CHILLER IOM
Contents
1. LENNOX INSTALLATION OPERATING amp MAINTENANCE MANUAL g SOLUTIONS CHILLERS 4 Sai sx LIST OF CONTENTS 1 DELIVERY OF EQUIPMENT ON SITE e erre 3 1 1 VERIFICATION OF EQUIPMENT DELIVERED ims etus 3 STORA HM 4 4 21 PRELIMINARY CHEOK G eesi 4 22 CIF TNG AND HANDLING 4 UNITPLA CEMENT 4 24 WATER CONNECTIONS sensisse 6 2 9 ELECTRICALCONNECTIONS Dr 7 ZOA OUND EE VEL ireann bM USUS 7 2 7 UNITS MOUN TED ON RECEIVERS erect cee 8 UD 10 3A PRELIMINARY ar GS vce sce 10 ILUN START e 11 Se IMI ORTAN T oee A E E 12 OPERATION re 12 12 B InEGL 7 40 p mr 12 D MAINTENANCE 17 MAINTENANO E detnr 17 Bee YEAREY ende 18 OS CLEANING THE 19 5 4 COMPRESSORS 19 SINF ORTAN E 19 6 TROUBLESHOOTING REPAIRS eurn rouen nun union annuum 20 LIST OF THE MOST COMMON PROBLEMS 202. Number of fans per circuit MES GEN 750 rpm fans 750 500 rpm fans 1 single speed 750 500 rpm motor PV1 directly with the compressor GV1 on PHP1 2 50 rpm motors V1 directly with the compressor V2 on PHP1 3 50 rpm motors V1 directly with the compressor V2 on PHP1 V3 on PHP2 4 750 rpm motors V1 directly with the compressor V2 on PHP1 V3 on PHP2 V4 on PHP3 5 750 rom motors V1 amp V2 directly with the compressor V3 on PHP1 V4 on PHP2 V5 on PHP3 500 rpm fans V1 on PHP1 V1 directly with the compressor V2 on PHP1 V1 directly with the compressor V2 on PHP1 V3 on PHP2 V1 directly with the compressor V2 on PHP1 V3 on PHP2 V4 on PHP3 V1 amp V2 directly with the compressor V3 on PHP1 V4 on PHP2 V5 on PHP3 Il Self contained units designed for 20 C ambients Number of fans per circuit 750 rpm fans 750 500 rpm fans 1 dual speed 750 500 rom motor PV1 on PHP1 GV1 on PHP2 1 750 500 rpm 1 750 rpm motor PV1 on PHP1 GV1 on thermostat V2 on PHP2 1 750 500 rpm 2 750 rpm motor PV1 on PHP1 GV1 on thermostat V2 on PHP2 V3 on PHP3 4 750 rpm motors V1 with cp and on thermostat V2 on PHP1 V3 on PHP2 V4 on PHP3 5 50 rpm motors V1 amp V2 with cp and on thermostat V3 PHP 1 V4 on PHP2 V5 on T HP 3 On PRA units propeller fans 640 rpm or 940 rpm 500 rpm fans Fan speed controller mandatory V1 with fan speed controller V2 on PHP1
3. 4 Inspect the chilled water circuit for any signs of leakage Check operation of the water circulating pump and its ancillaries Check the percentage of antifreeze in the chilled water circuit top up as necessary if antifreeze is used 5 Carry out all weekly maintenance duties The first and last inspection will include the seasonal shutdown procedure or the restarting procedure depending on the case These inspections should include the following operations Check the contacts of motor contactors and control devices Check the adjustment and operation of each control device Conduct an oil analysis to determine the acidity Record the results Chanage the oil if necessary WARNING Oil analyses should be carried out by a qualified technician Misinterpretation of the results could cause damage to the equipment Also analysis operations should be conducted according to the right procedures so as to avoid accidents and potential injury of service personnel Follow the recommendations given by HCF LENNOX as concerns compressor oil See the appropriate table Conduct a refrigerant leak test Check motor winding isolation Other operations may be necessary depending on the age and the number of hours of operation of the installation MES GEN 5 3 CLEANING THE CONDENSER 5 3 1 AIR COOLED CONDENSERS Clean the coils either with a vacuum cleaner cold water compressed air or with a soft brush non metallic On un
4. V1 with cp and on thermostat V2 on PHP1 V3 on PHP2 V1 with cp and on thermostat V2 on PHP1 V3 on PHP2 V4 on PHP3 V1 amp V2 with cp and on thermostat V3 on PHP1 V4 on PHP2 V5 Fans speeds vary from 0 to 100 depending on condensing temperature PRA units with centrifugal fans Fan speed is all or nothing depending on condensing temperature Condensing units for 6 C or 20 C ambient temperature On condensing units fans are all single speed whatever type of operation is envisaged 6 C or 20 C and what ever type of fan is used 750 tr min or 500 tr min Each fan is controlled by an automatic adjustable pressure switch IV Other cases a Heat recovery In heat recovery mode fan control on 6 or 20 C units described above is bypassed All fan stages are therefore controlled by automatic adjustable pressure switch Cut in points on these pressure switches should be adjusted so that fan operation enables leaving hot water temperature to be maintained at the value required b Desuperheating Controls described in I ll and IIl are used 16 MES GEN 5 MAINTENANCE The following maintenance instructions form a part of the operations required for this type of equipment However It is not possible to give fixed and precise rules for permanent maintenance procedures capable of keeping all units in perfect operating condition since too many factors depending on local conditions specific
5. Check the water pump Evaporator obstructed Determine the degree of fouling by measuring water pressure drop Evaporator frozen up Measure pressure drop in water circuit keep water circulating until evaporator has thawed completely Low refrigerant charge Check the refrigerant charge and add refrigerant if necessary G COMPRESSOR CUTS OUT Thermal protection tripped Check operation of thermal ON ITS MOTOR protection change it if necessary PROTECTION THERMAL RELAY Motor windings are not being Measure superheat in the sufficiently cooled evaporator adjust it if necessary 22 MES GEN H COMPRESSOR CUTS OUT THROUGH ACTION OF THE MAIN POWER FUSE I THE COMPRESSOR STARTS WITH DIFFICULTY J THE COMPRESSOR IS NOISY Compressor knocking Suction line is unusually cold High discharge pressure The water regulating valve or the pressure operated water valve taps or knocks Compressor shuts down through action of the oil pressure safety switch K DISCHARGE PRESSURE TOO HIGH Water is far too hot at condenser outlet Water is far too cold at the condenser outlet Condenser abnormally hot Chilled water leaving temperature too high MES GEN Power supply on two phases only Faulty motor windings Compressor seized Faulty windings Mechanical problem If starting on a single winding on compressors fitted with part winding start or wye delta Broken mecha
6. a Expansion valve opened to far b Expansion valve blocked in open position Suction line unusually cold Liquid refrigerant returns to compressor N SUCTION PRESSURE IS TOO HIGH Bubbles in sightglass Low refrigerant charge Excessive pressure drop across Filter drier obstructed the filter drier or the solenoid valve No refrigerant passing through the expansion valve Expansion valve bulb has lost its charge Loss of capacity Expansion valve obstructed Control thermostat contacts stuck in closed position Conditioned space too cold Capacity modulation setting too low Compressor short cycling Superheat value too high Excessive pressure drop in the evaporator Low pressure drop in the Low water flow evaporator 24 Adjust the pressure operated water valve or the thermostat on the cooling tower Repair the leak and add refrigerant Check the system a Adjust superheat and check that the expansion valve bulb is correctly fitted in place b Repair or replace Repair the leak and add refrigerant Replace the cartridge Replace the bulb Clean or replace Repair or replace Adjust Check the external equalizing line on the expansion valve Check water flow Check the condition of the filters look for obstructions in the chilled water circuit piping MES GEN CONTROL DEVICES Operation By reacting to compressor discharge pres
7. according to the results of the analysis We do not advise operation of the units with open loops which can cause problems with oxygenation nor operation with untreated ground water Use of untreated or improperly treated water can cause deposits of scale algae and sludge or cause corrosion and errosion It is advisable to call in a qualified water treatment specialist to determine what kind of treatment will be necessary The manufacturer cannot accept liability for damage caused by the use of untreated or improperly treated water salt water or brine 2 4 3 ANTIFREEZE PROTECTION a Use glycol water solution ADDITION OF GLYCOL IS THE ONLY EFFICIENT WAY TO PROTECT AGAINST FREEZE UP The glycol water solution must be sufficiently concentrated to ensure proper protection and prevent formation of ice at the lowest outdoor air temperatures expected on an installation Take precautions when using non passivated MEG antifreeze solutions Corrosion can occur with these antifreeze solutions in the presence of air b Drain the installation It is important to make sure that manual or automatic air bleeders are installed at all the high points of the water circuit To enable drainage of the circuit make sure that drain cocks are installed at all the low points of the circuit To drain the circuit the drain cocks must be opened and an air inlet ensured air bleeders are not designed to admit air FREEZE UP OF AN EVAPORATOR DUE TO COLD W
