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Installation, Operating, and Maintenance Instructions

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Installation, Operating, and Maintenance Instructions 19XR Positive Pressure Storage System 50/60 Hz Installation, Operating, and Maintenance Instructions SAFETY CONSIDERATIONS WARNING Positive pressure storage systems are designed to pro- vide safe and reliable service when operated within Failure to follow these procedures may result in personal design specifications. When operating this equipment, injury or death. use good judgment and safety precautions to avoid dam- DO NOT USE TORCH to remove any component. System age to equipment and property or injury to personnel. contains oil and refrigerant under pressure. Installation, start-up, and servicing of this equipment To remove a component, wear protective gloves and gog- can be hazardous due to system pressures, electrical gles and proceed as follows: components, and equipment location (roofs, elevated structures, etc.). Only trained, qualified installers and a. Shut off electrical power to unit. service technicians should install, start up, and service b. Recover refrigerant to relieve all pressure from sys- this equipment. tem using both high-pressure and low-pressure ports. Be sure you understand and follow the procedures and c. Traces of vapor should be displaced with nitrogen safety precautions contained in this guide. and the work area should be well ventilated. Refrig- erant in contact with an open flame produces toxic DANGER gases. d. Cut component connection tubing with tubing cutter, Failure to follow these procedures will result in severe per- and remove component from unit. Use a pan to catch sonal injury or death. any oil that may come out of the lines and as a gage DO NOT VENT refrigerant relief valves within a building. for how much oil to add to the system. Outlet from rupture disc or relief valve must be vented out- e. Carefully unsweat remaining tubing stubs when nec- doors in accordance with the latest edition of ASHRAE 15 essary. Oil can ignite when exposed to torch flame. (American Society of Heating, Refrigerating, and Air- Conditioning Engineers). The accumulation of refrigerant DO NOT USE eyebolts or eyebolt holes to rig machine in an enclosed space can displace oxygen and cause sections or the entire assembly. asphyxiation. DO NOT work on high-voltage equipment unless you are a PROVIDE adequate ventilation in accordance with qualified electrician. ASHRAE 15, especially for enclosed and low overhead DO NOT WORK ON electrical components, including spaces. Inhalation of high concentrations of vapor is harm- control panels, switches, starters, or oil heater until you are ful and may cause heart irregularities, unconsciousness, or sure ALL POWER IS OFF and no residual voltage can death. Misuse can be fatal. Vapor is heavier than air and leak from capacitors or solid-state components. reduces the amount of oxygen available for breathing. LOCK OPEN AND TAG electrical circuits during servic- Product causes eye and skin irritation. Decomposition ing. IF WORK IS INTERRUPTED, confirm that all cir- products are hazardous. cuits are de-energized before resuming work. DO NOT USE OXYGEN to purge lines or to pressurize a AVOID SPILLING liquid refrigerant on skin or getting it machine for any purpose. Oxygen gas reacts violently with into the eyes. USE SAFETY GOGGLES. Wash any spills oil, grease, and other common substances. from the skin with soap and water. If any enters the eyes, NEVER EXCEED specified test pressures, VERIFY the IMMEDIATELY FLUSH EYES with water and consult a allowable test pressure by checking the instruction litera- physician. ture and the design pressures on the equipment nameplate. NEVER APPLY an open flame or live steam to a refriger- DO NOT USE air for leak testing. Use only tracer gases ant cylinder. Dangerous overpressure can result. When and dry nitrogen. necessary to heat refrigerant, use only warm (110 F [43 C]) DO NOT VALVE OFF any safety device. water. BE SURE that all pressure relief devices are properly DO NOT REUSE disposable (nonreturnable) cylinders or installed and functioning before operating any machine. attempt to refill them. It is DANGEROUS AND ILLE- GAL. 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.) Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-531900050-01 Printed in U.S.A. Form 19XR-CLT-16SI Pg 1 5-17 Replaces: 19XR-6SI WARNING CAUTION CHECK THE REFRIGERANT TYPE before transferring refrigerant to the machine. The introduction of the wrong DO NOT re-use compressor oil or any oil that has been refrigerant can cause damage or malfunction to this exposed to the atmosphere. Dispose of oil per local codes machine. and regulations. Operation of this equipment with refrigerants other than DO NOT leave refrigerant system open to air any longer those cited herein should comply with ASHRAE 15 (latest than the actual time required to service the equipment. Seal edition). Contact Carrier for further information on use of circuits being serviced and charge with dry nitrogen to pre- this machine with other refrigerants. vent oil contamination when timely repairs cannot be ENSURE that refrigerant is only pumped to or stored in completed. tanks that are ASME (American Society of Mechanical Engineers) certified for the pressures appropriate to the CONTENTS refrigerant being handled. Page DO NOT ATTEMPT TO REMOVE fittings, covers, etc., SAFETY CONSIDERATIONS while machine is under pressure or while machine is run- . 