Carrier HERMETIC ABSORPTION LIQUID CHILLER 16JB User manual

Installation Instructions
For use with Absorption Liquid Chillers
SAFETY CONSIDERATIONS
Absorption liquid chillers provide safe and reliable service
when operated within design specifications. When operat-
ing this equipment, use good judgment and safety precau-
tions 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 USE OXYGEN to purge lines or to pressurize a ma-
chine for any purpose. Oxygen gas reacts violently with many
common substances. Use nitrogen.
NEVER EXCEED specified test pressures. VERIFY the allow-
able test pressure by checking the instruction literature.
DO NOT VALVE OFF any safety device.
BE SURE that any pressure relief devices are properly installed
and functioning before operating any machine.
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 quali-
fied electrician.
DO NOT WORK ON electrical components, including control
panels or switches, until you are sureALL POWER IS OFF and
no residual voltage can leak from capacitors or solid-state com-
ponents.
LOCK OPENAND TAG electrical circuits during servicing. IF
WORK IS INTERRUPTED, confirm that all circuits are de-
energized before resuming work.
DO NOT syphon lithium bromide or any other chemical by mouth.
WEAR goggles and suitable protective clothing when handling
lithium bromide, octyl alcohol, inhibitor, lithium hydroxide and
hydrobromic acid. IMMEDIATELY WASH any spills from the
skin with soap and water. IMMEDIATELYFLUSH EYES with
water and consult a physician.
BE SURE all hydrogen has been exhausted before cutting into
purge chambers. Hydrogen mixed with air can explode when
ignited.
WHEN FLAMECUTTING OR WELDING on an absorption
machine, some noxious fumes may be produced. Ventilate the
area thoroughly to avoid breathing concentrated fumes.
NEVER APPLY an open flame or live steam to a refrigerant
cylinder. Dangerous overpressure can result. When neces-
sary to heat refrigerant, use only warm (110 F/43 C) water.
DO NOT REUSE disposable (nonreturnable) cylinders nor at-
tempt to refill them. It is DANGEROUSAND ILLEGAL. When
cylinder is emptied, bleed off remaining gas pressure, loosen
the collar and unscrew and discard the valve stem. DO NOT
INCINERATE.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc. while
machine is under pressure or while machine is running.
CAREFULLY INSPECT rupture discs AT LEAST ONCE A
YEAR. If machine operates in a corrosive atmosphere, inspect
the devices at more frequent intervals.
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.
IMMEDIATELY wipe or flush the floor if lithium bromide or
octyl alcohol is spilled on it.
DO NOT climb over machine. Use platform, catwalk or stag-
ing. 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 such equipment when there is a risk
of slipping or losing your balance.
VALVE OFFANDTAG steam, water or brine lines before open-
ing them.
Be aware that certain automatic start arrangements CAN EN-
GAGE THE STARTER. Open the disconnectahead of the starter
in addition to shutting off the machine or pump.
USE only repair or replacement parts that meet the code re-
quirements of the original equipment.
DO NOT VENT OR DRAIN water boxes containing industrial
brines, liquid, gases or semisolids without permission of your
process control group.
DO NOT LOOSEN water box cover bolts until the water box
has been completely drained.
DOUBLE-CHECK that coupling nut wrenches, dial indicators
or other items have been removed before rotating any shafts.
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.
PROVIDEADRAIN connection in the vent line near each pres-
sure relief device to prevent a build-up of condensate or rain
water.
16JB
010-068
Hermetic Absorption Liquid Chillers
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
Tab 5b PC 211 Catalog No. 531-601 Printed in U.S.A. Form 16JB-5SI Page 1 1-91 Replaces: 16JB-4SI

ONE-PIECE UNIT
OVERALL DIMENSIONS (ft-in.)
