19XL Advance Packaged Hermetic Product Centrifu iqui i gal Liquid Chiller e > Data Nominal 300 to 500 Tons (1230 to 1750 kW) \AAVAVANNYS Carrier's 19XL Hermetic Liquid Chiller: ‘© superior design technology © quality/retiablity © the answer to the environmental and energy concerns of today and tomorrow Features/Benefits The 19XL chiller is designed to meet environmental re~ quirements with advanced technology and efficient operation. While providing full contain- ment of refrigerant, the 19XL reduces plant room alarm and ventilation costs ‘The 19XL uses environmentally acceptable HCFC-22, but has conver- sion capability for use of HFC-134a, ‘The chiller can be shipped with a full charge of HCFC-22, which means no loss of refrigerant to the environ- ment during charging. Other design features combine for careful control of refrigerant Optional isolation valves store refrigerant in condenser o cooler during service Brazed joints provide tight seals; flare connections are used for service joints only, Optional storage tank and puimpout system is available for refrigerant containment on multi-chiller installations. Aircraft-design O-ring seals on hermetically sealed compressor elim nate leaky gaskets Copyright 1991 Cartier Corporation Form 19XL-1APO‘The 19XL requiris no purge s1 tem, Thereby eliminating the release of refrigerant to the atmosphere. (RI1/ R123 systems require purges.) High-efficiency operation low- ers energy costs and ensures the minimum amount of global warming due to indirect ef- fects Efficiency ranges of 0.61 to 0.67 KW/ ton (IKWIUSRT) are obtained using high-speed turbine technology originally developed for jet engines The use of a new aerodynamic tunnel fuser ensures optimum efficiency under all operating conditions. Ideal for retrofit applications in existing buildings, the 19XL means minimal costs to in- stallers Compact design makes the 19XL. chiller 35% smaller than low-pressure chillers of comparable capacity Flanged modular construction allows installation of chiller components through a standard machine room door. Profle of largest component is only 3¥%4 ftx 5 ft (091 mm x 1509 mm). Installation costs are also reduced by the following features: Optional factory-mounted starter eliminates starter installation costs Refrigerant-cooled and oil-cooled, the 19XL does not require the instal- lation of oll cooler piping Single-point power connection module eliminates multiple electical connections (with factory mounted starter). Oil pump, compressor, ofl heaters and controls are pre-wired at the factory, Technologically-advanced control and monitoring of all chiller functions reduces service and operating costs By simplifying system planning and field integration, the advanced 40-character display microprocessor control reduces control-system design costs. The Product integrated Con- trol (PIC) can interface directly with the Cartier Comfort Network (CCN) Built-in features mean lower costs for service and repair All compressor components are ser viced from both ends of the col- lector housing, no need to remove the compressor from the chiller. Shutoff valve system allows oil fiter to be changed without pumpdown of reftig- cerant charge. Service valves are pro: vided for draining oil to closed containers, avoiding costly clean-up 2 STANDARD BooRWAY ‘TYPICAL RABBET-FIT ‘BOLT CONNECTOR FOR EASY REALIGNMENT and waste exposure. Waterbox cov- ers are small and lightweight, for easy removal during tube cleaning, The control system also helps to lower service costs. Nuisance shutdowns are avoided with the auto- ‘matic capacity override feature. This function unloads the compressor- whenever the key safety limits are approached. Service time is reduced by the control diagnostic capability, which informs the operator of proper corrective action for pre-set alarms.Built-in quality promises long life and trouble-free operation ‘The ASME U stamp for pressure vessel construction ensures the best in material and welding, All chiller ‘components are tested at 300 psig (2069 kPa) and then again at 375 psig (2586 kPa). Every chiller is factory tested for performance confirmation. Table of contents ‘Model Number Nomenclature Options and Accessories. Machine Components. Physical Data. Dimensions. Electrical Data. Optional Storage Tank andor Pumpout System (19XB) Performance Data. Application Data Controls... . ‘Typical Piping and Wiring. Guide Specifications Construction features provide long- term reliably Full .025/.028-in. enhanced wall thickness on standard tubing; optional tubing is available with wall thickness of .035 inches. Dynamically-balanced gas impel- Ters ensure low thrust loads. Model number nomenclature Model Description — Hermetic Centitugal Ligui Chiller Cooler Size 4043 (Frame 4) Condenser Size 4043 (Frame 4) 5053 (Frame 5) 19XL a 43 CANADIAN EQUIPMENT STANDARDS ‘U' STAMP TESTING ASSOCIATION LABS CERTIFIED Bearings are steel-backed and babbitted for long life. Fixed one-piece tunnel diffuser ensures optimum performance without movement, Helical gears conform to AGMA Standard 421 Quality Il for high- quality gearing Motor Size Compressor Size ARI (Air Conditioning ‘and Refrigeration Institute) PERFORMANCE, ‘CERTIFIEDOptions and accessories TEM ‘OPTION: ‘ACCESSORYE Export Grate x ‘Compressor Silencer ounted Solld-State/Wye-Deta Starior Full insulation GSA Certification (09-in, Wall Tubes, Enhanced 038 oF -035-in. Wall Tubes, Cupronlckal 026 oF 035:in. Wall Tubes, Not enhanced Flanged Nozzles ‘CoolariCondenser Isolation Val Storage Tank and Pumpout System ‘Soleplate Package ‘Spring isolators ‘Spare Sensor and Leads “Factory installed {Fie instal Storage Tank and Pumpout System It is Cartie's policy to provide protection for the environ- ‘ment by ensuring the containment of refrigerant during both operation and service. To help it meet this requirement, the 19XL chiller can be teamed with an optional partner The 19XB Storage Tank and Pumpout System, Storage vessels The pumpout-system storage vessels are supplied in 2 sizes, the smaller size designed to hold a charge of FICFC-22 for a typical 500-ton (1750 kW) machine. The larger tank will hold double that amount, for multiple chiller installations, Both vessels are designed to ASME Section VII, Div | ‘The vessels are equipped