Carrier 19XB Oxygen Equipment User Manual
Contents
1. 3 Total weight equals empty weight from chart and charge weight given on label ENTER OF GRAVITY STORAGE ABLE SON a kaa mm EMPTY WEIGHT ered oh O oe SE e 4 5A 1 77 2380 28 Ft 1353 505 1080 A 6 101 1 874 3460 52 Ft 2086 527 1569 Fig 4 Rigging Guide Table 2 Physical Data 19EA Pumpout Unit ENGLISH SI Pumpout Unit Weight Ib kg 210 95 Pumpout Condenser Water Flow Rate gpm L s 5 to 7 32 to 44 Pumpout Condenser Water Pressure Drop psig kPa 6 to 10 7 41 4 to 73 8 Maximum Entering Condenser Water Temperature F C 29 Maximum Leaving Condenser Water Temperature F C 37 Condenser Relief Valve Fusible Plug psig kPa 385 2655 Condenser Pressure Rating Refrigerant Side psig kPa 385 2655 Waterside psig kPa 150 1034 Compressor Rating 1750 rpm 29 r s Reciprocating cfm L s 8 7 25 Valves 4 Valve Manifold Copper with in OD Vo Vo Brass Turn Knob Valves 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 a fuse on off 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 disconnect switch is supplied by the customer 4 The condenser tube is copper Table 3 19XB Storage Tank Rated Dry Weight a2. PPS Contact Surface and Dimensions CHILLERS WITHOUT ISOLATION VALVES OIL SEPARATOR DISCHARGE VALVE PUMPOUT COMPRESSOR SUCTION VALVE VENTING VALVE PUMPOUT CONDENSER i WATER ONNECTIONS SEE NOTE 1 TO TOP OF HEAD CHILLER l N i COOLER OR N CONDENSERI TO ADDITIONAL CHILLERS 4 x SERVICE VALVE on ena SEE NOTES y 1 amp 2 i STORAGE TANK TO BOTTOM VAPOR VALVE OF CHILLER L N TO TOP OF COOLER AND Mn n mn p mn men mn m a STORAGE CONDENSER TANK FROM BOTTOM OF STORAGE TANK TEE FOR STORAGE TANK REFRIGERANT LIQUID REFRIGERANT CHARGING VALVE GENERAL PIPING CONNECTION SIZES CONNECTION SIZE in Refrigerant Transfer Connections 1 2 ODS female Condenser Water Cooling Connectors 1 2 NPT female Safety Relief Head Pumpdown Condenser 38 Flare male ODS Outside Diameter Sweat NOTES 1 The field supplied tubing is to be 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 78 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
3. 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 e a spring mounted reciprocating compressor with a direct drive motor e a water cooled refrigerant condenser e an oil separator e suction and discharge valves to control refrigerant flow e 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 Table 1 printed on the pumpout unit and storage tank name plates 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 unit from shipping conveyance If unit appears dam aged it should be inspected by a shipping inspector before removal File a claim with the shipping company if ship ment is damaged or incomplete The manufacturer is not re sponsible 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 Table 1 Positive Pressure System Assembly Numbers POSITIVE PRESSURE
4. 3 Remove any remaining refrigerant Transfer All Refrigerant to Chiller Condenser Vessel a Turn on chiller water pumps 1 Push refrigerant into chiller condenser vessel b Turn on pumpout condenser water a Turn on the chiller water pumps and monitor the chiller c Place valves in the following positions pressure VALVE ta 1b 2 3 4 5 6 7 8 10 11 connmon ce lel eleje VALVE ta ib 2 3 4 5 8 11 conpmion ele ec b Valve positions d Run the pumpout compressor until the chiller pres sure reaches 60 psig 414 kPa 30 psig 207 kPa c Equalize the refrigerant in the chiller cooler and then shut off the pumpout compressor Warm chiller condenser condenser water will boil off any entrapped liquid re d Turn off chiller water pumps and pumpout condenser frigerant and chiller pressure will rise water supply e When chiller pressure rises to 70 psig 483 kPa e Turn on pumpout compressor to push liquid out of the 40 psig 276 kPa turn on the pumpout compressor chiller cooler vessel until the pressure again reaches 60 psig 414 kPa 30 psig 207 kPa then turn off the pumpout com pressor Repeat this process until the chiller pressure f When all liquid has been pushed into the chiller con denser vessel close the cooler refrigerant isolation valve no longer rises then turn on the pumpout compressor an and pump out until the chiller pressure reaches g Tum on the chiller