8. electrical connections should be made to the two remote inter lock terminals dry contact 4 2 3 AUTOMATIC SEQUENCES Starting sequence press the unit start switch the power light will come on The control circuit cannot be energised if there is no power supply to the main power circuit Depending on the demand for cooling the control thermostat authorises start up of the compressor s which takes place in cascade The compressor run indicating lights come on Regulator stoppage sequence When the cooling load starts decreasing from its maximum value the multi stage control thermostat shuts down successive stages depending on the progressive reduction in return chilled liquid temperature Depending on machine equipment staged reduction consists either in shutting down a compressor or activa tion of a compressor capacity reducer This continues until the unit shuts down completely through action of the regulator The compressor regulation stoppage lights come on Safety shutdown sequence If a default occurs on a circuit it is detected by the appropriate safety device high pressure overshoot loss of oil pressure motor protection etc The relay in question initiates unconditional stoppage of the compressor on that circuit and the safety stoppage indicating light comes on Some defaults give rise to immediate stoppage of the entire unit Tripped flow switch Tripped antifreeze thermostat In cases other t
9. if if evaporating pressure drops below the value P 1 6 C ambient temperature machines standard P 2 4 bars relative 2 optional 20 C ambient temperature machines P 0 8 bars relative Fan control pressure switch and thermostat The function of these devices is to ensure a level of head pressure compatible with proper unit operation An increase in outdoor air temperature increases head pressure and this is maintained at its required value by fan operation or by fan stoppage if the temperature decreases Antifreeze function This function only exists on units designed for brine or glycol water chilling for which the freezing temperature depends on the concentration of the solution Whatever type of device is used See case 1 and 2 cut out by the antifreeze function causes immediate unit stoppage CASE 1 Antifreeze thermostat option This device monitors chilled liquid temperature at the evaporator outlet It triggers when the temperature goes below the minimum value 4 C for water CASE 2 Antifreeze pressure switch option This monitors evaporating pressure of the refrigerant It triggers when the temperature goes below the preset minimum value Note On units fitted with CLIMATIC or MASTERTECH controls see the appropriate user manual for more specific details Differential oil pressure safety switch only on units with semi hermetic compressors a Reciprocating compressors This pressure switch
10. initiates unconditional unit stoppage if differential oil pressure drops for more than two minutes below a preestablished minimum safety value Differential oil pressure is the difference between the oil pump discharge pressure and the gas pressure inside the compressor crankcase suction pressure The differential oil pressure safety switch is factory set and is not modifiable on site b Screw compressors This pressure switch initiates unconditional unit stoppage if differential oil pressure rises above a preset safety value Differential oil pressure in this case is high pressure less the compressor oil injection pressure 4 2 2 FUNCTIONS OF ELECTRICAL COMPONENTS Electronic or cam type anti short cycle relay This device limits the number of compressor start ups Compressor motor thermal protection This device stops the motor if winding temperature rises too high and enables it to start up again when temperature drops back to a normal value MES GEN 14 Fan overcurrent protection Circuit breaker designed to stop the fan motors in the event of phase overcurrent in relation to the permitted value Compressor motor overcurrent protection Circuit breaker designed to protect each motor winding against accidental overcurrent Indicator lights The electrical control box is fitted with indicator lights enabling visualisation of the state of operation or non operation of a function or given circuit There is also an indicato
11. machine has been selected for a given operating range it must be replaced with a model with the same reference from the same manufacturer Filter drier This is designed to remove all traces of humidity from within the refrigeration circuit since this can impair operation of the unit by acidification of the oil which causes slow disintegration of the varnish protecting the compressor motor windings High and low pressure gauges option Enables istantaneous readout of suction and discharge pressures Sightglass humidity indicator optional on units fitted with scroll type or reciprocating compressors Enables visual verification of the state of the liquid refrigerant monophase ou diphasic in the liquid line upstream of the thermostatic expansion valve Enables detection of humidity in the circuit MES GEN Crankcase heater Every compressor is fitted with a single phase crankcase heater that is activated when the compressor stops to ensure separation of the refrigerant and the compressor oil It is therefore powered up when the compressor is not running NB MANEUROP Scroll and reciprocating 6 C ambient type compressors are not fitted with a crankcase heater High pressure switch This pressostat initiates unconditional stoppage of the unit if compressor discharge pressure exceeds the operating limits Reset is automatic Low pressure switch This pressure switch initiates unconditional stoppage of the unit
12. rigid piping 2 7 2 INSTALLATION a Pressure test To avoid formation of copper oxide during brasing operations blow a little dry nitrogen through the pipes Piping must be made with tubing that is perfectly clean plugged during storage and between connection operations During these operations observe the following precautions 1 Do not work in a confined atmosphere refrigerant fluid can cause fainting Make sure there is sufficient ventilation 2 Do not use oxygen or acetylene instead of refrigerant fluid and nitrogen for leak testing this could cause a violent explosion 3 Always use a regulator valve isolating valves and a pressure gaUges to control test pressure in the system Excessive pressure can cause lines to burst damage to the unit and or cause an explosion with severe personal injury Ensure conduct liquid line and gas line pressure tests are in conformity with applicable legislation Before starting up a unit on a receiver the piping and the condenser must be dehydrated Dehydration should be carried out using a double stage vacuum pump capable of drawing 5 mmHg absolute pressure vacuum MES GEN Best results are obtained with a vacuum down to 1 mmHg To get down to this level at normal temperatures i e 15 C itis often necessary to leave the pump running for 10 to 20 hours The duration of pump operation is not a factor of efficiency The pressure level must be checked before the unit is put into servic
13. that the bubbles disappear progressively indicating a correct refrigerant charge and the absence of noncondensibles If the humidity indicator chan ges colour indicating the presence of humidity replace the filter drier cartridge if the latter is of the replaceable type c Check that when the cooling load has been balanced by the capacity of the unit the chilled liquid is at design temperature 5 Check the current values per phase on each compressor motor 6 Check the current values per phase on each fan motor 7 Check compressor discharge temperature 8 Check compressor oil pump temperatures semi hermetic reciprocating compressors 9 Check suction and discharge pressures and compressor suction and discharge temperatures 10 Check chilled liquid entering and leaving temperatures 11 Check outdoor air temperature 12 Check liquid refrigerant temperature at the condenser outlet MES GEN 12 These verifications should be made as quickly as possible with a stable cooling load i e the cooling load of the installation should be the same as the capacity developed by the unit Measurements taken without heeding this condition will result in unuseable and probably wrong values These verifications can only be made once the proper operation of all safety devices and unit controls has been established 3 2 2 OIL CHARGE Units have a complete operating charge of oil when they are shipped and there is no need to add any oil be
