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
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.
!
DANGER
WARNING
DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all refrigerant
(liquid and vapor)
placed with dr y air o r n itr og en and the wo rk are a sh ou ld b e wel l ven tilat ed .
erant 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 INTERRUPTED, confirm that all circuits are deenergized before resuming work.
DO NOT siphon refrigerant.
A VOID S PILL ING liquid refriger ant on skin or ge tting i t into t he eyes. USE SAFE TY
GOGGLES. W as h any sp ills f rom th e s kin with soap an d water. If liq uid refr ig era nt
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.
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has been removed from chiller. Traces of vapor should be dis-
WARNING
Refrig-
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, loo sen the collar, and unscrew and discard th e valve stem. DO NOT
INCINERA TE.
CHECK THE REFRIGERANT TYPE before adding refrigerant to the machine. The
introduction of the wrong refrigerant can cause machine damage or malfunction.
Operation of t his eq uipment with ref rigerants other than those cite d her ein shou ld
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 fit tings, cov ers, et c., while m achi ne is u nd er pr essure or while machine is running. Be sure pressure is at 0 psig (0 kPa) before
breaking any ref riger ant conne ctio n.
CAREFULLY INSPECT all relief valves, rupture discs, and other relief devices AT
LEAST ONCE A Y EAR. If machin e operat es in a corrosive atmosph ere, inspe ct the
devices at more frequent intervals.
DO NOT ATTEMPT T O REPAIR OR RECONDITION any relief valve whe n corros ion
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.
!
WARNING
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
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 equi pmen t.
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-C HECK that couplin g nut wrenc hes , dial indica tors, o r ot her it ems have
been removed before rotating any shafts.
!
CAUTION
ahead of
the starter,
CAUTION
DO NOT LOO SEN a packi ng gla nd nu t befor e check ing tha t the n ut has a po sitive
thread engagement.
PERIODICALLY INSPECT all valves , fittin gs, and pip ing fo r 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.
!
CAUTION
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
Contents
Rigging the Machine
Rig Machine Assembly
Install Machine Supports
Contents
Connect Piping
Install Water Piping to Heat Exchangers
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
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
Contents
List of Figures
Figure 1 — Model Number Identification
Figure 2 — Typical 19FA Installation (1400-2200 Tons
Figure 3 — Machine Rigging Guide
Figure 4 — 19FA Dimensions
Figure 5 — Machine Footprint
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)
Contents
[4922-7735 kW])
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
Contents
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
Figur e 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 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
Receiving the Machine
Inspect Shipment
Installation
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.
Inspect for shipping damage while machine is still on shipping conveyance. If machine
1.
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.
Check all items aga inst shipping list. Im mediately noti fy the nearest C arrier re presentative if
2.
any item is missing.
To prevent loss or damage, leave all parts in original packages until beginning installation.
3.
All openings are closed with covers or plugs to prevent dirt and debris from entering
Manufacturer is not responsible for any damage incurred in transit.
!
CAUTION
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
[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.
If machine is exp osed to freezing tempe ratur es af ter wa ter cir c uits ha ve be en insta lle d, op en
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 oi l cooler coi l. Foll ow the same proced ure wi th the pum pout unit con denser,
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 Figure 4 and
Table 1A and Table 1B.
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
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 Table 1A and Table 1B for machine weights.
Note: Th ese weig hts ar e b roken do wn int o com ponen t sect ion s. F or the complete
machine weig ht, add all com po nent sections an d refr ig eran t char ge to get her. See
Table 1A and Table 1B for machine component weights.
Lift machine only from the 4 points indicated in rigging guide.
!
WARNING
Each
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 and Figure 6.
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
shown in Figure 5 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 shi pped sep arately on m achines ordered with spring isolation. Specifi c 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 startup. To avoid damage to ma chine and pi ping, spring i solators m ust remai n 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
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 temperature sensors before welding connecting piping to water nozzles. Refer to Figure 2. 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.
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!
CAUTION
CAUTION
Provide openings in water piping for required pressure gages and thermometers. For
2.
thorough mixing and temperature stabilization, wells in the leaving water pipe should
extend inside pipe at least 2 in. (50 mm).
Install air vents at all high points in piping to remove air and prevent water hammer.
3.
Install pipe hangers where needed. Make sure no weight or stress is placed on waterbox
4.
nozzles or flanges.
Water flow direction must be as specified in Figure 7, Figure 8, Figure 9, Figure 10 and
5.
Figure 11.