5. Mechanical Engineers Boiler Pressure Vessel Code Section VIII Division 1 2 Allunits above are shipped with a 15 psig 103 kPa nitrogen charge 3 Nominal horsepower for all pumpout units is 3 0 Rig the Storage Tank The complete 19XB system can be rigged as a single assembly See the rigging instruc tions 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 A WARNING Lifting the assembly from points other than those speci fied 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 NOTE These weights are broken down into pumpout unit and storage tank weights For the complete assem bly weight add all components together VENT VALVE DISCHARGE SERVICE VALVE SUCTION SERVICE VALVE VALVES J 0 EE JI Yo 9 I TQS S CONTROL BOX WIRING BY VALVES e CONTRACTOR D COMPRESSOR RELIEF OIL SIGHT VALVE COMPRESSOR GLASS MTG SPRINGS CONDENSER REFRIGERANT CONDENSER WATER INLET VALVE CONNECTIONS FIELD PIPING 19EA PUMPOUT UNIT ALY 19XB 28 ft3 2 6 m3 HIGH PRESSURE SWITC
6. PUMPOUT UNIT SS GE P S ea ASSEMBLY NO REFRIGERANT 25 oun 28 cu f 28 cu fi 28 cu ft 28 cu ft 28 cu f 28 cu fi 28 cu fi None None None None None None None None 52 ou fi 52 ou fi 52 ou fi 52 ou fi 52 ou ft 52 ou fi 52 ou ft 52 ou fi 1 SXB042B020E 19XB04280206 19XB04280207 19XB04280208 19XB04280213 19XB04280214 19XB04280215 19XB04280216 19XB04280601 19XB04280602 19XB04280603 19XB04280604 19XB04280605 19XB04280606 19XB04280607 19XB04280608 19XB04520205 19XB04520206 19XB04520207 19XB04520208 19XB04520213 19XB04520214 19XB04520215 19XB04520216 LEGEND LRA Locked Rotor Amps RLA Rated Load Amps Mount the Pumpout Unit 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 pro vided with the chiller for mounting the pumpout unit A typi cal 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 446 in holes at the base of the pumpout unit Special isolation 1s unnecessary Contact sur face and dimensions for the pumpout unit are given in Fig 3 COMPRESSOR MOTOR MAXIMUM LRA STORAGE V Ph Hz RLA TANK NOTES 1 All storage vessels are 300 psig 2068 kPa designs per the ASME American Society of
7. YEL Y L YEL RED RED ALARM N C TOGGLE SWITCH Field Wiring Factory Wiring Contactor Term Z N Overload Term _ Pumpdown Term C Pumpdown Comprr Term GROUND CONN Fig 7 19XB Pumpout System Wiring Schematic Li c COMPR_MOTOR L3 C OL Po 13 4 3 Po Lu B 115 V SINGLE PHASE 50 60 HZ ON STOP fuy TSTAT YEL 0 o YEL SA HYEL 4 FRED O oE 8 EA ja RED OL R Ayo Ayo apa man OL HP LEGEND C Contactor Fu Fuse 3 Amps Compressor Terminal HP High Pressure Cutout L Compressor Motor Voltage Line 3 phase CD i LL Low Line Control Voltage single phase Pontacien vermin OL Compressor Overload ZON i T stat Internal Thermostat NEPLATENIA _ Pumpout Unit Terminal Bimetal thermal protector imbedded in motor winding Fig 8 Pumpout Unit Wiring Schematic 10 CONTROLS AND COMPONENTS Figure 1 shows the major components of the PPS system Pumpout Unit The pumpout unit consists of a spring mounted direct motor driven reciprocating compressor a water cooled refrigerant condenser an oil separator suction and discharge valves to control refrigerant flow and prewired safety and control devices The pumpout unit comes equipped with a 4 way transfer valve manifold to interconnect both liquid and vapor transfer and to pressurize the chiller during trans fer of refrigerant from chiller to storage tank CONTROLS The pumpout unit has the following c
8. ele elele d Gradually crack open valve 5 to increase chiller pres sure to 60 psig 414 kPa 30 psig 207 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 ta b 2 3 4 5 6 7 8 10 1 conpmion ele elele c Turn on pumpout condenser water d Run the pumpout compressor until the storage tank pressure reaches 5 psig 34 kPa 18 in Hg 41 kPa absolute e Turn off the pumpout compressor f Close valves la 1b 2 5 and 6 g Turn off pumpout condenser water vave ta t gt 2 3 4 5 6 7 8 1 1 CONDITION 4 Drain the contaminants from the bottom of the storage tank into a container Dispose of contaminants safely MAINTENANCE Periodic maintenance is necessary to keep all components functioning as designed A maintenance log is recom mended to ensure a proper maintenance schedule is followed Pumpout Unit For maintenance details refer to the 06D 07D Installation Start Up and Service Instructions PUMPOUT COMPRESSOR OIL CHARGE Use oil con forming to Carrier specifications for reciprocating compres sor use Oil requirements are listed in Table 6 Table 6 Pumpout Compressor Oil Requirements CARRIER ISO CARRIER REFRIGERANT viscosity SPECIFICATION
