OPERATION & MAINTENANCE MANUAL WATER / OIL / COOLANT CHILLER Werner Finley Pvt. Ltd. Industrial Cooling Systems Hot Line No. : 91-80-65369825Werner Finley CONTENT Chapter Description Page No Chapter 1 Certificates 1.2 Design data 3 Operating limits 4 Chapter 2 Introduction 4 General description 4 Inspection 4 Handling and lifting 5 Chapter 3 Locating 3 Foundation & Anti-vibration Mounts 5 Location 5 Tips 6 Chapter 4 Liquid Piping 7 Typical Piping Layout 8 Immersion Type 9 Installation Check Report 10 Chapter 5 Start-up & Operation Preparing the system for start up. ul Start up & operation 12 Emergeney Stop 13 Sequence of Operation 14 Chapter 6 Refrigeration 15 Refrigeration cycle 16 standard controls 17 Chapter 7 Trouble Shooting Chart 19 hanes Maintenance Chapter 8 Safety 21 system Maintenance 23 Tips for preventive maintenance 24 Schedule & warnings 25 Chapter 9 Service System Service Refrigeration Line Service Chapter 10 | Temperature Controller Dixell 30 Subzero 31 Chapter 11 | Technical data Temperature conversion chart 32 Pressure, Temperature Chart 33Werner Finley Pvt. Ltd. Industrial Cooling Systems #9, Cauvery Nagar, Near Swayam Prabha Kalyana Mantapa, Magadi Main Road, Kamakshipalya, Bangalore 560 079. Ph, 080-23289889, 23288371 Fax : 91-80-23283191 E-mail: info @wemerfinley.com TEST CERTIFICATE PRODUCT SERIAL NO. CUSTOMER P.O. No. It is certified that the above Chiller has been inspected for its specification, material inputs, workmanship capacity and performance. The results are found to be satisfactory For Werner Finley Pvt. Ltd.Werner Finley Pvt. Ltd. Industrial Cooling Systems #9, Cauvery Nagar, Near Swayam Prabha Kalyana Mantapa, Magadi Main Road, Kamakshipalya, Bangalore 560 079. Ph, 080-23289889, 23288371 Fax : 91-80-23283191 E-mail: info @wemerfinley.com GUARANTEE CERTIFICATE PRODUCT SERIAL NO. CUSTOMER P.O. No. We hereby guarantee to replace at free of cost any component found defective due to bad workmanship or faulty raw materials in the above supply. The defects, which occured due to transit, bad storage, misuse or mishandling of the equipment at customers site or due to normal wear and tear will not be entertained. This guarantee will be valid for a period of twelve months from the date of supply. For Werner Finley Pvt. Ltd.AY Cer a lil 01. UNIT SERIALNO. - 02. TYPEOF CHILLER - 03. COOLING CAPACITY - ss Kealttr 04. POWER SUPPLY - 1 PH, 230 V, AC, 50 HZ 3 PH, 440 V, AC, 50 HZ 05. POWER/CURRENT — - 06. APPLICATION - 07. LIQUIDTYPE & QTY. - 08 CONDENSERTYPE - AIR COOLED - WATER COOLED 09. NO. OF FANS - 10. EVAPORATOR TYPE - COIL IN TANK - SHELL AND TUBE - PHE 11, REFRIGERANT : Ri34a / R407 / R22 / RA04a 12 PUMP - FLOW, PRESSURE 13. TEMP.CONTROLLER - 14. COLOUR - SEIMENS GREY ADMIRAL GREY BLUE OTHERSAY Cer a lil OPERATING LIMITS, Standard Air-cooled, reciprocating, liquid chiller packages. Description Unit R22/R 134a Min/Max. liquid temperature *c 7/28 Leaving the evaporator Min/Max. liquid temperature ie 12/30 entering the evaporator. Min/Max. operating ambient temperatures. c 15/45 Min/Max. flow late of liquid across LPM 12/20 Evaporator per TR Units outside given standard operating limits are also available, for details please contact our Head Office at Bangalore. INTRODUCTION General deseription . Werner Finley liquid chillers are complete, self-contained, automatic refrigeration units that are ready for installation. . ‘These units include the latest engineered components and efficient Chiller. embled to provide a compact . Each unit is completely factory assembled, wired & pressure tested before charging of refrigerant. The unit undergoes thorough load test before dispatch Inspeetion . Upon receipt of the units at site, ensure the complete shipment against delivery note or Bill and also inspect the unit forany transit damage. . If transit damage is found, report the damage to the transporter and file for insurance claim, PyAY Cer a lil Handling andllifting « _ Alwayskeep the unitin vertical position as per arrow displayed on the wooden box. * _ Dismantle the wooden packing. * _Lifling hooks/eyebolts are provided at the top of unit. Use them forsafe lifting. ¢ _ Insome units where lifting hooks are not provided, sling the unit from base to lift safely. ¢ Handling of the unit should be done with the aid of qualified personnel's who are familiar and experienced with this type of equipment Note: I damage (o unit after acceptance will not be covered for rework under warrant LOCATING Foundation and Anti Vibration Mounts + Wemer Finley units have very minimum vibration units and do not require any special type of mounting. © These units can be set directly on the floor or rooftop or any platform with adequate support system, Shelter to be provided in case of outdoor installations. © Anti vibration mounts can be used and can be of Neoprene rubber material, «For Immersion type units beading should be provided on the frame where it is to be mounted, to avoid metal to metal contact. Location + Eachside of the unit must be accessible for periodic maintenance and service work. * Theunitshould maintain a good clearance from the surrounding walls for good air exchange. * Thearea should have good ventilation system or exhaust system. 