16DF013-050
Hermetic Absorption Liquid
Chiller/Heaters
Installation Instructions
SAFETY CONSIDERATIONS
Absorption liquid chiller/heaters provide safe and reliable
DO NOT perform any welding or flamecutting to a machine
service when operated within design specifications. When
operating this equipment, use good judgment and safety pre-
cautions to avoid damage to equipment and property or in-
jury to personnel.
while it is under a vacuum or pressurized condition.
NEVER APPLY an open flame or live steam to a refrigerant
cylinder. Dangerous overpressure can result. When necesary
to heat a cylinder, use only warm (110 F [43 C]) water.
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 REUSE disposable (nonreturnable) cylinders or at-
tempt to refill them. It is DANGEROUS AND ILLEGAL.
When cylinder is emptied, bleed off remaining gas pressure,
loosen the collar and unscrew and discard the valve stem.
DO NOT INCINERATE.
DO NOTATTEMPT TO REMOVE fittings, covers, etc., while
machine is under pressure or while machine is running. DO
NOT OPERATE or pressurize a machine without all cover
plates or bolts in place.
DO NOT USE OXYGEN or air to purge lines, leak test, or
pressurize a machine. Use nitrogen.
NEVER EXCEED specified test pressures. For the 16DF ma-
chine, the maximum pressure is 12 psig (83 kPa). For the
chilled/hot water and condensing water piping, the maxi-
mum pressure is stamped on the machine.
DO NOT climb over a machine. Use platform, catwalk, or
staging. Follow safe practices when using ladders.
DO NOT STEP ON machine piping. It might break or bend
and cause personal injury.
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 OFF AND TAG steam, water, or brine lines before
opening them.
DO NOT LOOSEN water box cover bolt until the water box
has been completely drained.
DO NOT VENT OR DRAIN water boxes containing indus-
trial brines, liquid, gases, or semisolids without permission
of your process control group.
BE AWARE that certain automatic start arrangements can
engage starters. Open the disconnects ahead of the starters
in addition to shutting off the machine or pump.
INVESTIGATE THE CAUSE of flame failure or any other
safety shutdown before attempting a restart.
WEAR goggles and suitable protective clothing when han-
dling lithium bromide, octyl alcohol, inhibitor, lithium hy-
droxide, and hydrobromic acid. IMMEDIATELY wash any
spills from the skin with soap and water. IMMEDIATELY
FLUSH EYES with water and consult a physician.
DO NOT USE eyebolts or eyebolt holes to rig maching sec-
tions or the entire assembly.
DO NOT work on high-voltage equipment unless you are a
qualified electrician.
DO NOT WORK ON electrical components, including con-
trol panels or switches, 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 servic-
ing. IF WORK IS INTERRUPTED, confirm that all circuits
are deenergized before resuming work.
NEVER DISCONNECT safety devices or bypass electric in-
terlocks and operate the machine. Also, never operate the
machine when any safety devices are not adjusted and func-
tioning normally.
DO NOT REPEAT unsuccessful ignition attempts or restart
after flame failure without assurance that post-purge and pre-
purge have eliminated combustible gas or oil vapors from
the combustion chamber. DO NOT EVER ATTEMPT IG-
NITION of a burner if there is shutdown leakage of gas or
oil through the fuel shutoff valves or from the fuel lines.
KEEP EYES sufficiently away from sight tubes or burner
openings, and wear a protective shield or safety glasses when
viewing a burner flame.
USE only repaired or replacement parts that meet the code
requirements of the original equipment.
DO NOTALLOW UNAUTHORIZED PERSONS to tamper
with burner equipment or machine safeties, or to make ma-
jor repairs.
DO NOT syphon lithium bromide or any other chemical by
mouth.
PERIODICALLY INSPECT all valves, fittings, piping, and
relief devices for corrosion, rust, leaks, or damage.
BE SURE all hydrogen has been exhausted before cutting
into pure chambers. Hydrogen mixed with air can explode
when ignited.
PROVIDE A DRAIN connection in the vent line near each
pressure relief device to prevent a build-up of condensate or
rain water.
WHEN FLAMECUTTING OR WELDING on an absorp-
tion machine, some noxious fumes may be produced. Ven-
tilate the area thoroughly to avoid breathing concentrated fumes.