Note:
6.
7.
8.
9.
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.
Water flow switches must be of vapor-tight con structio n and must be installed on top of pipe
in a horizontal run and at least 5 pipe diameters from any bend.
Install waterbox vent and drain piping in accordance with individual job data. All
connections are 3/4-in. FPT.
Install waterbox drain plugs in the unused waterbox drains and vent openings.
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 inl et fr om t he e ntering water line of th e m achine cool er. See Figure 12. Wat er le aving th e
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
(Typical)
Attach Water Supply to Pumpout Condenser
Obtain water from the source (usually city water) specified in the job data. Attach water
supply and ret urn lin es to 1/2-in . FPT connect ions 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
Figure 13.
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 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
Refrigerant discharged into confined spaces can displace oxygen and cause
asphyxiation.
If relief devi ces p iping i s m anifold ed, th e cro ss-secti on al ar ea of the r elief p ip e mu st at least
1.
equal the sum of the areas required for individual relief pipes.
Provide a pipe plug near outlet side of each relief device for leak testing. Provide pipe
2.
fittings that allow vent piping to be disconnected periodically for inspection of valve
mechanism.
Piping to relief devices must not apply stress to the device. Adequately support piping. A
3.
length of flexible tubing or piping near the device is essential on spring-isolated machines.
Cover the outdoor vent with a rain cap and place a condensation drain at the low point in
4.
the vent piping to prevent water build-up on the atmospheric side of the relief device.
Click here for Table 2 — Relief Device Locations
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DANGER
Make Electrical Connections
Field wiring must be installed in accordance with job wiring diagrams and all applicable
electrical codes.
CAUTION
Do not run 120-v wir ing into the contro l center . Th e contr ol cente r should on ly be
used for additional extra low-voltage wiring (50 v maximum).
Wiring information in this publication (Figure 15, Figure 16, Figure 17, Figure 18, Figure 19,
Figure 20, Fig ure 21, Figu re 22, Figure 23, Figure 24 and Figu re 25) are for reference only and
are not intended for use during actual installation; follow job specific wiring diagrams.
WARNING
Do not attempt to start compressor or oil pump (even for a rotation check) or
apply test vo ltage of any kind while machi ne is und er deh yd rat ion vacu um . Mo to r
insulation breakdown and serious damage may result.
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!
CAUTION
WARNING
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 and Figure 23.
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 opening s i n cond uit supp ort p lates. S ee Figur e 15 , Fi gu re 1 6, Fig ure 17, an d Fig ure 24.
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.
Figure 15, Figure 16, and Figure 17 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 compr essor motor terminals, le ad wire ends, and ele ctrical wire s 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.
1.
Overwrap putty with 4 layers of vinyl tape.
2.
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 installatio n. Vinyl tape is not acceptable ; a high voltage termina l methods must be used.
Connect Power Wires to Oil Pump Starter
See Figure 18. 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
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.
!
CAUTION
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 starte r to the machine powe r panel. All control wiring
must use shielded cable. Also, connect the communications cable. Refer to the job wiring diagrams for cab le type and cabl e numbe r . Mak e sure the con trol circu it is grou nded in accord ance
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 and Figure 21 illustrate
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 communicat ion connector m ust 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, chr ome vinyl, or Teflon with a minimum op eratin g temperat ure range of
-4 F to 140 F (-20 C to 60 C) is required. See table below for cables that meet the
requirements.
Manufacturer Cable No.
Alpha
American
Belden
Columbia
2413 or 5463
A22503
8772
02525
When connecting the CCN comm unicatio n bus to a syste m elem ent, a color code system for
the entire network is recommended to simplify installation and checkout. The following color
code is recommended:
Signal Type
+
Ground
-
If a cable with a dif ferent color scheme is selected, a si milar color cod e should be adopte d for
the entire network.
At each system eleme nt, the shields of its com munication bu s cables must be tied to gether. 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).
CCN Bus Conductor
Insulation Color
Red
White
Black
COMM1 Plug Pin No.
1
2
3
To connect the 19FA chiller to the network, proceed as follows (Figure 23):
Cut power to the Product Integrated Control (PIC) center.
1.
Remove the COMM1 plug from the processor module.
2.
Cut a CCN wire and strip the ends of the RED, WHITE, and BLACK conductors.
3.
Using a wirenut, connect the drain wires together.
4.
Insert and secure the RED wire to Terminal 1 of the COMM1 plug.
5.
