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.
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 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 NOTATTEMPT TO REMOVE fittings, covers, etc., while ma-
chine is under pressure or while machine is running. Be sure pres-
sure 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 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 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 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.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed and
functioning before operating any machine.
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.
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 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 OPENAND 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
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 211
Catalog No. 531-927
Printed in U.S.A.
Form 19XB-1SI
Pg 1
6-96
Replaces: New
Tab 5a
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Table 1 — Positive Pressure System Assembly Numbers
POSITIVE PRESSURE
SYSTEM ASSEMBLY
NUMBER
PUMPOUT UNIT
ASSEMBLY NO.
COMPRESSOR MOTOR
(V-Ph-Hz)
MAXIMUM
RLA
STORAGE
TANK
REFRIGERANT
LRA
19XB04280205
19XB04280206
19XB04280207
19XB04280208
19XB04280213
19XB04280214
19XB04280215
19XB04280216
19XB04280601
19XB04280602
19XB04280603
19XB04280604
19XB04280605
19XB04280606
19XB04280607
19XB04280608
19XB04520205
19XB04520206
19XB04520207
19XB04520208
19XB04520213
19XB04520214
19XB04520215
19XB04520216
19EA42-748
19EA44-748
19EA46-748
19EA47-748
19EA48-748
19EA49-748
19EA51-748
19EA52-748
19EA42-748
19EA44-748
19EA46-748
19EA47-748
19EA48-658
19EA49-658
19EA51-658
19EA52-658
19EA42-748
19EA44-748
19EA46-748
19EA47-748
19EA48-748
19EA49-748
19EA51-748
19EA52-748
R-22
R-22
208-3-60
230-3-60
13.2
11.5
5.8
63.5
57.5
28.8
23.0
63.5
57.5
28.8
23.0
63.5
57.5
28.8
23.0
63.5
57.5
28.8
23.0
63.5
57.5
28.8
23.0
63.5
57.5
28.8
23.0
28 cu ft
28 cu ft
28 cu ft
28 cu ft
28 cu ft
28 cu ft
28 cu ft
28 cu ft
None
R-22
400/460-3-50/60
575-3-60
R-22
4.6
R-134a
R-134a
R-134a
R-134a
R-22
208-3-60
13.2
11.5
5.8
230-3-60
400/460-3-50/60
575-3-60
4.6
208-3-60
13.2
11.5
5.8
R-22
230-3-60
None
R-22
400/460-3-50/60
575-3-60
None
R-22
4.6
None
R-134a
R-134a
R-134a
R-134a
R-22
208-3-60
13.2
11.5
5.8
None
230-3-60
None
400/460-3-50/60
575-3-60
None
4.6
None
208-3-60
13.2
11.5
5.8
52 cu ft
52 cu ft
52 cu ft
52 cu ft
52 cu ft
52 cu ft
52 cu ft
52 cu ft
R-22
230-3-60
R-22
400/460-3-50/60
575-3-60
R-22
4.6
R-134a
R-134a
R-134a
R-134a
208-3-60
13.2
11.5
5.8
230-3-60
400/460-3-50/60
575-3-60
4.6
LEGEND
NOTES:
1. All storage vessels are 300 psig (2068 kPa) designs per the ASME
(American Society of Mechanical Engineers) Boiler Pressure
Vessel Code, Section VIII Division 1.
2. All units above are shipped with a 15 psig (103 kPa) nitrogen charge.
3. Nominal horsepower for all pumpout units is 3.0.
LRA
RLA
—
—
Locked Rotor Amps
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.
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.
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 47⁄16 in. holes at the base of the
pumpout unit. Special isolation is unnecessary. Contact sur-
face and dimensions for the pumpout unit are given in
Fig. 3.
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.
3
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VENT VALVE
VALVES
CONTROL BOX
(WIRING BY
CONTRACTOR)
VALVES
COMPRESSOR
CONDENSER
WATER
CONNECTIONS
(FIELD PIPING)
REFRIGERANT
INLET VALVE
19EA PUMPOUT UNIT
19EA CONTROL BOX (INTERIOR)
19EA PUMPOUT UNITS
Fig. 1 — 19XB Positive Pressure Storage System
4
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*3⁄8-16 bolts × 1-in. lg; 4 required.