9. head per ASHRAE 15 American Society of Heating Refrigeration and Air Conditioning Engineers latest revision 2 The tubing and valve from the storage tank to the pumpout com pressor is factory supplied when the unit is factory mounted CHILLERS WITH ISOLATION VALVES WITH OR WITHOUT PUMPOUT STORAGE TANKS OIL SEPARATOR DISCHARGE VALVE PUMPOUT COMPRESSOR SUCTION VALVE VENTING VALVE PUMPOUT CONDENSER _ WATER CONNECTIONS SEE NOTE 1 SAFETY TO TOP OF HEAD CHILLER COOLER A A a SERVICE VA TO ADDITIONAL NE CHILLERS SEE NOTES x hd 182 Si i STORAGE TANK VAPOR VALVE reer LON e CONDENSER po an on me an n on a STORAGE TANK FROM BOTTOM OF STORAGE t TANK TEE FOR STORAGE TANK REFRIGERANT LIQUID REFRIGERANT CHARGING VALVE LEGEND Factory Supplied Tubing mwn Field Supplied Tubing m MM Field Supplied Tubing Multiple Chillers pl Service Valve Factory Supplied pq Service Valve Field Supplied Fig 6 Typical Pumpout Unit Chiller Connection Schematic Table 4 Relief Devices REQUIRED FACTOR STORAGE RELIEF VALVE QUANTITY Kg air TANK SIZE OUTLET SIZE min 1 in NPT 1 in NPT qpjeep B Si BLK OL ID 3 ee EL C OL aa a Da ea a A a 115 VOLT 50 60 HZ o MOTOR INTERNAL HIGH LEVEL GAUGE ALARM THERMOSTAT N C PRESSURE STAT LEGEND Ground YEL WHT YEL YEL ORN HIGH LEVEL GAUGE
10. lowered and the pressure in the other vessel must be simultaneously increased Under most circumstances creating the pressure differ ential 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 in stances 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 re duce the temperature and pressure in the tank Outdoor in stallations 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 conden
11. number of the part required e delivery address and method of shipment TROUBLESHOOTING Information on troubleshooting for the PPS is included in Table 7 Table 7 Troubleshooting SYMPTOM Compressor does not run PROBABLE CAUSE Main power line open Loose terminal connection Improperly wired controls Low line voltage Compressor motor defective Seized compressor High level gage alarm Compressor cycles on high pressure control Discharge valve partially closed Air in system Condenser scaled Condenser water pump or fans not operat Unit operates too long Isolation valves partially open System Noises Piping vibrations Compressor noisy High pressure control erratic in action 5 REMEDY Replace fuse or reset circuit breaker Check connections Check wiring and rewire Check line voltage determine location of voltage drop Check motor winding for open or short Replace compressor if necessary Replace compressor Check refrigerant level and remove excess Check capillary tube for pinches Set control as required Open valve Purge system Clean condenser Start pump or fans Close valves Support piping as required Check for loose pipe connectors Check valve plates for valve noise Replace compressor worn bearings Check for loose compressor holddown bolts Insufficient compressor oil Add oil Compressor Loses Oil Leak in system Plugged or stuck compressor oil return check valve Dirty
12. 11 Catalog No 531 927 Printed in U S A Form 19XB 1SI Pg 1 6 96 Replaces New Tab z CONTENTS Page SAFETY CONSIDERATIONS l INTRODUCTION 2 INSTALLATION 2 10 Complete Pre lnstallation Checks 2 e IDENTIFY UNIT e INSPECT SHIPMENT Mount the Pumpout Unit 3 e MOUNTING ON THE CHILLER e FLOOR MOUNTING Rig the Storage Tank 3 Make Piping Connections 7 e INSTALL VENT PIPING TO RELIEF DEVICES Make Electrical Connections 7 CONTROLS AND COMPONENTS 11 Pumpout Unit 11 e CONTROLS e SAFETY CONTROL SETTINGS e COMPRESSOR e CONDENSER e OIL SEPARATOR e SUCTION AND DISCHARGE VALVES Storage Tank aise enonse pas 11 e DRAIN VALVE e DUAL RELIEF VALVES e PRESSURE GAGE e LEVEL GAGE OPERATION se le nee ven wen ann 11 15 Overview sw a io art area ane ee a ol 11 e REFRIGERANT TRANSFER e TRANSFERRING LIQUID REFRIGERANT FROM THE CHILLER COOLER TO THE CHILLER CONDENSER OR PUMPOUT STORAGE TANK e TRANSFERRING LIQUID REFRIGERANT FROM THE CHILLER CONDENSER OR PUMPOUT STORAGE TANK TO THE CHILLER COOLER e DISTILLING THE REFRIGERANT Pumpout and Refrigerant Transfer Procedures 12 e OPERATING THE PUMPOUT UNIT e TO READ REFRIGERANT PRESSURES e POSITIVE PRESSURE CHILLER