IMMEDIATELY wipe or flush the floor if lithium bromide
or octyl alcohol is spilled on it.
BE SURE combustion air inlets to the equipment room are
open and clear of any blockage.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
PC 211
Catalog No. 531-602
Printed in U.S.A.
Form 16DF-1SI
Pg 1
3-92
Replaces: New
Tab 5b
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2
3
4
1
11
10
9
8
7
6
5
1
2
3
4
5
6
—
—
—
—
—
—
Condenser
7
8
—
—
—
—
—
Burner Control Panel
Solution Heat Exchanger
Chiller/Heater Control Panel
Absorber
Low-Stage Generator
Flue Stack
9
Separator
10
11
High-Stage Generator
Evaporator
Burner
Fig. 1 — Machine Components (Front View)
RIGGING AND POSITIONING
Rigging procedures vary depending on whether the ma-
chine is shipped in one or 2 pieces.
Rigging 2-Piece Units
PREPARATION — Two-piece units must be prepared for
installation before they can be rigged.
1. Open auxiliary evacuation valves to relieve pressure in
absorber-evaporator shell.
2. Open shipping valve on generator assembly to relieve
pressure.
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
machine weights and sizes. Refer to Table 1 for
machine weights, Fig. 2 and Tables 2 and 3 for overall
dimensions.
3. Remove all piping end plates by flamecutting the end plate
and weld flange around their outer diameter. Cut these
pieces as shown in Fig. 5 for proper reconnection.
4. Grind the cut pieces smooth for a close fit when the ma-
chine pieces are assembled.
Carefully position cables on machine to avoid damage to
small piping, controls, or wiring.
Keep shell horizontal when lifting or lowering so all legs
contact the floor at the same time.
To avoid contaminates and debris getting into chiller,
do not leave machine open any longer than necessary.
Rigging One-Piece Units — Lift entire assembly with
cable hooks and shackles connected to the 3 lifting holes on
the absorber-evaporator assembly (lower part of machine),
and with the center balance point location, as shown in
Fig. 3 and 4. Lifting from other holes or locations can dam-
age the machine. See Mounting the Burner section for burner
rigging instructions.
Do not remove any stock from pipe ends. Do not get
slag inside machine while flamecu<tting.
3
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Fig. 2 — 16DF Views (Typical)
⅜
—
Lifting Holes
Fig. 3 — Rigging One-Piece Units, Typical, Top View
4
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Fig. 4 — Rigging One-Piece Units, Typical, Side and End Views
Table 1 — Rigging Weights
English
SHIPPING WEIGHT (lb)
Absorber-
Evaporator
High-
OPERATING
WEIGHT
(lb)
UNIT
16DF
Temperature
Total
Weight
Low-Temperature Generator-
Generator
Assembly
Separator
Assembly
013*
015*
018*
020*
—
—
—
—
—
—
—
—
13,230
13,450
15,220
15,440
17,200
17,420
20,290
20,510
023
025
028
032
036
040
045
050
14,560
14,780
16,100
16,540
18,530
18,970
21,610
22,050
3,970
3,970
8,600
8,600
8,820
8,820
10,150
10,150
18,530
18,750
24,700
25,140
27,350
27,790
31,760
32,200
24,920
25,140
32,640
33,080
37,050
37,490
43,660
44,100
SI
SHIPPING WEIGHT (kg)
Absorber-
Evaporator
High-
OPERATING
WEIGHT
(kg)
UNIT
16DF
Temperature
Total
Weight
Low-Temperature Generator
Generator
Assembly
Separator
Assembly
Fig. 5 — Flamecutting and Welding Detail
013*
015*
018*
020*
—
—
—
—
—
—
—
—
6 000
6 100
6 900
7 000
7 800
7 900
9 200
9 300
023
025
028
032
036
040
045
050
6 600
6 700
7 300
7 500
8 400
8 600
9 800
10 000
1800
1800
3900
3900
4000
4000
4600
4600
8 400
8 500
11 300
11 400
14 800
15 000
16 800
17 000
19 800
20 000
11 200
11 400
12 400
12 600
14 400
14 600
*16 DF013-020 are shipped in one section as standard.
