Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
AIR-COOLED CHILLER UNITS Operation & Maintenance Manual
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
CONTENTS
1. SAFETY PRECAUTION 2. HANDLING, LOCATION AND FOUNDATION 2.1 Handing 2.2 Location 2.3 Foundation 2.4 The Precautions of Unit Installation With Diagram 2.5 Maintenance Space 3. APPLICATION LIMITED 3.1 Chiller water flow rate 3.2 Chiller water temperature 3.3 Hydraulic pressure of chiller water 3.4 Power source 3.5 Ambient condition 3.6 Re-start frequency 4. NOTICE FOR CHILLER OPERATION 4.1 General 4.2 Notice items for running beginning 4.3 Notice items for everyday running 5. INSPECTION AND NOTICE BEFORE DAILY RUNNING 5.1 Inspection before running 6. OPERATION SEQUENCE 6.1 Sequence of start 6.2 Sequence of stop 7. UNIT MAINTENANCE 7.1 Caution 7.2 Description 7.3 Preventive Maintenance Schedule
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
8. NOTICE FOR PROTECTIVE DEVICE 8.1 High pressure switch: 63H 8.2 Low pressure switch: 63L 9. GENERAL POSSIBLE CAUSES OF FAULT AND SYSTEM TROUBLE SHOOTING 10. ELECTRIC DIAGRAM & LAYOUT
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
1. Safety Precautions
● Before using your equipment, read this to understand its correct using method. ● In this instruction manual, the marks of WARNING and CAUTION emphasize dangerous and important information. 1. WARNING: wrong operation can cause a death or a serious injury on persons. 2. CAUTION: wrong operation can cause an injury on persons or a damage on only materials. 3. Please follow the instructions exactly to avoid causing the above-mentioned harm. 4. We request you to establish safety measures for safe operation and maintenance of your equipment and facilities according to various standards. 5. We are not liable at all for an accident caused by your neglecting these safety precautions. Important Safety Notices: (Please observe following important safety notices) ● Deformation of marks: Strictly prohibited
Follow instructions
Circuit engineering is required
● Keep this manual in a place where you can read it at any time. A. INSTALLATION PRECAUTIONS WARNING (1) Be sure the installation is performed by qualified persons. Improper installation may result in water leakage, electric shock or fire due to improper work.
(2) Installation movement must be performed by qualified and licensed persons to avoid tumbling or falling of the units.
(3) Be sure to install it in a place where it will not be exposed to water and wind. Water and wind could cause electric leakage and electric shock.
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
(4) Electric work must be conducted according to local Electrical wiring regulations. Use of
(5) If any replacement for the parts during installation, be sure to performed by qualified and licensed persons following manufacturer’s instructions. CAUTION (6) Proper grounding engineering work is necessary. Do not connect the ground wire to gas pipes, water pipes, lightning rod, or telephone lines. Improper groundng could cause damage of equipment or electric shock.
(7) Do not install the equipment near heat sources or the place where flammable substances nearby which may cause fire.
(8) Do not install the equipment in an environment like hot spring, coast area and oily places etc. These could cause corrosion, electric shock or fire.
(9) Standard unit (case material is SECC, condenser material is copper tube-aluminum fins) strictly forbid install near acid, alkali environment and hot spring.
B. OPERATION PRECAUTIONS WARNING (10) Do not put fingers or a rod in rotating parts (like fans and pumps etc.) which might cause injury.
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
(11) If the smell of burning arises, stop operation immediately. Asking for professional consulting to fix the problem. It could cause breakdown of the unit if keep operating.
