INSTALLATION, START-UP AND OPERATION MANUAL AIR COOLED SCREW LIQUID CHILLERS ASQ045B – ASQ440B
INDEX PAGE A. GENERAL Introduction………………………………………………………………………………………………………3 Scope of this Manual……………………………………………………………………………………………3 Safety Consideration & Symbols………………………………………………………………………………3-5 Warranty…………………………………………………………………………………………………………5 B.
INDEX PAGE Discharge pressure control……………………………………………………………………………………54 Electronic expansion valve……………………………………………………………………………………54-55 LCD display data……………………………………………………………………………………………… 55-56 Alarms……………………………………………………………………………………………………………57 Anti-freeze alarm……………………………………………………………………………………………… 57 Oil pressure alarm………………………………………………………………………………………………57 Compressor magnetic circuit breaker…………………………………………………………………………57 Compressor solid state protection system SSPS (winding thermistor)……………………………………57 57 P
GENERAL INTRODUCTION ZAMIL Cooline ASQ-Series liquid chillers are manufactured to provide engineering excellence in comfort air conditioning and industrial cooling with a superior combination of energy saving, performance, application flexibility, ease of service & maintenance, environmental friendliness and ability to withstand extreme ambient temperatures.
Foundation, Support & Isolation: Suitable structural support and vibration isolation must be provided as indicated in these instructions. Failure to do so may result in injury to the operator or damage to the equipment and/or building. Discard Intrusions: The units are not designed to bear additional loads or stresses from adjacent equipment, pipework or structures. Additional components must not be mounted on these units.
( ATTENTION is used to remind or highlight useful information. ATTENTION WARRANTY ZAMIL warrants all operating parts in this equipment against factory defects for a period formally agreed upon in the relevant sales contract. All warranty claims must be supported by proper documentary evidence like copies of invoices, start-up check out reports, maintenance records etc. to justify the validity of warranty.
PRODUCT INFORMATION MODEL DESIGNATION DETAILS 1,2 & 3 BASIC (SERIES) ASQ COOLINE AIR COOLED SCREW WATER CHILLERS 4,5 & 6 UNIT SIZE 45 50 55 60 70 80 90 100 115 130 140 150 160 170 180 190 200 220 230 240 250 260 270 280 300 320 330 340 350 360 380 400 420 440 7 REFRIGERANT B:R-134a 9 10 ELECTRICAL SUPPLY (V-Ph-Hz) 8 CONDENSER TYPE CIRCUIT BREAKER OPTIONS L:380/415-3-50 (4WIRE) A:ALUMINUM FINS A:STANDARD B:PRECOATED ALUM FINS B:COMPRESSOR CIRCUIT BREAKER C: COPPER FINS (SEE NOTE 1 BELOW) 1
STANDARD CONTROL & SAFETY DEVICES AND OTHER ACCESSORIES The chillers are provided with the following items as a standard practice: Microprocessor Controller: This controller monitors analog and digital inputs to achieve precise control & safety functions of the unit. Compressor In-Built Protection Device: Protect the compressor by monitoring: a. Motor winding temperature in case of overload. b. Discharge gas temperature in case of overheating. c. Phase reversal for direction of rotation.
Compressor Circuit Breakers: Protects against compressor branch circuit fault. When tripped (manually or automatically), the breaker opens the power supply to the compressor and control circuit through auxiliary contacts. Liquid Coolers: ASME code stamped liquid cooler. Pressure Gauges: Suction & discharge pressure gauges. Non-Fused Main Disconnect Switches: De-energize power supply during servicing/repair works as well as with door interlock.
