Safety Considerations - Carrier AquaEdge 19XR Series Start-Up, Operation And Maintenance Instructions Manual

PUMPOUT AND REFRIGERANT
TRANSFER PROCEDURES . . . . . . . . . . . . . . . . . 41
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Operating the Optional Pumpout Unit (Fig. 44) . . . 43
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . 46
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . 46
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . 46
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . 46
Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Test After Service, Repair, or Major Leak . . . . . . . . 46
Repair the Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . 46
Checking Guide Vanes . . . . . . . . . . . . . . . . . . . . . . . 46
Trim Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . 48
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 48
Check the Lubrication System . . . . . . . . . . . . . . . . . 48
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . 49
Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . 49
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
VFD Refrigerant Strainer (if equipped) . . . . . . . . . . 50
Oil Reclaim Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Inspect Refrigerant Float System . . . . . . . . . . . . . . 50
Inspect Relief Valves and Piping . . . . . . . . . . . . . . . 51
Compressor Bearing and Gear Maintenance . . . . . 51
Inspect the Heat Exchanger Tubes and
Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Inspect the Starting Equipment or VFD . . . . . . . . . . 51
Recalibrate Pressure Transducers . . . . . . . . . . . . . 52
Optional Pumpout System Maintenance . . . . . . . . . 52
Ordering Replacement Chiller Parts . . . . . . . . . . . . 52
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . 53
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Checking Display Messages . . . . . . . . . . . . . . . . . . 53
Checking Temperature Sensors . . . . . . . . . . . . . . . 53
Checking Pressure Transducers . . . . . . . . . . . . . . . 57
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . 57
Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Pumpdown/Lockout . . . . . . . . . . . . . . . . . . . . . . . . . 57
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
APPENDIX A - PIC 6 SCREEN AND TABLE
STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
APPENDIX B - CCN COMMUNICATION WIRING
FOR MULTIPLE CHILLERS (TYPICAL) . . . . . . . 112
APPENDIX C - MAINTENANCE SUMMARY
AND LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . 113
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
INITIAL START-UP CHECKLIST
FOR 19XR SEMI-HERMETIC TWO-STAGE
CENTRIFUGAL LIQUID CHILLER . . . . . . . . . . . CL-1

SAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safe and reliable
service when operated within design specifications. When operat-
ing 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 pre-
cautions contained in the chiller instructions as well as those listed
in this guide.
Failure to follow these procedures will result in severe person-
al injury or death.
DO NOT VENT refrigerant relief valves within a building.
Outlet from rupture disc or relief valve must be vented out-
doors in accordance with the latest edition of ANSI/ASHRAE
15 (American National Standards Institute/American Society
of Heating, Refrigerating, and Air-Conditioning Engineers).
The accumulation of refrigerant in an enclosed space can dis-
place oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/
ASHRAE 15, especially for enclosed and low overhead spac-
es. Inhalation of high concentrations of vapor is harmful and
may cause heart irregularities, unconsciousness, or death. Mis-
use 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
chiller for any purpose. Oxygen gas reacts violently with oil,
grease, and other common substances.
NEVER EXCEED specified test pressures; VERIFY the al-
lowable test pressure by checking the instruction literature
and the design pressures on the equipment nameplate.
DO NOT USE air for leak testing. Use only refrigerant or dry
nitrogen.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed
and functioning before operating any chiller.
RISK OF INJURY OR DEATH by electrocution. High volt-
age is present on motor leads even though the motor is not run-
ning when a solid-state or wye-delta mechanical starter is
used. Open the power supply disconnect before touching mo-
tor leads or terminals.
Failure to follow these procedures may result in personal inju-
ry or death.
DO NOT USE TORCH to remove any component. System
contains oil and refrigerant under pressure.
To remove a component, wear protective gloves and goggles
and proceed as follows:
1. Shut off electrical power to unit.
2. Recover refrigerant to relieve all pressure from system
using both high-pressure and low pressure ports.
3. Traces of vapor should be displaced with nitrogen and
the work area should be well ventilated. Refrigerant in
contact with an open flame produces toxic gases.
4. Cut component connection tubing with tubing cutter
and remove component from unit. Use a pan to catch
any oil that may come out of the lines and as a gage for
how much oil to add to the system.
5. Carefully unsweat remaining tubing stubs when neces-
sary. Oil can ignite when exposed to torch flame.
(Warnings continued on next page.)
2
DANGER
WARNING