Carrier 19XR User Manual
Positive Pressure Storage System
Installation, Operating, and
Maintenance Instructions
19XR
50/60 Hz
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.
Installation, start-up, and servicing of this equipment can
be hazardous due to system pressures, electrical components, and equipment location (roofs, elevated structures,
etc.). Only trained, qualified installers and service technicians should install, start up, and service this equipment.
Be sure you understand and follow the procedures and
safety precautions contained in this guide.
DANGER
Failure to follow these procedures will result in severe personal injury or death.
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 of ASHRAE 15
(American Society of Heating, Refrigerating, and AirConditioning Engineers). The accumulation of refrigerant in
an enclosed space can displace oxygen and cause
asphyxiation.
PROVIDE adequate ventilation in accordance with 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. Misuse can be
fatal. Vapor is 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.
WARNING
Failure to follow these procedures may result in personal
injury or death.
DO NOT USE TORCH to remove any component. System
contains oil and refrigerant under pressure.
To remove a component, wear protective gloves and goggles
and proceed as follows:
a. Shut off electrical power to unit.
b. Recover refrigerant to relieve all pressure from system
using both high-pressure and low-pressure ports.
c. Traces of vapor should be displaced with nitrogen and
the work area should be well ventilated. Refrigerant in
contact with an open flame produces toxic gases.
d. Cut component connection tubing with tubing cutter,
and remove component from unit. Use a pan to catch any
oil that may come out of the lines and as a gage for how
much oil to add to the system.
e. Carefully unsweat remaining tubing stubs when neces-
sary. Oil can ignite when exposed to torch flame.
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 voltage can leak from
capacitors or solid-state components.
LOCK OPEN AND TAG electrical circuits during servicing.
IF WORK IS INTERRUPTED, confirm that all circuits are
de-energized before resuming work.
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 any 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 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 DANGEROUS AND ILLEGAL.
When cylinder is emptied, evacuate remaining gas pressure,
loosen the collar and unscrew and discard the valve stem. DO
NOT INCINERATE.
(Warnings continued on next page.)
Catalog No. 04-531900050-01 Printed in U.S.A. Form 19XR-CLT-16SI Rev. A Pg 1 8-19 Replaces: 19XR-6SI
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
WARNING
CHECK THE REFRIGERANT TYPE before transferring
refrigerant to the machine. The introduction of the wrong
refrigerant can cause damage or malfunction to this machine.
Operation of this equipment with refrigerants other than those
cited herein should comply with ASHRAE 15 (latest edition).
Contact Carrier for further information on use of this machine
with other refrigerants.
ENSURE that refrigerant is only pumped to or stored in tanks
that are ASME (American Society of Mechanical Engineers)
certified for the pressures appropriate to the refrigerant being
handled.
DO NOT ATTEMPT 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 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.
CAUTION
Failure to follow these procedures may result in personal
injury or damage to equipment.
EQUIPMENT should be operated by certified personnel only.
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 NOT MIX REFRIGERANT from chillers that use different compressor oils. Compressor damage can result.
DO NOT re-use compressor oil or any oil that has been
exposed to the atmosphere. Dispose of oil per local codes and
regulations.
DO NOT leave refrigerant system open to air any longer than
the actual time required to service the equipment. Seal circuits
being serviced and charge with dry nitrogen to prevent oil contamination when timely repairs cannot be completed.
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Step 1 — Complete Pre-Installation Checks . . . . . . 3
• IDENTIFY UNIT
• INSPECT SHIPMENT
Step 2 — Mount the Pumpout Unit . . . . . . . . . . . . . . 3
• MOUNTING ON THE CHILLER
• FLOOR MOUNTING
Step 3 — Rig the Storage Tank . . . . . . . . . . . . . . . . . 3
Step 4 — Make Piping Connections . . . . . . . . . . . . . 6
• INSTALL VENT PIPING TO RELIEF DEVICES
Step 5 — Make Electrical Connections . . . . . . . . . . 6
CONTROLS AND COMPONENTS . . . . . . . . . . . . . . 10
Pumpout Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
• 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
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
• PREPARATION
• OPERATING THE OPTIONAL PUMPOUT UNIT (FIG. 9)
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Storage Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . 17
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 17
INTRODUCTION
The 19XR Positive Pressure Storage (PPS) system has been designed to help owners and operators of positive pressure chillers
store HFC-134a refrigerant during service and repair work. The
19XR system conserves this refrigerant and prevents the release of
excessive amounts of refrigerant into the atmosphere. The proper
use of this equipment minimizes the loss of HFCs.