PHYSICAL DATA UNIT SIZE ASQ045B ASQ050B ASQ055B ASQ060B ASQ070B ASQ080B ASQ090B ASQ100B ASQ115B 80068315 80068315 80068318 80068321 80068324 80068315 80068315 80068318 80068321 NUMBER OF COMPRESSORS 1 1 1 1 1 2 2 2 2 OIL CHARGE/COMPRESSOR (liters) 15 15 22 22 22 15 15 22 22 400 600 600 COMPRESSOR PART NUMBER (380/415V-3ph-50Hz) 100-25 100-50 CAPACITY CONTROL RANGE (STEPLESS) ELECTRONIC MOTOR OVERLOAD PROTECTION (INTERNAL) INJECTION OIL LUBRICATION TOTAL CRANK
PHYSICAL DATA UNIT SIZE ASQ130B ASQ140B ASQ150B ASQ160B ASQ170B ASQ180B ASQ190B ASQ200B ASQ220B 80068324 80068324 80068324 80068318 80068318 80068321 80068321 80068324 NUMBER OF COMPRESSORS 2 2 2 3 3 3 3 3 4 OIL CHARGE/COMPRESSOR (liters) 22 22 22 22 22 22 22 22 22 COMPRESSOR PART NUMBER (380/415V-3ph-50Hz) 100-16.3 100-25 CAPACITY CONTROL RANGE (STEPLESS) 80068321(2) 80068318(2) 100-12.
PHYSICAL DATA UNIT SIZE ASQ230B ASQ240B ASQ250B ASQ260B ASQ270B ASQ280B 80068324 80068324 ASQ300B ASQ320B COMPRESSOR PART NUMBER (380/415V-3ph-50Hz) 80068321 80068324(1) 80068324(2) 80068324(2) 80068321(3) 80068321(2) 80068321(2) 80068318(4) 80068315(2) 80068318 NUMBER OF COMPRESSORS 4 4 4 4 4 4 6 6 OIL CHARGE/COMPRESSOR (liters) 22 22 22 22 22 22 22/15 22 100-12.5 CAPACITY CONTROL RANGE (STEPLESS) 100-8.
PHYSICAL DATA UNIT SIZE ASQ330B ASQ340B ASQ350B ASQ360B 80068318 80068321 80068321 80068321 NUMBER OF COMPRESSORS 6 6 6 6 OIL CHARGE/COMPRESSOR (liters) 22 22 22 22 ASQ380B ASQ400B ASQ420B ASQ440B 80068324 80068324 80068324 6 6 6 6 22 22 22 22 1800 1800 1800 COMPRESSOR PART NUMBER (380/415V-3ph-50Hz) CAPACITY CONTROL RANGE (STEPLESS) 80068324(4) 80068321(2) 100-8.
MICROPROCESSOR CONTROLLER The microprocessor controller works on a state of art microprocessor technology. This controller monitors analog and digital inputs to achieve precise control & safety functions of the unit. The Software works on the Proportional Integral Derivative (PID) algorithm for precise control logic. The simple to use push button keyboard allows accessing to the operating conditions, control set points & alarm history that are clearly displayed on a multi-line back illuminated LCD panel.
BASIC REFRIGERANT FLOW AND PROCESS & INS. DIAGRAM These chillers work on the concept of Vapor Compression Refrigeration. At the start of operation cycle, the water (or other liquid) flows through the water piping system, the flow switch contact is made, and if the controller calls for cooling and all safety devices are closed, the compressor will start. The compressor raises the pressure of the refrigerant and it is pumped to the condenser.
HANDLING AND STORAGE INSPECTION Upon delivery of equipment, it is important that the following inspection is performed in the presence of transporters and/or Zamil’s representatives: • Check all crates and cartons received against the Invoice / shipping papers to be sure they are complete. • Check model numbers and electrical characteristics on the nameplates of the units delivered to determine if they are correct.
LIFT MODELS:ASQ045B TO ASQ200B LIFT SPREADER BAR PROPER CLEARANCE TO BE PROVIDED Figure A LIFT MODELS:ASQ220B TO ASQ280B SPREADER BAR PROPER CLEARANCE TO BE PROVIDED Figure B MODELS:ASQ300B TO ASQ440B SPREADER BAR PROPER CLEARANCE TO BE PROVIDED Figure C 16 LIFT
STORAGE INSTRUCTIONS If the unit is to be put into storage prior to installation, observe the following precautions: • Store in a dry and clean place preferably sheltered or shaded area. • Place the units on a flat solid surface so that the chiller base does not bend or sag. • Protect equipment from physical damages, store in a location where there is minimal activity, in order to limit the risk of accidental physical damage.
INSTALLATION PROCEDURES PRE-INSTALLATION GUIDELINES These chillers are designed for outdoor installation and can be installed at ground level or on a suitable rooftop location.
