Carrier 19FA Series Installation Instructions Manual
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Carrier 19FA Series Installation Instructions Manual

50/60 hz hermetic centrifugal liquid chillers hfc-134a
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See also: Application Data , User Manual
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and
without incurring obligations.
PC 211
Catalog No. 531-965
Centrifugal 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.
Hermetic Centrifugal Liquid Chillers
®
Installation Instructions
Form 19FA-3SI
Copyright 1995 Carrier Corporation

Safety Considerations

2-95
Replaces: 19FA-2SI
19FA
50/60 Hz
HFC-134a

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Summary of Contents for Carrier 19FA Series

  • Page 1: Safety Considerations

    Catalog No. 531-965 Form 19FA-3SI 2-95 Replaces: 19FA-2SI Copyright 1995 Carrier Corporation Safety Considerations Centrifugal 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.
  • Page 2 DANGER DANGER DO NOT VENT refrigerant relief devices within a building. Outlet from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of American National Standards Institute/American Society of Heating, Refrigeration and Air Conditioning Engineers (ANSI/ASHRAE) 15. The accumulation of refriger- ant in an enclosed space can displace oxygen and cause asphyxiation.
  • Page 3 WARNING WARNING DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all refrigerant (liquid and vapor) has been removed from chiller. Traces of vapor should be dis- placed with dry air or nitrogen and the work area should be well ventilated. Refrig- erant in contact with an open flame produces toxic gases.
  • Page 4 Operation of this equipment with refrigerants other than those cited herein should comply with ANSI/ASHRAE-15 (latest edition). Contact Carrier for further informa- tion on use of this machine with other refrigerants.
  • Page 5 CAUTION CAUTION DO NOT STEP on refrigerant lines. Broken lines can whip about and release refrigerant, causing personal injury. DO NOT climb over a machine. Use platform, catwalk, or staging. Follow safe practices when using ladders. USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move inspection cov- ers or other heavy components.
  • Page 6 CAUTION CAUTION DO NOT LOOSEN a packing gland nut before checking that the nut has a positive thread engagement. PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks, or damage. PROVIDE A DRAIN connection in the vent line near each pressure relief device to prevent a build-up of condensate or rain water.

  • Page 7: Table Of Contents

    Contents List of Tables List of Figures Safety Considerations Introduction General Job Data Equipment Required Installation Receiving the Machine Inspect Shipment Identify Machine Provide Machine Protection Rigging the Machine Rig Machine Assembly Install Machine Supports...
  • Page 8 Install Water Piping to Oil Cooler Attach Water Supply to Pumpout Condenser Install Vent Piping to Relief Devices Make Electrical Connections Connect Control Inputs Connect Control Outputs Connect Free-Standing Field Installed Starter Carrier Comfort Network Interface Install Field Insulation Installation Start-Up Request Checklist...
  • Page 9 Contents List of Tables Table 1A — Rigging and Operating Weights — English (lb) Table 1B — Rigging and Operating Weights — SI (kg) Table 2 — Relief Device Locations Table 3 — Insulation Areas...
  • Page 10 Figure 11 — Piping Flow Data (Condenser, NIH Waterboxes) Figure 12 — Water Piping, Oil Cooler to Chilled Water Circuit (Typical) Figure 13 — Pumpout Unit Figure 14 — Typical 19FA Relief Valve Tree for Storage Vessel Figure 15 — Compressor Terminal Arrangement 18-Lead, Rear Inlet...
  • Page 11 Figure 19 — Oil Heater and Control Power Wiring Figure 20 — Pumpout Unit Controls Figure 21 — Pumpout Unit Wiring Schematic Figure 22 — Carrier Comfort Network Communication Bus Wiring Figure 23 — COMM1 CCN Communication Wiring for Multiple Chillers (Typical) Figure 24 —...

  • Page 12: Introduction

    Introduction General The 19FA machine is factory assembled, wired, and leak tested. Installation (not by Carrier) consists primarily of establishing water and electrical services to the machine. The rigging, installation, field wiring, field piping, and insulation are the responsibility of the contractor and/or customer.