(12) Do not turn the switches (ON & OFF) very frequently in a short period. It may result in damage of the equipment. (13) Do not change second refrigerant type (city water) and concentration. If change second refrigerant type and concentration make chiller exchanger (evaporator) frozen, damaged or chiller unit breakdown and damaged. CAUTION (14) Do not touch switches on the panel or operate with wet hands. Doing so may cause electric shock/
(15) Check the installation area from time to time after the units starting running. Insufficient reinforcement or poor balance would cause water leakage, noise or tumbling of the equipment. (16) The cleaning of air cooling condenser must be performed by professional personnel. Improper handling or any negligence for the cleaning may cause human injury (electric shock CHAPTER 1 etc.) 1.1 TECHNICAL DATA OF MACHINE (17) Be sure to turn off the equipment when cleaning or inspecting the cooling tower fan, etc. ATFM-60Z-C Tube in Filler is applicable theby filling Failure to doAutomatic so may result electric shock or for injury the and fan. sealing of metal tube. Main technical data is marked on the specification Machine Plate of the machine. Nameplate is on the back and lower part of the electric cabinet. The nameplate size is 80 mm × 130 mm. (18) Use only fuses of the specified capacity. Using materials out of the specifications may result in damage to the equipment or cause fire etc. 1.2 CONTENT ON THE NAMEPLATE. (Main technical data) Production (30-60 Tubes/min.) (19) Do not place heavy things on the equipment, starting panel. Injury might happened if the Matching Motor (1.1 Kw) things fall.. External Dimension 1250 x 750 x 1750 mm
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
(20) Please follow this manual about the quality to supply good cooling or chilled water. Bad water quality will bring leaking.
(21) Please add chiller or free water from piping during stop unit for a long time or not run in winter. It will bring leaking when water filled piping all the time.
(22) Do not run the unit by push magnetic contactor compulsively. Abnormal running will catch electric shock or fire.
(23) Do not change settings of safety devices and protective devices. Operation under improper settings may result in damage to the equipment. (If setting value is different between this manual and protective devices label, please comply with devices label.) (24) Do not touch the high temperature side of the compressor & refrigerant tabulation with bare hand. It may cause ambustion to touch the high temperature surface.
C. PRECAUTIONS FOR TRANSPORTATION, REPAIR AND DISPOSAL. WARNING (25) Repair and maintain by professional or ask for them help. Wrong repair will catch electric shock or fire.
(26) Do not reassemble unit. Reassemble unit will catch electric shock or fire.
(27) Order a qualified person or consulting a licensed pro to transport or move the equipment. Improper work may result in water leak, electric shock or fire.
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
CAUTION
(28) Do not use wrong refrigerant or refrigeration oil. Use wrong refrigerant or refrigeration oil will catch blast.
(29) Dispose the detergent properly according to the relative law. Illegal disposal may cause against of law and harm the environment & health of the public.
(30) Do not short circuit of protective device to running chiller. It may be the reason to catch fire or blast.
(31) Once the safety device or protective device trips, remove the cause before restarting the equipment. Restarting without removing the cause may result in damage to the equipment or fire. (32) Do not locked fusible plug of refrigerant. Abnormal fusible plug will catch blast.
(33) Do not touch the air side heat exchanger. Prohibition touch to the heat exchange may cause injury.
(34) Do not change refrigerant type. Refrigerant different from original maybe unit breakdown and damaged.
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
2. Handling, Location and Foundation 2.1 Handling 1) Be careful to avoid rough handling of the chiller unit. Do not push or pull the unit from anything other than the base. Block the pushing vehicle away from the unit to prevent damage to the sheet metal cabinet and end frame. 2) It is must use roller or wire rope to transport unit. Don’t striking or ring the frangible parts that like as cooper tube, valve body or control box...etc. Put cushion material between the wire rope and the unit. Arrange spreader bars and cables to prevent damage to the condenser coils or cabinet (please see next figure).
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
Remarks: Must place the support frame above the chiler, must pay attention to the personal security and prevent chiller’s appearance from being damaged while freighting. 3) It is must to conform the local safety requirement for transport the chiller unit. When handing the unit, ought to consign someone for command and offer the warning device to keep the safety of human and mechanism. 4) Take sufficient care for transport unit and avert excessive swing and shock to prevent damaging the unit and injuring human or building. 5) In the first, please carry out the transport plan of unit that the content ought to include moving date, outline dimensions, unit weight, preparatory opening and transport/hang tool. Like as next table. Table 2-1 Inspect Items for Handling. Items Trasnport
Modify Path
Inspect Items Path
1. Discuss conveyable path (hallway, stair or door...etc.) 2. Discuss hanging path (rooftop, subterranean...etc.)
Unloading
1. Discuss the weight of facilities. 2. Prepare unloading tools. 3. Discuss the temporary area for deposit.
Moving
1. If possible, the large chiller ought to disassemble for delivery and reassemble in the location. 2. If the chiller can’t be disassembling, it is necessary to retaining preparatory opening on the wall or floor for transportation or hang. If necessary, please modify the wall or floor for transportation expendiently.
