TC Manual Air Cooled Chillers

Page 1 of 26
Temperature Control Manual Air Cooled Chillers
Version 0.1 Date: 1/02/2007 Prepared By: Justin Day Engineering Department
Temperature Control Manual
AIR COOLED CHILLERS
TC Manual Air Cooled Chillers.doc
Aggreko Australia Pacific
Page 2 of 26

TABLE OF CONTENTS
Section
Page
IMPORTANT INFORMATION.............................................................................................................3 SERVICE BULLETIN.............................................................................................................................4 1 1.1 1.3 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 1.3.6 1.4 1.5 1.5.1 1.5.2 2 3 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.3 3.3.1 3.4 3.4.1 3.4.2 3.4.3 3.4.2 3.5 3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.6.9 1.6 4 INTRODUCTION................................................................................................................5 Description........................................................................................................................5 Equipment .........................................................................................................................5 Compressor ..................................................................................................................5 Oil Separator ................................................................................................................6 Condenser ....................................................................................................................6 Expansion Valve ..........................................................................................................7 Evaporator....................................................................................................................7 Control Devices ...........................................................................................................7 Applications ......................................................................................................................7 Process ..............................................................................................................................8 Refrigerant Cycle.........................................................................................................8 Oil Cycle ......................................................................................................................8 TECHNICAL DATA ...........................................................................................................9 INSTALLATION, OPERATION AND MAINTENANCE (IOM)................................15 Installation.......................................................................................................................15 Handling.....................................................................................................................15 Foundation .................................................................................................................15 Water Drain Hole.......................................................................................................15 Clearances..................................................................................................................15 Water to Evaporator Connection ...............................................................................15 Commissioning ...............................................................................................................16 Starting the Unit.........................................................................................................16 Operation.........................................................................................................................16 Temporary Shut Down and Restart............................................................................16 Emergency Stop.........................................................................................................16 Final Check ................................................................................................................17 Principal of Operation................................................................................................17 Decommissioning ...........................................................................................................17 Maintenance Procedures .................................................................................................18 Condenser ..................................................................................................................18 Refrigerant Charge.....................................................................................................18 Weekly Maintenance and Checks..............................................................................18 Monthly Maintenance and Checks.............................................................................18 Annual Maintenance ..................................................................................................18 Maintenance Schedules..............................................................................................19 Troubleshooting ..............................................................................................................22 ELECTRICAL ...................................................................................................................25
Page 3 of 26

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
Page 4 of 26

SERVICE BULLETIN
BULLETIN NUMBER REFERENCE SUBJECT
ASB0088A
ISSUE DATE
4th September 2006
YCAS chillers supplied to Aggreko N/A
WITHDRAWAL DATE
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 been especially modified so that they will operate on normal air conditioning duty down to 4oC, low temperature glycol duty down to -12oC and ultra low temperature glycol duty down to -19oC. As for a standard machine, for air conditioning duty dip switch number one must be in the open position. For normal glycol mode (down to -12oC) dip switch number one must be in the closed position. If ultra low temperature glycol is required (down to -19oC) a special procedure is required. Procedure for ultra low temperature glycol operation (down to -19oC). 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). CAUTION Do not operate the chiller in a lower temperature mode than is required for a particular application. Low temperature operation does require close attention to glycol concentration so only ever select glycol mode or ultra low temperature mode when absolutely necessary.
Graham Parry Technical support.
PLEASE FILE THIS BULLETIN IN YOUR APPLIED BULLETIN BINDER AND POST ON THE APPLIED SECTION OF YOUR BULLETIN NOTICE BOARD. TC Manual Air Cooled Chillers.doc Aggreko Australia Pacific
Page 5 of 26

1 INTRODUCTION
This manual contains directions regarding the descriptions, installation, and operations of the Aggreko Air Cooled Fluid Chillers.
1.1
Description
The units are intended for the cooling of water or non corrosive fluids. They are designed to be located outside (rooftop or ground), not in an enclosed plant room or sealed 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 6C water mixture to the lower temperatures of -19C (50% water / glycol mixture).
1.3 1.3.1
Equipment Compressor
The air cooled chiller consists of two distinct components; motor and rotor. A two pole, hermetic, squirrel cage induction motor directly drives the compressor rotors. The motor is cooled by suction refrigerant gas from the evaporator, entering the end of the motor housing through the suction line. The compressor is a semi-hermetic direct drive helical rotor compressor. Each compressor 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 the motor barrel, through a suction strainer screen, across the motor, and into the intake of the compressor rotor section. The gas is then compressed and discharged directly into the discharge line.
Page 6 of 26

