Carrier 19FA Liquid Chiller Installation Instructions
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19FA
50/60 Hz
Hermetic Centrifugal Liquid Chillers
HFC-134a
®
Installation Instructions
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 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.
Be sure you understand and follow the procedures and safety precautions contained in the machine instructions, as well as those listed in this guide.
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 refrigerant in an enclosed space can displace oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/ASHRAE 15, especially for enclosed and low overhead spaces. Inhalation of high concentrations of vapor is harmful and may cause heart irregularities, unconsciousness, or death. Intentional misuse can be fatal. Vapor is heavier than air and reduces the amount of oxygen available for breathing. Product causes eye and skin irritation. Decomposition products are hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a machine for any purpose.
Oxygen gas reacts violently with oil, grease, and other common substances.
DO NOT USE air to leak test. Use only refrigerant or dry nitrogen.
NEVER EXCEED specified test pressures. VERIFY the allowable test pressure by checking the instruction literature and the design pressures on the equipment nameplate.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed and functioning before operating any machine.
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 displaced with dry air or nitrogen and the work area should be well ventilated. Refrigerant in contact with an open flame produces toxic gases.
DO NOT USE eyebolts or eyebolt holes to rig machine sections or the entire assembly.
DO NOT work on high-voltage equipment unless you are a qualified electrician.
DO NOT WORK ON electrical components, including control panels, switches, starters, or oil heater until you are sure ALL POWER IS OFF and no residual voltage can leak from capacitors or solid-state components.
LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTER-
RUPTED, confirm that all circuits are deenergized before resuming work.
DO NOT siphon refrigerant.
AVOID SPILLING liquid refrigerant on skin or getting it into the eyes. USE SAFETY
GOGGLES. Wash any spills from the skin with soap and water. If liquid refrigerant enters the eyes, IMMEDIATELY FLUSH EYES with water and consult a physician.
NEVER APPLY an open flame or live steam to a refrigerant cylinder. Dangerous over pressure can result. When it is necessary to heat refrigerant, use only warm
(110 F [43 C]) water.
WARNING
!
WARNING
DO NOT REUSE disposable (nonreturnable) cylinders or attempt to refill them. It is DANGEROUS AND ILLEGAL. When cylinder is emptied, evacuate remaining gas pressure, loosen the collar, and unscrew and discard the valve stem. DO NOT
INCINERATE.
CHECK THE REFRIGERANT TYPE before adding refrigerant to the machine. The introduction of the wrong refrigerant can cause machine damage or malfunction.
Operation of this equipment with refrigerants other than those cited herein should comply with ANSI/ASHRAE-15 (latest edition). Contact Carrier for further information on use of this machine with other refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while machine is under pressure or while machine is running. Be sure pressure is at 0 psig (0 kPa) before breaking any refrigerant connection.
CAREFULLY INSPECT all relief valves, rupture discs, and other relief devices AT
LEAST ONCE A YEAR. If machine operates in a corrosive atmosphere, inspect the devices at more frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief valve when corrosion or build-up of foreign material (rust, dirt, scale, etc.) is found within the valve body or mechanism. Replace the valve.
DO NOT install relief devices in series or backwards.
USE CARE when working near or in line with a compressed spring. Sudden release of the spring can cause it and objects in its path to act as projectiles.
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 covers or other heavy components. Even if components are light, use mechanical equipment when there is a risk of slipping or losing your balance.
BE AWARE that certain automatic start arrangements CAN ENGAGE THE
STARTER, TOWER FAN, OR PUMPS. Open the disconnect ahead of the starter, tower fan, and pumps. Shut off the machine or pump before servicing equipment.
USE only repaired or replacement parts that meet the code requirements of the original equipment.
DO NOT VENT OR DRAIN waterboxes containing industrial brines, liquid, gases, or semisolids without the permission of your process control group.
DO NOT LOOSEN waterbox cover bolts until the waterbox has been completely drained.
DOUBLE-CHECK that coupling nut wrenches, dial indicators, or other items have been removed before rotating any shafts.
