TC Manual Air Cooled Chillers

8/14/2019 TC Manual Air Cooled Chillers

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Version 0.1Date: 1/02/2007Prepared By: Justin Day

Temperature Control Manual Air Cooled Chillers

Engineering Department

TC Manual Air Cooled Chillers.doc Aggreko Australia Pacific

Temperature Control Manual

AIR COOLED CHILLERS


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TABLE OF CONTENTS

Section Page

IMPORTANT INFORMATION.............................................................................................................3

SERVICE BULLETIN.............................................................................................................................4

1 INTRODUCTION................................................................................................................5 1.1 Description........................................................................................................................5 1.3 Equipment.........................................................................................................................5 1.3.1 Compressor ..................................... ........................................... .................................. 5 1.3.2 Oil Separator................................................................................................................6 1.3.3 Condenser ........................................... ............................................... .......................... 6 1.3.4 Expansion Valve ............................................ ......................................... ..................... 7 1.3.5 Evaporator....................................................................................................................7 1.3.6 Control Devices ..................................... ......................................... ............................. 7 1.4 Applications ...................................... ........................................... ..................................... 7 1.5 Process .......................................... ........................................... ......................................... 8 1.5.1 Refrigerant Cycle.........................................................................................................8 1.5.2 Oil Cycle......................................................................................................................8

2 TECHNICAL DATA ........................................ ......................................... .......................... 9

3 INSTALLATION, OPERATION AND MAINTENANCE (IOM)................................15 3.1 Installation.......................................................................................................................15 3.1.1 Handling.....................................................................................................................15 3.1.2 Foundation .......................................... ........................................... ............................ 15 3.1.3 Water Drain Hole.......................................................................................................15 3.1.4 Clearances..................................................................................................................15 3.1.5 Water to Evaporator Connection .................................... ........................................... 15 3.3 Commissioning ........................................... ........................................... ......................... 16 3.3.1 Starting the Unit.........................................................................................................16 3.4 Operation.........................................................................................................................16 3.4.1 Temporary Shut Down and Restart............................................................................16 3.4.2 Emergency Stop.........................................................................................................16 3.4.3 Final Check................................................................................................................17 3.4.2 Principal of Operation................................................................................................17 3.5 Decommissioning ....................................... ........................................ ............................ 17 3.6 Maintenance Procedures ........................................ ........................................ ................. 18 3.6.1 Condenser ........................................... ............................................... ........................ 18 3.6.2 Refrigerant Charge.....................................................................................................18 3.6.3 Weekly Maintenance and Checks..............................................................................18 3.6.4 Monthly Maintenance and Checks.............................................................................18 3.6.5 Annual Maintenance ......................................... ............................................... ..........18 3.6.9 Maintenance Schedules..............................................................................................19 1.6 Troubleshooting .......................................... ........................................... ......................... 22

4 ELECTRICAL ........................................ ........................................... ................................ 25


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IMPORTANT INFORMATION

Fluid Flow through the chiller:

Fluid pump MUST always feed into the Chiller

Proper flow MUST be established for optimum operation

The pressure across the chiller barrel is set to 40kPa delta p

(delta p = fluid press entering the chiller minus fluid leaving the chiller)

Correct Pump size

Installation:

Have technical information with you at all times to refer to Position equipment on a level surface and leave room for air intake and room to work

Keep hosing lengths as short as possible and tidy

Complete a commissioning report

Chiller Settings:

Leaving fluid temperature setting (Set Point)

Cut in / Cut out temperature settings (Range / Dead Band)

Low water temperature cut out setting

Low refrigerant cut out setting

Fluid Flow (delta p)

Chiller Safety:

Contamination of chiller barrels

Proper fluid flow

Correct Power Supply

Correct Phase Rotation

PRE HEAT CHILLERS (minimum 24 hrs)

Service valves

Follow manufacturers recommendations

Install strainers


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SERVICE BULLETIN

BULLETIN NUMBER ASB0088A ISSUE DATE 4 th September 2006

REFERENCE

SUBJECT YCAS chillers supplied to Aggreko

WITHDRAWAL DATE N/A

Re: YCAS0623 chillers supplied to Aggreko for the chiller rental market

A number of YCAS chillers have been supplied to Aggreko for use as rental chillers. These machines have beenespecially modified so that they will operate on normal air conditioning duty down to 4 oC, low temperature glycolduty down to -12 oC and ultra low temperature glycol duty down to -19 oC.

As for a standard machine, for air conditioning duty dip switch number one must be in the open position. Fornormal glycol mode (down to -12 oC) dip switch number one must be in the closed position. If ultra lowtemperature glycol is required (down to -19 oC) a special procedure is required.

