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.
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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.
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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.
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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.
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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.
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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.
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...
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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...
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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...
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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...
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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 —...
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.
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.
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.
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...
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...
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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.
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.
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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.
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 —...
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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.
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.
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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.
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...
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...
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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.
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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.
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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.
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Click here for Figure 20 — Pumpout Unit Controls Click here for Figure 21 — Pumpout Unit Wiring Schematic...
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.
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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...
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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.
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-...
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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...
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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...
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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...
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.
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Cooler Nozzle No. No. of Passes Figure 11 — Piping Flow Data (Condenser, NIH Waterboxes)
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...
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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.