5Werner Finley Tips on Location Select Location w.r.t. clearances from adjacent walls / obstructions Electrical cabin XQ coco ty Water Inlet / Outlet Note: Upper side clearance should be atleast 2 m from the top of the chiller Inait-cooled units, condenser air inlet and condenser fan air discharge must be free from any obstructions. Units that are not given enough clearance, will experience coil starvation and hot air re-circulation and would affect the performance of the chiller. Hence, free air supply and free hot air ventilation is a mustat the site of installation of an air-cooled chiller. ‘The discharge of the condenser is hot and is exhausted out through the cut out provided (normally top) Ifrequired, ducts can be used to vent this hotair out. Aprofessional should take up the ducting workAY Cer a lil LIQUID PIPING In most chillers, the pump is included in the package and only the end connections are to bemade at the site. [he pipeline could be of flexible hose or pipe one depending on the pressure and preferences. Flexible hose should be properly clamped to avoid leakage. * Flexiblehosescan subjected to pinching if supports are not provided. + Theinlev/outlet pipeline diameters should not be reduced or increased. Rigid pipeline should be of stainless steel or any non corrosive material pipe to avoid rusting, «Provide isolation valves at inlet / outlet connection to chiller. Providing vibration isolators of the right diameters at the inlevoutlet of the chiller, where ever the piping its rigid. Providing an air vent in the pipeline is a good practice to vent the trapped air in the pipeline during startup, ¢ _ Itis recommended to use a wire mesh strainer at the inlet to chiller, The size of the strainer should be at par with the rate of flow of impurity through the pipeline running above the tank. « NRV[Non Return Valve] should be provided in case of lengthy pipelines ru tank. ning above the «Incase, where flow consistency cannot be assured, it is highly recommended to install a flow switch in discharge pipeline and interlock the same with the chiller. «As much as possible try giving a positive suction to the pump. If not, use a self priming pump with a foot valve at the suction, Also provide an opening with a valve in the discharge line for priming the pump. «Please inform our engineering team well before if the pump is subjected to negative suction «Sharp and too many bends will create a back pressure and reduce the liquid flow through the system. ‘¢ Ifthereisa heavy condensation, insulation to be provided for the liquid lines. ¢ Usingunions or flanges of correct sizes wherever necessary helps for easy maintenance. Note: Werner Finley will not be responsible if chiller or pump fails or malfunctions due to foreign particle entry, reduction in flow, bad piping, pump starvation, freezing of heat exchangers, ete.AY Cer a lil Typical Piping Layout LABELS WATER PRESSURE GAUt VALVES, BRATION ELIMINATOR Y-STRAINER AIR VENTSee at y Immersion Type Chiller Complete coil to be immersed in fluid. Electrical float switch is a must. . Stirrer for larger tank is a must for agitation. . Lifting arrangement is a must for periodic coil cleaning. NOTE: SOFT WATER OR DM WATER CAN BE USED AS THE FLUID. PEROIDIC CLEANING OF TANK AND REFILLING OF FRESH WATER ISAMUST. FLUID CONTAMINATION CAN LEAD TO PUMP FAILURE, FREEZING OF HEAT EXCHANGERS & EVENTUALLY COMPRESSOR FAILURE. ILURE DUE TO ABOVE REASONS WILL VOID THE TILLER WARRANAY Cer a lil ALLATION CHECK REPORT Customer Unit SL. No. Unit Cap PARTICULARS 01 | Incase of transit damage, has it be attended completely? YesNo. 02 | Is there any damage during installations? YesNo. 03 | Have damages as per list been attended? Yes/No. 04 | Whether unit is mounted as per recommendation? Yes/No. 05. | Is there free space to attend chiller? Yes/No. 06 | Has the piping & insulation been done as per recommendation? Yes/No. 07 _ | Has sufficient space been left for condenser air entry and service facility? Yes/No. 08 | Sufficient space to clean evaporator? Yes/No. 09 | Power supply & supply cable as per recommendation? Yes/No. 10 ient space for attending electrical panel? Yes/No. 10See at y START UP AND OPERATION NOTE: DO NOT ATTEMPT TO START THE CHILLER UNTILL THE FOLLOWING CHECKS HAVE BEEN COMPLE’ e With mains disconnected, check all electrical connections in control panel. All though all connections are tightened at factory, they might have loosened up during shipment, which may cause system to malfunction, Check the actual line voltage to the unit to make sure itis the same as specified on the chiller tion plate within _+10% and that the phase voltage imbalance does not exceed 6. Verify that adequate power supply & capacity is available to meet the required load % OfVolta; imbalance 100 xMax. Voltage deviation from average average voltage The maximum voltage deviation in the large: difference between a voltage measurement across two legsand the average acrossall thr EXAMPLE a) Supply voltage is 415V - 3PH-S0Hz Voltage across RY - 410V YB - 419V BR - — 405V Average = 411.33 b) Maximum deviation from average voltage RY =1.33V; YB=7.6V; BR =6.33 V Hence Max. deviation is 7.6 V. c) %voltageimbalance=100 x 767UU = 1.86% 411.33 than the allowable 10% imbalance. 