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
0’- 3 1/2"
[89mm]
2’- 9 7/8"
[860mm]
2’- 5"
[737mm]
0’- 9 7/8"
[249mm]
4’- 9 1/2"
[1451mm]
6’- 4 3/16"
[1935mm]
1" NPT
LIQUID CONN.
0’- 9"
[229mm]
TYPICAL
3’- 1 1/4"
[946mm]
3’- 4 5/8"
[1032mm]
3’- 4 7/8"
[1038mm]
2’- 9 9/16"
[852mm]
VAPOR
3/4" NPT
PUMPOUT CONDENSER
WATER INLET CONN.
1/2" MALE FLARE
VAPOR CONN.
3/4" NPT
PUMPOUT CONDENSER
WATER OUTLET CONN.
ELECTRICAL SERVICE
ACCESS SPACE
20 3/4" X 8 3/4" X 4 1/2"
(BOTH SIDES)
28 CU.FT. [.79 CU. METER]
STORGE TANK WITH PUMPOUT UNIT
10’- 5 "
[3175mm]
NOTES:
1. Denotes center of gravity.
2. Dimensions in [ ] are in millimeters.
3. The weights and center of gravity values given are for an empty
storage tank.
4. For additional information on the pumpout unit, see certified
drawings.
5. Conduit knockout is located on the side of the control box.
6. Storage tank weight: 2334 lb (1059 kg).
TOP VIEW
FRONT VIEW
1’-0 3/4"
[324mm]
3/8" MALE FLARE
RELIEF VALVE CONN.
1/2" DIA. K.O.
ELECTRICAL CONN.
(PUMPOUT POWER)
(FAR SIDE)
3’- 11 3/8"
[1203mm]
3’- 9"
[1143mm]
0’- 3 1/4"
[83mm]
0’- 10"
[254mm]
1’- 7 7/8"
[505mm]
4’- 4 1/4"
[1327mm]
0’- 2 3/4"
[70mm]
0’- 7 15/16"
[202mm]
(FARSIDE)
28 CU FT [0.8 CU METER] STORAGE TANK WITH PUMPOUT UNIT
LEFT SIDE VIEW
LEVEL GAGE
a19-2442
a19-1585
a19-1584
0' - 5 1/2"
[140mm]
2'- 5 3/4"
[756mm]
3/8" MALE FLARE
RELIEF VALVE CONN.
1/2" DIA. K.O.
ELECTRICAL CONN.
(PUMPOUT POWER)
0' - 9 "
[229mm]
TYPICAL
2' - 4 3/4 "
[730mm]
PRESSURE GAGE
2' - 0 3/8"
[619mm]
1' - 7 "
[483mm]
5' - 0 1/4 "
[1530mm]
9' - 10 "
[2997mm]
(2) 1-1/4" NPT RELIEF
VALVE OUTLET (SEE FIELD
INSTALLATION NOTES)
0' - 5 7/8 "
[149mm]
1' - 2 3/8 "
[365mm]
Fig. 5 — Storage Tank with Pumpout Unit
7
2'-6"
[762mm]
3/8" MALE FLARE
RELIEF VALVE CONN.
1/2" DIA. K.O.
ELECTRICAL CONN.
(PUMPOUT POWER)
0'-9"
[229 mm]
TYPICAL
2'-8 1/2"
[826 mm]
1'-4 1/4"
[413 mm]
14'-4 1/2"
[4381mm]
0'-5 7/8"
[149mm]
(2) 1-1/4" NPT RELIEF
VALVE OUTLET (SEE FIELD
INSTALLATION NOTES)
5'-0 1/2"
[1537mm]
1'-7"
[483mm]
2'-0 5/8"
[625mm]
PRESSURE GAGE
0'-5 1/2"
[140mm]
LEVEL GAGE
0’ - 3 3/8"
[86mm]
2’ - 10 1/8"
[867mm]
2’ - 5 1/4"
[742mm]
6’ - 11 5/8"
[2124mm]
0’ - 9 7/8"
[249mm]
7’ - 2 1/4"
[2191mm]
14’ - 11 1/4"
[4553mm]
1" NPT
LIQUID CONN.
52 CU. FT. [1.47 CU. METER]
STORAGE TANK WITH PUMPOUT UNIT
3’ - 8 3/4"
[1137mm]
3’ - 1 7/16"
[951mm]
0’ - 9 "
[229mm]
TYPICAL
3’ - 8 1/2 "
[1130mm]
3’ - 4 1/2"
[1029mm]
ELECTRICAL SERVICE
ACCESS SPACE
20 3/4" X 8 3/4" X 4 1/2"
(BOTH SIDES)
3/4" NPT
PUMPOUT CONDENSER
WATER OUTLET CONN.
1/2" MALE FLARE
VAPOR CONN.
3/4" NPT
PUMPOUT CONDENSER
WATER INLET CONN.
VAPOR
1’ - 0 3/4"
[324mm]
3/8" MALE FLARE
RELIEF VALVE CONN.
1/2" DIA. K.O.
ELECTRICAL CONN.
