.
8. The customer’s operators will be available to receive instruc­tions for proper operation of the chiller after start-up.
DATE TO BE
COMPLETED
Concerns about the installation/request for additional assistance:
I am aware that the start-up time for a Carrier chiller can take between 2 and 6 days depending on the model of the machine and the options and accessories used with it.
Your contact at the job site will be Phone number Beeper number Fax number
In accordance with our contract, we hereby request the services of your technician to render start-up services per contract terms for this job on (Date). I understand that the technician’s time will be charged as extra services due to correcting items in this checklist that are incomplete.
Signature of Purchaser Signature of Job Site Supervisor
CUT ALONG DOTTED LINE
Copyright 1996 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2 2 Tab 5a 5d
PC 211 Catalog No. 531-749 Printed in U.S.A. Form 17/19EX-2SI Pg CL-2 3-96 Replaces: 17/19EX-1SI
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