Introduction; Installation Safety Considerations - Carrier AQUAFORCE 30XW Series Installation, Operation And Maintenance Instructions

1 - INTRODUCTION

The 30XW Aquaforce units are designed to cool water for the air
conditioning of buildings and industrial procsses.
Prior to the initial start-up of the 30XW units, the people involved
in the on-site installation, start-up, operation, and maintenance of
this unit should be thoroughly familiar with these instructions and
the specific project data for the installation site.
The 30XW liquid chillers are designed to provide a very high level
of safety during installation, start-up, operation and maintenance.
They will provide safe and reliable service when operated within
their application range.
They are designed for an operating life of 15 years by assuming
a 75% utilisation factor; that is approximately 100,000 operating
hours.
This manual provides the necessary information to fami-liarize
yourself with the control system before performing start-up
procedures. The procedures in this manual are arranged in the
sequence required for machine installation, start-up, operation
and maintenance.
Always ensure that all required safety measures are followed,
including those in this document, such as: wearing protec-tive
clothing (gloves, safety glasses and shoes) using appro-priate
tools, employing qualified and skilled technicians (electricians,
refrigeration engineers) and following local regulations.
To find out, if these products comply with European directives
(machine safety, low voltage, electromagnetic compatibility,
equipment under pressure etc.) check the declarations of
conformity for these products.

1.1 - Installation safety considerations

Access to the unit must be reserved to authorised personnel,
qualified and trained in monitoring and maintenance. The access
limitation device must be installed by the customer (e.g. cut-off,
enclosure).
After the unit has been received, when it is ready to be installed
or reinstalled, and before it is started up, it must be inspected for
damage. Check that the refrigerant circuit(s) is (are) intact,
especially that no components or pipes have shifted (e.g. following
a shock). If in doubt, carry out a leak tightness check and verify
with the manufacturer that the circuit integrity has not been impaired.
If damage is detected upon receipt, immediately file a claim with
the shipping company.
Carrier strongly recommends employing a specialised
company to unload the machine.
It is compulsory to wear personal protection equipment.
Do not remove the skid or the packaging until the unit is in
its final position. These units can be moved with a fork lift
truck, as long as the forks are positioned in the right place
and direction on the unit.
The units can also be lifted with slings, using only the
designated lifting points marked on the unit.
Use slings or lifting beams with the correct capacity, and
always follow the lifting instructions on the certified drawings
supplied with the unit. Do not tilt the unit more than 15°.
Safety is only guaranteed, if these instructions are carefully
followed. If this is not the case, there is a risk of material
deterioration and injuries to personnel.
Never cover any protection devices.
This applies to the relief valves (if used) in the refrigerant or
heat transfer medium circuits, the fuse plugs and the pressure
switches.
Ensure that the valves are correctly installed, before operating
the unit.
DO NOT OBSTRUCT ANY PROTECTIVE DEVICES:
This applies to any fusible plugs, rupture disks and valves
fitted on the refrigerant or heat transfer fluid circuits. Check
whether the original protection plugs are still present at the
valve outlets. These plugs are generally made of plastic and
should not be used. If they are still present, please remove
them. Fit devices at the valve or discharge piping outlets to
prevent the penetration of foreign bodies (dust, building
debris, etc.) and atmospheric agents (water can form rust or
ice). These devices, as well as the discharge piping, must not
impair operation or lead to a pressure drop that is higher than
10% of the set pressure.
Classification and control
In accordance with the Pressure Equipment Directive and
national usage monitoring regulations in the European Union
the protection devices for these machines are classified as
follows:
Classification of safety devices
Refrigerant side
High pressure safety loop (3)
External relief valve (4)
Rupture disk
Heat transfer fluid side
External relief valve
(1) Classified for protection in normal service situations.
(2) Classified for protection in abnormal service situations. These devices are sized
for fires with a thermal flow of 10kW/m². No combustible matter should be placed
within 6.5m of the unit.
(3) High pressure safety loop = SRMCR as described in component section of this
manual and in electrical diagram.
(4) The instantaneous over-pressure limitation of 10% of the operating pressure
does not apply to this abnormal service situation. The setting of the device to a
value above the service pressure is allowed and complies with the applicable
standards. In this case either the design temperature or the high pressure safety
loop ensures that the maximum allowable pressure is not exceeded in normal
service situations.
(5) The selection of these relief valves must be made by the personnel responsible
for completing the hydraulic installation.
If the relief valves are installed on a change-over valve, this is
equipped with a relief valve on each of the two outlets. Only
one of the two relief valves is in operation, the other one is
isolated. Never leave the change-over valve in the intermediate
position, i.e. with both ways open bring the actuator in
abutment, front or back according to the outlet to isolate. If
a relief valve is removed for checking or replacement please
ensure that there is always an active relief valve on each of
the change-over valves installed in the unit.
All factory-installed relief valves are lead-sealed to prevent any
calibration change.
The external relief valves must always be vented to outside
if the units are installed in a closed space. Refer to the
installation regulations, for example those of European
standard EN 378 and EN 13136. These pipes must be installed
in a way that ensures that people and property are not
exposed to vented refrigerant. As the fluids can be diffused
in the air, ensure that refrigerant is discharged away from
building air intakes, relief valves must be checked periodically.
The valves must be checked periodically.
The external relief valves and the fuses are designed and
installed to ensure damage limitation in case of a fire.
In accordance with the regulations applied for the design, the
European directive on equipment under pressure and in
accordance with the national usage regulations:
• These relief valves and fuses are not safety accessories
but damage limitation accessories in case of a fire,
• The high pressure switches are the safety accessories.
Device for damage
Safety
limitation in the event of
device
(1)
an external fire
x
x
x
(5) (5)
(2)
5