Oil-Free Centrifugal Chiller - Coward Environmental Systems
Contents
1. Check all electronic modules are secure Check physical condition of all exposed Printed Circuit Boards PCB s Check all exposed PCB s for dust build up and clean if necessary Check calibration pressure temperature sensors Refrigeration Check operation of IGV assembly Check system refrigeration charge Check superheat level control if applicable Check system and motor cooling liquid line to ensure sufficient subcooling Check operating conditions external to the compressor Clean inspect motor cooling strainers if service has taken place As Required TROUBLESHOOTING The performance of the chiller set is largely dependent on the correct operation of the water circuits and the refrigeration system When evaluating the refrigeration system it is important to check the operation of the water circuits first Failure to do this may lead to misdiagnosis of the refrigeration circuit Ensure that the chiller has sufficient water flows in both the evaporator and condenser as per specifications Table 2 Fault diagnosis chart Low suction pressure High discharge pressure water cooled machines High discharge pressure air cooled machines Low chilled water flow Chilled water temperature too low Faulty pressure transducer Insufficient refrigerant charge Restricted refrigerant flow Suction valve closed Compressor IGV stuck open Condenser water temp2. NOTE Suction and discharge valves are meant to be used for service only Do not run the unit or leave open for extended periods of time If it is intended it will be open for extended periods use planking plates with gaskets and test of leaks HEAT EXCHANGER SERVICE Air Cooled Condenser The Smardt condenser is a vertical air flow cross finned coil heat exchanger design The coil is horizontal and incorporates a separate sub cooling circuit and may have a liquid receiver located between the main and sub cooling circuits to ensure that the main circuit does not liquid lock No regular service is required however the following checks should be made on a regular basis e Ensure that the motors protection devices in the main cubicle are not tripped e Check the general state of the fin surfaces for built up soiling A build up of dust adhering to the fins in greasy environments can lead to air flow reduction and poor heat exchange Generally steam or pressure spray cleaning in the most appropriate cleaning method Evaporator shell and tube type Shell and tube type evaporators should be treated as described for condensers above Evaporator shell and plate type An alternative Smardt flooded shell and plate evaporator may be fitted This type is not mechanically cleanable Chemical cleaning methods may be used but it is essential to ensure that the chemicals used are compatible with and will result in no harm to the materials of c
3. system is in parallel with other chillers If the water circuits are not shut down condensation will occur in the refrigeration pipe work leading to longer than normal evacuation times due to the presence of moisture in the system Refrigerant leak testing Leak testing can be performed by the following means e Electronic leak detector e Soapy water 21 Both of the above methods are adequate to locate leaks Once the leak is isolated the system should be shut down and the affected component s repaired Machine not operating no charge 1 Connect the service manifold set to the chiller as per procedure 4 2 2 Connect gauge set up to the R134A refrigerant cylinder and add a trace gas only required if electronic detection device is used 3 Connect the gauge set up to an industrial grade nitrogen cylinder and increase the pressure in the system to 1500 kpa 4 Carry out leak detection as per the above procedure Once the leak has been repaired pressurize the system with nitrogen and leave undisturbed for 24 hrs Check the pressure gauge noting any change in pressure and ambient temperatures from the previous day There may be slight pressure changes if the ambient temperature has changed dramatically If the pressure in the system is maintained the nitrogen can be removed and the dehydration procedure 4 5 can be performed on the chiller Dehydration procedure When the system has been open for a lengthy period and contami
4. too high Low condenser water flow Fouled water tubes Blocked water strainer Faulty pressure transducer Non condensable in system System overcharged Discharge valve closed Restriction in pipe work Blocked restricted airflow Air re circulation Fans reversed Electrical overload s tripped Motor failure Faulty pressure transducer Non condensable in system System overcharged Discharge valve closed Restriction in pipe work Check flow as per design Check set points Check transducer Check evaporator liquid level Check sub cooling Check discharge temperature Check EXV operation Check filter driers Check valve position Check indicated position and carry out standard IGV checks Check tower set point Check flow as per design Clean tubes Clean strainer Replace transducer Dehydrate system Adjust charge Check valve position Correct pipe work Remove obstructions Remove cause of re circulation Correct power supply connection Reset investigate cause Repair replace Replace transducer Dehydrate system Adjust charge Check valve position Correct pipe work 19 Chilled water temperature too High evaporator pressure high Pressure sensor faulty IGV failure Insufficient refrigerant charge Low refrigerant temperature cutout Faulty sensor Water temperature too low Water flow blocked No motor cooling Drive temperature too high Insufficient sub cooling Faulty se