14. AR CHECKS TO BE MADE CHILLER UNIT ENVIRONMENT CHILLED WATER CIRCUIT Inlet Outlet pressure guages for pressure Evaporator inlet temperature Evaporator outlet temperature CON COMICS ION 1 te nection me operational ET Chilled water pump interlock nnns Filter on water CIPCUIE CONDENSER WATER CIRCUIT Inlet Outlet pressure guages for pressure Condenser inlet temperature nennen nnns Condenser outlet temperature seeeeeeessssseeeseeeeeeeeenenn nnne Regulation on condenser water inlet Condenser pump interlock Filter on water Unrestricted air flow on condenser coils 2 ELECTRICAL POWER SUPPLY Control eicit VON oveeddeunedsneooyeusbeceetee Power circuit power supply voltag
15. EATHER CONDITIONS CANNOT GIVE RISE TO A WARRANTY CLAIM 2 4 4 ELECTROLYTIC CORROSION We would like to draw your attention to the problems of corrosion due to electrolytic corrosion caused by an imbalance between earthing points AN EVAPORATOR THAT IS PUNCTURED BY ELECTROLYTIC CORROSION IS NOT COVERED BY THE UNIT WARRANTY 2 4 5 MINIMUM WATER CAPACITY The minimum volume of the chilled water circuit must equal 10 of the volume of water circulating per hour through the unit If necessary install a buffer tank Proper operation of regulating and safety devices can only be ensured if the volume of water is sufficient MES GEN 2 4 6 FLOW SWITCH A flow switch must be installed on the evaporator water inlet or outlet so as to enable detection of water flow through the heat exchanger before the unit is started up This will protect the compressors against any eventual liquid slugging during the starting phase and prevent accidental ice formation in the evaporator if the flow of water is interrupted Flow switches are available on option The normally open contact of the flow switch should be connected to the terminals provided to that effect in the unit electrical box See the wiring diagram supplied with the unit The normally closed contact can be used as an indication of a lack of flow condition 2 5 ELECTRICAL CONNECTIONS First of all make sure that power supplies from the building to the place where the unit is installed are prope
16. ES OR RUNS CONTINUOUSLY Temperature too low in the conditioned space Bubbles in sightglass Noisy compressor or abnormally high suction pressure or low discharge pressure MES GEN Low pressure safety switch trip out Low refrigerant charge Filter drier obstructed Solenoid valve closed Expansion valve closed Compressor suction valve obstructed High pressure safety switch trip out Low air water flow in condenser or dirty condenser coil poor heat exchange Incondensibles in the refrigeration circuit Faulty control thermostat Chilled water thermostat set too low Low refrigerant charge Filtrer drier partly obstructed Expansion valve partly closed Liquid line valve not open far enough Leaky compressor valves Check low pressure safety switch differential Check the charge through the sightglass on the liquid line carry out a leak test then top up the refrigerant charge Check the state of the drier and replace the filter Check that the valve is operating properly Check bulb and capillaries operation of the valve Check the filter Check high pressure safety switch differential Check that pumps are operating correctly or the state of cleanliness of the coils check fan operation Bleed from circuit and top up the refrigerant charge Check operation Adjust it Check the refrigerant charge in the sightglass a
17. LL COIMPRESOR S NUMBER OF RECOMMENDED PREVENTIVE MAINTENANCE VISITS Tube analysis Year Start up Visit Major technical Inspection 500 1000 H inspection visit Every year 3 times a Every 3 year years This table is published for units operating under normal conditionswith an average annual runtime of 4000 hours In hostile industrial environments a specific maintenance visit schedule must be envisaged 1 Depending on the quality of the water CO MES GEN DESCRIPTION OF INSPECTION DUTIES LIQUID CHILLER WITH SCROLL COMPRESSOR S START UP Check unit installation Check water flow and water circuit ancillaries Check safety devices Check leaktightness Configuration of the microprocessor based management system if used Verification of operating parameters and unit performance Transmission of the machine service log 500 H 1000 H VISITS Post wear in inspection Oil acidity test leak test Replacement of the filter drier cartrides depending on the results of the test above Monitor unit performance and any eventual variations linked to use of the installation INSPECTION VISIT Leak test Operating test with record of measurements taken and functional analysis MAJOR TECHNICAL INSPECTION Inspection visit Acid test Oil change Replacement of filter drier cartridges check up on the microprocessor based man
18. Y IS PROPERLY SHUT OFF AND LOCKED OUT 2 2 HANDLING Handling operations must be carried out by qualified personnel Comply strictly with lifting instruction pasted on the unit Unit handling operations must be carried out carefully to avoid jolting the frame the panels the electrical box the condenser coil fins etc 2 3 UNIT PLACEMENT Before placing the unit check the following points Strength flatness water tightness of the concrete flooring slab hat there is sufficient free space around and above the unit for proper airflow as indicated on the unit dimensional drawings The number of pressure points and their locations 2 3 1 STRENGTH OF THE FLOORING SLAB The ground beneath the unit must be flat level and of sufficient strength to support the weight of the unit with its full liquid charge and the occasional presence of the usual service equipment It must be rainproof and very rigid to avoid loss of water tightness due to any eventual deformation MES GEN In locations exposed to frost the supporting surface if the unit is installed on the ground must be built on concrete stakes extending downwards beyond the normal depth of frost It is always advisable to build a supporting surface detached from the general building structure to avoid transmission of vibrations 2 3 2 VIBRATION ISOLATORS On normal applications unit rigidity and pressure point spacing enables installation without nuisance vibration Vibr
19. agement system if used Adjustment of safety devices Verification of unit interlocks Lubrication of bearings dampers if necessary TUBE ANALYSIS Inspection of water cooled evaporator and condenser tube bundles with an eddy current test to enable potentially serious problems to be anticipated Frequency Every 5 years up to 10 years depending on the quality of water then every 3 years MES GEN 31 MANUFACTURER S RECOMMENDED INSPECTIONS LIQUID CHILLERS WITH SCREW COMPRESSOR S NUMBER OF RECOMMENDED PREVENTIVE MAINTENANCE VISITS Major Year Start up 500 1000 H Technical Inspection 30 000 H Tube analysis isi inspection visit 3 times a year 30 000 Hrs Every 3 years Pa This table is published for units operating under normal conditionswith an average annual runtime of 4000 hours In hostile industrial environments a specific maintenance visit schedule must be envisaged 1 Depending on the quality of the water 2 N lt m L Q FH Z DESCRIPTION OF INSPECTION DUTIES LIQUID CHILLER WITH SCREW COMPRESSOR S START UP Check unit installation Check water flow and water circuit ancillaries Check safety devices Check leaktightness Configuration of the microprocessor based management system Verification of operating parameters and unit performance Transmission of the machine service log 500 H 1000 H VISITS Post wear in inspection Oil acidity test leak test Rep