2.2 Location 1) Chiller units can be mounted on a roof or ground level. Set chiller units on a solid and level foundation. For roof mounted applications, install the unit on a steel channel or I beam frame to support the unit above the roof. For ground level applications, install the unit on a substantial base that will not settle. 2) Be sure the foundation is level (within 12 mm over its length and width). On ground level applications protect the unit against vandalism by using the optional lower wire mesh guards or by erecting a screen fence. The fence must
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
allow free flow of air to the condenser coil for proper unit. 3) The flow of air to and from the condenser coils must not be limited. Restricting air flow or allowing air recirculation will result in a decrease in unit performance and efficiency. There must be no obstruction above the unit that would deflect discharge air downward where it could be recirculated back to the inlet of the condenser coil. 4) The condenser fans are propeller type and will not operate with ductwork on the fan outlet. Install the unit with enough side clearance for air entrance to the coil and for servicing. Provide service access to the evaporator, compressors, electrical control panel and piping components. 5) Each end of the unit must be accessible after installation for periodic service. The condenser fan and motors can be removed from the top of the unit. 6)
A. Unit must not be installed in a pit or enclosure that is deeper or taller than the height of the unit unless extra clearance is provided per not 4. B. Minimum clearance on each side is 2.5m when installed in a pit no deeper than the unit height. C. Minimum side clearance to a side wall or building taller than the unit height is 2.5m provided no solid wall above 2m is closer than 4m to the opposite side of the unit. D. The evaporator can be removed from the side of the unit. E. Do not mount electrical conduits, etc, above the side rail on either side if the unit. f. There must be no obstruction of the fan discharge.
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
2.3 Foundation
1) General air-cooled chiller unit outline: A. Hermetic compressor chiller unit
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
B. Semi-hermetic compressor chiller unit [Up-blast only]:
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
Table 2-2 Base refer dimensions Base refer dimensions Length (mm)
Width (mm)
Height (mm)
A+500
B+400
180
2) The foundation must be made of concrete or steel frame that sufficiently bears the operation weight. 3) When the foundation will locate on the concrete floor or roof, please make the projection and recess on the surface in contact with the foundation; next clean the surface and advisable perfusion before construct. 4) Produce the concrete by mixing cement, sand and gravel on scale1:2:4 and embed the anchor bolts according to the dimension of chiller unit. The foundation ought to finish and level. 5) Install the chiller unit after the concrete of foundation is rigidified. 6) The surrounding of foundation ought to keep smooth drain and don’t exist sump to worsen the ambient environment. 7) Each end of the unit must be accessible after installation for periodic service.
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
2.4 The precautions of unit installation with diagram 1) If the air-cooled unit lay side by side, distance shall be 2 times of the height of dispelling heating coil. (4-side air suction & up-blast type)
2) Air-cooled chillers (condensing unit) shall arrange with more than 1 meter between the rows. (2-side air suction, up-blast and raked-blast type)
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
3) When there are barriers around the air-cooled unit, the barrier can’t be higher than dispelling condenser coil
4) Side-blast type, because the dispelling heating coil is U type, while connecting in parallel, the distance shall be half of the height of dispelling condenser coil.
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
5) Side-blast and raked-blast type shall not connect in column parallel layout, it is apt to cause short cycle with hot wind.
2.5 Maintenance Space Install unit must condenser maintenance space for service hereafter. Suggest minimum maintenance space refer Fig 2-9 and 2-10.
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
3. Application Limited 3.1 Chiller Water Flow-rate
Table 3-1 Chiller Water Flow-rate Chiller Water Flow-rate Minimum
Maximum
-15%
+15% 85~115%
3.2 Chiller Water Temperature General condition:
Items Chiller water outlet temperature Chiller water inlet/outlet temperature difference
Minimum
Normal
Maximum
5ºC
7ºC
15ºC
3ºC
5ºC
7ºC
3.3 Hydraulic Pressure of Chiller Water
The hydraulic pressure of chilled water ought to operating under 6.5kg/cm2 (general hydraulic pressure).
3.4 Power Source
Rating value ±10% (the voltage drop between wiring shall not exceed 3% rating value).
3.5 Ambient Condition
The suitable ambient temperature for chiller running within Items Ambient temperature
Low Temp.
Normal
High Temp.
