ENVIRONMENT HEALTH & SAFETY INSTRUCTIONS

FOR CHILLERS AND HEAT PUMPS

CONTENTS

1 - Introduction..........................................................................................................................................................................2
2 - General safety considerations............................................................................................................................................2
3 - Storage and transportation safety considerations...........................................................................................................2
4 - Receipt safety considerations............................................................................................................................................3
5 - Handling/Installation on site safety considerations.........................................................................................................3
6 - Operation user safety considerations................................................................................................................................3
7 - Start-up safety considerations...........................................................................................................................................3
8 - Maintenance and repair safety considerations.................................................................................................................4
9 - Final shutdown safety considerations...............................................................................................................................6

The illustrations in this document are for illustrative purposes only and not part of any offer for sale or contract. The manufacturer reserves the right to change the
design at any time without notice.

Original instructions
1 - Introduction RISK OF BURN:
The surfaces of the machine and pipes can be very hot or cold
This safety manual applies for all types of chillers & heat pumps.
and cause the risk of burn
It refers, when necessary, to information included in the installation,
operation and maintenance (IOM) manual of your unit. The IOM MOVING PARTS :
is available on line (flash the QR code on the unit to access the Do not remove the guards from moving parts while the unit
IOM). is operating.
Prior to the initial start-up of the chiller, people involved in the Make sure that moving parts are fitted correctly before restarting
storage, transportation, handling, on-site installation, start-up, the unit.
operation, and maintenance of this unit should read, understand
RISK IN CASE OF LEAK:
and be thoroughly familiar with these instructions, the installation,
operation and maintenance manual and the specific project data Do not use your hands to check possible refrigerant leaks.
for the installation site. Ensure good ventilation, as accumulation of refrigerant in an
Units are designed to cool/heat water for the air conditioning of enclosed space can displace oxygen and cause asphyxiation or
buildings and industrial processes. explosions.
Units are designed to provide a very high level of safety during Inhalation of high concentrations of vapor is harmful and may
installation, start-up, operation and maintenance. They will provide cause heart irregularities, unconsciousness, or death. Vapor is
safe and reliable service when operated within their application heavier than air and reduces the amount of oxygen available for
range. breathing. These products cause eye and skin irritation.
Decomposition products are hazardous.
The manufacturer recommends to perform a periodic requalification
of the refrigerant circuit according to applicable local regulations. Avoid contact with liquid refrigerant. Wash any spills from the skin
Except in case of a most restrictive local regulation, the with soap and water. If liquid refrigerant enters the eyes,
manufacturer then recommends a 5 years periodicity requalification. immediately and abundantly flush the eyes with water and consult
a doctor.
It is user’s responsibility to ensure that the final installation respects
all local, national and international regulations. The accidental releases of the refrigerant, due to small leaks or
significant discharges following the rupture of a pipe or an
This manual provides the necessary information to safely do all
unexpected release from a relief valve, can cause frostbites and
operations on the equipment from installation to dismantling.
burns to personnel exposed. Do not ignore such injuries. Installers,
owners and especially service engineers for these units must:
2 - General safety considerations - Seek medical attention before treating such injuries.
The unit must be installed in a place that is not accessible to - Have access to a first-aid kit, especially for treating eye
the public or protected against access by non-authorized injuries.
persons. The units are not intended to operate in an ATEX Never apply an open flame or live steam to a refrigerant container.
area, unless specified in the IOM. Dangerous overpressure can result.
Do not modify or bypass any of the safety guards or switched In case of combustion of refrigerant, do not clean combustion
in the system. by-products with water, the mixture is highly corrosive.
The main working place for the operator of the unit is in front of RISK OF FLAMMABILITY:
the control panel (see IOM for the position of the operator
If the unit contains refrigerant other than A1, always
workstation).
usea certified detector for the refrigerant used when
All operations on the unit must be carried out by authorized, near the unit.
qualified and trained people to do it using appropriate tools.
Default atex zone is 0.6m around the unit. for more
All persons who have to work with the equipment must wear details on your unit zone (for refrigerant other than
personal protective equipment adapted to the intervention on the A1), please refer to the dedicated instruction,
unit: operation & maintenance (IOM) instruction.
- Safety shoes
- Safety gloves or specific hand protection (cut resistant gloves, RISK OF EXPLOSION:
chemical gloves, thermic gloves, …)
- Head protection Never exceed the specified maximum allowable
- Ears protection pressures.
- Eyes or face protection (safety glasses, goggles, facial shed) Verify the allowable maximum high-side and low-side
- A2L detector if A2L gas in the chiller pressures by given on the unit name plate and...
Additional equipment may be required, depending on the risk checking the instructions in this manual.
analysis that must be done prior to any intervention.
Do not wear clothes or accessories that can get caught or sucked 3 - Storage and transportation safety
in by flows of air, tie back long hair before entering the unit. considerations
No combustible matter should be placed within 6.5m of the When it is necessary to store the unit before installation, it is
unit. mandatory to observe some precautions :
RISK OF FALLING: - do not remove the protection,
- protect the unit from dust and bad weather
No part of the unit must be used as a walk-way, rack
or support. Periodically check and repair or if The units are intended to be stored and operated in an environment
necessary replace any component or piping that where the ambient temperature must not be lower than the
shows signs of damage. minimum allowable temperature not be higher than the maximum
allowable temperature indicated on the nameplate.
The refrigerant lines can break under the weight and release Never cover any protective device.
refrigerant, causing personal injury. This applies to any relief valves (if used) in the refrigerant or heat
Use a platform, or staging to work at higher levels. transfer medium circuits and the pressure switches.
Do not obstruct any protective device.
This applies to any rupture disks and valves fitted on the refrigerant
or heat transfer fluid circuits.