(PUMPOUT POWER)
(FAR SIDE)
0’ - 0 15/16"
[202mm]
(FARSIDE)
0’ - 2 3/4"
[70mm]
4’ - 3 1/4"
[1302mm]
4’ - 1"
[1225mm]
0’ - 3 1/4"
[83mm]
0’ - 10"
[254mm]
1’ - 8 3/4"
[527mm]
4’ - 8 1/4"
[1429mm]
NOTES:
1. Denotes center of gravity.
2. Dimensions in [ ] are in millimeters.
3. The weights and center of gravity values given are for an empty
storage tank.
4. For additional information on the pumpout unit, see certified
drawings.
5. Conduit knockout is located on the side of the control box.
6. Storage tank weight: 3414 lb (1549 kg).
FRONT VIEW
TOP VIEW
LEFT SIDE VIEW
52 CU FT [1.5 CU METER] STORAGE TANK WITH PUMPOUT UNIT
a19-2443
a19-1583
a19-1582
Fig. 5 — Storage Tank with Pumpout Unit (cont)
8
SERVICE VALVES
PUMPOUT
COMPRESSOR
PRESSURE RELIEF
VALV E
OIL
SEPARATOR
PUMPOUT
CONDENSER
WATER
CONNECTIONS
2
3
4
5
TO TOP OF
STORAGE TANK
STORAGE TANK
VAPOR VALVE
FROM BOTTOM
OF STORAGE TANK
STORAGE TANK
LIQUID REFRIGERANT VALVE
TEE FOR
REFRIGERANT
CHARGING
TO TOP OF
CHILLER
CONDENSER
SEE NOTE
# 1
TO TOP OF
CHILLER
COOLER
SEE NOTES
# 1 AND 2
CHECK
VALV E
SERVICE VALVES
PUMPOUT
COMPRESSOR
PRESSURE RELIEF
VALV E
OIL
SEPARATOR
PUMPOUT
CONDENSER
WATER
CONNECTIONS
2
3
4
5
TO TOP OF
STORAGE TANK
STORAGE TANK
VAPOR VALVE
FROM BOTTOM
OF STORAGE TANK
STORAGE TANK
LIQUID REFRIGERANT VALVE
TEE FOR
REFRIGERANT
CHARGING
TO BOTTOM OF
COOLER AND
CHILLER
CONDENSER
SEE NOTE
# 1
TO TOP OF
CHILLER
COOLER
OR CONDENSER
SEE NOTES
# 1 AND 2
TO ADDITIONAL
CHILLERS
CHECK
VALV E
CHILLERS WITHOUT ISOLATION VALVES
CHILLERS WITH ISOLATION VALVES
(WITH OR WITHOUT PUMPOUT STORAGE TANKS)
GENERAL PIPING CONNECTION SIZES
NOTES:
1. The field-supplied tubing is to be 1/2-in. OD tubing (min.) and
must be arranged and supported to avoid stresses on the equipment, transmission of vibrations, and interference with routine
access during the reading, adjusting, and servicing of the equipment. If the distance from the chiller to the pumpout unit is over
50 ft, then
7
/8-in. OD tubing (min.) must be used. Provisions
should be made for adjustment in each plane of the tubing and
for both periodic and major servicing of the equipment. Special
care must be taken so that the safety head does not experience
tubing strain. Vent the safety head per ASHRAE 15 (American
Society of Heating, Refrigerating, and Air-Conditioning Engineers), latest revision.
2. The tubing and valve from the storage tank to the pumpout compressor is factory supplied when the unit is factory mounted.
CONNECTION SIZE (in.)
Refrigerant Transfer Connections
1
/2 Flare (male)
Condenser Water Cooling Connectors
3
/4 NPT (female)
Safety Relief Head Pumpdown
3
/8 Flare (male)
LEGEND
Factory-Supplied Tubing
Field-Supplied Tubing
Field-Supplied Tubing (Multiple Chillers)
Service Valve (Factory Supplied)
Service Valve (Field Supplied)
a19-1575ef
a19-1576ef
STORAGE
TANK SIZE
cu ft (cu m)
28 (0.8)
52 (1.5)
Fig. 6 — Typical Pumpout Unit/Chiller Connection Schematic
RELIEF VALVE
OUTLET SIZE
1
1
/4 in. NPT
Female Connector
1
1
/4 in. NPT
Female Connector
Table 4 — Relief Devices
QUANTITY
2 34.5 15.6
2 52.3 23.7
9
REQUIRED “C” FACTOR
lb air
min
kg air
min
a19-2447
LOW PRESSURE CONTROL
NC OPEN < 7 psia (-15.7 in. HG)
CLOSE > 9 psia (-11.6 in. HG)
HIGH PRESSURE
SAFETY
NC OPEN > 185psig
CONTROL POWER
TRANSFORMER
XFMR-1
69 VA
PUMP OUT
COMPRESSOR
CRANKCASE HEATER
240-600v
27-40 WATT
COPELAND PN 081-0031-03
WHT
RED
ORN
HIGH LEVEL
GAGE ALARM
(NC-OPEN AT
90% STORAGE
TANK LEVEL)
WHT
X2
C
5
4
X2
X2
1
X1
FU3
0.5A
H1
H4
FU1
FU2
0.25A
0.25A
GND
2
2
3
SS-1
OFF
AUTO ON
2
L2
L1
8
7
HTR-1
MTR-1
2 OL
2 OL
2 OL
C
C
C
LEVEL GAGE
ALARM SWITCH
NO
NC
LEGEND
C—Contactor
FU — Fuse
GND — Ground
HTR — Heater
MTR — Motor
NC — Normally Closed
OL — Overload
SS — Selector Switch
a19-2448
LOW PRESSURE CONTROL
NC OPEN < 7 psia {-15.7 in. HG}
CLOSE > 9 psia {-11.6 in. HG}
HIGH PRESSURE
SAFETY
NC OPEN > 185psig
CONTROL POWER
TRANSFORMER
XFMR-1
69 VA
PUMP OUT
COMPRESSOR
CRANKCASE HEATER
240-600v
27-40 WATT
X2
C
5
4
X2
X2
1
X1
FU3
0.5A
H1
H4
FU1
FU2
0.25A
0.25A
GND
2
2
3
SS-1
OFF
AUTO ON
2
L2
L1
8
7
HTR-1
MTR-1
2 OL
2 OL
2 OL
C
C
C
LEGEND
C—Contactor
FU — Fuse
GND — Ground
HTR — Heater
MTR — Motor
NC — Normally Closed
OL — Overload
SS — Selector Switch
Fig. 7 — 19XR Pumpout System Wiring Schematic
Figure 1 shows the major components of the PPS system.
