Carrier 19XR Series, Installation, Operating And Maintenance Instructions

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CONTENTS
Page
SAFETY CONSIDERATIONS
. . . . . . . . . . . . . . . . . . . . 1,2
INTRODUCTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,3
INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
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
. . . . . . . . . . . . . . . . . . . 4
Step 4 — Make Piping Connections
. . . . . . . . . . . . . . 6
• INSTALL VENT PIPING TO RELIEF DEVICES
Step 5 — Make Electrical Connections
. . . . . . . . . . . 6
CONTROLS AND COMPONENTS
. . . . . . . . . . . . . . . . 11
Pumpout Unit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
• CONTROLS
• SAFETY CONTROL SETTINGS
• COMPRESSOR
• CONDENSER
• OIL SEPARATOR
• SUCTION AND DISCHARGE VALVES
Storage Tank
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
• DRAIN VALVE
• DUAL RELIEF VALVES
• PRESSURE GAGE
• LEVEL GAGE
OPERATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17
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
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
• PREPARATION
• OPERATING THE PUMPOUT UNIT
MAINTENANCE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pumpout Compressor Oil Charge
. . . . . . . . . . . . . . . 17
Storage Tank
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Ordering Replacement Parts
. . . . . . . . . . . . . . . . . . . . 17
TROUBLESHOOTING
. . . . . . . . . . . . . . . . . . . . . . . . 17,18
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 pre-
vents the release of excessive amounts of refrigerant into the
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 run-
ning. 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 com-
pressed 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 indi-
cators, 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 dif-
ferent compressor oils. Compressor damage can result.
(Cautions continued in next column.)
CAUTION
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 pre-
vent oil contamination when timely repairs cannot be
completed.