2
4 - Receipt safety considerations Check that the protective devices are well installed and not
covered before operating the unit.
Check that the unit and the accessories have not been damaged
The unit complies with the pressure equipment regulation.
during transport and that no parts are missing. If the unit and the
The list of pressure equipment integrated in the unit is given
accessories have been damaged or the shipment is incomplete,
in the declaration of conformity.
send a claim to the shipping company.
NOTE: Pressure equipment for the hydraulic side (optional)
Compare the name plate data with the order.
are delivered as separate items. Their integration in the
The name plate is attached in two places to the unit : complete hydraulic installation remain under the user’s
- On the outside of one of the unit frames, responsibility.
- On the electrical cabinet, inside.
In accordance with local regulation :
The unit name plate must include the following information: - Pressure equipment must be checked periodically, see in the
- Model number and size, maintenance part of this manual.
- Leak tightness test date, - The relief valves are not safety accessories but damage
- Fluid used for transport, limitation accessories in case of an external fire.
- Refrigerant used with his GWP,
Do not remove valves, even if the fire risk is under control for a
- Refrigerant charge per circuit,
particular installation. There is no guarantee that the accessories
- PS: Min./max. allowable pressure (high and low pressure
have been re-installed if the system is changed or for transport
side),
with a gas charge.
- TS: Min./max. allowable temperature (high and low pressure
side), SAFETY DEVICES CLASSIFICATION
- Pressure switch cut-out pressure, Over pressure
- Voltage, frequency, number of phases, Safety
protection in case of an
accessories(1)
- Maximum current, external fire(2)
- Maximum power input, Refrigerant side
- Unit net weight. High-pressure switch X
External relief valve(3) X
5 - Handling/Installation on site safety Rupture disk X
considerations Heat transfer fluid side
Do not remove the skid or the packaging until the unit is in External relief valve (4) (4)
its final position.
(1) Classified for protection in normal service situations.
Do not throw away lifting instruction present on the tarpaulin. (2) Classified for protection in abnormal service situations. These accessories are
The manufacturer strongly recommends employing a specialized sized for fires with a thermal flow of 10kW/m².
(3) The instantaneous over-pressure limitation of 10% of the operating pressure
company to load or unload the machine.
does not apply to this abnormal service situation (see EN 764-7 §7.2 / Guideline
Lift the unit using the lifting instruction provided. E-02 / EN378-2 §6.2.2.3).
(4) The selection of these discharge valves must be made by the personnel
Unit’s weight is indicated on the nameplate. responsible for completing the hydraulic installation.
Units can be moved with a fork lift truck, as long as the forks are NEVER COVER ANY PROTECTIVE DEVICE.
positioned in the correct place and direction on the unit.
This applies to any relief valves (if used) in the refrigerant or heat
The units can also be lifted with slings, using only the designated transfer medium circuit sand the pressure switches.
lifting points marked on the unit according the lifting instructions
DO NOT OBSTRUCT ANY PROTECTIVE DEVICE.
on the certified drawings supplied with the unit. Use slings or lifting
beams with the correct capacity that have been tested and certified. This applies to any rupture disks and valves fitted on the refrigerant
or heat transfer fluid circuits.
Do not tilt the unit more than 15°.
Check whether the original protection plugs are still present at the
The unit must be placed on hard ground or concrete.
valve outlets. These plugs are generally made of plastic and should
CAUTION: Before lifting the unit, check that all casing panels not be used. If there are still present, please remove them.
and grilles are securely fixed in place. Lift and set down the
Fit devices at the valve or discharge piping outlets to prevent
unit with great car. Tilting and jarring can damage the unit.
the penetration of foreign bodies (dust, building debris, etc.)
WARNING: never apply pressure or leverage to any of the and atmospheric agents (water can form rust or ice).
unit's panels or uprights; only the base of the unit frame is
These devices, as well as the discharge piping, must not impair
designed to withstand such stresses. No force or effort must
operation or lead to a pressure drop that is higher than 10% of
be applied to pressurised parts, especially via pipes
the set pressure.
connected to the water-cooled heat exchanger (with or
without the hydraulic kit if the unit is equipped with this). 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
6 - Operation user safety considerations of the two relief valves is in operation, the other one is isolated.
Never leave the change-over valve in the intermediate
Ensure you read and understood this instruction before accessing
position, i.e. with both ways open bring the actuator in
the unit.
abutment, front or back according to the outlet to isolate.