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
Installation
Contents
Install Water Piping to Heat Exchangers
Install Water Piping to Oil Cooler
Attach Water Supply to Pumpout Condenser
Install Vent Piping to Relief Devices
Connect Free-Standing Field Installed Starter
Carrier Comfort Network Interface
Installation Start-Up Request Checklist
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
Contents
List of Figures
Figure 1 — Model Number Identification
Figure 2 — Typical 19FA Installation (1400-2200 Tons
Figure 3 — Machine Rigging Guide
Figure 6 — Machine Contact Surfaces with Anchor Bolts
Figure 7 — Typical Nozzle Piping
Figure 8 — Piping Flow Data (Cooler, Marine Waterboxes)
Figure 9 — Piping Flow Data (Cooler, NIH Waterboxes)
Figure 10 — Piping Flow Data (Condenser, Marine Waterboxes)
Figure 11 — Piping Flow Data (Condenser, NIH Waterboxes)
Figure 12 — Water Piping, Oil Cooler to Chilled Water Circuit (Typical)
Figure 14 — Typical 19FA Relief Valve Tree for Storage Vessel
Figure 15 — Compressor Terminal Arrangement 18-Lead, Rear Inlet
Contents
Figure 16 — Compressor Terminal Arrangement 18-Lead, Top Inlet
Figure 17 — Compressor Terminal Arrangement 18-Lead, Side Inlet
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
Figure 24 — Typical 19FA With Free-Standing Starter
Figure 25 — Field Wiring (Low Voltage Motors) of
PIC (Product Integrated Control) Free-Standing Starter
Figure 26 — 19FA Insulation Area
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. Carrier has no installation responsibilities for the equipment.
Job Data
Necessary information consists of:
• job contract or specifications
• machine location prints
• rigging information
• piping prints and details
• field wiring drawings
• starter manufacturer's installation details
• Carrier certified drawings
Equipment Required
• mechanic’s tools (refrigeration)
• volt-ohmmeter and clamp-on ammeter
• leak detector (halide or electronic)
• absolute pressure manometer or wet-bulb vacuum indicator
• portable vacuum pumps
Installation
Receiving the Machine
Inspect Shipment
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 refrigerant 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.
1. Inspect for shipping damage while machine is still on shipping conveyance. If machine appears to be damaged or has been torn loose from its anchorage, have it examined by transportation inspectors before removal. Forward claim papers directly to transportation company. Manufacturer is not responsible for any damage incurred in transit.
2. Check all items against shipping list. Immediately notify the nearest Carrier representative if any item is missing.
3. To prevent loss or damage, leave all parts in original packages until beginning installation.
All openings are closed with covers or plugs to prevent dirt and debris from entering
machine components during shipping. A full operating oil charge is placed in the oil sump before shipment.
Identify Machine
The machine model number, serial number, and heat exchanger sizes are stamped on the
machine identification nameplate ( Figure 1
and
Figure 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
Provide Machine Protection
Protect machine and starter from construction dirt and moisture. Keep protective shipping covers in place until machine is ready for installation.
If machine is exposed to freezing temperatures after water circuits have been installed, open waterbox drains and remove all water from cooler and condenser. Leave drains open until system is filled.
Drain all water from oil cooler coil. See Figure 2 . Disconnect water supply line, if already
installed. Remove the drain plug on the waterbox covers and use compressed air to remove any water from the oil cooler coil. 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 Figure 3
and
and Table 1B . Lift machine only from the 4 points indicated in rigging guide. Each
lifting cable or chain must be capable of supporting the entire weight of the machine.
A spreader bar may be used to reduce chain height.
WARNING
!
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
Note: These weights are broken down into component sections. For the complete machine weight, add all component sections and refrigerant charge together. See
for machine component weights.
Click here for Figure 3 — Machine Rigging Guide
Click here for Table 1A — Rigging and Operating Weights — English (lb)
Click here for Table 1B — Rigging and Operating Weights — SI (kg)
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
mounting are shown in Figure 5
When isolation pads are specified by the customer, 7 shear flex pads are shipped with the machine and strapped to the cooler shell. These pads are placed under the machine base as
and Figure 6 . If desired, the base may be anchored through four 1 1/2 in.
(38 mm) diameter holes located on the machine base assembly that provide for optional, customer-supplied anchor bolts.