20. airs the quality of the oil Darkening of the colour of the oil or degradation of its qualities can also be caused by the presence of humidity in the system When the oil has changed colour or has been degraded it must be changed In this event before putting the unit back into service the compressor and the refrigeration circuit will have to be evacuated 5 5 IMPORTANT Before proceeding with any service opertations make sure that the power supply to the unit is switched off When the refrigeration circuit has been opened it will have to be evacuated recharged and inspected to ensure that it is perfectly clean filter drier and leaktight Remember that only trained and qualified personnel are authorised to open a refrigeration circuit Regulations stipulate recovery of refrigerants and forbid willful discharge of refrigerants into the atmosphere MES GEN 6 TROUBLESHOOTING REPAIRS 6 1 LIST OF THE MOST COMMON PROBLEMS PROBLEMS SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION A THE COMPRESSOR DOES NOT START Motor control circuits established the compressor does not run Low voltage reading on voltmeter The system does not start up 20 No power supply Compressor motor burnt out Voltage too low Breaker tripped or fuses blown No water flow in the evaporator Flow switch contacts open Anti short cycle relay action Faulty control thermostat Oil pressure switch tripped Antifre
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22. alves in their operating positions and start the water circulating pumps 2 Make sure that the power supplied to the unit corresponds to its operating voltage and that phase rotation corresponds to the direction of rotation of the compressors screw amp scroll 3 Make sure that the water circuits mentioned in 1 are completely filled with water or brine as the case may be with the air bled out of all high points including the evaporator ensuring they are perfectly clean and leaktight In the case of machines with water cooled condensers the condenser water circuit must be ready to operate filled with water pressure tested bled filter cleaned after 2 hours of operation of the water pump Cooling tower in operating condition water supply and overflow checked fan in operating condition 4 Check the cleanliness and the tightness of all electrical connections both the connections made at the factory and the connections made on site Also make sure that all thermostat bulbs are correctly inserted and tightened in the various wells if necessary add heat conducting paste to improve contact Make sure all sensors are correctly fitted and that all capillary tubes are fastened The technical data printed at the top of the wiring diagram should correspond with those indicated on the unit nameplate 5 Reset all manually resetting safety devices where necessary Open power circuits to all components compressors fans 6 Power up the unit
23. ation isolators may be used by contractors on installations requiring particularly low vibration levels Use of vibration isolators MUST be accompanied by installation of flexible connections in the unit water piping Vibration isolators must also be fixed to the unit BEFORE being fixed to the ground Selection of isolator vibration absorbing capacity is not HCF LENNOX s responsibility The unit must be bolted to the vibration isolators and the latter solidly fixed into the concrete slab Check that vibration isolator contact surfaces fit flush to the floor If necessary use spacers or re surface the flooring but in all events make sure that the isolators seat flatly on the supporting surface 2 3 3 CLEARANCES REQUIRED lt is essential that the units be installed with sufficient free space around them to enable proper circulation of air ejected by the condensers and to provide easy access to all unit components for servicing and maintenance If the air rejected by the condenser encounters any obstacles it will tend to be recycled by the fans This will cause an increase in the temperature of the air used to cool the condensers Obstruction of the air outlet will also impair air distribution across the entire heat exchanging surface of the condenser Both of these conditions which reduce the heat exchange capacity of the coils will cause an increase in condensing pressure This will lead to a loss of capacity and an increase in compressor power inp
24. dding any oil Check the oil level every 30 minutes If the level does not reach the level indicated above contact a qualified refrigeration mechanic TYPE OF OIL RECOMMENDED BY HCF LENNOX Reciprocating Reciprocating Scroll Copeland Maneurop Maneurop Maneurop Maneurop Kyoseki 160P PU 30N Mobil Maneurop Maneurop Emkarate EAL 160SE Arctic 22 160P 16054 RL220H 3 This table is valid for self contained chillers only or chillers mounted on receivers on which the leaving water temperature is not lower than 5 For other cases consult the documentation shipped with the machine 2 Overcharging with oil can be as dangerous to a compressor as a lack of oil Before topping up contact a qualified technician Only use oils recommended by the manufacturer 3 Check the oil pressure 4 The flow of liquid refrigerant through the sightglass should be steady and without bubbles Bubbles are a sign of a low charge a possible leak or of a restriction in the liquid line Contact a qualified technician MES GEN 18 Each sightglass is fitted with a humidity indicator The colour of the element changes according to the level of humidity in the refrigerant but also according to temperature It should indicate dry refrigerant If it shows wet or CAUTION contact a qualified refrigeration technician CAUTION When starting up the unit run the compressor for at least 2 hours before taking a humidity reading The humidity detect
25. e b Charge Chiller units can be charged either in the liquid phase or in the vapor phase In liquid phase connect either to a liquid isolating valve or to the quick connector on the liquid line at the valve outlet In the vapor phase connect up to the suction valve Never charge a machine operating on R407C in the vapour phase vapor the composition of the mixture could be modified Note Units mounted on receivers are supplied with a refrigerant nitrogen holding charge Before pulling down the vacuum for dehydration completely purge the unit Charge the unit until there is a constant flow of bubble free liquid in the sight glass indicating that there is sufficient charge and that subcooling is correct In all cases do not top up the charge until the unit reaches a stable state of operation It is pointless to overcharge a system this can adversely affect operation Overcharging causes 1 Excessive discharge pressure 2 A risk of damage to the compressor 3 Excessive power consumption c Oil charge All units are delivered with a complete oil charge In the case of units mounted on receivers it may be necessary due to the length of piping installed to add a certain amount of oil compatible with the type of compressor and refrigerant used d Air cooled condensers An air cooled condenser connected to a unit must have the same number of circuits as the unit Selection of the condenser must be made car
26. e 1 2 Power circuit power supply voltage 12 3 Power circuit power supply voltage 1 1 Depending on the application 2 According to the type of unit MES GEN VALUE DkPa DkPa 27 MANUFACTURER S RECOMMENDED INSPECTIONS LIQUID CHILLERS WITH RECIPROCATING COMPRESSOR S NUMBER OF RECOMMENDED PREVENTIVE MAINTENANCE VISITS Major Year Start up 500 1000 technical Inspection 15000 H 30000 H inspection ISI Inspection Inspection Tube analysis gt lt 3 times a year 15 000 Hrs 30 000 Hrs Every 3 ans This table is published for units operating under normal conditionswith an average annual runtime of 4000 hours In hostile industrial environments a specific maintenance visit schedule must be envisaged 1 Depending on the quality of the water 8 MES GEN NO DESCRIPTION OF INSPECTION DUTIES LIQUID CHILLER WITH RECIPROCATING COMPRESSOR S START UP Check unit installation Check water flow and water circuit ancillaries Check safety devices Check leaktightness Configuration of the microprocessor based management system if used Verification of operating parameters and unit performance Transmission of the machine service log 500 H 1000 H VISITS Post wear in inspection Oil acidity test leak