Fig. 2 — 19EA Pumpout Unit: Typical Chiller Mount
ELECTRICAL CONNECTION
OPTION LIST
TRADE SIZE
QTY
LOCATION
1
⁄
⁄
2
؆
1
1
1
1
TOP
3
4؆
BOTTOM
MIDDLE
MIDDLE
1؆
11⁄4
؆
Fig. 3 — Pumpout Unit Contact Surfaces and Dimensions
5
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NOTES:
1. Each chain must be capable of supporting the entire weight of the
machine.
2. Minimum chain length:
28 ft3 tank — 10Ј-0Љ
52 ft3 tank — 15Ј-6Љ
3. Total weight equals empty weight from chart and charge weight
given on label.
CENTER OF GRAVITY
STORAGE
TANK SIZE
EMPTY WEIGHT
LB (Kg)
APPROX. DIM. — ft-in. (mm)
A
B
4- 51⁄4
1-77⁄8
2380
28 Ft3
52 Ft3
(1353)
(505)
(1080)
6-101⁄8
(2086)
1-83⁄4
(527)
3460
(1569)
Fig. 4 — Rigging Guide
Table 2 — Physical Data
19EA Pumpout Unit
ENGLISH
(SI)
Pumpout Unit Weight*
Pumpout Condenser Water Flow Rate
lb (kg)
gpm (L/s)
210
5 to 7
(95)
(.32 to .44)
Pumpout Condenser Water Pressure Drop
psig (kPa)
6 to 10.7
85
(41.4 to 73.8)
(29)
Maximum Entering Condenser Water Temperature
Maximum Leaving Condenser Water Temperature
Condenser Relief Valve (Fusible Plug)
F (C)
F (C)
100
(37)
psig (kPa)
385
(2655)
Condenser Pressure Rating
Refrigerant Side
Waterside
psig (kPa)
psig (kPa)
385
150
(2655)
(1034)
Compressor Rating 1750 rpm (29 r/s) Reciprocating
Valves (4-Valve Manifold, Copper with
Brass Turn Knob Valves)
cfm (L/s)
in. OD
8.7
(.25)
1
1
⁄
2
⁄
2
*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.
6
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Table 3 — 19XB Storage Tank Rated Dry Weight and Refrigerant Capacity
English
MAXIMUM REFRIGERANT CAPACITY (lb)
TANK OD
(in.)
DRY WEIGHT*
(lb)
SIZE CODE
ASHRAE/ANSI 15
UL 1963
R-22
R-134a
1860
R-22
1704
3264
R-134a
1716
0428
0452
24.00
27.25
2380
3460
1842
3527
3563
3286
SI
MAXIMUM REFRIGERANT CAPACITY (kg)
ASHRAE/ANSI 15 UL 1963
TANK OD
(mm)
DRY WEIGHT*
(kg)
SIZE CODE
R-22
836
R-134a
844
R-22
773
R-134a
778
0428
0452
610
592
1080
1569
1600
1616
1481
1491
LEGEND
ANSI
—
—
American National Standards Institute
American Society of Heating, Refrigeration,
and Air Conditioning Engineers
ASHRAE
UL
—
Underwriters’ Laboratories
*The above dry weight includes the pumpout unit weight of 210 lbs (95 kg).
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.
Make Piping Connections — Figure 6 represents typi-
cal pumpout unit/chiller piping connections. Standard con-
1
nections for ⁄2-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
7
⁄
8-in. OD copper tubing to minimize pressure drop.
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.
Pumpout unit water piping connections are shown in
Fig. 6. Both connections are 1⁄2-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 devices. 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).
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 storage 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.
Refrigerant discharged into confined spaces can dis-
place oxygen and cause asphyxiation.
NOTE: Use copper conductors only.
7
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DIMENSIONS
ENGLISH (ft-in.)