41AY Cer a lil © Make sure that all interlock wiring is as per the wiring diagram provided in the control panel pouch © Check lubrication oil level in the compressor sight gle should beat least 1/3 of the sight glass. s. The oil level before start up © Now turn the main switch on, this will energize the crankease heater. (Crankcase heater is available on models above 4 TR capacity) NOTE: Crankcase heaters have to operate at least 12 hrs prior to start up. Crankcase should be warm. © Inunits that have suction, discharge valve on compressor and liquid line hand shut off valve, check for them to be in open condition. © Check all liquid line valves and keep them open, Now switch on pump and check for leakage in pump & pipeline. © Set the required flow & pressure by using the balancing valves at the discharges, by pass & return line. Measure the flow using a graduated vessel & ensure it is inline with the system requirement. START-UP & OPERATION: @ Please check whether all the MCB/MPCB are in on condition. Now once the proper flow is assured by switching on the pump, then tum on the switches for the compressor & fan simultaneously. © The fluid temperature is now sensed & if its higher than the set point, the comp & fan will start to operate & the crankcase heater will turn offautomatically. @ Once again check the setting of the OLR, HP, LP & AFT switches for correctness.AY Cer a lil Now the compressor will work to bring down the fluid temperature to the set point. Once the fluid temperature reaches set point, the compressor & fan will cut off and the pump will still be in operation. © Again as the fluid gains temperature & raises equivalent to the set differential, the signal is taken up by the delay timer, after a preset delay of 3 minutes, the compressor & fan again cuts in to lower the fluid temperature * While unit is fully loaded, check suction pressure, dischar comp/fan/pump current and compressor shell temp. e pressure, * Should you face any problem, refer to the chapter on trouble shooting. EMERGENCY STOP * _ Tumoffthe rotary switch during such situations © Stopon weekend or temporary shut down. * Switch off the circuit breakers in the control panel & keep the main switch on during such shutdowns. ¢ Extended shutdown In larger units where there is a liquid line hand shut off valve, close the valve, run the system & monitor the suction discharge pressure through gauges. Allow all the gas to pump down to the condenser side & switch off the unit. Now close the suction discharge valves in the compressor, close the liquid isolation valvesas well. ¢ — Tostart the unit again, follow the steps from START UP. NOTE: Crankcase heaters have to operate at least for 12 hrs before start up & the crankease should be warm. Open all valves before starting 13See at y SEQUENCE OF OPERATION FOR LIQUID CHILLERS. ACTIONS REMARKS Step 1 a) Check all electrical connections are tight. | ) Shall be wi Initial b) Check the supply voltage is within 10% permissible limits. ©) Check the entire refrigerant & liquid cireuit valves are open. 4) Should be 13rd d) Check oil level in oil sight glass. or 1/2 the sight e) Check flow across evaporator. glass. 1) Check compressor shell temperature Step 2 a) Check all safety interlocks b) Cheek pressures Pp Sequen b) Start pump & liquid flow at pump discharge of starting ¢) Start the unit as recommended in unit & measure flow. startup section Step 3 a) Afier steady operation at design condition, Observation see that the refrigerant pressures are stabilized. b) Take all readings like comp. Suction & discharge pressures, comp/fan/pump current, comp shell temp, pump flow & pressure, ait | 6 & yet should be flow across condenser, ete. between % & 13 ©) Periodical oil level check of sight glass, d) Abnormal noise & vibration. a 5 - ©) Arrest all vibrations. ) Vibration of refrigeration and liquid pipelines. 1) No switch gear components are running hot Step 4 a) Turn off the circuit switch. 3) ino asa Stopping b) Check for oil return in crankcase. Whole unit in on c) Close all valves if required. cireuit breakers in the panel & switeh off the ‘comp, fan, and then pump in the same order & then turn of the main switeh. 14AY Cer a lil REFRIGERATION A liquid whose Saturation temperature at normal atmospheric pressure is below the temperature that is to be produced by refrigeration is chosen as the working liquid in the refrigerator and is known as refrigerant. Such a liquid will evaporate at lower temperatures and will absorb heat as it does so. This heat is extracted from the surroundings. The vapour formed in this way is compressed in a compre ‘or. Afier compression the refrigerant may be in the vapour state or, in the liquid state if its temperature after compression is not greater than the saturation temperature at that increased pressure. The low temperature vapor is condensed ina condenser. Asa result of condensation in the condenser, it gives off the heat in the condense: Now the condensed liquid repeated. in doing so it lowers its temperature below the surroundings. s expanded to a lower pressure and the cycle of refrigeration is VAPOUR COMPRESSION REFRIGERATOR Liquid refrigerant partly apour at low ure & pressure Fairly dry refrigerant vapo at lov pi Dry refrigerant vapour at high pressure Compressor 2 Figure shows a vapour compression refrigerator. 