The 19XR PPS system shown in Fig. 1 consists of a pump-out
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 19XR PPS systems are factory tested and certified to the
American Society of Mechanical Engineers (ASME) pres-sure
vessel code. The tanks are constructed of certified steel and are
pressure rated at 185 psig (1276 kPa). The PPS storage tank is
equipped with dual relief valves for proper venting per ASHRAE
15 (American Society of Heating, Refrigerating, and Air-Conditioning Engineers) guidelines. An automatic level switch is prewired to the control circuit to ensure proper storage levels.
2
The 19XR pumpout unit is a complete, hermetic, compact unit
that consists of:
• a hermetic 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.
INSTALLATION
Step 1 — Complete Pre-Installation Checks
IDENTIFY UNIT
Identify the assembly number (see Table 1) printed on the pumpout unit and storage tank nameplates. Check this information
against the job requirements. Figure 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 unit from shipping con-
ping 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.
Step 2 —
Mount the Pumpout Unit
The pumpout unit, if purchased 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 mounting the pumpout unit. A typical chiller mount is shown in Fig. 2.
FLOOR MOUNTING
Select a ventilated and accessible area, free of traffic or other hazards. Remove and discard the 4 angle supports at the base of the
pumpout unit and bolt the unit to the floor through the holes at the
base of the pumpout unit. Special isolation is unnecessary. Contact
surface and dimensions for the pumpout unit are given in Fig. 3.
veyance. If unit appears damaged, it should be inspected by a ship-
Table 1 — Positive Pressure System Assembly Numbers (R-134a)
PUMPOUT
SYSTEM
ARRANGEMENT
NUMBER
19XR04027401 19XR04035801 208/230-3-50/60 15.8 105.0 28 cu ft (0.8 cu m)
19XR04027402 19XR04035802 460-3-60 7.8 52.0 28 cu ft (0.8 cu m)
19XR04027403 19XR04035803 400-3-50 7.8 52.0 28 cu ft (0.8 cu m)
19XR04027501 19XR04035801 208/230-3-50/60 15.8 105.0 52 cu ft (1.5 cu m)
19XR04027502 19XR04035802 460-3-60 7.8 52.0 52 cu ft (1.5 cu m)
19XR04027503 19XR04035803 400-3-50 7.8 52.0 52 cu ft (1.5 cu m)
19XR04026801 19XR04035801 208/230-3-50/60 15.8 105.0 Free-standing
19XR04026802 19XR04035802 460-3-60 7.8 52.0 Free-standing
19XR04026803 19XR04035803 400-3-50 7.8 52.0 Free-standing
19XR14017801 19XR04035801 208/230-3-50/60 15.8 105.0 Unit-mounted, frame 1
19XR14017802 19XR04035802 460-3-60 7.8 52.0 Unit-mounted, frame 1
19XR14017803 19XR04035803 400-3-50 7.8 52.0 Unit-mounted, frame 1
19XR34017801 19XR04035801 208/230-3-50/60 15.8 105.0 Unit-mounted, frame 2 or 3
19XR34017802 19XR04035802 460-3-60 7.8 52.0 Unit-mounted, frame 2 or 3
19XR34017803 19XR04035803 400-3-50 7.8 52.0 Unit-mounted, frame 2 or 3
19XR44017801 19XR04035801 208/230-3-50/60 15.8 105.0 Unit-mounted, frame 4
19XR44017802 19XR04035802 460-3-60 7.8 52.0 Unit-mounted, frame 4
19XR44017803 19XR04035803 400-3-50 7.8 52.0 Unit-mounted, frame 4
19XR54017801 19XR04035801 208/230-3-50/60 15.8 105.0 Unit-mounted, frame 5
19XR54017802 19XR04035803 460-3-60 7.8 52.0 Unit-mounted, frame 5
19XR54017803 19XR04035803 400-3-50 7.8 52.0 Unit-mounted, frame 5
19XR64017801 19XR04035801 208/230-3-50/60 15.8 105.0 Unit-mounted, frame 6
19XR64017802 19XR04035802 460-3-60 7.8 52.0 Unit-mounted, frame 6
19XR64017803 19XR04035803 400-3-50 7.8 52.0 Unit-mounted, frame 6
19XR74017801 19XR04035801 208/230-3-50/60 15.8 105.0 Unit-mounted, frame 7
19XR74017802 19XR04035802 460-3-60 7.8 52.0 Unit-mounted, frame 7
19XR74017803 19XR04035803 400-3-50 7.8 52.0 Unit-mounted, frame 7
19XR84017801 19XR04035801 208/230-3-50/60 15.8 105.0 Unit-mounted, frame 8
19XR84017802 19XR04035802 460-3-60 7.8 52.0 Unit-mounted, frame 8
19XR84017803 19XR04035803 400-3-50 7.8 52.0 Unit-mounted, frame 8
LEGEND NOTES:
LRA — Locked Rotor Amps
RLA — Rated Load Amps
PUMPOUT UNIT
ASSEMBLY NUMBER
COMPRESSOR MOTOR
(V-PH-Hz)