19
20
21
22
23
24
25
26
CLEARANCES The installation clearances to be maintained for the various unit models are as follows: B WALL A 2000 B FIGURE 1 STRAIGHT WALL FIGURE 2 CORNER WALL 2000 Notes: 1. All above dimensions are in mm. 2. PIT INSTALLATION: If unit is installed in special pit, please observe the same tolerance for walls. Pit heights should not exceed Chiller height.
28
29
RECOMMENDATIONS FOR SPRING TYPE VIBRATION ISOLATOR SELECTION The following types of spring isolators are recommended for various applications. Any of these spring isolators can be supplied by ZAMIL as optional items. Standard Applications: The SLR series vertically restrained spring isolation mounts are recommended as a noise and vibration isolator for chillers to reduce the transmission of noise and vibration into supporting structures.
LOAD DISTRIBUTION, kgs.
LOAD DISTRIBUTION, kgs.
UNIT INSTALLATION Based on the specific project requirements, choose the type of vibration isolators best suited for the application. Carefully select the vibration isolators’ models / configuration based on the respective point loads and place each mount in its correct position following the foregoing Load Distribution Data and Mounting Points Drawing provided herewith.
COOLER PIPING CONNECTIONS After the unit has been leveled, the external water piping may be made up. The following piping guidelines are served to ensure satisfactory operation of the units. Failure to follow these recommendations may cause damage to the unit or loss of performance and may nullify the warranty. • Water piping must be connected correctly to the unit i.e., water must enter from the inlet connection on the cooler and leave from the outlet connection.
• Thermometer and pressure gauge connections should be provided on the inlet and outlet connections of each cooler. Pressure gauges are recommended to check the water pressure before and after the cooler and to determine if any variations occur in the cooler and system. When installing pressure taps to measure the amount of pressure drop across the water side of the cooler, the taps should be located in the water piping a minimum of 24 inches downstream from any connection (flange etc.
COOLER CONNECTION TYPES Standard chilled liquid connections on all coolers* are of the Victaulic type as shown below: Flanged Cooler Connections as shown below are available as an option and should be specified with the equipment order: WATER REQUIREMENTS Coolers used in these units are made of carbon steel, copper and brass and are suitable for operation with well maintained water systems.
ELECTRICAL CONNECTIONS, POWER AND CONTROL WIRING All units are wired completely at the factory prior to delivery. The connections that must be made by the installer are to the main power source and interlocking with water flow switch, pumps, remote monitoring system and two barrel units water temperature sensor, if any. In connecting power wiring to the unit, the following guidelines must be followed to ensure safe and satisfactory operation of the units.
In regards to the controls and their wiring, please ensure compliance to the following points to avoid Electro Magnetic Interference and to optimise the efficiency of EMI filters: • Make sure that the conducting area around board support holes on main, auxiliary and user boards are very well grounded to the mounting plates through conducting studs, screws and metal spacers.