TANK
SIZE
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
0428 10- 5
9-10
4-9
2-43⁄4 1-23⁄8 3-13⁄16 4-11
3-81⁄8 3- 8
2-97⁄16 3-2
0-31⁄2 4-83⁄4 1-77⁄8 1-75⁄16 3-73⁄4 5-01⁄4
0452 14-111⁄4 14- 41⁄2 5-07⁄8 2-81⁄2 1-41⁄4 3-47⁄16 7- 21⁄4 4-0
3-117⁄8 3-15⁄16 3-57⁄8 0-33⁄8 7-11⁄2 1-83⁄4 1-79⁄16 3-8
5-01⁄2
SI (mm)
TANK
SIZE
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
0428
0452
3175
4553
2997
4382
1448
1546
730
826
365
413
945
1499
2191
1121
1219
1118
1216
849
948
965
89
86
1442
2172
505
528
491
497
1111
1118
1530
1537
1027
1064
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. The available conduit knockout sizes are:
TRADE
SIZE
QTY
LOCATION
1
⁄
⁄
2
؆
1
1
1
1
top
3
4؆
bottom
middle
middle
1؆
11⁄4
؆
Fig. 5 — PPS Contact Surface and Dimensions
8
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CHILLERS WITHOUT ISOLATION VALVES
CHILLERS WITH ISOLATION VALVES
(WITH OR WITHOUT PUMPOUT STORAGE TANKS)
LEGEND
GENERAL PIPING CONNECTION SIZES
Factory-Supplied Tubing
CONNECTION
SIZE (in.)
Field-Supplied Tubing
1
1
3
Refrigerant Transfer Connections
Condenser Water Cooling Connectors
Safety Relief Head Pumpdown Condenser
⁄
⁄
⁄
2
2
8
ODS (female)
NPT (female)
Flare (male)
Field-Supplied Tubing (Multiple Chillers)
Service Valve (Factory Supplied)
Service Valve (Field Supplied)
ODS
—
Outside Diameter, Sweat
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,
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.
Fig. 6 — Typical Pumpout Unit/Chiller Connection Schematic
9
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Table 4 — Relief Devices
REQUIRED FACTOR
STORAGE
TANK SIZE
RELIEF VALVE
OUTLET SIZE
QUANTITY
lb air
min
Kg air
min
1 in. NPT
28
52
2
2
31.4
52.3
14.2
23.7
Female Connector
1 in. NPT
Female Connector
LEGEND
Ground
Field Wiring
Factory Wiring
Contactor Term.
Overload Term.
Pumpdown Term.
Pumpdown Comp’r.
Term.
Fig. 7 — 19XB Pumpout System Wiring Schematic
LEGEND
C
—
—
—
—
—
—
—
Contactor
Fu
HP
L
Fuse, 3 Amps
Compressor Terminal
High-Pressure Cutout
Compressor Motor Voltage Line (3-phase)
Low-Line Control Voltage (single-phase)
Compressor Overload
Contactor Terminal
Overload Terminal
Pumpout Unit Terminal
LL
OL
T’stat
Internal Thermostat
*Bimetal thermal protector imbedded in motor winding.
Fig. 8 — Pumpout Unit Wiring Schematic
10
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LEVEL GAGE — Liquid level gage (magnetically coupled
dial type) with electronic shut-off at 90% liquid capacity.
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.
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.
CONTROLS — The pumpout unit has the following con-
trols: an on/off switch, a 3-amp fuse, compressor overloads,
an internal thermostat, a compressor contactor, and a refrig-
erant high pressure cutout.
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 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.
SAFETY CONTROL SETTINGS — The pumpout unit high-
pressure switch (Fig. 1) 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
HIGH-PRESSURE SWITCH
REFRIGERANT
Cutout
CutIn
+ 0
R-134a
R-22
161 ± 5 psig
130 − 5 psig
+ 0
185 − 5 psig
220 ± 5 psig
SI
HIGH-PRESSURE SWITCH
REFRIGERANT
Cutout
Cut-In
+ 0
R-134a
R-22
1110 ± 34 kPa
896 − 34 kPa
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.