16JB 010,012,014 018,021 024,028 032,036 041,047
A168-10
7
⁄ 8 9168-11
3
⁄ 4 9178-0
1
⁄ 8 9168-11
7
⁄ 8 9178-2
1
⁄ 4 9
B38-8
5
⁄ 8 948-5
1
⁄ 8 958-1
1
⁄ 8 968-3
1
⁄ 4 978-59
C78-3
1
⁄ 2 978-9
7
⁄ 8 988-9
1
⁄ 2 9108-1
1
⁄ 4 9118 -6
1
⁄ 8 9
OVERALL DIMENSIONS (mm)
A5153 5175.2 5184.8 5178.4 5238.7
B1133.5 1349.4 1558.9 1911.4 2260.6
C2222.5 2384.4 2679.7 3092.4 3381.4
NOTE: Allow 148-49(4368.8 mm) for tube removal when locating machine
(either end).
TWO-PIECE UNIT
OVERALL DIMENSIONS (ft-in.)
16JB 054,057 061,068
A218-11
1
⁄ 4 9218-8
1
⁄ 8 9
B68-4
3
⁄ 4 978-4
1
⁄ 4 9
C118 -109138-2
1
⁄ 4 9
OVERALL DIMENSIONS (mm)
A6686.5 6607.2
B1949.4 2241.5
C3606.8 4019.5
NOTE: Allow 198-39(5867.4 mm) for tube removal
when locating machine (either end).
LEGEND
1—Generator-Condenser Assembly
2—Purge Exhaust Valve
3—Absorber-Evaporator Assembly
4—Thermoswitch Wells
5—Optional Shipping Skids
6—Condensate Drain
7—Lift Lugs (both ends)
8—Condenser Water Box
9—Auxiliary Evacuation Valve
10—Refrigerant Low-Temp Cutout Well
(on refrigerant pump sump)
11 — Weld Connections-front view
(054-068 units only)
12—Weld Connections-rear view
(054-068 units only)
13—Rupture Disc Assembly (hot water
machines only)
Fig. 1 — Rigging and Dimensions Diagram
2

INTRODUCTION
General— The 16JB machine is factory assembled, wired
and leak tested. Installation (not by Carrier) consists prima-
rily of establishing water and electrical services to the ma-
chine. Rigging, installation, field wiring and field piping are
the responsibility of the contractor and/or customer. Carrier
has no installation responsibilities for the equipment. The
scope of Carrier’s duties at time of start-up are listed in In-
troduction portion of the 16JB Start-Up, Operation and Main-
tenance Instructions.
Job Data — Necessary information consists of: Machine
location drawings, piping drawings, field wiring diagrams
and rigging guide.
RECEIVING AND INSTALLATION
Step 1 — Check Equipment
IDENTIFY MACHINE — The machine model number and
serial number are stamped on machine identification plate.
Check this information against shipping papers and job data.
INSPECT SHIPMENT — The machine is at a deep
vacuum when shipped. Do not open any valves until the vacuum
has been noted. Refer to Shipping Vacuum Check.
Inspect for shipping damage while machine is still on ship-
ping conveyance. If machine appears to be damaged or has
been torn loose from its anchorage, have it examined by trans-
portation inspectors before removal. Forward claim papers
directly to transportation company. Manufacturer is not re-
sponsible for any damage incurred in transit.
Check all items against shipping list. Immediately notify
the nearest Carrier Air Conditioning office if any item is
missing.
To prevent loss or damage, leave all parts in original pack-
ages until installation.
CHECK SHIPPING VACUUM — To check for leaks that
have occurred during shipment:
a. Connect an absolute pressure gage to places listed in
Table 1.
b. Record the absolute pressure of each assembly. If ves-
sel pressure is greater than 0.28 in. (7mm) of mercury,
the machine has acquired a leak in shipping, and must
be leak tested. Refer to the Machine Leak Test proce-
dure for instructions.