13. 19XB 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 pro vide safe and reliable service when operated within de sign 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 A DANGER DO NOT VENT refrigerant relief valves within a building Outlet from rupture disc or relief valve must be vented outdoors in ac cordance with the latest edition of ASHRAE 15 American Society of Heating Refrigeration and Air Conditioning Engineers The accumulation of refrigerant in an enclosed space can displace oxy gen 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 irregulari ties 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 substance
14. G THE REFRIGERANT Refrigerant vapor is transferred from the chiller cooler vessel or pumpout stor age tank through the pumpout condenser condensed to a liq uid 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 sec tion gives step by step instructions on performing these operations Pumpout and Refrigerant Transfer Procedures Three possibilities are available 1 If there are no isolation valves on the chiller a complete pumpout system with a pumpout storage tank and pump out unit is needed 2 Whether or not isolation valves are available on the chiller the refrigerant can be pumped to and isolated in a pump out storage tank by using the pumpout unit 3 If isolation valves are available on the chiller the refrig erant can be pumped to either the cooler vessel or the condenser vessel using the pumpout unit The following procedures describe how to transfer refrig erant from one vessel to another and how to evacuate the chiller 4 CAUTION Do not mix refrigerants from chillers that use different compressor oils Compressor damage can result For ex ample the compressor oil in a 23X
15. H x TEN j los S 6 FUSE Al ar M HHH JE Fa ae assay ON STOP T a eB wa VIL GROUND LWE Sk CONNECTION no MEA FZA BOX LAE CONTACTOR D lt q s J na a 7 19EA CONTROL BOX INTERIOR iS 19EA PUMPOUT UNITS 19XB 52 ft3 4 8 m3 STORAGE TANK STORAGE TANK Fig 1 19XB Positive Pressure Storage System COMPRESSOR CONTROL BOX CONDENSER SUPPORT PLATE HOLD DOWN BOLTS FIELD SUPPLIED FIELD AND INSTALLED SUPPLIED 38 16 bolts x 1 in lg 4 required van ee Gn i 01 54 Mete mip Nii Ie ELECTRICAL CONNECTION a VAPOR a it ar 7 OPTION LIST mn PH I Li a DI LOCATION iy Poel S TOP BOTTOM VAPOR CONN VAROR MIDDLE 3 4 16UNF 2B ME MIDDLE SEE ELECTRICAL CONNECTION OPTION LIST ELECTRICAL SERVICE ACCESS SPACE VAPOR CONNECTION 1 2 ODS OUTSIDE DIAMETER SWEAT ELECTRICAL SERVICE ACCESS SPACE LEAVING CONDENSER WATER CONNECTION 1 2 NPT FEMALE Ak ENTERING CONDENSER 7 WATER CONNECTION ee 1 2 NPT FEMALE 5 TO 7 GPM REQUIRED S 75i A AB 2 2 SAFETY HEAD 1 TYP 3 8 FLARE fig MALE 7 16 DIA A 5 4 HOLES ou 12 4 EN ana Vp 07 04 10 1 1 1 4g Fig 3 Pumpout Unit Contact Surfaces and Dimensions SEE NOTE 2 NOTES 1 Each chain must be capable of supporting the entire weight of the machine 2 Minimum chain length 28 ft tank 10 O 52 ft tank 15 6
16. L chiller that uses HCFC 22 refrigerant can cause severe lubrication prob lems in a 19XL chiller that uses HCFC 22 refrigerant OPERATING THE PUMPOUT UNIT 1 Be sure that the suction and the discharge service valves on the pumpout compressor Fig 9 are open back seated during operation Rotate the valve stem fully coun terclockwise to open Frontseating the valve closes the refrigerant line and opens the gage port to compressor pressure 2 Make sure that the pumpout compressor holddown bolts Fig 2 have been loosened to allow free spring travel A CAUTION Transfer addition or removal of refrigerant in spring isolated chillers may place severe stress on external pip ing if springs on the chiller have not been blocked in both up and down directions 3 Open the refrigerant inlet valve Fig 9 on the pumpout compressor 4 Oil should be visible in the pumpout compressor sight glass under all operating conditions and during shut down If oil is low add oil as described in the Mainte nance section TO READ REFRIGERANT PRESSURES During pump out or leak testing 1 Refer to the display on the chiller control center to de termine refrigerant side pressures and low soft vacuum Use a quality vacuum indicator or manometer to measure evacuation and dehydration and to ensure the desired range and accuracy OILRETURN DISCHARGE VENT VALVE 8 LINE SERVICE T CONNECTION VALVE PUMPOUT IL C