Springs are shipped separately on machines ordered with spring isolation. Specific details on spring mounting and machine weight distribution should be obtained from your individual job data.
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. To avoid damage to machine and piping, spring isolators must remain blocked until machine is started.
Click here for Figure 5 — Machine Footprint
Click here for Figure 6 — Machine Contact Surfaces with Anchor Bolts
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 7 .
CAUTION
!
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
!
CAUTION
Remove chilled and condenser water temperature sensors before welding con-
necting piping to water nozzles. Refer to
. Replace sensors 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 since access will be blocked.
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. Install pipe hangers where needed. Make sure no weight or stress is placed on waterbox nozzles or flanges.
5. Water flow direction must be as specified in Figure 7 ,
and
Note: On 2-pass machines, entering water is always the lower of the 2 nozzles. Leaving water is always the upper nozzle for cooler or condenser.
6. Water flow switches must be of vapor-tight construction and must be installed on top of pipe in a horizontal run and at least 5 pipe diameters from any bend.
7. Install waterbox vent and drain piping in accordance with individual job data. All connections are 3/4-in. FPT.
8. Install waterbox drain plugs in the unused waterbox drains and vent openings.
9. Install optional pumpout system or pumpout system and storage tank.
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 — Piping Flow Data (Condenser, NIH Waterboxes)
Install Water Piping To Oil Cooler
Water supply may be either city water or chilled water. See Figure 12 .
City water must be clean and noncorrosive. Water-side erosion or corrosion of the oil cooler coil may lead to extensive machine damage not covered by the standard warranty.
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 . Water leaving the
oil cooler should connect to the leaving water line of the machine cooler to a point downstream from the chilled water sensor, so that oil cooler leaving water temperature does not affect the
sensor readings. See Figure 12 .
Locate the oil cooler leaving water connection at some distance from any chilled water temperature indicator. On single-pass machines, water leaving the oil cooler should be connected into the suction side of the chilled water pump so that adequate pressure drop is assured for oil cooling.
The nominal conditions for oil cooler water flow are:
Flow rate . . . . . . . . . . . . . . . . . . . 30 gpm (114 L/s)
Leaving temperature (max) . . . . . 85 F to 100 F (29 to 39 C)
Pressure drop at oil cooler . . . . . . 10.5 ft (3.2 m)
Max differential pressure across
closed solenoid valve . . . . . . . . . 150 psid (1029 kPa)
The oil cooler water connections at the plug valve are 1-in. FPT.
Click here for Figure 12 — Water Piping, Oil Cooler to Chilled Water Circuit
Attach Water Supply to Pumpout Condenser
Obtain water from the source (usually city water) specified in the job data. Attach water supply and return lines to 1/2-in. FPT connections at end of pumpout condenser. Shut-off valves or other controls are field supplied. Water must be clean and noncorrosive. Pipe the leaving water to an open sight drain and provide for water drainage during extended shutdown. See
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.
and
Table 2 for size and location of relief devices. Vent relief devices to the
outdoors in accordance with ASHRAE 15, latest edition, and all other applicable codes. To ensure relief valve serviceability of the storage vessel and as required in ASHRAE 15, latest
edition, 3-way valves and redundant relief valves are installed. See Figure 14 . Only one half of
the total number of relief valves listed in Table 2 are in service at any time.
Click here for Figure 14 — Typical 19FA Relief Valve Tree for Storage Vessel
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. 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.
Click here for Table 2 — Relief Device Locations
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 15
,
and Figure 25 ) are for reference only and
are not intended for use during actual installation; follow job specific wiring diagrams.
WARNING
!
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
Connect the control input wiring from the chilled and condenser water flow switches to the starter terminal strip. Wiring may also be specified for a spare safety switch, and a remote start/stop contact can be wired to the starter terminal strip. Additional spare sensors and
Carrier Comfort Network modules may be specified as well. These are wired to the machine
control center as indicated in Figure 22
Connect Control Outputs
Connect auxiliary equipment, chilled and condenser water pumps, and spare alarms as required and indicated on job wiring drawings.