+ 0
1517 ± 34 kPa
1276 − 34 kPa
NOTES:
1. R-22 units use high-pressure cutout switch HK01UA181.
2. R-134a units use high-pressure cutout switch HK01UA187.
COMPRESSOR — The pumpout compressor assembly has
a positive displacement of 1750 rpm (29 r/s) and 8.7 cfm
(0.004 m3/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.
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.
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 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 ves-
sel codes with a minimum of 300 psig (2068 kPa) rating.
The tank components include:
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.
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
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NOTE: During this operation, maintain water circulation
through the chiller cooler and condenser vessels to prevent
tube freeze-up.
VENT VALVE 8
OIL RETURN
LINE
CONNECTION
DISTILLING 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
CONTROL BOX
(WIRING BY
CONTRACTOR)
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.
CONDENSER
WATER
CONNECTIONS
REFRIGERANT
INLET VALVE
Fig. 9 — Pumpout Unit
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.
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 ЉCЉ indicates a closed valve.
Figures 9 and 10 show the locations of the valves.
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.
Do not mix refrigerants from chillers that use different
compressor oils. Compressor damage can result. For ex-
ample, the compressor oil in a 23XL 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
Transfer Refrigerant from Pumpout Storage Tank to Chiller:
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.
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.
2. Make sure that the pumpout compressor holddown bolts
(Fig. 2) have been loosened to allow free spring travel.
1. Equalize refrigerant pressure.
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.
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 refrigerant charging valve 7; open chiller
isolation valve 11 and any other chiller isolation valves,
if present.
3. Open the refrigerant inlet valve (Fig. 9) on the pumpout
compressor.
c. Open pumpout and storage tank valves 3 and 6; open
chiller valves 1a and 1b.
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.
VALVE
1a 1b
2
3
4
5
6
7
8
10 11
C
CONDITION
C
C
C
C
C
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.
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.
12
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Fig. 10 — Valve Locations for 19XB Pumpout Unit With 19XB Storage Tank
e. Open valve 5 fully after the chiller pressure rises above k. Close valves 1a, 1b, 2, 5, and 6.
the freezing point of the refrigerant. Let the storage
tank and chiller pressure equalize. Open refrigerant charg-
ing valve 7 and storage tank charging valve 10 to let
liquid refrigerant drain into the chiller.
VALVE
1a 1b
2
3
4
5
6
7
8
10 11
C
CONDITION
C
C
C
C
C
C
C
C
C
l. Turn off pumpout condenser water.
VALVE
1a 1b
2
3
4
5
6
7
8
10 11
Transfer the Refrigerant from Chiller to Pumpout Storage
Tank.
CONDITION
C
C
C
2. Transfer remaining refrigerant.
a. Close valve 5 and open valve 4.
1. Equalize refrigerant pressure.
a. Valve positions:
VALVE
1a 1b
2
3
4
5
6
7
8
10 11
CONDITION
C
C
C
VALVE
1a 1b
2
3
4
5
6
7
8
10 11
C
CONDITION
C
C
C
C
C
b. Turn off the pumpout condenser water, and turn on the
pumpout compressor to push liquid refrigerant out of
the storage tank. Monitor the storage tank level until
the tank is empty.
b. Slowly open valve 5 and refrigerant charging valves 7
and 10 to allow liquid refrigerant to drain by gravity
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. Close valves 3 and 4.
VALVE
1a 1b
2
3
4
5
6
7
8
10 11
CONDITION
C
C
C
2. Transfer the remaining liquid.
a. Turn off pumpout condenser water. Place valves in the
following positions:
g. Open valves 2 and 5.
VALVE
1a 1b
2
3
4
5
6
7
8
10 11
C
VALVE
1a 1b
2
3
4
5
6
7
8
10 11
CONDITION
C
C
C
C
CONDITION
C
C
C
h. Turn on pumpout condenser water.
b. Run the pumpout compressor for approximately 30 min-
utes, then close valve 7 and 10.
i. Run the pumpout compressor until the storage tank pres-
sure reaches 5 psig (34 kPa), 18 in. Hg (41 kPa
absolute).