27. efully to enable transfer of the heat capacity of the unit even at the highest temperatures expected on an installation e Head pressure control A system has to be envisaged to enable the unit to operate whatever the season A variety of different systems may be used but the most simple and efficient of these modulates fan operation using a pressure or temperature control On condensers fitted with a small number of fans 1 or 2 it may be necessay to vary the speed of the fans Head pressure control systems that operate by flooding the condenser with liquid refrigerant should be avoided since they entail very large refrigerant charges and can cause serious problems if they are not correctly controlled MES GEN 10 3 START UP 3 1 PRELIMINARY CHECKS Before proceeding with start up even for a test of short duration check the following points after having made sure that all the valves on the refrigeration circuit are fully open discharge valves and liquid valves Starting up a compressor with the discharge valve closed will either trip the HP safety switch or blow the cylinder head gasket or the internal pressure safety disc 1 The liquid pump s and other apparatus interlocked with the unit coils air handling units dry coolers cooling towers terminals such as fan coil units etc are in working order as required by the installation and according to their own specific requirements Place all water valves and refrigerant v
28. eze thermostat or low pressure safety switch tripped Compressor thermal protection relay tripped High pressure safety switch tripped Check main power supply and switch positions Replace Contact power company Determine the cause If the system is in running order close the disconnect Check condition of fuses Measure flow check the water pump and water circuitry and filters Find the cause of the trip out Check circulation of liquid in the evaporator and the condition of the flow switch Wait until the anti short cycle time delay has expired Check for proper operation set points contacts Check the oil pressure switch and determine the cause of the trip out Check evaporating pressure the condition of the antifreeze thermostat and the low pressure safety switch Check for proper operation of the relay Check the condensing pressure and the condition of the high pressure safety switch MES GEN B THE COMPRESSOR SHORT CYCLES ON LOW PRESSURE SAFETY SWITCH TRIP OUT Normal operation with too freqquent starts and stoppages due to action of the low pressure safety switch Bubbles in sightglass Or normal compressor operation but the low pressure safety switch trips out and resets frequently Suction pressure too low Filter drier frozen up C THE COMPRESSOR SHORT CYCLES ON HIGH PRESSURE SAFETY SWITCH TRIP OUT D THE COMPRESSOR RUNS IN LONG CYCL
29. fore start up or afterwards Note that unit shutdowns by the differential oil pressure switch are usually caused by other problems than a lack of oil in the refrigeration circuits Overcharging with oil can cause serious problems on an installation particularly for the compressors The only time any oil might need adding is when a compressor is replaced 3 2 3 REFRIGERANT CHARGE Self contained units have a complete refrigerant charge at the time they are shipped This charge may need to be topped up when the unit is installed or at other times during the service life of the unit Additional charge can be introduced through the Schrader valves on the suction line Every time fluid is added check the state of the charge with the sightglass provided to that effect on the liquid line and also by the amount of liquid subcooling at the condenser outlet 3 3 IMPORTANT Start up and commissioning must be conducted under the supervision of a refrigeration expert Never shut of power to the crankcase heaters except for lengthy service operations or seasonal shutdown Remember to power up the crankcase heaters at least 24 hours before the unit is restarted 4 OPERATION 4 1 CLIMATIC CONTROL cf See the specific CLIMATIC manual cf See the specific MASTERTECH manual for PRA units 4 2 UNIT OPERATION 4 2 1 FUNCTIONS OF REFRIGERATION CIRCUIT COMPONENTS Thermostatic expansion valve Very important The thermostatic expansion valve fitted on each
30. han that of manually reset safety devices starting of the circuit or the machine takes place automatically once the default has been cleared MES GEN Loss of power supply There are no problems restarting the machine after a loss of power supply of short duration up to about one hour If loss of power supply lasts longer than this when power supply is resumed set the unit to OFF with the compressor crankcase heaters activated for as long as it takes to bring sump oil back up to temperature then restart the unit Pressostatic water valve This device is available as an option for low capacity water cooled condensing units PLCW RLZ units The pressostatic water valve should be installed on the condenser outlet It enables water flow through the heat exchanger to be varied so as to maintain condensing pressure at an appropriate value Fan motor control The product ranges concerned are those not equipped with CLIMATIC control as standard equipment PLCA D RLA SV DV PLCA DC RLASC DC GCA SC DC Meanings of the abbreviations above Vn Fann Pvn Low fan speed fan n Gvn High fan speed fan n PHP1 HP pressure switch P100 cuts in at 15 5 bars cuts out at 10 3 bars PHP2 HP pressure switch P100 cuts in at 17 2 bars cuts out at 11 7 bars HP pressure switch P100 cuts in at 19 bars cuts out at 13 5 bars Self contained units designed for 6 C ambient GCA SV DV GCAD GCA DC PRA C
31. ing chilled water temperature C Outdoor air temp _____ Min 26 Power supply voltage V Ph Hz Refrigerant type 1 Date and time measurements were taken Outdoor air temperature C Company responsible for measurements _ Name of technician Remarks CIRCUIT 1 CIRCUIT 2 CIRCUIT 3 CIRCUIT 4 Comp Comp Comp Comp Comp Comp Comp 1 2 1 2 1 2 1 Number of hours of operation po po a Compressors in service percicut T T Evaporating pressure _ Suction piping temperature 5 _ Condensing pressure ferf Discharge piping temperate Jol _ EMEN ipmpempeue Jel _ E 1 Que Cumenton phase 1 percompressor Cumenton phase 2percompressor l Cumenton phase percompressor L Liquid ine temperate fof f f Evaporator pressure drop far o chiles water Jof Leaving chiled water temperature Condenser pressuredop ferf Condenser entering water temperature Condenser leaving water temperare Low pressure switch cutin fef __ On pressure switch cutout fear _ d d d d d odo Antifreeze pressure switch cut out cut out bar Fan pressure switch cut out C 26 MES GEN 6 3 REGUL
32. its complete and in working order Pipe heaters installed on all piping exposed to freezing temperatures All unions tightenend with a torque wrench GENERAL 1 Cooling load available minimum 50 96 Coordination between different professions for final commissioning COMMENTS HCF LENNOX REFERENCE SIGNATURE CUSTOMER ORDER NUMBER NAME DESIGNATION MES GEN GREAT BRITAIN IRELAND BELGIUM CZECH REPUBLIC FRANCE GERMANY NETHERLANDS POLAND PORTUGAL RUSSIA SLOVAKIA UKRAINE OTHER EUROPEAN COUNTRIES AFRICA MIDDLE EAST MES CHILLER GB 02 98 LENNOX INDUSTRIES LTD tel 44 1604 599400 fax 44 1604 594200 e mail marketing lennoxind com LENNOX BENELUX N V S A tel 32 3 633 30 45 fax 32 3 633 00 89 e mail info be lennoxbenelux com JANKA RADOTIN AS tel 420 2510 88 111 fax 420 2 579 10 393 e mail janka gjanka cz LENNOX FRANCE tel 33 16017 88 88 fax 33 1 60 17 86 58 e mail accueii lennoxfrance com LENNOX DEUTSCHLAND GmbH tel 49 69 42 0979 0 fax 49 69 42 09 79 40 e mail info de glennoxdeutschland com LENNOX BENELUX B V tel 31 33 2471 800 fax 31 33 2459 220 e mail info lennoxbenelux com LENNOX POLSKA Sp z o o tel 48 22 832 26 61 fax 48 22 832 26 62 e mail lennoxpolska ginetia pl LENNOX CLIMATIZACAO LDA tel 351 22 999 84 60 fax 351 22 999 84 68 e mail info lennoxportug
33. its installed in a corrosive atmosphere coil cleaning should be part of the regular maintenance program On this type of installation all dust gathered on the coils should be quickly removed by regular cleaning Caution do not use high pressure cleaners that could cause permanent damage to the aluminium coil fins 5 3 2 MULTITUBE WATER COOLED CONDENSERS Use a cylindrical brush to remove sludge and other substances in suspension inside the condenser tubes Use a non corrosive solvent to remove scale deposits The water circuit in the condenser is manufactured in steel and copper A water treatment specialist given the right information will be able to recommend the right solvent for removing scale The equipment to be used for external water circulation the quantity of solvent and the safety measures to be taken must be approved by the company supplying the cleaning products or by the company conducting these operations 5 4 COMPRESSORS OIL DRAINAGE Oil for refrigeration equipment is clear and transparent It keeps its colour over a long period of operation Given that a correctly designed and installed refrigeration system will operate without any problems there is no need to replace the compressor oil even after a very long period of operation Oil that has become dark in colour has been exposed to impurities in the refrigeration piping system or to excessive temperatures on the discharge side of the compressor and this inevitably imp