17. OMPRESSOR SUCTION PW SERVICE as VALVE e VALVE 2 a QD VALVE 3 0 6 VALVE Ji gt GO N PUMPOUT A S CONTROL BOX VALVE 4 A Ne WIRING BY lt CONTRACTOR WA i RELIEF AN Rs OIL SIGHT VALVE JA se 3 COMPRESSOR GLASS gt MTG SPRIN CONDENSER No gt GSPRINGS PUMPOUT REFRIGERANT CONDENSER vin INLET VALVE CONNECTIONS Fig 9 Pumpout Unit 2 Attach a 30 in 0 400 psi 101 0 2760 kPa gage to the storage tank to determine its pressure 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 4 WARNING Always run chiller cooler and condenser water pumps and always charge or transfer refrigerant as a gas when chiller vessel pressure is less than 60 psig 414 kPa 30 psig 207 kPa Below these pressures liquid re frigerant flashes into gas resulting in extremely low tem peratures in the cooler condenser tubes and possibly causing tube freeze up Transfer Refrigerant from Pumpout Storage Tank to Chiller 4 WARNING During transfer of refrigerant into and out of the 19XB 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 dam age to the tank and personal injury 1 Equalize refrigerant pressure a Turn on chiller water pump
18. PART NO E 8 R 22 PP49 7 PP23BZ101 R 134a PP47 31 PP23BZ103 The total oil charge 4 5 pints 2 6 L consists of 3 5 pints 2 0 L for the compressor and one additional pint 0 6 L for the oil separator Oil should be visible in one of the pumpout compressor sight glasses both during operation and at shutdown Always check the oil level before operating the pumpout compres sor Before adding or changing oil relieve the refrigerant pressure as follows 1 Attach a pressure gage to the gage port of either pumpout compressor service valve Fig 10 2 Close the suction service valve and open the discharge line to the pumpout storage tank or the chiller 3 Operate the compressor until the crankcase pressure drops to 2 psig 13 kPa 4 Stop the pumpout compressor and isolate the pumpout system by closing the discharge service valve 5 Slowly remove the oil return line connection Fig 9 Add oil as required 6 Replace the connections and reopen the pumpout com pressor service valves Storage Tank To prevent moisture and contami nants from entering the storage tank maintain positive pres sure in the tank when not transferring refrigerant Leak test the storage tank according to your normal vessel leak test procedures and schedule Ordering Replacement Parts The following in formation must accompany an order for Carrier specified parts e machine model number and serial number e name quantity and part
19. S WITH STORAGE TANKS e CHILLERS WITH ISOLATION VALVES e DISTILLING THE REFRIGERANT MAINTENANCE 15 16 Pumpout Unit 15 e 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 pres sure chillers store refrigerants HCFC 22 and HFC 134a dur ing service and repair work The 19XB system conserves these refrigerants and prevents the release of excessive amounts of refrigerant into the atmosphere The proper use of this equipment minimizes the loss of HFCs and HCFCS The 19XB PPS system shown in Fig consists of a pump out unit mounted on a storage tank The pumpout unit is of fered 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 the American Society of Mechanical Engineers ASME pres sure vessel code The tanks are constructed of certified steel and are pressure rated at 300 psig 2068 kPa The PPS stor age tank is equipped with dual relief valves for proper vent ing per ASHRAE 15 American Society of Heating Refrig eration and Air Conditioning Engineers
20. accumulator Copyright 1996 Carrier Corporation Locate and repair leak Repair or replace valve Clean accumulator Book 2 PC 211 Tab 5a Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 531 927 Printed in U S A Form 19XB 1SI Pg 16 6 96 Replaces New
21. er water 1 Turn off chiller water pumps and lock out chiller com pressor Return Refrigerant to Normal Operating Conditions 1 Be sure that the chiller vessel that was opened has been evacuated 2 Turn on chiller water pumps 3 Open valves la 1b and 3 vave ia fib 2 afafsfefn conpmion ce elelee Crack open valve 5 gradually increasing pressure in the evacuated chiller vessel to 60 psig 414 kPa 30 psig 207 kPa Feed refrigerant slowly to prevent tube freeze up Leak test to ensure chiller vessel integrity P LA 15 6 Open valve 5 fully vave iafib 2 afa fsfe mr conomon ec e e c 7 Close valves la 1b 3 and 5 8 Open chiller isolation valve 11 and any other isolation valves if present VALVE a tb 2 3 4 5 8 141 CONDITION 9 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 the Refrigerant from Chiller to Pumpout Storage Tank section Equalize the refrigerant pressure a Turn on chiller water pumps and monitor chiller pressures b Close pumpout and storage tank valves 2 4 5 8 and 10 and close chiller charging valve 7 open chiller iso lation valve 11 and any other chiller isolation valves if present L c Open pumpout and storage tank valves 3 and 6 open chiller valves la and 1b VALVE tafib 2 a a s e efre n conomon ce
