Carrier 19XB User Manual
Positive Pressure Storage System
50/60 Hz
Installation, Operating, and Maintenance
Instructions
For Use With Positive Pressure Chillers
SAFETY CONSIDERATIONS
Positive pressure storage systems 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 this guide.
DO NOT VENT refrigerant relief valves within a building. Outlet
from rupture disc or relief valve must be vented outdoors in accordance with the latest edition ofASHRAE 15 (American Society
of Heating, Refrigeration, and Air Conditioning Engineers). The
accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ASHRAE 15,
especially forenclosed and low overheadspaces. Inhalation of high
concentrations of vapor is harmful and may cause heart irregularities, unconsciousness,or death. Misusecan be fatal.Vaporis 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.
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 USE air for leak testing. Use only tracer gases and dry
nitrogen.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed and
functioning before operating any machine.
with soapand water.If any entersthe eyes, IMMEDIATELYFLUSH
EYES with water and consult a physician.
NEVER APPLY an open flame or live steam to a refrigerant cylinder. Dangerous overpressure can result. When necessary to heat
refrigerant, use only warm (110 F [43 C]) water.
DO NOT REUSE disposable (nonreturnable) cylinders or
attempt to refill them. It is DANGEROUSAND 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 transferring refrigerant to the machine. Theintroduction of the wrong refrigerant can
cause damage or malfunction to this machine.
Operation of this equipment with refrigerants other than those
cited herein shouldcomply with ASHRAE 15 (latest edition). Contact Carrierfor further information on use of thismachine with other
refrigerants.
DO NOTATTEMPT TO REMOVE fittings, covers, etc., while machine is under pressure or while machine is running. Be sure pressure is at 0 psig (0 kPa) before breaking any refrigerant
connection.
CAREFULLY INSPECT all relief devices, 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
device when corrosion or build-up of foreign material (rust, dirt,
scale, etc.) is found within the valve body or mechanism. Replace
the device.
DO NOT install relief devices in series or backwards.
USE CAREwhen working near orin line witha compressed spring.
Sudden release of the spring can cause it and objects in its path to
act as projectiles.
19XB
DO NOT WELD OR FLAMECUT any refrigerant line or vessel
until allrefrigerant (liquid andvapor) has beenremoved from chiller.
Traces of vapor should be displaced with dry air or nitrogen and
the work area should be well ventilated. Refrigerant 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 NOTWORK ON electricalcomponents, including control panels, switches, starters, or oil heater until you are sureALL POWER
IS OFF and no residual voltage can leak from capacitors or solidstate components.
LOCK OPEN ANDTAGelectrical circuits during servicing.IF WORK
IS INTERRUPTED, confirm that all circuits are deenergized before resuming work.
DO NOT syphon refrigerant by mouth.
AVOID SPILLING liquid refrigerant on skin or getting it into the
eyes. USE SAFETY GOGGLES. Wash any spills from the skin
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. 531-927 Printed in U.S.A. Form 19XB-1SI Pg 1 6-96 Replaces: New
DO NOT STEP on refrigerant lines. Broken lines can whip about
and cause personal injury and damage to the machine.
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 such equipment when there is a risk of slipping or losing your balance.
BE AWARE that certain automatic start arrangements CAN ENGAGE THE STARTER. Open the disconnect ahead of the starter
in addition to shutting off the machine or pump.
USE only repair or replacement parts that meet the code requirements of the original equipment.
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.
DO NOTMIX REFRIGERANTfrom chillers thatuse differentcompressor oils. Compressor damage can result.