5
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Table 2 — Overall Dimensions, 16DF013-025
English
OVERALL DIMENSIONS (ft-in.)
UNIT
16DF
013
015
018
020
023
025
LENGTH
WIDTH
HEIGHT
11-10
6- 7
7- 9
11-10
6- 7
7- 9
11-10
7- 8
7- 9
11-10
7- 8
7- 9
11-10
8- 3
8- 3
11-10
8- 3
8- 3
SI
OVERALL DIMENSIONS (mm)
UNIT
16DF
013
015
018
020
023
025
LENGTH
WIDTH
HEIGHT
3600
1995
2350
3600
1995
2350
3600
2330
2350
3600
2330
2350
3600
2520
2500
3600
2520
2500
Table 3 — Overall Dimensions, 16DF028-050
English
Absorber-Evaporator Low-Temperature Generator Assembly
OVERALL DIMENSIONS (ft-in.)
UNIT
16DF
028
032
036
040
045
050
LENGTH
WIDTH
HEIGHT
15-4
9-4
8-6
15-4
9-4
8-6
15- 4
9-10
8-10
15- 4
9-10
8-10
15-4
10-6
9-8
15-4
10-6
9-8
SI
OVERALL DIMENSIONS (mm)
UNIT
16DF
028
032
036
040
045
050
LENGTH
WIDTH
HEIGHT
4660
2850
2595
4660
2850
2595
4660
3000
2695
4660
3000
2695
4660
3200
2950
4660
3200
2950
RIGGING — The 2 pieces are the high-temperature generator-
separator assembly and absorber-evaporator low-temperature
generator assembly (Fig. 6).
1. Lift each assembly with cable, hooks, and shackles con-
nected to the 4 lifting holes on each assembly. Lifting
from other holes or locations can damage the machine.
High-Temperature Generator-Separator Assembly
Fig. 6 — Rigging 2-Piece Units, Sizes 16DF023-050
2. Position and level the absorber-evaporator-assembly first.
See Position and Level the Equipment section.
3. Move the generator-separator assembly into place beside
the absorber-evaporator assembly.
4. Align connecting piping for generator-separator and absorber-
evaporator assemblies. Make sure serial numbers corre-
spond on both assemblies.
5. See Mounting the Burner section for burner rigging
instructions.
Position and Level the Equipment — Isolation
pads are not necessary for most installations. However, for
cases where isolation pads are required, refer to Fig. 7 for
typical installation.
Both 16DF machine assemblies must be level within
1
⁄4
in. per 20 ft (6.3 mm per 6 m), both lengthwise and di-
agonally. To level the machine, proceed as follows:
1. Completely fill 50-ft (15 m) length of clear flexible tub-
ing with water.
2. Use water gage and leveling reference points stamped on
tube sheets to level machine.
3. Level machine with shims until requirements are met. If
isolation assembly is used, shim under the soleplate. Be
sure matching piping is in alignment.
NOTES:
1. Be sure only the machine base is on the isolation pad at each
corner.
2. Shim under soleplate to level machine.
Fig. 7 — Typical Isolation Assembly
6
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MACHINE ASSEMBLY
Machine Leak Test — All field-welded joints on the
chiller must be leak tested prior to starting the machine. Leak
test as follows:
No assembly is required for one-piece units (16DF013-
020) other than installing the burner. See Mounting the Burner
section.
1. Close all external service valves.
2. If machine is under vacuum, bring to atmospheric pres-
sure with dry air or dry nitrogen.
3. Pressurize to 6 psig (40 kPa) with tracer gas. Charge through
auxiliary evacuation valve.
4. Increase the machine pressure to 12 psig (80 kPa) with
dry air or dry nitrogen.
Assemble 2-Piece Units (Fig. 8 and 9)
1. Weld piping connections and make sure weld connec-
tions are vacuum leak tight.
2. Install the burner. See Mounting the Burner section.
Exceeding 12 psi (80 kPa) can cause severe damage
to chiller.
5. Leak test all field-welded joints with electronic leak de-
tectors or equivalent. If machine has acquired a leak in
shipment or rigging, all joints must be leak tested.
6. After leak testing has been completed and leaks have been
corrected, release the machine pressure.
