19XR (PIC II) Hermetic Centrifugal Liquid Chillers 50 Hz - Carrier

19XR (PIC II)
Hermetic Centrifugal
Liquid Chillers
50 Hz
Installation, Operation and Maintenance Instructions

The cover illustrations are for illustrative purposes only and is not part of any offer for sale or contract.
2
TABLE OF CONTENTS
INITIAL START-UP CHECKLIST FOR 19XR HERMETIC CENTRIFUGAL LIQUID CHILLERS .................................. 5
1 - SAFETY CONSIDERATIONS ................................................................................................................................................... 9
1.1 - Installation safety considerations ................................................................................................................................................ 9
1.2 - Maintenance safety considerations ............................................................................................................................................. 9
1.3 - Operating checks ......................................................................................................................................................................... 9
1.4 - Equipment and components under pressure ............................................................................................................................. 10
1.5 - Repair safety considerations ..................................................................................................................................................... 10
2 - INTRODUCTION AND CHILLER FAMILIARIZATION................................................................................................... 11
2.1 - C.E. Mark .................................................................................................................................................................................. 11
2.2 - Abbreviations and explanations ................................................................................................................................................ 11
2.3 - Chiller familiarization ............................................................................................................................................................... 12
2.3.1 - Chiller information plate .................................................................................................................................................. 12
2.3.2 - System Components ......................................................................................................................................................... 12
2.3.3 - Cooler ............................................................................................................................................................................... 12
2.3.4 - Condenser ......................................................................................................................................................................... 12
2.3.5 - Motor-Compressor ........................................................................................................................................................... 12
2.3.6 - Control Centre .................................................................................................................................................................. 12
2.3.7 - Factory-Mounted Starter (Optional) ................................................................................................................................. 13
2.3.8 - Storage Vessel (Optional) ................................................................................................................................................. 13
2.4 - Refrigeration cycle .................................................................................................................................................................... 13
2.5 - Motor/oil refrigeration cooling cycle ........................................................................................................................................ 14
2.6 - Lubrication cycle....................................................................................................................................................................... 14
2.6.1 - Summary .......................................................................................................................................................................... 14
2.6.2 - Details ............................................................................................................................................................................... 14
2.7 - Power equipment....................................................................................................................................................................... 15
3 - INSTALLATION ........................................................................................................................................................................ 17
3.1 - Introduction ............................................................................................................................................................................... 17
3.2 - Receiving the machine .............................................................................................................................................................. 17
3.2.1 - Inspect shipment ............................................................................................................................................................... 17
3.2.2 - Provide machine protection .............................................................................................................................................. 17
3.3 - Rigging the Machine ................................................................................................................................................................. 17
3.3.1 - Rigging the complete machine ......................................................................................................................................... 17
3.3.2 - Rig machine components ................................................................................................................................................. 18
3.3.3 - Physical data ..................................................................................................................................................................... 19
3.4 - Install machine supports............................................................................................................................................................ 25
3.4.1 - Install standard isolation ................................................................................................................................................... 25
3.4.2 - Installation of a levelling accessory (if necessary) ........................................................................................................... 25
3.4.3 - Install spring isolation ...................................................................................................................................................... 26
3.5 - Connection of water piping ....................................................................................................................................................... 26
3.5.1 - Install water piping to heat exchanger.............................................................................................................................. 26
3.5.2 - Install vent piping to relief devices .................................................................................................................................. 30
3.6 - Make electrical connections ...................................................................................................................................................... 30
3.6.1 - Installation standards and precautions.............................................................................................................................. 30
3.6.2 - Electrical characteristics of the motors ............................................................................................................................ 31
3.6.3 - Communication wiring ..................................................................................................................................................... 34
3.6.4 - Make the necessary connections for the outgoing control signals ................................................................................... 35
3.6.5 - Connect the starting cabinet ............................................................................................................................................. 35
3.6.6 - Connect the starting cabinet to the control box ................................................................................................................ 37
3.6.7 - Carrier Comfort Network interface (CCN) ...................................................................................................................... 37
3.7 - Install Field Insulation .............................................................................................................................................................. 38

TABLE OF CONTENTS (cont'd)
4 - BEFORE INITIAL START-UP................................................................................................................................................. 39
4.1 - Necessary checks ...................................................................................................................................................................... 39
4.1.1 - Job Data Required ............................................................................................................................................................ 39
4.1.2 - Equipment Required ......................................................................................................................................................... 39
4.1.3 - Using the Optional Storage Tank and Pumpout System .................................................................................................. 39
4.1.4 - Remove Shipping Packaging ........................................................................................................................................... 39
4.1.5 - Open Oil Circuit Valves.................................................................................................................................................... 39
4.1.6 - Tighten All Gasketed Joints and Guide Vane Shaft Packing (torque depends on screw diameter) ................................. 39
4.1.7 - Inspect Water Piping......................................................................................................................................................... 39
4.1.8 - Check Relief Devices ....................................................................................................................................................... 40
4.2 - Chiller Tightness ....................................................................................................................................................................... 40
4.2.1 - Check chiller tightness ..................................................................................................................................................... 40
4.2.2 - Refrigerant Tracer............................................................................................................................................................. 40
4.2.3 - Leak Test Chiller .............................................................................................................................................................. 40
4.3 - Standing Vacuum Test ............................................................................................................................................................... 41
4.4 - Chiller Dehydration................................................................................................................................................................... 41
4.5 - Inspect Wiring ........................................................................................................................................................................... 43
4.6 - Carrier Comfort Network Interface (see Fig. 22) ..................................................................................................................... 43
4.7 - Check Starter ............................................................................................................................................................................. 43
4.8 - Oil Charge ................................................................................................................................................................................. 44
4.9 - Power Up the Controls and Check the Oil Heater .................................................................................................................... 44
4.10 - Check Optional Pumpout System Controls and Compressor ................................................................................................. 44
4.11 - High Altitude Locations .......................................................................................................................................................... 44
4.12 - Charge Refrigerant into Chiller............................................................................................................................................... 44
4.13 - 19XR chiller equalization without pumpout unit ................................................................................................................... 44
4.14 - 19XR chiller equalization with pumpout unit ......................................................................................................................... 45
4.15 - Trimming refrigerant charge ................................................................................................................................................... 45
5 - INITIAL START-UP .................................................................................................................................................................. 46
5.1 - Preparation ................................................................................................................................................................................ 46
5.2 - Dry Run to Test Start-Up Sequence .......................................................................................................................................... 46
5.3 - Check Rotation .......................................................................................................................................................................... 46
5.4 - Check Oil Pressure and Compressor Stop ................................................................................................................................ 46
5.5 - To Prevent Accidental Start-Up ................................................................................................................................................ 46
5.6 - Check Chiller Operating Condition .......................................................................................................................................... 47
5.7 - Instruct the Customer Operator ................................................................................................................................................. 47
6 - OPERATING INSTRUCTIONS .............................................................................................................................................. 47
6.1 - Operator Duties ......................................................................................................................................................................... 47
6.2 - To Start the Chiller .................................................................................................................................................................... 47
6.3 - Check the Running System ....................................................................................................................................................... 47
6.4 - To Stop the Chiller .................................................................................................................................................................... 48
6.5 - After Limited Shutdown............................................................................................................................................................ 48
6.6 - Extended Shutdown .................................................................................................................................................................. 48
6.7 - After Extended Shutdown ......................................................................................................................................................... 48
6.8 - Cold Weather Operation ............................................................................................................................................................ 48
6.9 - Manual Guide Vane Operation .................................................................................................................................................. 48
6.10 - Refrigeration Log .................................................................................................................................................................... 48
7 - MAINTENANCE ....................................................................................................................................................................... 50
7.1 - General maintenance ................................................................................................................................................................. 50
7.2 - Soldering and welding .............................................................................................................................................................. 50
7.1.2 - Refrigerant Properties....................................................................................................................................................... 50
7.1.3 - Adding Refrigerant ........................................................................................................................................................... 50
7.1.4 - Removing Refrigerant ...................................................................................................................................................... 50
7.1.5 - Adjusting the Refrigerant Charge ..................................................................................................................................... 50
7.1.6 - Refrigerant Leak Testing .................................................................................................................................................. 50
7.1.7 - Checking Guide Vane Linkage ......................................................................................................................................... 51
7.1.8 - Trim Refrigerant Charge .................................................................................................................................................. 51
3

4
TABLE OF CONTENTS (cont'd)
7.2 - Weekly maintenance ................................................................................................................................................................. 51
7.3 - Scheduled maintenance ............................................................................................................................................................. 52
7.3.1 - Service Ontime ................................................................................................................................................................. 52
7.3.2 - Inspect the Control Centre ................................................................................................................................................ 52
7.3.3 - Changing Oil Filter ........................................................................................................................................................... 52
7.3.4 - Oil Specification ............................................................................................................................................................... 52
7.3.5 - Refrigerant Filter .............................................................................................................................................................. 53
7.3.6 - Oil Reclaim Filter ............................................................................................................................................................. 53
7.3.7 - Inspect Refrigerant Float System ..................................................................................................................................... 53
7.3.8 - Inspect Relief Valves and Piping (see chapter 'Safety considerations') ........................................................................... 53
7.3.9 - Verification of the pressure switch calibration ................................................................................................................. 53
7.3.10 - Compressor Bearing and Gear Maintenance.................................................................................................................. 53
7.3.11 - Inspect the Heat Exchanger Tubes ................................................................................................................................. 53
7.3.12 - Water Leaks .................................................................................................................................................................... 54
7.3.13 - Inspect the Starting Equipment ...................................................................................................................................... 54
7.3.14 - Check Pressure Transducers ........................................................................................................................................... 54
7.3.15 - Corrosion control ............................................................................................................................................................ 54
LIST OF FIGURES
Fig. 1 - Model number meaning ........................................................................................................................................................ 12
Fig. 2 - 19XR machine components .................................................................................................................................................. 12
Fig. 3 - Refrigerant motor cooling and oil cooling cycles ................................................................................................................ 13
Fig. 4 - Lubrication system................................................................................................................................................................ 15
Fig. 5A - Starter cabinet - internal view with internal door closed ................................................................................................... 16
Fig. 5B - Starter cabinet - internal view with internal door open...................................................................................................... 16
Fig. 6 - Machine rigging guide .......................................................................................................................................................... 18
Fig. 7 - Dimensional drawing ............................................................................................................................................................ 22
Fig. 8 - Dimensional drawing - cooler, side view ............................................................................................................................. 23
Fig. 9 - 19XR chiller top view ........................................................................................................................................................... 23
Fig. 10 - Compressor detail ............................................................................................................................................................... 24
Fig. 11 - Unit rear view ..................................................................................................................................................................... 24
Fig. 12 - Chiller footprint .................................................................................................................................................................. 25
Fig. 13 - Standard isolation ............................................................................................................................................................... 26
Fig. 14 - Accessory isolation ............................................................................................................................................................. 26
Fig. 15 - 19XR Accessory spring isolation........................................................................................................................................ 26
Fig. 16 - Typical nozzle piping .......................................................................................................................................................... 27
Fig. 17 - Nozzle arrangements - nozzle-in-head waterboxes ............................................................................................................ 28
Fig. 18 - Optional pumpout system piping schematic with storage tank .......................................................................................... 29
Fig. 19 - Pumpout system piping schematic with storage tank ......................................................................................................... 29
Fig. 20 - Relief device locations ........................................................................................................................................................ 30
Fig. 21 - COMM1 CCN communication wiring for multiple chillers (typical) ................................................................................ 34
Fig. 22 - 19XR with optional unit-mounted starter ........................................................................................................................... 35
Fig. 23 - 19XR with freestanding starter ........................................................................................................................................... 36
Fig. 24 - Machine isolation................................................................................................................................................................ 38
Fig. 25 - 19XR leak detection procedure .......................................................................................................................................... 42
Fig. 26 - Dehydration cold trap ......................................................................................................................................................... 43
Fig. 27 - Rotation diagram ................................................................................................................................................................ 46
Fig. 28 - Refrigeration log ................................................................................................................................................................. 48
Fig. 29 - Guide vane actuator linkage ............................................................................................................................................... 51
Fig. 30 - 19XR float valve design ..................................................................................................................................................... 53
Fig. 31 - Compressor fits and clearances .......................................................................................................................................... 55

INITIAL START-UP CHECKLIST FOR 19XR HERMETIC CENTRIFUGAL LIQUID CHILLERS
Name: _____________________________________________________________________________________________
Address: ____________________________________________________________________________________________
Town: ______________________________________________________________________________________________
Country: ____________________________________________________________________________________________
Post code: ___________________________________________________________________________________________
Job No.: _____________________________________________________________________________________________
Model: ______________________________________________________________________________________________
Serial No.: ____________________________________________________________________________________________
Design conditions:
Evaporator
Condenser
Cooling Brine Flow Temperature Temperature Pressure Pass Suction Condensing
capacity rate in out drop temperature temperature
Compressor: Volts _______________________ RLA: _______________________ OLTA: __________________
Starter: Mfg ________________________ Type: _______________________
Oil pump: Volts _______________________ RLA: _______________________ OLTA: __________________
Control/oil heater: 115 Volts ___________ 230 Volts ___________
Refrigerant: Type _______________ Charge (kg) __________
Carrier obligations:
Assemble: Yes ________ No ________
Leak test: Yes ________ No ________
Dehydrate: Yes ________ No ________
Charging: Yes ________ No ________
Operating instructions: ____________ Hours
START-UP TO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UP INSTRUCTIONS
Job data required:
1. Machine installation instructions 19XR Yes ________ No ________
2. Machine assembly, wiring and piping diagrams Yes ________ No ________
3. Starting equipment details and wiring diagrams Yes ________ No ________
4. Applicable design data (see above) Yes ________ No ________
5. Diagrams and instructions for special controls Yes ________ No ________
Initial machine pressure: __________________
Was machine tight? Yes ________ No ________
If not, were leaks corrected? Yes ________ No ________
Was machine dehydrated after repairs? Yes ________ No ________
Check oil level and record:
Add oil: Yes ________ No ________
Amount: ___________________________
_______ 3/4 _______ 3/4
_______ 1/2 Top sight glass _______ 1/2 Bottom sight glass
_______ 1/4 _______ 1/4
Record pressure drops:
Evaporator ________________ Condenser ________________
Refrigerant charge:
Initial charge _______________ Final charge after trim ______________
5

INSPECT WIRING AND RECORD ELECTRICAL DATA:
Ratings:
Motor voltage: ________ Motor(s) amps: ________ Oil pump voltage: ________ Starter amps: ________
Line voltages: Motor: _____________ Oil pump: _____________ Controls/oil heater: ____________
Field-installed starters only:
Check continuity T1 to T1, etc (motor to starter power wiring).
Megger starter: Do not megger a motor connected to a solid-state starter, unless the leads to the motor are disconnected and
meggered.
Megger motor Phase to phase Phase to ground
T1-T2 T1-T3 T2-T3 T1-G T2-G T3-G
10-second readings
60-second readings
Polarization ratio
Starter:
Electro-mechanical __________ Electronic __________
Motor load current transformer ratio _____ : _____ Signal resistor size ________ Ohms
Transition timer time __________ seconds
Check magnetic overloads: Add dash pot oil Yes _______ No _______
Solid-state overloadsYes _______ No _______
Solid-state starter: Initial voltage __________ Volts Ramp setting __________ seconds
Controls: safety, operating, etc
Perform controls test Yes _______ No _______
CAUTION: Compressor motor and control centre must be properly and individually connected back to the earth ground in the
starter (in accordance with certified drawings). Yes _______
Run machine:
Do these safeties shut down the machine?
Condenser water flow switch: Yes ________ No ________
Chilled water flow switch: Yes ________ No ________
Pump interlocks: Yes ________ No ________
Initial start:
Line up all valves in accordance with instruction manual: _______ Start water pumps and establish water flow: ________
Oil level and temperature correct: ________ Check oil pump rotation pressure ________
Check compressor motor rotation (motor end sight glass) and record: Clockwise ________
Restart compressor. Bring up to speed. Shut down. Any abnormal coastdown noise?: Yes* ________ No ________
* If yes, determine cause
Start machine and operate. Complete the following:
A. Trim charge and record.
B. Complete any remaining control calibration and record.
C. Take at least 2 sets of operational log readings and record.
D. After machine has been successfully run and set up, shut down and mark shutdown oil and refrigerant levels.
E. Give operating instructions to owner's operating personnel. Hours given: ________ hrs
F. Call your Carrier factory representative to report chiller start-up.
Signature: ______________________________________ Date: _________
(Carrier technician)
Signature: ______________________________________ Date: _________
(Customer representative)
6

19XR HERMETIC CENTRIFUGAL LIQUID CHILLER CONFIGURATION SETTINGS LOG
(Remove and use for job file)
Controller name: Bus No.:
Element No.
Table description: Table name: SETPOINT
Setpoint table configuration sheet 19XR
Description Range Units Default Value
Base demand limit 40 to 100 % 100
LCW setpoint 12.2 to 48.9 °C 50
ECW setpoint 12.2 to 48.9 °C 60
Controller name: Bus No.:
Element No.
Table description: Table name: OCCP01S
Local mode time schedule configuration sheet - 19XR PIC II control - OCCP01S
Day Occupied time Unoccupied time
M T W T F Sa Su H
Period 1
Period 2
Period 3
Period 4
Period 5
Period 6
Period 7
Period 8
Note: Default setting is occupied 24 hours/day
Local mode time schedule configuration sheet - 19XR PIC II control - OCCP01S
Day Occupied time Unoccupied time
M T W T F Sa Su H
Period 1
Period 2
Period 3
Period 4
Period 5
Period 6
Period 7
Period 8
Note: Default setting is occupied 24 hours/day
Controller name: Bus No.:
Element No.
Table description: Table name: HOLIDEFS
Holiday configuration sheet
Description Range Units Value
Holiday start month 1-12
Holiday start day 1-31
Duration 0-99 Days
7

Table description: Table name: HOLIDEFS
Holiday configuration sheet
Description Range Units Value
Holiday start month 1-12
Holiday start day 1-31
Duration 0-99 Days
Table description: Table name: HOLIDEFS
Holiday configuration sheet
Description Range Units Value
Holiday start month 1-12
Holiday start day 1-31
Duration 0-99 Days
8

1 - SAFETY CONSIDERATIONS
19XR liquid chillers are designed to provide safe and reliable
service when operated within design specifications. When
operating this equipment, use good judgment and safety
precautions to avoid damage to equipment and property or
injury to personnel.
Be sure you understand and follow the procedures and safety
precautions contained in the machine instructions as well as
those listed in this guide.
1.1 - Installation safety considerations
In certain cases the safety stops are installed on ball valves.
These valves are factory-supplied lead-sealed in the open
position. This system permits isolating and removing the
safety stop for checking and replacing. The safety stops are
designed and installed to ensure protection against fire risk.
Removing the safety stops is only permitted if the fire risk is
fully controlled and the responsibility of the user.
All factory-installed safety valves are lead-sealed to prevent
any calibration change. If a safety stop is removed for
checking or replacement please ensure that there is always an
active safety stop on each of the reversing valves installed in
the unit.
The safety valves must be connected to discharge pipes. These
pipes must be installed in a way that ensures that people and
property are not exposed to refrigerant leaks. These fluids
may be diffused in the air, but far away from any building air
intake, or they must be discharged in a quantity that is
appropriate for a suitably absorbing environment.
Periodic check of the safety valves: See paragraph
“Maintenance safety considerations”.
DANGER:
DO NOT VENT refrigerant relief valves within a building.
Outlet from relief valve must be vented outdoors. The accumulation
of refrigerant in an enclosed space can displace oxygen
and cause asphyxiation.
PROVIDE adequate ventilation, especially for enclosed and
low overhead spaces. Inhalation of high concentrations of
vapour is harmful and may cause heart irregularities, unconsciousness,
or death. Misuse can be fatal. Vapour 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.
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 USE air for leak testing. Use only refrigerant or dry
nitrogen.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly
installed before operating any machine.
1.2 - Maintenance safety considerations
Engineers working on the electric or refrigeration components
must be authorized, trained and fully qualified to do so.
All refrigerant circuit repairs must be carried out by a trained
person, fully qualified to work on these units. He must have
been trained and be familiar with the equipment and the
installation. All welding operations must be carried out by
qualified specialists.
Any manipulation (opening or closing) of a shut-off valve
must be carried out by a qualified and authorised engineer.
These procedures must be carried out with the unit shut-down.
NOTE: The unit must never be left shut down with the liquid
line valve closed, as liquid refrigerant can be trapped between
this valve and the expansion device. (This valve is situated on
the liquid line before the filter drier box.)
During any handling, maintenance and service operations the
engineers working on the unit must be equipped with safety
gloves, glasses, shoes and protective clothing.
WARNING:
DO NOT WELD OR FLAMECUT any refrigerant line or
vessel until all refrigerant (liquid and vapour) has been
removed from chiller. Traces of vapour should be displaced
with dry air nitrogen and the work area should be well
ventilated. Refrigerant in contact with an open flame produces
toxic gases.
DO NOT work on high-voltage equipment unless you are a
qualified electrician.
DO NOT WORK ON electrical components, including control
panels, switches, relays etc, until you are sure ALL POWER
IS OFF; residual voltage can leak from capacitors or solid
state components.
LOCK OPEN AND TAG electrical circuits during servicing.
IF WORK IS INTERRUPTED, confirm that all circuits are
de-energized before resuming work.
1.3 - Operating checks
During the life-time of the system, inspection and tests must
be carried out in accordance with national regulations.
The information on operating inspections given in annex C of
standard EN378-2 can be used if no similar criteria exist in
the national regulations.
Safety device checks (annex C6 – EN378-2): The safety
devices must be checked on site once a year for safety devices
(high-pressure switches), and every five years for external
overpressure devices (safety globe valves).
9