ELECTRICAL DATA Supply Voltage UNIT SIZE ASQ045B ASQ050B ASQ055B ASQ060B ASQ070B ASQ080B ASQ090B ASQ100B ASQ115B ASQ130B ASQ140B ASQ150B ASQ160B ASQ170B ASQ180B ASQ190B ASQ200B ASQ220B ASQ230B ASQ240B ASQ250B ASQ260B ASQ270B ASQ280B ASQ300B ASQ320B ASQ330B ASQ340B ASQ350B ASQ360B ASQ380B ASQ400B ASQ420B ASQ440B LEGENDS: MCA MOCP RLA LRA CB FCA MTA MOC HP PH PW Nominal (V-Ph-Hz) 380/415-3-50 380/415-3-50 380/415-3-50 380/415-3-50 380/415-3-50 380/415-3-50 380/415-3-50 380/415-3-50 380/415-3-50 380/415-3-50
TYPICAL SCHEMATIC WIRING DIAGRAM (PART WINDING START) HVTB L1 POWER SUPPLY 380V-3PH-60HZ & NEUTRAL 380V/415V-3PH-50HZ & NEUTRAL SEE UNIT NAME PLATE L2 L3 CC4 OLR3 OLR2 OLR4 T1B T2B T3B CB17 CB18 FMC1 CB20 L1J L1K L1L L2I L2J L2K L2L L3I L3J L3K FMC2 FMC3 L3L FMC6 FMC5 FMC4 FMC7 FMC8 1B FM 8 FM 4 FM 2 2 230V-1PH CCA1-1 3A CCA2-1 3B COMP2 OILHTR 2HTR T1 CCA3-1 1J T1 CCA4-1 1K ATB COMP1 OILHTR 1HTR SSPS1 D1 SSPS2 D1 T2 T2 COMP1 SSPS COMP2 SSPS S1( CONTROL POWER)
TYPICAL SCHEMATIC WIRING DIAGRAM COMP LAYOUT COMP1 COMP2 CONTROL PANEL FAN LAYOUT COMP FAN 1 FAN1 CONTROL PANEL FAN3 FAN2 FAN5 FAN4 FAN7 FAN6 FAN8 COMP FAN 2 COMPRESSOR PART WIND WITH CIRCUIT BREAKER OPTION LPS CONNECTION WITH OUT CB (OPTIONAL) L1 MAIN BOARD A7/D7 CC1 OLR1 LPS1 63A CB1A-1 D2(MB) CB3A-1 22A 23A LPS2 1 63B CB2A-1 CB4A-1 22B 23B REMOVE JP3 CC2 OLR2 COMP 2 CBA4-1 CBA2-1 22B 1 CC1 CC2 2 12A CC1A-2 TO CC2A-2 61A 2 CC1A-2 1 ECONOMIZER CONNECTION (OPTION
INSTALLATION INSPECTION It is the responsibility of contractor or owner to verify and ensure that the following essential requirements are complied: Unit installed on flat concrete base and meets the specified clearances. Vibration isolators are installed properly. Ensure that all valves including balancing valves, globe valves, stop valves, motorized valves, drain & air vent connections and flow meters are installed as per the requirement.
START-UP, COMMISSIONING & OPERATING PROCEDURES GENERAL The Start-up and Commissioning of units must be carried out by suitably trained and qualified personnel only preferably by Zamil in accordance with the following instructions. Upon completion of Start-up and Commissioning, duly filled up and certified check out forms for each unit (sample check out form given in appendix of this manual) must be forwarded to Zamil Head Office - Dammam in order to avail the warranty.
• Turn on the chilled water pump, check direction of rotation and adjust the water flow through the cooler to the specified flow rate. Bleed off all entrained air. • Calibrated pressure gauges have been connected to the suction, discharge and oil pressure ports. • Manually energize the condenser fan starters and check the fan rotation which can be changed on 3-phase motors by interchanging any two wires on the main terminal block. • Check the power supply voltage.
System Checkout: • Check all operating pressures & temperatures and subcooling & superheat. • Check liquid line sight glass. The refrigerant shall be bubbles-free clear liquid. Existence of bubbles indicates under charged circuit. • Check the compressor crankcase sight glass for oil level. It should be at or slightly above the center of this sight glass while the compressor is in operation. If not, see below mentioned instructions on “Lubrication”.
Model ASQ-B 045 050 055 060 070 080 090 100 115 130 140 150 160 170 180 190 200 220 230 240 250 260 270 280 300 320 330 340 350 360 380 400 420 440 CURVE NO.
NORMAL OPERATION AND CYCLING Once the unit has been started, all operations are fully automatic. After an initial period at minimum capacity on the lead compressor, the control system will adjust the unit load depending on the chilled liquid temperature and rate of temperature change. If high heat load is present, the controller will increase the capacity of the lead compressor and/or start-up the other compressor.
CAPACITY CONTROL STEPS Capacity control is achieved by cycling compressor ON/OFF and slider capacity control valve. On multiple compressor units, capacity is controlled by a combination of slider capacity control valve and compressor staging. These chillers are equipped with stepless capacity control system on compressors as a standard feature for very accurate response to load requirements and best part load efficiency.
MICROPROCESSOR CONTROL SYSTEM INTRODUCTION This section is to describe the chiller control system. The hardware will have the following characteristics: • Components UL approved. • The components legends, polarity and pin #1 of IC are identifiable on silk screen on PCB. • QC check will be marked on each tested PCB.