Table 1 — Absolute Pressure Gage
Test Connections
UNIT
16JB GAGE CONNECTION
010-047 At auxiliary evacuation valve (item 9, Fig.1)
054-068
Generator-Condenser: At condenser-purge
suction line (Fig. 2)
Absorber-Evaporator: At auxiliary evacuation
valve (item 9, Fig. 1)
STORAGE PROTECTION — If the machine is not going
to be installed immediately, it is very important to use a drop
cloth or plastic covering to protect the machine from con-
struction dirt and moisture before installation. Also, do not
remove protective shipping cover on control panel until ready
to use.
Step 2 — Rigging and Installation
PREPARING 2-PIECE UNIT — Two-piece units must be
prepared for installation before they can be rigged.
1. Open auxiliary evacuation valve to break vacuum in
absorber-evaporator shell.
2. Open shipping valve (Fig. 2) on generator-condenser
assembly.
3. Protect machine insulation with a leather or wet canvas
cover when welding or cutting.
4. Remove all piping end plates as shown in Fig. 2.
5. Remove the weld elbow and shipping valve on the
condenser-purge suction line.
To avoid contaminates and debris getting into chiller,
do not leave machine open any longer than necessary.
Be careful not to remove any stock from pipe ends. Do
not get slag inside machine while flame cutting.
RIG MACHINE PROPERLY — Refer to rigging instruc-
tions in plastic envelope attached to machine. Rigging in-
structions vary for one-piece units and 2-piece units.
Lifting machine from points other than those specified
may result in serious damage and personal injury. Rig-
ging equipment and procedure must be adequate for ma-
chine weight. Refer to Table 2 for machine weights.
Table 2 — Rigging Weights
UNIT
16JB WEIGHT (lb) WEIGHT (kg)
1-PIECE UNITS
010 9,000 4,082
012 9,100 4,128
014 9,100 4,128
018 11,500 5,216
021 12,300 5,579
024 14,600 6,622
028 14,800 6,713
032 18,500 8,391
036 18,900 8,573
041 23,000 10,433
047 23,500 10,659
2-PIECE UNITS
Absorber Generator Absorber Generator
041 18,000 5,500 8,165 2,495
047 18,500 5,500 8,392 2,495
054 21,500 7,000 9,752 3,175
057 22,000 7,000 9,979 3,175
061 26,500 7,000 12,020 3,175
068 28,000 7,400 12,701 3,357
Rigging One-Piece Units — One-piece units consist of all
units from 010-036 and, when specified, units 041-047. Lift
with cable slings under condenser water boxes. Refer to Fig. 1.
Fig. 2 — Weld Breaking Instructions
3

Rigging 2-Piece Units— Two-piece units consist of all units
from 054-068 and, when specified, units 041-047. Refer to
the following procedure for rigging.
1. Absorber-evaporator assembly — Lift the absorber-
evaporator assembly from lift lugs at each end of ma-
chine. Refer to Fig. 1.
2. Generator-condenser assembly
a. Lift with cable slings placed under condenser water
boxes. Refer to Fig. 1.
b. Place generator-condenser assembly on top of absorber-
evaporator assembly.
c. Align the match marks stamped on one leg of each
generator-condenser and absorber-evaporator assem-
blies.
d. Make sure stamped serial numbers accompanying the
match marks correspond on both assemblies.
POSITION AND LEVEL THE EQUIPMENT — Isolation
pads are not necessary for most installations. However, for
cases where isolation pads are required, refer to Fig. 3 and
Table 3 for installation data.
It is not necessary to level the generator-condenser as-
sembly as both assemblies are designed to be level when the
absorber-evaporator assembly has been leveled.
The 16JB machine must be level within
1
⁄ 4 in. per 20 ft,
both lengthwise and diagonally. To level the machine, pro-
ceed as follows:
1. Fill 50-ft length of clear flexible tubing completely with
water.
2. Use water gage and leveling reference points stamped on
absorber-evaporator shell to level machine. Leveling marks
on evaporator shell are covered by small removable one-
in. squares of insulation.
3. Level machine with shims until requirements are met. If
isolation assembly is used, shim under the soleplate.