If the machine operates in a corrosive environment, inspect
the protection devices more frequently.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any
safety devices when corrosion or build-up of foreign material
(rust, dirt, scale, etc.) is found within the valve body or
mechanism. If necessary, replace the device.
DO NOT install safety valves in series or backwards.
PROVIDE A DRAIN connection in the vent line near each
pressure relief device to prevent a build-up of condensate or
rain water.
1.4 - Equipment and components under pressure
These products incorporate equipment or components under
pressure, manufactured by Carrier or other manufacturers. We
recommend that you consult your appropriate national trade
association or the owner of the equipment or components under
pressure (declaration, re-qualification, retesting, etc.). The
characteristics of this equipment/these components are given
on the nameplate or in the required documentation, supplied
with the products.
1.5 - Repair safety considerations
All installation parts must be maintained by the personnel in
charge, in order to avoid material deterioration and injuries to
people. Faults and leaks must be repaired immediately. The
authorized technician must have the responsibility to repair the
fault immediately. Each time repairs have been carried out to
the unit, the operation of the safety devices must be re-checked.
If a leak occurs or if the refrigerant becomes polluted (e.g. by a
short circuit in a motor) remove the complete charge using a
recovery unit and store the refrigerant in mobile containers.
Repair the leak detected and recharge the circuit with the total
R134a charge, as indicated on the unit name plate.
DO NOT siphon refrigerant.
AVOID SPILLING liquid refrigerant on skin or getting it
into the eyes. USE SAFETY GOGGLES AND SAFETY
GLOVES. Wash any spills from the skin with soap and water.
If liquid refrigerant enters the eyes, IMMEDIATELY FLUSH
EYES with water and consult a physician.
NEVER APPLY an open flame or live steam to refrigerant
cylinder. Dangerous overpressure can result. If it is necessary
to heat refrigerant, use only warm water.
DO NOT REUSE disposable (non-returnable) cylinders or
attempt to refill them. It is DANGEROUS AND ILLEGAL.
When cylinders are emptied, evacuate remaining gas pressure,
loosen the collar and unscrew and discard the valve stem. DO
NOT INCINERATE.
During refrigerant operations, CHECK THE REFRIGERANT
TYPE before adding refrigerant to the machine. The introduction
of the wrong refrigerant can cause damage or malfunction
to this machine.
10
ATTENTION: No part of the unit must use feet, racks or
supports during operation. Periodically monitor and repair or
if necessary replace any component or piping that shows
signs of damage.
DO NOT climb over a machine. Use platform, or staging.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift
or move heavy components. Even if components are light, use
mechanical equipment when there is a risk of slipping or losing
your balance.
DO NOT USE eyelets to lift any part of the machine or the
complete machine.
BE AWARE that certain automatic start arrangements CAN
ENGAGE TOWER FAN, OR PUMPS. Open the disconnect
ahead of the tower fans, or pumps.
USE only repair or replacement parts that meet the code
requirements of the original equipment.
DO NOT VENT OR DRAIN water boxes containing industrial
brines, without the permission of your process control group.
DO NOT LOOSEN water box bolts until the water box has
been completely drained.
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.
During refrigerant removal and storage operations follow applicable
regulations. These regulations, permitting conditioning and
recovery of halogenated hydrocarbons under optimum quality
conditions for the products and optimum safety conditions for
people, property and the environment are described in standard
NFE 29795.
Any refrigerant transfer and recovery operations must be carried
out using a transfer unit. A 3/8” SAE connector on the manual
liquid line valve is supplied with all units for connection to the
transfer station. The units must never be modified to add refrigerant
and oil charging, removal and purging devices. All these
devices are provided with the units. Please refer to the certified
dimensional drawings for the units.

2 - INTRODUCTION AND CHILLER FAMILIARIZATION
Prior to initial start-up of the 19XR unit, those involved in the
start-up, operation, and maintenance should be thoroughly
familiar with these instructions and other necessary job data. This
book is outlined so that you may become familiar with the control
system before performing start-up procedures. Procedures
in this manual are arranged in the sequence required for proper
chiller start-up and operation.
Maximum outside temperature:
For transport and storage of the 19XR units the minimum and
maximum allowable temperatures are –20°C and +48°C.
Unit operating range
Evaporator 19XR Minimum Maximum
Evaporator entering water temperature* °C 6 17
Evaporator leaving water temperature* °C 3.3 10
Condenser (water-cooled) 19XR Minimum Maximum
Condenser entering water temperature* °C 16 35
Condenser leaving water temperature* °C 13.3 44
* For application requiring brine operation, contact Carrier s.a. for unit selection
using the Carrier electronic catalog.
WARNING: This unit uses a microprocessor control system.
Do not short or jumper between terminations on circuit
boards or modules; control or board failure may result.
Be aware of electrostatic discharge (static electricity) when
handling or making contact with circuit boards or module
connections. Always touch a chassis (grounded) part to
dissipate body electrostatic charge before working inside control
centre.
Use extreme care when handling tools near boards and when
connecting or disconnecting terminal plugs. Circuit boards
can easily be damaged. Always hold boards by the edges and
avoid touching components and connections.
This equipment uses, and can radiate, radio frequency energy.
If not installed and used in accordance with the instruction
manual, it may cause interference to radio communications. It
has been tested and found to comply with European Directive
89/336/EEC, on Electromagnetic Compatibility. Operation of
this equipment in a residential area is likely to cause interference,
in which case the user, at his own expense, will be
required to take whatever measures may be required to correct
the interference. Always store and transport replacement or
defective boards in anti-static shipping bag.
2.1 - C.E. Mark
Compliance with European Directives
All 19XR machines carry the CE mark, which is mandatory for
their sale within the EU. The declaration supplied with the
machines specifies the regulations to which they are subject:
73/23/EEC Low voltage
89/336/EEC Electromagnetic compatibility (EMC)*
and if the machine is supplied complete (with starter and relief
valves): 89/392/EEC Machinery safety
Therefore, units will be delivered with the following
certificates:
With starter Without starter or relief
valve
Low voltage Conformity Conformity
EMC Conformity Conformity
Machinery safety Conformity Incorporation
* The generic standards enabling compliance with the requirements of the EMC
directives for an industrial environment are as follows:
EN 50082-2 for immunity
EN 50081-2 for emissions
2.2 - Abbreviations and explanations
Frequently used abbreviations in this manual include:
CCM - Chiller Control Module
CCN - Carrier Comfort Network
CCW - Counterclockwise
CVC - Chiller Visual Control
CW - Clockwise
ECW - Entering Chilled Water
ECDW - Entering Condenser Water
EMS - Energy Management System
HGBP - Hot Gas Bypass
I/O - Input/Output
ISM - Integrated Starter Module
LCD - Liquid Crystal Display
LCDW - Leaving Condenser Water
LCW - Leaving Chilled Water
LED - Light-Emitting Diode
OLTA - Overload Trip Amps
PIC II - Product Integrated Control II
RLA - Rated Load Amps
SI - International System of Units
TXV - Thermostatic Expansion Valve
The CVC software version number of your 19XR unit will be
located on the CVC module.
Information on the unit control is not included in this manual.
Refer to separate control manual.
11

2.3 - Chiller familiarization
2.3.1 - Chiller information plate
The information plate is located below the control box.
12
Chronological number
19XR 41 43 CP 362 S EE
Model description Exchanger code
Hermetic centrifugal
liquid chiller
EE - SDM
A - TUV
B - ISPESL
D - SA
S: standard efficiency
H: high efficiency
Motor size
Evaporator size Condenser size
Compressor type
Fig. 1 - Model number meaning
2.3.2 - System Components
The components include the cooler and condenser heat exchangers
in separate vessels, motor-compressor, lubrication package,
control centre, and motor starter. All connections from pressure
vessels have external threads to enable each component to be
pressure tested with a threaded pipe cap during factory assembly.
14
13 12
11
10
3
9
1 2
1. Guide vane actuator
2. Suction elbow
3. Compressor
4. Cooler, auto reset relief valve*
5. Cooler pressure transducer
6. Condenser in/out temperature thermistors
7. Cooler in/out temperature thermistors
8. Machine identification nameplate (situated on the starter cabinet side) - see
right-hand figure 'Rear view'
9. Refrigerant charging valve
10. Typical flange connections
11. Oil drain valve
12. Oil level sight glass
13. Refrigerant oil cooler (hidden)
14. Branch circuit control box
* One relief valve is standard. Dual relief valves as an option
4
5
7
6
Fig. 2 - 19XR machine components
2.3.3 - Cooler
This vessel (also known as the evaporator) is located underneath
the compressor. The cooler is maintained at lower temperature/
pressure so that evaporating refrigerant can remove heat from
water flowing through its internal tubes.
2.3.4 - Condenser
The condenser operates at a higher temperature/pressure than
the cooler and has water flowing through its internal tubes in
order to remove heat from the refrigerant.
2.3.5 - Motor-Compressor
This component maintains system temperature/pressure
differences and moves the heat carrying refrigerant from the
cooler to the condenser.
2.3.6 - Control Centre
The control centre is the user interface for controlling the
chiller. It regulates the chiller’s capacity as required to maintain
proper leaving chilled water temperature.
Front view Rear view
31
32
30
15. Condenser auto reset relief valves*
16. Circuit breaker
17. CVC
18. Unit-mounted starter (optional)
19. Motor sight glass
20. Cooler return-end waterbox cover
21. Cooler nameplate
22. Condenser nameplate
23. Typical waterbox drain port
24. Condenser return-end waterbox cover
25. Refrigerant moisture/flow indicator
26. Refrigerant filter/drier
27. Liquid line isolation valve (optional)
28. Linear float valve chamber
29. Vessel take-apart connector
30. Discharge isolation valve (optional)
31. Pumpout valve
32. Condenser pressure transducer
15
8
18 19
29 28 27 26 25 24 23 22
17
16
20
21

The control centre:
registers cooler, condenser, and lubricating system pressures
shows chiller operating condition and alarm shutdown
conditions
records the total chiller operating hours
sequences chiller start, stop, and recycle under microprocessor
control
provides access to other CCN (Carrier Comfort Network)
devices
2.3.7 - Factory-Mounted Starter (Optional)
The starter allows for the proper start and disconnect of electrical
energy for the compressor-motor, oil pump, oil heater,
and control panels.
2.3.8 Storage Vessel (Optional)
There are 2 sizes of storage vessels available. The vessels have
relief valves, a drain valve and a male flare vapour connection
for the pumpout unit.
NOTE: If a storage vessel is not used at the jobsite, factoryinstalled
isolation valves on the chiller may be used to isolate
the chiller charge in either the cooler or condenser. An optional
pump-out system is used to transfer refrigerant from vessel to
vessel.
1. FLASC chamber
2. Condenser water
3. Condenser
4. Condenser isolation valve
5. Transmission
6. Diffuser
7. Guide vane motor
8. Motor
9. Guide vanes
10. Impeller
11. Compressor
12. Back pressure orifice
13. Oil cooling
14. Oil filter
15. Oil pump
16. Stator
17. Rotor
18. Refrigerant cooling isolation valve
19. Float valve chamber
20. Filter drier
2.4 - Refrigeration cycle
The compressor continuously draws refrigerant vapour from
the cooler at a rate set by the amount of guide vane opening.
As the compressor suction reduces the pressure in the cooler,
the remain-ing refrigerant boils at a fairly low temperature
(typically 3 to 6°C). The energy required for boiling is obtained
from the water flowing through the cooler tubes. With heat
energy removed, the water becomes cold enough for use in an
air conditioning circuit or process liquid cooling.
After taking heat from the water, the refrigerant vapour is compressed.
Compression adds still more heat energy, and the refrigerant
is quite warm (typically 37 to 40°C) when it is discharged
from the compressor into the condenser.
Relatively cool (typically 18 to 32°C) water flowing into the
condenser tubes removes heat from the refrigerant and the
vapour condenses to liquid.
Fig. 3 - Refrigerant motor cooling and oil cooling cycles
The liquid refrigerant passes through orifices into the FLASC
(Flash Subcooler) chamber (Fig. 3). Since the FLASC chamber
is at a lower pressure, part of the liquid refrigerant flashes to
vapour, thereby cooling the remaining liquid. The FLASC vapour
21. Orificed fitting
22. Moisture/flow indicator
23. Orificed fitting
24. Thermostatic expansion valves (TXV)
25. Distribution pipe
26. Cooler isolation valve
27. Evaporator
28. Chilled water
29. Refrigerant liquid
30. Refrigerant vapour
31. Refrigerant liquid/vapour
13

is recondensed on the tubes which are cooled by entering condenser
water. The liquid drains into a float chamber between the
FLASC chamber and cooler. Here a float valve forms a liquid
seal to keep FLASC chamber vapour from entering the cooler.
When liquid refrigerant passes through the valve, some of it flashes
to vapour in the reduced pressure on the cooler side. In flashing,
it removes heat from the remaining liquid. The refrigerant is
now at a temperature and pressure at which the cycle began.
2.5 - Motor/oil refrigeration cooling cycle
The motor and the lubricating oil are cooled by liquid refrigerant
taken from the bottom of the condenser vessel (Fig. 3). Flow of
refrigerant is maintained by the pressure differential that exists
due to compressor operation. After the refrigerant flows past an
isolation valve, an in-line filter, and a sight glass/moisture indicator,
the flow is split between motor cooling and oil cooling
systems.
Flow to the motor flows through an orifice and into the motor.
Once past the orifice, the refrigerant is directed over the motor
by a spray nozzle. The refrigerant collects in the bottom of the
motor casing and then is drained back into the cooler through
the motor refrigerant drain line. A back pressure valve or an
orifice in this line maintains a higher pressure in the motor
shell than in the cooler/oil sump. The motor is protected by a
temperature sensor imbedded in the stator windings. A further
increase in motor winding temperature past the motor override
set point will override the temperature capacity control to hold,
and if the motor temperature rises 5.5 K above this set point,
will close the inlet guide vanes. If the temperature rises above
the safety limit, the compressor will shut down.
Refrigerant that flows to the oil cooling system is regulated by
thermostatic expansion valves (TXVs). The TXVs regulate flow
into the oil/refrigerant plate and frame-type heat exchanger. The
expansion valve bulbs control oil temperature to the bearings.
The refrigerant leaving the heat exchanger then returns to the
cooler.
2.6 - Lubrication cycle
2.6.1 - Summary
The oil pump, oil filter, and oil cooler make up a package located
partially in the transmission casting of the compressor-motor
assembly. The oil is pumped into a filter assembly to remove
foreign particles and is then forced into an oil cooler heat exchanger
where the oil is cooled to proper operational temperatures.
After the oil cooler, part of the flow is directed to the gears and
the high speed shaft bearings; the remaining flow is directed to
the motor shaft bearings. Oil drains into the transmission oil
sump to com-plete the cycle (Fig. 4).
2.6.2 - Details
Oil is charged into the lubrication system through a hand valve.
Two sight glasses in the oil reservoir permit oil level observation.
Normal oil level is between the middle of the upper sight glass
and the top of the lower sight glass when the compressor is
shut down. The oil level should be visible in at least one of the
2 sight glasses during operation.
Oil sump temperature is displayed on the CVC default screen.
Oil sump temperature ranges during compressor operation
between 52 to 66°C.
14
The oil pump suction is fed from the oil reservoir. An oil pressure
relief valve maintains 124 to 172 kPa differential pressure in
the system at the pump discharge. This differential pressure
can be read directly from the CVC default screen.
The oil pump discharges oil to the oil filter assembly. This filter
can be closed to permit removal of the filter without draining
the entire oil system. The oil is then piped to the oil cooler.
This heat exchanger uses refrigerant from the condenser as the
coolant. The refrigerant cools the oil to a temperature between
49 and 60°C.
As the oil leaves the oil cooler, it passes the oil pressure transducer
and the thermal bulb for the refrigerant expansion valve on the
oil cooler. The oil is then divided, with a portion flowing to the
thrust bearing, forward pinion bearing, and gear spray. The
balance then lubricates the motor shaft bearings and the rear
pinion bearing. The oil temperature is measured as the oil leaves
the thrust and forward journal bearings within the bearing
housing. The oil then drains into the oil reservoir at the base of
the compressor. The PIC II (Product Integrated Control)
measures the temperature of the oil in the sump and maintains
the temperature during shut-down. This temperature is read on
the CVC default screen.
During the chiller start-up, the PIC II will energize the oil pump
and provide 15 seconds of prelubrication to the bearings after
pressure is verified before starting the compressor. During shut
down, the oil pump will run for 60 seconds to post-lubricate
after the compressor shuts down. The oil pump can also be
energized for testing purposes in the Control Test.
Ramp loading can slow the rate of guide vane opening to
minimize oil foaming at start-up. If the guide vanes open quickly,
the sudden drop in suction pressure can cause any refrigerant
in the oil to flash. The resulting oil foam cannot be pumped
efficiently; therefore, oil pressure falls off and lubrication is
poor. If oil pressure falls below 103 kPa differential, the PIC II
will shut down the compressor.
If the controls are subject to a power failure that lasts more than 3
hours, the oil pump will be energized periodically when the
power is restored. This helps to eliminate refrigerant that has
migrated to the oil sump during the power failure. The controls
will energize the pump for 60 seconds every 30 minutes until
the chiller is started.
Oil Reclaim System
The oil reclaim system returns oil lost from the compressor
housing back to the oil reservoir by recovering the oil from 2
areas on the chiller. The guide vane housing is the primary area
of recovery. Oil is also recovered by skimming it from the
operating refrigerant level in the cooler vessel.
Primary oil recovery mode
Oil is normally recovered through the guide vane housing on
the chiller. This is possible because oil is normally entrained
with the refrigerant in the chiller. As the compressor pulls the
refrigerant up from the cooler into the guide vane housing to
be compressed, the oil normally drops out at this point and falls
to the bottom of the guide vane housing where it accumulates.
Using discharge gas pressure to power an eductor, the oil is
drawn from the housing and is discharged into the oil reservoir.