34. lacement of the filter drier cartrides depending on the results of the test above Monitor unit performance and any eventual variations linked to use of the installation INSPECTION VISIT Leak test Operating test with record of measurements taken and functional analysis MAJOR TECHNICAL INSPECTION Inspection visit Acid test Oil change Replacement of filter drier cartridges check up on the microprocessor based management system Adjustment of safety devices Verification of unit interlocks Lubrication of bearings dampers if necessary 30 000 H VISIT Replacement of the compressor and return of the old one for revision with replacement of bearings and inspection of compressor geometry Major technical inspection Start up of the installation again TUBE ANALYSIS Inspection of water cooled evaporator and condenser tube bundles with an eddy current test to enable potentially serious problems to be anticipated Frequency Every 5 years up to 10 years depending on the quality of water then every 3 years MES GEN 33 34 CHECK LIST This check list should be filled in by the contractor to make sure that unit installation takes place according to appropriate industry practices WARNING Disconnect the power supply before carrying out any inspections on the unit If the unit must be left powered up proceed with precaution to avoid risk of electrocution RECEPTION Check absence of tra
35. nd top up if necessary Check the drier and replace as required change the filter cartridge Check expansion valve bulb and capillary measure superheat Open the valve completely Check valve gas tightness replace the valve plate if necessary Tighten compressor nuts and bolts 21 E COMPRESSOR CUTS OUT ON OIL PRESSURE SAFETY SWITCH Oil pressur switch tripped Check operation of the oil pressure safety switch Oil level in sightglass is too low Oil pressure too low Check the oil level in the sightglass on the crankcase check the cleanliness of the oil filter check the oil pump Visible oil leak Oil level too low Low oil charge Check that there is no leakage and add Leaky oil sump Repair and add oil Suction line unusually cold Liquid refrigerant present in the Check appearance of the oil in compressor noisy compressor crankcase the sightglass Measure temperature of the oil pump measure superheat at the expansion valve check that the valve bulb is tightly attached Poor heat exchange in the Check water flow Check fouling evaporator by measuring the water pressure drop Excessive oil migration in the circuit measure evaporating pressure superheat and the temperature of the oil pump F COMPRESSOR CUTS OUT Antifreeze pressure switch tripped Check that the pressure switch is ON ANTIFREEZE PRESSURE operating properly SWITCH Low water flow in the evaporator
36. nical parts inside compressor a Liquid slugging b Expansion valve blocked in open position Broken suction valves Pressure operated water valve fouled water pressure is to high or irregular Low oil charge Water flow to low or water temperature too high in the condenser Condenser tubes fouled Presence of air or incondensibles in the circuit or excessive refrigerant charge Excessive cooling load Check power supply voltage Replace the compressor Replace the compressor Replace the compressor Replace the compressor Check operation of the starter contacts the start up time delay and the condition of the windings Replace the compressor a Check superheat and that the expansion valve bulb is correctly installed b Repair or replace Replace broken valves Clean the valve Install and expansion tank upstream of the valve Add oil Adjust the pressure operated water valve or the thermostat on the cooling tower Clean the tubes Purge incondensibles and or air and recover excess refrigerant Reduce load reduce water flow if necessary 23 L DISCHARGE PRESSURE IS TOO LOW Condenser water flow too high or water temperature is too low Water is very cold at condenser outlet Bubbles in sightglass Low refrigerant charge M SUCTION PRESSURE IS TOO HIGH The compressor runs continuously Too much cooling demand on the evaporator
37. nsport damage Check for missing items Availability of suitable liftin gear slings and spacers UNIT PLACEMENT 0 Shipping crate removed 1 Clearances checked Vibration isolators mounted O Unit set in place Unit levelled CHILLED WATER CIRCUIT All piping checked for leakage Thermometers installed Water pressure regulator installed 1 Balancing valves installed L Flow switch installed System rinsed cleand and filled before being connected to the unit Checked presence of filter on unit inlet and state of cleanliness of the filter Checked operation of the pump and evaporator pressure drop CONDENSER WATER CIRCUIT Checked order of power supply phases for scroll and screw compressor units All piping checked for leakage Thermometers installed Water pressure regulator installed System balancing valves installed System rinsed cleand and filled before being connected to the unit Checked presence of filter on unit inlet and state of cleanliness of the filter Checked operation of the pump and condenser pressure drop ELECTRICAL EQUIPMENT Checked order of power supply phases for scroll and screw compressor units Checked correct direction of rotation of fan motors and proper operation of the latter Direction of rotation of pump correct Control cabinet wired up L Power supply conforms with unit nameplate indications Pump starter and flow switch circu
38. oe UP mee 26 6 3 REGULAR INSPECTIONS 27 6 4 MANUFACTURERS RECOMMENDED INSPECTIONS RECIPROCATING COMPRESSOR 28 30 COMPRESSC 32 Arie OIS HY 34 MES GEN MES GEN 1 RECEPTION OF EQUIPMENT ON SITE 1 1 VERIFICATION OF EQUIPMENT DELIVERED 1 1 1 TRANSPORT Carriage of the equipment is at the risk and peril of the recipitent and the latter is obliged after delivery and unpacking to Check the external appearance of the equipment Check the absence of any shock damage or deformation 1 1 2 DELIVERY OF THE EQUIPMENT Upon delivery the contractor must check that the equipment is in good condition and make sure that the lifting and handling gear is adapted to the configuration of the equipment and that it corresponds to the specifications indicated on the rigging label pasted on the machine the accessories ordered for site assembly have been delivered and are in good condition the equipment delivered corresponds with the order and with the list on the carrier s shipment documents if the unit is delivered with its operating charge of refrigerant that there has been no leakage use an electronic detector Please be reminded that the HCF LENNOX guarantee doe
39. or is also sensitive to temperature and as a consequence the system must be at normal operating temperature to give a meaningful reading 5 Check operating pressures If they are higher or lower than those recorded when the machine was put into service see the chapter on operating incidents p 20 to 25 6 Inspect the entire system so as to detect any eventual abnormality noisy compressor loose casing panels leaky pipes or juddering contacts 7 Record temperatures pressures dates et times and any other observations in the service log 5 2 ANNUAL MAINTENANCE On units with water cooled condensers it is important that the unit be serviced regularly by a qualified technican at least once every year or every 1000 hours of operation Failure to observe this rule can lead to cancellation of the warranty and will clear HCF LENNOX of whatever responsibility A service visit by a qualified technician is also recommended after the first 500 hours of operation after the unit is first put into service 1 Inspect valves and piping Clean the filters if necessary clean the condenser tubes see cleaning the condenser 2 Clean the chilled water piping filters CAUTION The chilled water circuit may be pressurised Observe the usual precautions when depressurising the circuit before opening it Failure to observe these rules could lead to accidents and cause injury to service personnel 3 Clean any corroded surfaces and repaint them