7 - Start-up safety considerations If a relief valve is removed for checking or replacement,

ensure that there is always an active relief valve on each of
After the unit has been received, when it is ready to be installed the change-over valves installed in the unit.
or reinstalled, and before it is started up, it must be inspected for All factory installed relief valves are lead-sealed to prevent any
damage: calibration change.
- Check that the refrigerant circuit(s) is (are) intact, especially
that no components or pipes have shifted (e.g. following a The external relief valves must always be vented to outside
shock). if the units are installed in a closed space.
- If in doubt, carry out a leak tightness check and verify with Refer to the installation regulations, for example those of standard
the manufacturer that the circuit integrity has not been EN 378-3 and EN 13136.
impaired.
- If damage is detected up on receipt, immediately fill a claim
with the shipping company.

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These pipes must be installed in a way that ensures that people carried out by a qualified and authorized engineer. These
and property are not exposed to vented refrigerant. As the fluids procedures must be carried out with the unit shut-down.
can be diffused in the air, ensure that refrigerant is discharged Never work on any of the electrical components, until all the power
away from building air intakes, or they must be discharged in a supplies have been isolated using the disconnect switch(is) in the
quantity that is appropriate for a suitably absorbing environment. control box(is), locked and tagged out.
It is recommended to install an indicating device to show if part of Do not access the electrical components if water and/or moisture
the refrigerant has leaked from the valve. The presence of oil at are present.
the outlet orifice is a useful indicator that refrigerant has leaked.
If any maintenance operations are carried out on the unit, lock the
Keep this orifice clean to ensure that any leaks are obvious. power supply circuit in the open position ahead of the machine.
Provide a drain in the discharge circuit, close to each relief valve, If the work is interrupted, always ensure that all circuits are still
to avoid an accumulation of condensate or rain water. deenergized before resuming the work.
Relief valves must be checked periodically. ATTENTION: Even if the unit has been switched off, the power
circuit remains energized, unless the unit or circuit disconnect
External relief
valves Model
3060-- 3061-- Other Model switch is open.
Remplacement Cycle Every 5 years Every 9 years Every 5 years For example the variable frequency drives (VFD) which take twenty
(20) minutes to discharge. Refer to the wiring diagram for further
When the unit is subjected to fire, relief devices prevent rupture details.
due to over-pressure by releasing refrigerant. The fluid may then IMPORTANT INFORMATION REGARDING THE REFRIGERANT
be decomposed into toxic residues when subjected to the flame: USED:
- Stay away from the unit
This product may contain fluorinated greenhouse gas covered
- Set up warnings and recommendations for personnel in
by the Kyoto protocol. For the fluid type refer to the name
charge to stop the fire.
plate.
- Fire extinguishers appropriate to the system and the
refrigerant type must be easily accessible. 1. Any intervention on the refrigerant circuit of this product
- Do not clean combustion by-products with water, the mixture should be performed in accordance with the applicable
is highly corrosive. legislation. The regulation is called F-Gas, N°517/2014.