15)AY Cer a lil REFRIGERATION CYCLE 1. Compressors are used in vapour compression cycles. It is the heart of the system and it sucks low-pressure refrigerant vapour from the evaporator and compresses it to a pressure corresponding to the saturation temperature that will be higher than the air available to condense the refrigerant. The compressor also aids to continuously re-circulate the refrigerant through the system. 2. Air-cooled condensers are heat exchangers, which reject heat from the condensing refrigerant to the atmosphere. The function of condenser in a refrigerated system is to de-superheat and condense the compressed discharge refrigerant vapour. High- speed fans are mostly used to speed up the pro S. 3. At the exit of the condenser the refrigerant loses temperature but still is in high- pressure state, The temperature falls down a little high to the ambient. 4. Dryers are mainly used to capture the moisture content if any mixed with the refrigerant. When the refrigerant passes through its thin filter mesh the moisture gets trapped on the silica gel and clean refrigerant flows through. 5. Throttle valve (also called as Expansion valve) is also a very important component of the vapour compress devi ion refrigeration system. The function of an expansion is to expand the liquid refrigerant from the condensing pressure to the evaporating pressure. Also it throttles the required flow into the evaporator depending on the load conditions. Commonly used expansion devices are capillary tubes, thermostatic expansion valves and constant pressure expansion valves. 6. Any liquid when evaporates creates a cooling effect. Same applies here, when the refrigerant exits expansion valve it is partly in vapour state at low temperature and pressure. It flows through the evaporator and exchanges heat with the surroundings 7. After exiting the evaporator it has gained heat from the surrounding media, thus lowering the temperature in the freezing compartment. This superheated vapour passes further and is drawn by the compressor, which compresses it, and delivers to condenser, thus, completing the reftigeration cycle 16AY Cer a lil STANDARD CONTROLS «[HP] HIGH PRESS URE This is a manual reset type pressure controlled electromechanical device used as a safety cutout against high discharge pressure of the refrigerant. The reset button is located on the HP/LP switch. 2. [LP] LOWPRESSURE This is an automatic reset type pressure controlled clectromechanical device used as safety cutout against low suction pres re. The unit trips & resets automatically till the pressure completely drops below the desired level 3. OILPRESSURE [COMPRESSOR LUBRICATION] In larger semi hermetic compressors there is an in-built oil pump assistant for the s the lubrication of the compressor. There is an oil pressure cutout switch that sens discharge pressure of this pump & the suction pressure of the compressor & opens the compressor motor power circuit in case of a trip. The reset in this cause is done manually. 4, THERMISTOR TRIP In compressors above STR, the compressor motor is embeded with temperature sensor. As the motor winding temperature, execeds the permissible limits the thermistor cuts out the power supply to the compressor motor. The reset is automatic, for which the motor has to cool naturally. As the compressor cuts off, there is an indication on the panel that remains glowing until the auto resct happens. ” [SPP] SINGLE PHASE PREVENTER This device safeguards the chiller from: Single phasing, phase reverse & voltage imbalance. Under or over voltage + 10%. 17See at y 6. ANTIFREEZE TRIP This is a manual reset type thermostat. As the liquid temperature falls below safety set point, the thermostat trips the compressor & the liquid pump. The reset button is located on the thermostat itself. 7. [OLR] OVER LOAD RELAY TRIP All the motors of the compressor, fan & liquid pump are wired through an over load relay. As the respective motor draws higher than the set current value, the OLR trips off the motor & an indication is generated on the panel 8. WATER LEVELLOW In chillers with in-built tank the float switch aids in maintaining an optimum level in the tank. The whole system comes to a halt as the water level goes low and an indication on the reset push button is generated on the panel. As the water level is made up & the reset button is pushed, the chiller resumes its operation. 9. FLOW SWITCH TRIP In chillers, where flow switch is installed in the liquid circuit, the whole system tripsasa lack of adequate flow. An indication is generated on the panel and resets automatically when flow is initiated 18AY Cer a lil TROUBLE SHOOTING PROBLEM POSSIBLE CAUSE ACTION O1 | Unit not switching ON > | MCB/OLR are kept off when | Ensure the MCB/OLR of the the unit is dispatched unit are in ON condition. > | Voltage imbalance Cheek voltage 02. | SPP trip > | Phase Failure Cheek voltage. > | Incorrect phase sequence Interchange the phases. 