with double relief valves, sized in accordance with ASHRAE/ANSI 15 Mechanical Refrigeration. The tanks are also equipped with a liquid gage (magnet- ically coupled dial type) as a standard component. Pumpout condensing unit — The 19XB pumpout con- densing unit is the same unit used on Carter's industrial chillers. The unit requires separate power for the control cir. cuit (115 v) and the compressor motor (see table on page 9). The refrigerant side design pressure is 300 (2069) psig and the high-pressure cutout setting is 2205 psig (1517 +34 KPa), with an automatic reset at 185, +0,—7 psig (1276, +0, -48 kPa) The water-cooled condenser requires field water connection through two Yin. FPT connections Safety Code forMachine components FRONT VIEW Uni-Mounted starter Poligorant FiteDrior Rotrigerant Dry-Eye indcator Motor Sight Glass Religorant Motor Orain Oi Fihor Access Cover Retigerant O1 Cooler ‘Gearisearing Inspection Port Oi Lover sight Glasses Guide Vane Actuator ‘Typeal Flange Connection Leal Intertace Display Control ‘ASME Namepiate, Cooler Take-apa, abba Connecter (Lower) ‘igotant Charging Valve Cooler Refrigerant isolation Valve Oil Drain Valo ‘unilaty Power Pana! Revro-Pt Ags Place Beams ‘Typeal Water Box Drain Port Cooler Roturn-ena Water Box Cover SME Nameplate Condenser Condenser Return End Water Box Cover ‘Yako-Apart, Fabbot-Ft Connector (Upper) Protective truck Hoie-Down Lugs umpdown Valve Cooler Auto-Reset, Rete! Valves Machine dentition Nameplato ‘Suction Eloow Gi Rectaim Demister Line Oi Temperature Transducers Condenser Isolation Valve tom Vattage Accoss Door, Stator ‘acim es e Actose Door, Starter imp Volt Gages Rotigorant Supply Sumo Condenser Pressure Transducer Liu Sei Feat Chamber ASI Nameplate Float Chamber 40 — Condenser Auto Reset Rete! Valves 4 — Condenser inOut Temperature Transducers 42 — Geoter Intout Temperatura TransducorsPhysical data ‘COMPRESSOR WEIGHTS LOW.VOLTAGE WEIGHTS (60 Hs) ASSEMBLY Tora] —foroR | —woror move. | CoMpnESsoR disse woron | wetarr | Welont | eNO BELL % ra Epo ee TORE TTS Ee —| 7208 Osan a|0s | si ce | ie | soe | 337 | toe | oso | tte ct | iat | ste | 2te | ite | so | tte COMPONENT WEIGHTS: cm 1225 | 566 | 254 | 115 | 250 114 en | tae | sro | aaa | tie | aso | tte poaceeatre = m7 ce | tow | sos | ase | tat | aso | te on Elbow s Suslon Eo = z &o_| sxe | sso | fo | te | oso | ie Coniot Sabinett & i Spinal Mounted Start 0 a “clues in ota ompresor waht tinclued in al coolr woah “"Vloght of optonal actor. aunted sare isnot inde and must Be aed (heat exchanger waits HEAT EXCHANGER WEIGHTS ENGLISH SIMETRIC [Rear 7 Taine Charge T Tiina Wa Machine Charge Tay COPE cooler | cond | Retigeran Water——|Gooler | cond | —Fotigerant Water Only Only [Cooler | Cond | Cooler [ Cond | Only Only [Cooler [ Cond | Cooler | Cond aC CL aa | ~a670_| “sto | —ora | ~a0a | se [ses | aes [enon | ae] 78] 22 [amr] soso | vio —[s6t sor] 00] a0 [ave | ~ 0a | “178 | oss 30 | ores | es0e [aves [a0] 60] 701 | aa08 [anno | ~s08 | 178 | a [aia St [e261 [esos |v200 | 306] 726 | 75 | anes [ arte sar | “100 | a0 [air 52 _|esee | rose_| rast | aor] 708 | aa] 2076 [ ea0e | ~o08 | tae | a —| a 8 [arse] reas [rae art or0 eet] ae [aa [or | iar fs a NOTE: Goole and condenser gig weight ar wh bes of standard wal thine For 05m copper wal texness, mule raging welts bythe Volowing” Cooler — 1073 Conder = 1.052 WATER BOX COVER WEIGHTS* Famez Faas wear | warennox | ssophiptoatnra) | 150 pei teat ua) exchanen | oscmbnion [121 Wr 0 = Tz pas —[ 385 Ta at 7 meee NIN, 3 pass 2a 135 a5 190 WH 2passt [256 “a 35 107 CONDENSER NIRS. pass EI Tt OT 185 NIH — NozzieWwhead “These woights are given for reterence only They have been nckded in eat ‘pechangor weights ‘show above ee +fTho 2-pass woightsgivan ar for the cover with pipe nozzles NOTE: The lat box cover weight is 283 fo (128 kg).Dimensions ‘Tube REMOVAL SPACE EITHER END (2st) tan Dt |SERVICE AREA HEAT EXCHANGER A(CENGTAY NOZZLE SIZE (in (COOLER and 7 BquoTHy | c (HEIGHT CoOL en Pass Paes (NOMINAL PIPE SIZE) size) fin [ mm [Rin [mm | fin | mm | fein [mm | 2 Pass | oPass 20-43 Term [are [ivan | aa60_| sex | 1670 | 72% | 2000 é e 30-53 138 ae | 1am | asee | 60% | 1095 | rem | 2340 @ 6 “pass length apples if ther (or both) cooler or condensor Isa S-pass design MOTOR SERVICE CLEARANCE NOTES. [——cLEARANGED—— _1 Seivioe access should be provided per ANSUASHAAE 15, Latest Editon, ‘CLEARANCE D. DESIGN VOLTAGE i = [NFPA 70 and local saety odo, BOBO SOO RE = TE 2. Catled drawings avaiable upon requestElectrical data i 0 HERTZ MOTORS ‘BO HERTZ MOTORS moron | tone, Tow Vorts = Tow Vor cnanactenisnics [HEFT 200v | za0v | seov | asov | svsv | Max | za0v | a86v | a00v FLA por RW se | ae |e |e |e Bear | co | LAA Star zoo | sia8 | tore | 676 | 406 | 405 | 200 | oor | 679 | 60 LRA Delia assi_| stex_| ar | 1510 | 1265 zse7_| toe | 1761 LA por RW sas} 265 | 173} 143 aie 2as_| 190] 168 ce | LRA Star zo | 1505 | toa | ee | 462 | ozs | av | ites | 700 | Ges LRA Delia asso_|_czes | 1045 | reas | 1165 v6ao_| 2436 | 2078 LA por RW 3z8 | 285 473 |e ae zee) ta? | 102 cu | LRA Star za | tars | tr | 740 | sae | 60 | 243 | itor | ore | rex LRA Detia sese_| sees | 2240 | tor | 124s sra0_| 2506 | 2as0 LA por RW sa] 260 | 175) 148 | 115 279] tes} 160 om | LRA Star vor | iso | taze | oat | see | 408 | 267 | ise | eso | 730 LRA Data aais_| a4es | 2028 | 1757_| 1556 asi9_| 2003 | 2280 A por RW sae_| 2a [173 | 143 | 114 219} 188} 170 on | Una Star zos | tesa | tas | 98s | oes | sto | 205 | sess | o54 | 606 LRA Dota sise_| ater_| eroe_| 207s | 1008 45i8_|_2670_| 2600 FA por WT aa) ame | in | tat] 119 zee] 187 | 168 cp | LRA Star aes | ior | i430 | os: | rio | cor | sea | tsa | 1020 | 51 LRA Dota soos_| a4es | 2os0_| 2247 | 1078 area_|_sia7_| 2573 FCA par WT 3a) 205 | 178 | tas | 114 273|_198 | 1.60 ca | tna Star aso | iai2 | tex | ose | too | Gre | 60 | tsi2 | isos | st LBA Data sore_| sizi_| 206s | 125 | cose asro_| sort | 2073 LEGEND 2. To establish electrical data for your eslected voltage if thar than kW — Compressor Motor Powor Input (Kilowatt) LRA — Locked Rotor Amps GLTA — Overload Trp Amps ( BLA’ — Ratod Load Amps NoTEs: 1. Standard Volages: onZ LA x 108) BORZ Voll] For use on supply valtages | Valt[ For use on supply votages: 200] — 20070 208 v systems — [230 230| 22010 240 system | 