Liquid Chillers Ingenium

Refrigerating Capacity: 100 - 400 kW

Commissioning checklist

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COMMISSIONING CHECKLIST

LIQUID CHILLERS INGENIUM

REFRIGERATING CAPACITY: 100 - 400 KW

COPYRIGHT
All Rights reserved.
No part of this publication may be copied or
published by means of printing, photocopying,
microfilm or otherwise without prior written consent
of
• GEA Grasso GmbH
or
• GEA Grasso GmbH Halle,
herein after called Grasso. This restriction also
applies to the corresponding drawings and diagrams.
LEGAL NOTICE
This documentation has been written in all
conscience. Grasso takes no responsibility for any
errors occurring in this publication nor for their
consequences.

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COMMISSIONING CHECKLIST

LIQUID CHILLERS INGENIUM

REFRIGERATING CAPACITY: 100 - 400 KW

SYMBOLS USED IN THIS MANUAL

Danger!
This is an important warning. Non-
observance these warnings can cause
accidents with relevant damages on
persons or serious damages on the
compressor or refrigerating plant.

Warning! Caution!

Important!

Hint!

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COMMISSIONING CHECKLIST

LIQUID CHILLERS INGENIUM

REFRIGERATING CAPACITY: 100 - 400 KW

PREFACE
GENERAL INFORMATION

Hint!
Before commissioning the unit and
putting it into service, carefully read the
operating manual of the liquid chiller of
the Ingenium series as well as the user
handbook of the Grasso System Control
and proceed in accordance with the
instructions given in them. The
instructions in the "Safety Instructions
Refrigerant Ammonia" brochure must be
followed.

Tools and accessories required for commissioning

the unit and putting it into service are:
— Filling tube with connecting fittings
— Refrigerant cylinder
— Scales for refrigerant cylinder
— Vacuum pump
Prerequisites for commissioning the unit and
putting it into service are:
— Space for construction
— Cooling load of approx. 70% of project values
— Closed wiring and power supply
— Closed piping
— Heating and cooling agent filled and vented, set
volume flows in accordance with the project
values (see also operating manual: Chapter 2
Commissioning/Operation, Section 2.2)
It must be possible to contact the appropriate
contact partners of the electrical installation and
operating company. After the unit has been
commissioned and put into service, this is followed
by training of the operating company and handover
to the client.

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COMMISSIONING CHECKLIST

LIQUID CHILLERS INGENIUM

REFRIGERATING CAPACITY: 100 - 400 KW

TABLE OF CONTENTS
1 Checklist.................................................................................................................................................. 6
2 Measurement sheet ............................................................................................................................... 9
2.1 Operating parameters of refrigerant circuit ............................................................................ 9

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COMMISSIONING CHECKLIST

LIQUID CHILLERS INGENIUM

REFRIGERATING CAPACITY: 100 - 400 KW

1 CHECKLIST

Unit type: ……………

Reg. no.: ……………
Year of construction: ……………
Date: ……………

Steps OK / completed Not OK / measure, comment

Check the status on delivery

— Protective gas filling (connect check manometer to service
valve, item 2505)
— Insulation
— Painting
— Oil level, compressor
— Plumbing of safety pressure switch (set to 22 bar in the
factory)

Check installation
(see Operating Manual, Chapter 2 Commissioning / Operation,
Sections 1.3-1.7)
— Spring elements (optional)
— Water piping, (for installation on spring elements,
connection must be made using compensators; Installation
of dirt filter)
— Arrangement of set point temperature probe or flow
controller; (see Operating Manual, Chapter 2
Commissioning / Operation, Section 1.4 Cooling agent
system)
— Connection of the liquid-cooled cylinder covers (optional;
see Operating Manual, Chapter 2 Commissioning /
Operation, Section 1.8 Connection of liquid-cooled cylinder
covers)
— Safety valve connection (blow-off line)
— Check the valve positions
— Electrical connections