VALVE
1a 1b
2
3
4
5
6
7
8
10 11
C
CONDITION
C
C
C
C
j. Turn off the pumpout compressor.
c. Turn off the pumpout compressor.
13
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3. Remove any remaining refrigerant.
a. Turn on chiller water pumps.
Transfer All Refrigerant to Chiller Condenser Vessel:
1. Push refrigerant into chiller condenser vessel.
b. Turn on pumpout condenser water.
c. Place valves in the following positions:
a. Turn on the chiller water pumps and monitor the chiller
pressure.
b. Valve positions:
VALVE
1a 1b
2
3
4
5
6
7
8
10 11
C
VALVE
1a
1b
2
3
4
5
8
11
CONDITION
C
C
C
C
CONDITION
C
C
C
d. Run the pumpout compressor until the chiller pres-
sure reaches 60 psig (414 kPa), [30 psig (207 kPa)];
then, shut off the pumpout compressor. Warm chiller
condenser water will boil off any entrapped liquid re-
frigerant and chiller pressure will rise.
c. Equalize the refrigerant in the chiller cooler and
condenser.
d. Turn off chiller water pumps and pumpout condenser
water supply.
e. When chiller pressure rises to 70 psig (483 kPa),
[40 psig (276 kPa)]; turn on the pumpout compressor
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
no longer rises; then, turn on the pumpout compressor
and pump out until the chiller pressure reaches
18 in. Hg (41 kPa absolute).
e. Turn on pumpout compressor to push liquid out of the
chiller cooler vessel.
f. When all liquid has been pushed into the chiller con-
denser vessel, close the cooler refrigerant isolation valve
(11).
g. Turn on the chiller water pumps.
h. Turn off the pumpout compressor.
f. Close valves 1a, 1b, 3, 4, and 6.
2. Evacuate gas from chiller cooler vessel.
a. Close pumpout valves 2 and 5; open valves 3 and 4.
VALVE
1a 1b
2
3
4
5
6
7
8
10 11
C
CONDITION
C
C
C
C
C
C
C
C
C
VALVE
1a
1b
2
3
4
5
8
11
C
CONDITION
C
C
C
g. Turn off the pumpout condenser water.
4. Establish vacuum for service. To conserve refrigerant, op-
erate the pumpout compressor as described in Step 3e un-
til the chiller pressure is reduced to 18 in. Hg (41 kPa
absolute).
b. Turn on pumpout condenser water.
c. Run pumpout compressor until the chiller cooler ves-
sel pressure reaches 18 in. Hg vac (41 kPa absolute).
Monitor pressures on the chiller control panel and on
refrigerant gages.
CHILLERS WITH ISOLATION VALVES — The valves re-
ferred to in the following instructions are shown in Fig. 9
and 11. Valve 7 remains closed.
Fig. 11 — Valve Locations for 19XB Pumpout Unit Without Storage Tank
14
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d. Close valve 1a.
6. Open valve 5 fully.
e. Turn off pumpout compressor.
f. Close valves 1b, 3, and 4.
VALVE
1a
1b
2
3
4
5
8
11
C
CONDITION
C
C
C
VALVE
1a
C
1b
C
2
3
4
5
8
11
C
7. Close valves 1a, 1b, 3, and 5.
8. Open chiller isolation valve 11 and any other isolation
valves, if present.
CONDITION
C
C
C
C
C
g. Turn off pumpout condenser water.
h. Turn off chiller water pumps and lock out chiller
compressor.
VALVE
1a
C
1b
C
2
3
4
5
8
11
CONDITION
C
C
C
C
C
Transfer All Refrigerant to Chiller Cooler Vessel:
1. Push refrigerant into the chiller cooler vessel.
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.
a. Turn on the chiller water pumps and monitor the chiller
pressure.
b. Valve positions:
VALVE
1a
1b
2
3
4
5
8
11
2. Equalize the refrigerant pressure.
CONDITION
C
C
C
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.