Procedure for ultra low temperature glycol operation (down to -19 oC).1. Program chiller panel for imperial units mode (ultra low temperature duty will not operate in SI units

mode).2. Enter special password code 7522. The display will indicate standard mode.3. Using the scroll buttons select low temperature mode.4. Once low temperature mode is selected the desired leaving liquid control temperature, leaving liquid

temperature cut out and suction pressure cut out can be programmed in the usual manner (settings must be in Fahrenheit for temperature and PSIG for pressure).

CAUTIONDo not operate the chiller in a lower temperature mode than is required for a particular application. Lowtemperature operation does require close attention to glycol concentration so only ever select glycol mode or ultralow temperature mode when absolutely necessary.

Graham ParryTechnical support.

PLEASE FILE THIS BULLETIN IN YOUR APPLIED BULLETIN BINDER AND POST ON THE APPLIED SECTION OF

YOUR BULLETIN NOTICE BOARD.


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1 INTRODUCTION

This manual contains directions regarding the descriptions, installation, and operationsof the Aggreko Air Cooled Fluid Chillers.

1.1 Description

The units are intended for the cooling of water or non corrosive fluids. They aredesigned to be located outside (rooftop or ground), not in an enclosed plant room orsealed building.

They are used for a wide variety of applications in the mining, process, HVAC, Food,Industrial, and Manufacturing industries.

The outlet temperatures for the chillers vary from our standard 6 C water mixture tothe lower temperatures of -19 C (50% water / glycol mixture).

1.3 Equipment

1.3.1 Compressor

The air cooled chiller consists of two distinct components; motor and rotor.

A two pole, hermetic, squirrel cage induction motor directly drives the compressorrotors. The motor is cooled by suction refrigerant gas from the evaporator, entering theend of the motor housing through the suction line.

The compressor is a semi-hermetic direct drive helical rotor compressor. Eachcompressor has only 3 moving parts, 2 rotors and a slide valve to control the capacity.The male rotor is attached to, and driven by the motor.

The refrigerant from the evaporator is drawn into the suction opening at the end of themotor barrel, through a suction strainer screen, across the motor, and into the intake ofthe compressor rotor section. The gas is then compressed and discharged directly intothe discharge line.


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1.3.2 Oil Separator

The oil leaves the compressor entrained within the discharged refrigerant vapour, and itis the oil separator that recovers this oil.

The separator consists of a vertical cylinder surrounding an exit passageway. As therefrigerant and oil mixture is discharged into this passageway the oil is forced outward

by centrifugal force, collects on the walls of the cylinder and drains to the bottom. Thisaccumulated oil drains out of the cylinder and collects in the oil sump located near the

bottom of the chiller.

The oil sump is heated to ensure proper lubrication and minimise refrigerantcondensation in the sump.

1.3.3 Condenser

The air cooled condenser coils have aluminium fins mechanically bonded to internallyfinned seamless copper tubing. The condenser coil has an integral sub cooling circuit.

Direct drive vertical discharge airfoil condenser fans are dynamically balanced.

The water is pumped through the tubes of the shell and tube heat exchanger whilerefrigerant vapour fills the shell space surrounding the tubes. The condenser has a

baffle plate that helps distribute the refrigerant evenly within the shell. As heat istransferred from hot, high pressure refrigerant vapour to the water, refrigerantcondenses on the tube surfaces.


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1.3.4 Expansion Valve

The expansion valve is used to maintain the pressure difference between the highpressure (condenser) and the low pressure (evaporator) sides of the system, as

established by the compressor. This pressure difference allows the evaporatortemperature to be low enough to absorb heat from the water being cooled, whilstallowing the refrigerant to be at high enough temperature in the condenser to reject heatto water at normally available temperatures.

High pressure liquid refrigerant flows through the expansion device, causing a large pressure drop that reduces the refrigerant pressure to that of the evaporator. This pressure reduction causes a small portion of the liquid to boil off, or flash, cooling theremaining refrigerant to the desired temperature.

1.3.5 Evaporator

The evaporator is a tube in shell heat exchanger design, with internally finned copper

tubes roller expanded into the tube sheet.

The evaporator is designed for a waterside working pressure of 14 bar. Waterconnections are grooved pipe for victaulic couplings. Each shell includes a vent, adrain, and fitting for temperature control sensors, and is insulated.

Evaporator heaters with thermostats provide protection to the evaporator from freezingat ambient temperatures of -29 C.

1.3.6 Control Devices

The unit controls are housed in a weather tight enclosure with removable plates toallow for connection of power wiring and remote interlocks.

Microcomputer controls provide all control functions including startup and shutdown,leaving chilled water temperature control, compressor and electronic expansion valvemodulation, fan sequencing, anti-recycle logic, automatic lead/lag compressor startingand load limiting.

The controls also automatically take action to avoid unit shutdown due to abnormaloperating conditions associated with low refrigerant pressure, high condensing

pressure, and motor current overload. Unit protective functions include loss of chilledwater flow, evaporator freezing, loss of refrigerant, low/high refrigerant pressure, phasereversal, and loss of oil flow.

