Carrier 19FA Series User manual

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.
®

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.
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. Inten-
tional misuse can be fatal. Vapor is heavier than air and reduces the amount of
oxygen available for breathing. Product causes eye and skin irritation. Decompo-
sition 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 !DANGER

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.
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 volt-
age 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 informa-
tion on use of this machine with other refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while machine is under pres-
sure 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.
WARNING !WARNING

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. 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
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

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

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

Contents
List of Figures
Figure 1 — Model Number Identification
Figure 2 — Typical 19FA Installation (1400-2200 Tons
[4922-7735 kW])
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)
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
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 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
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
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.

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.
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.
Click here for Figure 1 — Model Number Identification
Click here for Figure 2 — Typical 19FA Installation (1400-2200 Tons
[4922-7735 kW])

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 Figure 4 and
Table 1A 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.
Lifting machine from points other than those specified may result in serious dam-
age 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: These weights are broken down into component sections. For the complete
machine weight, add all component sections and refrigerant charge together. See
Table 1A and Table 1B for machine component weights.
WARNING !WARNING

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.
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

(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.
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.
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 Figure 2. Replace sensors after welding
is complete.

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,Figure 8,Figure 9,Figure 10 and
Figure 11.
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.