Connect Free-Standing, Field Installed Starter
Assemble and install compressor terminal box in desired orientation, and cut necessary
conduit openings in conduit support plates. See Figure 15 ,
Attach power leads to compressor terminals in accordance with job wiring drawings, observing caution label in terminal box. Use only copper conductors. The motor must be grounded in accordance with NEC (National Electrical Code), applicable local codes, and job wiring diagrams. Installer is responsible for any damage caused by improper wiring between starter and compressor motor.
illustrate 3 methods for assembling multiple lead wires within the compressor terminal box. 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. 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.
1. Insulate each terminal by wrapping with one layer of insulation putty.
2. Overwrap putty with 4 layers of vinyl tape.
Click here for Figure 15 — Compressor Terminal Arrangement 18-Lead, Rear Inlet
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 highvoltage installation. Vinyl tape is not acceptable; a high voltage terminal methods must be used.
Connect Power Wires to Oil Pump Starter
Connect power wires to oil pump starter mounted in machine power panel.
Use separate fused disconnect or circuit breaker as shown on job wiring diagrams and
Figure 25 . Check that power supply voltage agrees with oil pump voltage. Follow correct
phasing for proper motor rotation.
CAUTION
!
CAUTION
Do not punch holes or drill into the top surface of the power panel. Knockouts are provided in the bottom of the power panel for wiring connections.
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. All control wiring must use shielded cable. Also, connect the communications cable. Refer to the job wiring diagrams for cable type and cable number. Make sure the control circuit is grounded in accordance with applicable electrical codes and instructions on machine control wiring label.
Click here for Figure 18 — Oil Pump Wiring
Click here for Figure 19 — Oil Heater and Control Power Wiring
Connect Pumpout Unit Wiring
Connect power wires to contactor in pumpout control box as shown on job wiring drawings.
Check pumpout compressor nameplate for proper voltage. Figure 20
typical pumpout controls and wiring. Use a separate disconnect for the pumpout unit.
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. 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
Figure 22 for location of the CCN network connector (COMM1) on the processor module.
Note: Conductors and drain wire must be 20 AWG (American Wire Gage) minimum stranded, tinned copper. Individual conductors must be insulated with PVC, PVC/nylon, vinyl,
Teflon, or polyethylene. An aluminum/polyester 100% foil shield and an outer jacket of
PVC, PVC/nylon, chrome vinyl, or Teflon with a minimum operating temperature range of
-4 F to 140 F (-20 C to 60 C) is required. See table below for cables that meet the requirements.
Manufacturer
Alpha
American
Belden
Columbia
Cable No.
2413 or 5463
A22503
8772
02525
When connecting the CCN communication bus to a system element, a color code system for the entire network is recommended to simplify installation and checkout. The following color code is recommended:
Signal Type
+
Ground
-
CCN Bus Conductor
Insulation Color
Red
White
Black
COMM1 Plug Pin No.
1
2
3
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 Figure 23 . 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 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.
4. Using a wirenut, connect the drain wires together.
5. Insert and secure the RED wire to Terminal 1 of the COMM1 plug.
6. Insert and secure the WHITE wire to Terminal 2 of the COMM1 plug.
7. Insert and secure the BLACK wire to Terminal 3 of the COMM1 plug.
8. 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.
Click here for Figure 22 — Carrier Comfort Network Communication Bus Wiring
Click here for Figure 23 — COMM1 CCN Communication Wiring for Multiple
Click here for Figure 24 — Typical 19FA With Free-Standing Starter
Install Field Insulation
Apply insulation as specified in the job data and Figure 26 . If the pressure gage reading
(above) indicates a significant loss of the 10 psig (68 kPa) holding charge, the machine may require dehydration. Do not apply insulation before dehydration.
Standard factory insulation covers the compressor motor shell, motor end cover, motor cooling line, and refrigerant drain from the compressor. Field coverage may include the compressor suction housing and suction elbow, flash economizer, and the cooler. The approximate square footage required for insulating this area is given in
insulating the cooler waterboxes and economizer, apply insulation so that all covers may be removed for service access. Do not cover nameplates.