1.3.2 Oil Separator
The oil leaves the compressor entrained within the discharged refrigerant vapour, and it is the oil separator that recovers this oil. The separator consists of a vertical cylinder surrounding an exit passageway. As the refrigerant 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. This accumulated 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 refrigerant condensation in the sump.
1.3.3
Condenser
The air cooled condenser coils have aluminium fins mechanically bonded to internally finned 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 while refrigerant 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 is transferred from hot, high pressure refrigerant vapour to the water, refrigerant condenses on the tube surfaces.
Page 7 of 26

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 evaporator temperature to be low enough to absorb heat from the water being cooled, whilst allowing the refrigerant to be at high enough temperature in the condenser to reject heat to 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 the remaining 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. Water connections are grooved pipe for victaulic couplings. Each shell includes a vent, a drain, and fitting for temperature control sensors, and is insulated. Evaporator heaters with thermostats provide protection to the evaporator from freezing at ambient temperatures of -29C.
1.3.6
Control Devices
The unit controls are housed in a weather tight enclosure with removable plates to allow 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 valve modulation, fan sequencing, anti-recycle logic, automatic lead/lag compressor starting and load limiting. The controls also automatically take action to avoid unit shutdown due to abnormal operating conditions associated with low refrigerant pressure, high condensing pressure, and motor current overload. Unit protective functions include loss of chilled water flow, evaporator freezing, loss of refrigerant, low/high refrigerant pressure, phase reversal, and loss of oil flow.
1.4
Applications
The air cooled chiller can be used in a wide variety of applications in various industries. The chiller is often used in conjunction with other Aggreko equipment such as cooling towers, fluid pumps, and heat exchangers.
Page 8 of 26

1.5 1.5.1 Process Refrigerant Cycle
Saturated refrigerant vapour from the evaporator is drawn into the suction opening of the screw compressor. The gas is compressed and discharged through a check valve into 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 refrigerant condenses). In the sub-cooler, which is a part of the condenser, the refrigerant is cooled 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 liquid and gas are separated, the vapour is directed to the evaporator suction. The liquid is evenly 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 of refrigerant evaporates on the surface of the tube, refrigerant vapour exits the evaporator through the suction baffle where is mixes with the vapour from the liquid vapour separator.
1.5.2
Oil Cycle
The compressor oil supply is obtained from the oil separator. Due to the pressure differential between discharge and suction pressure, oil is injected via the oil cooler into the compression chamber and the bearings of the compressor from where it is returned together with the compressed gas to the oil separator. The oil and gas are separated, oil flows down to the bottom of the separator, from where it again flows to the compressor. Oil that gets past the oil separator flows through the condenser, sub-cooler and expansion valve into the evaporator. This oil is collected in the pool of refrigerant that is maintained in the bottom of the evaporator. A small amount of oil and refrigerant from this pool is returned through a line that is connected to the compressor down stream of the motor. This oil and refrigerant mixes with the refrigerant vapour that was drawn out of the evaporator.
Page 9 of 26

2 TECHNICAL DATA
aggreko
Prepared by: Discipline: Section:
Adam Hentschel
Date:
17.12.2002
Revision:
Page 9 of 26
Document number
Fluid Chillers
AIR COOLED SCROLL FC50A
au.1.3
1.
INTRODUCTION
The Aggreko -C- range air cooled fluid chillers are designed for water or water-Glycol cooling. All units are designed to be located outside. The units are completely assembled with all interconnecting refrigerant 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 52 kW at 6 degrees leaving water temperature 19 kW +15 C to -12 C 43C 2.36 metres 1.20 metres 2.11 metres 1250 kg
Cooling Capacity Absorbed Power Temperature Range Maximum ambient temp. Dimensions length width height Weight 3. LAYOUT
Page 10 of 26
aggreko
Adam Hentschel
Date:
17.12.2002
Revision:
Page 10 of 26
Document number
Fluid Chillers