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.
c. Open pumpout and storage tank valves 3 and 6; open
chiller valves 1a and 1b.
VALVE
1a 1b
2
3
4
5
6
7
8
10 11
C
CONDITION
C
C
C
C
C
g. Turn off the pumpout compressor.
2. Evacuate gas from chiller condenser vessel.
a. Turn on chiller water pumps.
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.
b. Make sure that pumpout valves 3 and 4 are closed and
valves 2 and 5 are open.
VALVE
1a
1b
2
3
4
5
8
11
C
CONDITION
C
C
C
3. Transfer remaining refrigerant.
a. Close valve 3.
c. Turn on pumpout condenser water.
b. Open valve 2.
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.
VALVE
1a 1b
2
3
4
5
6
7
8
10 11
C
CONDITION
C
C
C
C
e. Close valve 1b.
f. Turn off pumpout compressor.
g. Close valves 1a, 2, and 5.
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 1a, 1b, 2, 5, and 6.
g. Turn off pumpout condenser water.
VALVE
1a
C
1b
C
2
3
4
5
8
11
C
CONDITION
C
C
C
C
C
h. Turn off pumpout condenser water.
i. Turn off chiller water pumps and lock out chiller com-
pressor.
VALVE
1a 1b
2
3
4
5
6
7
8
10 11
C
CONDITION
C
C
C
C
C
C
C
C
C
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 1a, 1b, and 3.
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.
VALVE
1a
1b
2
3
4
5
8
11
C
CONDITION
C
C
C
C
4. 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.
Pumpout Unit — For maintenance details, refer to the
06D, 07D Installation, Start-Up, and Service Instructions.
5. Leak test to ensure chiller vessel integrity.
15
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PUMPOUT COMPRESSOR OIL CHARGE — Use oil con-
forming to Carrier specifications for reciprocating compres-
sor use. Oil requirements are listed in Table 6.
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.
Table 6 — Pumpout Compressor Oil Requirements
CARRIER
SPECIFICATION
NO.
ISO
VISCOSITY
CARRIER
PART NO.
REFRIGERANT
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.
R-22
86
68
PP49-7
PP23BZ101
PP23BZ103
R-134a
PP47-31
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:
Ordering Replacement Parts — The following in-
formation 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
1. Attach a pressure gage to the gage port of either pumpout
compressor service valve (Fig. 10).
TROUBLESHOOTING
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).
Information on troubleshooting for the PPS is included in
Table 7.
Table 7 — Troubleshooting
SYMPTOM
PROBABLE CAUSE
Main power line open
REMEDY
Replace fuse or reset circuit breaker.
Check connections.
Compressor does not run
Loose terminal connection
Improperly wired controls
Low line voltage
Check wiring and rewire.
Check line voltage; determine location of voltage drop.
Compressor motor defective
Check motor winding for open or short. Replace compressor if
necessary.
Seized compressor
Replace compressor.
High level gage alarm
High-pressure control erratic in action
Discharge valve partially closed.
Air in system
Check refrigerant level and remove excess.
Check capillary tube for pinches. Set control as required..
Open valve.
Compressor cycles on
high-pressure control
Purge system.
Condenser scaled.
Clean condenser.
Condenser water pump or fans not operat- Start pump or fans.
ing.
Unit operates too long
System Noises
Isolation valves partially open
Piping vibrations
Close valves.
Support piping as required. Check for loose pipe connectors.
Compressor noisy
Check valve plates for valve noise. Replace compressor (worn
bearings). Check for loose compressor holddown bolts.
Insufficient compressor oil
Leak in system
Add oil.
Compressor Loses Oil
Locate and repair leak.
Repair or replace valve.
Plugged or stuck compressor oil return
check valve
Dirty accumulator
Clean accumulator.
Copyright 1996 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
PC 211
Catalog No. 531-927
Printed in U.S.A.
Form 19XB-1SI
Pg 16
6-96
Replaces: New
Tab 5a
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