5. for a pre configured period of not less than 180seconds after which time the fault will be automatically reset and the chiller placed back to IDLE where the 180second anti recycle timer is started again Compressor faults If a fault is generated inside the compistesrmal Operating Values e Ifthe fault is reset able such as a suction pressure bearing displacement or motor over temperature fault the chiller controller attempts to automatically reset the fault and make the compressor useful again e f the fault is not able to be reset such as a compressor over current trip or system component failure the chiller controller places that compressor in a not useable state and flags on touch screen that the compressor is LOCKED OUT A maximum of three compressor faults per hour are tolerated if more than three faults in an hour are generated the compressor is placed offline for a 20minute period until fault time expires If compressor does fault while the chiller is running and then reset that compressor is then selected as the last compressor to startup when the load increases MAINTENANCE Maintenance inspections The following list of preventative maintenance items must be carried out by authorized and qualified personal in a timely fashion Owner s responsibilities e Report any damage to the chiller set e Report any faults that occur with the chiller set e Turn off the chiller if fault condition persists e Maintain a
6. liquid level sensor If the liquid level sensor is operating correctly use the chiller controller interface to manually drive the EXV Verify that the liquid level fluctuates according to the drive signal as observed through the sight glass on the cooler If the EXV fails to respond to the manual input the EXV is defective and requires replacement Checking liquid level sensor operation Be sure control type Level is selected in the controller The level sensors have a display on the back of the sensor Observe the indicated level to see that it varies particularly during startup At stable conditions the level should be maintained within 5 96 of the set point normally 45 to 55 96 The sensor is a 0 to 90 ohm resistive element 45 ohms at indicated 50 REMOVAL AND INSTALLATION OF COMPRESSORS NDANGER Before performing any service on the compressor electrical power must be isolated To ensure safe and clear access to the compressor follow these procedures 1 Switch off the AC mains at the disconnect switch Install a lock out device or place a placard at the switch alerting others that compressor servicing is in progress Wait at least 10 minutes before opening any of the compressor access covers A When AC power is first removed from the compressor the DC link capacitors store enough energy to cause electrocution Allow sufficient time for the capacitors to discharge before proceeding 2 Using a 25 bit remove th
7. safe working environment in the plant room free from obstructions and debris Provide adequate lighting e Ensure plant room ventilation is adequate and as per government regulations e Maintain water treatment to the chiller as per government regulations and maintain water quality to prevent premature failure of the system Smardt recommends that on site operational checks be carried out as per Table Operational checks evaluate the system performance fault history and trends Table 1 Frequency of maintenance for Smardt chillers Electrical checks Electronic inspections Compressor refrigeration circuit inspections Chilled water circuit inspection TASK Frequency Check Main power supply voltages i Check Electrical terminals are tight Check Hot spots discoloration on power cables Check Amperages are as per design Check communication cables are secure Check pressure and temperature sensor connections are secure Check there are no signs of physical damage discoloration on printed circuit boards Check the printed circuit boards are free of dust Check EXV winding resistance do NOT disturb connections unless repair is required Check all mounting bolts are secure Check for refrigerant leaks Check for mechanical damage Check operating temperatures and pressures Check for Insulation damage Check chilled water sensors are secure and installed with adequate heat transfer medium Check water
8. sequence of operation for the Smardt oil free centrifugal chiller It is intended that this document be used with the applicable installation Starting with stopped chiller chiller at idle 1 Enable signal sent from BAS sets digital input on chiller control to true a Chiller controller waits 5 seconds before acting on BAS enable 2 If the leaving chilled water temperature is greater than or equal to the set point temperature plus the AT over set point and there are compressors available to run the chiller is set to PULL DOWN STATE 3 Depending on the number of compressors configured to start up initially and the number of compressors available to run compressors interlocks are closed and 15 demand is sent to each of the selected compressors 13 4 Once the selected compressors are started up and begin to run the chiller demand is increased at a fixed ramp rate of 596 per minute until a demand of 100 is reached or the temperature is less than or equal to the set point a Atany point during this demand ramp up temperature pull down if the chiller demand goes over the Demand Stage Up setting and a compressor is available to run a new compressor will be turned on OR b Atany point during this demand ramp up temperature pull down if the chiller power goes over a calculated optimum number to switch on another compressor and a compressor is available to run a new compressor will be turned on Each time a n