TECHNICAL SPECIFICATIONS
UNITS kW C / C C / C C / C C C / C
au.1.3
4.
ITEM Performance Data Design Capacity Design Operation Fluid Temperature IN / OUT Minimum / Maximum Outlet Fluid Temperature Minimum / Maximum Chilled Liquid Temperature Difference Design Ambient Temperature Minimum / Maximum Ambient Temperature Compressor Compressor Type Number Of Compressors Number Of Capacity Steps Evaporator Data Evaporator Type Evaporator Material Design Flow Minimum / Maximum Flow Evaporator Capacity Evaporator Maximum Working Pressure Design Chiller Barrel Pressure Drop Recommended System Fluid Volume Condenser Data Number Of Condenser Fans kW per Fan Total Air Volume External Static Pressure Refrigerant Data Refrigerant Type Number of Circuits Refrigerant Charge circuit 1 / 2 Type Of Compressor Oil Oil Charge circuit 1 / 2 Electrical Data Design Electrical Supply Voltage Design Electrical Rating Design / Maximum Operating Current Starting Current Pre-Heating Supply Recommended Generator Set Required Cable Size per Phase Electrical Connection Noise Data Sound Pressure Level at 10 metres - Lp(A) Sound Power Level - Lw(A) Physical Data Overall Length Overall Width Overall Height Weight Fluid Coupling Size
VALUE 52 12 / 6 -12 / +15 3.5 / 10.2 35 3 / +43 Semi Hermetic Scroll 2 2/ 50 Plate S.Steel & Copper 2.07 1/4 4 1000 30 315 1 1.2 5.5 0 R22 1 9 025E 7.6
No. / %
l/s l/s / l/s litres kPa kPa litres
kW m/s Pa
kg litres
Volts kVA / kW Ampere Ampere Volts / VA kVA mm
440 3ph / 50/60hz 22 / 19.1 30 / 45 107 N/a 30 10 40A Clipsal Plug 54 82 2.30 1.20 2.11 1250 50 / 2" Camlock
dB(A) dB(A) metres metres metres kg mm / inch
NOTE: Contact Technical Department If Application Conditions Differs From Design Conditions
Page 11 of 26
aggreko
Adam Hentschel
Date:
14.04.1999
Revision:
Page 11 of 26
Document number
Fluid Chillers
au.1.2
1.
INTRODUCTION
The Aggreko -C- range air cooled fluid chillers are designed for water or water-Glycol cooling. All units are designed to be located outside. The units are completely assembled with all interconnecting refrigerant 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 157 kW at 7 degrees leaving water temperature 71 kW +15 C to -12 C 43C 2.80 metres 2.20 metres 2.08 metres 2400 kg
Cooling Capacity Absorbed Power Temperature Range Maximum ambient temp. Dimensions length width height Weight
3.
LAYOUT
Page 12 of 26
aggreko
Adam Hentschel
Date:
14.04.1999
Revision:
Page 12 of 26
Document number
Fluid Chillers

