Operating instructions
36
The instructions below apply to the standard machine and
for all cases. For 19XRV machines additional checks are
required: please refer to chapters 8 to 14 of this document.
4.1.1 - Job data required
Checks before system start-up: Before the start-up of the
refrigeration system, the complete installation, including
the refrigeration system must be verified against the
installation drawings, dimensional drawings, system piping
and instrumentation diagrams and the wiring diagrams.
During the installation test national regulations must be
followed. If no national regulation exists, paragraph 9-5 of
standard EN 378-2 can be used as a guide.
External visual installation checks:
• Compare the complete installation with the refrigeration
system and power circuit diagrams.
• Check that all components comply with the design
specifications.
• Check that all safety documents and equipments
required by the applicable European standard are
present.
• Verify that all safety and environmental protection
devices and arrangements are in place and comply
with the applicable European standard.
• Verify that all documents for pressure containers, certifi-
cates, name plates, files, instruction manuals required
by the applicable European standard are present.
• Verify the free passage of access and safety routes.
• Check that ventilation in the plant room is adequate.
• Check that refrigerant detectors are present.
• Verify that the instructions and directives to prevent
the deliberate removal of refrigerant gases that are
harmful to the environment are being applied.
• Verify the installation of connections.
• Verify the supports and fixing elements (materials,
routing and connection).
• Verify the quality of welds and other joints.
• Check the mechanical integrity of the machine.
• Check the protection against heat.
• Check the protection of moving parts.
• Verify the accessibility for maintenance or repair and
to check the piping.
• Verify the status of the valves.
• Verify the quality of the thermal insulation and of the
vapour barriers.
4.1.2 - Equipment required
• mechanic’s tools (refrigeration)
• digital volt-ohmmeter (DVM)
• clamp-on ammeter
• electronic leak detector
• absolute pressure manometer or wet-bulb vacuum
indicator
• 500-V insulation tester (megohmmeter) for compressor
motors with nameplate voltage of 1000 V or less, or a
5000-V insulation tester for compressor motor rated
above 1000 V.
4.1.3 - Using the optional storage tank and pumpout system
Refer to the transfer unit installation manual, document
order no. 19999, chapter “Pumpout and refrigerant transfer
procedures” section for: pumpout system preparation,
refrigerant transfer, and chiller evacuation.
4.1.4 - Remove shipping packaging
After receipt remove any packaging material from the unit.
4.1.5 - Open oil circuit valves
Check that the oil filter isolation valves (see Fig. 4 - “Lubri-
cation system”) are open by removing the valve cap and
checking the valve stem.
4.1.6 - Tighten all gasketed joints and guide vane shaft
packing (torque depends on screw diameter)
Gaskets and packing normally relax by the time the chiller
arrives at the jobsite. Tighten all gasketed joints and the
guide vane shaft packing to ensure a leak tight chiller.
4.1.7 - Inspect water piping
Refer to piping diagrams provided in the certified drawings,
and the piping instructions in the 19XR Installation
Instructions manual. Inspect the piping to the cooler and
condenser. Be sure that flow directions are correct and
that all piping specifications have been met.
Do not introduce any significant static or dynamic pressure
into the heat exchange circuit (with regard to the design
operating pressures).
Before any start-up verify that the heat exchange fluid is
compatible with the materials and the water circuit coating.
In case additives or other fluids than those recommended by
Carrier are used, ensure that the fluids are not considered
as a gas, and that they belong to class 2, as defined in
directive 97/23/EC.
Carrier recommendations on heat exchange fluids:
• No NH
4+
ammonium ions in the water, they are very
detrimental for copper. This is one of the most
important factors for the operating life of copper
piping. A content of several tenths of mg/l will badly
corrode the copper over time.
• Cl
-
Chloride ions are detrimental for copper with a
risk of perforations by corrosion by puncture. If
possible keep below 10 mg/l.
• SO
4
2-
sulphate ions can cause perforating corrosion, if
their content is above 30 mg/l.
• No fluoride ions (<0.1 mg/l).
• No Fe
2+
and Fe
3+
ions with non negligible levels of
dissolved oxygen must be present. Dissolved iron < 5
mg/l with dissolved oxygen < 5 mg/l.
• Dissolved silicon: silicon is an acid element of water
and can also lead to corrosion risks. Content < 1mg/l.
• Water hardness: >0.5 mmol/l. Values between 1 and
2.5 mmol/l can be recommended. This will facilitate scale
deposit that can limit corrosion of copper. Values that
are too high can cause piping blockage over time. A
carbonate hardness (TAC) below 100 is desirable.