9. the chilled water and condenser water pumps 2 Connect up charging lines to the bottom of the evaporator vessel and the charging cylinder 3 Purge lines removing non condensables 4 Add the correct amount of refrigerant charge to the evaporator vessel as indicated by the name plate In the event that a minimum of 75 of the total refrigerant charge cannot be added to the chiller use an approved refrigerant pump to attain the minimum charge The machine will require restarting and the gas charge added during operation NOTE The Turbocor compressors rely upon liquid refrigerant for the cooling of their mechanical electro mechanical and electronic components Therefore in order to bring the system to the correct operational refrigerant charge it may be necessary to connect your charging lines onto the bypass port on the operational compressor and provide liquid to it during is operation This will ensure adequate cooling for the compressor whilst completing the charging of the system Refer to procedures 4 7 and 4 8 to determine the operational refrigerant charge to ensure system does not become over charged During this procedure it may be necessary to bypass some control functions in order to maintain chiller operation and thereby reach the desired refrigerant charge Check sub cooling Sub cooling measurement procedure 1 Set up the service manifold as per procedure 4 2 however connect the discharge hose red to the liquid
10. 514 426 8989 Fax 1514 426 5757 TABLE OF CONTENTS Terms and Definitions ssssssss II I nmm meer Installation and Safety Guidelines ssesss HH RIGGING Penne E COMMISSIONING NOTE E oS Control Wiring Reference iio otn cadveuceutdu pune ira RR LESS SERENE SENSE da Rx ud Rss senere Sequence of Operation sssssssssssssssssssssssssesse senes e sensn nenne METIRI MIA TERTCUCTEPLPT O E Troubleshooting Guide sssssssssssssssssssssssessese semen e enne menses Service Procedures sssssssssssssse I e eme seen erre enses r rre ens Removal and Installation of Compressors ssesssssssssseee Heat Exchanger Service sss seen enne Incident Report Procedure cccccccec eee e cence eee eee ee neces eh me e e me serene Downloadable Forms http interactions smardt com Docs SmardtCommissioningForm pdf http interactions smardt com Docs SmardtControlWiringConnections pdf http interactions smardt com Docs Smardt_RequestStartUp AcrobatForm pdf http interactions smardt com Docs Smardt_IncidentReport_AcrobatForm pdf 11 12 13 17 19 20 25 INSTALLATION and SAFETY GUIDELINES The purpose of this manual is to inform contractors building owners and engineers of installation sequence of operation and service requirements for the Smardt oil free water cooled centrifugal chiller It i
11. SMARDT Oil Free Chiller Manual Centrifugal Chiller Installation Operation amp Maintenance Manual IOM WC rev1 This publication contains information proprietary and confidential to Smardt Inc Smardt Any reproduction disclosure or unauthorized use of this publication is expressly prohibited without written approval from Smardt Smardt reserves the right to make changes without notice in product or component design as warranted by evolution in user needs or progress in engineering of manufacturing technology Smardt has exercised its best efforts to ensure that the information contained in the manual is correct However no warranty or reliability or accuracy is given with respect to the information and Smardt is not and shall not be responsible or liable for the correctness or suitability of the information or for any effort or omission All brand names and product names used in the manual are trademarks registered trademarks or trade names of their respective holders TERMS AND DEFINITIONS BMS Building Management System EXV Electronic Expansion Valve HP LP High Pressure Low Pressure MCA Minimum Circuit Ampacity MOCP Maximum Over Current Protection PLC Programmable Logic Controller RH Relative Humidity VFD Variable Frequency Drive For product support issues corrections or enquiries contact Product Support productsupport smardt com Smardt Inc 1800 Trans Canada Hwy Dorval QC Canada H9P 1H7 Tel 1
12. bar l beam combination should be used to safely position the chiller set into its final location The typical rigging details are shown below in Figure 1 Smardt is not responsible for the rigging and placement of the unit Arrangements can be made through a local equipment mover SPREADER BARN Figure 1 Rigging Diagram Unit Placement Install the chiller set on approved anti vibration mounts Each corner should be supported on vibration eliminators and steel plate or suitably isolated from the plant room floor Generally waffle pads are considered suitable as the Smardt chiller is virtually vibration free The chiller should be protected from excessive ground or pipe borne vibration from external sources such as pumps Once installed remove the rigging equipment and check for longitudinal and transverse alignment Add shims if necessary to level the unit along both axes Table 1 Dimensions and clearances MODEL H W L Lbs Clearances Tube removal Controls access Service top side SW840S 3A 81 4 41 53 165 19000 150 from tubesheet 36 min side 12 min above Includes full refrigerant charge water circuits empty Weights may vary with individual tube count NOTE Values shown are typical Refer to Smarat for product specific values Local codes ma
13. d hose to the access valve provided at the discharge ball valve 3 Purge both gauge lines to ensure that non condensables which can lead to false pressure readings are removed from the line Once this is complete the service technician can evaluate the refrigeration system Removing refrigerant Whenever removing refrigerant from the evaporator and condenser vessels water flow must be established prior to carrying out this procedure Water flow prevents a freeze up condition that will cause leaks between the water and refrigerant circuits leading to major component failure This procedure may vary depending on the type of service required 1 Install the gauge manifold set or refrigerant recovery lines to the chiller set in the appropriate area of service Connect the common refrigerant hose to the suction side of an approved refrigerant recovery system 2 Connect a hose between the discharge side of the recovery system and the recovery container 3 Purge all lines of non condensables 4 Switch on the recovery system and transfer the refrigerant The time of transfer depends on the type of transfer system and the volume of refrigerant To assist the transfer it is important to maintain a cool recovery cylinder Once the system pressure is approximately 10 kPa the system can be opened up to atmosphere and the necessary repairs carried out Once the system is open for inspection turn the water pumps off or isolate flow if the