  • Page 13: Equipment Required

    Equipment Required • mechanic’s tools (refrigeration) • volt-ohmmeter and clamp-on ammeter • leak detector (halide or electronic) • absolute pressure manometer or wet-bulb vacuum indicator • portable vacuum pumps...

  • Page 14: Installation

    CAUTION CAUTION Do not open any valves or loosen any connections. The 19FA machine may be shipped with the entire refrigerant charge in the storage tank and a small refrig- erant holding charge in the cooler and condenser. Some machines may be shipped with a nitrogen holding charge in the machine and the refrigerant shipped separately.

  • Page 15: Identify Machine

    2). Check this information against shipping papers and job data. Click here for Figure 1 — Model Number Identification Click here for Figure 2 — Typical 19FA Installation (1400-2200 Tons [4922-7735 kW]) Provide Machine Protection Protect machine and starter from construction dirt and moisture. Keep protective shipping covers in place until machine is ready for installation.

  • Page 16: Rigging The Machine

    Follow the same procedure with the pumpout unit condenser, if supplied. Rigging the Machine The 19FA machine is rigged as an entire assembly. Rig Machine Assembly See rigging instructions on label attached to machine. Refer to...

  • Page 17: Install Machine Supports

    Click here for Figure 4 — 19FA Dimensions Install Machine Supports The 19FA machines are typically placed directly on a level floor and do not require isolation equipment. Check job data for specific information. The standard contact surfaces for floor...
  • Page 18 At the time of installation, the 19FA machine has refrigerant in excess of 2000 lb (90 kg) in the integral storage tank. This refrigerant is redistributed throughout the machine at initial start- up.

  • Page 19: Connect Piping

    Connect Piping Install Water Piping to Heat Exchangers Install piping using job data, piping drawings, and the procedures outlined below. A typical piping installation is shown in Figure CAUTION CAUTION Factory-supplied insulation is not flammable but can be damaged by welding sparks and open flame.
  • Page 20 2. Provide openings in water piping for required pressure gages and thermometers. For thorough mixing and temperature stabilization, wells in the leaving water pipe should extend inside pipe at least 2 in. (50 mm). 3. Install air vents at all high points in piping to remove air and prevent water hammer. 4.

  • Page 21: Install Water Piping To Oil Cooler

    Click here for Figure 7 — Typical Nozzle Piping Click here for Figure 8 — Piping Flow Data (Cooler, Marine Waterboxes) Click here for Figure 9 — Piping Flow Data (Cooler, NIH Waterboxes) Click here for Figure 10 — Piping Flow Data (Condenser, Marine Waterboxes) Click here for Figure 11 —...
  • Page 22 City water should be piped to an open sight drain. If water from the machine chilled water circuit is used for oil cooling, it should enter the oil cooler inlet from the entering water line of the machine cooler. See Figure 12.

  • Page 23: Attach Water Supply To Pumpout Condenser

    See Figure Click here for Figure 13 — Pumpout Unit Install Vent Piping to Relief Devices The 19FA chiller is factory equipped with relief devices on the cooler and storage vessels. Refer to Figure 2 Table 2 for size and location of relief devices.
  • Page 24 DANGER DANGER Refrigerant discharged into confined spaces can displace oxygen and cause asphyxiation. 1. If relief devices piping is manifolded, the cross-sectional area of the relief pipe must at least equal the sum of the areas required for individual relief pipes. 2.

  • Page 25: Make Electrical Connections

    Make Electrical Connections Field wiring must be installed in accordance with job wiring diagrams and all applicable electrical codes. CAUTION CAUTION Do not run 120-v wiring into the control center. The control center should only be used for additional extra low-voltage wiring (50 v maximum). Wiring information in this publication (Figure Figure...