03: | OLR tip > | Pump, Compressor, Fan Contact Vendor Motor taking high current 04. | Water Level Low > | Low water level in the tank | Fill up the water, reset. > | Leaks in the pipeline Reetify the leaks 05. | Antifreeze trip > | No water circulation Clean the strainer > | Pump Failure Contact Vendor > | Pump suction valve closed | Open the valve > | Low load Optimize load > | Evaporator blocked Clean Evaporator coil 06 | Flow switch trip > | No water circulation Clean the strainer > | Pump Failure Contact Vendor > | Pump uction valve closed Open the valve > | Dry running of pump Prime the pump 07. | Oi1 Pressure trip > | Compressor oil pump failure | Contact vendor Low compressor oil Contact vendor 08. | Thermistor trip > | Compressor shell temperature | Allow the compressor to cool > | very high automatic restart > | Low refrigerant Contact vendor 09 | Low pressure > | Low refrigerant Contact vendor > | Refrigerant filter choke Contact vendor > | Low load Optimize load > | Evaporator blocked Clean Evaporator coil 19)AY Cer a lil PROBLEM POSSIBLE CAUSE ACTION ot | High pressure > | Clogged filters Clean filters and condenser > | Clogged condenser with air pressure > | Condenser fa lure Contact vendor > | Hot air re-circulation Provide ventilation > | Obstruction in air flow Clear obstruction > | High pressure side choke Contact vendor 02 | UnitON > | Compressor on timer, initial but compressor not starting | time delay 3mins. > | Timer not working Contact vendor > | Thermostat device open Wait tll temperature exceeds set temp by 20 > | Compressor accessories not | Accessories to be changed, working > | Overload Protector Tripped | Contact Vendor > | No continuity in compressor | Compressor to be replaced. terminals Contact Vendor 05 | Compressor starts but > | Low Voltage Cheek the voltage makes humming noise > | Start eapacitor defective Change capacitor > | Compressor windings Replace the compressor. defective > | High Discharge Pressure | Contact Vendor. 06. | Compressor starts but trips > | Low Voltage Check the voltage immediately > | Compressor accessories Change the defective defective accessories: > | Compressor taking high Contact Vendor current > | Windings defective Contact Vendor. 07 | High Temperature > | Compressor not getting on. | Follow instruction No. 2 > | Filter clogged with dirt Clean the filter > | Compressor taking less current] Low Refrigerant, > | Compressor over heated Contact Vendor > | Low refrigerant Contact Vendor > | Set temperature altered Check the settings 09. | Low Temperature > | Thermostat not working Replace. C ‘ntact Vendor 09 | Freezing in E > | Improper water flow Cheek for obstruction > | Pump failure Contact Vendor 20See at y MAINTENANCE SAFETY CONSIDERATIONS Installation, starting-up and servicing of process chillers can be hazardous duc to system pressures, electrical components and equivalent location viz. roofs, elevated structures, etc Werner Finley make liquid chillers are designed for safe and reliable, when operated within de: ign limits. When operating this equipment, use judgement and safety precautions to avoid damage to equipment, property or injury to personnel. Be sure that you understand and follow the safety precautions. NOTE: ONLY TRAINED, QUALIFIED INSTALLERS AND SERVICE METCHANICS SHOULD INSTALL, START-UP AND SERVICE TE EQUIPMENT. SOME OF THE SAF PS: GENERAL: 1. DO NOT CLIMB over the chiller and DO NOT STEP on refrigerant lines Broken lines can release high-pressure refrigerant and cause injury to personnel. 2. NEVER SHORT-CIRCUIT any controls in the system 3. Care in HANDLING & RIGGING; check weight, use appropriate lifting equipment, use lifting hooks, or use base frame for lifting equipment. 4. PERIODICALLY INSPECT all valves leaks and damages. fittings, and piping for corrosion, 5. Drain liquid completely before loosening or attending to liquid lines. 21See at y PRESSURE TEST 1. Usconly dry Nitrogen. Use regulating valve with pressure gauge. 2. DONOTUSE OXYGEN or ACETYLENE, both could c: xplosion. 3. HANDLE THE CYLINDERS VERY carefully. 4. NEVER EXCEED 300 PSI during pressure testing the equipment. REFRIGERANT 1, DONOT VENT refrigerant in closed room as it could displace oxygen and cause asphyxiation. As per ASHRAE Std 15, refrigerant to be vented out in the open or through the ventilator in the plant room. Though R22/R134a/R407¢/404a are non-toxic, spillage of liquid refrigerant on skin & eyes could cause severe damage to the tissue. Use safety goggles and gloves. In case of refrigerant burn on skin flush with cold water immediately. If liquid refrigerant enters the eyes, IMMEDIATELY FLUSH EYES with water. Consult a physician immedi: 3. DO NOT WELD or FLAME CUT any reftigerant line before completing evacuating the reftigerant from the system. Dry Nitrogen to be used to flush final traces of Reftigerant and place to be well ventilated. Refrigerant with open flame produces toxic gases 4. CHECK REFRIGERANT TYPE before charging into the system. In case of wrong charge, the system could get damaged or malfunctioning could occur. 5. NEVER HEAT refrigerant cylinder with open flame, ONLY use warm water (43) to heat cylinder.AY Cer a lil Electrical: 1 DO NOT WORK ON HIGH VOLTAGE equipment unl S you are a qualified electrician. 2. DO NOT WORK ON electrical components, including control panels, switches, starters or oil heaters unit you are sure ALL POWER IS OFF & NO RESIDUAL. VOLTAGE can leak from capacitors or solid state components. 