1. Rear motor bearing
2. Forward motor bearing
3. Labyrinth gas line
4. Oil supply to forward high speed bearing
5. Isolation valve
6. Filter
7. Sight glass
8. Isolation valve
9. Check valve
10. Filter
11. Eductor
12. Oil heater
Secondary oil recovery method
The secondary method of oil recovery is significant under light
load conditions, when the refrigerant going up to the compressor
suction does not have enough velocity to bring oil along with it.
Under these conditions, oil normally collects in a greater concentration
at the top level of the refrigerant in the cooler. This
oil and refrigerant mixture is skimmed from the side of the
cooler and is then drawn up to the guide vane housing. There is
a filter in this line. Because the guide vane housing pressure is
much lower than the cooler pressure, the refrigerant boils off,
leaving the oil behind to be collected by the primary oil recovery
method.
Fig. 4 - Lubrication system
2.7 - Power equipment
13. Oil pump
14. Oil motor
15. Oil cooler
16. Isolation valve
17. Pressure transducer
18. TXV bulb
19. Motor cooling line
The 19XR requires a starter cabinet to control a hermetic
turbo-compressor motor, the oil pump and various auxiliary
units. This cabinet serves as a user interface. Only one type of
cabinet is currently available from Carrier SA: electronic starting
(see specification Z375 and EE038 for specific requirements
for the starter cabinet). All cabinets must comply with these
specifications with the aim of achieving correct compressor
starting and satisfying the mechanical safety requirements.
The cabinets may be supplied separately from the units, and
either function on a remote basis or are mounted directly on the
unit (optional for low voltages only).
15

Factory-mounted electronic starter (optional) - see Figures
5A and 5B
NOTE: The main circuit breaker QF101* on the front of the
starter disconnects all circuits.
Circuit breaker QF66* supplies power to the control centre, the
oil heater and the compressor starter control circuit. Circuit
breaker QF4* supplies power to the oil pump. Circuit breaker
QF11* supplies power to the control circuit. All three circuit
breakers are connected downstream of QF101* so that they do
not remain energized if the QF101* disconnect is in the “off”
position.
16
4
7
1
8 3
7
6
5
Fig. 5A - Starter cabinet - internal view with internal
door closed
1. ISM module
2. Circuit breaker
3. CCM module
4. CVC module
5. Electronic starter
6. Contactor
7. Door closed (Fig. 5A above) or open (Fig. 5B opposite)
8. Conductor for field connection
4
The starter cabinet includes:
The electronic starter that provides on/off phase control as its
primary function, also reduces starting torque and motor inrush
current, thus reducing mechanical stress and increasing the
useful life of the motor.
The ISM module controls the motor start-up, the control
section and the PIC II control.
* For more details refer to the wiring diagram supplied with
the unit.
2
8
Fig. 5B - Starter cabinet - internal view with internal
door open
2

3 - INSTALLATION
3.1 - Introduction
The 19XR machine is factory assembled, wired, leak tested
and electrically tested. Installation (not by Carrier) consists
primarily of establishing water and electrical services to the
machine. The rigging, installation, field wiring, field piping,
and insulation of waterbox covers are the responsibilty of the
contractor and/or customer. Carrier has no installation
responsibilities for the equipment.
3.2 - Receiving the machine
3.2.1 - Inspect shipment
CAUTION: Do not open any valves or loosen any connections.
The standard 19XR machine is shipped with a full refrigerant
charge. Some machines may be shipped with a nitrogen holding
charge as an option.
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.
Confirm that the unit received is the one ordered. Compare
the name plate data with the order.
The unit name plate must include the following
information:
- Version number
- Model number
- CE marking
- Serial number
- Year of manufacture and test date
- Refrigerant used and refrigerant class
- Refrigerant charge per circuit
- Containment fluid to be used
- PS: Min./max. allowable pressure (high and low
pressure side)
- TS: Min./max. allowable temperature (high and low
pressure side)
- Globe valve cut-out pressure
- Pressure switch cut-out pressure
- Unit leak test pressure
- Voltage, frequency, number of phases
- Maximum current drawn
- Maximum power input
- Unit net weight
High pressure Low pressure
Min. Max. Min. Max.
PS (bar) -0.9 12.5 -0.9 12.5
TS (°C) -20 48 -20 48
Pressure switch cut-out pressure (bar) 11 -
Valve cut-out pressure (bar) 12.5 12.5
Test pressure, unit leak test (bar) 10
Check all items against shipping list. Immediately notify the
nearest Carrier representative if any item is missing.
To prevent loss or damage (standard EN 378-2 11.22 k, annex
A and B), leave all parts in original packages until beginning
installation. All openings are closed with covers or plugs to
prevent dirt and debris from entering machine components
during shipping. A full operating oil charge is placed in the
oil sump before shipment.
3.2.2 - Provide machine protection
Protect machine and starter from construction dirt and moisture.
Keep protective shipping covers in place until machine is ready
for installation.
Do not keep the 19XR units outside where they are exposed to
the weather, as the sensitive control mechanism and the
electronic modules may be damaged.
The unit must be checked periodically during its whole
operating life to ensure that no shocks (handling accessories,
tools etc.) have damaged it. If necessary, the damaged parts
must be repaired or replaced. See also chapter “Maintenance”.
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.
3.3 - Rigging the Machine
The 19XR machine can be rigged as an entire assembly. It also
has flanged connections that allow the compressor, cooler, and
condenser sections to be separated and rigged individually.
3.3.1 - Rigging the complete machine
See rigging instructions on label attached to machine. Also refer
to physical data and Tables 1-7 (chapter 3.3.3). Lift machine
only from the points indicated in the instructions supplied and
in the machine rigging drawings. Each lifting cable or chain
must be capable of supporting the entire weight of the machine.
WARNING: 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 Tables 1-7 (chapter 3.3.3) 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. See Tables 1-7 (chapter 3.3.3) for
machine component weights.
IMPORTANT: Make sure that rigging cable is over the rigging
bar before lifting.
17

3.3.2 - Rig machine components
Refer to instructions below, Fig. 8-11, and Carrier Certified
Prints for machine component disassembly.
IMPORTANT: Only a qualified service technician should
perform this operation.
WARNING: 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.
CAUTION: Before rigging the compressor, disconnect all wires
entering the control box.
NOTE: If the cooler and condenser vessels must be
separated, the heat exchangers should be kept level by
placing a support plate under the tube sheets. The support
plate will also help to keep the vessels level and aligned when
the vessels are bolted back together.
NOTE: Wiring must also be disconnected. Label each wire
before removal (see Carrier Certified Prints). In order to disconnect
the starter from the machine, remove wiring for the
oil pump, oil heater, control wiring at the control box, and the
main motor leads at the starter lugs.
Remove all transducer and sensor wires at the sensor. Clip all
wire ties necessary to pull heat exchangers apart.
18
1
2
3
762
"A"
1. Optional mounted starter
2. Chain must run over to motor side of bolt
3. Chain B (see note 2)
4. Chain C (see note 2)
5. Chain D (see note 2)
6. Minimum height above floor
Notes:
1. Each chain must be capable of supporting the entire weight of the chiller. The
maximum weight of each chiller is listed in the table below.
2. Chain lengths shown are typical for 4570 mm lifting height. Some minor
adjustment may be required.
Machine Compressor Machine Length Dim. Chain length
code size weight A B C D
30-32 2 & 3 9526 12' 1766 4115 4013 4038
35-37 2 & 3 10206 14' 2236 4318 4064 4064
1066
Fig. 6 - Machine rigging guide
4
4570
5
6

3.3.3 - Physical data
Table 1
Motor weight (standard and high efficiency motors)
Motor size Stator weight* Motor weight Casing
kg kg kg
50 Hz 50 Hz
Compressor 19XR2*, low voltage motor
BD 467 109 84
BE 485 113 84
BF 508 120 84
BG 533 132 84
BH 533 132 84
Compressor 19XR3*, low and medium voltage motor
CD 616 142 125
CE 624 145 125
CL 651 151 125
CM 660 154 125
CN 665 155 125
CP 671 156 125
CQ 671 156 125
Compressor 19XR4*, low and medium voltage motor**
DB 762 177 107
DC 786 183 107
DD 800 186 107
DE 832 195 107
DF 854 201 107
DG 872 207 107
DH 1001 261 107
DJ 1045 266 107
Compressor 19XR5*, low and medium voltage motor***
EH 1415 341 188
EJ 1415 341 188
EK 1474 341 188
EL 1529 363 188
EM 1529 363 188
EN 1597 386 188
EP 1597 386 188
* Stator weight includes stator and shell.
** The rotor weight includes the weights of the rotor, the shaft and the lubrication
systems.
Note: For each motor size the weight given is that of the nearest motor (based on
voltage).
Table 2
Compressor weight
Components Frame 2** Frame 3** Frame 4** Frame 5**
Compressor* Compressor* Compressor* Compressor*
kg kg kg kg
Suction elbow
Discharge
23 24 79 95
elbow 27 21 71 63
Transmission*
Suction
145 331 298 454
housing
Impeller
136 159 202 544
shroud 16 36 57 113
Crankcase 571 476 721 1676
Diffuser 16 32 59 136
Oil pump 57 68 68 84
Miscellaneous 45 61 65 100
Total weight*** 1043 1207 1684 3107
* The transmission weight does not include the weight of the rotor, nor that of
the shaft, and that of the lubrication system (see table above).
** The first figure of the 'compressor type' (Fig. 1) is the compressor size.
*** ±15% (less motor and elbows)
Table 3
Miscellaneous additional weights (kg)
Compressor size 2/3 4/5
Control box 34 34
Factory-mounted starter box 275 350
Isolation valve (optional) 52 52
Table 4
19XR Heat exchanger weight
Code No. of tubes Rigging Machine charge
weight Refr. weight Water weight
kg kg kg
Evap. Cond. Evap. Cond. Evap. Cond. Evap. Cond.
30 200 218 1876 1675 159 118 210 210
31 240 267 1958 1768 190 118 241 246
32 280 315 2046 1859 222 118 273 282
35 200 218 2000 2089 181 141 232 233
36 240 267 2094 2195 218 141 266 273
37 280 315 2193 2300 249 141 303 314
40 324 370 2675 2745 254 127 338 362
41 364 417 2757 2839 286 127 368 398
42 400 463 2832 2932 313 127 396 434
45 324 370 2881 3001 290 150 372 399
46 364 417 2976 3107 327 150 407 440
47 400 463 3060 3213 358 150 438 481
50 431 509 3181 3304 340 181 435 482
51 485 556 3293 3397 381 181 477 518
52 519 602 3364 3484 408 181 502 552
55 431 509 3428 3619 395 222 481 534
56 485 556 3555 3725 426 222 527 575
57 519 602 3635 3825 444 222 557 613
60 557 648 3751 3758 426 190 546 601
61 599 695 3838 3847 444 190 578 636
62 633 741 3908 3935 462 190 604 669
65 557 648 4056 4174 462 231 605 668
66 599 695 4155 4276 481 231 641 707
67 633 741 4235 4376 494 231 671 745
70 644 781 5621 5959 453 354 846 790
71 726 870 5814 6153 531 354 917 865
72 790 956 5965 6335 589 334 972 936
75 644 781 6028 6445 506 420 926 883
76 726 870 6259 6667 592 420 1007 969
77 790 956 6421 6875 660 420 1070 1050
80 829 990 7326 7141 653 327 1078 998
81 901 1080 7496 7336 716 327 1141 1073
82 976 1170 7673 7531 785 327 1205 1148
85 829 990 7844 7710 730 390 1181 1116
86 901 1080 8037 7933 798 390 1252 1202
87 976 1170 8240 8156 880 390 1326 1288
Notes regarding cooler data:
Based on a cooler with standard wall tubing (TB3 0.025 in), 2-pass, nozzle-in-head
waterbox with victaulic grooves. Weight includes suction elbow, control panel, and
distribution piping. Weight does not include compressor.
Notes regarding condenser data:
Based on a condenser with standard wall tubing (SPK2 0.025 in), 2-pass, nozzlein-head
waterbox with victaulic grooves. Weight includes the float valve, discharge
elbow, and distribution piping. Weight does not include unit-mounted starter,
isolation valves, and pumpout unit.
Table 5
Marine water box additional weight*
Heat exchanger passes and frame
kPa Rigging weight Water volume
kg l
Frame 3, passes 1 and 2 1034 331 317
Frame 3, pass 2 1034 166 159
Frame 4, passes 1 and 3 1034 481 465
Frame 4, pass 2 1034 240 231
Frame 5, passes 1 and 3 1034 562 526
Frame 5, pass 2 1034 281 263
Frame 6, passes 1 and 3 1034 680 612
Frame 6, pass 2 1034 340 306
Frame 7, passes 1 and 3 1034 912 1234
Frame 7, pass 2 1034 336 617
Frame 8, passes 1 and 3 1034 841 1537
Frame 8, pass 2 1034 265 768
Frame 3, passes 1 and 3 2068 390 317
Frame 3, pass 2 2068 195 159
Frame 4, passes 1 and 3 2068 549 465
Frame 4, pass 2 2068 272 231
Frame 5, passes 1 and 3 2068 626 526
Frame 5, pass 2 2068 313 263
Frame 6, passes 1 and 3 2068 748 612
Frame 6, pass 2 2068 374 306
Frame 7, passes 1 and 3 2068 1406 1234
Frame 7, pass 2 2068 830 617
Frame 8, passes 1 and 3 2068 1245 1533
Frame 8, pass 2 2068 739 768
* Add to base heat exchanger data for total weights or volumes.
Note: The additional weights are the same for coolers and condensers of the same
frame size.
19

Table 6
19XR water box casing weight
Heat exchanger Water box type Frame 3 Frame 4
Standard Flanged Standard Flanged
connections connections connectiions connections
Evaporator/condenser NIH, perforated end cover, 1 pass, 1034 kPa 145 159 220 236
NIH, perforated end cover, 2 passes, 10343 kPa 145 159 221 245
NIH, perforated end cover, 3 passes, 1034 kPa 141 154 229 236
NIH/NWB, plain end cover, 1034 kPa 136 136 172 172
NIH, perforated end cover, 1 pass, 2068 kPa 186 220 269 303
NIH, perforated end cover, 2 passes, 2068 kPa 186 235 269 318
NIH, perforated end cover, 3 passes, 2068 kPa 196 212 282 298
NIH/NWB, plain end cover, 2068 kPa 181 181 258 258
Heat exchanger Water box type Frame 5 Frame 6
Standard Flanged Standard Flanged
connections connections connectiions connections
Evaporator/condenser NIH, perforated end cover, 1 pass, 1034 kPa 279 296 364 380
NIH, perforated end cover, 2 passes, 10343 kPa 268 301 349 382
NIH, perforated end cover, 3 passes, 1034 kPa 285 297 371 382
NIH/NWB, plain end cover, 1034 kPa 194 194 264 265
NIH, perforated end cover, 1 pass, 2068 kPa 347 381 399 434
NIH, perforated end cover, 2 passes, 2068 kPa 345 398 383 451
NIH, perforated end cover, 3 passes, 2068 kPa 361 380 409 432
NIH/NWB, plain end cover, 2068 kPa 323 323 378 378
Heat exchanger Water box type Frame 7 - evaporator Frame 7 - condenser
Standard Flanged Standard Flanged
connections connections connectiions connections
Evaporator/condenser NIH, perforated end cover, 1 pass, 1034 kPa 631 666 547 581
NIH, perforated end cover, 2 passes, 10343 kPa 610 663 528 580
NIH, perforated end cover, 3 passes, 1034 kPa 650 667 554 580
NIH/NWB, plain end cover, 1034 kPa 464 464 417 417
NIH, perforated end cover, 1 pass, 2068 kPa 900 975 767 839
NIH, perforated end cover, 2 passes, 2068 kPa 877 986 738 845
NIH, perforated end cover, 3 passes, 2068 kPa 911 948 777 831
NIH/NWB, plain end cover, 2068 kPa 711 711 653 653
Heat exchanger Water box type Frame 8 - evaporator Frame 8 - condenser
Standard Flanged Standard Flanged
connections connections connectiions connections
Evaporator/condenser NIH, perforated end cover, 1 pass, 1034 kPa 830 866 763 798
NIH, perforated end cover, 2 passes, 10343 kPa 789 859 721 791
NIH, perforated end cover, 3 passes, 1034 kPa 840 866 772 799
NIH/NWB, plain end cover, 1034 kPa 671 671 557 557
NIH, perforated end cover, 1 pass, 2068 kPa 1220 1295 1085 1156
NIH, perforated end cover, 2 passes, 2068 kPa 1177 1326 1029 1169
NIH, perforated end cover, 3 passes, 2068 kPa 1224 1298 1096 1147
Notes:
NIH Nozzle-in-head water box
NWB Marine water box
NIH/NWB, plain end cover, 2068 kPa 872 872 802 802
Note: The weight of nozzle-in-head water boxes, 2 passes, 1034 kPa is included in the heat exchanger weights (see table 4).
Table 7
Standard machine operating weights
Compressor with starter cabinet without starter cabinet
Points A B C D A B C D
Frame 30-32 2426 1304 2358 1667 2426 1304 2358 1440
35-37 2562 1576 2494 1939 2562 1576 2494 1712
Frame 3 30-32 2653 1338 2517 1927 2653 1338 2517 1701
35-37 2789 1610 2653 2200 2789 1610 2653 1973
40-42 3175 1973 3038 2562 3175 1973 3038 2336
45-47 3356 2177 3220 2766 3356 2177 3220 2540
50-52 3583 2358 3447 2948 3583 2358 3447 2721
55-57 3788 2608 3651 3197 3788 2608 3651 2970
Frame 4 40-42 3583 1973 3447 2562 3583 1973 3447 2336
45-47 3764 2177 3628 2766 3764 2177 3628 2540
50-52 3991 2358 3855 2948 3991 2358 3855 2721
55-57 4195 2608 4059 3197 4195 2608 4059 2970
60-62 4354 2698 4218 3288 4354 2698 4218 3061
65-67 4603 2971 4467 3560 4603 2971 4467 3333
70-72 - - - - 5715 4172 5578 4535
Frame 5 70-72 - - - - 6395 4218 7256 4127
75-77 - - - - 6757 4626 7619 4535
80-82 - - - - 7483 4989 8345 4898
85-87 - - - - 7891 5420 8753 5329
Note: The weights are approximate. They include the weight of refrigerant, water, NIH water boxes and the thickest tubes.
* Looking at the control panel
A = Right-hand foot evaporator
B = Rear right-hand foot condenser
C = Left-hand foot evaporator
D = Rear left-hand foot condenser
See illustration on page 22.
20

Maximum and minimum heat exchanger flow rates (l/s)*
Evaporator 1 pass 2 passes 3 passes Condenser 1 pass 2 passes 3 passes
Model Size Min. Max. Min. Max. Min. Max. Model Size Min. Max. Min. Max. Min. Max.
1 10 27 108 13 54 9 36 1 10 34 135 17 67 11 45
11 31 123 15 62 10 41 11 37 149 19 75 12 50
12 35 139 17 69 12 46 12 42 168 21 84 14 56
15 27 108 13 54 9 36 15 34 135 17 67 11 45
16 31 123 15 62 10 41 16 37 149 19 75 12 50
17 35 139 17 69 12 46 17 42 168 21 84 14 56
2 20 39 154 19 77 13 51 2 20 41 163 20 81 14 54
21 46 185 23 93 15 62 21 50 200 25 100 17 67
22 54 217 27 109 18 72 22 59 235 29 118 20 78
3 30 38 154 19 77 13 51 3 30 41 163 20 81 14 54
31 46 185 23 92 15 62 31 50 199 25 100 17 67
32 54 215 27 108 18 72 32 59 235 29 118 20 79
35 38 154 19 77 13 51 35 41 163 20 81 14 54
36 46 185 23 92 15 62 36 50 199 25 100 17 67
37 54 215 27 108 18 72 37 59 235 29 118 20 79
4 40 62 249 31 125 21 83 4 40 69 277 35 138 23 92
41 70 281 35 140 23 93 41 78 312 39 156 26 104
42 77 307 38 154 26 112 42 86 346 43 173 29 115
45 62 249 31 125 21 93 45 69 277 35 138 23 92
46 70 281 35 140 23 93 46 78 312 39 156 26 104
47 77 307 38 154 26 112 47 86 346 43 173 29 115
5 50 83 332 42 166 28 111 5 50 95 380 48 190 32 127
51 93 374 47 187 31 125 51 104 416 52 208 35 138
52 100 400 50 200 33 133 52 112 450 56 225 37 150
55 83 332 42 166 28 111 55 95 380 48 190 32 127
56 93 374 47 187 31 125 56 104 416 52 208 35 138
57 100 400 50 200 33 133 57 112 450 56 225 37 150
6 60 107 429 54 215 36 143 6 60 121 484 61 242 40 161
61 115 462 58 231 38 154 61 130 519 65 260 43 173
62 122 488 61 244 41 163 62 138 554 69 277 46 185
65 107 429 54 215 36 143 65 121 484 61 242 40 161
66 115 462 58 231 38 154 66 130 519 65 260 43 173
67 122 488 61 244 41 163 67 138 554 69 277 46 185
7 70 124 496 62 248 41 165 7 70 146 583 73 291 49 194
71 140 560 70 280 47 187 71 163 650 81 325 54 217
72 152 609 76 305 51 203 72 178 713 89 356 59 238
75 124 596 62 248 41 165 75 146 583 73 291 49 194
76 140 560 70 280 47 187 76 163 650 81 325 54 217
77 152 609 76 305 51 203 77 178 713 89 356 69 238
8 80 140 562 70 281 47 187 8 80 185 740 92 370 62 247
81 174 695 87 347 58 232 81 202 807 101 404 67 269
82 188 752 94 376 63 251 82 219 874 109 437 73 291
85 160 639 80 320 53 213 85 185 740 92 370 62 247
86 174 695 87 347 58 232 86 202 807 101 404 67 269
87 188 752 94 376 63 251 87 219 874 109 437 73 291
* Flow rates based on standard tubes in the cooler and condenser. Minimum flow based on tube velocity of 0,91 m/s; maximum flow based on tube velocity of 3.66 m/s.
21