22. evices Vent the relief devices to the outdoors in ac cordance with ANSI ASHRAE 15 Safety Code latest edi tion for Mechanical Refrigeration and all other applicable codes Relief devices are set to relieve at 300 psig 2068 kPa A DANGER Refrigerant discharged into confined spaces can dis place oxygen and cause asphyxiation MAXIMUM REFRIGERANT CAPACITY kg ASHRAE ANSI 15 UL 1963 R22 RiMa R22 RI a 836 778 1569 1600 1616 1481 1491 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 pip ing to be disconnected periodically for inspection of valve mechanism 3 Piping to relief devices must not apply stress to the de vice Adequately support piping A length of flexible tub ing or piping near the device is essential on spring isolated machines 4 Cover the outdoor vent with a rain cap and place a con densation drain at the low point in the vent piping to pre vent water build up on the atmospheric side of the relief device 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 Fig 7 is the wiring schematic for a complete system that includes the 19XB sto
23. h water and consult a physician NEVER APPLY an open flame or live steam to a refrigerant cyl inder 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 CHECK THE REFRIGERANT TYPE before transferring refrig erant 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 Con tact Carrier for further information on use of this machine with other refrigerants DO NOT ATTEMPT TO REMOVE fittings covers etc while ma chine is under pressure or while machine is running Be sure pres sure is at O psig O 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 serie
24. nd Refrigerant Capacity TANK OD in Ib DRY WEIGHT SIZE CODE MAXIMUM REFRIGERANT CAPACITY Ib ASHRAE ANSI 15 UL 1963 R22 R 134a R 22 R 134a 0428 24 00 2380 1842 1860 1704 1716 0452 27 25 3460 3527 3563 3264 3286 TANK OD DRY WEIGHT SIZE CODE mm kg 0428 1080 0452 592 LEGEND ANSI American National Standards Institute ASHRAE American Society of Heating Refrigeration and Air Conditioning Engineers UL Underwriters Laboratories The above dry weight includes the pumpout unit weight of 210 Ibs 95 kg Make Piping Connections Figure 6 represents typi cal pumpout unit chiller piping connections Standard con nections for 12 in OD copper tubing are provided Install the field supplied FPT tee with pipe plug in the piping as shown in Fig 6 This tee is used for refrigerant charging NOTE If any field piping runs exceed 50 ft in length use 8 1n OD copper tubing to minimize pressure drop Pumpout unit water piping connections are shown in Fig 6 Both connections are 2 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 shut down 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 de vices Refer to Fig 5 and Table 2 for size and location of the relief d
25. on trols an on off switch a 3 amp fuse compressor overloads an internal thermostat a compressor contactor and a refrig erant high pressure cutout SAFETY CONTROL SETTINGS The pumpout unit high pressure switch Fig l 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 con denser water Table 5 High Condition Pressure Switch Settings English REFRIGERANT HIGH PRESSURE SWITCH Cutin R 134a 161 5 psig he b l R 22 220 5 psig me e SI REFRIGERANT HIGH PRESSURE SWITCH Cut In 0 0 NOTES 1 R 22 units use high pressure cutout switch HKO1UA181 2 R 134a units use high pressure cutout switch HKO1UA187 COMPRESSOR The pumpout compressor assembly has a positive displacement of 1750 rpm 29 r s and 8 7 cfm 0 004 m s It comes equipped with thermal protection on the motor and an in line oil separator CONDENSER The water cooled condenser is fully ASME constructed During transfer it condenses refrigerant vapor to liquid The condenser transfer tank safety relief valves com ply with ASHRAE 15 standards OIL SEPARATOR The pumpout unit includes an in line oil separator to remove oil that becomes mixed with refrig erant and returns the oil to the compressor SUCTION AND DISCHARGE VALVES The pumpout unit comes with a 4 way transfer valve manifold to inter connect both liquid and vapo