-20~43°C (High pressure control)
20~43°C (35°C)
21~50°C (Large condenser)
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
3.6 Re-Start Frequency
The re-start frequency of this chiller is limited. Circulating time per cycle (Stop-Stop or Start-Stop): over 10 minutes, stop time: 5 minutes. The chilled water temperature sensor (fixed temperature difference is 2°C) of chiller unit will conform to above necessary, and then the chilled water quantity of circulating piping must maintain the suggested value that listed in the next table. Minimum water quantity (L) = Normal chiller flow-rate (LPM)x 5 (min) Poor water quantity supplied and low loading will cause start/stop frequently, and then the compressor reduces its working day. Therefore, we ought to calculate the volume of chiller water in circulating system by the diameter and length of piping during design work. It is necessary to add buffer tank on the piping system to avoid frequent start/ stop damage compressors if water quantity (water volume of chilled water piping system) less than the suggested value that listed in the above table.
4. Notice For Chiller Unit Operation 4.1 General 1. Conform the limited operation condition that describe in section 3 is necesary, and care the start/stop frequency of compressor especially. 2. If any operating value is installed on the liquid line, it is must full open during chiller unit running. 3. Please inspect the protective device periodically. The suggest period is listed in the next table. Pressure gauge
Least one per year
Full chiller models
Pressure switch
One year
Full chiller models
The chiller unit must be located on the open circumstance where if refrigerant leaking will not cause worker hard breathing or asphyxiation during maintenance. 4. Ground wiring is necessary for chiller unit.
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
5. Chiller unit ought to interlock control with chilled water pump. When the water pump running, then circulating water will actuate the flow switch to start chiller unit.
4.2 Notice Items For Running Beginning Please don’t operating under overload condition in the running beginning because the operating condition of early months will affect the working days of compressor. All valves (if possible) on the liquid line must be full opened during running test. 1. Running the chiller unit under steady condition. Care to keep the stability of high/low pressure and system temperature. Frequent start/stop operating is the main reason of compressor coil burns down. 2. Inspect and then re-start the compressor after 5 minutes if it stops abnormally. 3. The outlet temperature of chiller water ought to keep over normal value -4°C. 4. Inspect water quality and treat it periodically. 5. Please repair it if piping leaking. 6. Inspect fouling condition and clean it. Replace circulating water by fresh water after one week and one month in the running beginning.
4.3 Notice Items For Everyday Running 1. Mechanical items A) Inspect the vibration and noise of any component. B) Check oil leaking or not. C) Check oil level of screw compressor is normal or not. D) Inspect the value of high/low pressure gauge that on the control panel.
Ambient temperature 20~45°C
High pressure gauge (kg/cm2 G)
Low pressure gauge (kg/cm2 G)
{R-22}→15.5~21.5 {R-134a}→9~16
{R-22}→3.4~5.5 {R-134a}→1.5~2.7
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
2. Electric items A) Check the rating voltage is ±10% or not 3.Items for chiller A) Check the chiller water flow rate is normal or not. (±15%) B) Check the temperature of chiller water is too low or not. (>normal value -4°C) C) Check the outlet temperature of chiller water is steady or not. D) Check expansion valve is working normally and the suction line of compressor is frosted or not. Wet compression is always not allowed under any conditions. E) Keep super-heating degree within 8~12°C. 4. Items of condenser A) Check the condenser temperature is too high or not. The value of high pressure must less than 22kg/cm2 G [R22], 15kg/cm2 G [R-134a] under 35°C ambient temperature. B) Check refrigerant leaking or not. The high/low pressure and amphere (full load) will reduce if refrigerant leaking. C) Keep sub-colled degree within 3~8°C. 5. Others A) Check the regular solenoid valve is working normally or not. B) Check protective device is working normally or not. C) Record running condition.
7. Unit Maintenance 7.1 Caution 1) Service on this chiller unit is to be performed by qualified refrigeration personnel familiar with chiller unit operation, maintenance, correct servicing procedures, and the safety hazards inherent in this work. Causes for repeated tripping of equipment protection controls must be investigated and corrected. 2) Disconnect all power before doing any service and maintenance. 3) Anyone servicing this equipment shall comply with the requirements set forth by the local ordinances in regards to refrigerant reclamation and venting.