Cooler and condenser waterboxes are not factory insulated. Insulation must be field supplied and installed at the jobsite by the installation contractor. 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
Table 1A — Rigging and Operating Weights — English (lb)
Heat Exchanger Combinations
Condenser
Cooler
Economizer
Steel Base (includes Storage Tank)
Compressor
Motor
Pumpout
Suction Elbow
Miscellaneous Piping
Control Center
Total Rigging Weight
Refrigerant Charge (HFC-134a)
Cooler Water
Condenser Water
Total Operating Weight
6032
750
100
78,450
5,050
4,250*
3,100†
90,850
22,000
31,000
1,900
11,000
6,000
5,000
200
500
6032L
750
100
84,450
5,850
4,250*
4,300†
98,850
28,000
31,000
1,900
11,000
6,000
5,000
200
500
Legend
MWB — Marine Waterbox
NIH — Nozzle-In-Head Waterbox
*Based on 2 pass NIH waterboxes. If 2 pass MWB are used, add an additional 2,250 lb (1021 kg).
†Based on 2 pass NIH waterboxes. If 2 pass MWB are used, add an additional 2,100 lb (953 kg).
Table 1B — Rigging and Operating Weights — SI (kg)
Heat Exchanger Combinations 6032 6032L
Condenser
9,979 12,701
Cooler 14,061 14,061
Economizer 862 862
Steel Base (includes Storage Tank) 4,990 4,990
Compressor 2,721 2,721
Motor 2,268 2,268
Pumpout 91 91
Suction Elbow 227 227
Miscellaneous Piping 340 340
Control Center 45 45
Total Rigging Weight 35,584 38,306
Refrigerant Charge (HFC-134a) 2,291 2,654
Cooler Water 1,928* 1,938*
Condenser Water 1,406† 1,950†
Total Operating Weight 41,209 44,838
Legend
MWB — Marine Waterbox
NIH — Nozzle-In-Head Waterbox
*Based on 2 pass NIH waterboxes. If 2 pass MWB are used, add an additional 2,250 lb (1021 kg).
†Based on 2 pass NIH waterboxes. If 2 pass MWB are used, add an additional 2,100 lb (953 kg).
Table 2 — Relief Device Locations
Relief Valve Outlet Size
1 1/4-in. NPT Female Connector
1 1/4-in. NPT Female Connector
3/8-in. Male Flare
Location
Cooler
Storage Vessel
Optional Pumpout Unit
Quantity
3
2*
1
Table 3 — Insulation Areas
Pass
Arrangement
Cooler*
Flash
Economizer†
Compressors
Suction Housing
Total ft
2 m
2 ft
2 m
2 ft
2 m
2 ft
2 m
2
1 505 47 45 4.2 15 1.4 565 52.6
2 460 43 45 4.2 15 1.4 520 48.6
†Includes low side float chamber and shell.
Figure 1 — Model Number Identification
Figure 2 — Typical 19FA Installation
(1400-2200 Tons [4922-7735 kW])
3. Indicates center of gravity.
Figure 3 — Machine Rigging Guide
Component
Motor DM-DQ
Motor EA-EE
Service Clearance
A (Diameter) ft-in.
1 - 11 1/4
2 - 2 3/4
mm
591
679
B (Length) ft-in.
3 - 7 1/2
4 - 1 1/4
mm
1105
1251
Nozzle
Type
Marine
NIH
Cooler Passes
1
14
20
2
14
12
Nozzle Sizes (in.)
Condenser Passes
1
18
24
2
18
18
3
14
14
4
12
12
32
32L
Condenser Tube Pull
Condenser Size ft-in.
12-3
17-1 1/2
C (Length) mm
3734
5220
Figure 4 — 19FA Dimensions
Figure 5 — Machine Footprint
Figure 6 — Machine Contact Surfaces with Anchor Bolts
†Locate flow switch between the waterbox cover and the first water isolation valve.
Figure 7 — Typical Nozzle Piping
No. of Passes
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Cooler Nozzle No.
In
48
48
48
49
44
47
47
47
49
49
43
43
44
44
42
42
42
43
Legend
ANSI — American National Standards Institute
RF — Raised Face
Out
42
43
44
42
49
42
43
44
43
44
48
49
47
48
47
18
49
47
Nozzle Arrangements
Cooler Marine Waterboxes
No. of Passes
2
2
2
2
2
2
2
2
2
2
2
2
Cooler Nozzle No.