346, 380| 36010 400 v systems | 400 460 | 440 10480 v systome 575] 550 10 600 v sysioms 720 to 240 sysioms £320 to 260 v systoms, 380 0 415 v systoms, ‘Motor sameplates canbe stampodfor any vokaga win he ated sph votage range. Griers shall not be soloed at vlages above or Below {he tsted supply voltage range Compressor motor controllers Compressor motors as well as controls and accessories re Quire the use of starting equipment systems specifically de~ signed for 19 Series Chillers. Refer to Application Data, Starting Equipment publications or consult Caner regard ing design information for selection of controllers Istod voltage, us tho folowing Yormla: ted votage = feted ALA x Usted wotage RLA = listed LA x ced volage ited votage TA = tted OLTA x eles age oe WSO OTA X cia ‘voltage LRA = tted LRA Sleted votiage Tsiod votage Example: Find tho rated load amperage fora 675-v motor lated at {71 amps per ki input for use st 580 vols FLA = 1.14 2, 550 119 Capacitors/power factors Power factor considerations may indicate use of capacitors Properly sized capacitors improve power factors, especially at part load. Contact Syracuse for further information on power factors,Optional storage tank and/or pumpout system (19XB) PHYSICAL DATA ENGLISH @ Taw | Oey TARA REFRIGERANT CRPROTTY 1B) SBE | "OOS | watch | —reRRREANSTS ARTS | UNTO [eae ray amy [aT aT ear Gace ae eee ae [| aes 3270. 73525 | ~3880_| 3420 aiss [3465 3055, si merc =a aU REFRIGERANT CRPRGTY Wa ae | "8B | wR [raters nT um) ka) T2a)_|_ (12) | (500) | (22) | (Ria) | (P00) oC se [-we—| ae [aso eefst—Pastteef 30 — Outie Diner "The above ey weght ns he prod conan uk weg 20. (5k) 19XB ELECTRICAL DATA STOR EOGE CoRR UT —VorTS PARE [WAAC TR " TEN TEs aE t oars | amansco | os | as : ters | wots | 2) | Be TRA — Locked Rotor Arps LA — Ratod Load AmpsOptional storage tank and/or pumpout system (19XB) (cont) EF AVES en 2ame (a4) 10976" (268) DIMENSIONS (ft-in.) ree | amen [mn fe |r [centr [eae Tomes | oa | eae em ee | [see] OS [ea ee oT] BO rae oe Toxpoase [ivi | teze [om [oa [rae] 32 [eine] 30 [owe som Lor [eae] Sion] 1 Loam DIMENSIONS (mm) a] =e ]e]o[t'[ryTe,wf[ij[s]«]t[wu [nye [GE D007 20] Tena AT] TOO. EH 12] BHC | TAow GO| 1170 72 | 206 BD | TONE GD | TaaT WS |THE BD] 10H OO] STs [NSH “TORBDASE | A552 05 | 1990 70] ToHG 2] BIG 0] s1275 1504 D2] 2179 55] Ie 49 [27679] THH0 To] zTO7 20] TesH.05 1814 gs |59a. 40 [8 7S 19XL Performance data AUXILIARY RATINGS (3 PHASE, 50/60 HZ) AUXILIARY RATINGS (115 VOLT, 1 PHASE, 50/60 HZ) CESIGN ‘OUTPUT | SEALED | ~ AVERAGE "AVERAGE surety ] seaeD | nqusi eM rrem | AVERAGE] Gram | guPpLy | SEALED [insu vous | a ae = ‘CONTROL 24 0.16 0.16 Tas psosea | Banas os} Sa5 rooue 130 [oseo| Seoaeo | oe | ees Sli| 137 | ses3e0| over | $30 | in] KYA — Kiovotranes rie | 2z0ss0| aoa | 111 | exe tas_|2ess0| Séne0 | 12 | S70 10‘TYPICAL COOLER PRESSURE DROP 2 PASS COOLER FRESHWATER AT 90 DEGREES F WATER VELOCITIES FROM 2 70.12 FUSEC Flow (L/s) PRESSURE DROP (FT. OF WATER) | FLOW (GPM) 3 PASS COOLER, FRESHWATER AT 30 DEGREES F [WATE VELOCITIES FROM 2 10 12 FUSEC. now (5) 5 jij ec 07 - ae i : oe FLow (GPM) 1. Hx designations are cooler heat exchanger sizes 2. Todetermine pressure drops more accuraaly and o compensate fo actual water temperature, {Se'RS Computonzed solecson sonice avarablo trough your teal Carr Sales ofc, PRESSURE DROP (kPa) u19XL Performance data (cont) Flow (L/s) Y ‘CONDENSER PRESSURE DROP ‘2 PASS CONDENSER FRESHWATER AT'90 DEGHEES F WATER VELOCITIES FROM 2 TO 12 FTISEC Heese PRESSURE OROP (FT. OF WATER) i | FLOW (GPM) Flow (L/s) 3 PASS CONDENSER FRESHWATER AT 90 DEGREES F (WATER VELOCITIES FROM 2 70 12 FHSEC PRESSURE DROP (FT. OF WATER) FLOW (GPM) NOTES: 1. Hoe designations ao condenser heat exchanger sizes w 2, To dtermino pressure drops more accurately and to compensate fot actual water temperature, se the computerized selection service avaiable trough your foal Carrer Sale oles. PRESSURE DROP (kFo) PRESSURE DROP (kFo)Application data DRIVE END "soe eae wien o 4 vessns 1 -—- ae ky COMPRESSOR ENO mH Dimensions in parenthesis are in millimeters: (co SSREE on Prem rr oar Stas oPmoNat ts0.ATION a Cu see wore a 1 ftom scene S72) - i i pesanenns erareen ore eee sh STANDARD ISOLATION supra rue eric aoe SHEAR FLEX PAD (36 (95) THK) ISOUTION WITH SQLATIONPISKGE ONLY TADIEDD 13Application data (cont) et. eo eer RIVE END cowpaesson £N0 “a a ut oo FRONT VIEW saesesam 20 ‘COOLER WATERBOXES ‘CONDENSER WATERSORES ‘ARRANGENENT wy ] ARRANGEMENT pass | m | our ory pass | w | ov a 2 eT e ¢ 2 TTT es = i 5 ne ea § sys = 7 + elise jee F oils Q TWORINAL PIPE SIE fy ‘eta Pipe 15 Wad Frawe | PASS [~cooten | CONDENSER | COOLER | CONDENSER, 7 z 7 z 781 Teer 5 5 5 5050 3s z 7 = 738 781 z a 6 5 Bes Ses 10 — freee Diameter Vent and drain connections With the exception of the cooler vent connection, located in the water box shell all vents and drain connections are found in the water box covers. Connection size is ¥4 in. FPT, Provide high points of the machine piping system with vents and the low points with drains. If shutoff valves are provided in the main water pipes near the unit, a minimum, amount of system water is lost when the heat exchangers are drained, This reduces the time required for drainage and saves on the cost of re-treating the system water. Itisrecommended that pressure gages be provided at points, of entering and leaving water to measure pressure drop through the heat exchanger. Gages may be installed as shown in Pressure Gage Location table Pressure gages installed at the vent and drain connections do not include nozzle pres sure losses. Use a reliable manometer to measure pressure differen. water chilling applications of 350 to 500 tons (1230 to 1750 AW) using refrigerant R-22. ASME stamping AIL19XL heat exchangers are constructed in accordance with, ANSI/ASHRAE 15 Safety Code for Mechanical Refrigera- tion (latest edition). This code, in turn, requires conformance with ASME Code for Unfired Pressure Vessels wherever ap- plicable. Relief-valve discharge pipe sizing ‘The 19KL is equipped with 4 relief valves; 2 on the cooler and 2 on the condenser. ‘The optional 19XB storage vessel also is equipped with 2 relief valves. Relie-valve dscharge piping sizing should be calculated per the current version of the ANSVASHRAE 15 code using the tabulated C factors for each vessel shown below: tial when determining water flow. Regular gages are insen- vesss: | VEG | MEUEEVALVESRE | CracoR sitive and do not provide accurate measurement of flow 1s Te z conditions. 