- Do not restart the unit after it has been submitted to a fire. 2. Ensure that the refrigerant is never released to the
Material may have been seriously damaged by the heat. atmosphere during installation, maintenance or equipment
- Restart may only be possible after detailed verification by a disposal.
competent personnel in order to insure that the unit has not 3. The deliberate gas release into the atmosphere is not
suffered any damage. allowed.
4. If a refrigerant leak is detected, ensure that it is stopped
8 - Maintenance and repair safety considerations
and repaired as quickly as possible.
Never work on a unit that is still energized. 5. Only a qualified and certified personnel can perform
All installation parts must be maintained by the personnel in installation operations, maintenance, refrigerant circuit
charge, in order to avoid material deterioration and injuries to leak test as well as the equipment disposal and the
people. refrigerant recovering.
Faults and leaks must be repaired immediately. The authorized 6. The gas recovery for recycling, regeneration or destruction
technician must have the responsibility to repair the fault is at customer charge.
immediately. Each time repairs have been carried out to the unit, 7. Periodic leak tests have to be carried out by the customer
the operation of the protection devices must be re-checked. or by third parties. The regulation set the periodicity here
All maintenance and repair operation must be done in after:
compliance with regulations and IOM. System WITHOUT 12 No
Only use original replacement parts for any repair or leakage detection Months 6 Months 3 Months
Check
component replacement. System WITH leakage 24 No
Consult the list of replacement parts that corresponds to the detection Months 12 Months 6 Months
Check
specification of the original equipment. 5≤ 50 ≤
Refrigerant charge/ Charge >
circuit (CO2 equivalent) < 5 Tons Charge < Charge < 500
The manufacturer recommends the following drafting for a logbook Tons (1)
50 Tons 500 Tons
(the table below should not be considered as reference and does R32 (2) 7,4 ≤ 74,1 ≤
not involve the manufacturer responsibility): Charge < Charge >
(GWP 675, 7,4 kg
Charge < Charge <
740,8 kg
following AR4) 7,4 kg 740,8 kg
Name of the Applicable
Refrigerant charge/ Circuit (kg)

Intervention Verification R134A (2) 3,5 ≤ 34,9 ≤

Charge Charge < Charge < Charge
commissioning national >
organism (GWP 1430,
Date Nature (1)
engineer regulations < 3,5 kg 349,7 kg
following AR4) 34,9 kg 349,7 kg
R407C (2) 2,8 ≤ 28,2 ≤
Charge Charge >
< 2,8 kg Charge
(GWP 1774, < Charge < 281,9 kg
following AR4) 28,2 kg 281,9 kg
R410A (2) 2,4 ≤ 23,9 ≤
Charge < Charge < Charge Charge >
(1) Maintenance, repairs, regular verifications (See EN 378), leakage, etc. (GWP 2088, <
2,4 kg 239,5 kg
Engineers working on the electric or refrigeration components following AR4) 23,9 kg 239,5 kg
must be authorized, trained and fully qualified to do so. R515B (2) 17,1 ≤ 170,6 ≤
Charge < Charge Charge >
17,1 kg 170,6 kg< 1706,5
(GWP 293, Charge <
All refrigerant circuit repairs must be carried out by a trained 1706,5 kg
following AR4) kg
person, fully qualified to work on these units. HFO’s: R1234ze
He must have been trained and be familiar with the equipment (A2L refrigerant
and GWP<1,
No requirement
and the installation. following AR5)
All welding operations must be carried out by qualified
specialists. (1) From 01/01/2017, units must be equipped with a leakage detection system.
(2) Fluorinated greenhouse gas covered by the Kyoto protocol and the F-gas
The insulation must be removed and heat generation must be N°517/2014
limited by using a wet cloth.
Any manipulation (opening or closing) of a shut-off valve must be