14. dbmd 3 TS mendis 39 DerivaiveGan f 3 RT CmeMn amp Max Slew Rate 5 AT Above Set point to Start aF mop Stop Chiller Temp Safe shut down Set above alarm Condenser Control Settings Minimum Set point temperature Maximum Set point temperature Starting Starting Timer Starting Set point Set point change per minute Proportional Band Integral Gain Control Min Max Slew Rate Alarm Settings Suction pressure alarm Suction pressure trip Suction trip timer Discharge pressure alarm Discharge pressure trip Discharge trip timer System amp alarm Chiller specific System amp trip Chiller specific Over amp trip timer Leaving temperature alarm Leaving temperature trip Leaving high temp limit while running Leaving high temp time limit Condenser water high temp alarm Condenser water high temp trip Auto fault reset delay timer Demand Stage Up RPM Stage Up RPM Stage Down Power Stage Up Stage up time delay Stage down time delay 31 Pressure ratio limit IGV before stage down dependent pea mim apsemia s based on return temp is selected as reset mode 54 F buedonseumtemp i seletedas roset mod ase based on return temp is selected as reset mode 45 F Display Units Comp Mode Pass Code Chiller Address RS485Baud Chiller to BAS comms Evaporator VFD Tuning Condenser VFD Tuning Desi
15. diately Consult a Inhalation of gaseous unconsciousness Risk of doctor immediately refrigerant suffocation If patient stops breathing artificial resuscitation Inform the poison control center Storage and Handling e Only use refrigerant in ventilated areas e Ensure that the container is sealed appropriately cap chain e Only use containers which are suitable for Refrigerant R 134a and for the intended pressure and temperature e Store containers at a temperature of less than 50 C in a ventilated area e Avoid long periods of exposure to heat Stability and Reactivity Stability Stable under normal conditions Refrigerant reacts strongly with alkali metals and alkaline earth metals Pulverized aluminum and pulverized zinc catalyzes the decomposition of the refrigerant Substances to be avoided If escaping vapors come into contact with fire or very hot objects they form decomposition products which produce a high degree of Other information irritation and have strong thermal effects It is possible that an explosive mixture could be formed under high pressure and with a high proportion of air AN WARNING Low voltage in electrical equipment is potentially lethal Isolate incoming electrical power before attempting installation or service of the equipment When AC power is first removed from the compressor the capacitors store enough energy to cause injury It is essential to allow suffici
16. drop across each heat exchanger Evaporator and condenser water circuits Strainers should be located on the inlet side of the evaporator and condenser Water inlets to the chiller must be connected to the lower headers of the evaporator and condenser The water circuits should be arranged so that the pumps discharge through the evaporator and condenser and controlled as necessary to maintain essentially constant chilled and condenser water flows through the unit at all load conditions Control wiring reference data The primary chiller control functions are implemented via a Carel amp PLC or the Kiltech Controller which looks after the control of chilled water temperature interlocks and interfacing to the building system These connections are made at a 24 v terminal strip inside the control cubicle The Smardt Control Wiring Connections Form is on line at http interactions smardt com Docs SmardtControlWiringConnections pdf Chiller Controller I O Functions for water cooled chillers 1 6 Compressors Temperature 1 EnChW_temp Entering chilled water temperature for control and monitoring Temperature 2 LvgChW temp Leaving chilled water temperature for control and monitoring Temperature 3 EntCw temp Entering condenser water temperature for control and monitoring Temperature 4 LvgCw temp Leaving condenser water temperature for control and monitoring Temperature 5 LiguidRefrig temp Liquid refrigerant temperature before the ex
17. e four Torx screws that secure the mains input cover to the main compressor housing Refer to Figure 5 3 NOTE Ensure the removal of all four Torx screws paying special attention to the removal of the screw in the top left of the mains input cover as failure to remove may result in damage to the cover 25 Lift away the mains input cover and set aside With a voltmeter verify that there is no voltage present on all three phases Using a 25 bit remove the Torx screws that secure the top cover to the main compressor housing Lift away the top cover and set aside With a voltmeter verify that there is no voltage present on the DC bus Remove the screws that secure the service side cover 0 Lift away the service side cover and set aside oos ON Figure 5 Compressor Access Covers Top Cover Mains Input Cover Service side Cover Refrigerant Containment Isolation and recovery of the refrigerant must be performed by a qualified service technician 1 Close the suction butterfly valve 2 Close the discharge ball valve 3 Close the inter stage ball valve if fitted 4 Close the motor cooling shut off valve 5 Connect the service gauge as per procedure 4 2 6 Connect an approved refrigerant recovery system to the compressor as per procedure 4 3 and transfer the refrigerant into a clean cylinder Compressor Removal Refer to 5 1 Preparation for Service steps 1 through 7 prior to commencing the remo