50-53 % 544 PRESSURE GAGE LOCATION Be in aa TOBE. GAGELOGATION = 7 Sie PASSES «costo Consencen zg i BE 3 | SS Carrier further recommends that an oxygen sensor be in- pve guages water = stalled to protect personnel. This sensor should detect oxy- Range of application ‘The I9XL reftigeration machine is designed for standard 4 ‘gen at @ minimum of 19.5%Design pressures Design and test pressures for 19XL heat exchangers are listed below. DESIGN AND TEST PRESSURES SHELL sibe ] TUBE SDE a ater) pa_[_Pa_|_pal_| Wa Design 300 | 208150 | 08 iyerosatie Teat_| —— Bes] Ts6F BicTost cc HEAT EXCHANGER MATERIAL SPECIFICATIONS: Ten ATERAL ‘SPECICATION 8 toa ASME sasie GF.70 HR Sea Sve Sast6 GE 70 BR Sea SME Snare GE 68 Fiiiod Copper SVE SB ‘Seat ASME SATS Insulation INSULATION REQUIREMENTS din Se eneuaro ‘size © a co 75 7 suction elbow, compressor motors and motor refrigerant drain lines). Insulation applied at the factory is 34 in, (19.0 mm) thick ang has a thermal conductivity K value of 0.28 Btu « infhr « ft¢« °F (0.0404 Wim « °C). Insulation conforms with UL Standard 94, Classification 94HBF. Insulation at jobsite — As indicated in the Condensation. vs Relative Humidity table, the factory insulation provides excellent protection against condensation under most oper- ating conditions. If temperatures in the equipment area ex- ceed the maximum design conditions, extra insulation is recommended Hf the machine is to be field insulated, obtain the approx- imate areas from insulation drawing. Insulation of water box covers is made only in the field and. this area is not included in Insulation table. When insulating the covers, allow for service access and removal of covers. CONDENSATION VS RELATIVE HUMIDITY* ‘ROOM ORY BULB TEN cONSEHSATON ro | wre [WF EEC Fata oT Tre = = = Bier e = ¥ Ean a 5 4 Factory insulation (optional) — Optional factory insula tion is available for the evaporator shell and tube sheets, Tas soproimas toute ae based on 95 F (17 ©) sual suction temper ‘ura E'S sc anange stud suc tempers eoanges Bee sve homay unt oy eine sama dracon INSULATION AREA FACTORY INSTALLED INSULATION PLAN VIEW cave exo, soreness 20. FRONT VIEW 15Controls eroprocessor conta Conrot tem Features comers Ne ae it a coNOnatnts cen Capacity Control Leaving Chilled Water Control Entering Chilled Water Control Soft Loading Contal by Temperature or Load Ramping Guide Vane Actuetor Module Hlot Gas Bypass Valve Power (Demand) Limiter ‘Auto. Chilled Water Reset Interlocks ‘Manual/Automatic Remote Start Starting'Stopping Sequence Pre-LubelPos Lube re-Flow/Pos Flow ‘Compressor Starter Run Interlock Pre-Start Check of Safeties and Alerts Low Chilled Water (Load) Recycle Monitor/Numbe: Compressor Starts and Run Hours ‘Manual Reset of Safeties Indications Chiller Operating Status Messages Power-On Pre-Start Dingnoste Check Compressor Moter Amps Pre-Alarm Alert§ Alarm Contact for Remete Alarm Safety Shutdown Messages Elapsed Time (Hours of Operation) ‘These can be configured by user to provide alert indleation at user defined lt, Override protecton: Causes compressor to fist unload and then, sf necessary, shut down, | Required: Field or factory supplied (installed at jobsite) {By display code only, MICROPROCESSOR CONTROL PANEL CLOSE-UP VIEWS OF DISPLAY 16Typical piping and wiring 19XL CHILLER WITH OPTIONAL UNIT-MOUNTED STARTER xy coupaesson MOTO POWER ‘TOCHILLED WATER PUMP. ‘TO CONDENSER WATER PUMP ‘TO COOLING TOWER FAN: pnd Sti. wane < = Sine .. < x \ : \- “ 4 = Glos wate up Saar NoTES: 2 = Condonaor Water Pump Star + Wiring and piping shown are for goneral pinto cannecton only ond are not intended to § = lolng Toner Fan Stator stom detall fore spools talaion Caton tad wring ant tmensonaldagrans aie 4 = Goraneor Water mo alate an request § = Choa Wor Pum 2 Al wing must comply with applicable codes Refer to Carter System Design Manual for detls regarding piping techniques 44. Wiring not shown for optional devices suct as: ‘¢ Romote StariStop '* Fomote Alarm {Optional Safety Device #410 20 mA Resets © Optional Remote Sensors 7Typical piping and wiring (cont) 19XL CHILLER WITH FREE STANDING STARTER van Peter ‘TO CHILLED WATER PUNE. ‘TO CONDENSER WATER PUNE TO COOLNG TOWER FAN: = Png = Celio. wane SNEWS 7 > hited wie Pump Saree ores: ondonser Water Pump Stator + Wing anapiping shown are foc ganar pono connection only and arent intended {Gootng Tower Fan Sater {0 show detala for 8 specie nstlahon. Cortes toe wing. and cimensional Gandoncor Water Pump Gagrams are avalabo on request hd War Par twang must comely wah pied codes Bi Bina Dacomect (See nt 9 Foto to Carta’ Sys Del Maral fr datas regarding ping tectnaues Fusdatang els tg Sane itn dn or anal Gove oh Cortese Gor eral Box Sere SPR er Pa ¢ Remote Sip * Optional Safety Device © 410 20% Resets © Optional Remote Sensors 5 Oi pump disconnect may be located within the enclosure of Item 8 — Freestanding ‘Compressor Motor Starter. PEreeeniet 18Guide specifications Packaged Hermetic Centrifugal Liquid Chiller Size Range: 300 to 500 Tons (1230 to 1750 kW) Cartier Model Number: 19XL Part 1 — General 1.01 SYSTEM DESCRIPTION A, Microprocessor-controlled liquid chiller utilizing asingle- stage semi-hetmetic centrifugal compressor using Re frigerant HCFC-22. Chillers using CFC refigeranis such as CFC-11, 12, oF 500 are not acceptable. If a manufacturer proposes a liquid chiller utilizing HCFC-123 refrigerant, the manufacturer shall include in the chiller price: 1. A vapor activated alarm capable of sensing up to ‘rat 100 ppm Allowable Exposure Limit (AEL), 2. External refigerant storage tank and pumpout unit, 3. High efficiency purge unit. 1,02 QUALITY ASSURANCE ‘A. Chiller performance shall be rated in accordance with Air Conditioning & Refrigeration Institute (ARI) Stan- dard 550-90. B. Equipment and installation shall be in compliance with Safety Code for Mechanical Refrigeration, ANSI/ ASHRAE 15 (latest edition) C. Cooler and condenser shall include ASME “'U” stamp ‘and nameplate certifying compliance with ASME sec- tion VII, division 1 code for unfired pressure vessels