1. All storage vessels are 185 psig (1276 kPa) designs per the ASME
2. All units above are shipped with a 15 psig (103 kPa) nitrogen
3. Nominal horsepower for all pumpout units is 3.0.
MAXIMUM
RLA
(American Society of Mechanical Engineers) Boiler Pressure Vessel Code, Section VIII Division 1.
charge.
LRA STORAGE TANK
3
Step 3 —
CONTACTOR
TERMINAL
STRIP
FUSES
TRANSFORMER
SWITCH
19XR PUMPOUT UNIT
19XR CONTROL BOX (INTERIOR)
a19-2444
a19-2444
a19-1569ef
COMPRESSOR
CONTROL
BOX
VALV E
ASSEMBLY
CONDENSER
OIL
SEPARATOR
a19-1570ef
Rig the Storage Tank
The complete 19XR 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.
FRAME
ASSEMBLY
COMPRESSOR
VALVE 2
VALVE 3
VALVE 4
VALVE 5
CONTROL
PANEL
WARNING
Lifting the assembly from points other than those specified
may result in serious damage to the assembly and personal
injury. Rigging equipment and procedures must be adequate
for assembly. See Tables 2 and 3 for weights. (These weights
are broken down into pumpout unit and storage tank weights.
For the complete assembly weight, add all components
together.)
ENTERING
WATER
LEAVING
WATER CONDENSER
OIL
OIL
SEPARATOR
HEATER
Fig. 1 — 19XR Positive Pressure Storage System
Fig. 2 — 19XR Pumpout Unit: Typical Chiller Mount
4
NOTE: Dimensions in inches (millimeters).
VAPOR CONNECTIONS
ELECTRICAL CONNECTION OPTION LIST
TRADE SIZE
(in.)
QTY LOCATION
1
/
2
1TOP
3
/
4
1BOTTOM
1 1 MIDDLE
1
1
/
4
1 MIDDLE
a19-2445
NOTES:
1. Each chain must be capable of supporting the entire weight of the machine.
2. Minimum chain length:
28 ft
3
(0.79 m3) tank — 10-0 (3098 mm)
52 ft
3
(1.47 m3) tank — 15-6 (4724 mm)
STORAGE
TANK
SIZE
CENTER OF
GRAVITY
DIMENSIONS
(APPROX.)
ft-in. (mm)
OVERALL DIMENSIONS
(APPROX.)
