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PowerPac

PACKAGED CHILLER UNITS

Form 170.600-IOM (JUN 2011)INSTALLATION - OPERATION - MAINTENANCE

File: SERVICE MANUAL - Section 170Replaces: S170-600 IOM (JUN 08)Dist: 3, 3a, 3b, 3c

THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP,AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY

BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESEINSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH,

DAMAGE TO THE UNIT, OR IMPROPER OPERATION.

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Contents

PREFACE........................................................................................................................................................................................3JOB INSPECTION ...........................................................................................................................................................................3TRANSIT DAMAGE CLAIMS ...........................................................................................................................................................3CHILLER AND UNIT IDENTIFICATION ..............................................................................................................................................3

PACkAGED AMMONIA CHILLER UNITS ..........................................................................................................................................4COMPRESSOR ...............................................................................................................................................................................4COMPRESSOR CAPACITY CONTROL .............................................................................................................................................4LUBRICATION SYSTEM ..................................................................................................................................................................4OIL SEPARATOR/RESERVOIR .........................................................................................................................................................5OIL COOLING .................................................................................................................................................................................5MOTOR .........................................................................................................................................................................................5SEMIWELDED PLATE CONDENSER .................................................................................................................................................5SEMIWELDED PLATE EVAPORATOR ...............................................................................................................................................5QUANTUMLX CONTROL CENTER .................................................................................................................................................5LIQUID REFRIGERANT SEPARATOR ................................................................................................................................................6

INSTALLATION ............................................................................................................................................... 7FOUNDATION ................................................................................................................................................................................7HANDLING AND MOVING ..............................................................................................................................................................7

BRINE / WATER SYSTEMS .............................................................................................................................................................8ELECTRIC WIRING ..........................................................................................................................................................................8HOLDING CHARGE AND STORAGE.................................................................................................................................................9

OPERATION .................................................................................................................................................10PRESTART CHECkLIST .................................................................................................................................................................10CHECkING MOTOR/COMPRESSOR ROTATION .................................................................................................................................10COMPRESSOR/MOTOR COUPLING INSTALLATION .......................................................................................................................10COMPRESSOR UNIT OIL .............................................................................................................................................................. 11EVACUATION ............................................................................................................................................................................... 11CHARGING REFRIGERANT ............................................................................................................................................................ 11DRAINING REFRIGERANT ............................................................................................................................................................. 11SYSTEM PUMPDOWN ................................................................................................................................................................. 11OPERATING LOG .......................................................................................................................................................................... 12HIGH PRESSURE REGULATING SYSTEM ....................................................................................................................................... 12

PURGING THE SYSTEM ................................................................................................................................................................ 13AUTOMATIC OIL RETURN SYSTEM .............................................................................................................................................. 13

MAINTENANCE ............................................................................................................................................14TROUBLESHOOTING AND CAPACITY MEASUREMENT .................................................................................................................14CAPACITY MEASUREMENT ..........................................................................................................................................................14INCORRECT CAPACITY MEASURING ............................................................................................................................................14FIRST AID IN CASE OF AMMONIA ACCIDENTS .............................................................................................................................. 15GENERAL .....................................................................................................................................................................................15EYE INJURIES FROM LIQUID SPLASHES OR CONCENTRATED VAPOR .......................................................................................... 15SkIN BURNS FROM LIQUID SPLASHES OR CONCENTRATED VAPOR ........................................................................................... 15ADDITIONAL FACTS ABOUT R-717: ............................................................................................................................................. 15PROTECTING THE ENVIRONMENT ............................................................................................................................................... 15ADDITIONAL FACTS ABOUT REFRIGERANTS ............................................................................................................................... 15VENTILATING A REFRIGERATION PLANT......................................................................................................................................16

COOLING AGENTS .......................................................................................................................................................................16OILS ............................................................................................................................................................................................ 16FORMS ........................................................................................................................................................................................ 17

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PREFACE

This manual has been prepared to acquaint the owner andserviceman with the INSTALLATION, OPERATION, and MAIN-TENANCE procedures as recommended by Johnson Controls-Fric for PowerPacChiller Units.

Dangers resulting from failure to comply with safety pre-cautions when operating the equipment and performingmaintenance tass.

How to start, operate and stop the equipment safely.

How to respond when problems occur durin