22
1
Heat A B C D
exchanger (length with nozzle (width) (height) (tube
in-head water box) removal
2-pass* 1- or 3-pass** space)
mm mm mm mm mm
30-32 4172 4350 1670 2073 3747
35-37 4693 4870 1670 2073 4343
40-42 4242 4426 1880 2153 3747
45-47 4763 4947 1880 2153 4343
50-52 4248 4439 1994 2207 3747
55-57 4769 4959 1994 2207 4343
60-62 4261 4451 2096 2257 3747
65-67 4782 4972 2096 2257 4343
70-72 4978 5194 2426 2985 4267
75-77 5588 5804 2426 2985 4877
80-82 4997 5220 2711 3029 4267
85-87 5607 5829 2711 3029 4877
6
Starter cabinet (optional)
Identification drawing for table 7
2 3
A
Fig. 7 - Dimensional drawing
5
B
1. Tube removal space compressor end and motor end (see column D)
2. Motor service space (1219 mm)
3. Recommended clearance above the machine (915 mm)
4. 362 mm
5. 610 mm
C
4

1. Hot gas bypass (cut)
2. Compressor suction elbow (unbolt)
3. Oil reclaim line
4. Starter connector (unbolt)
5. Heat exchanger assembly (unbolt)
1. Guide vane motor
2. Branch circuit control box
6. Tube sheet
7. Refrigerant motor cooling line (cut)
8. Motor drain
9. Compressor mounting (unbolt)
10. Cooler liquid feed line
Fig. 8 - Dimensional drawing - cooler, side view
Fig. 9 - 19XR chiller top view
3. Compressor discharge elbow joints
4. Condenser transducer cable
A Condenser
B Cooler
C Compressor
23

1. Motor temperature sensor cable
2. Bearing temperature sensor cable connection (inside box)
3. Compressor oil sump pressure cable
1. Guide vane motor cable
2. Diffuser motor (only XR5 compressor)
3. Condenser leaving water pressure cable
4. Condenser leaving water temperature cable
5. Condenser entering water temperature cable
6. Condenser entering water pressure cable
24
10
9
8
Fig. 10 - Compressor detail
12 1 2
4. Compressor oil sump temperature sensor cable
5. Compressor oil discharge pressure cable
6. Discharge temperature sensor cable
7. Connection for high pressurestat (DBK/SDBK)
7 6
Fig. 11 - Unit rear view
7. Evaporator entering water temperature cable
8. Evaporator entering water pressure cable
9. Evaporator leaving water temperature cable
10. Evaporator leaving water pressure cable
11. Chiller Visual Control (CVC)
12. Guide vane motor
11
3
4
5

3.4 - Install machine supports
Typical applications of these units are in refrigeration
systems, and they do not require earthquake resistance.
Earthquake resistance has not been verified.
3.4.1 - Install standard isolation
Figs. 12 and 13 show the position of support plates and shear
flex pads which together form the standard machine support
system.
3.4.2 - Installation of a levelling accessory (if necessary)
Where a floor surface is irregular or uneven, it may prove
necessary to use accessory spring isolators (supplied by Carrier
for field installation) and levelling pads (see Figs. 13 and 15).
Place the unit levelly, using the spring isolator jacking screws.
Use a level at least 600 mm long.
1
In order to provide adequate, long-lasting support for the unit,
it is essential to choose the right grout and to apply it properly.
Carrier advise using an epoxy-type, pre-mixed, non-shrinking
grout only. Follow the manufacturer’s instructions for applying
the grout.
Check the unit layout plans to determine the required
grout thickness.
Apply wax to the jacking screws to facilitate subsequent
removal from the grout.
The grout must be applied up to the top of the base of the
spring isolator, and there must be no gap in the grout
below the spring isolators.
Allow the grout to dry and set in accordance with the
manufacturer’s instructions before starting up the unit.
Remove the jacking screws from the soleplates once the
grout has set.
1. Soleplate detail
2.
3.
Condenser
Evaporator Heat exchanger size
Evaporator/condenser A B
mm mm
30-32 4001 1670
35-37 4525 1670
40-42 4001 1880
45-47 4525 1880
50-52 4001 1994
55-57 4525 1994
60-62 4001 2096
65-67 4525 2096
70-72 4620 2426
75-77 5229 2426
80-82 4620 2711
85-87 5229 2711
Fig. 12 - Chiller footprint
2
3
25

1. Support plate
2. Tube sheet
Note: The isolation package includes 4 shear flex pads.
26
Fig. 13 - Standard isolation
3.4.3 - Install spring isolation
Spring isolation may be purchased as an accessory from Carrier
for field installation. It may also be field supplied and installed.
Spring isolators may be placed directly under machine support
plates or located under machine soleplates. See Fig. 15.
Obtain specific details on spring mounting and machine weight
distribution from job data. Also, check job data for methods to
support and isolate pipes that are attached to spring isolated
machines.
1. See notes
3. Support plate
4. Tube sheet
5. Jacking screw (see note 3)
3. Level base line
4. Shear flex pad
6. Level base line
7. 35 mm
8. Levelling pad
Notes:
1. Dimensions are in mm.
2. Accessory (Carrier supplied, field-installed) soleplate package includes 4
soleplates, 16 jacking screws and levelling pads.
3. Jacking screws to be removed after grout has set.
4. Thickness of grout will vary, depending on the amount necessary to level
chiller. Use only pre-mixed non-shrinking grout. Celcote HT-648 or Master
Builders 636, 38.1 to 57 mm thick.
Fig. 14 - Accessory isolation
1. Accessory spring isolator
2. Soleplate (accessory) attaches securely to isolator
3. Level foundation
4. Resilient shear flex pad, bonded to top and bottom of spring mount
5. Support plate - attach securely to soleplate
Fig. 15 - 19XR Accessory spring isolation
3.5 - Connection of water piping
For size and position of the heat exchanger water inlet and
outlet connections refer to the certified dimensional drawings
supplied with the unit.
The water pipes must not transmit any radial or axial force to
the heat exchangers nor any vibration.
The water supply must be analysed and appropriate filtering,
treatment, control devices, isolation and bleed valves and
circuits built in, to prevent corrosion, fouling and deterioration
of the pump fittings. Consult either a water treatment specialist
or appropriate literature on the subject.
3.5.1 - Install water piping to heat exchanger
Install piping using job data, piping drawings, and procedures
outlined below. A typical piping installation is shown in Fig. 16.
CAUTION: Factory-supplied insulation is not flammable but
can be damaged by welding sparks and open flame. Protect
insulation with a wet canvas cover.
CAUTION: Remove chilled and condenser water sensors and
probes before welding connecting piping to the connections.
Refer to Fig. 11. Replace sensors and probes after welding is
complete.
1. Offset pipe flanges to permit removal of waterbox cover
for maintenance and to provide clearance for pipe cleaning.
No flanges are necessary with marine waterbox option;
however, water piping should not cross in front of the
waterbox or access will be blocked.
2. Provide openings in water piping for required pressure
gauges and thermometers. For thorough mixing and temperature
stabilization, wells in the leaving water pipe should
extend inside pipe at least 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. Use flexible connections to reduce the transmission of
vibrations.
6. Water flow direction must be as specified in Fig. 16.
NOTE: Entering water is always the lower of the 2 nozzles.
Leaving water is always the upper nozzle for cooler or
condenser.
7. Water flow switches must be of vapour-tight construction
and must be installed on top of pipe in a horizontal run
and at least 5 pipe diameters from any bend.
8. Install waterbox vent and drain piping in accordance with
individual job data. All connections are 3/4 -in. FPT.
9. Install waterbox drain plugs in the unused waterbox drains
and vent openings.
10. Install optional pumpout system or pumpout system and
storage tank.

1. Air vent
2. Leaving condenser water
3. Entering condenser water
4. Isolation valve
5. Pressure gauges
6. Thermometer openings (optional)
7. Pipe hangers
8. Entering chilled water
9. Leaving chilled water
10. Water drain
Fig. 16 - Typical nozzle piping
27

Frames 3 - 4 - 5 - 6 (see table below)
W - Drive end
X - Compressor end
Y - Condenser
Z - Evaporator
Frames 7 - 8 (see table below)
28
Nozzle arrangement codes for all 19XR nozzle-in-head waterboxes
Pass Evaporator waterbox Condenser waterbox
Inlet Outlet Arrangement code* Inlet Outlet Arrangement code*
1 8 5 A 11 2 P
5 8 B 2 11 Q
2 7 9 C 10 12 R
4 6 D 1 3 S
3 7 6 E 10 3 T
4 9 F 1 12 U
* Refer to certified drawings
Fig. 17 - Nozzle arrangements - nozzle-in-head waterboxes

1a. Safety valve on machine
1b. Safety valve on machine
2. Service valve on pumpout unit
3. Service valve on pumpout unit
4. Service valve on pumpout unit
5. Service valve on pumpout unit
6. Storage tank vent
7. Machine charging valve
8. Compressor discharge valve
10. Refrigerant charging valve
1a. Service valve on machine
1b. Service valve on machine
2. Service valve on pumpout unit
3. Service valve on pumpout unit
4. Service valve on pumpout unit
5. Service valve on pumpout unit
7. Machine charging valve
8. Compressor discharge valve
11. Cooler isolation valve
12. Condenser isolation valve
13. Refrigerant cooling valve
14. Optional hot gas isolation valve
15. Hot gas bypass solenoid valve
16. Linear float
17. Condenser
18. Cooler
19. Storage tank
20. Tee for charging
Fig. 18 - Optional pumpout system piping schematic with storage tank
11. Cooler isolation valve
12. Condenser isolation valve
13. Refrigerant cooling valve
14. Optional hot gas isolation valve
15. Hot gas bypass solenoid valve
16. Linear float
17. Condenser
18. Evaporator
Fig. 19 - Pumpout system piping schematic with storage tank
21. Compressor discharge valve
22. Compressor suction valve
23. Pumpout compressor
24. Oil separator
25. Condenser water supply and return
26. Pumpout condenser
A Service valve on pumpout unit
B Service valve on machine
C Maintain at least 610 mm clearance around storage tank
for service and operation work
19. Compressor discharge valve
20. Compressor suction valve
21. Pumpout compressor
22. Oil separator
23. Condenser water supply and return
24. Pumpout condenser
A Service valve on pumpout unit
B Service valve on machine
29

3.5.2 - Install vent piping to relief devices
The 19XR chiller is factory equipped with relief devices on the
cooler and condenser shells. Refer to Fig. 20 for size and
location of relief devices.
The safety valves are installed on ball valves, that are leadsealed
in the open position.
These valves permit isolating and removing the safety valve
for calibration and replacement.
If a safety valve is replaced, do not leave the machine without
safety valves. Only remove the safety valve, if the risk of fire
is completely controlled and under the responsibility of the
user. Half the safety valves are enough to protect against fire.
The other half can be removed for replacement (see "Safety
considerations".
Vent relief devices to the outdoors in accordance with the
applicable national standard (for example, NFE 35400 in
France and EN 378 when applicable) for the safety of chilling
devices as well as any other applicable codes.
DANGER: Refrigerant discharged into confined spaces can
displace oxygen and cause asphyxiation.
1. If relief devices are 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 spring-isolated
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.
5. Equip the piping with connections allowing disconnection
for the inspection of the piping.
30
Fig. 20 - Relief device locations
3.6 - Make electrical connections
Field wiring must be installed in accordance with job wiring
diagrams and all applicable electrical local regulations.
Wiring diagrams in this publication (Fig. 21-23) are for reference
only and are not intended for use during actual installation;
follow job specific wiring diagrams.
NOTE: Wires are generally of the 05VK or 07VK type, nontinned
copper core, withstanding a constant 105ºC on the core.
Cross sections are not smaller than those specified in standard
EN 60204-1.
The thicknesses and quality of the insulation are, wherever
necessary, adapted to the constraints of the placing and preparation
of the wiring, terminal spade tagging, the fitting of
specific connectors, etc.
The wire colours are generally as follows: red, black and
white for the 3 bus wires, red for all the common 24, 115, 230
VAC wires, orange for all the wires of the excluded circuits,
blue for the DC circuits, brown for all the other wires.
The wires are marked all along their length, one mark approx.
every 40 mm, according to an equipotential system. The reference
mark numbers are those of the Carrier wiring diagram.
The wires are attached by a clip around the components and
are routed in a self-extinguishing PVC chute! The connectors
terminate the bus strand in conformity with Carrier drawings.
CAUTION: Do not run low voltage wiring into the control
cabinet. The control cabinet should only be used for
additional extra-low voltage wiring (50 V maximum).
WARNING: 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
Wiring may be specified for a spare safety switch, and a
remote start/stop contact can be wired to the starter terminal
strip. Additional spare sensors and Carrier Comfort Network
modules may be specified as well. These are wired to the
machine control panel as indicated in Fig. 21.
3.6.1 Installation standards and precautions
The units have just one power connection point.
The starter cabinet (optional) includes:
the starting-up equipment (standard)
the motor protection (standard)
the Integrated Starter Module ISM
the Chiller Control Module CCM
the Chiller Visual Control CVC

The control cabinet (standard unit) includes mainly:
the control circuit transformer
the oil pump control and the oil heater control
the Chiller Control Module CCM
the Chiller Visual Control CVC
Connection on the jobsite:
All connections to the network and the power wiring must be
carried out in accordance with the applicable codes at the place
of installation *.
In France, for example, the requirements of standard
NFC 15 100, among others, must be complied with.
Carrier 19XR units are designed for easy compliance with these
codes *, with European standard EN 60204-1* (machinery safety
- electrical equipment of the machines - Part I: general rules)
being taken into account to design the electrical equipment of
the machine.
NOTE: Standard EN 60204-1 is a good means of responding
to the requirements of the machinery directive and 1.5.1.
In general, nominal recommendation IEC 364 is recognized
for responding to the requirements of the installation directives.
Annexe B of standard EN 60204-1 enables the machine electrical
equipment characteristics to be taken into account. See
Part 3.6.2 for the electrical characteristics of the 19XR units.
The operating environment for 19XRs is specified below:
Ambient temperature range: +5 to 40ºC**
(Non-condensable) humidity range:
- 90% RH at 20ºC
- 50% RH at 40ºC. (If installation conditions so
require, advocate the tropicalization option.)
Altitude: 2000 m.
Installation inside premises
Presence of water: category AD2** (possibility of falling
water droplets)
Presence of solid bodies: category AE2** (presence of
non-significant dust)
Personnel qualifications:
Must be a qualified refrigeration technician who has
undergone specific training on a 19XR-type product
Category BA4** (qualified personnel according to IEC
364) up to 1000 V.
Presence of corrosive and polluting substances: category
AF1 (negligible)
Vibrations, shocks: AG2**, AH2**
Frequency variations: ± 2 Hz.
** The level of protection required with regard to these codes is IP21B (according
to reference document IEC 529).
All 19XR units, as they meet IP23B, fulfil this protection condition.
If installation conditions so require, select the reinforced IP option.
Protection of power leads against overcurrents is not supplied
with the unit.
The heating circuit, oil pump power and starter control are not
disconnected by the main isolating switch (orange wire).
NOTE: If particular aspects of an installation require
different characteristics from those listed above (or not
mentioned), contact the factory.
3.6.2 - Electrical characteristics of the motors
NOTE: For 60 Hz units contact Carrier.
50Hz - Standard efficiency motors
Size B
Low voltage
Motor Motor electrical Max. IkW Low voltage
size data 230 V 346 V 400 V
BDS RLA per IkW 100 2.85 1.87 1.62
LRA Star 546 339 300
LRA Delta 1763 1093 966
BES RLA per IkW 135 2.80 1.86 1.61
LRA Star 655 438 372
LRA Delta 2114 1414 1200
BFS RLA per IkW 170 2.78 1.85 1.60
LRA Star 801 534 475
LRA Delta 2585 1723 1533
BGS RLA per IkW 204 2.79 1.84 1.59
LRA Star 1033 615 532
LRA Delta 3333 1983 1715
BHS RLA per IkW 247 2.72 1.81 1.56
LRA Star 1192 784 627
LRA Delta 4133 2729 2191
50Hz - Standard efficiency motors
Size C
Low and medium voltage
Motor Motor electrical Max. IkW Low voltage Medium voltage
size data 230 V 346 V 400 V 3000 V 3300 V
CDS RLA per IkW 199 2.92 1.95 1.63 0.22 0.20
LRA Star 1432 959 653 - -
LRA Delta 4495 3008 2055 194 194
CES RLA per IkW 219 2.86 1.86 1.62 0.22 0.2
LRA Star 1523 921 653 - -
LRA Delta 4784 2904 2055 214 212
CLS RLA per IkW 243 2.93 1.92 1.65 0.21 0.2
LRA Star 1727 1082 825 - -
LRA Delta 5404 3394 2591 241 236
CMS RLA per IkW 267 2.79 1.83 1.60 0.22 0.2
LRA Star 1542 833 730 - -
LRA Delta 4820 2603 2281 258 254
CNS RLA per IkW 295 2.79 1.83 1.68 0.22 0.19
LRA Star 1446 2670 896 - -
LRA Delta 4518 854 2800 291 285
CPS RLA per IkW 323 2.76 1.83 1.62 0.21 0.2
LRA Star 1534 1020 952 - -
LRA Delta 4795 3187 2973 325 292
CQS RLA per IkW 360 2.76 1.94 1.6 0.21 0.19
LRA Star 1542 1303 952 - -
LRA Delta 4820 4072 2973 346 343
See legend on page 33
31