1,2 ning. Be sure pressure is at 0 psig (0 kPa) before breaking INTRODUCTION . 2,3 any refrigerant connection. INSTALLATION. 3-10 CAREFULLY INSPECT all relief devices, rupture discs, Step 1 — Complete Pre-Installation Checks . 3 and other relief devices AT LEAST ONCE A YEAR. If • IDENTIFY UNIT machine operates in a corrosive atmosphere, inspect the • INSPECT SHIPMENT devices at more frequent intervals. Step 2 — Mount the Pumpout Unit . 3 DO NOT ATTEMPT TO REPAIR OR RECONDITION • MOUNTING ON THE CHILLER • FLOOR MOUNTING any relief device when corrosion or build-up of foreign Step 3 — Rig the Storage Tank . 4 material (rust, dirt, scale, etc.) is found within the valve Step 4 — Make Piping Connections body or mechanism. Replace the device. 6 • INSTALL VENT PIPING TO RELIEF DEVICES DO NOT install relief devices in series or backwards. Step 5 — Make Electrical Connections . 6 USE CARE when working near or in line with a com- CONTROLS AND COMPONENTS . 11 pressed spring. Sudden release of the spring can cause it Pumpout Unit . 11 and objects in its path to act as projectiles. • CONTROLS • SAFETY CONTROL SETTINGS •COMPRESSOR CAUTION • CONDENSER •OIL SEPARATOR Failure to follow these procedures may result in personal • SUCTION AND DISCHARGE VALVES injury or damage to equipment. Storage Tank . 11 EQUIPMENT should be operated by certified personnel •DRAIN VALVE only. • DUAL RELIEF VALVES DO NOT STEP on refrigerant lines. Broken lines can whip • PRESSURE GAGE about and cause personal injury and damage to the • LEVEL GAGE machine. OPERATION. 11-17 DO NOT climb over a machine. Use platform, catwalk, or Overview . 11 staging. Follow safe practices when using ladders. • REFRIGERANT TRANSFER • TRANSFERRING LIQUID REFRIGERANT FROM USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to THE CHILLER COOLER TO THE CHILLER lift or move inspection covers or other heavy components. CONDENSER OR PUMPOUT STORAGE TANK Even if components are light, use such equipment when • TRANSFERRING LIQUID REFRIGERANT FROM there is a risk of slipping or losing your balance. THE CHILLER CONDENSER OR PUMPOUT BE AWARE that certain automatic start arrangements STORAGE TANK TO THE CHILLER COOLER CAN ENGAGE THE STARTER. Open the disconnect • DISTILLING THE REFRIGERANT ahead of the starter in addition to shutting off the machine Pumpout and Refrigerant Transfer or pump. Procedures. 11 USE only repair or replacement parts that meet the code • PREPARATION requirements of the original equipment. • OPERATING THE PUMPOUT UNIT DOUBLE-CHECK that coupling nut wrenches, dial indi- MAINTENANCE. 17 cators, or other items have been removed before rotating Pumpout Compressor Oil Charge . 17 any shafts. Storage Tank . 17 Ordering Replacement Parts . 17 DO NOT LOOSEN a packing gland nut before checking that the nut has a positive thread engagement. TROUBLESHOOTING . 17,18 PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks, or damage. INTRODUCTION DO NOT MIX REFRIGERANT from chillers that use dif- The 19XR Positive Pressure Storage (PPS) system has been ferent compressor oils. Compressor damage can result. designed to help owners and operators of positive pressure (Cautions continued in next column.) 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 2 atmosphere. The proper use of this equipment minimizes the INSTALLATION loss of HFCs. Step 1 — Complete Pre-Installation Checks The 19XR PPS system shown in Fig. 1 consists of a pump- out unit mounted on a storage tank. The pumpout unit is IDENTIFY UNIT — Identify the assembly number (see offered as a free-standing unit that can be used with chillers Table 1) printed on the pumpout unit and storage tank name- that have an existing storage tank or with chillers that have iso- plates. Check this information against the job requirements. lation valves that permit built-in refrigerant storage. Figure 1 shows the PPS system and its major components. Refer to Tables 2 and 3 for physical data. The 19XR PPS systems are factory tested and certified to the American Society of Mechanical Engineers (ASME) pres- INSPECT SHIPMENT — Inspect unit for damage before sure vessel code. The tanks are constructed of certified steel removing unit from shipping conveyance. If unit appears dam- and are pressure rated at 185 psig (1276 kPa). The PPS storage aged, it should be inspected by a shipping inspector before tank is equipped with dual relief valves for proper venting per removal.
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