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. 10) to auxil-
iary evacuation valve. Be sure that the line is as short as
possible and that line size is not smaller than connection
to auxiliary device. A check valve or oil trap must be used
on the suction lines to keep vacuum pump oil out of the
chiller. Be sure that all connections are vacuum tight.
2. Close external service valve(s).
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.
Fig. 8 — Machine Piping Assembly
Diagram, End View
Fig. 9 — Machine Piping Assembly Diagram, Side View
7
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4. Close auxiliary evacuation valve and shut off auxiliary
evacuation device.
5. Note and record absolute pressure gage reading.
Frontplate and Burner Installation To prevent leak-
age of high-temperature combustion gases with this type of
forced draft burner, a high-temperature insulating gasket or
1/2-in. Fiberfrax® rope seal is required between the genera-
tor and the front plate assembly, and between the front plate
and the burner assembly.
6. Coat all machine field-welded joints with weld sealant.
Either the gasket or the rope may be provided with the
burner, depending on manufacturer’s availability.
When using high-temperature insulating rope, it must
be wrapped around the flange circumference INSIDE of
the mounting studs or bolt holes, with overlapping ends,
to provide a complete gas tight seal. Wrapping the rope
around the outside of the studs or bolt holes could allow
high-temperature gas leakage through the holes in the
attached plates.Use either gasket cement or masking tape
to hold the ropes in place during installation of the front
plate and burner assemblies.
Fig. 10 — Auxiliary Evacuation Device
MOUNTING THE BURNER
The burner is shipped and installed as 3 separate sub-
assemblies (Fig. 11):
1. Place the high-temperature gasket or insulating rope on
the generator mounting flange, inside the bolt holes.
• front plate and refractory assembly, which is attached to
the generator
2. Position the frontplate and refractory assembly against the
generator mounting flange, with the refractory can ex-
tending into the generator fire tube. Secure in place with
washers, nuts, and bolts.
• burner assembly, which is attached to the frontplate
• gas train and/or oil supply system, which are connected to
the burner
3. Place the high-temperature gasket or insulating rope on
Rigging — Rigging should be used to position both the
front plate assembly and the burner assembly because of their
weights. Refer to the shipping container or paperwork for
the weight of these units. For the front plate, either webbed
strapping placed around the refractory can or a lifting bar in
the center opening may be used.
the frontplate flange, inside the studs.
4. Position the burner assembly with the burner head ex-
tending into the front plate and refractory assembly, mak-
ing sure it is plumb. Secure in place with the retaining
lugs on the frontplate studs to ensure a rigid mounting.
Keep the control panel door closed during the burner in-
stallation to avoid damage. Also, it is good practice to
remove the flame safeguard chassis during installation and
to store it in a safe, dry place until start-up.
5. Measure and fabricate burner support pedestal from pipe(s)
with pipe thread on both ends. Screw the support pipe
into the support receptacle, and then screw the opposite
end into the collar that is welded to the underside of the
burner housing. Adjust or shim until the burner is level
and firmly supported.
IMPORTANT: Be careful that the assembly does not
slip off.
For burner assemblies which do not have lifting lugs, place
webbed strapping around a central balance area of the burner.
IMPORTANT: Be careful to avoid damage to small
piping, controls, or wiring.
Fig. 11 — Burner Mounting
8
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Fuel System Installation — See Fig. 12-14 for typi-
cal gas train and oil supply system arrangements. Refer to
burner manual supplied with the burner for installation in-
structions on the particular version of gas train and/or oil
supply system used with your application. These systems are
supplied pre-assembled, and with pre-installed interconnec-
tion fittings.
Do not use Teflon tape on any threaded connections as
a gas or oil pipe sealant. Loose tape pieces can cause
valve leakage and are a safety hazard. Use a pipe joint
compound.
GAS TRAIN — The high-gas pressure switch is mounted
on the gas train piping for convenience only, and does not
NOTES:
1. Oil system schematic shown in high fire
position.
2. Supply pressure must not exceed 3 psi
(20 kPa) or pump seals may be dam-
aged.
Fig. 13 — Mechanical Pressure Atomizing, Light Oil (Pump with External Regulating Relief Valve)
NOTES:
1. Oil system schematic shown in high fire
position.
