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1 - INTRODUCTION
The 30XAS Aquaforce units are designed to cool water for the air
conditioning of buildings and industrial processes.
Prior to the initial start-up of the 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 30XAS 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 t ive
clothing (gloves, ear defenders, safety glasses and shoes), using
appropriate 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, immediately file a claim with the
shipping company.
Carrier strongly recommends employing a specialised
company to unload the machine.
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.
These units are not designed to be lifted from above. Use
slings with the correct capacity, and always follow the lifting
instructions on the certified drawings supplied with the unit.
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.
DO NOT COVER ANY PROTECTION DEVICES.
This applies to fuse plugs and relief valves (if used) in the
refrigerant or heat transfer medium circuits. Check if 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. Install
devices at the valve outlets or drain piping that 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 drain piping, must not impair operation
and not lead to a pressure drop that is higher than 10% of the
control 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:
Safety
accessory
Refrigerant side
High-pressure switch
External relief valve***
Rupture disk
Fuse plug
Heat transfer fluid side
External relief valve
(1) Classified for protection in normal service situations.
(2) Classified for protection in abnormal service situations.
(3) The instantaneous over-pressure limited to 10% of the operating pressure does
not apply to this abnormal service situation. The control pressure can be higher
than the service pressure. In this case either the design temperature or the
high-pressure switch ensures that the service pressure is not exceeded in normal
service situations.
(4) The classification of these relief valves must be made by the personnel that
completes the whole hydraulic installation.
Do not remove these valves and fuses, even if the fire risk is
under control for a particular installation. There is no
guarantee that the accessories are re-installed if the instal-
lation is changed or for transport with a gas charge.
When the unit is subjected to fire, safety devices prevent
rupture due to over-pressure by releasing the refrigerant. The
fluid may then be decomposed into toxic residues when
subjected to the flame:
- Stay away from the unit.
- Set up warnings and recommendations for personnel in
charge to stop the fire.
- Fire extinguishers appropriate to the system and the
refrigerant type must be easily accessible.
All factory-installed relief valves are lead-sealed to prevent any
calibration change. 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.
The external relief valves must always be connected to drain
pipes for units installed in a closed room. 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 refrigerant leaks. As
the fluids can be diffused in the air, ensure that the outlet is
far away from any building air intake, or that they are
discharged in a quantity that is appropriate for a suitably
absorbing environment.
Periodic check of the relief valves: See paragraph 1.3
"Maintenance safety considerations".
Provide a drain in the discharge circuit, close to each relief
valve, to avoid an accumulation of condensate or rain water.
All precautions concerning handling of refrigerant must be
observed in accordance with local regulations.
Ensure good ventilation, as accumulation of refrigerant in an
enclosed space can displace oxygen and cause asphyxiation
or explosions.
Inhalation of high concentrations of vapour is harmful and
may cause heart irregularities, unconsciousness, or death.
Vapour is heavier than air and reduces the amount of oxygen
available for breathing. These products cause eye and skin
irritation. Decomposition products are hazardous.
Damage limitation
accessory
(2)
(1)
in case of an external fire
x
x
x
x
(4)
(4)
5
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