Electrical characteristics of the motors (cont'd)
50 Hz - Standard efficiency motors*
Size D
Low, medium and high voltage
Motor Motor Low voltage Medium voltage High voltage
size electrical Max. Max. Max.
data IkW 230 V 346 V 400 V IkW 3000 V 3300 V IkW 6300 V
DBS RLA per IkW 340 2.70 1.79 1.55 339 0.218 0.197 - -
LRA Star 1679 1160 963 - - - -
LRA Delta 5468 3776 3142 332 301 - -
DCS RLA per IkW 366 2.70 1.79 1.55 370 0.216 0.197 - -
LRA Star 1681 1163 965 - - - -
LRA Delta 5483 3794 3147 373 344 - -
DDS RLA per IkW 394 2.70 1.79 1.55 395 0.217 0.197 391 0.103
LRA Star 1821 1184 1025 - - -
LRA Delta 5926 3865 2248 439 378 252
DES RLA per IkW 416 2.68 1.78 1.54 419 0.217 0.197 415 0.103
LRA Star 2185 1418 1260 - - -
LRA Delta 7083 4609 4096 439 378 256
DFS RLA per IkW 449 2.68 1.78 1.54 453 0.216 0.196 447 0.103
LRA Star 2189 1421 1262 - - -
LRA Delta 7110 4626 4108 419 427 256
DGS RLA per IkW 485 2.68 1.78 1.54 499 0.215 0.196 492 0.103
LRA Star 2644 1581 1402 - - -
LRA Delta 8593 5150 4563 480 422 312
DHS RLA per IkW 528 2.74 1.78 1.54 525 0.213 0.192 527 0.103
LRA Star 2397 1837 1561 - - -
LRA Delta 7490 5972 5075 513 563 309
DJS RLA per IkW 597 - 1.78 1.54 565 0.214 0.193 563 0.103
LRA Star - 1727 1437 - - -
LRA Delta - 5640 4692 513 565 313
50 Hz - Standard efficiency motors*
Size E
Low and medium voltage
Motor Motor Low voltage Medium voltage
size electrical data Max. IkW 400 V Max. IkW 3000 V 3300 V
EHS RLA per IkW 603 1.62 607 0.214 0.194
LRA Star 1.988 - -
LRA Delta 6.308 675 578
EJS RLA per IkW 646 1.62 648 0.213 0.192
LRA Star 2.289 - -
LRA Delta 7.266 753 631
EKS RLA per IkW 692 1.58 701 0.211 0.192
LRA Star 2.192 - -
LRA Delta 6.984 767 749
ELS RLA per IkW 746 1.60 756 0.210 0.191
LRA Star 2.493 - -
LRA Delta 7.927 940 838
EMS RLA per IkW 809 1.59 819 0.210 0.191
LRA Star 2.493 - -
LRA Delta 7.927 937 841
ENS RLA per IkW 876 1.64 886 0.209 0.190
LRA Star 3.394 - -
LRA Delta 10.498 1058 963
EPS RLA per IkW 931 1.62 943 0.210 0.191
LRA Star 3.466 - -
LRA Delta 11.004 1061 965
50 Hz - High efficiency motors
Size B*
Low voltage
Motor Motor Low voltage
size electrical data Max. IkW 230 V 346 V 400 V
BDH RLA per IkW 99 2.87 1.91 1.67
LRA Star 801 534 475
LRA Delta 2585 1723 1533
BEH RLA per IkW 134 2.87 1.86 1.61
LRA Star 1033 615 532
LRA Delta 3333 1983 1715
BFH RLA per IkW 171 2.72 1.83 1.58
LRA Star 1040 791 656
LRA Delta 3598 2739 2282
BGH RLA per IkW 206 2.75 1.80 1.58
LRA Star 1455 787 821
LRA Delta 5023 2742 2842
BHH RLA per IkW 241 2.73 1.79 1.56
LRA Star 1453 786 819
LRA Delta 5047 2745 2846
32
50 Hz - High efficiency motors
Size C
Low and medium voltage
Motor Motor electrical Max. IkW Low voltage Medium voltage
size data 230 V 346 V 400 V 3000 V 3300 V
CDH RLA per IkW 196 2.86 1.90 1.64 0.22 0.20
LRA Star 1586 1061 902 - -
LRA Delta 5002 3345 2848 236 229
CEH RLA per IkW 214 2.77 1.88 1.63 0.22 0.20
LRA Star 1577 1142 1013 - -
LRA Delta 5087 3685 3266 288 242
CLH RLA per IkW 239 2.76 1.83 1.59 0.22 0.20
LRA Star 1768 1165 1032 - -
LRA Delta 5703 3758 3328 331 287
CMH RLA per IkW 263 2.92 1.93 1.63 0.22 0.20
LRA Star 1959 1253 928 - -
LRA Delta 6765 4343 3227 333 291
CNH RLA per IkW 292 2.87 1.90 1.70 0.22 0.20
LRA Star 1922 1233 1278 - -
LRA Delta 6663 4278 4417 393 364
CPH RLA per IkW 320 2.83 1.91 1.67 0.22 0.20
LRA Star 1897 1385 1263 - -
LRA Delta 6592 4801 4370 395 369
CQH RLA per IkW 358 2.88 1.89 1.65 0.22 0.20
LRA Star 2243 1384 1263 - -
LRA Delta 7751 4812 4389 460 389
50 Hz - High efficiency motors
Size D*
Low, medium and high voltage
Motor Motor Low voltage Medium voltage High voltage
size electrical Max. Max. Max.
data IkW 230 V 346 V 400 V IkW 3000 V 3300 V IkW 6300 V
DBH RLA per IkW 337 2.68 1.78 1.54 333 0.218 0.197
LRA Star 1831 1228 1027 - - - -
LRA Delta 5966 4008 3350 440 395
DCH RLA per IkW 361 2.69 1.78 1.54 365 0.216 0.197
LRA Star 2064 1297 1097 - - - -
LRA Delta 6707 4230 3574 468 423
DDH RLA per IkW 390 2.68 1.78 1.54 391 0.217 0.197 391 0.103
LRA Star 2016 1401 1161 - - -
LRA Delta 6567 4561 3790 506 450 278
DEH RLA per IkW 413 2.68 1.78 1.55 414 0.216 0.197 414 0.104
LRA Star 2017 1399 1240 - - -
LRA Delta 6564 4570 4038 546 523 304
DFH RLA per IkW 438 2.69 1.78 1.54 442 0.215 0.195 446 0.103
LRA Star 2544 1648 1292 - - -
LRA Delta 8288 5366 4217 580 510 302
DGH RLA per IkW 480 - 1.78 1.54 488 0.215 0.197 489 0.102
LRA Star - 1740 1478 - - -
LRA Delta - 5673 4817 624 615 321
DHH RLA per IkW 513 - 1.78 1.54 516 0.213 0.193 523 0.103
LRA Star - 1740 1478 - - -
LRA Delta - 5679 4823 894 832 367
DJH RLA per IkW 552 - 1.78 1.54 550 0.21 0.194 556 0.103
LRA Star - 1741 1480 - - -
LRA Delta - 5689 4837 851 928 403
See legend on page 33

Electrical characteristics of the motors (cont'd)
50 Hz - High efficiency motors
Size E
Low, medium and high voltage
Motor Motor
voltage
Low voltage Medium voltage High
size electrical data Max. Max. Max.
IkW 400 V IkW 3000 V 3300 V IkW 6300 V
EHH RLA per IkW 602 1.60 604 0.210 0.193 608 0.100
LRA Star 2.075 - - -
LRA Delta 6.600 672 697 338
EJH RLA per IkW 645 1.58 646 0.210 0.190 651 0.100
LRA Star 2.192 - - -
LRA Delta 6.984 807 707 397
EKH RLA per IkW 689 1.57 692 0.210 0.192 696 0.100
LRA Star 2.347 - - -
LRA Delta 7.505 872 827 426
ELH RLA per IkW 744 1.57 750 0.210 0.191 754 0.100
LRA Star 2.347 - - -
LRA Delta 7.505 1055 901 467
EMH RLA per IkW 808 1.58 811 0.210 0.191 817 0.100
LRA Star 2.738 - - -
LRA Delta 8.720 1047 901 465
ENH RLA per IkW 875 1.61 879 0.210 0.191 883 0.100
LRA Star 3.541 - - -
LRA Delta 11.257 1154 1137 586
EPH RLA per IkW 930 1.60 937 0.210 0.191 941 0.100
LRA Star 3.499 - - -
LRA Delta 11.124 1151 1130 586
Legend:
IkW - Compressor power input kW
LRA Star - Locked rotor amps - star configuration
LRA Delta - Locked rotor amps - delta configuration
OLTA - Overcurrent (= RLA x 1.08)
RLA - Rated load amps
* 19XR only
Notes:
1. Standard voltages:
50Hz
Nominal voltage Range
230 220-240 V
346 320-360 V
400 380-415 V
3000 2900-3100 V
3300 3200-3400 V
6300 600-6600 V
Motor nameplates can be stamped for any voltage within the listed supply/
coltage range. Chillers shall not be selected at voltages above or below the
listed supply voltage range.
2. To establish electrical data for your selected voltage, if other than listed
voltage, use the following formula:
RLA = listed RLA x
OLTA = listed OLTA x
LRA = listed RLA x
Listed voltage
Selected voltage
Listed voltage
Selected voltage
Listed voltage
Selected voltage
Example: Find the rated load amperage for a motor listed at 1.14 amps per kW
input and 550 volts.
575
RLA = 1.14 x = 1.19
550
Electrical data for electric components
(3 phase, 50/60 Hz)
Item Average Nom. power Min./Max. Inrush Sealed
supply motor
kW V-ph-Hz voltage kVA kVA
Oil pump 1.35 220-3-60 200/240 9.34 1.65
1.50 230-3-50 220/240 11.15 1.93
393-3-50 346/440 8.30 1.76
Note:
FLA (full load amps) = sealed kVA x 1000/( 3 x volts)
LRA (locked rotor amps) = inrush kVA x 1000/( 3 x volts)
Electrical data for electric components
(115/230 Volt, 1 phase, 50/60 Hz)
Item Power Sealed kVA Average (Watts)
Control 24 V AC 0.16 160
Crankcase 115-230/1/50-60 - 1500
heater (frame 2 compressors)
1800
(frame 3,4 compressors)
2200
(frame 5 compressors)
Notes:
1. The crankcase heater only operates when the compressor is off.
2. Power to the crankcase heater control must be on circuits that can provide
continuous service when the compressor is disconnected.
33

3.6.3 - Communication wiring
The CCN may easily be converted to JBUS mode.
Cable type: LIYCY
0. Alarm
1. Ground wire
2. Ground
3. Black
34
J7
J1
J6
J6
}
G
+
SERVICE
0
24 VAC
-
R
CVC
J7
J1
J6
J6
}
SERVICE
24 VAC
-
G
+
4. White
5. Red
6. Terminal strip
7. Chassis ground
0
R
Fig. 21 - COMM1 CCN communication wiring for multiple chillers (typical)
CVC
J7
J1
J6
J6
}
24 VAC
-
G
+
SERVICE
0
R
CVC
8. Chiller Visual Control CVC
9. 19XR chillers
10. Factory-wiring
11. Field-wiring

3.6.4 - Make the necessary connections for the outgoing
control signals
Connect the auxiliary equipment, the chilled water pumps and
the condenser water pumps, as well as the additional alarms, as
indicated in the job wiring diagrams.
3.6.5 - Connect the starting cabinet
The 19XR is available either with a unit-mounted, factoryinstalled
starter cabinet (optional), or with a freestanding, fieldinstalled
starter (Figs. 22 and 23).
17
18
19
1. Disconnect
2. Unit mounted starter with control (factory-installed)
3. Guide vane motor
4. Oil pump terminal box
5. Vents
6. Pressure gauges
7. Chilled water pump
8. Condenser water pump
9. Chilled water pump starter
10. Condenser water pump starter
11. Cooling tower fan starter
12. To cooling tower
13. From cooling tower
14. To load
15. From load
16. Drain
17. Piping
18. Control wiring
19. Power wiring
8
7
13
18
12
15
14
Fig. 22 - 19XR with optional unit-mounted starter
3.6.5.1 - Unit-mounted factory-installed starter cabinet
Connect the power leads of the auxiliary equipment, chilled
and condenser water pump as well as the associated alarms,
using the conductor provided (see Fig. 22).
NOTE:
Connection of power leads:
When the section switch is chosen as a main circuitbreaker
device, it is necessary to install a protection
against short circuits upstream of the cabinet.
16
IMPORTANT: Ensure correct phasing is followed for proper
motor rotation.
NOTES:
1. Wiring and piping shown are for general point-ofconnection
only and are not intended to show details for a
specific installation. Certified field wiring and dimensional
diagrams are available on request.
2. All wiring must comply with applicable codes.
3. Refer to Carrier System Design Manual for details
regarding piping techniques.
4. Wiring not shown for optional devices such as:
remote start-stop
remote alarm
optional safety device
4 to 20 mA resets
optional remote sensors
3
35

3.6.5.2 - Freestanding, Field-Installed Starter
The starters must be designed and manufactured in accordance
with Carrier instruction EE38 for the 19XR. Assemble and
install compressor terminal box in desired orientation, and cut
necessary conduit openings in conduit support plates (see Fig.
23). Attach power leads to compressor terminals in accordance
with job wiring drawings, observing caution label in terminal
box. Use only copper conductors.
36
20
21
22
16
1. Disconnect
2. Freestanding compressor motor starter
3. Compressor motor terminal box
4. Oil pump terminal box
5. Control cabinet
6. Vents
7. Pressure gauges
8. Chilled water pump
9. Condenser water pump
10. Chilled water pump starter
11. Condensing water pump starter
12. Cooling tower fan starter
13. Disconnect
14. Oil pump disconnect (see Note 5)
15. To cooling tower
16. From cooling tower
17. To load
18. From load
19. Drain
20. Piping
21. Control wiring
22. Power wiring
15
18
17
Fig. 23 - 19XR with freestanding starter
The motor must be earthed in accordance with applicable codes,
local regulations and the project wiring diagrams.
Installer is responsible for any damage caused by improper
wiring between starter and compressor motor.
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 (clockwise).
19
NOTES:
1. Wiring and piping shown are for general point-ofconnection
only and are not intended to show details for
a specific installation. Certified field wiring and dimensional
diagrams are available on request.
2. All wiring must comply with applicable codes.
3. Refer to Carrier System Design Manual for details
regarding piping techniques.
4. Wiring not shown for optional devices such as:
remote start-stop
remote alarm
optional safety device
4 to 20 mA resets
optional remote sensors
5. Oil pump disconnect may be located within the enclosure
of item 2 - freestanding compressor motor starter
cabinet.

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), obtain insulation
material from machine shipping package consisting of 3 rolls
of insulation putty and one roll of vinyl tape.
Insulate each terminal by wrapping with one layer of
insulation putty.
Overwrap putty with 4 layers of vinyl tape.
High-voltage units
High-voltage units require special terminal preparation. Follow
electrical codes for high-voltage installation. Vinyl tape is not
acceptable; a high voltage terminal method must be used.
CAUTION: A cable conduit is provided in the bottom of the
control box for field wiring connections.
General remarks on Fig. 23
All field-supplied conductors, devices, field-installation
wiring, and termination of conductors and devices must be
in compliance with all applicable codes and job specifications.
The routing of field-installed conduit and conductors and
the location of field-installed devices must not interfere with
equipment access or the reading, adjusting, or servicing of
any component.
Equipment, installation, and all starting and control devices
must comply with details in equipment submittal drawings
and literature.
Contacts and switches are shown in the position they would
assume with the circuit deenergized and the chiller shut down.
Installer is responsible for any damage caused by improper
wiring between starter and machine.
Electrical connection of the starter
The compressor motor and the regulating part must be earthed
to the starter cabinet.
Control wiring
Do not use the regulating transformer to supply the pilot relays.
The wiring running between starter and regulation must be
shielded and connected on both sides (600 V/ 80ºC cables min.).
If the oil pump disconnect is not included in the starter, it must
be installed in view of the unit with appropriate wiring.
Wiring between the starter and the compressor motor
Low voltage (600 V or less) compressors have six terminal studs.
Between 3 and 6 leads must be run to the starter, depending on
the type of starter employed. If only 3 are used, jumper the
terminals as follows: 1 to 6, 2 to 4 and 3 to 5. Centre-to-centre
distance between terminals is 82/125 mm (frame 3 compressor/
frame 4 compressor). The starter must have a nameplate stamped
as conforming with the requirements of Carrier Technical
Specifications EE038.
The terminal studs must not take the weight of the leads: if
necessary, use intermediate supports. Use a torque spanner to
tighten the terminal nuts to 200 N maximum, maintaining the
terminal with an additional spanner.
Compressor Diameter Distance between terminals (from centre line)
3 15.9 82
4 15.9 82
5 22.2 125
3.6.6 - Connect the starting cabinet to the control box
See Fig. 24 - Connect the starter cabinet to the unit control box.
In addition, connect the communication cable (SIO) directly
from the control box to the starter cabinet. All regulating cables
must be shielded. Connect the communication cable (shielded
cable, type LIYCY).
Consult the job wiring diagrams for cable type and number.
Ensure that the control circuit is properly earthed in accordance
with electrical standards and with the instructions on the machine
control wiring label.
3.6.7 - Carrier Comfort Network interface (CCN)
The Carrier Comfort Network (CCN) communication bus wiring
is supplied and installed by the electrical contractor. It consists
of shielded, 3-conductor cable with metallic braiding.
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. 21 for location
of the CCN network connector on the CVC (J1) module.
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:
Signal CVC connector CCN Bus conductor
type* insulation colour
+ 1 Red
Ground 2 White
- 3 Black
* Cable type to be used: shielded cable LIYCY
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. 21).
If the communication bus cable exits from one building and
enters another, the shields must be connected to ground at the
lightening suppressor in each building where the cable enters
or exits the building (one point only).
To connect the 19XR chiller to the network, proceed as follows
(Fig. 21):
1. Cut power to the PIC II control panel.
2. Find connector J1 on the CVC.
37

3. Cut a CCN wire and strip the ends of the RED, WHITE,
and BLACK conductors (Molex type strippable
connectors - supplier ref. No. 08-50-0189).
4. Using a wirenut, connect the drain wires together.
5. Insert and secure the RED wire to Terminal 1 of the J1
connector.
6. Insert and secure the WHITE wire to Terminal 2 of the J1
connector.
7. Insert and secure the BLACK wire to Terminal 3 of the J1
connector.
8. Mount a terminal strip in a convenient location.
9. Connect the opposite ends of each conductor to separate
terminals on the terminal strip.
10. Cut another CCN wire and strip the ends of the
conductors.
11. Connect the RED wire to the matching location on the
terminal strip.
12. Connect the WHITE wire to the matching location on the
terminal strip.
13. Connect the BLACK wire to the matching location on the
terminal strip.
38
A
B C
Fig. 24 - Machine isolation
3.7 - Install Field Insulation
CAUTION: 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 following
components:
compressor motor
cooler shell
cooler tube sheets
suction piping
motor cooling drain
oil reclaim piping
oil cooler refrigerant side tubing
refrigerant liquid line to cooler
waterbox covers
A. Top view
B. Front view
C. End view