18. ed out by certified companies that specialize in refrigeration units Smardt recommends having the service department install set up service and clean the system Safe handling staff Staff involved with operation of the Smardt chiller should receive instruction with regard to the following points at regular intervals a minimum of once a year e Risks involved in dealing with refrigeration units e Safety stipulations e Conduct in the event of accidents and malfunctions e Measures in the event of accidents and malfunctions Personal safety equipment Operator s obligations e To provide equipment to protect against the effects of refrigerants and coolants e To store fully operational personal safety equipment outside of the at risk areas within easy reach Personal safety equipment consists of e Protective gloves made from leather e Protective goggles for use with chemicals A RISK of SUFFOCATION R 134a is ASPHYXIATING Common name of the substance 1 1 1 2 tetrafluoroethane Chemical name CF3 CH2F In the event that refrigerant escapes please observe the following e Have first aid equipment on hand Have emergency shower on hand Wear self contained breathing apparatus R134a is asphyxiating Ensure that everyone leaves the danger area immediately Follow first aid measures relevant to refrigerant Inform the local safety personnel Only enter rooms where refrigerant has escaped if wearing the appropriate safety equipm
19. ent Ventilate rooms in which refrigerant has escaped Ventilate the hazardous area Stop the gas escaping Ensure that the refrigerant does not escape into the sewage system or into the environment If the refrigerant concentration is more than 0 25 kg m e Wear self contained breathing apparatus e Ensure that at least one person with the necessary safety equipment is standing by to come to your aid If the following are possible without putting yourself at further risk e Switch off the Smardt chilling system using the emergency stop button or the master switch e Close the valves on the suction and liquid pipes e Observe instructions on the safety data sheet In case of contact with refrigerant observe the following Cause Symptoms Measures Gaseous refrigerant Rinse with plenty of clean water has come into contact Eye irritation immediately Consult a doctor with the eyes immediately Liquid refrigerant has Extreme eye irritation watery Rinse with plenty of clean water come into contact with eyes redness and swollen immediately Consult a doctor the eyes eyelids immediately Gaseous refrigerant has come into contact No risk with the skin Liquid refrigerant has come into contact with Rinse with plenty of clean water Frostbite with burn like skin immediately Consult a doctor problems redness blistering the skin immediately Take person out into the fresh Inability to move air imme
20. ent time for the capacitors to discharge before proceeding Only a qualified electrician should work on low voltage electronic equipment Wait at least 10 minutes after isolating power before opening compressor access covers Before installing the chiller set ensure that the supporting floor meets the load bearing requirements Smardt is not responsible for the load bearing capacity of the floor Adequate clearance around the chiller set is essential to facilitate maintenance and service Required minimum clearances are tabulated under Dimensions and clearances on page 8 Ensure relief valves vent outside a building in accordance with national safety regulations and Jurisdictional requirements Concentrations of refrigerant in enclosed spaces can displace oxygen and lead to asphyxiation When unpacking the unit carefully inspect it for visible signs of damage Check for damaged evaporator insulation broken wires and loose piping and bolts Any damage should be reported to the shipping company immediately Open all containers and verify all parts against the packing list Report any shortages to Smardt Care must be exercised at all times when rigging or handling the chiller set to protect it from damage Four rigging points two at each end are provided on the evaporator tube sheet corners The chiller s high center of gravity must be considered when rigging to ensure that the chiller is secure and balanced when suspended A spreader
21. erating capacity is at 100 e Ensure that test operation is possible at a minimum of half capacity over a number of hours e Ensure that the cooling water circuit has been filled purged and is operational Check that a heat load is available during start up Check that insulation work has been completed Clean dust and rubbish from the unit Ensure that the unit is accessible from all directions Check refrigerant or protective gas filling at least once a month if commissioning does not take place within 4 weeks after delivery If this is the case instruct the relevant service office to do this e Inform the relevant service office of any damages prior to commissioning e Agree on the commissioning date with the Smardt service office 11 e All materials needed for commissioning refrigerant etc are to be requested or made available Clearances Adequate clearance around the chiller set is essential to facilitate maintenance and service Note and report if clearances are considered inadequate re Installation Guidelines Damage inspection Inspect it for visible signs of damage Check for damaged evaporator insulation broken wires and loose piping and bolts Note any damage and report it to the appropriate personnel on site Piping connections All external piping must be adequately supported and aligned to prevent strain and distortion on the chiller headers and couplings Provision should be made to measure pressure