Pumpout Unit
The pumpout unit consists of a hermetic compressor, a water
cooled refrigerant condenser, an oil separator, and prewired safety
and control devices. The pumpout unit comes equipped with a 4way transfer valve manifold to interconnect both liquid and vapor
CONTROLS AND COMPONENTS
Fig. 8 — Pumpout Unit Wiring Schematic
transfer and to pressurize the chiller during transfer of refrigerant
from chiller to storage tank.
CONTROLS
The pumpout unit has the following controls: manual/off/automatic selector switch, transformer, .25 amp fuses for the primary side
of the transformer, 5 amp fuse for the secondary side of the transformer, contactor, terminal strip, high pressure cutout switch and
low pressure switch.
10
SAFETY CONTROL SETTINGS
The pumpout unit high-pressure switch (Fig. 3) is set to open at
the settings listed in Table 5. The switch setting is checked by operating the pumpout condenser and slowly throttling the pumpout
condenser water.
When the selector switch is in the Automatic position, the pumpout will cycle on a low pressure/vacuum switch. This switch will
shut down the pumpout compressor when suction pressure reaches 7 ± 1.5 psia or 15 ± 3 in. Hg vacuum (51.7 kPa absolute). When
the selector switch is in the On position, the pumpout compressor
will continue to run until refrigerant vapor flow is so low that the
compressor motor overheats. At this time the compressor motor
overload will shut off the compressor. This is NOT recommended.
Table 5 — High Pressure Switch Settings
REFRIGERANT
R-134a
HIGH-PRESSURE SWITCH
CUTOUT CUT-IN
185 ± 10 psig
(1276 ± 69 kPa)
140 ± 10 psig
(965 ± 69 kPa)
COMPRESSOR
The hermetic compressor assembly comes equipped with internal
thermal protection on the motor and a self-regulating crankcase
heater.
CONDENSER
The water-cooled condenser is a brazed plate heat exchanger.
During transfer, it condenses refrigerant vapor to liquid.
OIL SEPARATOR
The pumpout unit includes an in-line oil separator to remove oil
that becomes mixed with refrigerant and returns the oil to the compressor.
SUCTION AND DISCHARGE VALVES
The pumpout unit comes with a 4-way transfer valve manifold to
interconnect both liquid and vapor transfer and to pressurize the
chiller during transfer of refrigerant from chiller to storage tank or
from one chiller vessel to another.
Storage Tank
The storage tank is rated for positive pressure refrigerants under
ASME Section VIII pressure vessel codes with a minimum of
185 psig (1276 kPa) rating. The tank components include:
DRAIN VALVE
Located at its lowest point of drain with a minimum of 1 in. NPT.
DUAL RELIEF VALVES
Two relief valves and a 3-way shut-off valve.
PRESSURE GAGE
A 30 in. Hg vacuum -0-400 psig (101-0-2760 kPa) compound
pressure gage.
LEVEL GAGE
Liquid level gage (magnetically coupled dial type) with electronic
shut-off at 90% liquid capacity.
WARNING
During transfer of refrigerant into and out of the pumpout storage tank, carefully monitor the storage tank level gage. Do not
fill the tank more than 90% of capacity to allow for refrigerant
expansion. Overfilling may result in damage to the tank and
personal injury. For maximum refrigerant capacity, refer to
Table 3.
OPERATION
Overview
Transferring refrigerant from one vessel to another is accomplished by using either gravity or pressure differential. A difference in elevation between 2 vessels results in a gravity flow of liquid; a difference in pressure forces the liquid from one vessel to
the other. The latter method requires lowering the pressure in one
vessel. If there is liquid in that vessel, its temperature must be lowered, and the pressure in the other vessel must be simultaneously
increased.
Under most circumstances, creating the pressure differential is not
a difficult process. Some applications, such as ice storage, outdoor
installations, or installations with high temperature differentials
between the storage tank and the chiller may require additional
consideration. In some instances, it may be necessary to add auxiliary heat to one of the vessels or to insulate the storage tank at job
sites where high ambient temperature or sun load make it difficult
to reduce the temperature and pressure in the tank. Outdoor installations must have a roof or cover over the storage tank to ensure
that the pressure in the tank does not exceed the chiller relief pressure setting.