The following figure represents schematically the front panel of the controller: On/Off SET COOLINE AIR CONDITIONERS TOUT = 10°C TIN = 15°C COOLING 75% Menu Esc USER SEQUENCE OF OPERATION Machine starting: • If OFF the machine is started pushing the ON/OFF key. • The on LED will be lit. • After 15 seconds of delay the system will be running. Machine shut-down: • If ON the machine is halted pushing again the ON/OFF key. • The on LED will be off.
TEMPERATURE CONTROL Initially, the Control on Leaving or Return Water temperature is being decided and the required water temperature set point (SP) for the plant has to be decided based on the requirement and entered in the corresponding parameters. This set point becomes the reference point for the controller for the staging logic. Now, when the system is started up, the software starts to check al the necessary inputs (Analog) to start the unit.
Effective power 100 (given by chiller) In % of chiller 75 power Step4 Step3 50 Step2 25 Step1 25 50 75 100 Required power (output of PI controller) 8. When a compressor must be switched on the algorithm takes from the available compressors the less used one (not blocked by alarm or timer). This is not applicable if the set up parameter M24 says no compressor hours equalisation. 9. When a compressor must be switched off the system takes the more used one.
Discharge pressure control This procedure is repeated for each circuit controlling locally the discharge pressure. • Fans are switched ON & OFF with a discrete Proportional Integral (PI) like algorithm, which also takes care to equalize the running time of each fan (Equalizing or not is determined by setup parameter M38). • Option is Proportional Speed Control achieved using an analog output 0÷10 V dc that can be enabled through a set up parameter (M34).
MOP management MOP is the maximum allowed value of SP: if SP > M82 the control algorithm is bypassed and the Electronic Expansion Valve should be closed to reach the MOP value: SP < MOP: PI control is enabled MOP< SP < MOP + 5 PSI: the control output is locked SP > MOP + 5: the control output decrease of 0.5% Pulsed Hot Gas Bypass Solenoids The Hot Gas Bypass Solenoid will be managed in pulsed mode, if setup parameter M60 <> 0 and the Unloading are enabled without HGBS (M21=2).
EV12T:xxx EV34T:xxx Evaporators temperatures (show only if M16 =1) RT : Run time HGBS : Hot gas bypass solenoid (xxx = NO/ON/OFF) STAGE : Number of stages (x = 0…8) CP : Number of compressor ON (x = 0….
ALARMS Alarms are handled only if the controller is in ‘on’ status. In case of system failure, the controller displays on the U.I. LCD the relevant error messages complete with the faulty circuit number. Once the alarm condition has been reset, the error messages disappear automatically or, in some particular cases remain until the ESC key is pressed (as shown in the display). When an alarm is present the General Alarm Indication relay is activated.
• Compressor is halted without pump down procedure • Message: ” ALARM COMPRESSOR X SUCTION PRES LOW” • Manual reset through the ESC key after the reset of the alarm condition Discharge Pressure Alarm If PD > (PD_alarm M67) • Compressor is halted without pump down procedure • Message: ” ALARM COMPRESSOR X DISCHARGE PRESS HIGH ” • Manual reset through the ESC key High Pressure Alarm If the HP input is high: • Message: ”ALARM COMPRESSOR N° X HIGH PRESSURE FAULT ” • The system is halted • Manual reset through t
• The compressor is halted • Automatic reset. Fan Protection Alarm If the FP digital input is active: • Message: ” ALARM COMPRESSOR N.X FAN PROTECTION”; • The compressor is not halted (it is a warning, not alarm) • Automatic reset. SYSTEM SETUP Set Point Change The key allow the user to modify (knowing the user password M2), through the keys the control temperature set point (Set_T). The new value will be accepted upon pressing again the button.
Remote Monitoring through gateway Site GSM and Telephone net Chiller unit #1 Chiller controller SB2 IS485 Modem GSM RS232 Chiller unit #2 Chiller controller SB2 GATEWAY • • • • Alarm history Trends recording Real Time Controllers configuration Real time graphs Modem RS232 PC Remote monitoring software IS485 RS485 cable Chiller unit #8 Chiller controller SB2 IS485 TESTING FEATURES Some testing features are embedded in the software to consent a manual control of the board hardware.