22. ew compressor is turned on the chiller controller is placed into a STAGE UP state initially in this state the demand to each of the operating compressors is reduced in order to lower the AP across the evaporator and condenser such that a new compressor easily without risk of surging This may last for roughly 120seconds When a new compressor is started it is started at the same demand as the other operating compressors once this new compressor has reached the same RPM as the other operating compressors the STAGE UP sequence finishes and the fixed ramp to set point continues again 5 Once the set point temperature is reached the chiller control mode is changed from PULL DOWN to RUN MODE When the chiller is placed in RUN MODE the fuzzy pid loop takes over control of supplying demand to the compressors based on the error between the set point and leaving chilled water temperature a If the chilled water temperature drops below the set point temperature for a period greater than 5 continuous seconds the chiller controller starts to look if it should shut down a compressor The prerequisites for shutting down a compressor are i The compressor RPM must be reduced to within 5 of the compressors lowest speed for the existing suction and discharge pressure ii The minimum time between compressor turn offs has expired generally set to 120seconds iii The inlet guide vane must have remained at a position lower than the chi
23. flow pressure drops are as per design Check flow switch operation Check for water leaks Check water strainers X lt WE ys ii SOSS Condenser water circuit inspection if fitted Air cooled condenser inspection if fitted Check condenser water sensors are secure and installed with adequate heat transfer medium Check water flow pressure drops are as per design Check flow switch operation Check for water leaks Check water strainers Clean condenser tubes Check cooling tower operation refer manufacturers specification s Check airflow is not obstructed Check fin surfaces are clean Check fans rotation direction Check fan motor overload devices Table 2 Frequency of Maintenance Turbocor compressor Item Task Frequency 6 mths 12 mths 60 mths General inspections Electrical inspections Check for visible mechanical damage to compressor Check for excessive vibration from other rotating equipment Check main power supply voltages refer to p 47 Turbocor service manual Check electrical terminals are tight Check for signs of hotspots discoloration on power cables Check amperages as per design Check DC Bus voltage Check capacitor mid bus voltage NINN Replace capacitor set Check operation of all system safety devices and interlocks Electronic inspections Check all communications cables are secure and tight EN
24. g 96 Max SH Set point Minimum Sub cooling Manual Valve Step Count Record of compressor controller settings SETTING DESCRIPTION COMMENT Compressor Alarm and Trip Settings Compressor Control Mode Modbus Display Units Discharge pressure alarm limit 155 pc UN Discharge temperature alarm limit B Suction pressure alarm limit EE Leaving temperature alarm limit EE Current alarm limit Chiller dependant Discharge pressure trip limit NEN Discharge temperature trip limit Suction pressure trip limit NENNEN DENN Leaving temperature trip limit Current trip limit Chiller dependant Electronic Expansion Valve Settings Modular Chillers Only Liquid Level 1 Auto Manual Auto Stepper Startup 25 Stepper Startup position delay Control Mode Stepper control set point Stepper control loop speed Stepper minimum count Maximum step count RS485 Modbus Settings 33 Slave Address Compressor dependent 1 6
25. gn kW input Chiller dependent System Setup Number of compressors chiller dependent Xxx Number of refrigerant circuits chiller dependent Xxx Three phase VAC Site dependent Xxx Compressor Type TT300 73 Evaporator Type Flooded Water Control Mode PID Leaving Cond Condenser Control Mode Water In Im m Tewewremsemok AMS Hot Gas Valve Settings moe miBmd E A Integral gain 190 Control Min oe 3 Max Slew Rate 05 Starting Timer 180sc Set point AT Below the set point SEE d Manual Valve 96 05 Sensor amp Analogue Input Settings Temperature Input 1 Offset FORE dE Temperature Input 2 Offset ES Temperature Input 3 Offset o Temperature Input 4 Offset QR Temperature Input 5 Offset oR Temperature Input 6 Offset oR Temperature Input 7 Offset oR Temperature Input 8 Offset OR AI 2 Chilled Water Pump VFD Speed Feed Back ooo f AI 3 Condenser Water Pump VFD Speed Feed Back ooo f AI 4 BAS Load Limit input 0 50 100 AL S Set point Reset owe AI 6 Refrigerant Level Sensor 00100 ALT Remote Temp Sensor emn AL Remote RHY Sensor ww TT Electronic Expansion Valve Settings Proportional Band eg integral gain 3 TT Control Minimum min valve position per compressor D 7 o d 5 Max Slew Rate Startin