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8. A logbook must be established for equipment subject to Do not use oxygen to purge lines or to pressurize a machine for
periodic leak tests. It should contain the quantity and the any purpose. Oxygen gas reacts violently with oil, grease, and
type of fluid present within the installation (added and other common substances.
recovered), the quantity of recycled fluid, regenerated or Never exceed the specified maximum operating pressures.
destroyed, the date and output of the leak test, the
Verify the allowable maximum high-side and low-side test
designation of the operator and its belonging company,
pressures by checking the instructions in this manual and
etc.
the pressures given on the unit name plate.
9. Contact your local dealer or installer if you have any
Do not use air for leak testing. Use only oxygen free nitrogen.
questions.
Do not unweld or flamecut the refrigerant lines or any refrigerant
If a leak occurs or if the refrigerant becomes contaminated (e.g.
circuit component until all refrigerant (liquid and vapor) has been
by a short circuit in a motor) remove the complete charge using
removed from chiller. Traces of vapor should be displaced with
a recovery unit and store the refrigerant in mobile certified
oxygen free nitrogen. Refrigerant in contact with an open flame
containers.
produces toxic gases.
Repair the leak detected and recharge the circuit with the total
The necessary protection equipment must be available, and
refrigerant charge, as indicated on the unit name plate. Some
appropriate fire extinguishers for the system and the refrigerant
parts of the circuit can be isolated. Only charge liquid refrigerant
type used must be within easy reach.
at the liquid line.
Do not clean the unit with hot water or steam. This may cause the
Ensure that you are using the correct refrigerant type before
refrigerant pressure to rise.
recharging the unit.
HIGH PRESSURE SAFETY LOOP (SRMCR):
Charging any refrigerant other than the original charge type will
impair machine operation and can even lead to a destruction of Each circuits of the unit is equipped with a high pressure safety
the compressors. The compressors are lubricated with a synthetic loop, also known as safety related measurement control and
polyolester oil. regulation system (SRMCR), consisting of:
- High pressure switches (HPS) located on the high pressure
Periodic inspections of the safety devices and external
side of compressor. PZHH (manual) or PSH (automatic) type,
overpressure devices (external relief valves) must be carried out
depending on the compressor technology
in accordance with national regulations.
- A control relay on the compressor board.
The safety device shall be tested at least once a year to verify - Compressor(s) main contactor(s)
good operation and cut out value.
See the wiring diagram and bill of material of the unit for details
The company or organization that conducts a pressure switch test of identification and references.
shall establish and implement a detailed procedure to fix:
This safety loop is designed to be reliable for the whole life of the
- Safety measures
chiller providing adequate annual testing is performed or tests in
- Measuring equipment calibration
accordance with national regulations, at the earliest opportunity.
- Validating operation of protective devices
- Test protocols FUNCTION DESCRIPTION AND RESET:
- Recommissioning of the equipment. Switches and compressor contactors are closed during normal
CAUTION: If the test leads to replacing the pressure switch, operation. A pressure above the set value opens the switch(es)
it is necessary to recover the refrigerant charge, these which open the compressor(s) contactor(s) stopping the power
pressure switches are not installed on automatic valves supply to compressors.
(Schraëder type). Shortly after compressor shutdown, the pressure in the system
At least once a year thoroughly inspect the protection devices comes back to equilibrium.
(valves). If the machine operates in a corrosive environment, Restart after high pressure detection.
inspect the protection devices more frequently.
After safety loop activation:
Ensure regularly that the vibration levels remain acceptable and - reset manually the triggered pressure switch (screw type
close to those at the initial unit start-up. compressors only).
Before opening a refrigerant circuit, purge, consult the pressure - Clear the alarm on the unit control panel. This has to be done
gauges and ensure that the circuit has been purged physically on the panel, not remotely.
Change the refrigerant when there are equipment failures, carry CHECKS IN CASE OF APPARENT FAILURE OF THE SAFETY
out a refrigerant analysis in a specialist laboratory. ACCESSORY:
If the refrigerant circuit remains open for longer than a day after If the maximum allowable pressure of the unit appears to have
an intervention (such as a component replacement), the openings been exceeded (for example: after opening of the relief valves),
must be plugged and the circuit must be charged with oxygen free the unit must be stopped immediately. The unit and the safety loop
nitrogen (inertia principle). The objective is to prevent penetration must pass periodic testing procedure successfully before any
of atmospheric humidity and the resulting corrosion on the internal possible restart.
walls and on non-protected steel surfaces. If the test reveals any malfunctions that could have led to exceed
If work on the evaporator is required, ensure that the piping from the maximum allowable pressure (PS) of the device, a complete
the compressor is no longer pressurized (as the valve is not leak check of all pressure equipment must be performed to verify their
tight in the compressor direction.) mechanical integrity.
Any refrigerant transfer and recovery operations must be carried In order to verify the full integrity of the safety loop, the following
out using a transfer unit. A 3/8” SAE connector on the manual checks have to be performed periodically:
liquid line valve is supplied with all units for connection to the - High pressure safety loop periodic test
transfer station. The units must never be modified to add refrigerant - Contactors check
and oil charging, removal and purging devices. All these devices - Complete loop operation check
are provided with the units. Please refer to the installation,
operation and maintenance manual of the unit.
Do not re-use disposable (non-returnable) cylinders or attempt to
refill them. It is dangerous and illegal. When cylinders are empty,
evacuate the remaining gas pressure, and move the cylinders to
a place designated for their recovery. Do not incinerate.