4 - BEFORE INITIAL START-UP
4.1 - Necessary checks
4.1.1 - Job Data Required
Checks before system start-up
Before the start-up of the refrigeration system, the complete
installation, including the refrigeration system must be verified
against the installation drawings, dimensional drawings, system
piping and instrumentation diagrams and the wiring diagrams.
During the installation test national regulations must be
followed. If no national regulation exists, paragraph 9-5 of
standard EN 378-2 can be used as a guide.
External visual installation checks:
Compare the complete installation with the refrigeration
system and power circuit diagrams.
Check that all components comply with the design
specifications.
Check that all safety documents and equipments that are
required by current European standards are present.
Verify that all safety and environmental protection
devices and arrangements are in place and comply with
the current European standard.
Verify that all document for pressure containers,
certificates, name plates, files, instruction manuals that are
required documents required by the current European
standards are present.
Verify the free passage of access and safety routes.
Check that ventilation in the plant room is adequate.
Check that refrigerant detectors are present.
Verify the instructions and directives to prevent the
deliberate removal of refrigerant gases that are harmful to
the environment.
Verify the installation of connections.
Verify the supports and fixing elements (materials,
routing and connection).
Verify the quality of welds and other joints.
Check the protection against mechanical damage.
Check the protection against heat.
Check the protection of moving parts.
Verify the accessibility for maintenance or repair and to
check the piping.
Verify the status of the valves.
Verify the quality of the thermal insulation and of the
vapour barriers.
4.1.2 - Equipment Required
mechanic’s tools (refrigeration)
digital volt-ohmmeter (DVM)
clamp-on ammeter
electronic leak detector
absolute pressure manometer or wet-bulb vacuum
indicator
500-V insulation tester (megohmmeter) for compressor
motors with nameplate voltage of 600 V or less, or a 5000-V
insulation tester for compressor motor rated above 600 V.
4.1.3 - Using the Optional Storage Tank and Pumpout
System
Refer to Pumpout and Refrigerant Transfer Procedures section,
for: pumpout system preparation, refrigerant transfer, and
chiller evacuation.
4.1.4 - Remove Shipping Packaging
Remove any packaging material from the control centre,
control box, guide vane actuator, motor cooling and oil reclaim
solenoids, motor and bearing temperature sensor covers, and
the factory-mounted starter.
4.1.5 - Open Oil Circuit Valves
Check that the oil filter isolation valves (Fig. 4) are open by
removing the valve cap and checking the valve stem.
4.1.6 - Tighten All Gasketed Joints and Guide Vane Shaft
Packing (torque depends on screw diameter)
Gaskets and packing normally relax by the time the chiller
arrives at the jobsite. Tighten all gasketed joints and the guide
vane shaft packing to ensure a leak tight chiller.
4.1.7 - Inspect Water Piping
Refer to piping diagrams provided in the certified drawings, and
the piping instructions in the 19XR Installation Instructions
manual. Inspect the piping to the cooler and condenser. Be sure
that flow directions are correct and that all piping specifications
have been met.
Do not introduce any significant static or dynamic pressure
into the heat exchange circuit (with regard to the design
operating pressures).
Before any start-up verify that the heat exchange fluid is
compatible with the materials and the water circuit coating.
In case additives or other fluids than those recommended by
Carrier s.a are used, ensure that the fluids are not considered as
a gas, and that they belong to class 2, as defined in directive
97/23/EC.
Carrier s.a. recommendations on heat exchange fluids:
1. No NH4+ ammonium ions in the water, they are very
detrimental for copper. This is one of the most important
factors for the operating life of copper piping. A content
of several tenths of mg/l will badly corrode the copper
over time.
2. Cl- Chloride ions are detrimental for copper with a risk of
perforations by corrosion by puncture. If possible keep
below 10 mg/l.
2- 3. SO sulphate ions can cause perforating corrosion, if
4
their content is above 30 mg/l.
4. No fluoride ions (2.8 K. Values between 10 and 25
can be recommended. This will facilitate scale deposit that
can limit corrosion of copper. TH values that are too high
can cause piping blockage over time. A total alkalimetric
titre (TAC) below 100 is desirable.
39

8. Dissolved oxygen: Any sudden change in water oxygenation
conditions must be avoided. It is as detrimental to
deoxygenate the water by mixing it with inert gas as it is
to over-oxygenate it by mixing it with pure oxygen. The
disturbance of the oxygenation conditions encourages
destabilisation of copper hydroxides and enlargement of
particles.
9. Specific resistance – electric conductivity: the higher the
specific resistance, the slower the corrosion tendency.
Values above 3000 Ohm/cm are desirable. A neutral
environment favours maximum specific resistance values.
For electric conductivity values in the order of 200-6000
S/cm can be recommended.
10. pH: Ideal case pH neutral at 20-25°C
7 < pH < 8
If the water circuit must be emptied for longer than one month,
the complete circuit must be placed under nitrogen charge to
avoid any risk of corrosion by differential aeration.
Charging and removing heat exchange fluids should be done
with devices that must be included on the water circuit by the
installer. Never use the unit heat exchangers to add heat
exchange fluid.
Piping systems must be properly vented, with no stress on
waterbox nozzles and covers. Use flexible connections to
reduce the transmission of vibrations. Water flows through the
cooler and condenser must meet job requirements. Measure the
pressure drop across cooler and across condenser and compare
this with the nominal values (see selection document).
If the optional pumpout storage tank and/or pumpout system
are installed, check to ensure the pumpout condenser water has
been piped in. Check for field-supplied shutoff valves and
controls as specified in the job data. Check for refrigerant leaks
on field-installed piping. See Fig. 19 and 20.
4.1.8 Check Relief Devices
Be sure that relief devices have been piped to the outdoors in
compliance with standard EN 378-2. Piping connections must
allow for access to the valve mechanism for periodic inspection
and leak testing. 19XR relief valves are set to relieve at 1275 kPa
chiller heat exchanger design pressure.
4.2 - Chiller Tightness
4.2.1 - Check chiller tightness
Figure 25 outlines the proper sequence and procedures for leak
testing.
19XR chillers are shipped with the refrigerant contained in the
condenser shell and the oil charge shipped in the compressor.
The cooler will have a 225 kPa refrigerant charge. Units may
be ordered with the refrigerant shipped separately, along with a
225 kPa nitrogen-holding charge in each vessel. To determine if
there are any leaks, the chiller should be charged with refrigerant.
Use an electronic leak detector to check all flanges and solder
joints after the chiller is pressurized. If any leaks are detected,
follow the leak test procedure.
40
If the chiller is spring isolated, keep all springs blocked in both
directions in order to prevent possible piping stress and damage
during the transfer of refrigerant from vessel to vessel during the
leak test process, or any time refrigerant is transferred. Adjust
the springs when the refrigerant is in operating condition, and
when the water circuits are full.
4.2.2 - Refrigerant Tracer
Carrier recommends the use of an environmentally acceptable
refrigerant tracer for leak testing with an electronic detector.
Ultrasonic leak detectors also can be used if the chiller is under
pressure.
WARNING: Do not use air or oxygen as a means of pressurizing
the chiller. Mixtures of HFC-134a and air can undergo
combustion.
4.2.3 - Leak Test Chiller
Due to regulations regarding refrigerant emissions and the difficulties
associated with separating contaminants from refrigerant,
Carrier recommends the following leak test procedures. See
Fig. 25 for an outline of the leak test procedures.
1. If the pressure readings are normal for chiller condition:
a. Evacuate the holding charge from the vessels, if
present.
b. Raise the chiller pressure, if necessary, by adding
refrigerant until pressure is at equivalent saturated
pressure for the surrounding temperature. Follow the
pumpout procedures in the Transfer Refrigerant from
Pumpout Storage Tank to Chiller section, Steps 1a - e.
WARNING: Never charge liquid refrigerant into the
chiller if the pressure in the chiller is less than 241 kPa
for HFC-134a. Charge as a gas only, with the cooler and
condenser pumps running, until this pressure is reached,
using PUMP-DOWN LOCKOUT and TERMINATE
LOCKOUT mode on the PIC II. Flashing of liquid
refrigerant at low pressures can cause tube freeze-up
and considerable damage.
c. Leak test chiller as outlined in Steps 3 -9.
2. If the pressure readings are abnormal for chiller
condition:
a. Prepare to leak test chillers shipped with refrigerant
(Step 2h).
b. Check for large leaks by connecting a nitrogen bottle
and raising the pressure to 207 kPa. Soap test all joints.
If the test pressure holds for 30 minutes, prepare the
test for small leaks (Steps 2g - h).
c. Plainly mark any leaks which are found.
d. Release the pressure in the system.
e. Repair all leaks.
f. Retest the joints that were repaired.
g. After successfully completing the test for large leaks,
remove as much nitrogen, air, and moisture as possible,
given the fact that small leaks may be present in the
system. This can be accomplished by following the
dehydration procedure, outlined in the Chiller Dehydration
section below.

h. Slowly raise the system pressure to a maximum of
1103 kPa but no less than 241 kPa for HFC-134a by
adding refrigerant. Proceed with the test for small
leaks (Steps 3-9).
3. Check the chiller carefully with an electronic leak
detector, or soap bubble solution.
4. Leak Determination - If an electronic leak detector indicates
a leak, use a soap bubble solution, if possible, to
confirm. Total all leak rates for the entire chiller.
Leakage at rates greater than 0.45 kg/year for the
entire chiller must be repaired. Note total chiller leak
rate on the start-up report.
5. If no leak is found during initial start-up procedures,
complete the transfer of refrigerant gas from the
pumpout storage tank to the chiller (see Pumpout and
Refrigerant Transfer Procedures, Chillers with
Pumpout Storage Tanks section (option).
6. If no leak is found after a retest:
a. Transfer the refrigerant to the pumpout storage tank
and perform a standing vacuum test as outlined in the
Standing Vacuum Test section, this page.
b. If the chiller fails this test, check for large leaks (Step
2b).
c. Dehydrate the chiller if it passes the standing vacuum
test. Follow the procedure in the Chiller Dehydration
section. Charge chiller with refrigerant (see Pumpout
and Refrigerant Transfer Procedures, Chillers
with Pumpout Storage Tanks section, Steps 1a-e).
7. If a leak is found, pump the refrigerant back into the
pumpout storage tank, or if isolation valves are present,
pump into the non-leaking vessel (see Pumpout and
Refrigerant Transfer procedures section).
8. Transfer the refrigerant until chiller pressure is at 40
kPa absolute.
9. Repair the leak and repeat the procedure, beginning
from Step 2h to ensure a leaktight repair. (If chiller is
opened to the atmosphere for an extended period,
evacuate it before repeating leak test.)
10. The circuit openings must be plugged during repair, if
this does not take longer than one day. If it takes
longer, the circuits must be charged with nitrogen.
4.3 - Standing Vacuum Test
When performing the standing vacuum test or chiller dehydration,
use a manometer or a wet bulb indicator. Dial gauges
cannot indicate the small amount of acceptable leakage during
a short period of time.
1. Attach an absolute pressure manometer or wet bulb indicator
to the chiller.
2. Evacuate the vessel (see Pumpout and Refrigerant Transfer
Procedures section) to at least 41 kPa, using a vacuum
pump or the pumpout unit.
3. Valve off the pump to hold the vacuum and record the
manometer or indicator reading.
4. a. If the leakage rate is less than 0.17 kPa in 24 hours,
the chiller is sufficiently tight.
b. If the leakage rate exceeds 0.17 kPa in 24 hours,
repressurize the vessel and test for leaks. If refrigerant
is available in the other vessel, pressurize by following
Steps 2-10 of Return Refrigerant To Normal Operating
Conditions section. If not, use nitrogen and a refrigerant
tracer. Raise the vessel pressure in increments until
the leak is detected. If refrigerant is used, the maximum
gas pressure is approximately 483 kPa for HFC-134a
at normal ambient temperature. If nitrogen is used,
limit the leak test pressure to 1103 kPa maximum.
5. Repair leak, retest, and proceed with dehydration.
4.4 - Chiller Dehydration
Dehydration is recommended if the chiller has been open for a
considerable period of time, if the chiller is known to contain
moisture, or if there has been a complete loss of chiller holding
charge or refrigerant pressure.
WARNING: Do not start or megohm-test the compressor motor
or oil pump motor, even for a rotation check, if the chiller is
under dehydration vacuum. Insulation breakdown and severe
damage may result.
Dehydration is readily accomplished at room temperatures.
Use of a cold trap (Fig. 26) may substantially reduce the time
required to complete the dehydration. The higher the room
temperature, the faster dehydration takes place. At low room
temperatures, a very deep vacuum is required for boiling off any
moisture. If low ambient temperatures are involved, contact a
qualified service representative for the dehydration techniques
required.
Perform dehydration as follows:
1. Connect a high capacity vacuum pump (0.002 m 3 /s or
larger is recommended) to the refrigerant charging valve
(Fig. 2). Tubing from the pump to the chiller should be as
short and as large a diameter as possible to provide least
resistance to gas flow.
2. Use an absolute pressure manometer or a wet bulb
vacuum indicator to measure the vacuum. Open the
shutoff valve to the vacuum indicator only when taking a
reading. Leave the valve open for 3 minutes to allow the
indicator vacuum to equalize with the chiller vacuum.
3. Open all isolation valves (if present), if the entire chiller is
to be dehydrated.
4. With the chiller ambient temperature at 15.6°C or higher,
operate the vacuum pump until the manometer reads
-100.61 kPa or a vacuum indicator reads 1.7°C. Operate
the pump an additional 2 hours.
5. Do not apply greater vacuum than 100.96 kPa or go below
0.56°C on the wet bulb vacuum indicator. At this
tempera-ture/pressure, isolated pockets of moisture can turn
into ice. The slow rate of evaporation (sublimination) of
ice at these low temperatures/ pressures greatly increases
dehydration time.
41

42
Pressure on condenser vessel is at refrigerant
saturated conditions (see refrigerant pressuretemperature
tables 5A and 5D)
Cooler pressure reading is 103 kPa or higher
Record pressures
Power up controls to ensure oil heater
is on and oil is hot. Equalizer pressure
between cooler and condenser
No leaks found
Perform leak test
Leaks found
Machines with refrigerant charge
Leak test of 19XR
1 - Attach compound gauge -101-0-3000 kPa to each vessel
2 - Note ambient temperature gauge readings
Pressure on condenser vessel is less than
saturated refrigerant pressure (see refrigerant
pressure-temperature tables 5A and 5D)
Cooler pressure reading is below 103 kPa
Leak suspected
Record pressures
Is either vessel at 0 kPa?
Power up controls to ensure oil heater
is on and oil is hot. Equalizer pressure
between cooler and condenser
Add refrigerant until pressure is
above 241 kPa
Leaks found
Locate and mark
all leak sources
Recover
refrigerant from
vessel
Repair all leaks
No
Perform leak test
No leaks found
Recover
refrigerant from
vessel
Perform standing
vacuum test
Pass
Fail
Yes
Dehydrate vessel if vessel was at
atmospheric pressure or lower
Fig. 25 - 19XR leak detection procedure
Machines with nitrogen holding charge
Pressure reading is less than 103 kPa but
greater than 0 kPa
Leak suspected
Raise pressure to 483 kPa with
nitrogen (if using electronic detector,
add tracer gas now)
Perform leak test using soap bubble
solution, ultrasonics or electronic
detector
No leaks
found
Evacuate vessel
Complete charging machine
Leaks found
Locate and mark
all leak sources
Release the pressure in the vessel
Repair all leaks
Retest only those joints that were
repaired
Pressure is at 103 kPa (factory charge)
Release nitrogen and evacuate
holding charge from vessels
Add refrigerant until pressure is
above 241 kPa
Perform leak test
Leaks found No leaks
found

6. Valve off the vacuum pump, stop the pump, and record
the instrument reading.
7. After a 2-hour wait, take another instrument reading. If
the reading has not changed, dehydration is complete. If
the reading indicates vacuum loss, repeat Steps 4 and 5.
8. If the reading continues to change after several attempts,
perform a leak test up to the maximum 1103 kPa pressure.
Locate and repair the leak, and repeat dehydration.
1. To vacuum pump
2. Mixture of dry ice and methyl alcohol
3. Moisture condenses on cold surface
4. From system
4.5 - Inspect Wiring
Fig. 26 - Dehydration cold trap
WARNING: Do not check voltage supply without proper
equipment and precautions. Serious injury may result. Follow
power company recommendations.
CAUTION: Do not apply any kind of test voltage, even for a
rotation check, if the chiller is under a dehydration vacuum.
Insulation breakdown and serious damage may result.
1. Examine wiring for conformance to job wiring diagrams
and to all applicable electrical codes.
2. On low-voltage compressors (600 V or less) connect voltmeter
across the power wires to the compressor starter and
measure the voltage. Compare this reading with the voltage
rating on the compressor and starter nameplates.
3. Compare the ampere rating on the starter nameplate with
the compressor nameplate. The overload trip amps must
not be more than 108% of the rated load amps.
4. The starter for a centrifugal compressor motor must contain
the components and terminals required for PIC II refrigeration
control. Check certified drawings.
5. Check the voltage to the following components and compare
to the nameplate values: oil pump contact, pumpout
compressor starter, and control box.
6. Be sure that disconnects have been supplied for the oil
pump, control box, and pumpout unit.
7. Check that all electrical equipment and controls are properly
grounded in accordance with job drawings, certified drawings,
and all applicable electrical codes.
8. Make sure that the customer’s contractor has verified
proper operation of the pumps, cooling tower fans, and
associated auxiliary equipment. This includes ensuring
that motors are properly lubricated and have proper electrical
supply and proper rotation.
9. For field-installed starters only, test the chiller compressor
motor and its power lead insulation resistance with a
500-V insulation tester such as a megohmmeter. (Use a
5000-V tester for motors rated over 600 V.) Factorymounted
starters do not require a megohm test.
a. Open the starter main disconnect switch and follow
lockout/tagout rules.
b. With the tester connected to the motor leads, take 10second
and 60-second megohm readings as follows:
6-Lead Motor -Tie all 6 leads together and test between the
lead group and ground. Next tie leads in pairs, 1 and 4, 2
and 5, and 3 and 6. Test between each pair while grounding
the third pair.
3-Lead Motor - Tie terminals 1, 2, and 3 together and test
between the group and ground.
- Divide the 60-second resistance reading by the 10second
reading. The ratio, or polarization index, must
be one or higher. Both the 10- and 60-second
readings must be at least 50 megohms.
- If the readings on a field-installed starter are unsatisfactory,
repeat the test at the motor with the power
leads disconnected. Satisfactory readings in this second
test indicate the fault is in the power leads.
NOTE: Unit-mounted starters do not have to be megohm
tested.
10. Tighten up all wiring connections to the plugs on the ISM,
8-input, and CCM modules.
11. Ensure that the voltage selector switch inside the control
box is switched to the incoming voltage rating.
12. On chillers with free-standing starters, inspect the control
box to ensure that the contractor has fed the wires into the
bottom of the panel. Wiring into the top of the panel can
cause debris to fall into the contactors. Clean and inspect
the contactors if this has occurred.
4.6 - Carrier Comfort Network Interface (see Fig. 21)
The Carrier Comfort Network (CCN) communication bus
wiring is supplied and installed by the electrical contractor. It
consists of shielded, 3-conductor cable with metallic braiding.
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 signal ground pins.
To attach the CCN communication bus wiring, refer to the
certified drawings and wiring diagrams. The wire is inserted
into the CCN communications plug (J1) on the CVC module.
4.7 - Check Starter
CAUTION: BE AWARE that certain automatic start
arrange-ments can engage the starter. Open the disconnect
ahead of the starter in addition to shutting off the chiller or
pump.
Use the instruction and service manual supplied by the starter
manufacturer to verify that the starter has been installed
correctly, to set up and calibrate the starter, and for complete
troubleshooting information.
43

CAUTION: The main disconnect on the starter front panel
may not deenergize all internal circuits. Open all internal and
remote disconnects before servicing the starter.
Whenever a starter safety trip device activates, wait at least 30
seconds before resetting the safety. The microprocessor maintains
its output for 10 seconds to determine the fault mode of failure.
Electronic starters
Check all field wiring connections for tightness, clearance
from moving parts, and correct connection.
The starter is factory-programmed and supplied with a notice
SIEMENS 3ZX 1012-ORW22---. The disconnect is type QF101.
4.8 - Oil Charge
The 19XR compressor holds approximately 18.9 l of oil for
Frame 2 compressors; 30 l of oil for Frame 3 compressors; 38 l of
oil for Frame 4 compressors and 67.8 l for Frame 5 compressors.
The chiller will be shipped with oil in the compressor. When
the sump is full, the oil level should be no higher than the middle
of the upper sight glass, and minimum level is the bottom of the
lower sight glass (Fig. 2). If oil is added, it must meet Carrier’s
specification for centrifugal compressor usage as described in the
Oil Specification section. Charge the oil through the oil charging
valve, located near the bottom of the transmission housing
(Fig. 2). The oil must be pumped from the oil container through
the charging valve due to higher refrigerant pressure. The
pumping device must be able to lift from 0 to 1380 kPa or
above unit pressure. Oil should only be charged or removed
when the chiller is shut down.
The oil cylinder must not be opened until charging begins.
Only use new oil cylinders.
4.9 - Power Up the Controls and Check the Oil Heater
Ensure that an oil level is visible in the compressor before
energizing controls. A circuit breaker in the starter energizes the
oil heater and the control circuit. When first powered, the CVC
should display the default screen within a short period of time.
The oil heater is energized by powering the control circuit. This
should be done several hours before start-up to minimize oilrefrigerant
migration. The oil heater is controlled by the PIC II
and is powered through a contactor in the control box. Starters
contain a separate circuit breaker to power the heater and the
control circuit.
This set up allows the heater to energize when the main motor
circuit breaker is off for service work or extended shutdowns.
The oil heater relay status can be viewed on the Status02 table
on the CVC. Oil sump temperature can be viewed on the CVC
default screen.
4.10 - Check Optional Pumpout System Controls and
Compressor
Controls include an on/off switch, the compressor overloads, an
internal thermostat, a compressor contactor, and a refrigerant
high pressure cutout. The high pressure cutout is factory set to
open at a pressure which depends on the approval code. Check
44
that the water-cooled condenser has been connected. Loosen the
compressor holddown bolts to allow free spring travel. Open
the compressor suction and discharge service valves. Check that
oil is visible in the compressor sight glass. Add oil if necessary.
See Pumpout and Refrigerant Transfer Procedures and Optional
Pumpout System Maintenance sections, for details on transfer
of refrigerant, oil specifications, etc.
4.11 - High Altitude Locations
Recalibration of the pressure transducers will be necessary,
because the chiller was initially calibrated at sea level.
4.12 - Charge Refrigerant into Chiller
CAUTION: The transfer, addition, or removal of refrigerant
in spring isolated chillers may place severe stress on external
piping if springs have not been blocked in both up and down
directions.
The standard 19XR chiller will have the refrigerant already
charged in the vessels. The 19XR may be ordered with a
nitrogen holding charge. Evacuate the entire chiller, and charge
chiller from refrigerant cylinders.
4.13 - 19XR chiller equalization without pumpout unit
WARNING: When equalizing refrigerant pressure on the
19XR chiller after service work or during the initial chiller
start-up, do not use the discharge isolation valve to equalize.
Either the motor cooling isolation valve or charging hose
(connected between pumpout valves on top of cooler and
condenser) is to be used as the equalization valve.
For safety reasons this valve is supplied locked from the
factory. To manipulate the other valves a special tool (key
type) is required.
Manipulation of the valves must always be done by a
qualified person.
To equalize the pressure differential on a refrigerant isolated
19XL chiller, use the TERMINATE LOCKOUT function of the
Control Test in the SERVICE menu. This will help to turn on
pumps and advise the proper procedure. The following procedure
describes how to equalize refrigerant pressure on an isolated
19XR chiller without a pumpout unit:
1. Access TERMINATE LOCKOUT function on the Control
Test.
2. Turn on the chilled water and condenser water pumps to
ensure against freezing.
3. Slowly open the refrigerant cooling isolation valve. The
chiller cooler and condenser pressures will gradually
equalize. This process will take approximately 15 minutes.
4. Once the pressures have equalized, the cooler isolation
valve, the condenser isolation valve, and the hot gas isolation
valve may now be opened.
WARNING: Whenever turning the discharge isolation valve,
be sure to re-attach the valve locking device. This will prevent
the valve from opening or closing during service work or
during chiller operation.