REFRIGERANT TRANSFER
When refrigerant is being evacuated from the chiller cooler or
condenser vessels, any liquid refrigerant left in a vessel will flash
off, lowering the temperature in that vessel enough to freeze the
fluid (usually water) flowing through the cooler or condenser
tubes. This event, called tube freeze-up, can cause extensive damage to the chiller; therefore, all liquid refrigerant must be removed
from a vessel before evacuation of refrigerant vapor is started. If
all the liquid cannot be removed, then the cooler water and condenser water pumps must be operated throughout the process of
evacuating refrigerant vapor to keep fluid moving through the
cooler and condenser tubes.
TRANSFERRING LIQUID REFRIGERANT FROM THE CHILLER COOLER TO THE CHILLER CONDENSER OR PUMPOUT STORAGE TANK
Chiller and pumpout unit valves are set to permit the pumpout
compressor to discharge refrigerant vapor into the cooler vessel,
lowering pressure in the condenser vessel/storage tank. The pressure differential forces liquid from the cooler vessel into the condenser vessel/storage tank. After all the liquid is transferred, the
refrigerant vapor remaining in the cooler vessel can be drawn off
by reducing pressure in the chiller and discharging the vapor
through the pumpout unit condenser into the condenser vessel/
storage tank.
NOTE: The pumpout selector switch can be placed in On or Automatic mode. In Automatic mode, the compressor will shut off automatically once the suction pressure drops to 7 psia or 15 in. Hg
vacuum (51.7 kPa absolute). In On mode, the unit will continue to
pumpout regardless of the suction (vacuum) pressure.
TRANSFERRING LIQUID REFRIGERANT FROM THE CHILLER CONDENSER OR PUMPOUT STORAGE TANK TO THE CHILLER COOLER
Chiller and pump-out unit valves are set to increase pressure in the
chiller condenser vessel/storage tank and to reduce pressure in the
cooler vessel. Pressure in the cooler vessel is lowered to correspond to a saturated refrigerant liquid temperature 2°F (1.1°C)
above the freezing temperature of the liquid circulating through
the chiller cooler/condenser tubes (34°F [1.1°C] for water). The
valves are set so that the pressure in the cooler vessel is lower than
that of the condenser vessel/storage tank, forcing the liquid into
the cooler vessel.
NOTE: The pumpout selector switch can be placed in On or Automatic mode. In Automatic mode, the compressor will shut off automatically once the suction pressure drops to 7 psia or 15 in. Hg
11
vacuum (51.7 kPa absolute). In On mode, the unit will continue to
pumpout regardless of the suction (vacuum) pressure.
NOTE: During this operation, maintain water circulation through
the chiller cooler and condenser vessels to prevent tube freeze-up.
DISTILLING THE REFRIGERANT
Refrigerant vapor is transferred from the chiller cooler vessel or
pumpout storage tank through the pumpout condenser, condensed
to a liquid, and pumped to the chiller condenser vessel. During this
operation, water circulation must be maintained in the pump-out
condenser. Refrigerant impurities left in the chiller cooler vessel or
storage tank are then drained off. This operation can take from 4 to
14 hours, depending on the type and amount of refrigerant being
distilled.
The Pumpout and Refrigerant Transfer Procedures section gives
step-by-step instructions on performing these operations.
Pumpout and Refrigerant Transfer Procedures
PREPARATION
The 19XR chiller may come equipped with an optional pumpout
storage tank, pumpout system, or pumpout compressor. The refrigerant can be pumped for service work to either the chiller compressor vessel or chiller condenser vessel by using the optional
pumpout system. If a pumpout storage tank is supplied, the refrigerant can be isolated in the storage tank. The following procedures
describe how to transfer refrigerant from vessel to vessel and perform chiller evacuation.
CAUTION
Do not mix refrigerants from chillers that use different compressor oils. Compressor damage can result. The pumpout oil
separator comes pre-charged with 13 oz of ISO viscosity 220
POE (Polyol Ester) oil. The pumpout compressor is approved
for use with ISO viscosity 220 POE oil or ISO viscosity 68
POE oil. The pumpout compressor is also factory precharged
with oil.
OPERATING THE OPTIONAL PUMPOUT UNIT (Fig. 9)
Oil should be visible in the pumpout unit compressor sight glass
under all operating conditions and during shutdown. If oil is low,
add oil as described under Maintenance section, page 17. The
pumpout unit control wiring schematic is detailed in Fig. 8.
To Read Refrigerant Pressures (during pumpout or leak testing):
1. The ICVC display on the chiller control panel is suitable for
determining refrigerant-side pressures and low (soft) vacuum.
To assure the desired range and accuracy when measuring
evacuation and dehydration, use a quality vacuum indicator
or manometer. This can be placed on the Schrader connections on each vessel by removing the pressure transducer.
2. To determine pumpout storage tank pressure, a 30 in. Hg vacuum -0-400 psi (-101-0-2769 kPa) gage is attached to the
storage tank.