26. r 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 ves sel codes with a minimum of 300 psig 2068 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 0 400 psig 101 0 2760 kPa compound pressure gage 11 LEVEL GAGE Liquid level gage magnetically coupled dial type with electronic shut off at 90 liquid capacity 4 WARNING During transfer of refrigerant into and out of the pump out 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 maxi mum refrigerant capacity refer to Table 2 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 re sults 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 liq uid in that vessel its temperature must be
27. rage tank and the pumpout unit Fig 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 PRESSURE GAGE 0 9 LI 229 TYP VAPOR 0 0 1 8 4 a ntl 7 LEVEL GAGE ELECTRICAL SERVICE ACCESS SPACE RELIEF VALVES 1 NPT FEMALE J VAPOR CONN 1 2 FLARE CONDENSER WATER CONN 2 1 2 NPT FEMALE SEE NOTE 5 ELECTRICAL SERVICE FEMALE ACCESS SPACE SAFETY HEAD 0 5 7 8 149 3 8 FLAREN MALE 0 1 7 8 48 1 1 1 4 0 2 51 337 H IN L LIQUID CONN 1 NPT FEMALE kai G 0 9 A 229 TYP DIMENSIONS ENGLISH ft in we ae f ejo e r oc s k e m n e a s o 0428 5 01 0452 3 8 5 0 SI mm we ale fe o e o s k e w n o a s o 0428 3175 2997 1448 730 365 945 1499 1121 1118 849 965 89 1442 505 491 1111 1530 0452 4553 4382 1546 826 413 1027 2191 1219 1216 948 1064 86 2172 528 497 1118 1537 NOTES 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 The available conduit knockout sizes are TRADE SIZE LOCATION Yo top 3 4 bottom de middle 11 4 middle Fig 5
28. s 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 4 WARNING DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all refrigerant liquid and vapor has been removed 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 quali fied electrician DO NOT WORK ON electrical components including control pan els 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 deenergized be fore 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 with soap and water If any enters the eyes IMMEDIATELY FLUSH EYES wit
29. s and monitor chiller pressures b Close pumpout and storage tank valves 2 4 5 8 and 10 and close refrigerant 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 la and 1b VALVE ta ib 2 3 4 5 6 7 8 10 1 conpmion e fete elele d Gradually crack open valve 5 to increase chiller pres sure to 60 psig 414 kPa 30 psig 207 kPa Slowly feed refrigerant to prevent freeze up 16 SERVICE VALVE i CHILLER Pae CONDENSER i a l SERVICE a VALVE a JE A ji DS 7 L CHILLER l COOLER VESSEL pi a OES a M J a a iii li n emi i COOLER x REFRIGERANT SO STORAGE ISOLATION TANK VALVE PUMPOUT COMPRESSOR TANK IOI REFRIGERANT 7 CHARGING VALVE Bit PUMPOUT COMPRESSOR Beer SUCTION VALVE EMEGIT CONDENSER PUMPOUT WATER SUPPLY PUMPOUT SERVICE VALVEON SHILLER FIELD CONDENSER MAINTAIN AT LEAST 2 FT 610 mm CLEARANCE AROUND STORAGE TANK FOR SERVICE AND OPERATION WORK Fig 10 Valve Locations for 19XB Pumpout Unit With 19XB Storage Tank 2 STORAGE TANK Z VAPOR VALVE e Open valve 5 fully after the chiller pressure rises above k Close valves la 1b 2 5 and 6 the freezing point of the refrigerant Let the storage tank and chiller pressure equalize Open refrigerant charg VALVE ta ib 2 3 4 5 6 7 8 10 11 ing val
30. s 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 4 CAUTION 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 com ponents are light use such equipment when there is a risk of slip ping or losing your balance BE AWARE that certain automatic start arrangements CAN EN GAGE 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 require ments 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 cor rosion rust leaks or damage DO NOT MIX REFRIGERANT from chillers that use different com pressor oils Compressor damage can result Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 2 PC 2
31. ser 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 dis charge refrigerant vapor into the cooler vessel lowering pres sure in the condenser vessel storage tank The pressure dif ferential forces liquid from the cooler vessel into the condenser vessel storage tank After all the liquid is transferred the re frigerant 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 con denser vessel storage tank TRANSFERRING LIQUID REFRIGERANT FROM THE CHILLER CONDENSER OR PUMPOUT STORAGE TANK TO THE CHILLER COOLER Chiller and pumpout unit valves are set to increase pressure in the chiller condenser vessel storage tank and to reduce pressure in the cooler ves sel 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 During this operation maintain water circulation through the chiller cooler and condenser vessels to prevent tube freeze up DISTILLIN