The valve is opened counter-clockwise, and closed clockwise.
4.14 - 19XR chiller equalization with pumpout unit
The following procedure describes how to equalize refrigerant
pressure on an isolated 19XR chiller using the pumpout unit:
1. Access the TERMINATE LOCKOUT mode in the
Control Test.
2. Turn on the chilled water and condenser water pumps to
prevent possible freezing.
3. Open valve 4 on the pumpout unit and open valves 1a and
1b on the chiller cooler and condenser, Fig. 18 and 19.
Slowly open valve 2 on the pumpout unit to equalize the
pressure. This process will take approximately 15 minutes.
4. Once the pressures have equalized, the discharge isolation
valve, cooler isolation valve, optional hot gas bypass isolation
valve, and the refrigerant isolation valve can be opened.
Close valves 1a and 1b, and all pumpout unit valves.
The full refrigerant charge on the 19XR will vary with chiller
components and design conditions, indicated on the job data
specifications. An approximate charge may be found by adding
the condenser charge to the cooler charge listed in Table 7.
Always operate the condenser and chilled water pumps during
charging operations to prevent freeze-ups. Use the Control Test
Terminate Lockout to monitor conditions and start the pumps.
If the chiller has been shipped with a holding charge, the
refrigerant will be added through the refrigerant charging valve
(Fig. 18 and 19, valve 7) or to the pumpout charging connection.
First evacuate the nitrogen holding charge from the chiller
vessels. Charge the refrigerant as a gas until the system pressure
exceeds 141 kPa for HFC-134a. After the chiller is beyond this
pressure the refrigerant should be charged as a liquid until all
the recommended refrigerant charge has been added.
4.15 Trimming refrigerant charge
The 19XR is shipped with the correct charge for the design duty
of the chiller. Trimming the charge can best be accomplished
when design load is available. To trim, check the temperature
difference between leaving chilled water temperature and
cooler refrigerant temperature at full load design conditions. If
necessary, add or remove refrigerant to bring the temperature
difference to design conditions or minimum differential. If the
unit incorporates a sight glass (option) and has a full charge,
bubbling must take place in the upper level of the vessel.
Evaporator size Refrigerant charge (kg)
30 277
31 308
32 340
35 322
36 359
37 391
40 381
41 413
42 440
45 440
46 477
47 508
50 520
51 560
52 589
55 617
56 648
57 667
60 616
61 635
62 653
65 694
66 712
67 725
70 907
71 962
72 1007
75 1039
76 1103
77 1157
80 1007
81 1062
82 1112
85 1156
86 1215
87 1270
45

5 - INITIAL START-UP
5.1 - Preparation
Before starting the chiller, check that the:
1. Power is on to the main starter, oil pump relay, tower fan
starter, oil heater relay, and the chiller control centre.
2. Cooling tower water is at proper level and at or below
design entering temperature.
3. Chiller is charged with refrigerant and all refrigerant and
oil valves are in their proper operating position.
4. Oil is at the proper level in the reservoir sight glasses.
5. Oil reservoir temperature is above 60°C or refrigerant
temperature plus 28°C.
6. Valves in the evaporator and condenser water circuits are
open. NOTE: If pumps are not automatic, make sure water
is circulating properly.
NOTE: If the pumps are not automatic, check that the water
is circulating correctly.
WARNING: Do not permit water or brine that is warmer than
52°C to flow through the cooler or condenser. Refrigerant
overpressure may discharge through the relief devices and
result in the loss of refrigerant charge.
7. 'Control test' screen access
At the control screen press the scroll keys to access the
start-up menu option (Terminate lockout option).
46
Press the selection that permits chiller start-up and answer
'YES' to restart it in operating mode. The unit is locked at
the factory to prevent accidental start-up.
5.2 - Dry Run to Test Start-Up Sequence
1. Disengage the main motor disconnect (QF101 for the
factory-mounted starter) on the starter front panel. This
should only disconnect the motor power. Power to the
controls, oil pump, and starter control circuit should still
be energized.
2. Look at the default screen on the local interface: the Status
message in the upper left-hand corner will read, “Manually
Stopped’’. Press CCN or Local to start. If the chiller controls
do not go into a start mode, go to the Schedule screen and
override the schedule or change the occupied time. Press the
LOCAL softkey to begin the start-up sequences.
3. Check that chilled water and condenser water pumps
energize.
4. Check that the oil pump starts and pressurizes the lubrication
system. After the oil pump has run about 45 seconds,
the starter will be energized and go through its start-up
sequence.
5. Check the main contactor for proper operation.
6. The PIC II will eventually show an alarm for motor amps
not sensed. Reset this alarm and continue with the initial
start-up.
5.3 - Check Rotation
1. Engage the main motor disconnect on the front of the
starter panel. The motor is now ready for rotation check.
2. After the default screen Status message states “Ready for
Start’’ press the LOCAL softkey; start-up checks will be
made by the control.
3. When the starter is energized and the motor begins to
turn, check for clockwise rotation (Fig. 27).
IF ROTATION IS PROPER, allow the compressor to come
up to speed.
IF THE MOTOR ROTATION IS NOT CLOCKWISE (as
viewed through the sight glass), reverse any 2 of the 3 incoming
power leads to the starter and recheck rotation.
CAUTION: Do not check motor rotation during coastdown.
Rotation may have reversed during equalization of vessel
pressures.
ROTATION
Fig. 27 - Rotation diagram
Correct motor rotation is clockwise when viewed through
turbine sight glass.
To check rotation, energize compressor motor momentarily.
Do not let machine develop condenser pressure. Check rotation
immediately.
Allowing condenser pressure to build or checking rotation
while machine coasts down may give a false indication due to
gas pressure equalizing through compressor.
5.4 - Check Oil Pressure and Compressor Stop
1. When the motor is up to full speed, note the differential
oil pressure reading on the CVC default screen. It should
be between 124 to 206 kPa.
2. Press the Stop button and listen for any unusual sounds
from the compressor as it coasts to a stop.
5.5 - To Prevent Accidental Start-Up
A chiller STOP override setting may be entered to prevent accidental
start-up during service or whenever necessary. Access
the MAINSTAT screen and using the NEXT or PREVIOUS
softkeys, highlight the CHILLER START/STOP parameter.
Override the current START value by pressing the SELECT
softkey. Press the STOP softkey followed by the ENTER softkey.
The word SUPVSR! displays on the CVC indicating the
override is in place.
To restart the chiller the STOP override setting must be removed.
Access the MAINSTAT screen and using NEXT or PREVIOUS
softkeys highlight CHILLER START/STOP. The 3 softkeys
that appear represent 3 choices:
START - forces the chiller ON
STOP - forces the chiller OFF
RELEASE - puts the chiller under remote or schedule
control.

To return the chiller to normal control, press the RELEASE
softkey followed by the ENTER softkey. For more information,
see the chapters relating to start-up.
The default screen message line indicates which command is in
effect. Open the disconnects or the high-voltage circuit breakers.
5.6 - Check Chiller Operating Condition
Check to be sure that chiller temperatures, pressures, water
flows, and oil and refrigerant levels indicate that the system is
functioning properly.
5.7 - Instruct the Customer Operator
Check to be sure that the operator(s) understand all operating
and maintenance procedures. Point out the various chiller parts
and explain their function as part of the complete system.
Cooler-Condenser
Float chamber, relief devices, refrigerant charging valve,
temperature sensor locations, pressure transducer locations,
Schrader fittings, waterboxes and tubes, and vents and drains.
Optional pumpout storage tank and pumpout system
Transfer valves and pumpout system, refrigerant charging and
pumpdown procedure, and relief devices.
Motor compressor assembly
Guide vane actuator, transmission, motor cooling system, oil
cooling system, temperature and pressure sensors, oil sight
glasses, integral oil pump, isolatable oil filter, extra oil and motor
temperature sensors, synthetic oil, and compressor serviceability.
Motor compressor lubrication system
Oil pump, cooler filter, oil heater, oil charge and specification,
operating and shutdown oil level, temperature and pressure,
and oil charging connections.
Control system
CCN and CVC start, reset, menu, softkey functions, local
interface operation, occupancy schedule, set points, safety
controls, and auxiliary and optional controls.
Auxiliary equipment
Starters and disconnects, separate electrical sources, pumps,
and cooling tower.
Describe chiller cycles
Refrigerant, motor cooling, lubrication, and oil reclaim.
Review maintenance
Scheduled, routine, and extended shutdowns, importance of a
log sheet, importance of water treatment and tube cleaning, and
importance of maintaining a leak-free chiller.
Safety devices and procedures
Electrical disconnects, relief device inspection, and handling
refrigerant.
Check operator knowledge
Start, stop, and shut-down procedures, safety and operating
controls, refrigerant and oil charging, and job safety.
6 - OPERATING INSTRUCTIONS
6.1 - Operator Duties
1. Become familiar with refrigeration chiller and related
equipment before operating the chiller.
2. Prepare the system for start-up, start and stop the chiller,
and place the system in a shutdown condition.
3. Maintain a log of operating conditions and document any
abnormal readings.
4. Inspect the equipment, make routine adjustments, and
perform a Control Test. Maintain the proper oil and
refrigerant levels.
5. Protect the system from damage during shutdown periods.
6. Maintain the set point, time schedules, and other PIC II
functions.
Prepare the Chiller for Start-Up
Follow the steps described in the Initial Start-Up section.
6.2 - To Start the Chiller
1. Start the water pumps, if they are not automatic.
2. On the CVC default screen, press the LOCAL or CCN
softkey to start the system. If the chiller is in the
OCCUPIED mode and the start timers have expired, the
start sequence will start. Follow the procedure described
in the Start-Up/Shutdown/Recycle section.
6.3 - Check the Running System
After the compressor starts, the operator should monitor the
CVC display and observe the parameters for normal operating
conditions:
1. The oil reservoir temperature should be above 49°C during
shutdown, and above 52°C during compressor operation.
2. The bearing oil temperature accessed on the 'COM-PRESS'
status screen should be 49 to 74°C. If the bearing temperature
reads more than 83°C with the oil pump running, stop
the chiller and determine the cause of the high temperature.
Do not restart the chiller until corrected.
3. The oil level should be visible anywhere in one of the two
sight glasses. Foaming oil is acceptable as long as the oil
pressure and temperature are within limits.
4. The oil pressure should be between 124 to 207 kPa differential,
as seen on the CVC default screen. Typically the
reading will be 124 to 172 kPa at initial start-up.
5. The moisture indicator sight glass on the refrigerant motor
cooling line should indicate refrigerant flow and a dry
condition.
6. The condenser pressure and temperature varies with the
chiller design conditions. Typically the temperature range
will be 15 to 41°C. The condenser entering water temperature
should be controlled below the specified design
entering water temperature to save on compressor kilowatt
requirements.
7. Cooler pressure and temperature also will vary with the
design conditions. Typically the temperature range will be
1 to 8°C.
47

8. The compressor may operate at full capacity for a short
time after the pulldown ramping has ended, even though
the building load is small. The active electrical demand
setting can be overridden to limit the compressor IkW, or
the pulldown rate can be decreased to avoid a high demand
charge for the short period of high demand operation. Pulldown
rate can be based on power output or temperature rate.
It is accessed on the equipment service screen 'RAMP DEM'.
6.4 - To Stop the Chiller
1. The occupancy schedule will start and stop the chiller
automatically once the time schedule is set up.
2. By pressing the STOP button for one second, the alarm
light will blink once to confirm that the button has been
pressed. Then, the compressor will follow the normal shutdown
sequence as described in the Controls section. The
chiller will not restart until the CCN or LOCAL softkey is
pressed. The chiller is now in the 'Off control' mode.
Do not attempt to stop the chiller by opening an isolating switch.
High-intensity arcing may occur. Do not restart the chiller
until the problem is diagnosed and corrected.
6.5 - After Limited Shutdown
No special preparations should be necessary. Follow the regular
preliminary checks and starting procedures.
6.6 - Extended Shutdown
The refrigerant should be transferred into the pumpout storage
tank (if supplied; see Pumpout and Refrigerant Transfer Procedures)
in order to reduce chiller pressure and the possibility of
leaks. Maintain a holding charge of 2.27 to 4.5 kg of refrigerant
or nitrogen to prevent air from leaking into the chiller.
If freezing temperatures are likely to occur in the chiller area,
drain the chilled water, condenser water, and the pumpout
condenser water circuits to avoid freeze-up. Keep the waterbox
drains open.
Leave the oil charge in the chiller with the oil heater and controls
energized to maintain the minimum oil reservoir temperature.
6.7 - After Extended Shutdown
Be sure that the water system drains are closed. It may be
advisable to flush the water circuits to remove any soft rust
which may have formed. This is a good time to clean the tube
vessel and inspect the probe pressure taps and change them, if
necessary.
Check the cooler pressure on the CVC default screen, and compare
to the original holding charge that was left in the chiller. If
(after adjusting for ambient temperature changes) any loss in
pressure is indicated, check for refrigerant leaks. See Check
Chiller Tightness section.
Recharge the chiller by transferring refrigerant from the pumpout
storage tank (if supplied). Follow the Pumpout and Refrigerant
Transfer Procedures section. Observe freeze-up precautions.
48
Carefully make all regular preliminary and running system
checks. Perform a Control Test before start-up. If the compressor
oil level appears abnormally high, the oil may have absorbed
refrigerant. Make sure that the oil temperature is above 60°C or
cooler refrigerant temperature 27°C.
6.8 - Cold Weather Operation
When the entering condenser water drops very low, the
operator should automatically cycle the cooling tower fans off
to keep the temperature up. The PIC II controls have a tower
fan output (terminals 11 and 12 of the ISM).
6.9 - Manual Guide Vane Operation
Manual operation of the guide vanes in order to check control
operation or control of the guide vanes in an emergency operation
is possible by overriding the target guide vane position.
Access the 'COMPRESS' screen on the interface, and highlight
TARGET GUIDE VANE POSITION. To control the position,
enter a percentage of guide vane opening that is desired. Zero
percent is fully closed, 100% is fully open. To release the guide
vanes to AUTOMATIC mode, press the RELEASE softkey.
NOTE: Manual control will increase the guide vanes and
override the pulldown rate during start-up. Motor current
above the electrical demand setting, capacity overrides, and
chilled water below control point will override the manual
target and close the guide vanes. For descriptions of capacity
overrides and set points, see the Capacity Override section
(Controls IOM).
6.10 - Refrigeration Log
A refrigeration log, such as the one shown in Fig. 28, provides
a convenient checklist for routine inspection and maintenance
and provides a continuous record of chiller performance. It is
an aid in scheduling routine maintenance and in diagnosing
chiller problems.
Keep a record of the chiller pressures, temperatures, and liquid
levels on a sheet similar to that shown. Automatic recording of
PIC II data is possible through the use of CCN devices such as
the Data Collection module and a Building Supervisor. Contact
your Carrier representative for more information.