2. Supply pressure must not exceed 3 psi
(20 kPa) or pump seals may be dam-
aged.
Fig. 14 — Mechanical Pressure Atomizing, Light Oil (Pump with Integral Regulating Relief Valve)
10
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4. Water flow direction must be as specified in job flow dia-
grams or water flow markings on water boxes, and con-
nections must be to the correct entering and leaving wa-
ter box nozzles.
2. Do not loosen or disconnect fusible plug while connect-
ing relief pipe to it.
3. Make sure connections to fusible plug are threaded and
allow easy piping removal for leak test and maintenance.
5. Install water box vent and drain piping in accordance with
individual job data. Air vents should be at all high points
in piping to eliminate water hammer.
4. Install pipe hangers where needed to be sure no weight or
stress is placed on the fusible plug.
6. Location of the chilled hot water and cooling water pumps
as well as the expansion tank must allow for the hydro-
static and water heads, to ensure that the total pressure
does not exceed the water box design working pressure.
7. A cooling tower bypass valve should be installed if the
cooling water temperature might fall below 59 F (15 C)
during chiller operation.
8. Install thermometer wells and thermometers on the en-
tering and leaving chilled/hot water pipes, absorber en-
tering and leaving cooling water pipes, and condenser leaving
cooling water pipe. Thermometer wells should extend into
1
the pipe a minimum of ⁄3 pipe diameter.
9. Install pressure gage taps and pressure gages on the en-
tering and leaving chilled/hot water pipes and cooling wa-
ter pipes.
Fusible Plug Drain Piping (Fig. 16)
1. Connect drain piping to discharge hot water to safe area.
Fig. 16 — Fusible Plug Drain Piping
LEG
—
—
PRESSURE GAGE
THERMOMETER
—
STRAINER
—
—
CHECK VALVE
—
FLOW METER
MACHINE ENVELOPE
Fig. 15 — Piping Flow Schematic
11
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Connect Rupture Disc Piping — Vent rupture disc
to the outside of the building for safety. Model 16DF ma-
chines sometimes are factory equipped with a rupture disc
assembly on the generator-vapor transfer area.
1. 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 disconnected pe-
riodically for inspection of disc. Provide pipe plug on out-
let side of relief device for leak testing.
2. Cover outdoor vent with a rain cap to prevent excessive
moisture from entering the vent line.
3. 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.
Connect Fuel Piping — Connect fuel lines to burner
fuel system and install separate fuel fittings using job data,
piping drawings, and general guidelines found in the burner
manual supplied by the burner manufacturer. Installation re-
quirements will vary for local building and insurance codes,
and for different application conditions.
Do not use Teflon Tape as an oil or gas pipe sealant.
Tape can cause valves to fail, creating a safety hazard.
Use a pipe joint compound.
1. Use a full size dirt pocket or trap in gas piping ahead of
the main manual shutoff.
2. Piping must be sized to provide the minimum specified
oil or gas pressure at the main manual shutoff when op-
erating at the maximum input.
3. A 2-pipe system with suction and return lines must be
used for oil burners, and the lines should be run in a trench
or under the floor when possible. Copper tubing with flare
fittings should be used for oil lines.
4. Hand valves must not be installed on discharge side of oil
pump or return line without a bypass relief installed to
the tank. An oil shut-off valve should be provided in the
suction line near the burner.
5. Oil suction lines should be pitched back slightly to the
tank and care should be taken to avoid any air traps in the
line.
6. The fuel system must be pressure tested with air or inert
gas and proven leak tight. Gas systems should be tested
for at least 3 times the gas pressure that will be used.
Connect Exhaust Duct — Connect combustion ex-
haust ducting using job data and piping drawings. Systems
will vary for different application conditions.
1. Sharp bends and restrictions should be avoided to allow
smooth gas flow.
2. The outlet should be arranged to prevent rainwater entry
into the machine exhaust, and drains should be provided
to remove condensate or water.
3. Exhaust gas dampers and draft regulators must be in-
stalled correctly for proper operation.
INSULATION AND PAINT
Insulation (If Required) — Apply insulation as in-
dicated in job data, after machine assembly and field piping
have been completed. If shipping vacuum or pressure test
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