3. Lock OPEN & TAG electrical circuits during servicing IF WORK IS INTERRUPTED, confirm thatall circuits are de-energized before resuming work, SYSTEM MAINTENANCE, A conscientiously administered and maintenance program will enhance the value of the package chiller by: . Increasing the life of the unit . Assuring the proper operation without costly shutdown at critical times, . Minimizing the repair cost . Assuring operation of the chillerat maximum eff Under normal conditions, the package chiller will require nothing more than periodic thorough visual insp. tion to assure operation at maximum performance. Qualified personnel shall handle maintenance and inspection only. If the operator has limited refrigeration and electrical knowledge, he should confine his maintenance of the equipment to periodic inspection, cleaning of filter and condenser coils only 23AY Cer a lil TIPS FOR PREVENTIVE MAINTENANCE ‘To ensure proper unit operation and to avoid damage to unit components, follow periodic inspection set up. . Maintain log book and record essential readings like ambient temperature, liquid temperature, current, suction / discharge pressure, fluid pressure ete . Maintain history of parts used with date and reason for replacement. . Check oil level to be close to 1/3" of the oil sight glass in the compressor. . Clean condenser / dust filter often & keep it free for good airflow. . Clean filter/Y Strainer in liquid circuit often & keep it free from contamination. . In case of coil type evaporator, clean coil with water jet & keep free from scaling & contamination . In case of shell & tube type evaporator, during break down or other maintenance schedule, cleaning can be done by circulating de-scaling agents, before restarting the unit. . In case of PHE type evaporator, reverse flush the unit & circulate cleaning agent & ensure to flush it with water before restarting. . Ensure to maintain good liquid quality at all times. . Ensure the use of genuine refrigeration parts in the chiller. . Never close valves during unit in operation. . Tighten the cables & electrical connections every month. Study the wiring diagram before attending the clectrical panel. . If liquid back flood occurs in compressor, do not run the compressor. Investigate & rectify the defects ALWAYS DE-ENERGIZE THE ELECTRICAL PANEL, BEFORE ATTENDING TO ANY PROBLEM. 24See at y RECOMMENDED PREVENTIVE MAINTENANCE SCHEDULE: Ne ‘Type of Operation Weekly Monthly | Quarterly | Yearly O1 | Liquid Temperature * 02 | Ambient Temperature * 03 | Current * 04 | Oil level * 05 | Supply Voltage * 06 | Compressor shell temp. * 07 | Setting of safety devices + 08 | Operations of all valves * 09 | Proper operation of controls * 10 | Contacts of motor starters + 11 | Evaporator Cleaning * 12 | Condenser Cleaning 13 | Connections in Electrical cabin * * WARNINGS . ‘The warranty is void if the wiring is notas per WFPL specification. . .¢ warranty is void ifany setting for protection devices are altered. . ‘The warranty is void ifany kind of mishandling of the unit is observed. * A blown circuit breaker / fuse or tripped protector indicates a short ground or overload * Before replacing the device or restarting the compressor, the cause must be found & corrected. © Unqualified tampering with the controls can cause serious damage to the equipment and void the warranty. * _ Allsafety trips should be immediately attended and ensured that the unit runs only after rectification Do not reset the safety trip unless complete failure ¢: 25 jetected & repaired.AY Cer a lil SERVICE * Chiller Cleaning Remove all the doors [except the electrical cabin] of the chiller. Regularly clean dust depositions and ensure no contamination of the fabricated body with rust or water accumulation. © Electrical Cabin Vacuum the cabin dust frec. Do not use compressed air, moisture contents can damage the components. Ensure for loose contacts. ¢ Condenser Clea ig The dust filter and condenser to be kept free from dust to enable good air movement through the condenser. Use soft nylon brush & cleaning agents that do not damage the copper tubes & aluminium fins. A gentle jet of compressed air can also be used for condenser cleaning, ensuring no damage or bending of fins. © Evaporator CI aning Coil type evaporator can be cleaned using water jet and nylon brush, Shell & tube evaporator can be flushed with dilute caustic soda solution & should be refreshed with water «Stra er Cleaning The liquid line strainer to be cleaned often to retain optimum flow across the evaporator. © Liquid Quality The liquid passing through the chiller shall not contain particle impurity, sludge, ctc., purity & filtration level of liquid is very critical. 26AY Cer a lil REFRIGERATION LINE SERVICE Refrigerant leaks, compressor failures, choked drier/filter are common problems that occur in refrigeration. Intensive care should be observed while rectifying such kind of problems. Refrigerant Leak: «Release the remaining refrigerant from the system. * Pressurize the circuit with dry nitrogen up to 300 PSI «Use an electronic leak detector or soap solution to detect the leak Arresting the Leak: «Ifthe leak is in flair joints, the joint should be completely replaced. « Assure no cri diameter. in the copper line, if pre: ent replace with new copper pipe of same * Flare the line, apply teflon tape & redo. « Ifthere is leak in the brazing joints, mark the area & release the nitrogen pressure. * Ifelbows or U-bends are cracked, replace with new. «If weak brazing observed, rework the joint. «Now once again recharge the system with dry nitrogen Check whether the leak has been positively arrested. « Indoubiful cases, leave the system under 300 PSI of Nitrogen overnight & check for pressure retention after 12 hours. On