ASSEMBLE 2-PIECE UNIT — Assemble 2-piece unit (see
procedure below). Then leak test and evacuate machine as
described in Leak Test and Machine Evacuation Procedures.
a. Bolt leg assemblies.
b. Weld the piping connections and make sure weld con-
nections are vacuum tight.
If chiller is assembled before it is rigged, do not lift ma-
chine under condenser water boxes to avoid damage to
machine. Machine should be lifted using lift lugs lo-
cated at each end of the machine.
Table 3 — Isolation Pad
and Soleplate Specifications
UNIT
16JB NO. (EACH)
OF PADS AND
SOLEPLATES
DIMENSIONS
(in.) DIMENSIONS (mm)
Pad Soleplate Pad Soleplate
010
012
014 4 9 x 6.4 10 x 7.5 228 x 162 254 x 191
018
021 4 9 x 10.4 10 x 11.5 228 x 263 254 x 292
024
028 4 9 x 12.4 10 x 13.5 228 x 315 254 x 343
032
036 4 9 x 14.4 10 x 15.5 228 x 365 254 x 394
041
047 4 9 x 18.4 10 x 19.5 228 x 465 254 x 495
054
057 4 12 x 18.4 13 x 19.5 305 x 465 331 x 495
061
068 4 14 x 18.4 15 x 19.5 356 x 465 381 x 495
NOTE: Higher isolation efficiencies may be obtained with double-
layer pads. Double-layer pads, factory-fused together, are available
from various manufacturers. If 2 single-layer pads are used, a metal
divider equal to pad dimensions should be inserted between layers.
MACHINE LEAK TEST—All field-weld joints on the chiller
must be leak tested prior to starting the machine. Leak test
as follows:
1. Close all pump service valves, auxiliary evacuation valve
(Fig. 4) and purge exhaust valve (Fig. 5).
2. Refer to Table 4 for amount of refrigerant and nitrogen
required for leak testing.
3. If machine is under vacuum, bring to atmospheric pres-
sure with dry air or dry nitrogen.
4. Pressurize to 8 psig with Refrigerant 22. Charge through
auxiliary evacuation valve (item 9, Fig. 1).
5. Increase the machine pressure to 20 psig with dry air or
dry nitrogen.
Exceeding 20 psi will cause severe damage to chiller.
NOTES:
1. If optional shipping rails are on unit, be sure only the machine
base is on the isolation pad at each corner.
2. Shim under soleplate if necessary to level machine.
Fig. 3 — Typical Isolation Assembly Fig. 4 — Auxiliary Evacuation Device
4

6. Leak test all field weld joints with electronic leak detec-
tors or equivalent. If machine has acquired a leak in ship-
ment or rigging, all joints must be leak tested.
7. After leak testing has been completed and leaks have been
corrected, release the machine pressure.
Table 4 — Quantity of Refrigerant and Nitrogen
Required for Leak Testing
UNIT
16JB
REFRIGERANT 22
(No. of Cylinders) NITROGEN (No. of Cylinders)
25 lb 12 lb 300 cu ft vol
11.3 kg 5.4 kg 8.5 cu meters
010
012
014 1 0 1.0
018
021 1 1 1.0
024
028 2 1 2.5
032
036 2 1 2.5
041
047 4 0 3.5
054
057 4 0 3.5
061
068 5 0 4.5
MACHINE EVACUATION — Removal of non-condensables
from the machine is required after machine has been opened.
To evacuate the machine, proceed as follows:
1. Connect auxiliary evacuation device (Fig. 4) to auxiliary
evacuation valve. Be sure that the line is as short as pos-
sible and that line size is not smaller than connection to
auxiliary device. A check valve must be used on the suc-
tion lines to keep vacuum pump oil out of the chiller. Be
sure that all connections are vacuum tight.
2. Close refrigerant pump service valve(s), solution service
valve, auxiliary evacuation valve, and purge exhaust valve.