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
7.2 Description
1) On initial start-up and periodically during operation, it will be necessary to perform certain routine service checks. Among these are checking the liquid line sight-glasses, taking condensing and suction pressure readings. A recommended maintenance schedule is located at the end of this section. 2) It is suggested that the maintenance log be completed on a weekly basis. The log will serve as a useful tool for a service technician in the event service is required. 3) No routine lubrication is required chiller units. The fan motor bearings are permanently lubricated and no further lubrication is required. Excessive fan motor bearing noise is an indication of a potential bearing failure. 4) Electrical terminals should be checked semi-annually for tightness. 5) The condensers are air-cooled and no maintenance is ordinarily required except the routine removal of dirt and debris from the outside surface of the fins.
7.3 Preventive Maintenance Schedule Operation
Weekly
Monthly (1)
Annual (2)
Complete unit log and review (3) Visually inspect unit for loose or damaged components Inspect thermal insulation for integrity Clean and paint as required Check terminals for tightness, tighten as necessary Clean control panel interior Visually inspect components for signs of overheating Verify compressor heater operation Test and calibrate all safety on operating controls Leak test Check sight glasses for clear flow Check filter-drier pressure drop
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
Operation
Weekly
Monthly (1)
Annual (2)
Perform compressor vibration test Clean condenser coils (4) Check fan blades for tightness on shaft (5) Check fans for loose rivets and cracks Check coil fins for damage
1. Monthly operations include all weekly operations. 2. Annual (or spring start-up) operations include all weekly and monthly operations. 3. Log readings can be taken daily for a higher level of unit observation. 4. Coil cleaning can be required more frequently in areas with a high level of airborne particles. 5. Be sure fan motors are electrically locked out. Accessories Pressure gauge, solenoid valve, liquid indicator, filter drier, receiver, angle valve.
8. Notice For Protective Device The necessary protect devices or switches are installed in the inner of power panel to keep chiller unit running safety and automatically. The initial trip setting has finished by fabricator. Please check the setting of protective device per year and attend something like as follow: 1) To avoid accident, the protective device need inspect by professional. 2) Check the liquid line valve and safety valve are all open. 3) If protective device tripped and then reset to re-start, please check the device is normal or not after 5 minutes.
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
8.1 High pressure switch: 63H Trip Value [R-22]→28kg/cm2 G
Trip & Cut out
[R-134a]→18kg/cm2 G
Check process 1) Disconnect secondary side wiring of electromagnetic switch of fan motor. It is necessary to connect the hose of high-pressure gauge to liquid line in the high-pressure side if unit no high- pressure gauge. 2) Turn on the main power and control unit. 3) Power on chilled water pump. 4) Push button or switch to [ON] and then chiller unit running. 5) High pressure uprising, and then record the value of high pressure when the high-pressure switch tripped. Push the button [OFF] to stop unit if the high-pressure switch not trip when high pressure is come to 0.7kg/cm2 G [R-22], 18kg/cm2 G [R-134a]. 6) Recover the water quantity of condenser to the normal value, and then push the reset switch when running after 5 minutes. The abnormal indicator of high pressure will go out. 7) Turn off the power of chiller unit. 8) Push the button [OFF] to stop after inspection. 9) Power off the chiller water pump.
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
8.2 Low pressure switch 63L Trip Value [R-22]→ G
Trip & Cut out
[R-134a]→ 1kg/cm2 G
Check process 1) Turn on the main power and control circuit. 2) Power on chiller water pump. 3) Push button or switch to [ON] and then chiller unit running. 4) Close the liquid angle valve of condenser slowly, and then record the value of low pressure when the low-pressure switch tripped. Please keep the low pressure over 0.5kg/cm2 to avoid non-condensable gas inrush to refrigerant system. 5) Full open liquid angle valve and low pressure uprising then push the reset switch. The abnormal indicator of low pressure will go out. 6) Push the button [OFF] to stop after inspection. 7) Turn off the power of chiller. 8) Power off cooling and chilled water pump.
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
9. General Possible Causes Of Fault & System Troubleshooting. Problem
Possible Causes
Possible corrective steps or methods
Compressor will not run
1. No power supply. 2. Fuse blown. Circuit breakers open. 3. over-replay of compressor tripped 4. Defective contactor or coil. 5. System shutdown by safety devices 6. Liquid line solenoid will not open 7. Motor electrical trouble 8. Loose wiring for control circuit
1. Check and power on 2. Check electrical circuits and motor winding for shorts or grounds. Investigate for possible overloading. Replace fuse or reset breakers after fault is corrected. Check for loose or corroded connections. 3. Check, repair and replace 4. Repair or replace 5. Determine type and cause of shutdown and correct it before resetting safety switch 6. Repair or replace solenoid coil. Check wiring 7. Check motor for opens, shorts, or burnout 8. Check all wire junctions. Tighten all terminal screws.