7. USER TEST • All led are switched on, display shows “8.8.8.” and every pixel of LCD display is black; To exit the test mode: • Switch board off; • reset dip switch address • switch board on SOFTWARE TEST MODE To enter software test mode: • Switch board off; • set dip switch address to 15 (all dip switch ON) • switch board on The board will act as a master with address #1, and the user interface is active, but the unit can not be switched on. During software test mode all eeprom parameter can be changed.
A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 FP1 TH2 CB2 O2 HP2 FP2 FL EXEN EMERGENCY TBD TBD TBD TBD TBD TBD SSPS (Thermistors) (second compressor) MT Circuit breaker (second compressor); Oil level alarm (second compressor); (only for screw compressor) High Pressure Switch (second compressor) Fans MT protection (second circuit) Flow switch (used only in mother board) External Enable Emergency Mode Enable Spare Pump 1 MT protection; TBC Pump 2 MT protection; TBC Available TBC Available TBC A
MALFUNCTIONS AND CORRECTIVE ACTIONS 1) Controller does not respond to keyboard a) Check serial cable integrity. b) Check serial cable connections on both the User Interface Board and the Main Board. c) Check correct and tight insertion of jumpers TU1 and TD1 on the User Interface Board, main and/or auxiliary board. d) Check dip switches and integrity on the User Interface Board. 2) Several analog values reading incorrectly a) Check correct and tight connection of the probes to the board.
APPENDIX
APPENDIX Page 1 of 2 START - UP AND COMMISSIONING CHECK LIST FOR CHILLERS PRE -START- UP INSPECTION FOR INSTALLATION Description Yes No Yes No Yes No 1. Ensure the presence of vibration isolators. 2. Check the flexible hose connections on chilled water lines. 3. Ensure the water flow switches are in correct locations. 4. Ensure that strainer is installed on chilled water line. 5. Ensure that balancing valves, globe valves, motorized valves etc are installed as per the requirement. 6.
APPENDIX Page 2 of 2 STEPS FOR START-UP & COMMISSIONING Description Yes No 1. Switch on the chilled water pump. 2. Ensure the water-flow is as per design data. 3. Ensure that the flow-switches are functioning properly. 4. Switch on the AHUs to create load. 5. Check motorized valves operation. 6. Open all the refrigerant circuit valves. 7. Ensure correct oil level in the compressor. 8.
APPENDIX Page 1 of 4 CHECK OUT REPORT IMPORTANT: This check out report must be completely filled out and signed (on page 4).In order for the warranty to be valid, send copy of the report to Chiller Eng'g. Manager, Zamil Airconditioners, P.O. Box 14440, Dammam 31424, Saudi Arabia. INSTRUCTIONS: The format of this report is such, that it can be used for a wide range of equipment. Therefore, when filling out this report, complete only the applicable parts.
APPENDIX Page 2 of 4 INSTALLATION DATA Refrigerant type________________________________________________________________ Application: Air Conditioning Refrigeration Liquid line Heat exchanger (economizer) installed? Process cooling Yes Other_______________________ No Liquid line filter drier installed Yes No Liquid line solenoid valve installed? Yes No Liquid line sight glass installed? Yes No Water flow through chiller barrel: Parallel flow Cooler flow : # 1 _______________∆P_____________GPM
APPENDIX Page 3 of 4 UNIT SPECIFICATIONS This information can be obtained from concerned sales engineer or the service manager.
APPENDIX Page 4 of 4 TEMPERATURE READINGS LOCATION CR1 CR2 CR3 CR4 CR5 CR6 CR7 CR8 CR6 CR7 CR8 1. Discharge line at compressor 2. Suction line at compressor 3. Saturation temperature corresponding to suction pressure 4. Suction superheat (2 minus 3) 5. Liquid line entering sub-cooler (economizer) 6. Liquid line leaving sub-cooler (economizer) 7. Saturation temperature corresponding to discharge pressure 8. Liquid line leaving condenser 9. Condenser subcooling (7 minus 8) 10.Condenser air on 11.