confirmation release the nitrogen & subject the system for vacuum: Vacuuming + Use a good quality vacuum pump especially designed for refrigeration Run the vacuum pump till the gauge reads 29 PSI below 0 PSI in the vacuum gauge. «If the power is interrupted to the vacuum pump while in process, restart again # Close the valve of the refrigeration line before switching off the vacuum pump 27AY Cer a lil Charging the Refrigerant Shut down your equipment/machine while gas charging in progress © Conncet the charging tube between the suction service valve & refrigerant cylinder. e Remove the trapped air, by purging some refrigerant across the tube. * Without switching on the unit, idle charge the system till the pressure equalizes. Before switching on the unit, ensure the fluid is at room temperature. Switch on the unit and consistently observe the current drawn by the compressor. * Slowly charge the reftigerant by monitoring discharge / suction pressures & compressor current. * Touchand feel the compressor shell for overheating. * Ensurethe flow of the fluid through the evaporator. Once the required liquid temperature matches to that of the rated suction/discharge pressures & compressor current, stop the charging, © Close the refrigerant cylinder valve and the service valve. Apply soap water for leak detection on the valves © Observe optimum efficiency of the unit Compressor replacement: * Evacuate the refrigerant present in the line. * Cutthesuetion/ discharge copper linc or open the service valves on the compressor. Seal the compressor & the refrigeration lines. «Replace the defective compressor, connect the suction/discharge lines & follow the procedure for leak detection, vacuuming & charging of the refrigerant. Always replace anew filter/drier along with the new compressor. Choked Filter/Drier * Shutdown the system, and close the inlet/outlet valves to the filter. © Loosen or cut open the lines & replace new filter/drier. Release the trapped air by purging out the refrigerant across the filter. © Whilereplacing the compressor or recharging with refrigerant, itis recommended to replace anew filter/drier. 28AY Cer a lil NOTE: . Disconneet mains while compressor changing & gas charging procedure. . Use gas reclamation unit or cylinder dipped in ice bucket to retrieve refrigerant. . Use refrigerant pressure/temperature chart while charging. . Use calibrated pressure gauges. . Read safety instructions before servicing. . Use original spare parts only. . Maintain record for each service . Do not over charge / under charge the system: . Always take up service by bringing working fluid to room temperature else moisture will enter the refrigeration system . Check oil quantity & replace during service. . Always use dry nitrogen for pressure testing. . Use a regulating valve for the nitrogen cylinder. . If water has entered the system, thorough nitrogen flushing & extensive vacuuming is necessary . Leak testing of R22/ R134a, R407c¢/R404a can be done with refrigerant charge also, as the standing pressure of the refrigerant is very much above the atmospheric pressure. . Try to retrieve the refrigerant as much as possible. 29Ace a TEMPERATURE CONTROLLERS . dixeil XR3OC-DIGITAL CONTROLLER WITH OFF CYCLE DEFROST om! Digital controller with off cycle defost designed for rehigeration applications on WT. It provides two relay outputs, one fo the comprssr, the thar one canbe usa for alarm signaling or auslary output The probe input con be sled betwen PIC or NIC. The instrument has dg input, for olarm signaling, fr witching the xian utpt or fr sa a des ce [a fot t]92) nae SOI : " XR30C oe rs 6{7[8| seven ney HOT KEY sul ese sl7l8 ti Power surety st | ‘33 HOW TO SEE THE SET POINT SET) Push and immediatly release the SET key; the display wil show the set pont valu. 2) Psh and immed reles he SET kay or wait fr 5 secnds to display the robe vlue agin ‘3,4 HOW TO CHANGE THE SET POINT 1) Push he SET key fr more than 2s. 2) Te value ofthe st point wl be dsplyed end theaELED str blinking 3) To change the se volue push the A ov atows within 10s 4) To memset new setpoint volue push the SET key again or wait 10s 30See at y TEMPERATURE CONTROLLER SETTING éub-Zero MAIN FUNCTIONS : HOW TO SEE THE SETPOINT SeT=e) 1. Push and immediately release the SET key the display will show the Set Point value; HOW TO CHANGE THE SETPOINT 3% SEB) 1. Push the SET key for more than 2 seconds to change the set point value; 2. The value of the set point will be displayed and the © LED starts blinking; 3. To change the Set value push thea orw arrows within 10s. 4. To memorise the new set point value push the SET key again or wait 10s. 1. Set Point Function : To set the cutout point of the controller. Press &hold Display will change to set point 1 and flash. set key for 4 seconds and release. SZ-7552-P R11 will flash along with respective setpoint 1 for compressor. Set Point 1/2 The setpoint 1 range can now be changed by usingthe UP/DOWN iin. | Max.] Fac.] Keys. After achieving the desired range, press the set key and oc 150°C | o°¢] YouWwill see *- - --" which confirms that the set point has been stored in memory. ‘$Z-7552-P. Set Point 1/2 Min. | Max. | Fac. R2 will flash along with respective setpoint 2 for compressor 2 “50°C| eg | 0°C | Inthe similar manner use UP/DOWN key to set the desired range and press set key to confirm the settings. 