ft-in. (mm)
EMPTY
WEIGHT
lb (kg)
ABCDE
28 CU FT
(0.8 CU M)
4-9
1
/8
(1451)
1-77/
8
(505)
10-5
(3175)
2-4
3
/
4
(730)
4-4
1
/
4
(1327)
2,385
(1082)
52 CU FT
(1.5 CU M)
6-11
5
/
8
(2124)
1-8
3
/
4
(527)
14-11
1
/
4
(4553)
2-8
1
/
2
(826)
4-8
1
/
4
(1429)
3,415
(1549)
a19-1572ef
WATER CONNECTIONS
3/4" FNPT
1/2" MALE FLARE
ELECTRICAL
CONNECTION
LOCATION
3.25
(83)
CONTROL PANEL
28.45
(723)
24.75
(629)
VACUUM SWITCH
OIL SEPARATORHIGH-PRESSURE SWITCH
COMPRESSOR
23.00
(584)
13.12
(333)
1.00
9.74
(247)
(25)
2.88
(73)
4.58
(116)
18.13
(461)
11.59
(294)
8.21
(209)
4.25
(108)
9.50
(241)
13.25
(337)
9.48
(250)
19.00
(438)
CONDENSER
(2X) 1.82
(33)
7.94
(202)
Fig. 3 — Pumpout Unit Contact Surfaces and Dimensions
OIL SIGHTGLASS
10.50
(267)
MOUNTING HOLES
Fig. 4 — Rigging Guide
5
Table 2 — Physical Data — 19XR Pumpout Unit
ENGLISH SI
Pumpout Unit Weight* lb (kg) 164 (75)
Pumpout Condenser Water Flow Rate gpm (L/s) 7-9 (.45-.58)
Pumpout Condenser Water Pressure Drop psig (kPa) 0.3 (2.0)
Maximum Entering Condenser Water Temperature F (C) 85 (29)
Maximum Leaving Condenser Water Temperature F (C) 100 (37)
Relief Valve psig (kPa) 235 (1620)
Condenser Pressure Rating
Refrigerant Side psig (kPa) 450 (3102)
Waterside psig (kPa) 450 (3102)
*The pumpout unit weight includes the compressor/condenser, control
box, and the oil separator.
NOTES:
1. The motor is hermetic with thermal protection.
2. The control box is mounted and wired with an ON/OFF/AUTO.
switch according to NEMA 1 (National Electrical Manufacturing
Association).
3. The starter contactor is located in the control box. The overloads
on the motor are wired and the internal disconnect switch is supplied by the customer.
Table 3 — 19XR Storage Tank Rated Dry Weight and Refrigerant Capacity
SIZE
cu ft (cu m)
28 (0.8) 24.00 (610) 2334 (1059) 1860 (844) 1716 (778)
52 (1.5) 27.25 (692) 3414 (1549) 3563 (1616) 3286 (1491)
LEGEND
ANSI — American National Standards Institute
ASHRAE — American Society of Heating, Refrigeration,
UL — Underwriters’ Laboratories
*The above dry weight includes the pumpout unit weight of 164 lb
(75 kg).
and Air-Conditioning Engineers
TANK OD
in. (mm)
DRY WEIGHT*
lb (kg)
MAXIMUM REFRIGERANT CAPACITY LB (KG)
ASHRAE/ANSI 15 UL 1963
R-134a R-134a
Step 4 — Make Piping Connections
Figure 5 represents typical pumpout unit/chiller piping connections. Standard connections for
1
/2-in. OD copper tubing are provided. Install the field-supplied FPT tee with pipe plug in the piping as shown in Fig. 5. This tee is used for refrigerant charging.
NOTE: If any field piping runs exceed 50 ft in length, use
7
/8-in.
OD copper tubing to minimize pressure drop.
Pumpout unit water piping connections are shown in Fig. 5. Both
connections are
3
/4-in. NPT (female). A shutoff valve should be
installed in the water line. Provide a means for blowing water
from the condenser coil at winter shutdown to prevent freeze-up
damage. Refer to the Job Data for water piping particulars.
INSTALL VENT PIPING TO RELIEF DEVICES
The pumpout storage tank is factory-equipped with relief devices.
Refer to Fig. 6 and Table 4 for size and location of the relief devices. Vent the relief devices to the outdoors in accordance with
ANSI/ASHRAE 15 Safety Code (latest edition) for Mechanical
Refrigeration and all other applicable codes. Pumpout unit relief
devices are set to relieve at 235 psig (1620 kPa). Storage tank relief devices are set to relieve at 185 psig (1276 kPa).
DANGER
Refrigerant discharged into confined spaces can displace oxygen and cause asphyxiation.
1. If relief devices are manifolded, the cross-sectional area of
the relief pipe must at least equal the sum of the areas
required for individual relief pipes.
2. Provide a pipe plug near outlet side of each relief device for
leak testing. Provide pipe fittings that allow vent piping to be
disconnected periodically for inspection 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.
Step 5 —
Make Electrical Connections
See nameplate on compressor of pumpout unit and Table 1 for
motor electrical data. Wire unit according to the diagram inside
the control box.
Figure 7 is the wiring schematic for a complete system that includes the 19XR storage tank and the pumpout unit. Figure 8 is the
wiring schematic for the pumpout unit. Use this schematic for installations that do not include an auxiliary pumpout storage tank.
NOTE: Use copper conductors only.
6
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