3. Refer to Fig. 10 and 11 for valve locations and numbers.
CAUTION
The power to the pumpout compressor oil heater must be on
whenever any valve connecting the pumpout compressor to
the chiller or storage tank is open. Leaving the heater off will
result in oil dilution by refrigerant and can lead to compressor
failure.
If the compressor is found with the heater off and a valve open
the heater must be on for at least 4 hours to drive the refrigerant from the oil. When heating the oil the compressor suction
must be open to a vessel to give the refrigerant a means to
leave the compressor.
CAUTION
Always run the chiller cooler and condenser water pumps and
always charge or transfer refrigerant as a gas when the chiller
pressure is less than 35 psig (241 kPa). Below these pressures,
liquid refrigerant flashes into gas, resulting in extremely low
temperatures in the cooler/condenser tubes and possibly causing tube freeze-up.
DANGER
During transfer of refrigerant into and out of the optional storage tank, carefully monitor the storage tank level gage. Do not
fill the tank more than 90% of capacity to allow for refrigerant
expansion. Overfilling may result in damage to the tank or the
release of refrigerant which will result in personal injury or
death.
CAUTION
Transfer, addition, or removal of refrigerant in spring-isolated
chillers may place severe stress on external piping if springs
have not been blocked in both up and down directions.
Positive Pressure Chillers With Storage Tanks
In the Valve/Condition tables that accompany these instructions,
the letter “C” indicates a closed valve. Figures 9 and 10 show the
locations of the valves.
CAUTION
Always run chiller cooler and condenser water pumps and
always charge or transfer refrigerant as a gas when chiller vessel pressure is less than 35 psig (241 kPa). Below these pressures, liquid refrigerant flashes into gas, resulting in extremely
low temperatures in the cooler/condenser tubes and possibly
causing tube freeze-up.
CAUTION
The power to the pumpout compressor oil heater must be on
whenever any valve connecting the pumpout compressor to
the chiller or storage tank is open. Leaving the heater off will
result in oil dilution by refrigerant and can lead to compressor
failure.
If the compressor is found with the heater off and a valve open
the heater must be on for at least 4 hours to drive the refrigerant from the oil. When heating the oil the compressor suction
must be open to a vessel to give the refrigerant a means to
leave the compressor.
12
a19-2446
FRAME
ASSEMBLY
CONTROL
PANEL
VALVE 2
VALVE 4
VALVE 5
VALVE 3
ENTERING
WATER
LEAVING
WATER CONDENSER
OIL
SEPARATOR
OIL
HEATER
COMPRESSOR
a19-
2444
Fig. 9 — Pumpout Unit
Transfer Refrigerant from Storage Tank Vessel to Chiller
WARNING
During transfer of refrigerant into and out of the 19XR storage
tank, carefully monitor the storage tank level gage. Do not fill
the tank more than 90% of capacity to allow for refrigerant
expansion. Overfilling may result in damage to the tank and
personal injury.
1. Equalize refrigerant pressure.
a. Turn on chiller water pumps, establishing water flow
(assumes vacuum condition in chiller system).
b. Close pumpout and storage tank valves 2, 4, 5, 7, 8, 10
(if present open isolation valve 11 and other isolation
valves between cooler and condenser). Open storage
tank valve 6; open chiller valves 1A and 1B.
VALVE 1A 1B 2 3 4 5 6 7 8 10 11
CONDITION C C C C C C
c. Gradually open valve 5 to slowly increase chiller pres-
sure to 35 psig (241 kPa) to reduce the potential of tube
freeze up.
d. Open valve 5 fully after the chiller pressure reaches
35 psig (241 kPa) or greater. Let chiller pressure reach
40 psig (276 kPa), then chiller water pumps can be
turned off. Fully close valve 5.
VALVE 1A1B23456781011
CONDITION C C C C C C
CONDITION C C C C
2. Push liquid to chiller, them remove remaining vapor from
CONDITION C C C
e. Open valve 8 and 10 to let higher pressure in the recov-
ery tank push liquid refrigerant into the condenser float
chamber and heat exchangers until the refrigerant pressure equalizes between the recovery tank and chiller.
VALVE 1A1B23456781011
storage tank:
a. To prepare for liquid, push open valve 4.
VALVE 1A1B23456781011
OIL FILL 1/4-IN. FLARE VALVE
b. Ensure pumpout condenser water is off, then turn on the
pumpout compressor in manual mode to push liquid to
chiller. Monitor the storage tank level until tank is empty
of liquid refrigerant.
c. Close charging valves 8 and 10.
d. Turn off the pumpout compressor.
e. To prepare for removal of remaining refrigerant vapor in
storage tank, close pumpout valves 3 and 4 and open
valves 2 and 5.
VALVE 1A1B23456781011
CONDITION C C C C C
f. Turn on pumpout condenser water.
g. Run pumpout unit in auto until the vacuum switch is sat-
isfied. This occurs approximately at 15 in Hg vacuum
(48 kPa absolute or 7 psia), removing the residual refrig-
erant vapor from the recovery tank and condensing to a
liquid in the chiller.
h. Close valves 1A, 1B, 2, 5, 6.
VALVE 1A1B23456781011
CONDITIONCCCCCCCCCC
i. Turn off pumpout condenser water.