  • Page 26: Connect Control Inputs

    Wiring may also 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 center as indicated in...
  • Page 27 For the purposes of illustration, the terminal insulation has been omitted. 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. Insulate Motor Terminals and Lead Wire Ends Insulate compressor motor terminals, lead wire ends, and electrical wires to prevent moisture condensation and electrical arcing.
  • Page 28 Click here for Figure 16 — Compressor Terminal Arrangement 18-Lead, Top Inlet Click here for Figure 17 — Compressor Terminal Arrangement 18-Lead, Side Inlet High Voltage Units High-voltage units require special terminal preparation. Follow local electrical codes for high- voltage installation. Vinyl tape is not acceptable; a high voltage terminal methods must be used. Connect Power Wires to Oil Pump Starter Figure 18.
  • Page 29 Connect Power Wires to Oil Heater Contactor Connect power wiring to oil heater contactor using a separate power source and fused disconnect. Refer to Figure 19 and wiring label on the machine power panel. Connect Wiring from Starter to Power Panel Connect control wiring from main motor starter to the machine power panel.
  • Page 30 Click here for Figure 20 — Pumpout Unit Controls Click here for Figure 21 — Pumpout Unit Wiring Schematic...

  • Page 31: Carrier Comfort Network Interface

    Carrier Comfort Network Interface The Carrier Comfort Network (CCN) communication bus wiring is supplied and installed by the electrical contractor. It consists of shielded, 3-conductor cable with drain wire. The system elements are connected to the communication bus in a daisy chain arrangement.
  • Page 32 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: CCN Bus Conductor Signal Type COMM1 Plug Pin No. Insulation Color Ground White...
  • Page 33 To connect the 19FA chiller to the network, proceed as follows (Figure 23): 1. Cut power to the Product Integrated Control (PIC) center. 2. Remove the COMM1 plug from the processor module. 3. Cut a CCN wire and strip the ends of the RED, WHITE, and BLACK conductors.

  • Page 34: Install Field Insulation

    Click here for Figure 23 — COMM1 CCN Communication Wiring for Multiple Chillers (Typical) Click here for Figure 24 — Typical 19FA With Free-Standing Starter Click here for Figure 25 — Field Wiring (Low Voltage Motors) of PIC (Product Inte-...
  • Page 35 Field insulation of other small lines and fittings may be required. If system conditions lead to condensation, the condenser and storage tank may require field supplied and installed insulation. Click here for Table 3 — Insulation Areas Click here for Figure 26 — 19FA Insulation Area...
  • Page 36 Table 1A — Rigging and Operating Weights — English (lb) Heat Exchanger Combinations 6032 6032L Condenser 22,000 28,000 Cooler 31,000 31,000 Economizer 1,900 1,900 Steel Base (includes Storage Tank) 11,000 11,000 Compressor 6,000 6,000 Motor 5,000 5,000 Pumpout Suction Elbow Miscellaneous Piping Control Center Total Rigging Weight...
  • Page 37 Table 1B — Rigging and Operating Weights — SI (kg) Heat Exchanger Combinations 6032 6032L Condenser 9,979 12,701 Cooler 14,061 14,061 Economizer Steel Base (includes Storage Tank) 4,990 4,990 Compressor 2,721 2,721 Motor 2,268 2,268 Pumpout Suction Elbow Miscellaneous Piping Control Center Total Rigging Weight 35,584...
  • Page 38 Table 2 — Relief Device Locations Relief Valve Outlet Size Location Quantity 1 1/4-in. NPT Female Connector Cooler 1 1/4-in. NPT Female Connector Storage Vessel 3/8-in. Male Flare Optional Pumpout Unit...
  • Page 39 Table 3 — Insulation Areas Flash Compressors Cooler* Pass Total Economizer† Suction Housing Arrange- ment 52.6 48.6 †Includes low side float chamber and shell.

  • Page 40: Figure 1 - Model Number Identification

    Figure 1 — Model Number Identification...

  • Page 41: Figure 2 - Typical 19Fa Installation (1400-2200 Tons [4922-7735 Kw])

    Figure 2 — Typical 19FA Installation (1400-2200 Tons [4922-7735 kW])

  • Page 42: Figure 3 - Machine Rigging Guide

    Indicates center of gravity. Figure 3 — Machine Rigging Guide...