UNITS kW C / C C / C C / C C C / C VALUE
au.1.2
4.
ITEM Performance Data Design Capacity Design Operation Fluid Temperature IN / OUT Minimum / Maximum Outlet Fluid Temperature Minimum / Maximum Chilled Liquid Temperature Difference Design Ambient Temperature Minimum / Maximum Ambient Temperature Compressor Compressor Type Number Of Compressors Number Of Capacity Steps Evaporator Data Evaporator Type Evaporator Material Design Flow Minimum / Maximum Flow Evaporator Capacity Evaporator Maximum Working Pressure Design Chiller Barrel Pressure Drop Recommended System Fluid Volume Condenser Data Number Of Condenser Fans kW per Fan Total Air Volume External Static Pressure Refrigerant Data Refrigerant Type Number of Circuits Refrigerant Charge circuit 1 / 2 Type Of Compressor Oil Oil Charge circuit 1 / 2 Electrical Data Design Electrical Supply Voltage Design Electrical Rating Design / Maximum Operating Current Starting Current Pre-Heating Supply Recommended Generator Set Required Cable Size per Phase Electrical Connection Noise Data Sound Pressure Level at 10 metres - Lp(A) Sound Power Level - Lw(A) Physical Data Overall Length Overall Width Overall Height Weight Fluid Coupling Size
157 12 / 6 -12 / +15 3.5 / 10.2 35 3 / +43 Semi Hermetic Scroll 4 4/ 25 Plate Steel & Copper 7.45 1 / 10 1400 40 208 4 1.2 16.2 0 R22 2 14.45/14.45 025E 11 / 11 440 3ph / 50/60hz 88 / 71 116 247 N/a 100 35 M12 63 91 2.80 2.20 2.02 2400 100 / 4"
No. / %
l/s l/s / l/s litres kPa kPa litres
kW m/s Pa
kg / kg litres Volts kVA / kW Ampere Ampere Volts / VA kVA mm
NOTE: Contact Technical Department If Application Conditions Differs From Design Conditions
Page 13 of 26
aggreko
Adam Hentschel
Date:
14.04.1999
Revision:
Page 13 of 26
Document number
Fluid Chillers
AIR COOLED SCREW FC600A
au.1.1
1.
INTRODUCTION
The Aggreko -C- range air cooled fluid chillers are designed for water or water-Glycol cooling. All units are designed to be located outside. The units are completely assembled with all interconnecting refrigerant piping and internal wiring, ready for installation. 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 612 kW at 6 degrees leaving water temperature 182 kW +15 C to -12 C 40 C standard ISO 20ft. Container. 6.05 metres 2.43 metres 2.59 metres 6820 kg
Cooling Capacity Absorbed Power Temperature Range Maximum ambient temp. Dimensions length width height Weight
3.
LAYOUT
Page 14 of 26
aggreko
Adam Hentschel
Date:
14.04.1999
Revision:
Page 14 of 26
Document number
Fluid Chillers
AIR COOLED SCREW FC600A
au.1.1
4.
UNITS kW C / C C / C C / C C C / C VALUE 612 12 / 6 -18 / +30 3.5 / 10.2 30 0 / +40 Semi Hermetic Screw 2 12.5 thru 100 Shell & Tube Steel & Copper 24.5 15 / 44 204 1000 34 5.66 2520 10 0.85 139 0 R22 2 62 / 62 ISO 68 17 / 17 400 3ph / 50 Hz 213 / 182 308 / 443 543 220 / 600 350 240 Busbar M12 66 94 6.0 2.4 2.6 6820 100 / 4"
ITEM Performance Data Design Capacity Design Operation Fluid Temperature IN / OUT Minimum / Maximum Outlet Fluid Temperature Minimum / Maximum Chilled Liquid Temperature Difference Design Ambient Temperature Minimum / Maximum Ambient Temperature Compressor Compressor Type Number Of Compressors Number Of Capacity Steps Evaporator Data Evaporator Type Evaporator Material Design Flow Minimum / Maximum Flow Chiller Barrel Capacity Chiller Barrel Maximum Working Pressure Design Chiller Barrel Pressure Drop Chiller Barrel Pressure Drop Factor Recommended System Water Volume Condenser Data Number Of Condenser Fans kW per Fan Total Air Volume External Static Pressure Refrigerant Data Refrigerant Type Number of Circuits Refrigerant Charge circuit 1 / 2 Type Of Compressor Oil Oil Charge circuit 1 / 2 Electrical Data Design Electrical Supply Voltage Design Electrical Rating Design / Maximum Operating Current Starting Current Pre-Heating Supply Recommended Generator Set Required Cable Size per Phase Electrical Connection Noise Data Sound Pressure Level at 10 metres - Lp(A) Sound Power Level - Lw(A) Physical Data Overall Length Overall Width Overall Height Weight Fluid Coupling Size
l/s l/s / l/s litres kPa kPa p.u. litres
kW m/h Pa
kg / kg litres Volts kVA / kW Ampere Ampere Volts / VA kVA mm
NOTE: Contact Technical Department If application conditions differ from design conditions
Page 15 of 26