Transfer Refrigerant from Chiller to Storage Tank Vessel
1. Equalize refrigerant pressure.
a. Dehydrate the refrigerant storage vessel, and connected
hoses/piping so there are no non-condensables mixed
with the refrigerant.
b. Locate valves as identified below:
VALVE 1A1B23456781011
CONDITION C C C C C C
c. Slowly open valve 5 until the refrigerant pressure
reaches 35 psig (241 kPa) in the storage tank, followed
by valves 7 and 10 to allow liquid refrigerant to drain by
gravity.
VALVE 1A1B23456781011
CONDITION C C C
13
2. Push remaining liquid, followed by refrigerant vapor removal
from chiller.
a. To prepare for liquid push, turn off the pumpout con-
denser water. Place valves in the following positions:
VALVE 1A1B23456781011
CONDITION C C C
b. Run the pumpout compressor in manual until all liquid is
pushed out of the chiller (approximately 45 minutes).
Close valves 2, 5, 7, and 10, then stop compressor.
VALVE 1A1B23456781011
CONDITION CCCC CCC
c. Turn on pumpout condenser water.
d. Open valves 3 and 4, and place valves in the following
positions:
VALVE 1A1B23456781011
CONDITION C C C C C
e. Run the pumpout compressor until the chiller pressure
reaches 35 psig (241 kPa), followed by turning off the
pumpout compressor. Warm chiller condenser water will
boil off any entrapped liquid refrigerant, and chiller pressure will rise.
f. When chiller pressure rises to 40 psig (276 kPa), turn on
the pumpout compressor until the pressure reaches
35 psig (241 kPa) again; then turn off the pumpout compressor. Repeat this process until the chiller pressure no
longer rises.
g. Start the chiller water pumps (condenser and cooler),
establishing water flow. At this point, turn on the pumpout compressor in auto until the vacuum switch is satisfied. This occurs at approximately 15 in Hg vacuum
(48 kPa absolute or 7 psia).
h. Close valves.
VALVE 1A1B23456781011
CONDITIONCCCCCCCCCC
i. Turn off the pumpout condenser water.
Chillers With Isolation Valves
In the Valve/Condition tables that accompany these instructions,
the letter “C” indicates a closed valve.
The valves referred to in the following instructions are shown in
Fig. 9 and 11. The cooler/condenser vessels can be used for refrigerant isolation for certain service conditions when the isolation
valve package is specified.
Transfer Refrigerant from Cooler to Condenser
a. Turn off chiller water pumps and pumpout condenser
water supply (if applicable). It is assumed that the starting point is as shown in the following table and that pressures in both vessels are above 35 psig (241 kPa).
VALVE 1A1B23457811
CONDITION CCCCCCCCC
b. Keeping valves 7 and 8 closed, install charging hose
from liquid line charging valve 7 to valve 8 on the condenser float chamber. Evacuate or purge hose of noncondensables. Note that this creates a flow path between
cooler and condenser that bypasses the linear float,
reducing the potential for damage during refrigerant
transfer.
c. Open valves 1A, 1B, 2, 5, and 8.
VALVE 1A1B23457811
CONDITION C C C C
d. Turn on pumpout compressor, generating a refrigerant
pressure differential of 10 to 20 psi (69 to 138 kPa) to
push liquid out of the chiller cooler vessel.
e. Slowly
open valve 7 to allow liquid transfer. Rapid open-
ing of valve 7 can result in float valve damage.
f. When all liquid has been pushed into the chiller con-
denser vessel, close valve 8.
VALVE 1A1B23457811
CONDITION C C C C
g. Turn off the pumpout compressor.
h. Close pumpout valves 2 and 5 while opening valve 3 and
4 to prepare for removal of remaining refrigerant vapor
in cooler vessel.
VALVE 1A1B23457811
CONDITION C C C C
i. Turn on pumpout condenser water.
j. Turn on pumpout compressor. Turn on the chiller water
pump to establish water flow when the cooler refrigerant
pressure is 35 psig (241 kPa). The water pumps have to
be in operation whenever the refrigerant pressure is
equal to or less than 35 psig (241 kPa) to reduce the
potential of tube damage.
k. Run the pumpout compressor until the cooler pressure
reaches 35 psig (241 kPa), then turn off the pumpout
compressor. Warm chiller cooler water will boil off any
entrapped liquid refrigerant, and chiller pressure will
rise. Repeat this process until the chiller pressure no longer rises.
l. Run pumpout unit in auto until the vacuum switch is sat-
isfied; this occurs at approximately 15 in. Hg vacuum
(48 kPa absolute or 7 psia). Close valve 1A.
VALVE 1A1B23457811
CONDITION C C C C C
m. Monitor that cooler pressure does not rise (if it does, then
repeat previous step).
n. With service valve 1A closed, shut down pumpout com-
pressor (if still running).
o. Close remaining valves.
VALVE 1A1B23457811
CONDITION CCCCCCCCC
p. Remove charging hose between 7 and 8 (evacuate prior
to removal).
q. Turn off pumpout condenser water.
r. Turn off chiller water pumps, and lockout chiller com-
pressor.
Transfer Refrigerant from Condenser to Cooler
a. Turn off chiller water pumps and pumpout condenser
water supply (if applicable). It is assumed that the start-
ing point is as shown in the following table and that pres-
sures in both vessels are above 35 psig (241 kPa).
