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9 - SYSTEM INITAL START-UP
9.1 - Checks before system start-up
Before commissioning the chiller the complete system must be
verified against the installation drawings, dimensional drawings,
system piping and instrumentation diagrams and the wiring
schematics. All measures must be taken to ensure that the
pressure and temperature limits, specifically those listed on the
unit nameplates, are not exceeded during operation, maintenance
and recycling. Heat exchange fluid temperatures above the
maximum recommended can lead to an increase in the refrigerant
pressure and can cause a loss of refrigerant due to the relief valve
discharge. National regulations must be followed during these
checks. If the national regulation does not specify any details,
refer to standard EN 378 as follows:
External visual installation checks:
■ Ensure that the machine is charged with refrigerant. Verify on
the unit nameplate that the 'fluid transported' is that
recommended for operation, and is not nitrogen.
■ Compare the complete system with the cooling system and
power circuit diagrams.
■ Check that all documents provided by the manufacturer
(dimensional drawings, pipe and instrument diagram (PID),
declarations, etc.) to comply with the regulations are present.
If any documentation is missing, order a replacement.
■ Verify that the environmental protection and safety devices and
arrangements provided by the manufacturer to comply with the
regulations are in place and compliant.
■ Check that the declaration of conformity for the pressurized
ensemble mentions all of the circuit equipments.
■ Verify that access and safety routes are unobstructed.
■ Verify the instructions and directives to prevent the deliberate
removal of refrigerant gases.
■ Verify the installation of connections.
■ Verify the supports and fixing elements (materials, routing and
connection).
■ Verify the quality of welds and other joints.
■ Check the protection against mechanical damage.
■ Check the protection against heat.
■ Check the protection of moving parts.
■ Verify the accessibility for maintenance or repair and to check
the piping.
■ Verify the status of the valves.
■ Verify the quality of the thermal insulation.
■ Check the condition of 400 V cable insulation.
IMPORTANT: If the compressors are equipped with
anti-vibration mounts, check whether these mounts have
clamping mechanisms. If they do, the clamping mechanisms
must be removed before system start-up. Clamping
mechanisms are identified by red collars and by a label affixed
to the compressor sub-assembly.
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9.2 - Commissioning
Always ensure you have read and fully understood the operating
instructions for the units before starting up the unit, and ensure
the following precautions have been taken:
■ Check the heat transfer fluid circulation pumps, the air handling
equipment, and any other equipment connected to the system.
■ Refer to these instructions.
■ Refer to the electrical diagram delivered with the unit.
■ Ensure that there is no refrigerant leak.
■ Check that all clamps securing the pipes are correctly tightened.
■ Check the power supply at the main connection point and the
order of phases.
■ Open the suction shut-off valves on each circuit for the
corresponding machines.
■ For units without the hydraulic module (option 116), the installer
is responsible for insulation and frost protection and the
connections relating to the system pump.
■ Check the operation of the oil heaters (present on the oil
separator) 24 hours before starting up the system.
IMPORTANT: Commissioning and start-up must be supervised
by a qualified engineer.
■ The system must have a heat load and water flowing in the
exchangers when it is started up and tested.
■ All setpoint adjustments and control tests must be carried out
before the unit is started up.
■ Refer to the Service guide.
Proceed with the unit commissioning.
Ensure that all safety devices are operational, checking specifically
that the high pressure switches are activated and that any alarms
have been cleared.
NOTE: If the manufacturer's recommendations (system, water
and power connections) are not observed, no claims made
under the warranty will be accepted.
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