  • Page 43: Figure 4 - 19Fa Dimensions

    1105 Motor EA-EE 2 - 2 3/4 4 - 1 1/4 1251 Nozzle Sizes (in.) Nozzle Cooler Passes Condenser Passes Type Marine Condenser Tube Pull C (Length) Condenser Size ft-in. 12-3 3734 17-1 1/2 5220 Figure 4 — 19FA Dimensions...

  • Page 44: Figure 5 - Machine Footprint

    Figure 5 — Machine Footprint...

  • Page 45: Figure 6 - Machine Contact Surfaces With Anchor Bolts

    Figure 6 — Machine Contact Surfaces with Anchor Bolts...

  • Page 46: Figure 7 - Typical Nozzle Piping

    †Locate flow switch between the waterbox cover and the first water isolation valve. Figure 7 — Typical Nozzle Piping...

  • Page 47: Figure 8 - Piping Flow Data (Cooler, Marine Waterboxes)

    Nozzle Arrangements Cooler Marine Waterboxes Cooler Nozzle No. Cooler Nozzle No. No. of Passes No. of Passes Legend ANSI — American National Standards Institute — Raised Face Figure 8 — Piping Flow Data (Cooler, Marine Waterboxes)

  • Page 48: Figure 9 - Piping Flow Data (Cooler, Nih Waterboxes)

    Cooler, NIH Waterboxes Cooler Nozzle No. No. of Passes Figure 9 — Piping Flow Data (Cooler, NIH Waterboxes)

  • Page 49: Figure 10 - Piping Flow Data (Condenser, Marine Waterboxes)

    Condenser Nozzle No. No. of Pass Legend ANSI — American National Standards Institute RF — Raised Face CAUTION CAUTION When the condenser is not a 1- pass arrangement and both the cooler and condenser have marine waterboxes, the overall height of the unit may need to be increased to obtain adequate piping clearances.
  • Page 50 Cooler Nozzle No. No. of Passes Figure 11 — Piping Flow Data (Condenser, NIH Waterboxes)

  • Page 51: Figure 12 - Water Piping, Oil Cooler To Chilled Water Circuit (Typical)

    Figure 12 — Water Piping, Oil Cooler to Chilled Water Circuit (Typical)

  • Page 52: Figure 13 - Pumpout Unit

    Figure 13 — Pumpout Unit...

  • Page 53: Figure 14 - Typical 19Fa Relief Valve Tree For Storage Vessel

    Figure 14 — Typical 19FA Relief Valve Tree for Storage Vessel...

  • Page 54: Figure 15 - Compressor Terminal Arrangement 18-Lead, Rear Inlet

    Figure 15 — Compressor Terminal Arrangement 18-Lead, Rear Inlet...
  • Page 55 Figure 16 — Compressor Terminal Arrangement 18-Lead, Top Inlet...
  • Page 56 Figure 17 — Compressor Terminal Arrangement 18-Lead, Side Inlet...
  • Page 57 Figure 18 — Oil Pump Wiring...
  • Page 58 Figure 19 — Oil Heater and Control Power Wiring...
  • Page 59 Figure 20 — Pumpout Unit Controls...
  • Page 60 Figure 21 — Pumpout Unit Wiring Schematic...
  • Page 61 Figure 22 — Carrier Comfort Network Communication Bus Wiring...
  • Page 62 Figure 23 — COMM1 CCN Communication Wiring For Multiple Chillers (Typical)
  • Page 63 Figure 24 — Typical 19FA With Free-Standing Starter...
  • Page 64 Figure 25 — Field Wiring (Low Voltage Motors) of PIC (Product Integrated Control) Free-Standing Starter...
  • Page 65 Figure 26 — 19FA Insulation...

  • Page 66: Installation Start-Up Request Checklist

    Other 9. The motor starter has not been supplied by Carrier. It has been installed according to the manufacturer’s instructions. 10. The motor starter has not been supplied by Carrier and it has been checked for proper operation. COMMENTS: CL-1...
  • Page 67 Concerns about the installation/request for additional assistance: I am aware that the start-up time for a Carrier chiller can take between 2 and 6 days depending on the model of the machine and the options and accessories used with it.

This manual is also suitable for:

Hfc-134a

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