1.4 Applications

The air cooled chiller can be used in a wide variety of applications in variousindustries. The chiller is often used in conjunction with other Aggreko equipment suchas cooling towers, fluid pumps, and heat exchangers.


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1.5 Process

1.5.1 Refrigerant Cycle

Saturated refrigerant vapour from the evaporator is drawn into the suction opening ofthe screw compressor. The gas is compressed and discharged through a check valveinto the discharge line.

An oil separator removes the oil from the refrigerant going to the air cooled condenser,where the heat of compression and cooling load are rejected, (the refrigerantcondenses). In the sub-cooler, which is a part of the condenser, the refrigerant iscooled down further. The refrigerant passes through the expansion valve, where the

pressure is dropped, which results in vaporisation of some of the refrigerant.

The liquid vapour refrigerant mixture enters the liquid vapour separator where liquidand gas are separated, the vapour is directed to the evaporator suction. The liquid isevenly distributed over the length of the evaporator by the distribution liquid system.

Heat is transferred from the water inside the tubes to the refrigerant as the film ofrefrigerant evaporates on the surface of the tube, refrigerant vapour exits the evaporatorthrough the suction baffle where is mixes with the vapour from the liquid vapourseparator.

1.5.2 Oil Cycle

The compressor oil supply is obtained from the oil separator. Due to the pressuredifferential between discharge and suction pressure, oil is injected via the oil coolerinto the compression chamber and the bearings of the compressor from where it isreturned together with the compressed gas to the oil separator.

The oil and gas are separated, oil flows down to the bottom of the separator, fromwhere it again flows to the compressor.

Oil that gets past the oil separator flows through the condenser, sub-cooler andexpansion valve into the evaporator. This oil is collected in the pool of refrigerant thatis maintained in the bottom of the evaporator. A small amount of oil and refrigerantfrom this pool is returned through a line that is connected to the compressor downstream of the motor.

This oil and refrigerant mixes with the refrigerant vapour that was drawn out of theevaporator.


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2 TECHNICAL DATA

aggrekoPrepared by: Adam Hentschel Date: 17.12.2002 Revision: A Page 9 of 26Discipline: Fluid Chillers Document number

Section: AIR COOLED SCROLL FC50A au.1.31. INTRODUCTION

The Aggreko -C- range air cooled fluid chillers are designed for water or water-Glycol cooling. All unitsare designed to be located outside. The units are completely assembled with all interconnectingrefrigerant piping and internal wiring, ready for installation.

The unit base and frame is of heavy-gauge steel and is fully tested and certified

2. KEY-DATA

Cooling Capacity 52 kW at 6 degrees leaving water temperature Absorbed Power 19 kWTemperature Range +15 C to -12 CMaximum ambient temp. 43CDimensions

length 2.36 metreswidth 1.20 metresheight 2.11 metresWeight 1250 kg

3. LAYOUT


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aggrekoPrepared by: Adam Hentschel Date: 17.12.2002 Revision: A Page 10 of 26

Discipline: Fluid Chillers Document numberSection: AIR COOLED SCROLL FC50A au.1.3

4. TECHNICAL SPECIFICATIONS

ITEM UNITS VALUE Performance DataDesign CapacityDesign Operation Fluid Temperature IN / OUTMinimum / Maximum Outlet Fluid TemperatureMinimum / Maximum Chilled Liquid Temperature DifferenceDesign Ambient TemperatureMinimum / Maximum Ambient Temperature

kWC / CC / CC / C

CC / C

5212 / 6

-12 / +153.5 / 10.2

353 / +43

Compressor Compressor TypeNumber Of CompressorsNumber Of Capacity Steps No. / %

Semi Hermetic Scroll2

2/ 50 Evaporator Data Evaporator TypeEvaporator MaterialDesign FlowMinimum / Maximum FlowEvaporator CapacityEvaporator Maximum Working PressureDesign Chiller Barrel Pressure DropRecommended System Fluid Volume

l/sl/s / l/slitreskPakPalitres

PlateS.Steel & Copper

2.071 / 4

41000

30315

Condenser Data Number Of Condenser FanskW per FanTotal Air VolumeExternal Static Pressure

kWm/sPa

11.25.50

Refrigerant Data

Refrigerant TypeNumber of CircuitsRefrigerant Charge circuit 1 / 2Type Of Compressor OilOil Charge circuit 1 / 2

kg

litres

R2219

025E7.6

Electrical Data Design Electrical Supply VoltageDesign Electrical RatingDesign / Maximum Operating CurrentStarting CurrentPre-Heating SupplyRecommended Generator SetRequired Cable Size per PhaseElectrical Connection