32. t Storage Tank 14 d Close valve la e Turn off pumpout compressor f Close valves 1b 3 and 4 VALVE ta th 2 3 4 5 8 11 CONDITION e g Turn off pumpout condenser water h Turn off chiller water pumps and lock out chiller compressor Transfer All Refrigerant to Chiller Cooler Vessel 1 Push refrigerant into the chiller cooler vessel a Turn on the chiller water pumps and monitor the chiller pressure b Valve positions vave ta fib 2 3fafsfe fmi conpmion ele je c Equalize the refrigerant in the chiller cooler and condenser d Turn off chiller water pumps and pumpout condenser water e Turn on pumpout compressor to push refrigerant out of the chiller condenser f When all liquid is out of the chiller condenser close valve 11 and any other liquid isolation valves on the chiller g Turn off the pumpout compressor 2 Evacuate gas from chiller condenser vessel a Turn on chiller water pumps b Make sure that pumpout valves 3 and 4 are closed and valves 2 and 5 are open vave ta 2 afafsfe nm conpmion ele ec c Turn on pumpout condenser water d Run the pumpout compressor until the chiller con denser reaches 18 in Hg 41 kPa absolute Monitor pressure at the chiller control panel and refrigerant gages e Close valve 1b f Turn off pumpout compressor g Close valves la 2 and 5 vave ta 2 3 4 5 e6 7 CONDITION e h Turn off pumpout condens
33. ve 7 and storage tank charging valve 10 to let CONDITION liquid refrigerant drain into the chiller l Turn off pumpout condenser water Transfer the Refrigerant from Chiller to Pumpout Storage Tank 2 Transfer remaining nee a Close valve 5 and open valve 4 1 Equalize refrigerant pressure vave ta ib a a a s e 7 e olm a Valve positions CONDITION C C C ie vave ia 1 2 a a s e 7 e ro n b Turn off the pumpout condenser water and turn on the CONDITION pep cic cic c pumpout compressor to push liquid refrigerant out of b Slowly open valve 5 and refrigerant charging valves 7 the storage tank Monitor the storage tank level until and 10 to allow liquid refrigerant to drain by gravity the tank is empty into the storage tank c Close refrigerant charging valves 7 and 10 d Turn off the pumpout compressor e Turn off the chiller water pumps f 8 Close valves 3 and 4 2 Transfer the remaining liquid Open valves 2 and 5 a Turn off pumpout condenser water Place valves in the following positions h Turn on pumpout condenser water pomp b Run the pumpout compressor for approximately 30 min 1 Run the pumpout compressor until the storage tank pres lites then close valve 7 and 10 sure reaches 5 psig 34 kPa 18 in Hg 41 kPa absolute vve ra te a 8 4 8 6 7 e wo j Turn off the pumpout compressor CONDITION clc lcicle c Turn off the pumpout compressor 13
34. water pumps 18 in Hg 41 kPa absolute h Turn off the pumpout compressor f Close valves la 1b 3 4 and 6 2 Evacuate gas from chiller cooler vessel VALVE qia ib 2 3 a s5 6 7 e 10 11 a Close pumpout valves 2 and 5 open valves 3 and 4 CONDITION moe aa a aioe ie g Turn off the pumpout condenser water CONDITION c c c ec 4 Establish vacuum for service To conserve refrigerant op b Turn on pumpout condenser water erate the pumpout compressor as described in Step 3e un til the chiller pressure is reduced to 18 in Hg 41 kPa sel pressure reaches 18 in Hg vac 41 kPa absolute absolute Monitor pressures on the chiller control panel and on CHILLERS WITH ISOLATION VALVES The valves re refrigerant gages ferred to in the following instructions are shown in Fig 9 and 11 Valve 7 remains closed c Run pumpout compressor until the chiller cooler ves ib SERVICE VALVE ral ee nel E CHILLER way a CONDENSER i AS m VESSEL ji li Mi A l f H see Li CHILLER li COOLER h VESSEL Ret LIL pa COOLER Q S REFRIGERANT COMPRESSOR a SERVICE VALVE ISOLATION REFRIGERANT DISCHARGE VALVE CHARGING OIL SANS L 7 SEPARATOR PUMPOUT COMPRESSOR SUCTION VALVE E CONDENSER PUMPOUT WATER SUPPLY COMPRESSOR AND RETURN PUMPOUT SERVICE VALVE ON 7 a SERVICE VALVE ON D kini PUMPOUT UNIT CHILLER 4 Fig 11 Valve Locations for 19XB Pumpout Unit Withou
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