Compressor noisy or vibrating
1. Compressor running in reverse 2. Improper piping support on suction or discharge 3. Worn compressor isolator bushing 4. Worn compressor
1. Check unit & compressor for correct phasing 2. Relocate, add, or remove hangers. 3. Replace 4. Replace
High Discharge Pressure
1. Non-condensable gas in system 2. System overcharged with refrigerant 3. Discharge shutoff valve partially closed 4. Fan wiring not correct 5. Fan not running 6. Dirty condenser coil 7. The motor of fan rotation reversed.
1. Purge the non-condensable gas used accepted practice 2. Remove excess, check liquid sub-cooling 3. Open valve 4. Check wiring 5. Check electrical circuit, check fan motor 6. Clean oil 7. Rewire for phase change
Low Discharge Pressure
1. Wind blowing into coil at low ambient 2. Faulty condenser temperature regulation 3. Poor refrigerant or refrigerant leaked 4. Low suction pressure 5. Only one compressor operating
1. Shield coil from direct wind 2. Check condenser control operation 3. Check for leaks. Repair and add refrigerant 4. See corrective steps for low suction pressure 5. See corrective steps for compressor will not stage up.
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Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
High Suction Pressure
1. Excessive water temperature 2. Excessive load 3. Expansion valve overfeeding 4. Compressors running in reverse
1. Check control settings 2. Reduce load or add additional equipment 3. Check remote bulb. Regulate superheat 4. Check for proper phasing
Low Suction Pressure
1. Lack of refrigerant 2. Clogged liquid line filter drier 3. Expansion valve malfunctioning 4. Condensing temperature to low 5. Compressor will not unload 6. Insufficient water flow 7. Air in the chiller pipe or chiller
1. Check for leaks, repair and add charge. Check liquid sight-glass 2. Check pressure drop across filter drier. Replace 3. Check and reset for proper supuerheat 4. Check means for regulating condenser temperature 5. See corrective steps for compressor staging intervals too low 6. Adjust flow 7. Air purge.
Compressor will not stage up
1. Defective capacity control 2. Faulty thermostat stage or broken wire 3. Stages not set for application
1. Replace 2. Replace 3. Reset thermostat setting for application
Compressor Staging Intervals to short
1. Thermostat control band not set properly 2. Erratic water thermostat 3. Insufficient water flow
1. Set control band wider 2. Replace 3. Adjust flow
Compressor Oil Level Too high or Too low
1. Low oil level 2. Loose fitting on oil line 3. Level too high 4. Insufficient water flow - level too high 5. Excessive liquid in crankcase – level too high
1. Check and add oil 2. Check and tighten system 3. Adjust thermal expansion valve 4. Adjust flow 5.Check crankcase heater. Reset expansion valve for higher superheat. Check liquid line solenoid valve operation.
Compressor loses oil
1. Lack of refrigerant 2. Excessive compression ring blow-by 3. Suction superheat too high 4. Crankcase heater burnout
1. Check for leaks and repair. Add refrigerant 2. Replace compressor 3. Adjust superheat 4. Replace crankcase heater
1. Low voltage during high load conditions 2. Defective or grounded wiring in motor 3. Loose power wiring 4. High condenser temperature 5. Power line fault causing unbalanced voltage
1. Check supply voltage for excessive line drop 2. Replace compressor motor 3. Check all connections and tighten 4. See corrective steps for high dishcarge press. 5. Check supply voltage. Notify power company. Do not start until fault is corrected.
Motor Overload Relays or Circuit Breakers Open
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1. Operating beyong design conditions 2. Discharge valve partially shut 3. Blown compressor internal gasket
Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
1. Add facilities so conditions are within allowable limits. 2. Open valve 3. Replace gasket
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10. Electric Diagram & Layout
Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
30 Layout 1
Operation & Maintenance Manual AIR-COOLED CHILLER UNITS
31 Layout 2
Operation & Maintenance Manual AIR-COOLED CHILLER UNITS