26. hilled water pump VFD feedback 4 20 mA Analog Input 3 Cw Pump VFD Feedback Condenser water pump VFD feedback 4 20mA Analog Input 4 BAS Load Limit Input Building Automation System Amp Input feedback 4 20mA Analog Input 5 Set Point Reset Input Set Point reset input 0 5 VDC 0 10 VDC or 4 20mA Analog Input 6 Level Sensor or EXV Input Refrigerant level sensor input for EXV 0 5 VDC 0 10 VDC 4 20mA Analog Input 7 Combo RH Temp Sensor T in Outside air temp input for tower control 0 5VDC 0 10VDC or 4 20mA Analog Input 8 Combo RH Temp Rh in Outside RH input for tower control 0 5 VDC 0 10 VDC or 4 20mA Analog Output1 Tower Fan VFD or 3 Way Valve VFD cooling tower fan output Controls Cw inlet temp 4 20mA Analog Output2 Cw Pump VFD Output VFD condenser pump output 4 20mA Analog Output3 ChW Pump VFD Output VFD chilled water pump output 4 20mA Analog Output4 Expansion Valve Output Stepper motor output Same loop for level control 4 20 mA Analog Output5 HotGas Bypass Output Hot gas bypass capacity control output 4 20mA or 0 10VDC Analog Output6 Power Output 0 600 kW Chiller power output power Power Wiring All wiring must be installed in accordance with appropriate local and national electrical codes and will require a circuit breaker or fuses to protect the main wiring run from the final distribution sub board to the unit SEQUENCE OF OPERATION General The purpose of this section is to provide guide on the
27. line upstream of the electronic expansion valve EXV 2 Note the corresponding saturation temperature of the refrigerant at the pressure indicated In order to have sub cooling the measured value must be less than the saturation temperature 3 With a temperature probe measure the temperature on the liquid line upstream of the EXV 4 Calculate the difference between the saturated temperature and the measured temperature This difference is the amount of sub cooling Design spec 9 15 F 5 8 C 23 Check superheat Superheat Measurement Procedure 1 Connect up the service manifold as per procedure 4 2 2 Note the corresponding saturation temperature of the refrigerant at the pressure indicated In order to have superheat the measured value must be greater than the saturation temperature 3 With a temperature probe measure the temperature on the suction line 4 Calculate the difference between the saturated temperature and the measured temperature This difference is the amount of superheat Design spec 0 5 F 0 3 C Soldering procedure When components in the refrigeration system require replacement soldering or sweating will be required to either remove or replace the components To protect the internal pipe work the use of industrial grade nitrogen must be used at all times during any procedure where a naked flame is applied to the pipe work The use of nitrogen prevents copper oxide formation in the in
28. ller controller IGV STAGE DOWN for 60 seconds OR iv The chiller demand has reduced to less than or equal to 1096 Minimum chiller loading 6 If while the chiller is in the RUN MODE the heat load on the chiller increases again the compressors are turned back on as detailed in the pull down sequence 7 While in RUN MODE if the chiller is unloaded where only one compressor is operational and the chilled water temperature drops to the chiller controller configured SHUT DOWN TEMP the chiller is turned off A 180 second anti recycle timer is started once this timer has expired the chiller control state is returned to IDLE and the chiller may be re started Abnormal operation sequences Chiller in alarm avoidance Chiller Management System continuously monitors for abnormal system conditions such as low suction pressure high discharge pressure low leaving temperature high amp draw and others The controller implements a three stage alarm management strategy in order to stay online as long as possible The alarm management routine operates as follows ALARM STATE ACTION REQUIRED One or more monitored If system is loading the system stops loading values is within 596 of the alarm setting 15 Discharge Pressure LARM LIMIT REACHED Chiller detected fault If at any time whilst the chiller isPynaings apibcosdiioO 96c 9 fo Ac piiqr ppl bcp it into fault state The chiller will remain in the fault state
29. nation has occurred it is important to dehydrate the system to remove any moisture ATTENTION Never apply power to the unit while under a vacuum NOTE Use the same hoses as in the leak testing procedure making sure the lines are free of leaks If possible use copper lines to minimize potential leaks between the chiller and the vacuum pump 1 Install the evacuation hoses between the chiller and the vacuum pump 2 Start the vacuum pump 3 Open all isolation valves on the chiller to ensure that there is a vacuum achieved throughout the system 4 Once a vacuum has been achieved connect an approved vacuum testing device and check the results If the vacuum reading is less than 500 microns isolate the vacuum hoses in the event that the reading is affected by the running vacuum pump 5 Let the chiller remain under vacuum for approx 1 hour Recheck the vacuum reading If the reading does not increase by 50 microns within this time the chiller is ready to be recharged with refrigerant If the system was severely contaminated by an internal electrical failure or by the presence of moisture a triple dehydration procedure should be carried out breaking the vacuum each time with refrigerant or nitrogen to remove all contamination During operation carry out refrigerant analysis on a regular basis and change filter driers as required Charging the refrigeration system Use pure refrigerant from non contaminated cylinders 1 Turn on
30. nsor Compressor does not start No cooling demand Faulty chilled water temperature sensors Faulty pressure sensors No mains power No chiller controller power Check temperature sensor Check for excessive water flow Replace transducer Check operation refer procedure Check refrigerant charge Replace sensor Check set points Find repair blockage Check pipe work valves Check compressor solenoids refer service manual Check refrigerant charge Check liquid line for restrictions Replace sensor Check temperature set points Replace faulty sensors Replace faulty sensors Check power at mains terminal block Check control circuit fuses CB s SERVICE PROCEDURES The following tools are required for servicing the chiller Service tools Allen key set up to 14mm Torx screwdriver 25 Manifold set Thermometer 1000VDC Multimeter Computer with Turbocor Monitoring Software Grounding wrist strap Connecting refrigerant gauges It is extremely important that the manifold set is free of moisture and dust It is also important that the gauge set is not contaminated with other refrigerants or oil When performing any service procedure that requires the addition of refrigerant do not use reclaimed refrigerant unless it is of guaranteed quality and oil free 1 Connect the low pressure hose blue hose to the access valve provided at the suction ball valve 2 Connect the high pressure hose re