3 3.1
INSTALLATION, OPERATION AND MAINTENANCE (IOM) Installation

Installation of the Chillers is of utmost importance. The operating life will be improved 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 the fluid 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 and able 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 the event of shutdown or repair. Note: Chemicals added to the chilled water system can affect the environment if drained. Ensure water is free of these before draining.
3.1.4
Clearances
Ensure there are sufficient clearances around the unit to allow maintenance operations to take place without obstruction. The following minimum distances are required to prevent condenser air recirculation and faulty operation: a. b. c. d. Front clearance of 1.5m Side and rear clearance of 1.5m Clearance above unit of 10m 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 the evaporator is under positive pressure. The water must enter the evaporator by the inlet connection. Pipe work and fittings must be separately supported to prevent any loading on the evaporator. Flexible connections or hoses are recommended.
Page 16 of 26

3.3 Commissioning
Before starting up the system, the following should be checked; a. b. c. d. e. f. e. Connect 32A auxiliary supply, min preheating time is 4hrs
Chilled water circuits ready to operate, filled with water, pressure and leak tests have been carried out and purging has taken place Ensure that all water and refrigerant valves are in the service position Where mechanical guards are provided these must be in position when the unit is running Check that all electrical connections are clean Close all panel doors Switch on supply circuit breaker
3.3.1
Starting the Unit

a. b. c. d. Switch on the main circuit breaker Start water pump, adjust flow rate with flow valve if necessary Reset alarm (if any) by pressing Reset all active Diagnostics in alarm tab 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 the following conditions are met: a. b. c. d. e. f. Supply voltages are within operating parameters Preheating time elapsed and oil temperature within parameters All anti-recycle timers are timed out All safety systems are within operating parameters Sufficient fluid flow Cooling demand exists
3.4 3.4.1
Operation Temporary Shut Down and Restart

a. b. Press the stop tab on the control panel, compressors will stop To restart the unit, press the Auto Tab
3.4.2
Emergency Stop
A push button located on the unit causes the unit to stop immediately. To restart the unit after an emergency stop, pull out the stop button and reset the alarm on the touch screen.
Page 17 of 26

3.4.3 Final Check
After start up, leave the unit in operation for at least 15 minutes, to ensure that the refrigerant pressures are stabilised. The following must then be checked: a. Both suction and pressure / temperature gauges must show approx 2 - 5C below leaving liquid temperature. (When running at low temp applications, this value can be higher) b. Both discharge pressure / temperature gauges must be approx 15C above ambient air 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. b. c. d. e. f. Press the stop tab on the control panel, compressors will stop Stop all fluid pumps Switch off unit power supplies Disconnect supply cable, lock access panel Drain the chilled water system Disconnect fluid hoses (water circuit to evaporator might be under pressure. Reduce before opening up the system
Page 18 of 26

3.6 3.6.1 Maintenance Procedures Condenser
In some environments the condenser coils may get dirty and shutdown due to high condensing pressure. If this happens, clean condenser coils with a brush or jet of water. 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. Check monthly 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, check the operating conditions and complete the following: a. b. Log the chiller Check evaporator and condenser pressures with gauges and compare to the reading 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. b. c. d. e. f. Review the operating log Clean all water strainers in both chilled and condensing water piping system Measure the oil filter pressure drop. Replace oil filter if required Measure and log the sub-cooling and superheat If operating conditions indicate a refrigerant shortage, leak check the unit using soap bubbles and repair all leaks 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. b. c. d. e. f. g. h. Perform all weekly and monthly maintenance procedures; Check refrigerant charge and oil level; Perform oil analysis; Check pressure drop across the oil filter; Inspect all piping for leakage and damage. Clean strainers; Clean and repaint; Test vent piping of all relief valves for presence of refrigerant to detect improperly sealed relief valves. Replace any leaking relief valves; and Inspect condenser tubes for fouling; clean if necessary.
Page 19 of 26