VoltskVA / kW Ampere AmpereVolts / VA

kVAmm

440 3ph / 50/60hz22 / 19.130 / 45

107N/a3010

40A Clipsal Plug Noise Data Sound Pressure Level at 10 metres - Lp(A)Sound Power Level - Lw(A)

dB(A)dB(A)

5482

Physical Data Overall LengthOverall WidthOverall HeightWeightFluid Coupling Size

metresmetresmetres

kgmm / inch

2.301.202.111250

50 / 2" Camlock NOTE: Contact Technical Department If Application Conditions Differs From Design Conditions


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1. INTRODUCTION


The unit base and frame is of heavy-gauge steel and is fully tested and certified

2. KEY-DATA

Cooling Capacity 157 kW at 7 degrees leaving water temperature Absorbed Power 71 kWTemperature Range +15 C to -12 CMaximum ambient temp. 43CDimensions


3. LAYOUT


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4. TECHNICAL SPECIFICATIONS

ITEM UNITS VALUE Performance DataDesign CapacityDesign Operation Fluid Temperature IN / OUTMinimum / Maximum Outlet Fluid TemperatureMinimum / Maximum Chilled Liquid Temperature DifferenceDesign Ambient TemperatureMinimum / Maximum Ambient Temperature

kWC / CC / CC / C

CC / C

15712 / 6

-12 / +153.5 / 10.2

353 / +43

Compressor Compressor Type

Number Of CompressorsNumber Of Capacity Steps No. / %

Semi Hermetic Scroll

44/ 25 Evaporator Data Evaporator TypeEvaporator MaterialDesign FlowMinimum / Maximum FlowEvaporator CapacityEvaporator Maximum Working PressureDesign Chiller Barrel Pressure DropRecommended System Fluid Volume

l/sl/s / l/slitreskPakPalitres

PlateSteel & Copper

7.451 / 10

140040

208 Condenser Data Number Of Condenser FanskW per FanTotal Air VolumeExternal Static Pressure

kWm/sPa

41.2

16.20

Refrigerant Data Refrigerant TypeNumber of CircuitsRefrigerant Charge circuit 1 / 2Type Of Compressor OilOil Charge circuit 1 / 2

kg / kg

litres

R222

14.45/14.45025E

11 / 11Electrical Data Design Electrical Supply VoltageDesign Electrical RatingDesign / Maximum Operating CurrentStarting CurrentPre-Heating SupplyRecommended Generator SetRequired Cable Size per PhaseElectrical Connection


kVAmm

440 3ph / 50/60hz88 / 71

116247N/a10035

M12 Noise Data Sound Pressure Level at 10 metres - Lp(A)Sound Power Level - Lw(A)

dB(A)dB(A)

6391

Physical Data Overall LengthOverall WidthOverall HeightWeightFluid Coupling Size

metresmetresmetres

kgmm / inch

2.802.202.022400

100 / 4"

NOTE: Contact Technical Department If Application Conditions Differs From Design Conditions


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Discipline: Fluid Chillers Document numberSection: AIR COOLED SCREW FC600A au.1.1

1. INTRODUCTION


The unit base and frame is of heavy-gauge steel with the dimensions of a standard 20 ft container tested and certified .

2. KEY-DATA

Cooling Capacity 612 kW at 6 degrees leaving water temperature Absorbed Power 182 kWTemperature Range +15 C to -12 CMaximum ambient temp. 40 CDimensions standard ISO 20ft. Container.


3. LAYOUT


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Discipline: Fluid Chillers Document numberSection: AIR COOLED SCREW FC600A au.1.1

4. TECHNICAL SPECIFICATIONSITEM UNITS VALUE Performance DataDesign CapacityDesign Operation Fluid Temperature IN / OUTMinimum / Maximum Outlet Fluid TemperatureMinimum / Maximum Chilled Liquid Temperature DifferenceDesign Ambient TemperatureMinimum / Maximum Ambient Temperature

kWC / CC / CC / C

CC / C

61212 / 6

-18 / +303.5 / 10.2

300 / +40

Compressor

Compressor TypeNumber Of CompressorsNumber Of Capacity Steps %

Semi Hermetic Screw212.5 thru 100

Evaporator Data Evaporator TypeEvaporator MaterialDesign FlowMinimum / Maximum FlowChiller Barrel CapacityChiller Barrel Maximum Working PressureDesign Chiller Barrel Pressure DropChiller Barrel Pressure Drop FactorRecommended System Water Volume

l/sl/s / l/slitreskPakPap.u.litres

Shell & TubeSteel & Copper

24.515 / 44

2041000

345.662520

Condenser Data Number Of Condenser FanskW per FanTotal Air VolumeExternal Static Pressure

kWm/hPa

100.85139

0 Refrigerant Data Refrigerant TypeNumber of CircuitsRefrigerant Charge circuit 1 / 2Type Of Compressor OilOil Charge circuit 1 / 2

kg / kg

litres

R222

62 / 62ISO 6817 / 17

Electrical Data Design Electrical Supply VoltageDesign Electrical RatingDesign / Maximum Operating CurrentStarting CurrentPre-Heating SupplyRecommended Generator SetRequired Cable Size per PhaseElectrical Connection


kVAmm

400 3ph / 50 Hz213 / 182308 / 443

543220 / 600

350240

Busbar M12 Noise Data Sound Pressure Level at 10 metres - Lp(A)