D. Chiller shall be designed and constructed to meet ETL ‘and CSA requirements and have labels appropriately affixed. E. Compressor impellers shall by dynamically balanced and over-speed tested by the manufacturer at a min- imum of 120% design operating speed. Each com- pressor assembly shall undergo. mechanical run-in test to check proper operation of various components and to verify vibration levels and oll pressures! temperatures are within acceptable limits. Each com- pressor assembly shall be pneumatically proof tested atminimum 375 psig (2586 kPa) and leak tested with a refrigerant tracer ges at 300 psig (2069 kPa) F, Both cooler and condenser shall be proof tested at 450 psig (3103 kPa) on the reftigerant side and leak tested with a refrigerant tracer gas at 300 psig (2069 kPa). The water side of each heat exchanger shall be hhydrostatically tested at 1.5 times the rated working pressure G. The entire chiller assembly shall be leak tested with a refrigerant tracer gas at 300 psig (2069 kPa). H._ Prior to shipment the chiller automated-controls test shall be executed to check for proper wiring and en sure correct controls operation, 1. Onchillers with unit-mounted compressor motor stat ers, chiller and starter shall be factory wired and tested together to very proper starter operation prior to ship- ment 1.03 DELIVERY, STORAGE AND HANDLING ‘A. Unit shall be stored and handled in accordance with ‘manufacturers instructions, B Unit shall be shipped with all refrigerant piping and control wiring factory installed. CC. Unit shall be shipped pre-charged with refigerant R- 22 and oil as specified on the equipment schedule. . Unit shall be shipped with firmly attached metal plates that indicate name of manufacturer, chiller model num- ber, chiller serial number, and refrigerant used Part 2 — Products 2.01 EQUIPMENT A, General Factory assembled, single piece, liquid chiller shall con- sist of compressor, motor, lubrication system, cooler, condenser, initial oil and refrigerant operating charges, ‘microprocessor control system, and documentation re- quired prior to start-up. Compressor motor starter shall bbe mounted on the chiller, wired, and tested by the chiller manufacturer. B, Compressor: 1. One centrifugal compressor of the high performance single-stage type. Connections to the compressor cas: ing shal. use O-rings to reduce occurrence of refrig- rant leakage 2 The open type impeller with machined shroud con- tours and impeller diameter optimize compressor ef- ficiency for each specified application. 3. A tunnd diffuser shall provide a highly efficient con- trolled difusion ratio by means of individually con toured, machined-in channels of circular ross section. 4, Compressor, motor, and transmission shall be her- metically sealed into a common assembly and ar- ranged for easy field servicing, Internal compressor parts are accessible for servicing without removing the compressor from the chiller. Connections to the com- pressor shall be flanged or bolted for easy disassembly. Joural bearings shall be steel-backed babbit type. 6. The high speed shaft thrust bearing shall be ofthe tit- ing pad multi-shoe kingsbury type with individually replaceeble shoes. The low speed shaft thrust bearing shall be of the tapered land type. 7, Transmission shall be single ratio, single helical, par- allel sheft speed increaser. Gears shall conform to ‘AGMA Standard 421 8, The compressor design shall include @ balancing pis- ton to offset impeller thrust forces. The gear thrust load shall act opposite fo impeller thrust loads 9. The variable inlet guide vanes at the inlet to the im- plier shall provide capacity modulation from 100% to 15% capacity, with 2.5° F (1.38°C) drop in enter- Ing condenser water temperature per 10% capacity reduction, while also providing pre-whit ofthe reftig erant vepor entering the impeller for more efficient compression at all loads, 10. Compressor shall be provided with a factory-installed lubrication system to deliver oil under pressure to bear ings and transmission. Included in the system shall be. a. Hermetic motor-driven oil pump with factory- installed motor starter’ with overload protection. 19Guide specifications (cont) b_ Refrigerant-cooled oil cooler. . Oil pressure regulator. . Twenty-micron oll filter with isolation valves to allow filer change without removal of refrig- terant charge. e, Oil sump heater (115/230 v, 50 or 60 Hz) con- ‘rolled from unit microprocessor. {, Oilreservoir temperature sensor with main con: ‘rol panel digital readout, 2. Oil pump and motor for 200-240, 380-480, or 507-619 v, 3 ph, 60 Hz power source, or 220- 240, 346-440, 3 ph, 50 Hz, 1, When factory-mounted compressor motor starter |s provided, all wiring to oil pump, oil heater and controls shall be prewired in the factory and power applied to check proper operation prior to shipment. C. Motor. 1. Compressor motor shall be of the hermetic liquid refrigerant cooled squirrel cage induction type suit- able for the voltage shown on the equipment sched- tule. If open motors are used in place of refrigerant cooled motors, the manufacturer shall supply curve of motor heat loss as a function of load to allow calculation of the additional ventilation or air conditioning load generated from the motor heat rejection. In addition, a mechanical room safety ‘alarm, wiring, and chiller emergency shutdown shall be included to prevent chiller operation if machine room temperature exceeds 104 F (40 C) 2, Motor design speed shall be 3550 rpm with 60 Hz power and 2950 rpm with 50 Hz power, 3. Motor stator shall be arranged for service or re- ‘moval with only minor compressor disassembly and without removing main refrigerant piping connections. Low voltage motors (600 v or less) shall be built to allow connection to Wye-Delta type reduced in- rush starters. 5. One motor winding (with one spare) temperature sensor shall be provided. Cooler and Condenser: 1 Cooler and condenser shall be of the shell and tube construction, each in separate shells. Both heat ex- changers shall be fabricated with high performance tubing, steel shell and tube sheets with fabricated stee! water boxes. Water boxes shall be nozzle-in-head type ‘with stubout nozzles having Vietaulie grooves to allow for use of Victaulic couplings. 