VALVE 1A1B23457811
CONDITION CCCCCCCCC
b. Set valves as shown below to allow the refrigerant to
equalize:
VALVE 1A 1B 2 3 4 5 7 8 11
CONDITION C C C C C
c. Turn on pumpout compressor, and develop a 10 to 20 psi
(69 to 138 kPa) refrigerant differential pressure between
the vessels.
14
d. Partially open valve 11 while maintaining a refrigerant
pressure differential to push liquid refrigerant out of the
chiller condenser to the cooler.
e. When all liquid is out of the chiller condenser, close
valve 11 and any other isolation valves on the chiller.
f. Turn off the pumpout compressor.
g. Close pumpout valves 3 and 4 while opening valve 2 and
5 to prepare for removal of remaining refrigerant vapor
in condenser vessel.
VALVE 1A1B23457811
CONDITION C C C C C
h. Turn on pumpout condenser water.
i. Turn on pumpout compressor.
j. Turn on the chiller water pumps, establishing water flow
when the condenser refrigerant pressure is 35 psig
(241 kPa). The water pumps have to be in operation
whenever the refrigerant pressure is equal to or less
than 35 psig (241 kPa) to reduce the potential of tube
damage.
k. Run the pumpout compressor until the condenser refrig-
erant pressure reaches 35 psig (241 kPa) then turn off the
pumpout compressor. Warm condenser water will boil
off any entrapped liquid refrigerant, and chiller pressure
will rise. Repeat this process until the chiller pressure no
longer rises.
l. Run pumpout unit in auto until the vacuum switch is sat-
isfied; this occurs at approximately 15 in. Hg vacuum
(48 kPa absolute or 7 psia). Close valve 1B.
VALVE 1A1B23457811
CONDITION C C C C C C
m. Monitor that condenser pressure does not rise (if it does,
then repeat previous step).
n. With service valve 1B closed, shut down pumpout com-
pressor (if still running).
o. Close remaining valves.
VALVE 1A1B23457811
CONDITION CCCCCCCCC
p. Turn off pumpout condenser water.
q. Turn off chiller water pumps, and lock out chiller com-
pressor.
Return Chiller to Normal Operating Conditions
1. Vapor Pressure Equalization:
a. Ensure that the chiller vessel that was exposed to ambi-
ent has been evacuated. Final vacuum prior to charging
with refrigerant should in all cases be 29.9 in. Hg
(500 microns, 0.07 kPa [abs]) or less.
b. Turn on chiller water pumps.
c. Open valves 1A, 1B, and 2.
VALVE 1A1B23457811
CONDITION CCCCCC
d. Slowly open valve 4, gradually increasing pressure in the
evacuated vessel to 35 psig (241 kPa).
e. Leak test to ensure chiller vessel integrity.
f. Open valve 4 fully for cooler and condenser pressure
equalization (vapor equalization).
VALVE 1A1B23457811
CONDITION C C C C C
g. Close valves 1A, 1B, 2, and 4.
VALVE 1A1B23457811
CONDITION CCCCCCCCC
1. Liquid equalization:
a. If refrigerant is stored in cooler, install a charging hose
between valves 7 and 8, and open both the valves and
any other isolation valves (except valve 11) for liquid to
drain into the condenser while bypassing the linear float
valve. If refrigerant is stored in the condenser, keep valve
11 and any other isolation valves open for liquid drain.
VALVE 1A1B23457811
CONDITION
(CHARGE IN
COOLER)
CONDITION
(CHARGE IN
CONDENSER)
CCCCCC C
CCCCCCCC
b. If valves 7 and 8 were used to bypass the linear float
valve, once the liquid transfer is complete, close these
valves, and slowly open valve 11.
c. Turn off chiller water pumps.
Distilling the Refrigerant
1. Transfer the refrigerant from the chiller to the pumpout storage tank as described in the Transfer Refrigerant from Chiller
to Storage Tank Vessel section.
2. Equalize the refrigerant pressure.
a. Turn on chiller water pumps and monitor chiller pres-
sures.
b. Close pumpout and storage tank valves 2, 4, 5, and 10,
and close chiller charging valve 7; open chiller isolation
valve 11 and any other chiller isolation valves, if present.
c. Open pumpout and storage tank valves 3 and 6; open
chiller valves 1a and 1b.
VALVE 1A1B2345671011
CONDITION C C C C C
d. Gradually crack open valve 5 to increase chiller pressure
to 35 psig (241 kPa). Slowly feed refrigerant to prevent
freeze-up.
e. Open valve 5 fully after the chiller pressure rises above
the freezing point of the refrigerant. Let the storage tank
and chiller pressure equalize.
3. Transfer remaining refrigerant.
a. Close valve 3.
b. Open valve 2.
VALVE 1A1B2345671011
CONDITION C C C C
c. Turn on pumpout condenser water.
d. Run the pumpout compressor until the storage tank pres-
sure reaches 5 psig (34 kPa), 18 in. Hg vacuum (41 kPa
absolute) in Manual or Automatic mode.
e. Turn off the pumpout compressor.
f. Close valves 1a, 1b, 2, 5, and 6. Turn off pumpout con-
denser water.
VALVE 1A1B2345671011
CONDITION CCCCCCCCC
4. Drain the contaminants from the bottom of the storage tank
into a container. Dispose of contaminants safely.
