Carrier AquaForce 30XB series Installation, Operation And Maintenance Instructions

Contents

4The AquaForce TM 30XB and 30XBP units are designed to coolwater for the air conditioning of buildings and industrial processes.Prior to the initial start-up of the 30XB units, the people involvedin the on-site installation, start-up, operation, and maintenance ofthis unit should be thoroughly familiar with these instructions andthe specific project data for the installation site.They are designed for an operating life of 15 years by assuminga 75% utilisation factor; that is approximately 100,000 operatinghours.The 30XB liquid chillers are designed to provide a very high levelof safety during installation, start-up, operation and maintenance.They will provide safe and reliable service when operated withintheir application range.This manual provides the necessary information to familiarizeyourself with the control system before performing start-upprocedures. The procedures in this manual are arranged in thesequence required for machine installation, start-up, operationand maintenance.Always ensure that all required safety measures are followed,including those in this document, such as, wearing protectiveclothing (gloves, ear defenders, safety glasses and shoes), usingappropriate tools, employing qualified and skilled technicians(electricians, refrigeration engineers) and following localregulations.To find out, if these products comply with European directives(machine safety, low voltage, electromagnetic compatibility,equipment under pressure etc.) check the declarations ofconformity for these products.1.1 - Installation safety considerationsAccess to the unit must be reserved to authorised personnel,qualified and trained in monitoring and maintenance. The accesslimitation 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 orreinstalled, and before it is started up, it must be inspected fordamage. Check that the refrigerant circuit(s) is (are) intact, especiallythat no components or pipes have shifted (e.g. following a shock).If in doubt, carry out a leak tightness check and verify with themanufacturer that the circuit integrity has not been impaired. Ifdamage is detected upon receipt, immediately file a claim with theshipping company.Carrier strongly recommends employing a specialisedcompany to unload the machine.Do not remove the skid or the packaging until the unit is inits final position. These units can be moved with a fork lifttruck, as long as the forks are positioned in the right placeand direction on the unit.The units can also be lifted with slings, using only thedesignated lifting points marked on the unit.These units are not designed to be lifted from above. Useslings with the correct capacity, and always follow the liftinginstructions on the certified drawings supplied with the unit.Safety is only guaranteed, if these instructions are carefullyfollowed. If this is not the case, there is a risk of materialdeterioration and injuries to personnel.DO NOT COVER ANY PROTECTION DEVICES.This applies to fuse plugs and relief valves (if used) in therefrigerant or heat transfer medium circuits. Check if theoriginal protection plugs are still present at the valve outlets.These plugs are generally made of plastic and should not beused. If they are still present, please remove them. Installdevices at the valve outlets or drain piping that prevent thepenetration of foreign bodies (dust, building debris, etc.) andatmospheric agents (water can form rust or ice). Thesedevices, as well as the drain piping, must not impair operationand not lead to a pressure drop that is higher than 10% of thecontrol pressure.Classification and controlIn accordance with the Pressure Equipment Directive andnational usage monitoring regulations in the European Unionthe protection devices for these machines are classified asfollows:Safetyaccessory (1)Over pressure protection incase of an external fire (2)Refrigerant SideHigh pressure switch XExternal relief valve (3) XRupture disk XFuse plug XHeat transfer fluid sideExternal relief valve (4) (4)(1) Classified for protection in normal service situations.(2) Classified for protection in abnormal service situations. These accessories aresized for fires with a thermal flow of 10kW/m². No combustible matter should beplaced within 6.5m of the unit.(3) The instantaneous overpressure limitation of 10% of the operating pressuredoes not apply to this abnormal service situation.The control pressure can be higher than the service pressure. In this case, eitherthe design temperature or the high pressure switch ensures that the servicepressure is not exceeded in normal service situations.(4) The selection of these relief valves must be made by the personnel responsiblefor completing the hydraulic installation.Do not remove these valves and fuses, even if the fire risk isunder control for a particular installation. There is noguarantee that the accessories are re-installed if the installationis changed or for transport with a gas charge.When the unit is subjected to fire, safety devices prevent rupturedue to over-pressure by releasing the refrigerant. The fluid maythen be decomposed into toxic residues when subjected to theflame:- Stay away from the unit.- Set up warnings and recommendations for personnelin charge to stop the fire.- Fire extinguishers appropriate to the system and therefrigerant type must be easily accessibleAll factory-installed relief valves are lead-sealed to prevent anycalibration change. If the relief valves are installed on achange-over valve, this is equipped with a relief valve on eachof the two outlets. Only one of the two relief valves is inoperation, the other one is isolated. Never leave the change-over valve in the intermediate position, i.e. with both waysopen (Bring the actuator in abutment, front or back accordingto the outlet to isolate).If a relief valve is removed for checking or replacement pleaseensure that there is always an active relief valve on each ofthe change-over valves installed in the unit.The external relief valves must always be connected to drainpipes for units installed in a closed room. Refer to theinstallation regulations, for example those of Europeanstandard EN 378 and EN 13136.1 - INTRODUCTION