Sound Power Level - Lw(A) dB(A)

dB(A) 66

94 Physical Data Overall LengthOverall WidthOverall HeightWeightFluid Coupling Size

metresmetresmetres

kgmm / inch

6.02.42.6

6820100 / 4"

NOTE: Contact Technical Department If application conditions differ from design conditions


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3 INSTALLATION, OPERATION AND MAINTENANCE (IOM)

3.1 Installation

Installation of the Chillers is of utmost importance. The operating life will beimproved with the correct installation of the equipment.

3.1.1 Handling

The fluid chiller can be handled by a forklift or slings. Ensure that the weight of thefluid chiller does not exceed the maximum allowable lifting capacity of the crane,slings or forklift. Ensure all doors are closed and locked before moving.

3.1.2 Foundation

A solid foundation is required for the positioning of the unit, and must be flat, level andable to withstand the weight of the unit.

3.1.3 Water Drain Hole

Ensure that there is a drain hole wide enough to drain any water from the unit in theevent of shutdown or repair.

Note: Chemicals added to the chilled water system can affect the environment ifdrained. Ensure water is free of these before draining.

3.1.4 Clearances

Ensure there are sufficient clearances around the unit to allow maintenance operationsto take place without obstruction. The following minimum distances are required to

prevent condenser air recirculation and faulty operation:a. Front clearance of 1.5m

b. Side and rear clearance of 1.5m

c. Clearance above unit of 10m

d. Distance between adjacent units of 3m.

3.1.5 Water to Evaporator Connection

Install the water circulation pump upstream of the evaporator, making sure that theevaporator is under positive pressure. The water must enter the evaporator by the inletconnection.

Pipe work and fittings must be separately supported to prevent any loading on theevaporator. Flexible connections or hoses are recommended.


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3.3 Commissioning

Before starting up the system, the following should be checked;

a. Connect 32A auxiliary supply, min preheating time is 4hrs

b. Chilled water circuits ready to operate, filled with water, pressure and leak testshave been carried out and purging has taken place

c. Ensure that all water and refrigerant valves are in the service position

d. Where mechanical guards are provided these must be in position when the unit isrunning

e. Check that all electrical connections are clean

f. Close all panel doors

e. Switch on supply circuit breaker

3.3.1 Starting the Unit

a. Switch on the main circuit breaker

b. Start water pump, adjust flow rate with flow valve if necessary

c. Reset alarm (if any) by pressing Reset all active Diagnostics in alarm tab

d. To start the unit, press the Auto tab on the unit control module

NOTE: The unit will automatically start and try to maintain the set temperatures if thefollowing conditions are met:

a. Supply voltages are within operating parameters

b. Preheating time elapsed and oil temperature within parameters

c. All anti-recycle timers are timed out

d. All safety systems are within operating parameters

e. Sufficient fluid flow

f. Cooling demand exists

3.4 Operation

3.4.1 Temporary Shut Down and Restart

a. Press the stop tab on the control panel, compressors will stop

b. To restart the unit, press the Auto Tab

3.4.2 Emergency StopA push button located on the unit causes the unit to stop immediately. To restart theunit after an emergency stop, pull out the stop button and reset the alarm on the touchscreen.


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3.4.3 Final Check

After start up, leave the unit in operation for at least 15 minutes, to ensure that therefrigerant pressures are stabilised. The following must then be checked:

a. Both suction and pressure / temperature gauges must show approx 2 - 5 C belowleaving liquid temperature. (When running at low temp applications, this value can

be higher)

b. Both discharge pressure / temperature gauges must be approx 15 C above ambientair temperature

c. The sight glass in expansion valve must be clear

d. Check for any noise and vibrations

3.4.2 Principal of Operation

3.5 Decommissioning

The decommissioning procedure is as follows:

a. Press the stop tab on the control panel, compressors will stop b. Stop all fluid pumps

c. Switch off unit power supplies

d. Disconnect supply cable, lock access panel

e. Drain the chilled water system

f. Disconnect fluid hoses (water circuit to evaporator might be under pressure.Reduce before opening up the system


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3.6 Maintenance Procedures

3.6.1 Condenser

In some environments the condenser coils may get dirty and shutdown due to highcondensing pressure. If this happens, clean condenser coils with a brush or jet ofwater. Note: Fins of condenser coils may be sharp, use appropriate PPE.