CONTENTS
Page
SAFETY CONSIDERATIONS ...................1
INTRODUCTION ..............................2
INSTALLATION .............................2-10
Complete Pre-Installation Checks .............2
• IDENTIFY UNIT
• INSPECT SHIPMENT
Mount the Pumpout Unit .....................3
• MOUNTING ON THE CHILLER
• FLOOR MOUNTING
Rig the Storage Tank .........................3
Make Piping Connections ....................7
• INSTALL VENT PIPING TO RELIEF DEVICES
Make Electrical Connections ..................7
CONTROLS AND COMPONENTS ..............11
Pumpout Unit ................................11
• CONTROLS
• SAFETY CONTROL SETTINGS
• COMPRESSOR
• CONDENSER
• OIL SEPARATOR
• SUCTION AND DISCHARGE VALVES
Storage Tank ................................11
• DRAIN VALVE
• DUAL RELIEF VALVES
• PRESSURE GAGE
• LEVEL GAGE
OPERATION ...............................11-15
Overview ...................................11
• REFRIGERANT TRANSFER
• TRANSFERRING LIQUID REFRIGERANT FROM
THE CHILLER COOLER TO THE CHILLER
CONDENSER OR PUMPOUT STORAGE TANK
• TRANSFERRING LIQUID REFRIGERANT FROM
THE CHILLER CONDENSER OR PUMPOUT
STORAGE TANK TO THE CHILLER COOLER
• DISTILLING THE REFRIGERANT
Pumpout and Refrigerant Transfer
Procedures ...............................12
• OPERATING THE PUMPOUT UNIT
• TO READ REFRIGERANT PRESSURES
• POSITIVE PRESSURE CHILLERS WITH STORAGE
TANKS
• CHILLERS WITH ISOLATION VALVES
• DISTILLING THE REFRIGERANT
MAINTENANCE ............................15,16
Pumpout Unit ...............................15
• PUMPOUT COMPRESSOR OIL CHARGE
Storage Tank ...............................16
Ordering Replacement Parts .................16
TROUBLESHOOTING ........................16
INTRODUCTION
The 19XB Positive Pressure Storage (PPS) System has
been designed to help owners and operators of positive pressure chillers store refrigerants HCFC-22 and HFC-134a during service and repair work. The 19XB system conserves
these refrigerantsand prevents the releaseofexcessive amounts
of refrigerant into the atmosphere. The proper use of this
equipment minimizes the loss of HFCs and HCFCs.
The 19XB PPS systemshownin Fig. 1 consists of a pumpout unit mounted on a storage tank. The pumpout unit is offered as a free-standing unit that can be used with chillers
that have an existing storage tank or with chillers that have
isolation valves that permit built-in refrigerant storage.
The 19XB PPS systems are factory tested and certified to
theAmerican Society of Mechanical Engineers(ASME)pressure vessel code. The tanks are constructed of certified steel
and are pressure rated at 300 psig (2068 kPa). The PPS storage tank is equipped with dual relief valves for proper venting per ASHRAE 15 (American Society of Heating Refrigeration, and Air Conditioning Engineers) guidelines. An
automatic level switch is prewired to the control circuit to
ensure proper storage levels.
The 19EA pumpout unit is a complete, hermetic, compact
unit that consists of:
• a spring-mounted reciprocating compressor with a direct-
drive motor
• a water-cooled refrigerant condenser
• an oil separator
• suction and discharge valves to control refrigerant flow
• prewired safety and control devices.
When referencing refrigerant charges in this manual, the
HCFC-22 charge will be listed first and the HFC-134a value
will follow in brackets.
INSTALLATION
Complete Pre-Installation Checks
IDENTIFY UNIT — Identify the assembly number
(T able1) printed on the pumpout unit andstoragetank nameplates. Check this information against the job requirements.
Fig. 1 shows the PPS system and its major components.
Refer to Tables 2 and 3 for physical data.
INSPECT SHIPMENT — Inspect unit for damage before
removing unitfromshipping conveyance. If unit appearsdamaged, it should be inspected by a shipping inspector before
removal. File a claim with the shipping company if shipment is damaged or incomplete. The manufacturer is not responsible for damage incurred during transit.
Check all components. Notify the supplier immediately if
any item is missing. To prevent loss or damage, leave all
parts in their original package until they are needed.