2 Tubing shall be copper, high-efficiency type, with in- tegral internal and external enhancement. Tubes shall be nominal 4-in, OD with minimum wall thickness of (025/,028-in. measured at the root of the fin, Tubes shall be rolled into tube sheets and shall be individu- ally replaceable. Tube sheet holes shall be double grooved for joint structural integrity. Cooler tubes shall be expanded into intermediate support sheets. Inter- ‘mediate support sheet spacing shall not exceed 36 20 10. inches. Water boxes and nozzle connections shall be designed for 150 psig (1034 kPa) minimum working pressure, unless otherwise noted, Nozzles should have grooves to allow use of Victaulic couplings. The tube sheets of the cooler and condenser shall be bolted together to allow for field disassembly and re- assembly. Each heat exchanger shall fit through asin gle doorway. ‘The vessel shall display an ASME nameplate which shows pressure and temperature data and the "U" stamp for ASME Sect. VIll, Div. 1. A pressure relief valve shall be installed on each heat exchanger. Water boxes shall have vents, drains and covers to permit tube cleaning within the space shown on the drawings. A temperature sensor shall be factory installed. Cooler shall be designed so as to prevent liquid re- frigerant from entering the compressor. Devices that introduce pressure losses (such as mist eliminators) are not accepiable because they are subject to structural failures that can result in extensive compressor damage Tubes shal be individually replaceable from either end of the heat exchanger without affecting strenath and durability ofthe tube sheet and without causing leak- age in adjacent tubes. The condenser shell shall include a thermal econo- rmizer which cools the condensed liquid refrigerant to a reduced temperature, thereby increasing the reftig- eration cycle efficiency A compressor discharge isolation valve shall be fac tory installed to allow isolation of the refigerant charge in the condenser. Refrigerant Flow Control To improve partload efficiency, liquid refrigerant shall bbe metered from the condenser to the cooler using a float type metering valve to maintain the proper liquid level of retigerant in the heat exchangers under both {ull and part load operating conditions. By maintain- ing a liquid seal at the flow orifice, bypassed hot gas from the condenser to the cooler ts eliminated. The float valve chamber shall have a bolted access cover. Controls, Safeties and Diagnostics 1. Contras: a, The chiller shall be provided with a factory: installed and wired microprocessor control cen- ter with individually replaceable modular com- ponent construction. Components incluced shall bbe the main processor/input-output module, power supply, starter management module (lo cated in starter cabinet), relay board, tempera- ture and pressure (thermistor and transducer) sensors, Two optional input modules (8 input channels each) can be factory or field installed. The control center includes a 16-line by 40- character liquid crystal display, 4 function keys, stop button, and alarm light. The microproces- sor can be configured to display either English (or SI metric units.b. The default standard display screen shall simul- taneously indicate the following information: # date and time of day © 24-character primary system status message © 24-character error message © chiller operating hours tering chilled water temperature leaving chilled water temperature evaporator refrigerant temperature entering condenser water temperature leaving condenser water temperature condenser refrigerant temperature oil supply pressure oil sump temperature percent motor rated load amps (RLA) ‘The default screen shall be displayed if there is. no manual activity at the control console for 15 minutes. The 4 function keys are identified as Status, Schedule, Set Point and Service. 1) Status Function: Inaddition to the default screen, status screens shall be accessible to view the status of ev- ery point monitored by the control center, including evaporator pressure condenser pressure compressor discharge temperature bearing oll supply temperature motor winding temperature {quantity of compressor starts control point settings Discrete output status of various devices 16 spare input channels ® compressor motor starter status 2) Schedule Function: Start-up and shutdown shall be manual or automatic. Automatic operation is activated boy the user establishing an occupaney sched: ule based on a 365-day realtime clock that shall automatically start and stop the chiller according toa configurable stored time, Clock shall have battery backup. A minimum of 8 separate occupied/unoccupied periods may be scheduled by the user The periods can have any day of the week or holiday as- signed to the occupied or unoccupied ps ‘ods, Up to 18 user-defined holidays can be configured up to one year in advance (month, day, and duration in days). Simultaneous dis- play of the occupancy schedules shall be viewable on the LCD screen, The chiller can also be started and stopped remotely by con- tact closure from a customer-supplied relay (once this option has been activated in the configuration mode), or from a building man agement system software command, Set Point Function: The leaving chilled water set point, entering chilled water set point and demand limit set point shall be entered, stored, viewed, or eccecee 3 4 changed by depressing the set point function key ‘The operator shall be able to modify these set points by entering the set point func- tion and modifying the set points anytime dur- ing chiller operating o shutdown periods. 