Leak-tightness test
(see Operating Manual, Chapter 2 Commissioning / Operation,
Section 2.3 Leak-tightness test)
— Only necessary if protective gas filling is leaking

System evacuation
(see Operating Manual, Chapter 2 Commissioning / Operation,
Section 2.4 System evacuation)
— Refrigerant circuit incl. refrigerant filling tube

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COMMISSIONING CHECKLIST

LIQUID CHILLERS INGENIUM

REFRIGERATING CAPACITY: 100 - 400 KW

Steps OK / completed Not OK / measure, comment

First refrigerant fill

(see Operating Manual, Chapter 2 Commissioning / Operation,
Section 2.6 First refrigerant fill)
— Connection of the refrigerant cylinder to the filling valve of
the unit with filling tube
— Fill amount of refrigerant according to weight
— If necessary, top up last amount of refrigerant after the
compressor is switched on
— Observe filling criteria:
1.1 Filling weight according to specification on the
maker's nameplate
1.2 After the initial start-up:
— Refrigerant level in evaporator sight glass approx.
1/3
— At full load, no amount of gas in sight glass of
liquid line
— At minimum partial load, some gas can be
detected in sight glass of liquid line (no overfilling
of the circuit)

Initial startup
(see Operating Manual, Chapter 2 Commissioning / Operation,
Sections 3.1 to 3.5 and GSC User Handbook)
— Check external locking mechanisms
— Voltage connection
— Release emergency stop button and acknowledge on
display with ACK button
— Select the control variable in Operating modes menu:
Cooling agent inlet/ outlet, heating agent inlet/ outlet
— Input of the setpoint temperature in accordance with the
project value
— Switch to "MANUAL" mode
— Switch "Compressor on"
— Increase output
— Check the refrigerant filling, top up with last refrigerant if
necessary

Chiller shut-down
(see Operating Manual, Chapter 2 Commissioning / Operation,
Section 3.6 Chiller shut-down)
— Switch to "MANUAL" mode
— Switch "Reduce output"
— Switch "Compressor off"
— Close stop valves if necessary

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COMMISSIONING CHECKLIST

LIQUID CHILLERS INGENIUM

REFRIGERATING CAPACITY: 100 - 400 KW

Steps OK / completed Not OK / measure, comment

Shut down in the event of dangerous situations

— Emergency stop button function

Automatic drive
(see Operating Manual, Chapter 2 Commissioning / Operation,
Section 3.7 Automatic mode)
Check the prerequisites:
— There is an enable signal from the Central I&C
— Switch-on conditions for compressor fulfilled
— There are no queued faults
— Required output (actual value > setpoint)
Switching sequence:
— Select automatic mode
— Drive to project values, to steady state if possible, check tk2
- to< 5K or tc- tW2 < 3K
— Read operating parameters in steady state with Servicelab
after approx. 20min.

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COMMISSIONING CHECKLIST

LIQUID CHILLERS INGENIUM

REFRIGERATING CAPACITY: 100 - 400 KW

2 MEASUREMENT SHEET

2.1 Operating parameters of refrigerant circuit

User

Refrigerant / Type of oil

Unit type / Manufacturer

Reg. no. / Year of construction
Type of compressor / Manufacturer
Reg. no. / Year of construction
Date/ Time

Operating hours OH

Rating class %

Psuc suction pressure bar

Pdis discharge pressure bar

Tdis compression end temperature °C

Tsuc-t0 overheating K

POiloil differential pressure bar

tC liquefaction temperature °C

tW1 Heating agent intlet temperature °C

tW2 Heating agent outlet °C

temperature
t0 evaporating temperature °C

tK1 Cooling agent inlet temperature °C

TK2 Cooling agent outlet °C

temperature
Oil level in sight glass of compressor
(should be 25-75% of sight glass)
Refrigerant level
in sight glass of evaporator
in sight glass of liquid line
at 100% load
at min. partial load

Remarks

Machinist / Service mechanic

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