3.6.9 Maintenance Schedules
The following are the Maintenance Schedules for the Aggreko Fluid Pumps:
Maintenance Schedule for Aggreko's Water-Cooled Liquid Chiller Fleet Series No: FC1200 (RTHA), FC1300 (RTHB), and FC1500 (RTHC) with Helical Rotary (Screw) Compressors:
On Hire and Installation Monthly or at 750 Hours 6-Monthly or at 4300 Hours Completion of Hiring and Decomm. At 36 Cumulative Months of Operation
Item No.
Installation, Operation, and Maintenance Instructions
General: Check and record the following operational data, as much as possible, on Commissioning and Start-up Report Sheet and check monthly and at decommissioning time: 1. ambient air dry bulb and wet bulb temperatures ( C) 2. compressor suction and discharge pressures (kPa) o 3. compressor suction and discharge temperatures ( C) o 4. compressor suction superheat temperature ( C) o 5. low refrigerant temp safety cut out set point ( C) o 6. chilled water leaving temperature set point value ( C) o 7. chilled water return temperature ( C) o 8. low chilled water temp. safety cut out set point ( C) o 9. condenser water leaving temperature ( C) o 10. condenser water return temperature ( 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) 15. current limit set point value (%) Check and record pressure drops through chilled water recirculation system and condenser water recirculation, and compare with design specifications and the job site-specific chiller selection/ rating data. Check and record sump heater operation when unit is off. Check and expedite any undue vibrations on the chiller unit. Seek for solution(s) to rectify. Check and record oil pressure. Compare with the operating range in chiller manufacturer's IOM manual. Check liquid refrigerant flow in sight glass for presence of moisture or any shortage of refrigerant. Check the settings of the HP and LP safety switches and oil control functions and compare with the allowable limit values in the manufacturer's IOM Manual. Reset if necessary. Check motor and drive and record the rated running load current in Amps. Check the existence of any refrigerant leaks. Report the leaks for rectification. Prove solenoid operation, as applicable. Check the functionality of the flow switches on chilled water system and condenser water system, as applicable.
o
3 4 5 6
X X X X X X X
X X
8 9 10
X X X
X X X X X
11
Page 20 of 26

Item No. On Hire and Installation Monthly or at 750 Hours 6-Monthly or at 4300 Hours
Maintenance and Servicing Instructions
Completion of Hiring and Decomm.
At 36 Cumulative Months of Operation
12 13 14
Check the TX valve or electronic expansion valve and superheat, as applicable. Check operation and calibration of chilled water temperature controller to maintain the intended design temperature. Check setting and operation of chilled water, low temperature safety thermostat, and record trip temperature. Check the thermal insulation over the chiller components. Replace or repair if necessary. Re-establish vapour seal around the chiller unit. Inspect corrosion protection device, as applicable. Remove insulation and water boxes. Clean and fit new gaskets. Clean chilled water tubes, plates, bolts, grease threads, and reassemble. Slug dose chilled water upon refilling or replenishing CHW in the recirculation system. Check and clean in-line strainers and scale traps on both the chilled water and condenser water recirculation systems, as necessary, depending on the type of cooling application and quality of the chilled water. Check oil level and top up if necessary. Test oil for acidity. Flush oil sump and change oil, if necessary. Check driers and change if necessary. Check oil filters and change if necessary. Check and align coupling and report on rubber wear. Set unit to work, prove operation. Lubricate and grease all points and linkages. Repair and paint any corrosion, clean generally. Electrical: Check for signs of burnt, hot connections and burnt contacts on starters and relays. Clean, rectify, and tighten. Replace any faulty indicator lights. Examine general condition of conduits, connectors, switches, and wiring, especially when chiller installed in damp and outdoor areas. Check operation of each item of equipment. Check for proper operation of Voltmeter and Ammeter as applicable. Replace faulty meters. Inspect, clean, and replace contacts, as necessary. Inspect relays. Replace faulty relays, as necessary. Check overload ratings against motor nameplate. Check connections to compressor motors, control panel/ MCCB (Motor Control Centre Board), and at points where the equipment is subjected to vibrations. Examine external switches for possible damages to seals. Check all time delays. Check all fuses for correct rating. Replace any safety warning, instructional, and operational labels that have fallen off, damaged, or removed. Check and rectify condition of exposed cable insulation. Strictly follow safe power isolation procedures prior to cable repair works. X X X X X X X X X X
15 16 17 18 19
X X
X X X X
20
21 22 23 24 25 26 27 28 29
X X X X
X X X X X X X X X
X X X
1 2 3 4 5 6 7 8 9 10 11 12 13
X X X X X X
X X
X X X X X X
X X X X X X X X
14
Page 21 of 26