4) Service Function: By depressing the service function key and entering a 4-cigit password the operator shall be able to: © View the alarm history file which contains up to 25 alarm/alert messages with time and date stamp. © Execute the chiller controls test function for quick identification of malfunctioning components. View/modify chiller configuration. View/modify chiller occupancy periods. © View/modify schedule holiday periods © View/modify schedule override periods, © View/modify system time and date. Capacity contol shall be by means of variable inlet guide vanes located at the impeller inlet Load modulation shall be from 100% to 15% of full load under normal ARI conditions with- out the use of hot gas bypass. The guide vanes are precisely positioned by a PID (proportional- integral-derivative) control algorithm to ensure precise control (+/— 5 degrees F or 3 de- grees C) of desired chilled water temperature without hunting or overshooting the set point ‘The microprocessor control system shall include a programmed sequence to meet pre-lube and ppost-lube needs prior to machine start-up and during coast-down after machine stop. The mi- ‘roprocessor shall automatically activate and in- terlock the chilled water pump, condenser wa- ter pump and cooling tower fans upon chiller activation Upon request to start the compressor, the con- trol system shall start the chilled water pump, condenser water pump and tower fans; verify that flow has been established; and then com- pare leaving chilled water temperature with the chilled water set point. Ifthe chilled water tem perature is less than the chilled water set point, the control system wil shut down the condenser ‘water pump and wait for the cooling load to be established. A.user-configurable ramp loading rate, effective during the chilled water temperature pulldown period, slows the rate of guide vane opening to prevent a rapid increase in compressor power consumption. Ramp loading limits the rate (degreesiminute) of chiled water temperature pulldown or % demand limit to the user Configurable rate, During the ramp loading pe- Hod, a message shall be displayed informing the operator that the chillers operating in ramp load- ing mode 21Guide specifications (cont) 22. hh, The contvol system shall include 2 compressor cycle-timers to protect the motor from rapid cycling. The star-inhibit timer shall prevent rapid compressor restart by limiting the start-to-start time to 15 minutes minimum and stop-to-start time to 3 minutes minimum. In addition, the compressor will be inhibited from restarting if more than 8 manual starts per 12-hour petiod have occurred. i. The control system shall automatically cycle the compressor off to minimize energy usage when- ever the leaving chilled water temperature is 5 degrees F below the desired chilled water set point. The chilled water pump wall remain on, and when the leaving chilled water temperature rises above the desired set point, the compres sor will automatically be recycled back on, Dur- ing the shutdown period, a message shall be displayed informing the operator a recycle re- start is pending, j. The control center will monitor line voltage and. if loss of voltage, high or low line voltage, or sin- gle cycle dropout is sensed, the chiller will shut down. Upon restoration of line voltage, ifthe auto- start after power failure algorithm was activated in the configuration mode, the chiller shall auto: ‘matically restart and resume the mode of oper- ation prior to shutdown, k, The control center will allow reset of chilled wa- ter temperature set point based on any one of the following criteria, © Chilled water reset based on an extemal 4- 20 mA signal. © Chilled water reset based on a remote tem- pperature sensor (such as outdoor air) © Chilled water reset based on water tempera: ture rise across the evaporator. When reset is active a message shall be dis- played indicating the source of the reset signal 1, The control center will limit amp draw of the com- pressor to the rated load amps or to. value lower based on the following criteria © Demand limit based on a user input ranging from 40% to 100% of compressor rated load amps. © Demand limit based on an extemal 4-20 mA signal When demand limit is active, a message shall be displayed indicating the source of the demand signal. 2. Safeties ‘a, Uni shall automatically shut down when any of the following conditions occurs: (Each of these protective limits shall require manual reset and cause an alarm message to be displayed on the LCD screen informing the operator of the shut- down cause) ‘© motor overcurrent © over voltage © under voltage # single cycle dropout ‘© beating oll high temperature low evaporator refrigerant temperature high condenser pressure '® high motor temperature ' high compressor discharge temperature © low oil pressure © prolonged surge ¢ loss of cooler water flow loss of condenser water flow © starter fault b. Thecontrol system shall detect conditions which approach protective limits and take self-conective action prior to an alarm occurring, The systern shal automatically reduce chiller capacity when any of the following is out of normal operating range: ¢ bigh condenser pressure © high motor temperature lew evaporator refrigerant temperature During the capacity override period, a pre-alarm (alert) message shall be displayed informing the ‘operator which condition is causing the capac: ity override. Once the concition is again within acceptable limits, the override condition shall be terminated and the chiller will revert to normal chilled water control. If during either condition the protective limitisteached, the chiller will shut doun and a message will be displayed inform- ing the operator which condition caused the shut- down and alarm, 3. Diagnostics and Service: a. Thecontrol system shall execute a series of pre- start checks whenever a start command is re- ceived to determine if pressutes, temperatures, and timers are within normal limits, thereby al- lowing a normal start-up to commence, If any of the limits are exceeded, an alert message will be displayed informing the operator ofthe cause of the prestart alert b. A self-diagnostic controls test shall be an inte- gfal part of the control system to allow quick identification of malfunctioning components Once the controls test has been initiated, all pres- sure and temperature sensors shall be checked to ensure they are within normal operating range. A pump tes will automatically energize the chilled water pump, condenser water pump and oil pump. The control system will confirm that water flow and oil pressure have been estab- lished and require operator confirmation prior to proceeding tothe next test. A guide vane ac- tuator test shall open and close the guide vanes to check for proper operation. The operator ‘manually acknowledges proper guide vane op: eration prior to proceeding to the next test. Inadditon to the automated