3.6.2 Refrigerant Charge

The amount and type of refrigerant charge is listed on the unit name plate. Checkmonthly for unit leaks. Oil marks can be symptoms of refrigerant leaks.

3.6.3 Weekly Maintenance and Checks

After the unit has operated for approx 30 minutes and the system has stabilised, checkthe operating conditions and complete the following:

a. Log the chiller

b. Check evaporator and condenser pressures with gauges and compare to thereading on the display. Pressure readings should fall within the operating ranges.

3.6.4 Monthly Maintenance and Checks

On a monthly basis, the following should be done:

a. Review the operating log

b. Clean all water strainers in both chilled and condensing water piping system

c. Measure the oil filter pressure drop. Replace oil filter if required

d. Measure and log the sub-cooling and superheate. If operating conditions indicate a refrigerant shortage, leak check the unit using

soap bubbles and repair all leaks

f. Trim refrigerant charge until the unit operates in accordance with settings.

3.6.5 Annual Maintenance

Shut down the chiller once per year to check the following:

a. Perform all weekly and monthly maintenance procedures;

b. Check refrigerant charge and oil level;

c. Perform oil analysis;

d. Check pressure drop across the oil filter;

e. Inspect all piping for leakage and damage. Clean strainers;

f. Clean and repaint;

g. Test vent piping of all relief valves for presence of refrigerant to detectimproperly sealed relief valves. Replace any leaking relief valves; and

h. Inspect condenser tubes for fouling; clean if necessary.


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3.6.9 Maintenance Schedules

The following are the Maintenance Schedules for the Aggreko Fluid Pumps:

Maintenance Schedule fo r Aggreko's Water-Cooled Liquid Chil ler Fleet Series No: FC1200(RTHA), FC1300 (RTHB), and FC1500 (RTHC) with Helical Rotary (Screw) Compressors:

ItemNo. Installation, Operation, and Maintenance Instructions

On Hireand

Installation

Monthlyor at750

Hours

6-Monthlyor at 4300

Hours

Completionof Hiring

andDecomm.

At 36CumulativeMonths ofOperation

General:

Check and record the following operational data, as muchas possible, on Commissioning and Start-up Report Sheet andcheck monthly and at decommissioning time:

1. ambient air dry bulb and wet bulb temperatures ( o C)2. compressor suction and discharge pressures (kPa)3. compressor suction and discharge temperatures ( o C)4. compressor suction superheat temperature ( o C)5. low refrigerant temp safety cut out set point ( o C)6. chilled water leaving temperature set point value ( o C)7. chilled water return temperature ( o C)8. low chilled water temp. safety cut out set point ( o C)9. condenser water leaving temperature ( o C)10. condenser water return temperature ( o C)11. condenser water return limit set point value (%)12. power supply Voltage (V) and frequency (Hz)13. FLC: full load current (Amps)14. phase currents (Amps)

1

15. current limit set point value (%)

X X X

2

Check and record pressure drops through chilled waterrecirculation system and condenser water recirculation, andcompare with design specifications and the job site-specificchiller selection/ rating data.

X X

3 Check and record sump heater operation when unit is off. X X

4 Check and expedite any undue vibrations on the chiller unit.Seek for solution(s) to rectify. X X

5 Check and record oil pressure. Compare with the operatingrange in chiller manufacturer's IOM manual. X X X

6 Check liquid refrigerant flow in sight glass for presence ofmoisture or any shortage of refrigerant. X X X

7Check the settings of the HP and LP safety switches and oil

control functions and compare with the allowable limit valuesin the manufacturer's IOM Manual. Reset if necessary.

X X X

8 Check motor and drive and record the rated running loadcurrent in Amps. X X

9 Check the existence of any refrigerant l eaks. Report theleaks for rectification. X X X

10 Prove solenoid operation, as applicable. X X X

11 Check the functionality of the flow switches on chilled watersystem and condenser water system, as applicable. X X


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ItemNo. Maintenance and Servicing Instructions

On Hireand

Installation

Monthlyor at750

Hours

6-Monthlyor at 4300

Hours

Completionof Hiring

andDecomm.


12 Check the TX valve or electronic expansion valve and

superheat, as applicable.X X

13 Check operation and calibration of chilled water temperaturecontroller to maintain the intended design temperature. X X

14 Check setting and operation of chill ed water, lowtemperature safety thermostat, and record trip temperature. X X

15Check the thermal insulation over the chiller components.

Replace or repair if necessary. Re-establish vapour sealaround the chiller unit.

X X X

16 Inspect corrosion protection device, as applicable. X X

17 Remove insulation and water boxes. Clean and fit newgaskets. X

18 Clean chilled water tubes, plates, bolts, grease threads, andreassemble. X

19 Slug dose chilled water upon refilling or replenishing CHW

in the recirculation system.X

20

Check and clean in-line strainers and scale traps on boththe chilled water and condenser water recirculation systems,as necessary, depending on the type of cooling applicationand quality of the chilled water.