Item No. On Hire and Installation Monthly or at 750 Hours 6-Monthly or at 4300 Hours
Maintenance and Servicing Instructions
Completion of Hiring and Decomm.
At 36 Cumulative Months of Operation
15 16 17 18
Vacuum clean interior of the control panel/ MCCB. Check and ensure that conduits are securely fixed. Examine and rectify the seals on the control panel/ MCCB. Check for the existence of electrical wiring diagram inside the control panel/ MCCB. Check the consistency of the electrical wiring diagram with the actual wiring and the components of the chiller. Ensure that it is 'as-installed'. Report any inconsistencies. Report any required revisions on the electrical diagram as per electrical modifications done or planned. Lubricate all pivot points. Use pure petroleum jelly. Piping and Fittings Associated with Chiller Installation: X X
X X X X
X X X X
19
20 21
X X
X X
1 2 3 4 5 6 7 8
Check rigid and flexible CHW and CDW pipework and valve glands for leaks, and repair leaks. Clean rigid and flexible pipework, wipe flexible pipe connections with grease, as applicable. Check and ensure that all valves are in correct position and orientation. Check proper functioning/ operation of all valves. Check strainers and clean, as necessary, as applicable. Vent all high points in the system, as applicable. Check all vents or scale pockets, vent or drain as necessary. Check condition of pipe insulation, test pipe insulation, as applicable.
X X X X X X X X
X X
X X
Page 22 of 26

1.6 Troubleshooting
Problem
No lights on panel Display A53 not on
Possible Cause
Mains supply to control system not on 1Q5-2 tripped (380V) 1Q5-2 tripped (24V) Power Supply Module A10 Incorrect Phase Rotation
Action
Switch on main supply if safe to do so Reset if safe to do so Reset if safe to do so Check fuse Check Phase Rotation, correct if req Check voltage according to name plate data Check / Replace 1U1 Reset Reset if safe to do so Reset if safe to do so Check / Replace Check / Replace Check / Replace Reset if safe to do so Reset if safe to do so Reset if safe to do so Check / Replace Check / Replace Check / Replace Reset if safe to do so Reset if safe to do so Reset if safe to do so Reset if safe to do so Check / Replace Check / Replace Check display on B31 module to confirm oil temp is slowly rising, check time remaining Check setting on dyna view module Wait until timers are timed out Check setting temp controller Check calibration temp sensors Check set point Check for airflow restrictions caused by blockage Check for fouling of condenser coils Check for damaged fins/return bends Check for correct fan operation Check for recirculation of ejected air Check ambient temp is above design conditions Check leaving water temp is below max operating limits Open service valves Check for signs of air in refrig. system Check sub-cooling is correct Check filter Check / Replace Check / Replace Check / Replace
Unit will not operate
Supply Fault Lit
Voltage outside operating parameters 1U1 faulty
Emergency Stop Main supply
Emergency Stop input is open 1Q531 tripped 1Q532 tripped K8 faulty D20-3 faulty K9 faulty 1Q4 tripped 1Q3 tripped 1Q5-33 tripped D20-4 faulty K10 faulty 1T71 fuse blown 1Q5-31 tripped (main supply) 1Q5-32 tripped (main supply) 1Q3 tripped (auxiliary supply) 1Q5-33 tripped (aux supply) B31 faulty Faulty sensor Oil temp has not reached working temp following power up / or still in 4 hr time delay cycle Set up not correct Unit held off by timers No heat load Incorrect temp reading Incorrect temp setting Discharge high pressure trip due to poor air flow through the condenser coil
Auxiliary Supply Preheating not operational No display
Temperature reading Oil heat delay light on/ compressor lockout Compressor will not start
Compressor locked out Run inhibit Temp Control Mod. Auto display
High Pressure Alarm
Unit operating above load limit
Service valve closed Excessive refrigerant charge Filter Iced up Temperature sensor fault Pressure transducer fault Communication loss Refrigerant filter blocked Bad sensor or LLID Bad sensor or LLID Faulty LLid
Page 23 of 26

