Carrier AquaEdge 19DV Series Start-up, Operation And Maintenance Instructions Manual

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Carrier AquaEdge 19DV Series Start-up, Operation And Maintenance Instructions Manual Manual pdf 18 page image

18Refrigerant TracerCarrier recommends the use of an environmentally acceptablerefrigerant tracer for leak testing with an electronic refrigerantdetector.Ultrasonic leak detectors can also be used if the chiller is underpressure.Leak Test ChillerDue to regulations regarding refrigerant emissions and the diffi-culties associated with separating contaminants from the refrig-erant, Carrier recommends the following leak test procedure.Refer to Table 5 for refrigerant pressure/temperature values.1. If the pressure readings are normal for the chiller condition:a. Evacuate the charge from the vessels, if present.b. Raise the chiller pressure, if necessary, by addingrefrigerant until pressure is at the equivalent saturatedpressure for the surrounding temperature.c. Leak test chiller as outlined in Steps 3 to 7.2. If the pressure readings are abnormal for the chiller condition:a. Prepare to leak test chiller.b. For cooling machines, check for leaks by connecting anitrogen bottle with added tracer to allow for elec-tronic leak detection if possible; otherwise, soap bub-ble solution is to be used. Raise the pressure to20 psig (138 kPa). If electronic leak detector is avail-able, ensure small amount of tracer material is added.c. Plainly mark any leaks that are found.d. Release the pressure in the system.e. Repair all leaks.f. Retest the joints that were repaired.NOTE: Suggested test pressure is 20 psig (138 kPa); maximum al-lowable test pressure 45 psig (310 kPa).3. Check the chiller carefully with an electronic leak detectoror soap bubble solution.4. Leak Determination — If an electronic leak detector indi-cates a leak, use a soap bubble solution, if possible, to con-firm. Total all leak rates for the entire chiller. Leakage atrates greater than 0.1% of the total charge per year shouldbe repaired. Local regulation governs the requirements forwhen repair of leaks become mandatory. Note the totalchiller leak rate as well as the full charge amount on thestart-up report.5. If no leak is found during the initial start-up procedures,complete the transfer of refrigerant gas from the storagetank to the chiller. Recover any gas used for leak detectionpurposes as required per local jurisdiction.6. If no leak is found after a retest:a. Perform a standing vacuum test as outlined in theStanding Vacuum Test section, below.b. If the chiller fails the standing vacuum test, repeatleak test and repair.c. If the chiller passes the standing vacuum test, dehy-drate the chiller. Follow the procedure in the ChillerDehydration section, page 20. Charge the chiller withrefrigerant.7. If the chiller is opened to the atmosphere for an extendedperiod, evacuate it before repeating the leak test. A nitro-gen purge should be maintained to reduce the potential forcorrosion when open to the atmosphere.NOTE: Alternate optional leak testing method is to isolate the wa-ter circuits and use a portable water heater to raise the temperatureof the evaporator and condenser water circuits to approximately100°F (38°C) which corresponds to a pressure of approximately14.40 psig (99.3 kPag).Standing Vacuum TestWhen performing the standing vacuum test or chiller dehydra-tion, use a manometer or a wet bulb indicator. Dial gages can-not indicate the small amount of acceptable leakage during ashort period of time.1. Attach an absolute pressure manometer or wet bulb indica-tor to the chiller.2. Evacuate the vessel to at least 18 in. Hg vac (41 kPa [abs]),using a vacuum pump or a pumpout unit.3. Valve off the pump to hold the vacuum and record themanometer or indicator reading.a. If the leakage rate is less than 0.05 in. Hg (0.17 kPa)in 24 hours, the chiller is sufficiently tight.b. If the leakage rate exceeds 0.05 in. Hg (0.17 kPa) in24 hours, re-pressurize the vessel and test for leaks.4. Repair the leak, retest, and proceed with dehydration.WARNINGDo not use air or oxygen as a means of pressurizing thechiller. Mixtures of HFO R-1233zd(E) and air at elevatedpressure can undergo combustion, resulting in equipmentdamage and possible personal injury.CAUTIONNever charge liquid refrigerant into the chiller if the pres-sure in the chiller is less than 15 in. Hg (vac) / 380 mm Hg(vac) for HFO R-1233zd(E). Charge as a gas only, with theevaporator and condenser pumps running, until this pres-sure is reached, using PUMPDOWN/LOCKOUT (locatedin the Maintenance menu) and END LOCKOUT mode onthe PIC6 control interface. Flashing of liquid refrigerant atlow pressures can cause tube freeze-up and considerabledamage.