2
Table 1 — Positive Pressure System Assembly Numbers
POSITIVE PRESSURE
SYSTEM ASSEMBLY
NUMBER
19XB04280205 19EA42-748 R-22 208-3-60 13.2 63.5 28 cu ft
19XB04280206 19EA44-748 R-22 230-3-60 11.5 57.5 28 cu ft
19XB04280207 19EA46-748 R-22 400/460-3-50/60 5.8 28.8 28 cu ft
19XB04280208 19EA47-748 R-22 575-3-60 4.6 23.0 28 cu ft
19XB04280213 19EA48-748 R-134a 208-3-60 13.2 63.5 28 cu ft
19XB04280214 19EA49-748 R-134a 230-3-60 11.5 57.5 28 cu ft
19XB04280215 19EA51-748 R-134a 400/460-3-50/60 5.8 28.8 28 cu ft
19XB04280216 19EA52-748 R-134a 575-3-60 4.6 23.0 28 cu ft
19XB04280601 19EA42-748 R-22 208-3-60 13.2 63.5 None
19XB04280602 19EA44-748 R-22 230-3-60 11.5 57.5 None
19XB04280603 19EA46-748 R-22 400/460-3-50/60 5.8 28.8 None
19XB04280604 19EA47-748 R-22 575-3-60 4.6 23.0 None
19XB04280605 19EA48-658 R-134a 208-3-60 13.2 63.5 None
19XB04280606 19EA49-658 R-134a 230-3-60 11.5 57.5 None
19XB04280607 19EA51-658 R-134a 400/460-3-50/60 5.8 28.8 None
19XB04280608 19EA52-658 R-134a 575-3-60 4.6 23.0 None
19XB04520205 19EA42-748 R-22 208-3-60 13.2 63.5 52 cu ft
19XB04520206 19EA44-748 R-22 230-3-60 11.5 57.5 52 cu ft
19XB04520207 19EA46-748 R-22 400/460-3-50/60 5.8 28.8 52 cu ft
19XB04520208 19EA47-748 R-22 575-3-60 4.6 23.0 52 cu ft
19XB04520213 19EA48-748 R-134a 208-3-60 13.2 63.5 52 cu ft
19XB04520214 19EA49-748 R-134a 230-3-60 11.5 57.5 52 cu ft
19XB04520215 19EA51-748 R-134a 400/460-3-50/60 5.8 28.8 52 cu ft
19XB04520216 19EA52-748 R-134a 575-3-60 4.6 23.0 52 cu ft
LEGEND
LRA — Locked RotorAmps
RLA — Rated LoadAmps
PUMPOUT UNIT
ASSEMBLY NO.
REFRIGERANT
COMPRESSOR MOTOR
(V-Ph-Hz)
NOTES:
1. Allstorage vesselsare 300 psig (2068 kPa)designs perthe ASME
(American Society of Mechanical Engineers) Boiler Pressure
Vessel Code, Section VIII Division 1.
2. Allunits aboveare shippedwitha 15psig (103kPa) nitrogencharge.
3. Nominal horsepower for all pumpout units is 3.0.
MAXIMUM
RLA
LRA
STORAGE
TANK
MountthePumpoutUnit— The pumpout unit, if pur-
chased separately, may be mounted directly on the chiller or
it may be floor mounted.
MOUNTING ON THE CHILLER — See instructions provided with the chiller for mountingthepumpout unit. Atypical chiller mount is shown in Fig. 2.
FLOOR MOUNTING — Select a ventilated and accessible
area, free of traffic or other hazards. Removeand discard the
4 angle supports at the base of the pumpout unit and bolt the
unit to the floor through the 4
pumpout unit. Special isolation is unnecessary. Contact surface and dimensions for the pumpout unit are given in
Fig. 3.
7
⁄16in. holes at the base of the
Rig the Storage Tank — The complete 19XB system
can be rigged as a single assembly. See the rigging instructions on the label attached to the assembly. Also refer to the
rigging guide (Fig. 4), physical data in Tables 2 and 3, and
contact surface and dimensions for the complete system in
Fig. 5. Lift the assembly only from the 4 points indicated in
the rigging guide. Each rigging cable must be capable of
supporting the entire weight of the assembly.
Lifting the assembly from points other than those specified may result in serious damage to the assembly and
personal injury. Riggingequipmentand procedures must
be adequate forassembly. See Tables 2 and 3for weights.
NOTE: These weights are broken down into pumpout
unit and storage tank weights. For the complete assembly weight, add all components together.
3
VALVES
VENT VALVE
VALVES
CONDENSER
WATER
CONNECTIONS
(FIELD PIPING)
REFRIGERANT
INLET VALVE
19EA PUMPOUT UNIT
CONTROL BOX
(WIRING BY
CONTRACTOR)
COMPRESSOR
19EA PUMPOUT UNITS
19EA CONTROL BOX (INTERIOR)
Fig. 1 — 19XB Positive Pressure Storage System
4
*3⁄8-16 bolts × 1-in. lg; 4 required.
Fig. 2 — 19EA Pumpout Unit: Typical Chiller Mount
ELECTRICAL CONNECTION
OPTION LIST
TRADE SIZE QTY LOCATION
1
⁄2( 1TOP
3
⁄
4
( 1 BOTTOM
1( 1 MIDDLE
1
1
⁄4( 1 MIDDLE
Fig. 3 — Pumpout Unit Contact Surfaces and Dimensions
5
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