3. Start auxiliary evacuation device. Open auxiliary evacu-
ation valve. Reduce machine pressure to one in. of mer-
cury absolute or lower. Check pressure with absolute pressure
gage at refrigerant pump service valve.
4. Close auxiliary evacuation valve and shut off auxiliary
evacuation device.
5. Note and record absolute pressure gage reading.
6. Coat all machine field-weld joints with weld sealant.
Step 3 — Connect Piping — Install piping using job
data, piping drawings and procedure outlined below. A typi-
cal piping installation is shown in Fig. 6.
Factory-supplied insulation is not flammable but can be
damaged by welding sparks and open flame. Protect in-
sulation with a wet canvas cover.
1. Make sure connections to water box covers allow re-
moval of covers for maintenance. Install a flange or Vic-
taulic grooved coupling in the piping between the absorber
outlet and condenser outlet.
2. Install pipe hangers where needed. Make sure no weight
or stress is placed on water box nozzles or flanges.
3. Install water box vent and drain piping in accordance with
individual job data. Vent and drain piping shown in Fig. 6
is typical only and may not conform to your arrange-
ment. Air vents should be at all high points in piping to
eliminate water hammer.
4. Install water box drain plugs (shipped with unit).
5. Water flow direction must be as specified in job flow dia-
grams or water flow markings on water boxes.
6. Install 5 thermometer wells and thermometers (not sup-
plied by Carrier). Thermometer wells should extend into
the pipe a minimum of
1
⁄ 3 pipe diameter.
Area Suggested Range
Entering chilled water 0 to 100 F
Leaving chilled water 0 to 100 F
Entering absorber water 30 to 120 F
Entering condenser water 30 to 120 F
Leaving condenser water 30 to 180 F
Step 4 — Install Steam or Hot Water Piping
STEAM MACHINE
1. Locate the steam control valve, a minimum of 3 ft from
the generator nozzle (Fig. 7) and install a pressure gage
between steam control valve and machine.
2. Install the steam trap, as close to the machine as possible
and at least 3 ft below the generator outlet. Piping from
the trap must be located as low as possible to prevent
condensate from backing up into the generator at part load.
When the condensate system is closed, an air vent of some
type must be part of the system. If a condensate receiver
is used, the vent should be part of the tank.
HOT WATER MACHINE
1. Install thermometer wells and connection for pressure gages.
For thorough mixing and temperature stabilization, wells
in leaving water pipe should be placed 6 to 10 pipe di-
ameters from water box and should extend inside the pipe
at least 2 in. (50 mm).
2. Vent rupture discs to the outside of the building for safety.
The 16JB hot water chillers are factory equipped with a
rupture disc assembly on the generator-condenser assem-
bly (see Fig. 1).
a. Add a flexible connection and adequate support to pipe,
as required, to eliminate any piping stress on rupture
disc. Provide fittings so vent piping can be discon-
nected periodically for inspection of disc. Provide pipe
plug on outlet side of relief device for leak testing.
Fig. 5 — Purge Exhaust Assembly
5

b. Cover outdoor vent with a rain cap to prevent exces-
sive moisture from entering the vent line.
c. Place a condensate drain at the low point in the piping
to prevent any water build-up on the atmospheric side
of the disc assembly.
Step 5 — Apply Field Insulation (If Required) —
Apply insulation as indicated in job data. If shipping vacuum
test indicates significant loss of machine vacuum, do not ap-
ply insulation. Protect insulation from weld heat damage and
weld splatter during installation.
Recommended Areas for Insulation
1. Steam or hot water condensate lines
2. Entering and leaving chilled water lines
3. Chilled water boxes (install drain plugs before
insulating)
4. Generator shell (if heat is objectionable)
5. Refrigerant pump and piping
Step 6 — Make Electrical or Pneumatic Con-
nections — Field wiring must be installed in accordance
with job wiring diagrams and all applicable electrical codes.