APPENDIX PREVENTIVE MAINTENANCE REQUIREMENT FOR ZAMIL ASQ- SERIES SCREW CHILLERS PROCEDURE WEEKLY COMPRESSORS: 1. Check system operating pressures and temperatures. 2. Check oil level. 3. Check condition of oil. 4. Check liquid injection operation. 5. Check operation of capacity control device (slider & solenoid valves) 6. Check crankcase heater operation. 7. Sample compressor oil. 8. Check integral check valve 9. Check pressure relief valve and roller bearings REFRIGERANT FLOW CIRCUIT: 1.
APPENDIX Troubleshooter's guide TROUBLESHOOTER'S GUIDE TO CHILLER PROBLEMS (To be used by suitably qualifed personnel only) SYMPTOMS 1. Unit will not start, no display on microprocessor controller panel. POSSIBLE CAUSE Main disconnect switch open. Close switch, if safe to do so. Faulty wiring or loose connections. Repair wiring or connections. UVM tripped-Fautly power supply. Contact electric utility company to investigate and rectify the problem. Switch ON, if safe to do so.
APPENDIX Troubleshooter's guide SYMPTOMS POSSIBLE CAUSE Reset differential in accordance with job conditions. Rapid fluctuations in cooling demand or Study the load profile carefully and take chiller is oversized. sutiable action. Capacity control slider/ solenoid valves not Check slider operation and its solenoid working properly. valves. Ensure that compressors modulate capacity correctly. 6. Unit / compressors operate Shortage of refrigerant. Repair leak and recharge.
APPENDIX Troubleshooter's guide SYMPTOMS 10. Suction pressure too high POSSIBLE CAUSE Excessive load or chiller is undersized. Insufficient compression - defective compressor. Overfeeding of expansion valve. Expansion valve stuck open. High discharge pressures. 11.Suction pressure too low. Possible Controller message: ALARM COMPRESSOR N.# SUCTION PRES. LOW. 12. Compressor is noisy. 13. Suction line sweating excessively or frosted. (liquid refrigerant flooding compressor) 14. a.
APPENDIX Troubleshooter's guide SYMPTOMS e. Incorrect measurement/ reading of system parameters. Possible controller message: ALARM MASTER X. TR. OUT OF RANGE OR ALARM COMPRESSOR N.# X TR. OUT OF RANGE. f. Unit provided with remote monitoring feature but serial communication with remote monitoring control not functioning properly. Possible controller message: ALARM MASTER SIM NOT READY OR ALARM MASTER GSM LOW SIGNAL 17. Chiller noisy 18. High chiller operating costs.
APPENDIX RECOMMENDED SPARE PARTS ONE YEAR SUPPLY ITEM Compressor Evaporator Condenser fan motor with fan TWO YEAR SUPPLY I UNIT 10 UNITS I UNIT 10 UNITS EACH EACH EACH EACH 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 2 2 1 1 2 - 1 1 1 4 1 1 4 - 1 1 1 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 2 1 2 1 Controls Microprocessor main board Microprocessor user interface board Electronic expansion valve board Electrical Compressor cont
PART LIST (Refer also to common parts list) MODEL NUMBER 045B 050B 055B 060B 070B 080B COMPRESSOR CONTACTOR ASQ 80009868 (2) 80009868 (2) 80009751 (2) 80009751 (2) 80009754 (2) 80009868 (4) COMPRESSOR OVERLOAD RELAY 80009894 (2) 80009894 (2) 80009722 (2) 80009722 (2) 80009722 (2) 80009894 (4) FAN MOTOR CIRCUIT BREAKER 80060685 (2) 80060685 (2) 80060685 (2) 80060685 (2) 80060685 (2) 80060685 (3) FAN MOTOR CONTACTOR 80009851 (4) 80009851 (4) 80009851 (4) 80009851 (4) 80009851