49
Date: ___________________________
Installation site: __________________________ Model No.: _________________ Series No.: __________________ Refrigerant type: __________________
Date - Evaporator Condenser Compressor Operator’s Notes
Time Refrigerant Water Refrigerant Water Bearing temperature initials
Pressure Temperature Pressure Temperature Pressure Temperature Pressure Temperature Oil Motor
(inlet/outlet l/s) (inlet/outlet) (inlet/outlet l/s) (inlet/outlet) Pressure Temperature Level (FLA - current*)
change
* or angle of guide vanes
Notes: Indicate shutdowns on safety controls, repairs made, oil or refrigerant added or removed, air exhausted and water drained from dehydrator. Include amounts.
Fig. 28 - Refrigeration log

7 - MAINTENANCE
7.1 - General maintenance
During the unit operating life the service checks and tests must
be carried out in accordance with applicable national regulations.
If there are no similar criteria in local regulations, the information
on checks during operation in annex C of standard EN 378-2
can be used.
External visual checks: annex A and B of standard EN 378-2.
Corrosion checks: annex D of standard EN 378-2.
These controls must be carried out:
- After an intervention that is likely to affect the resistance
or a change in use or change of high-pressure refrigerant,
or after a shut down of more than two years. Components
that do not comply, must be changed. Test pressures
above the respective component design pressure must not
be applied (annex B and D).
- After repair or significant modifications or significant
system or component extension (annex B)
- After re-installation at another site (annexes A, B and D)
- After repair following a refrigerant leak (annex D). The
frequency of refrigerant leak detection can vary from once
per year for systems with less than 1% leak rate per year
to once a day for systems with a leak rate of 35% per year
or more. The frequency is in proportion with the leak rate.
NOTE 1: High leak rates are not acceptable. The necessary
steps must be taken to eliminate any leak detected.
NOTE 2: Fixed refrigerant detectors are not leak detectors,
as they cannot locate the leak.
7.1.1 - Soldering and welding
Component, piping and connection soldering and welding
operations must be carried out using the correct procedures and
by qualified operators. Pressurised containers must not be
subjected to shocks, nor to large temperature variations during
maintenance and repair operations.
7.1.2 - Refrigerant Properties
HFC-134a is the standard refrigerant for the 19XR chiller. At
normal atmospheric pressure, HFC-134a will boil at -25°C) and
must, therefore, be kept in pressurized containers or storage
tanks. The refrigerant is practically odorless when mixed with air
and is non-combustible at atmospheric pressure. Read standard
EN 378-2 to learn more about safe handling of this refrigerant.
DANGER: HFC-134a will dissolve oil and some non-metallic
materials, dry the skin, and, in heavy concentrations, may displace
enough oxygen to cause asphyxiation. When handling
this refrigerant, protect the hands and eyes and avoid breathing
fumes.
All refrigerant removal and draining operations must be
carried out by a qualified technician and with the correct
material for the unit. Any inappropriate handling can lead to
uncontrolled fluid or pressure leaks.
50
7.1.3 - Adding Refrigerant
Follow the procedures described in Trimming Refrigerant
Charge section.
WARNING: Always use the compressor Pumpdown function
in the Control Test table to turn on the evaporator pump and
lock out the compressor when transferring refrigerant. Liquid
refrigerant may flash into a gas and cause possible freeze-up
when the chiller pressure is below 207 kPa for HFC-134a. Do
not use used refrigerant.
7.1.4 - Removing Refrigerant
If the optional pumpout system is used, the 19XR refrigerant
charge may be transferred to a pumpout storage tank or to the
chiller condenser or cooler vessels. Follow procedures in the
Pumpout and Refrigerant Transfer Procedures section when
removing refrigerant from the storage tank to a chiller vessel.
A valve under the condenser permits refrigerant removal
during the liquid phase.
7.1.5 - Adjusting the Refrigerant Charge
If the addition or removal of refrigerant is required for improved
chiller performance, follow the procedures given under the
Trim Refrigerant Charge section.
7.1.6 - Refrigerant Leak Testing
Because HFC-134a is above atmospheric pressure at room
temperature, leak testing can be performed with refrigerant in
the chiller. Use an electronic leak detector, soap bubble solution,
or ultrasonic leak detector. Be sure that the room is well
ventilated and free from concentration of refrigerant to keep false
readings to a minimum. Before making any necessary repairs
to a leak, transfer all refrigerant from the leaking vessel.
Leak rate
Recommendations are that chillers should be immediately taken
off-line and repaired if the refrigerant leak rate for the entire
chiller is more than 10% of the operating refrigerant charge per
year.
In addition, Carrier recommends that leaks totalling less than the
above rate but more than a rate of 0.5 kg per year should be
repaired during annual maintenance or whenever the refrigerant
is pumped over for other service work.
NOTE: Test after service, repair or major leak
If all refrigerant has been lost or if the chiller has been opened
for service, the chiller or the affected vessels must be pressured
and leak tested. Refer to the Leak Test Chiller section to perform
a leak test.
WARNING: HFC-134a should not be mixed with air or oxygen
and pressurized for leak testing. In general, this refrigerant
should not be present with high concentrations of air or oxygen
above atmospheric pressures, because the mixture can undergo
combustion.
Refrigerant tracer
Use an environmentally acceptable refrigerant as a tracer for
leak test procedures.

To pressurize with dry nitrogen
Another method of leak testing is to pressurize with nitrogen
only and to use a soap bubble solution or an ultrasonic leak
detector to determine if leaks are present. This should only be
done if all refrigerant has been evacuated from the vessel.
1. Connect a copper tube from the pressure regulator on the
cylinder to the refrigerant charging valve.
2. Never apply full cylinder pressure to the pressurizing line.
Follow the listed sequence.
3. Open the charging valve fully.
4. Slowly open the cylinder regulating valve.
5. Observe the pressure gauge on the chiller and close the
regulating valve when the pressure reaches test level. Do
not exceed 965 kPa.
6. Close the charging valve on the chiller. Remove the
copper tube if no longer required.
Repair the leak, retest and apply standing vacuum test
After pressurizing the chiller, test for leaks with an electronic
leak detector, soap bubble solution, or an ultrasonic leak
detector. Bring the chiller back to atmospheric pressure, repair
any leaks found, and retest.
After retesting and finding no leaks, apply a standing vacuum
test, and then dehydrate the chiller. Refer to the Standing
Vacuum Test and Chiller Dehydration in the Before Initial
Start-Up section.
7.1.7 - Checking Guide Vane Linkage
When the chiller is off, the guide vanes are closed and the
actuator mechanism is in the position shown in Fig. 29. If slack
develops in the drive chain, backlash can be eliminated as
follows:
1. With the chiller shut down and the actuator fully closed,
remove the chain guard and loosen the actuator bracket
holddown bolts.
2. Loosen guide vane sprocket adjusting bolts.
3. Pry bracket upwards to remove slack, then retighten the
bracket holddown bolts.
4. Retighten the guide vane sprocket adjusting bolts. Make
sure that the guide vane shaft is rotated fully in the
clockwise direction in order for it to be fully closed.
7.1.8 - Trim Refrigerant Charge
If, to obtain optimal chiller performance, it becomes necessary
to adjust the refrigerant charge, operate the chiller at design load
and then add or remove refrigerant slowly until the difference
between leaving chilled water temperature and the cooler refrigerant
temperature reaches design conditions or becomes a
minimum. Do not overcharge.
Refrigerant may be added either through the storage tank or
directly into the chiller as described in the Charge Refrigerant
into Chiller section.
To remove any excess refrigerant, follow the procedure in
Transfer Refrigerant from Chiller to Pumpout Storage Tank
section, Steps 1a and b.
1. Actuator sprocket
2. Chain guard
3. Guide vane shaft
4. Electronic vane actuator
5. Drive chain
6. Actuator bracket hold-down bolts
7. Guide vane sprocket
8. Guide vane sprocket adjusting bolts
Fig. 29 - Guide vane actuator linkage
7.2 - Weekly maintenance
Check the Lubrication System
Mark the oil level on the reservoir sight glass, and observe the
level each week while the chiller is shut down.
If the level goes below the lower sight glass, check the oil reclaim
system for proper operation. If additional oil is required, add it
through the oil drain charging valve (Fig. 4). A pump is required
for adding oil against refrigerant pressure. The oil charge is
approximately:
Compressor size Oil charge (l)
2 19
3 30
4 38
5 68
The added oil must meet Carrier specifications for the 19XR.
Refer to Changing Oil Filter and Oil Changes section on this
and the next page. Any additional oil that is added should be
logged by noting the amount and date. Any oil that is added
due to oil loss that is not related to service will eventually
return to the sump. It must be removed when the level is high.
51

A 1800-Watt oil heater is controlled by the PIC II to maintain
oil temperature (see the Controls section) when the compressor
is off. The Status02 screen of the local interface displays whether
the heater is energized or not. If the PIC II shows that the heater
is energized, but the sump is not heating up, the power to the oil
heater may be off or the oil level may be too low. Check the oil
level, the oil heater contactor voltage, and oil heater resistance.
The PIC II will not permit compressor start-up if the oil temperature
is too low. The control will continue with start-up only
after the temperature is within limits.
7.3 - Scheduled maintenance
Any work must be done by authorised personnel. Establish a
regular maintenance schedule based on the actual chiller
requirements such as chiller load, run hours, and water quality.
The time intervals listed in this section are offered as guides to
service only.
7.3.1 - Service Ontime
The CVC will display a SERVICE ONTIME value on the
'MAINSTAT' status screen. This value should be reset to zero
by the service person or the operator each time major service
work is completed so that time between service can be viewed.
7.3.2 - Inspect the Control Centre
Maintenance is limited to general cleaning and tightening of
connections. Vacuum the cabinet to eliminate dust build-up. If
the chiller control malfunctions, refer to the Troubleshooting
Guide section for control checks and adjustments.
CAUTION: Be sure power to the control centre is off when
cleaning and tightening connections inside the control centre.
Check Safety and Operating Controls Monthly
To ensure chiller protection, the Control Test Automated Test
should be done at least once per month. See Table 3 (Controls
IOM) for safety control settings (see chapter 'Verification of
the pressure switch calibration').
7.3.3 - Changing Oil Filter
Change the oil filter on a yearly basis or when the chiller is
opened for repairs. The 19XR has an isolatable oil filter so that
the filter may be changed with the refrigerant remaining in the
chiller. Use the following procedure:
1. Make sure that the compressor is off and the disconnect
for the compressor is open.
2. Disconnect the power to the oil pump.
3. Close the oil filter isolation valves (Fig. 4).
4. Connect an oil charging hose from the oil charging valve
(Fig. 4) and place the other end in a clean container suitable
for used oil. The oil drained from the filter housing should
be used as an oil sample and sent to a laboratory for proper
analysis. Do not contaminate this sample.
5. Slowly open the charging valve to drain the oil from the
housing.
52
CAUTION: The oil filter housing is at a high pressure.
Relieve this pressure slowly.
6. Once all oil has been drained, place some rags or absorbent
material under the oil filter housing to catch any drips
once the filter is opened. Remove the 4 bolts from the end
of the filter housing and remove the filter cover.
7. Remove the filter retainer by unscrewing the retainer nut.
The filter may now be removed and disposed of properly.
8. Replace the old filter with a new filter. Install the filter
retainer and tighten down the retainer nut. Install the filter
cover and tighten the 4 bolts.
9. Evacuate the filter housing by placing a vacuum pump on
the charging valve. Follow the normal evacuation procedures.
Shut the charging valve when done and reconnect the
valve so that new oil can be pumped into the filter housing.
Fill with the same amount that was removed, then close
the charging valve.
10. Remove the hose from the charging valve, open the isolation
valves to the filter housing, and turn on the power to
the pump and the motor.
7.3.4 - Oil Specification
If oil is added, it must meet the following Carrier specifications:
Oil Type for units using R-134a
Inhibited polyolester-based synthetic compressor oil formatted
for use with HFC, gear-driven, hermetic compressors
ISO Viscosity Grade 68
The polyolester-based oil (P/N: PP23BZ103) may be ordered
from your local Carrier representative.
Oil Changes
Carrier recommends changing the oil after the first year of operation
and every three years thereafter in addition to an oil analysis.
However, if a continuous oil monitoring system is used and a
yearly oil analysis is performed (Periodic Oil Diagnosis), time
between oil changes can be extended.
To change the oil
1. Transfer the refrigerant into the chiller condenser (for isolatable
vessels) or a pumpout storage tank.
2. Mark the existing oil level.
3. Open the control and oil heater circuit breaker.
4. When the chiller pressure is 34 kPa or less, drain the oil
reservoir by opening the oil charging valve (Fig. 2). Slowly
open the valve against refrigerant pressure (see chapter
'Safety Considerations').
5. Change the oil filter at this time.
6. Change the refrigerant filter at this time.
7. Charge the chiller with oil. Charge until the oil level is
equal to the oil level marked in Step 2. Turn on the power
to the oil heater and let the PIC II warm it up to at least
60°C. Operate the oil pump manually, through the Control
Test, for 2 minutes. The oil level should be full in the lower
sight glass for shutdown conditions. If the oil level is above
1/2 full in the upper sight glass, remove the excess oil.
The oil level should now be equal to the amount shown in
Step 2.

7.3.5 - Refrigerant Filter
A refrigerant filter/drier, located on the refrigerant cooling line
to the motor, should be changed once a year or more often if
filter condition indicates a need for more frequent replacement.
Change the filter by closing the filter isolation valves (Fig. 3)
and slowly opening the flare fittings with a wrench and back-up
wrench to relieve the pressure. A moisture indicator sight glass
is located beyond this filter to indicate the volume and moisture
in the refrigerant. If the moisture indicator indicates moisture,
locate the source of water immediately by performing a thorough
leak check.
7.3.6 - Oil Reclaim Filter
The oil reclaim system has a strainer on the eductor suction line, a
strainer on the discharge pressure line, and a filter on the cooler
scavanging line. Replace the filter once per year or more often
if filter condition indicates a need for more frequent replacement.
Change the filter by closing the filter isolation valves (Fig. 4)
and slowly opening the flare fitting with a wrench and back-up
wrench to relieve the pressure. Change the strainers once every
5 years or whenever the cooler is evacuated of refrigerant.
7.3.7 - Inspect Refrigerant Float System
Perform inspection every 5 years or when the condenser is
opened for service. Transfer the refrigerant into the cooler vessel
or into a pumpout storage tank. Remove the float access cover.
Clean the chamber and valve assembly thoroughly. Be sure that
the valve moves freely. Make sure that all openings are free of
obstructions. Examine the cover gasket and replace if necessary.
See Fig. 30 for a view of the float valve design. For linear float
valve designs, inspect orientation of the float slide pin. It must
be pointed toward the bubbler tube for proper operation.
1. Refrigerant inlet from FLASC chamber
2. Linear float assembly
3. Float screen
4. Bubble line
5. Float cover
6. Refrigerant outlet to cooler
7. Gasket
Fig. 30 - 19XR float valve design
7.3.8 - Inspect Relief Valves and Piping (see chapter 'Safety
considerations')
The relief valves on this chiller protect the system against the
potentially dangerous effects of overpressure. To ensure against
damage to the equipment and possible injury to personnel,
these devices must be kept in peak operating condition.
As a minimum, the following maintenance is required.
1. At least once a year, disconnect the vent piping at the valve
outlet and carefully inspect the valve body and mechanism
for any evidence of internal corrosion or rust, dirt, scale,
leakage, etc.
2. If corrosion or foreign material is found, do not attempt to
repair or recondition. Replace the valve.
3. If the chiller is installed in a corrosive atmosphere or the
relief valves are vented into a corrosive atmosphere, make
valve inspections at more frequent intervals.
7.3.9 - Verification of the pressure switch calibration
Reverse the three-way valve direction, and the standby
pressure switch will start operation.
Remove the first pressure switch and have its calibration
verified by a qualified body - see annex C paragraph C6-
EN378-2.
Once the calibration has been verified, re-install the pressure
switch on the three-way valve and again reverse the valve to
permit operation of the pressostat.
7.3.10 - Compressor Bearing and Gear Maintenance
The key to good bearing and gear maintenance is proper lubrication.
Use the proper grade of oil, maintained at recommended
level, temperature, and pressure. Inspect the lubrication system
regularly and thoroughly.
To inspect the bearings, a complete compressor teardown is
required. Only a trained service technician should remove and
examine the bearings. The cover plate on older compressor
bases was used for factory-test purposes and is not usable for
bearing or gear inspection. The bearings and gears should be
examined on a scheduled basis for signs of wear. The frequency
of examination is determined by the hours of chiller operation,
load conditions during operation, and the condition of the oil
and the lubrication system. Excessive bearing wear can sometimes
be detected through increased vibration or increased
bearing temperature. If either symptom appears, contact an
experienced and responsible service organization for assistance.
7.3.11 - Inspect the Heat Exchanger Tubes
Cooler
Inspect and clean the cooler tubes at the end of the first operating
season. Because these tubes have internal ridges, a rotary-type
tube cleaning system is necessary to fully clean the tubes. Upon
inspection, the tube condition will determine the scheduled frequency
for cleaning and will indicate whether water treatment is
adequate in the chilled water/ brine circuit. Inspect the entering
and leaving chilled water temperature sensors for signs of corrosion
or scale. If a sensor or the probe connections are scaled
or the water flow control probes are corroded, they should be
changed.
53

Verify the flow and speed with the Electronic CATalogue
selection program for the unit.
Condenser
Since this water circuit is usually an open-type system, the tubes
may be subject to contamination and scale. Clean the condenser
tubes with a rotary tube cleaning system at least once per year and
more often if the water is contaminated. Inspect the entering and
leaving condenser water sensors for signs of corrosion or scale.
Replace the sensor if corroded or remove any scale if found.
Verify the flow and speed with the Electronic CATalogue
selection program for the unit.
Higher than normal condenser pressures, together with the
inability to reach full refrigeration load, usually indicate dirty
tubes or air in the chiller. If the refrigeration log indicates a rise
above normal condenser pressures, check the condenser refrigerant
temperature against the leaving condenser water temperature.
If this reading is more than what the design difference is
supposed to be, then the condenser tubes may be dirty or water
flow may be incorrect. Because HFC134-a is a high-pressure
refrigerant, air usually does not enter the chiller.
In certain cases where a zinc anode (option) is used, regularly
check its condition.
During the tube cleaning process, use brushes especially designed to
avoid scraping and scratching the tube wall. Contact your Carrier
representative to obtain these brushes. Do not use wire brushes.
CAUTION: Hard scale may require chemical treatment for
its prevention or removal. Consult a water treatment specialist
for proper treatment.
7.3.12 - Water Leaks
Water is indicated during chiller operation by the refrigerant
moisture indicator (Fig. 2) on the refrigerant motor cooling
line. Water leaks should be repaired immediately (see chapter
'Water treatment').
CAUTION: Chiller must be dehydrated after repair of water
leaks. See Chiller Dehydration section.
Water Treatment
Untreated or improperly treated water may result in corrosion,
scaling, erosion, or algae. The services of a qualified water
treatment specialist should be obtained to develop and monitor
a treatment program.
CAUTION: Water must be within design flow limits, clean, and
treated to ensure proper chiller performance and reduce the
potential of tube damage due to corrosion, scaling, erosion,
and algae. Carrier assumes no responsibility for chiller damage
resulting from untreated or improperly treated water.
7.3.13 - Inspect the Starting Equipment
Before working on any starter, shut off the chiller and open all
disconnects supplying power to the starter.
The disconnect on the starter front panel does not de-energize
all internal circuits. Open all internal and remote disconnects
before servicing the starter. Check the cable tightness.
54
WARNING: Never open isolating switches while equipment is
operating. Electrical arcing can cause serious injury.
Inspect starter contact surfaces for wear or pitting on
mechanical-type starters. Do not sandpaper or file silverplated
contacts. Follow the starter manufacturer’s instructions for
contact replacement, lubrication, spare parts ordering, and other
maintenance requirements.
Periodically vacuum or blow off accumulated debris on the
internal parts with a high-velocity, low-pressure blower. Power
connections on newly installed starters may relax and loosen
after a month of operation. Turn power off and retighten.
Recheck annually thereafter.
CAUTION: Loose power connections can cause voltage
spikes, overheating, malfunctioning, or failures.
7.3.14 - Check Pressure Transducers
Once a year, the pressure transducers should be checked against a
pressure gauge reading. Check all four transducers: the 2 oil
differential pressure transducers, the condenser pressure transducer,
and the cooler pressure transducer, and the water-side
evaporation probes (two on the condenser and two on the
evaporator).
Note the evaporator and condenser pressure readings on the CVC
'HEAT-EX' status screen. Attach an accurate set of refrigeration
gauges to the cooler and condenser Schrader fittings. Compare
the two readings. If there is a difference in readings, the
transducer can be calibrated, as described in the Troubleshooting
Guide section. Oil differential pressure should be zero whenever
the compressor is off.
7.3.15 - Corrosion control
All metallic parts of the unit (chassis, casing panels, control
boxes, heat exchangers etc.) are protected against corrosion by
a coating of powder or liquid paint. To prevent the risk of
blistering corrosion that can appear when moisture penetrates
under the protective coatings, it is necessary to carry out
periodic checks of the coating (paint) condition.

X See view A
Y See view B
Z Thrust
A High speed shaft
2-3-4 See table
1. Thrust
Compressor transmission area
View A - Low speed shaft thrust disk
View B - High speed shaft
Compressor assembly torques
Item Description Torque Nm
1* Oil heater grommet nut 14
2 Motor terminals 68
3 Impeller retaining bolt 60-62
4* Demister bolts 20-26
5 Bull gear retaining bolt 108-115
6* Guide vane shaft seal nut 34
7 Motor terminals (high voltage)
- Insulator 2.7-5.4
- Packing nut 6.8
Legend:
* Not shown
- Brass jam nut 13.6
Nm - Newton metres
Notes:
1. All clearances for cylindrical surfaces are diametrical.
2. Dimensions are with rotor in thrust position.
3. Dimensions shown are in inches.
4. Impeller clearance to shroud: allows 0.024 in. forward movement from thrust
position for Frame 3 compressors; 0.030 in. for Frame 4 compressors.
1. Thrust
2. See note 4
3. Impeller shimming to be determined at assembly
Fig. 31 - Compressor fits and clearances
55

Manufactured by Carrier SA, Montluel, France.
Order No. 11997-76, 06.2002. Supersedes order No.: 11997-76, 11.1999. Printed on Totally Chlorine-Free Paper.
Manufacturer reserves the right to change any product specifications without notice. Printed in the Netherlands