31TEMPERATURE CONVERSION CHART FAHRENHEIT TO CENTIGRADE/CENTIGRADE TO FAHRENHEIT = c| =e] [Fe "e] (Fe *e] [Ze *e| [= *¢ “__ 30 sa] [ea te 78 | [i508 66 189| |2s72 114 a56| [5286 162 722 | [a0 210 969 202 -29 -33.9| [e52 19 -72 | [1526 67 194| [259 115 46.1| [3254 163 72.8 | [411 211 994 “18428 -33.3| [6s 2 67 | [1544 68 20 | [2408 116 167| [3272 164 733] [4136 212 100 166 27 228] [eos 21 61 | [1562 69 206] [2026 117 472] [220 165 729] [415.4 219 1003] 148-26 -32.2| [716 22 -56 | [158 70 21.1] [aaae 118 478 | |as08 165 74.4] [417.4 214 101.4 “13-25 -31.7| [73423 -5 | [1508 71 21.7| [2462 119 433 | |ss26 t67 75 | [ate 215 101.7 a2 2431.1] [752 24-44 | [i616 72 222] [pea 120 489 | [asa 168 756 | [208 216 1022 ‘94 23 206] [7 a9 | [1634 73 228] [208 121 404] [2962 169 76.1] [422.6 217 102.9] “76-22-30 | |788 -33 | [152 74 233 [2516 122 50 | [ase 170 76.7 | [aaa 218 1033 58 21-29) [e06 -28 | [167 75 239 |253.4 123 506 | |ss08 171 77.2 | [4262 219 1039 4-20 28.9) [aaa 22 | [1ea8 76 244 [2552 124 51.1| [acre 172 77.8 | [ze 220 1044 22-19 28.3] [e42 <7] [i708 725 | [257 125 s1.7| [sas4 173 78.3] [437 205 1072] 04-18 27.8) [96 11] [1724 78256 | [2568 126 52.2 | [3452 174 789 [446 290 110 1.417 27.2] [878 -06 | [1742 79 26.1 | [2606 127 528 | |s47 175 70.4 | [455 235 1128] 32 46 267) [aos 0 | [76 80 257 | [2624 128 533] [a1a8 176 0 | [aes 240 115.5] 515 26.1] fora 06 | [1778 81_272| [262 129 53.9] [350.6 177 806 | [473 245 1183] 68-14 25.6) [932 11 | [1796 a2 278 | [266 130 544| [3524 178 81.1] [42 250 1211 36 13-25 | [95 17| [te14 23285] [2678 131 55 | [3542 170 617] [491 255 125.9] 10.412 244] [oes 22 | [rea es 280 | [2696 122 556] [256 180 822] [500 260 126.7] 12.2 11-239] Joe 28 | [res 85 29.4 | [2714 133 56.1] [3578 181 828 | [500 255 120.4 a eases fs fs foe fess es |S as fg 14-10 233] |1004 38 33 | [1868 86 30 | [2732 134 56.7] [3596 122 03:3 | |518 270 1322] 158 9 228] [1022 39 39 | [1888 67306] [275 135 572| [ae1a 183 839] [527 275 135, 176-8 222] [ios 44 | [i904 a8 s1.1| [2768 136 57.8] [632 104 644 | [536 280 1373] 194-7 -21.7| [1058 41 5 | [1922 69 31.7] [2786 137 583] [305 185 a5 | [545 235 140. 212 6 21.1] [1076 42 56 | |1e4 @ 322] [2804 138 58.9] [3658 105 056 | |554 290 143.3] 23-5 -206| [1004 43 61 | [isa oi aze| |2a22 139 50.4] [a6 187 06.1 | [56a 205 146.1 2aa 4-20 | [utt2 266 3-194] [113 2642-169) [1148 67 | [iss 2 333| [284 14060 | [3704 18 a67| [572 300 1489] 72 | [1984 93 939 | [2858 141 606] [3722 189 87.2 | |5e1 905 151.7] 78 | [2012 04 344 | [2876 142 61.1] [374 100 67.8 | [590 310 154.4 4829 -128| [1346 57 139] [221 105 406| [3074 153 67.2] [3038 201 93.9] [oso 955 185 5010 122] [136.4 58 14.4] [2228 106 41.1 | [3092 154 67.8] [05.6 202 044 | [698 370 187.8] 518 11 -11.7| [1382 5915 | [2246 107 a17| [311 155 68.3] [307.4 203 95 | |707 375 190.5] 536 12 -11.1| [140 60 156] [2064 108 422| [9126 156 68.9] [3092 204 95.6 | |716 930 1933] 55.4 13 -106| [1418 61 16.1] [2282 109 428 | [3146 157 69.4] [401 205 96.1] [725 985 195.1 572 14 10 | [1496 62 167] [230 110 433] [3164 158 70 | [402m 208 967 | [724 390 19809] 5915-94 | [1454 63 172] [2518 111 439 [3182 159 706] [4046 207 97.2| |743 995 201.7| 08 16 -89| {1472 64 178] |2aa6 112 a44| [320 160 71.1] [aos4 208 97.8 | | 752 400 204.4 2617-83] [149 65 183] [2354 113 45 | [s218 ter 717] [4os2 209 083} [761 405 2072] 43 a4 45 46 302 1 18a] [ree 47 a2 | [203 05 as | [2804 143 17] [a75f 101 eea| [soo 215 1572] 320-178] [118.4 48 89 | [2048 06 956] [2012 144 622] |s776 192 889] [60s 320 160 3381 -172| [1202 49 94 | [2066 7 a61| [203 145 628] [a794 193 e94| [617 225 162.| 356 2 167] [122 50 10 | [2084 08 367 | [2088 146 633] [3512 104 00 | [626 330 165.5] 74a 161] [1288 s1 106] [2102 09 a72| [2086 147 63.9] [262 105 008| [eas a5 168.3 302 4 156) [1256 52 111] [or2 100 37.8 | [2084 148 61.4 | [38 196 91.1] [ea4 340 171.41 415-18 | [1274 sa 117] [21398 101 aa3| [3002 149 65 | [2066 197 91.7 | |osa 245 1739] 428 6 144] [1202 54122] [2156 102 a89| [302 150 656] [seas 198 02.2 | | 652 350 1767] 4467-139] [13155128] [2174 103 3a4| [3038 151 66.1] [3002 199 928 | [o71 _s55 179.4 46.4 6-133] [1328 56 133] [2192 104 40 | [3.56 152 66.7] [302 200 93.3 | |o80 960 1822| 57 58 For example, to fine the Centigrade equivalent of 104°F., locate the figure 104 in the central columns of the table and read off the temperature in degrees Centigrade in the coulumn immediately to the right (headed °C.) namely, 40°C. Similarly, to fine the Fahrenheit equivalent of 40°C, locate the figure 40 in the central columns and read off the temperature in degrees Fahrenheit in the left-hand column (headed °F), namely ‘32>('6i8q) ypul azenbg 10} spunoty ul s84IO ‘Ainoxew Jo SeyoU] WnNoBA ayBoIPUI SIMI eAOgE SBINEL . Pam over e0z srl ere ere 1u9 19E GE sty oll Ble Ob 6 cy rece ge6l Sel 08 ize Po eve Le eor 66 oor ez o£ Cy ples veot Seb Lee 66e gis gze St vee se zee ell os Ee ric oust oct == ealsOmest0p ie wets eueelh> sts to eh oon re io) mts sat op Wr0r ab do vrOr = EPEL ee Zo de WeOp = BPEL a ab AYVHO SHNSS3AYd SHNLVHAdWSAL 33A Seite a Cd SERVICE NETWORK © Kanpur © Bhopal © Ahmedabad Jamshedpur © © Nagpur © Nasik © Aurangabad Mumbai Also at © Pune —eHiyderabag = Singapore = Dubai = Kuwait = Indonesia @(Chennai Coimbatore @ Pondicherry Werner Finley Pvt. Ltd. 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