Insert and secure the WHITE wire to Terminal 2 of the COMM1 plug.
6.
Insert and secure the BLACK wire to Terminal 3 of the COMM1 plug.
7.
Mount a terminal strip in a convenient location.
8.
Connect the opposite ends of each conductor to separate terminals on the terminal strip.
9.
Cut another CCN wire and strip the ends of the conductors.
10.
Connect the RED wire to the matching location on the terminal strip.
11.
Connect the WHITE wire to the matching location on the terminal strip.
12.
Connect the BLACK wire to the matching location on the terminal strip.
13.
Click here for Figure 22 — Carrier Comfort Network Communication Bus Wiring
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 Integrated Control) 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 Table 3. When
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 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 200 200
Suction Elbow 500 500
Miscellaneous Piping 750 750
Control Center 100 100
Total Rigging Weight 78,450 84,450
Refrigerant Charge (HFC-134a) 5,050 5,850
Cooler Water 4,250* 4,250*
Condenser Water 3,100† 4,300†
Total Operating Weight 90,850 98,850
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 Location Quantity
1 1/4-in. NPT Female Connector Cooler 3
1 1/4-in. NPT Female Connector Storage Vessel 2*
3/8-in. Male Flare Optional Pumpout Unit 1
Table 3 — Insulation Areas
Pass
Cooler*
Arrange-
ment
1 505 47 45 4.2 15 1.4 565 52.6
2 460 43 45 4.2 15 1.4 520 48.6
2
ft
m
2
†Includes low side float chamber and shell.
Flash
Economizer†
2
ft
m
Compressors
Suction Housing
2
2
ft
m
Total
2
2
ft
m
2
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
Service Clearance
A (Diameter) B (Length)
Component
ft-in. mm ft-in. mm
Motor DM-DQ 1 - 11 1/4 591 3 - 7 1/2 1105
Motor EA-EE 2 - 2 3/4 679 4 - 1 1/4 1251
Nozzle Sizes (in.)
Nozzle
Type
Cooler Passes Condenser Passes
1 2 1 2 3 4
Marine 14 14 18 18 14 12
NIH 20 12 24 18 14 12
Condenser Tube Pull
C (Length)
Condenser Size
ft-in. mm
32 12-3 3734
32L 17-1 1/2 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
Nozzle Arrangements
Cooler Marine Waterboxes
Cooler Nozzle No.
No. of Passes
1 42 47
1 42 18
1 42 49
1 43 47
1 43 48
1 43 49
1 44 47
1 44 48
1 44 49
1 47 42
1 47 43
1 47 44
1 48 42
In Out
Cooler Nozzle No.
No. of Passes
2 40 42
2 40 43
2 40 44
2 41 42
2 41 43
2 41 44
2 45 47
2 45 48
2 45 49
2 46 47
2 46 48
2 46 49
In Out
1 48 43
1 48 44
1 49 42
1 49 43
1 49 44
Legend
ANSI — American National Standards Institute
RF — Raised Face
Figure 8 — Piping Flow Data (Cooler, Marine Waterboxes)
Cooler, NIH Waterboxes
Cooler Nozzle No.
No. of Passes
1 50 51
1 51 50
2 52 53
2 54 55
In Out
Figure 9 — Piping Flow Data (Cooler, NIH Waterboxes)
Condenser Nozzle No.
Legend
ANSI — American National Standards Institute
RF — Raised Face
No. of Pass
1
2
In Out
20 25
20 26
21 25
21 26
25 20
25 21
26 20
26 21
22 20
27 26
22 21
27 25
23 21
23 20
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.
!
CAUTION
Figure 10 — Piping Flow Data
(Condenser, Marine Waterboxes)
24 25
3
4
23 25
24 21
23 21
Cooler Nozzle No.
No. of Passes
1 3
2 5
3 4
4 4
In Out
8
8
10
9
9
3
1
6
7
2
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
INSTALLATION START-UP REQUEST CHECKLIST
Machine Model Number: 19FA Serial Number:
To:
Date
Project Name
Attn:
Carrier Job Number
The following information provides the status of the chiller installation.
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:
YES/NO
(N/A)
DATE TO BE
COMPLETED
CL-1
TESTING YES/NO
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.
DATE TO BE
COMPLETED
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.
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 thisjob on (Date). Iunderstand that the technician’stime will be charged as extra servicesdue to correcting items
in this checklist that are incomplete.
Signature of Purchaser
Signature of Job Site Supervisor
CUT ALONG DOTTED LINE
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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