X X

21 Check oil level and top up if necessary. X X X22 Test oil for acidity. X X23 Flush oil sump and change oil, if necessary. X24 Check driers and change if necessary. X X25 Check oil filters and change if necessary. X X26 Check and align coupling and report on rubber wear. X X27 Set unit to work, prove operation. X X X28 Lubricate and grease all points and linkages. X X29 Repair and paint any corrosion, clean generally. X X

Electrical:1 Check for signs of burnt, hot connections and burnt contactson starters and relays. Clean, rectify, and tighten. X X

2 Replace any faulty indicator lights. X X X

3Examine general condition of conduits, connectors,

switches, and wiring, especially when chiller installed in dampand outdoor areas.

X

4 Check operation of each item of equipment. X X X X

5 Check for proper operation of Voltmeter and Ammeter asapplicable. Replace faulty meters. X X X

6 Inspect, clean, and replace contacts, as necessary. X7 Inspect relays. Replace faulty relays, as necessary. X8 Check overload ratings against motor nameplate. X X

9

Check connections to compressor motors, control panel/

MCCB (Motor Control Centre Board), and at points where theequipment is subjected to vibrations. X X

10 Examine external switches for possible damages to seals. X X11 Check all time delays. X X12 Check all fuses for correct rating. X X

13 Replace any safety warning, instructional, and operationallabels that have fallen off, damaged, or removed. X X X X

14Check and rectify condition of exposed cable insulation.

Strictly follow safe power isolation procedures prior to cablerepair works.

X X X


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ItemNo. Maintenance and Servicing Instructions

On Hireand

Installation

Monthlyor at750

Hours

6-Monthlyor at 4300

Hours

Completionof Hiring

andDecomm.


15 Vacuum clean interior of the control panel/ MCCB. X X

16 Check and ensure that conduits are securely fixed. X X

17 Examine and rectify the seals on the control panel/ MCCB. X X

18 Check for the existence of electrical wiring diagram insidethe control panel/ MCCB. X X X X

19Check the consistency of the electrical wiring diagram with

the actual wiring and the components of the chiller. Ensurethat it is 'as-installed'. Report any inconsistencies.

X X

20 Report any required revisions on the electrical diagram asper electrical modifications done or planned. X X

21 Lubricate all pivot points. Use pure petroleum jelly. X X

Piping and Fittings Associated with Chiller Installation:

1 Check rigid and flexible CHW and CDW pipework and valveglands for leaks, and repair leaks. X X

2 Clean rigid and flexible pipework, wipe flexible pipeconnections with grease, as applicable. X

3 Check and ensure that all valves are in correct position andorientation. X

4 Check proper functioning/ operation of all valves. X X X X

5 Check strainers and clean, as necessary, as applicable. X X X

6 Vent all high points in the system, as applicable. X

7 Check all vents or scale pockets, vent or drain asnecessary. X

8 Check condition of pipe insulation, test pipe insulation, asapplicable. X X X


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1.6 Troubleshooting

Problem Possibl e Cause Action

No lights on panel

Display A53 not on

Mains supply to control system not on1Q5-2 tripped (380V)1Q5-2 tripped (24V)Power Supply Module A10

Switch on main supply if safe to do so

Reset if safe to do soReset if safe to do soCheck fuse

Unit will notoperate Supply Fault Lit

Incorrect Phase Rotation

Voltage outside operating parameters

1U1 faulty

Check Phase Rotation, correct if req

Check voltage according to nameplate data

Check / Replace 1U1

Emergency Stop Emergency Stop input is open Reset

Preheatingnot

operational

Main supply

Auxiliary Supply

No display

Temperature reading

1Q531 tripped1Q532 trippedK8 faultyD20-3 faultyK9 faulty1Q4 tripped1Q3 tripped1Q5-33 trippedD20-4 faultyK10 faulty1T71 fuse blown1Q5-31 tripped (main supply)1Q5-32 tripped (main supply)1Q3 tripped (auxiliary supply)1Q5-33 tripped (aux supply)B31 faulty

Faulty sensor

Reset if safe to do soReset if safe to do soCheck / ReplaceCheck / ReplaceCheck / ReplaceReset if safe to do soReset if safe to do soReset if safe to do soCheck / ReplaceCheck / ReplaceCheck / ReplaceReset if safe to do soReset if safe to do soReset if safe to do soReset if safe to do soCheck / Replace

Check / Replace

Compressorwill not start

Oil heat delay light on/compressor lockout

Compressor locked outRun inhibitTemp Control Mod. Autodisplay

Oil temp has not reached workingtemp following power up / or still in 4 hrtime delay cycleSet up not correctUnit held off by timersNo heat loadIncorrect temp readingIncorrect temp setting