Problem
Starter did not transition (Compressor) 180FO 182 Phase reversal (compressor)
Possible Cause
Starter module didnt receive a transition complete signal in designated time. A phase reversal was detected on the incoming current, on a compressor startup No current sensed on one or two of the current-transformer inputs while running or starting. If phase reversal protection is enabled and current is not sensed on one or both current transformer inputs, logic will detect and trip in a max of 0.3 sec after compressor start Compressor previously established currents while running, and then all three phases of current were lost A 40% phase current balance is detected on one phase, relative to all 3 phases (for 90 sec) Currents detected when only 1MI is closed, one of the other contactors is shorted Currents detected with only 1K3 closed. 1M contactor is shorted No currents detected within 1.6 sec during startup sequence The transition complete input found to be shorted before compressor started Compressor current exceeded overload time Line voltage above 10% of nominal Line voltage below 10% of nominal Intermediate oil pressure transducer out of acceptable range for 15 sec, while delta pressure greater then 2.45bar. System differential pressure for respective circuit below 2.45 bar for more than 140 bar-sec System differential pressure for respective circuit was above 19.25 bar for two consecutive Oil temp of respective circuit, as supplied to compressors exceeded 93C for 2 consecutive samples or for more then 10 seconds MP received fault signal from condenser fan Variable speed inverter drive and cant clear the fault The liquid level sensor is near low end of range for 80 continuous minutes while compressor is running
Action
Check power supply
19C 19E
Phase loss (compressor)
Check power supply
1A0 1A2 1B2 1B4 1E9 1EB 1ED 1EF 1F1 1F3 5AC 5AE B EC BC D7 D8 198 19B 1AE 1AF 1C6 1C7 1DD 1DF
Power loss (compressor)
Check power supply
Severe Phase Unbalance (compressor) Starter fault type 1 (compressor) Starter fault type 2 (compressor) Starter fault type 3 (compressor) Transition complete input shorted (compressor) Overload trip (compressor) Over voltage Under voltage Low oil flow (compressor)
Check power supply
Check contactors Check contactors Check contactors
Check compressor Check power supply Check power supply Check pressure transducers
Low differential refrigerant pressure High differential refrigerant pressure
High oil temperature
2A1 5B5 583 5B6
Condenser fan VSD fault
Check speed inverter Check fans Check refrigerant Check expansion valve operation Check liquid level sensor
Low evaporator liquid level
Page 24 of 26

Problem
584 5B7 High evaporator liquid level
Possible Cause
The liquid level sensor is near high end of range for 80 continuous minutes while compressor is running Input signal out of range (low / high or bad LLID)
Action
Check expansion valve operation Check liquid level sensor This info diagnostic will auto reset if input returns to normal range Check signal Change setting to front panel setpoint This info diagnostic will auto reset if input returns to normal range Check signal Change setting to front panel setpoint Run water pump until the diagnostic Auto resets Auto reset occurs when temp rises 1.1C above cutout for 2 mins. Check flow Check flow safety Check flow Check flow safety Reset the clock Check battery
87
External chilled water set point
89
External current limit set point
Input signal out of range (low / high or bad LLID) Leaving chilled water temp fell below leaving water temp cutout set point (chiller stopped) Chilled water temp fell below cutout set point while compressor running Evaporator water flow was not detected within 4.25 mins of unit being started Chilled water flow switch input open for more than 6-10 continuous seconds The real time clock had an error
C5 C6 384 ED 2E6
Low chilled water temp: unit off Low chilled water temp: unit on Evaporator water flow overdue Evaporator water flow lost Check Clock
Page 25 of 26

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)
Page 26 of 26
Chiller capacity
50 kw 157 kw 200 kw 500 kw 600 kw 1300 kw 1500 kw
Fluid pump 3 l/s 10 l/s 10 l/s 30 l/s 30 l/s 75 l/s 75 l/s

TC Manual Air Cooled Chillers

Transféré par

Informations du document

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

TC Manual Air Cooled Chillers

Transféré par

Droits d'auteur :

Formats disponibles

Page 1 of 26

Temperature Control Manual Air Cooled Chillers

Temperature Control Manual

AIR COOLED CHILLERS