4
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.
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
accessories
(1)
Over pressure protection in
case of an external fire
(2)
Refrigerant Side
High pressure switch
x
External relief valve
(3)
x
Rupture disk
x
Fuse plug
x
Heat transfert lfuid side
External relief valve
(4)
(4)
(1) Classified for protection in normal service situations.
(2) Classified for protection in abnormal service situations. These accessories are
sized for fires with a thermal flow of 10kW/m². No combustible matter should
be placed within 6.5m of the unit.
(3) The instantaneous over-pressure limitation of 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 selection of these discharge 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 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