PART LIST (Refer also to common parts list) MODEL NUMBER ASQ COMPRESSOR CONTACTOR COMPRESSOR OVERLOAD RELAY 160B 80009751 (6) 170B 80009751 (4) 180B 80009751 (4) 80009751 (2) 80009751 (2) 80009722 (6) 80009722 (4) 80009722 (4) 80009722 (2) 80009722 (2) 190B 80009751 (6) 200B 80009754 (6) 220B 80009751 (4) 80009722 (6) 80009722 (6) 80009722 (4) 80009751 (4) 80009722 (4) FAN MOTOR CIRCUIT BREAKER 80060685 (6) 80060685 (6) 80060685 (6) 80060685 (6) 80060685 (6) 80060685 (8) FAN MOTOR C
PART LIST (Refer also to common parts list) MODEL NUMBER 300B 80009751 (8) COMPRESSOR CONTACTOR 80009868 (4) 80009722 (8) COMPRESSOR OVERLOAD RELAY 80009894 (4) FAN MOTOR CIRCUIT BREAKER 80060685 (9) FAN MOTOR CONTACTOR 80009851 (18) CONDENSER FAN MOTOR with FAN & GRILL 80023700 (18) MICROPROCESSOR USER INTERFACE BOARD 80064650 MICROPROCESSOR MAIN BOARD 80064645 (3) 80018155 (4) ELECTRONIC EXPANSION VALVE 80018155 (2) ELECTRONIC EXPANSION VALVE BOARD 80064666 (3) SIGHT GLASS 80020100 (6) REPLACEABLE CORE F
APPENDIX MATERIAL SAFETY DATA SHEET SAFETY DATA Toxicity In Contact With Skin In Contact With Eyes Inhalation Stability Conditions to Avoid Materials to Avoid Hazardous Decomposition Products General Precautions Respiratory Protection REFRIGERANT R134a NIL Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous by skin absorption. Thaw affected areas with water. Remove contaminated clothing carefully - may adhere to skin in case of freeze burns.
APPENDIX PRESSURE TEMPERATURE CHART- R134a Temperature ºF 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 Pressure PSIA PSIG 21.2 22.2 23.3 24.3 25.5 26.6 27.8 29.1 30.4 31.7 33.1 34.5 36.0 37.5 39.1 40.7 42.4 44.2 45.9 47.8 49.7 51.6 53.7 55.7 57.9 60.0 62.3 64.6 67.0 69.5 72.0 74.6 77.2 80.0 82.8 85.7 88.6 91.6 94.8 97.9 101.2 104.6 108.0 111.5 6.5 7.5 8.6 9.6 10.8 11.9 13.2 14.4 15.7 17.0 18.4 19.8 21.3 22.9 24.4 26.1 27.
APPENDIX PRESSURE TEMPERATURE CHART- R134a Temperature ºF 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 130 132 134 136 138 140 142 144 146 148 150 152 154 156 158 160 162 164 166 168 170 Pressure PSIA PSIG 115.1 118.8 122.6 126.4 130.4 134.4 138.6 142.8 147.1 151.6 156.1 160.7 165.5 170.3 175.2 180.3 185.5 190.7 196.1 201.6 207.2 212.9 218.8 224.7 230.8 237.0 243.3 249.8 256.4 263.1 269.9 276.9 284.0 291.3 298.7 306.2 313.9 321.7 329.7 337.9 346.1 354.6 100.4 104.1 107.
APPENDIX USEFUL EQUATION AND DATA WATER SYSTEM EQUATION: H = 500 x GPM x ∆ T H GPM ∆T 500 = Total heat (Btu/ Hr.) = Water flow rate (Gallons per minute) = Temperature difference (°F) = Equation factor For systems with glycol solution, this equation can be used with a modified equation factor (depending on the glycol concentration as tabulated below: Ethylene Glycol % GLYCOL SOLUTION TEMPERATURE °F. SPECIFIC HEAT SPECIFIC GRAVITY (1) EQUATION FACTOR FREEZE POINT BOILING POINT 0 +32 212 1.
APPENDIX Valves: Fittings: 83
APPENDIX Piping Specialities: Electrical: 84
In order to ensure trouble-free operation and to avoid damage to this equipment, periodic maintenance is necessary. Careful maintenance attention can pay big dividends in efficient operation, lower operating cost, reduced down time and long satisfactory service life which can be ensured by drawing up a MAINTENANCE CONTRACT with a professional service company like Zamil CoolCare. For more information please contact them at their following addresses.