40. r to show that the unit is powered up an emergency stoppage indicator for each compressor an indicator to show stoppage of the compressor via the regulating system through the main control thermostat which is sensitive to chilled water temperature a run light per compressor and a general fan default stoppage indicator on air cooled units On units with CLIMATIC or MASTERTECH controls see the appropriate manual Time delay relay for starting compressor motors one winding at a time option This optional relay is supplied on units ordered with the part winding start system The time delay between starting the first winding and the second winding cannot exceed 0 8 seconds Chilled liquid pump interlock This interlock is made only if the the pump is supplied with the liquid chiller As soon as the unit is powered up and the remote on off for the unit is validated the pump starts running Prior operation of the pumps is mandatory for compressor operation Note on units with CLIMATIC control control of 1 or 2 water pumps is catered for by the control program Flow switch for the chilled liquid option This control device initiates unconditional unit stoppage as soon as the flow of chilled liquid water brine etc ensured by the pump becomes insufficient since this could cause rapid evaporator freeze up When the contact opens due to a lack of flow the unit must stop immediately If the purchaser installs a flow switch himself
41. resistance is lower than 2 m gaohms Never start any motor while the system is under a vacuum 3 2 UNIT START UP 3 2 1 CHECKS TO BE MADE DURING START UP Before starting the unit fill in the check sheet on page 34 of this manual and follow the instructions below to be sure that the unit is correctly installed and ready to operate 1 Thermometers and pressure switches installed in the chilled water circuit and the condenser water circuit Check these safety devices in this order high pressure switch differential oil pressure switch low pressure switch fan control pressure switches and thermostats anti short cycle relay Make sure all indicator lights operate correctly 2 Flow switch installed and wired into the control box 3 With the compressor running check the oil pressure If there is a fault do not restart the compressor again until the source of the problem has been located 4 Check that there is sufficient cooling load on the day the start up is conducted at least 50 96 of the nominal load PROCEDURE TO FOLLOW WHEN STARTING THE UNIT a Press the power ON OFF switch The compressor will only start if the evaporating pressure is greater than the cut in set point of the low pressure switch Evaporating pressure drops steadily the evaporator empties itself of the liquid refrigerant accumulated in it during storage After a few seconds the solenoid valve opens b Check on the sightglass upstream of the expansion valve
42. rly established and that wire gauges are in keeping with the start up and running currents Check tightness of all electrical connections You MUST make absolutely certain that the power supplies applied to the power and control circuits are those for which the electrical panel was manufactured A main isolator switch must be inserted between the end of the power supply cable and the unit to enable total isolation of the latter when necessary Chillers are supplied as standard without a main isolator switch This is available as an option CAUTION 1 Wiring must conform to applicable regulations The type and location of fused isolators must also conform with regulations For the sake of safety install them where they can be seen and in easy reach of the unit 2 Aback up power supply is provided for the crankcase and antifreeze heaters This power supply is independent from the main unit IMPORTANT Operation of a unit with the wrong power supply or with excessive phase imbalance constitutes abuse and is not covered by the HCF LENNOX warranty If phase imbalance exceeds 2 for voltage and 1 for current contact your local electricity company immediately before powering up the unit 2 6 SOUND LEVELS Liquid chillers are a significant source of noise in refrigeration and air conditioning systems Account is taken of technical constraintes both in design and manufacturing sound levels cannot be be improved much further than specified So
43. roper oil return in all cases and prevent liquid from returning into the cylinder heads when the compressor is stopped On units fitted with capacity reducers the piping sizes must be caculated so that gas velocity is sufficiently high when the unit is operating on capacity reduction Non application of these precautions will cancel the compressor warranty a Liquid line Determine the size of liquid lines using 1 Operating conditions at full load 2 Maximum pressure drop of 100 kPa 3 Liquid velocity under 3m s to avoid liquid slugging 4 For liquid risers make sure that liquid subcooling is sufficient to counteract the loss of static pressure and prevent gas flashing b Discharge lines Calculate these to obtain a gas velocity in horizontal and vertical sections that enables compressor oil migra tion and steady return to the compressor Determine the dimensions of liquid lines using 1 2 5 m s minimum in horizontal sections 2 5 0 m s minimum in vertical sections 3 Maximum velocity 15 m s 4 Total load loss in the piping lower than or equal to 1 C at saturation pressure Mechanical isolation of refrigerant lines Isolate refrigerant lines from the building to prevent the vibrations normally generated by the lines to the building structure Avoid bypassing the isolation system on the unit by fixing refrigerant lines or electrical conduits too tightly Any vibrations will be transmitted to the building by
44. s not cover the refrigerant charge In the event of any damage make precise and justifiable claims by registered mail to the transport company within 48 hours of delivery the day of delivery and bank holidays are not counted in this delay A copy of this letter should be addressed to HCF LENNOX and the sales agent or distributor so as to inform them Failing this no action can be taken against the transport company 1 1 3 UNIT NAMEPLATE This shows the complete reference number of the model and enables you to check that the unit corresponds with what was ordered Unit current draw at start up nominal current and unit power supply are also indicated The latter must not be exceeded by 10 15 Current draw at unit start up is the maximum value likely to be attained at the operating voltage indicated The customer s electrical installations must be able to withstand this current It is therefore important to make sure that the unit power supply shown on the unit nameplate agrees with available voltage L USINE DIJON T LES MBURIERES HCF LENNOX a 21600 LONGVIC FRANCE FRANCE peg Now T SERIE SEHIAL ALIMENTATION TE AMEN h ELEC SUPPLY A RUE IL DEMARR COMMANDE GM UP Ld CIA mL Y Kg CIRC 3 MES GEN 1 2 STORAGE When the units are delivered on site they are not always started up immediately and are placed in
45. storage If the units are stored for a medium or long period of time we recommended the following To make sure of the total absence of water in the water circuits To keep the coil protection installed To leave the protective plastic sheets in place To make sure that the electrical boxes are tightly closed To keep any components delivered separate for site assembly indoors in a clean and dry place until unit Start up It is strongly recommended to store units is a dry sheltered place in particular for units that will be installed indoors 2 INSTALLATION 2 1 SAFETY INSTRUCTIONS Installation start up and adjustment of this equipment can be dangerous if certain system specific factors are ignored such as operating pressures electrical components locations roofs terraces and other structures located well above ground level Only highly qualified contractors and technicians with sound knowledge of this type of equipment are authorised to install start up and service it During any service operations observe the recommendations given on labels or instructions sent with the equipment as well as any other applicable safety procedures Follow all safety rules and regulations Wear protective glasses and work gloves Handle heavy or bulky equipment carefully during lifting and moving operations and when setting it on the ground CAUTION BEFORE EACH SERVICE OPERATION MAKE SURE THAT THE UNIT POWER SUPPL
