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Carrier HFC-134a, Installation Instructions Manual

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Carrier HFC-134a Installation Instructions Manual Download Page 6

     

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.

Summary of Contents for HFC-134a

Page 1: ...eplaces 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 precautio...

Page 2: ...rt 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 t...

Page 3: ... 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 an...

Page 4: ...rigerants 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 T...

Page 5: ...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 ...

Page 6: ...ing 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 ...

Page 7: ...ures 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 ...

Page 8: ... 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 ...

Page 9: ...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 ...

Page 10: ... 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...

Page 11: ...ower 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 ...

Page 12: ...allation 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 dr...

Page 13: ...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 ...

Page 14: ...inst 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...

Page 15: ...nd 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 Figu...

Page 16: ... 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 wei...

Page 17: ...ion 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 a...

Page 18: ...ion 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 ...

Page 19: ...e 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 co...

Page 20: ...t 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 ...

Page 21: ...ler coil may lead to extensive machine damage not covered by the standard warranty 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 ...

Page 22: ...e 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 2...

Page 23: ...he 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 redundan...

Page 24: ...on 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 Refrigerant dis...

Page 25: ...e for reference only and are not intended for use during actual installation follow job specific wiring diagrams 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 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 d...

Page 26: ...illed 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 Figure 16 Figure 17 and Figure 24 Attach power leads to compressor terminals in accordance with job wiring drawin...

Page 27: ...ctrical 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 Important Do not insulate terminals until wiring arrangement has been checked and approved by Carrier start ...

Page 28: ...er 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 Click here for Figure 16 Compressor Terminal Arrangement 18 Lead Top Inlet Click here for Figure 17 Compressor Terminal Arrangement 18 Lead Side Inlet CAUTION CAUTION Do not punch holes ...

Page 29: ...able Refer to the job wiring dia grams 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 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 ...

Page 30: ...Click here for Figure 20 Pumpout Unit Controls Click here for Figure 21 Pumpout Unit Wiring Schematic ...

Page 31: ...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 oute...

Page 32: ... 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 e...

Page 33: ...TE 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 ...

Page 34: ... 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 Click here for Figure 23 COMM1 CCN Communication Wiring for Multiple Chillers Typical Click here for Figure 24 Typical 19FA With F...

Page 35: ...tory 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 ...

Page 36: ...ights 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 25...

Page 37: ...ating 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 Conden...

Page 38: ...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 ...

Page 39: ...e float chamber and shell Table 3 Insulation Areas Pass Arrange ment Cooler Flash Economizer Compressors Suction Housing Total ft2 m2 ft2 m2 ft2 m2 ft2 m2 1 505 47 45 4 2 15 1 4 565 52 6 2 460 43 45 4 2 15 1 4 520 48 6 ...

Page 40: ...Figure 1 Model Number Identification ...

Page 41: ...Figure 2 Typical 19FA Installation 1400 2200 Tons 4922 7735 kW ...

Page 42: ...Figure 3 Machine Rigging Guide 3 Indicates center of gravity ...

Page 43: ...1 4 591 3 7 1 2 1105 Motor EA EE 2 2 3 4 679 4 1 1 4 1251 Nozzle Type Nozzle Sizes in 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 Condenser Size C Length ft in mm 32 12 3 3734 32L 17 1 1 2 5220 Figure 4 19FA Dimensions ...

Page 44: ...Figure 5 Machine Footprint ...

Page 45: ...Figure 6 Machine Contact Surfaces with Anchor Bolts ...

Page 46: ... Locate flow switch between the waterbox cover and the first water isolation valve Figure 7 Typical Nozzle Piping ...

Page 47: ...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 1 48 43 1 48 44 1 49 42 1 49 43 1 49 44 Cooler Nozzle No No of Passes In Out 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 Nozzle Arrangements Cooler Marine Waterboxes Figure 8 Piping Flow Data Cooler Marine Waterboxes ...

Page 48: ...Cooler NIH Waterboxes Cooler Nozzle No No of Passes In Out 1 50 51 1 51 50 2 52 53 2 54 55 Figure 9 Piping Flow Data Cooler NIH Waterboxes ...

Page 49: ...24 21 23 21 Legend ANSI American National Standards Institute RF Raised Face CAUTION CAUTION Figure 10 Piping Flow Data Condenser Marine Waterboxes 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 ...

Page 50: ...Cooler Nozzle No No of Passes In Out 1 3 8 8 3 2 5 10 1 6 3 4 9 7 2 4 4 9 2 7 Figure 11 Piping Flow Data Condenser NIH Waterboxes ...

Page 51: ...Figure 12 Water Piping Oil Cooler to Chilled Water Circuit Typical ...

Page 52: ...Figure 13 Pumpout Unit ...

Page 53: ...Figure 14 Typical 19FA Relief Valve Tree for Storage Vessel ...

Page 54: ...Figure 15 Compressor Terminal Arrangement 18 Lead Rear Inlet ...

Page 55: ...Figure 16 Compressor Terminal Arrangement 18 Lead Top Inlet ...

Page 56: ...Figure 17 Compressor Terminal Arrangement 18 Lead Side Inlet ...

Page 57: ...Figure 18 Oil Pump Wiring ...

Page 58: ...Figure 19 Oil Heater and Control Power Wiring ...

Page 59: ...Figure 20 Pumpout Unit Controls ...

Page 60: ...Figure 21 Pumpout Unit Wiring Schematic ...

Page 61: ...Figure 22 Carrier Comfort Network Communication Bus Wiring ...

Page 62: ...Figure 23 COMM1 CCN Communication Wiring For Multiple Chillers Typical ...

Page 63: ...Figure 24 Typical 19FA With Free Standing Starter ...

Page 64: ...Figure 25 Field Wiring Low Voltage Motors of PIC Product Integrated Control Free Standing Starter ...

Page 65: ...Figure 26 19FA Insulation ...

Page 66: ...g 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 instruc...

Page 67: ...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 rende...

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