In
41
41
45
45
40
40
40
41
45
46
46
46
Out
43
44
47
48
42
43
44
42
49
47
48
49
Figure 8 — Piping Flow Data (Cooler, Marine Waterboxes)
Cooler, NIH Waterboxes
No. of Passes
1
1
2
2
Cooler Nozzle No.
In
50
51
52
54
Out
51
50
53
55
Figure 9 — Piping Flow Data (Cooler, NIH Waterboxes)
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.
1
2
3
4
Condenser Nozzle No.
No. of Pass
In
23
23
24
23
22
27
22
27
24
23
25
25
26
26
20
20
21
21
Out
21
20
25
25
20
26
21
25
21
21
20
21
20
21
25
26
25
26
Figure 10 — Piping Flow Data
(Condenser, Marine Waterboxes)
Cooler Nozzle No.
No. of Passes
In Out
1
2
3
3
8
5
10
4
9
1
6
8
3
7
2
4
4
9
2
7
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
Figure 16 — Compressor Terminal Arrangement
18-Lead, Top Inlet
Figure 17 — Compressor Terminal Arrangement
18-Lead, Side Inlet
Figure 18 — Oil Pump Wiring
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 — Typical 19FA With Free-Standing Starter
Figure 25 — Field Wiring (Low Voltage Motors) of PIC (Product Integrated Control) Free-Standing Starter
Figure 26 — 19FA Insulation
Machine Model Number: 19FA
To:
INSTALLATION START-UP REQUEST CHECKLIST
Serial Number:
Date
Project Name
Attn:
Carrier Job Number
The following information provides the status of the chiller installation.
YES/NO
(N/A)
1. The machine is level.
2. The machine components are installed and connected in accordance with the installation instructions.
3. The isolation package and grouting (if necessary) are installed.
4. The relief valves are piped to the atmosphere.
5. All piping is installed and supported. Direction of flow is indicated in accordance with the installation instructions and job prints.
a. Chilled water piping b. Condenser water piping c. Waterbox drain piping d. Oil cooler water piping e. Pumpout unit condenser water piping (if installed) f. Other
6. Flow switches are installed on both cooler and condenser water loops.
7. Gages are installed as called for on the job prints required to establish design flow for the cooler and condenser.
a. Water pressure gages IN and OUT
8. The machine’s starter wiring is complete. The wiring is installed per installation instructions and certified prints.
a. Power wiring to compressor motor. (Motor leads will not be taped until the Carrier technician megger tests the motor.) b. Oil pump wiring c. Oil heater/control wiring d. Flow switch wiring on cooler and condenser e. 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:
DATE TO BE
COMPLETED
CL-1
TESTING
1. The cooling tower fan has been checked for blade pitch and proper operation.
2. The chilled water and condenser water lines have been: a. Filled b. Tested c. Flushed d. Vented e. Strainers cleaned
3. The chilled water and condenser water pumps have been checked for proper rotation and flow.
4. The following cooling load will be available for start-up: a. 25% b. 50% c. 75% d. 100%
5. The refrigerant charge is at the machine.
6. Services such as electrical power and control air will be available at start-up.
7. The electrical and mechanical representatives will be available to assist in commissioning the machine.
8. The customer’s operators will be available to receive instructions for proper operation of the chiller after start-up.
Concerns about the installation/request for additional assistance:
YES/NO
DATE TO BE
COMPLETED
I am aware that the start-up time for a Carrier chiller can take between 2 and 6 days depending on the model of the machine and the options and accessories used with it.
Your contact at the job site will be
Phone number
Beeper number
Fax number
In accordance with our contract, we hereby request the services of your technician to render start-up services per contract terms for this job on (Date). I understand that the technician’s time will be charged as extra services due to correcting items in this checklist that are incomplete.
Signature of Purchaser
Signature of Job Site Supervisor
Copyright 1995 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
Tab 5a
PC 211 Catalog No. 531-965 Printed in U.S.A.
Form 19FA-3SI Pg CL-2 2-95 Replaces: 19FA-2SI
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