5
POWER CONTACTOR CHECK PROCEDURE: APPENDICES (PROVIDED WITH THE UNIT)
This procedure shall be applied for each compressor of the unit. 1 - Appendix 1: Declaration of conformity
1. Switch off the power of the electrical equipment. 2 - Appendix 2: Dimensional drawings
2. Measure the resistance between upstream and downstream
terminals of the main power contactors for each phase.
Note: calibrated Ohmmeter shall be used for this task.
3. Confirm resistance is more than 1.0 MOhm.
A resistance lower than 1.0 MOhm might indicate that contactor
is defective: further investigations are required.
COMPLETE SAFETY LOOP TEST:
The purpose of this periodic test is to verify the proper functioning
and setting of the high-pressure safety loop of a refrigerant circuit.
In order to reach the triggering pressure of the loop, the pressure
and temperature thresholds activating the discharge of the
compressor by the regulation system are raised.
This procedure must be repeated for each circuit of the unit:
1. Set up a calibrated pressure gauge on the high pressure part
of the circuit (compressor discharge)
2. Clear all activated alarms
3. Activate the HP test mode for the corresponding circuit via the
control interface.
Enable Quick Test Mode (Quick Test Menu> [ QCK_TEST ]
parameter active )
Activate the high pressure test for the desired circuit (Menu Quick
Test> parameter [HP_TEST] to 0 for circuit A or 1 for the B circuit.
The corresponding circuit starts to perform the HP test.
4. Start the unit
5. For water-cooled units, stop the circulation of the secondary
circuit to the condenser in order to stop the condensation and
cause the increase in pressure (this operation is managed by
the control on air-cooled machines)
6. Record the trigger value
7. Check if the trigger values are correct
The release values should be between -1.5 /+0 bars of nominal
values indicated on the unit.
8. Reset all alarms
For screw type compressors, this procedure should be repeated
if only one of the pressure switch has triggered. The triggered
pressure switch shall then be substituted with a mean of stopping
the system or a pressure switch with a higher triggering value.
Note:
Access to the maintenance functions can be protected by a
password. Contact your dealer or the manufacturer's service
department for more information.
The type of connector must be WAGO 231-302 or equivalent.

9 - Final shutdown safety considerations

Separate the units from their energy sources, allow them cool then
drain them completely
DISASSEMBLY
Comply with local environmental laws and guidelines.
Never work on a unit that is still energized.
At the end of its life, the unit must be disassembled, and
contaminated fluids removed by professionals and processed via
approved channels for waste electrical and electronic equipment.
Check whether any part of the unit can be recycled for another
purpose.
Refrigerant and oil must be removed from the machine, then
recycled in suitable industries before dismantling operations
Only a qualified and certified personnel can remove the
refrigerant from the equipment Use the original lifting
equipment.

6
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Order No.: 10532, 07.2021. Supersedes order No.: 10532, 02.2020. Manufacturer by: Carrier SCS, Montluel, France.
Manufacturer reserves the right to change any product specifications without notice. Printed in the European Union.