Check display on B31 module toconfirm oil temp is slowly rising,check time remainingCheck setting on dyna view moduleWait until timers are timed outCheck setting temp controllerCheck calibration temp sensorsCheck set point

HighPressure Alarm

Discharge high pressure trip due topoor air flow through the condensercoil

Unit operating above load limit

Service valve closedExcessive refrigerant charge

Check for airflow restrictions causedby blockageCheck for fouling of condenser coilsCheck for damaged fins/return bendsCheck for correct fan operationCheck for recirculation of ejected airCheck ambient temp is above designconditionsCheck leaving water temp is belowmax operating limitsOpen service valvesCheck for signs of air in refrig. systemCheck sub-cooling is correct

Filter Iced up Refrigerant filter blocked Check filterTemperature sensor fault Bad sensor or LLID Check / ReplacePressure transducer fault Bad sensor or LLID Check / ReplaceCommunication loss Faulty LLid Check / Replace


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180FO 182

Starter did not transition(Compressor)

Phase reversal (compressor)

Starter module didnt receive atransition complete signal indesignated time.

A phase reversal was detected on theincoming current, on a compressorstartup

Check power supply

19C19E Phase loss (compressor)

No current sensed on one or two of thecurrent-transformer inputs whilerunning or starting.If phase reversal protection is enabledand current is not sensed on one orboth current transformer inputs, logicwill detect and trip in a max of 0.3 secafter compressor start

Check power supply

1A01A2 Power loss (compressor)

Compressor previously establishedcurrents while running, and then allthree phases of current were lost

Check power supply

1B21B4

Severe Phase Unbalance(compressor)

A 40% phase current balance isdetected on one phase, relative to all 3phases (for 90 sec)

Check power supply

1E91EB

Starter fault type 1(compressor)

Currents detected when only 1MI isclosed, one of the other contactors isshorted

Check contactors

1ED1EF


Currents detected with only 1K3closed. 1M contactor is shorted Check contactors

1F11F3


No currents detected within 1.6 secduring startup sequence Check contactors

5AC5AE

Transition complete inputshorted (compressor)

The transition complete input found tobe shorted before compressor started

BEC

BC

Overload trip (compressor) Compressor current exceededoverload time Check compressor

D7 Over voltage Line voltage above 10% of nominal Check power supplyD8 Under voltage Line voltage below 10% of nominal Check power supply

19819B Low oil flow (compressor)

Intermediate oil pressure transducerout of acceptable range for 15 sec,while delta pressure greater then2.45bar.

Check pressure transducers

1AE1AF

Low differential refrigerantpressure

System differential pressure forrespective circuit below 2.45 bar formore than 140 bar-sec

1C61C7

High differential refrigerantpressure

System differential pressure forrespective circuit was above 19.25 barfor two consecutive

1DD1DF High oil temperature

Oil temp of respective circuit, assupplied to compressors exceeded93 C for 2 consecutive samples or formore then 10 seconds

2A15B5 Condenser fan VSD fault

MP received fault signal fromcondenser fan Variable speed inverterdrive and cant clear the fault

Check speed inverterCheck fans

5835B6 Low evaporator liquid level

The liquid level sensor is near low endof range for 80 continuous minuteswhile compressor is running

Check refrigerantCheck expansion valve operation

Check liquid level sensor


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5845B7 High evaporator liquid level

The liquid level sensor is near highend of range for 80 continuous

minutes while compressor is running

Check expansion valve operationCheck liquid level sensor

87 External chilled water set point Input signal out of range (low / high orbad LLID)

This info diagnostic will auto reset ifinput returns to normal range

Check signalChange setting to front panel setpoint

89 External current limit set point Input signal out of range (low / high orbad LLID)

This info diagnostic will auto reset ifinput returns to normal range

Check signalChange setting to front panel setpoint

C5 Low chilled water temp: unit offLeaving chilled water temp fell belowleaving water temp cutout set point(chiller stopped)

Run water pump until the diagnostic Auto resets

C6 Low chilled water temp: unit on Chilled water temp fell below cutoutset point while compressor running Auto reset occurs when temp rises

1.1 C above cutout for 2 mins.

384 Evaporator water flow overdueEvaporator water flow was notdetected within 4.25 mins of unit beingstarted

Check flow

Check flow safety

ED Evaporator water flow lost Chilled water flow switch input open formore than 6-10 continuous secondsCheck flow

Check flow safety

2E6 Check Clock The real time clock had an error Reset the clockCheck battery


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4 ELECTRICAL

The following schematics are based on the latest supply of the fluid pumps (3l/s, 10l/s,30l/s, 50l/s, 75l/s and 100l/s)


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Chiller capacity Fluid pump

50 kw 3 l/s157 kw 10 l/s200 kw 10 l/s500 kw 30 l/s600 kw 30 l/s1300 kw 75 l/s1500 kw 75 l/s

TC Manual Air Cooled Chillers

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