CHECKAVAILABLE POWER SUPPLYAND SAFETYIN-
TERLOCKS — Check available power supply and safety
interlocks to be sure they match the machine equipment. Job
voltage, amperage and values are circled in red on the panel
wiring diagram.
CHECK HEATERSAND FUSES — Check heaters and fuses
(located in a plastic bag inside the control panel) against a
sizing table located on the wiring diagram inside the control
panel door. Check the motor nameplate for full load ampere
rating. Do not install heater or fuses until safety controls have
been checked out at initial start-up.
CHECK MACHINES WITH PNEUMATIC CAPACITY
CONTROLS — Make sure they have a continuous supply
of clean, dry, 18 psig air with volume of at least 0.3 cfm. Also,
make sure the pneumatic supply fitting on machine control
panel is labeled.
INSTALL CAPACITY CONTROLVALVE(S) — The valve
can be either electronic or pneumatic.
Electronic Control Valve — Install wiring to control valve(s)
as shown on wiring diagram located inside control panel door.
Pneumatic Control Valve — Install
1
⁄ 4 -in. plastic tubing from
control panel to control valve(s) as shown on diagrams lo-
cated inside control panel door.
INSTALL CHILLED WATER SENSOR — The sensor is
either electronic or pneumatic depending on what type of
capacity control valve was installed. Refer to Fig. 8.
Fig. 7 — Low-Pressure (2 to 15 psig) Steam
Supply Piping
Fig. 6 — Typical Piping and Wiring
6

Electronic Sensor
1. Install sensor in
1
⁄ 2 in. (13 mm) coupling located in the
leaving chilled water nozzle.
2. Uncoil sensor wire in bottom of control panel and run it
to sensor assembly. Refer to control panel wiring dia-
gram for electrical connections.
Pneumatic Sensor
1. Install separable thermometer well in the leaving chilled
water nozzle.
2. Insert chilled water sensor in separable well.
3. Slide bracket into groove on head of separable well and
tighten mounting screws.
4. Install
1
⁄ 4 -in. (6 mm) plastic tubing from control panel to
sensor bulkhead fittings (connections are labeled oncon-
trol panel). Refer to diagram inside control panel door.
The
1
⁄ 4 -in. (6 mm) tubing is furnished and will be found,
coiled, inside the control panel.
INSTALL LOW-TEMPERATURE CUTOUT — A low-
temperature control is mounted inside control panel. Refer
to component arrangement diagram inside panel door for
location.
1. Uncoil capillary tubing and run it through a convenient
panel knockout and along absorber shell. Use tape or grom-
met to protect capillary where it goes through the panel.
2. Run tubing to well on refrigerant pump sump.
3. Secure sensing element in well. Apply heat-conductive
compound to sensing element after control has been cali-
brated at initial start-up.
INSTALL THERMOSWITCHES — Two switches are
mounted inside the control panel. Refer to the component
arrangement diagram inside panel door for location.
1. Uncoil capillary tubing and run it through a convenient
panel knockout and along absorber shell. Use tape or grom-
met to protect capillary where it goes through the panel.
2. Run tubing to 2 wells in strong solution line between heat
exchanger and spray header.
3. Secure sensing elements in wells. Heat-conductive com-
pound will be applied to sensing element after controls
have been calibrated at initial start-up.
Step 7 — Initial Solution and Refrigerant Charg-
ing — Lithium bromide solution and refrigerant (water)
will be placed in the machine at initial start-up.Do not charge
solution into the machine until the unit is ready for
operation.
Do not start any pump motors until the machine has been
charged with solution and refrigerant. The hermetic pumps
can be seriously damaged by dry operations.
Refer to 16JB 010-068 Start-up, Operation, and Mainte-
nance Instructions for charging procedures.
Fig. 8 — Electronic and Pneumatic
Chilled Water Sensor Assemblies
7

Copyright 1991 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 5b PC 211 Catalog No. 531-601 Printed in U.S.A. Form 16JB-5SI Page 8 1-91 Replaces: 16JB-4SI