controls test, a ther- misior test and transducer test shall allow dis play on the LCD screen of the actual reading of each transducer and each thermistor installed on the chiller. All sonsors will have quick dis- comects to allow replacement ofthe sensor with- cout replacement of entire sensor wire4, Building Control System Interface: The chiller control system shall have the ability to interface and communicate directly to the building control system without the use of additional fcld- installed hardware or software. The building con- trol system and the centrifugal chiller must be sup- plied by the same manufacturer. Muttiple Chiller Controt ‘Multiple chiller installations shall be capable of be- Ing regulated by the addition of a multiple chiller control module field installed in the control center ‘of one of the chillers, and not require any addi- tional hardware, software, or human interface to operate. If desired, other components of the chilled water plant, such as towers, pumps, and valves can be controlled by hardware and software supplied by the chiller manufacturer, coordinated with the Chillervisor System Manager (CSM). G. Low Voltage Unit Mounted Starter: A reduced voltage We-Delta unit mounted starter shall be inslalled, wired and tested at the chiller manufac- turer's factory prior to shipment. Customer electrical connections are limited to main power leads to the starter, wiring of cooler and condenser flow switches to the chiller control circuit, and wiring water pumps and tower fans to the chiller control circu. Included in the UL and CSA approved starter are: 1, NEMA 1 enclosure with integral fan cooling and: lockable hinged doors. 'b. Main power disconnect (non-fused type) ¢. Starter Management Module (SMM) which com- ‘municates with the chiller control system to per- form starting and stopping of the chiller, water pumps, and tower fans, as well as monitoring starter operation. Included in this module is sin- gle cycle dropout protection 4. Solid state 3-phase overtoad relay with manual reset. @. Branch oil pump circuit breaker. {, Two kva controloil heater transformers. 4. Branch circuit breaker for control power and oll heater. h. Pilot relays for control of chilled water pump, condenser water pump, tower fan, and cus. tomer remote alarm. Electrical Requirements: 1. Electrical contractor shall supply and install main electrical power line, disconnect switches, circuit breakers, and electrical protection devices per lo- cal code requirements and as indicated necessary by the chiller manufacturer 2. Electrical contractor shall wire the water flow switches to the chiller control circuit to ensure that chiller wil not operate until flows are established and maintained. 8, Electrical contractor shall wire the chilled water pump, condenser water pump, and tower fan con- frol circuit to the chiller control circuit. 4, Electrical contractor shall supply and install electr- cal wiring and devices required to interface the chiller controls with the building control system if applicable 5, Electrical power shall be supplied to the unit at the voltage, phase, and frequency listed in the equip- ment schedule. 1. Piping Requitements — Instrumentation and Safeties Mechanical Contractor shall 1. Supply and install pressure gages in readily acces: sible locations in piping adjacent to the chiller such that they can be easily read from a standing posi- tion on the floor. Gages shall be Marsh Master or equal with 4-in, (114 mm) nominal diameter face. Scale range shall be such that design values shall be indicated at approximately mid-scale. Gages shall be installed in the entering and leaving water pip- ing of the cooler and condenser. 2, Supply and install McDonald and Mller #575 or equal flow switches in chilled water and condenser water piping, Switches shall make contact when flow is established. Flow switches shall be installed in hotizontal runs at least 5 pipe diameters down- stream from any bend or tee. J. Insulation 1. Chilles provided with insulation applied at the chiller manufacturer's factory shall require the chilled wa- ter piping and cooler water boxes insulated by the contractor. 2. Chillers provided with no insulation shall be insu- lated at the jobsite per manufacturers instructions. 3, Insulation shall be %-in, (19 mm) thick, shall have a theynal conductivity notexcgecing.28 Bu in hr ff «°F (0.0404 Wim +°C), and shall conform to UL standard 94, classification 94HBF. K, Vibration Isolation: Chiller manufacturer shall furnish support plates and kkolator pads for mounting equipment on a level con- crete pad surface. L. Start-Up 1. The chiller manufacturer shall provide a factory: trained representative, employed by the chiller man- ufacturer, to perform the start-up procedures as outlined in the Start-up, Operation and Mainte: nance manual provided by the chiller manufacturer, 2, After the above services have been performed, the same factory-trained representative shall be avall able for a period of classroom instruction not to exceed one 8-hour day to instruct the owner’s per- sonnel in the proper operation and maintenance of the chiller. 3. Contactor shall supply the owner with the follow- ing literature as furnished by the manufacturer prior to startup: a. One complete set of installation drawings b. Field wiring diagrams. c. Installation instructions d. Startup, operation and instructions, ‘maintenance 23M. Optional: A freestanding refrigerant storage tank and pumpout system shall be provided, The storage vessels shall be designed per ASME section VIll Division 1 code with 300 psig (2069 kPa) design pressure. Double relief valves per ANSIASHRAE 15 Safety Code (latest dition) shall be provided. The tank shall include a Carrier Corporation @ Syracuse, New York 19221 liquid level gage and pressure gage. The pumpout sys- tem shall utilize a semi-hermetic reciprocating com- [pressor with water-cooled condenser. Condenser wa- tet piping, 3-phase motor power, and 115-v control ‘power shell be installed at the jobsite by the installing contractor, eat UNITED PEER oaes Manufacturer reserves the right to dlecontinue or change et any imo, specfctions or design witout notice and without incurring obigtions. Pago 26 Catalog No 521-958 Plitedin USA Pears Form ‘8XL1APD Replaces: Now