46. sure the high pressure switch monitors efficiency of the condenser Poor efficiency the result of an excessive condensing pressure is usually caused by A dirty condenser Low water flow Low air flow The low pressure switch monitors the pressure at which the refrigerant evaporates in the evaporator tubes Low evaporating pressure is usually caused by Low refrigerant charge A faulty expansion valve An obstructed liquid line filter drier Adamaged compressor cylinder bank unloader The control thermostat monitors chilled water temperature at the evaporator inlet The most common causes of subnormal temperatures in this zone are Low water flow Thermostat setting too low The oil pressure switch monitors oil injection pressure on the compressor Low oil pressure is usually caused by Low oil charge A worn or faulty oil pump A defective crankcase heater causing condensation of refrigerant in the oil sump The above information does not represent a complete analysis of the refrigeration system It is intended to familiarise the operator with unit operation and to provide him with the technical data required to enable him to recognise correct or report a fault Only trained and qualified personnel is authorised to service and maintain this equipment MES GEN 25 6 2 OPERATION AND START UP CHECK SHEET Machine identification File number Year of manufacture NORMAL CONDITIONS OF USE Leav
47. test Replacement of the filter drier cartrides depending on the results of the test above Monitor unit performance and any eventual variations linked to use of the installation INSPECTION VISIT Leak test Operating test with record of measurements taken and functional analysis MAJOR TECHNICAL INSPECTION Inspection visit Acid test Oil change if necessary Replacement of filter drier cartridges if necessary check up on the microprocessor based management system if used Adjustment of safety devices Verification of unit interlocks Lubrication of bearings dampers if necessary 15 000 H VISIT Major technical inspection Inspection of the compressor and replacement of valves springs and seals depending on the type of compressor 30 000 H VISIT Major technical inspection Inspection of the compressors with replacement of the valves springs seals and gaskets bearings discharge valve piston rings Dimensional inspection of the big ends and gudgeon pins replacement of parts as required quotation depending on the type of compressor TUBE ANALYSIS Inspection of water cooled evaporator and condenser tube bundles with an eddy current test to enable potentially serious problems to be anticipated Frequency Every 5 years up to 10 years depending on the quality of water then every 3 years MES GEN 29 VISITES PRECONISEES PAR LE CONSTRUCTEUR LIQUID CHILLERS WITH SCRO
48. to the installation the way the machine is operated the frequency of operation climatic conditions atmospheric pollution etc Only trained experienced personnel can establish strict maintenance procedures adapted to the conditions listed above Nonetheless we recommend a regular maintenance schedule 4 times a year for chillers operating all year long 2 times a year for chiller that only operate during the cooling season All operations must be performed in conformity with the maintenance plan this will extend the service life of the unit and reduce the number of serious and costly breakdowns It is essential to keep a service log for weekly records of operating conditions of the machine This log will serve as an excellent diagnostic tool for maintenance personnel likewise the machine operator by noting down changes in machine operating conditions will often be able to anticipate and avoid problems before they actually occur or worsen The manufacturer cannot be held responsible for any malfunctioning of any equipment it provides if it is caused by a lack of maintenance or by operating conditions beyond those recommended in this manual Shown below and as an illustration only are some of the most common rules applied for maintenance 5 1 WEEKLY MAINTENANCE 1 Check the compressor oil level This should be half way up the sightglass with the machine running at full load Let the compressor operate for 3 to 4 heures before a
49. und levels must therefore be accepted for what they are and the area surrounding the chillers should be treated as necessary The quality of installation can either improve or decrease initial sound characteristics it may be necessary to provide further treatment such as sound proofing or installation of screens around units installed externally The choice of the location for the installation can be of great importance reflection absorption transmission of vibrations The type of unit support is also very important inertia of the room and the structure of the walling interfere with the installation and its behaviour Before taking any other steps first determine whether the sound level is compatible or not with the environment what it is perfectly justifiable and that these measures envisaged will not cause unreasonable cost Determine what level of sound proofing is necessary on the equipment the installation silencer vibration isolators screens and on the building reinforcement of flooring false ceilings wall coverings It may be necessary to contact an engineering office that specialises in sound abatement MES GEN 2 7 UNITS MOUNTED ON RECEIVERS 2 1 CONNECTION OF UNITS ON RECEIVERS Connections between the unit and the condenser must be made by a qualified refrigeration engineer and require several important precautions In particular the shape and dimensions of the hot gas lines must be carefully designed to ensure p
50. ut To prevent air flow to be reversed due to prevaling winds units cannot be completely shrouded with a higher uninterrupted wind shield If such a configuration cannot be avoided an air ejection duct must be installed up to the same height as the surrounding sheild 2 m mini 1 25 m mini NNNNS N 77777777 Unit dimensional drawings enable the optimum position of the units to be determined both for installation and maintenance MES GEN 2 4 WATER CONNECTIONS 2 4 1 WATER CONNECTIONS EVAPORATOR The water circulating pump must be installed upstream so that the evaporator will be subjected to positive pressure Entering and leaving water connections are indicated on the certified drawing sent with the unit or shown in the sales brochure A drainage plug is located at the base of the evaporator A drainage pipe may be connected to this to enable drainage of evaporator water for service operations or for seasonal shut down If the unit uses plate type heat exchangers the use of a water filter in the water circuit upstream of the heat exchanger is mandatory These filters must remove all particles with a diameter greater than 1 mm They may be supplied as an option by the manufacturer 2 4 2 WATER ANALYSIS The water must be analysed the water circuitry installed must include all items necessary for treatment of the water filters additives intermediate exchangers bleed valves vents isolating valves etc
51. with the main disconnect switch option Visually check the oil level in the compressor crankcases bullseyes This level may vary from one compressor to another but should never be higher than the first third of the way up the bullseyes CAUTION Power up the compressor crankcase heaters at least 24 hours before starting the unit as standard this 230 V backed up power supply is user installed This will enable the refrigerant in the crankcases to evaporate off and prevents damage to compressors through lack of lubrication during start up 7 Start the pump s check the flow of liquid to be cooled through the heat exchangers note the inlet and outlet pressures of the latter and using the pressure drop curves calculate liquid flow by applying the following formula actual flow P2 non 2 where P2 pressure drop measured on site P1 pressure drop published by HCF LENNOX for a liquid flow of Q1 Q1 nominal flow MES GEN 8 On units with air cooled condensers check for correct operation of the fans and that the protective grilles are in good condition Make sure that rotation is in the right direction 9 Before making any electrical connections check that insulation resistances between power supply connection terminals is in keeping with applicable regulations Check the insulation of all electrical motors using a DC 500V megohmeter following the manufacturer s instructions CAUTION Do not start any motor whose insulation
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