15
a19-2434
5
COMPRESSOR
CONDENSER
NOTES:
1. Maintain at least 2 feet (610 mm) clearance around storage tank for service and operation work.
2. Valve 8 is only applicable for products with linear float valves.
a19-2435
5
PUMPOUT
COMPRESSOR
OIL
SEPARATOR
V
NOTE: Valve 8 is only applicable for products with linear float valves.
PUMPOUT
8
2
RELIEF
VALVE
OIL
SEPARATOR
PUMPOUT
CONDENSER
7
COOLER
6
STORAGE VESSEL
CHECK
VALVE
10
Fig. 10 — Typical Optional Pumpout System Piping Schematic with Storage Tank
RELIEF
ALVE
CONDENSER
8
2
7
COOLER
Fig. 11 — Typical Optional Pumpout System Piping Schematic without Storage Tank
16
PUMPOUT
CONDENSER
CHECK
VALVE
MAINTENANCE
Periodic maintenance is necessary to keep all components functioning as designed. A maintenance log is recommended to ensure
a proper maintenance schedule is followed.
Pumpout Compressor Oil Charge
Use oil conforming to Carrier specifications for centrifugal or
screw compressor use. Oil requirements are listed in Table 6.
Monitor and adjust compressor oil level as often as necessary.
When replacing lost oil, add the same type of oil that is used in the
chiller being pumped out.
Table 6 — Pumpout Compressor Requirements
REFRIGERANT
R-134a
ISO
VISCOSITY
68 PP47-31
220 PP47-32
The pumpout oil separator comes pre-charged with 13 oz of ISO
viscosity 220 POE (Polyol Ester) oil. The pumpout compressor is
approved for use with ISO viscosity 220 POE oil or ISO viscosity
68 POE oil. The pumpout compressor is also factory precharged
with POE oil.
Oil should be visible in the pumpout compressor sight glass both
during operation and at shutdown. Always check the oil level before operating the pumpout compressor.
Oil can be added to the 1/4-in. SAE flare access valve port running
from the top of the oil separator to the compressor while the compressor is running. Be careful not to overfill.
NOTE: Compressor access valve has a self-sealing fitting which
will require a hose connection with a depressor to open.
To change or remove oil, the compressor will have to be removed
from the assembly. Compressor can be disconnected from connected tubing by the quick connect fittings at suction and discharge and oil recovery line.
Prior to removal, close service valves 2, 3, 4, and 5, and run the
pumpout compressor in AUTOMATIC until the vacuum switch is
satisfied and the compressor shuts off. Move pumpout selector
switch to OFF, and turn off all power to unit prior to removing
CARRIER
SPECIFICATION NO.
compressor unit from pumpout assembly frame and connecting
tubing.
Service valves 2, 3, 4, and 5 remain closed while compressor is removed. Put compressor back in place. Use the torque values listed
in Table 7 for reassembly:
Table 7 — Torque Values for Reassembly
PARAMETER
Suction 80 to 100 109 to 136
Discharge 50 to 60 68 to 81
O-ring Face Seal 7 to 9 10 to 12
VALUES
ft-lb Nm
Be sure to use backup wrench and pull a deep vacuum in the serviced pumpout tubing prior to any refrigerant exposure. At this
point, confirm that the oil level is satisfactory and put the pumpout
back in service.
Storage Tank
To prevent moisture and contaminants from entering the storage
tank, maintain positive pressure in the tank when not transferring
refrigerant. Leak test the storage tank periodically.
Ordering Replacement Parts
The following information must accompany an order for Carrier
specified parts:
• machine model number and serial number
• name, quantity, and part number of the part required
• delivery address and method of shipment
TROUBLESHOOTING
Information on troubleshooting for the PPS system is included in
Tab le 8.
Table 8 — Troubleshooting
SYMPTOM PROBABLE CAUSE REMEDY
Compressor Does Not
Run
Compressor Cycles On
High-Pressure Control
Unit Operates Too Long Isolation valves partially open Close valves.
System Noises Piping vibrations Support piping as required. Check for loose pipe connectors.
Compressor Loses Oil Leak in system Locate and repair leak.
Main power line open Replace fuse or reset circuit breaker.
Loose terminal connection Check connections.
Improperly wired controls Check wiring and rewire.
Low line voltage Check line voltage; determine location of voltage drop.
Compressor motor defective Check motor winding for open or short. Replace compressor if
Seized compressor Replace compressor.
High level gage alarm Check refrigerant level and remove excess.
High-pressure control erratic in action Check capillary tube for pinches. Set control as required.
Discharge valve partially closed. Open valve.
Air in system Purge system.
Condenser scaled. Clean condenser.
Condenser water pump or fans not
operating.
Insufficient compressor oil Add oil.
Plugged or stuck compressor oil return check
valve
Liquid refrigerant carries oil out of
compressor
Motor shutdown on internal thermal protection high temperature cutout.
necessary.
Start pump or fans.
Repair or replace valve.
Check to ensure only refrigerant vapor enters compressor suction
line. Add oil as necessary.
High temperature cutout should reset within 120 minutes.
17
© Carrier Corporation 2019
Catalog No. 04-531900050-01 Printed in U.S.A. Form 19XR-CLT-16SI Rev. A Pg 20 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.
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