31. onstruction Materials are Copper coating heat exchange plates Stainless steel heat exchange plates Low carbon steel water connections Proceed generally as follows 1 Shut down the chiller set and isolate from the power 2 Isolate and drain down the cooler water circuit including the pump and inlet filter 3 Remove the inlet filter and inspect it for the possible cause of the problem 4 Replace the filter 5 Follow the chemical suppliers procedure to introduce the chemicals only to the cooler 6 Flush thoroughly afterwards then seal the water circuit and refill the system Bleed the water circuit 7 Re connect power and monitor the chiller operation at startup INCIDENT REPORT PROCEDURE Smardt strives for product excellence and maintains a competent staff of professionals in application design and service to serve our customers If you have a problem with a Smardt chiller we want to know about it To report an incident and request an RMA please submit a Chiller Incident Report This form is available on line at http interactions smardt com Docs Smardt IncidentReport AcrobatForm pdf 29 iagram D iring W I Josuag EUN HONOL OL SNNOD S8TS TANVd E Aiddng a J8MOg UBBJIS yNOL Jeued Yyono 0 Jewod wwOz r MA009 0 0 1ndino Jamo 12919913 9 OV wwoz p NANO ALA SEDOH s ov vwoz p ndino jonuo2 3407 uesa uay p OV ywoz r jeubis paeds G4A dund 1942M p vwoz y jeubis
32. or and condenser and should be controled as necessary to maintain essentially constant chilled and condenser water flows through the unit at all load conditions EVAPORATOR TAT CONDENSER Figure 3 Piping Schematic The primary chiller control functions are implemented either via a Carel PLC or the Kiltech controller which looks after the control of chilled water temperature interlocks and interfacing to the building system http interactions smardt com Docs SmardtControlWiringConnections pdf The mains power input connection for the Smardt range of chillers is a single point termination via a mains termination box supplied as standard on each chiller unit From the mains termination box each compressor control box power and controls is pre wired to the individual compressors All power wiring upstream of this point is the responsibility of the installing contractor All wiring must be installed in accordance with appropriate local and national electrical codes and will require a circuit breaker or fuses to protect the main wiring run from the final distribution sub board to the unit A neutral and an earth are essential Table 3 Pressure drops and Flows MODEL Voltage MCA MOCP SW series 460 v 60 Hz 3 Phases 260 300 NOTE Values shown are maximum Refer to Smardt for product specific values Compressor motors a
33. pansion valve Temperature 6 OutsideAirTemp Optional outside air temperature for data logging only Temperature 7 Not used Temperature 8 Not used Digital Input 1 BMS Enable BMS Enable contact starts and stops the chiller Digital Input 2 ChW Flow P roof Chilled water flow proof switch Digital Input 3 Cw Flow proof Condenser water flow proof switch Digital Input 4 Not used Digital Input 5 Ext LP Switch External low pressure switch Digital Input 6 Ext HP Switch External high pressure switch Digital Input 7 Gas Leak sensor Gas leakage sensor Digital Input 8 Ext FreezeStat External Freezestat input Digital Output 1 Comp Interlock Relay Compressor interlock relay output Digital Output 2 Tower VFD Enable Cooling tower VFD enable Digital Output 3 Chw Pump or vfd Relay Chilled water pump enable output Digital Output 4 Cw pump or vfd Relay Condenser water pump enable output Digital Output 5 Maximum capacity reached Maximum capacity reached output calls additional chillers Digital Output 6 Chiller Ready Closed when chiller is ready to run but not yet running Digital Output 7 Chiller Fault Closed when chiller is in fault state Digital Output 8 Chiller Run Closed when chiller is running Analog Input 1 Tower fan VFD Feedback Tower or condenser fan VFD feedback 4 20mA Analog Input 2 Chw Pump VFD Feedback C
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35. re designed to operate satisfactorily over a range of 10 percent of the standard design voltage Note A Neutral is required for control purposes The load is essentially a balanced 3 phase load and the neutral may be run in the minimum allowable cable size relative to the three phase mains COMMISSIONING NOTE Smardt requires equipment to be commissioned according to a detailed procedure and by a Smardt and Turbocor trained and certified technician In order to activate the warranty the commissioning form must be completed and submitted to Smardt An interactive Adobe Acrobat Form is available on line at http interactions smardt com Docs SmardtCommissioningForm pdf If Smardt is conducting the commissioning or you request a factory supervised start up please submit the Smardt request for Start Up Form available on line at http interactions smardt com Docs Smardt RequestStartUp AcrobatForm pdf Before commissioning e Obtain the Smardt Commissioning Form and understand its requirements e Ensure that all the electrical connections and any pneumatic connections have been set up in accordance with the plans and the local regulations e Ensure that the PLC control system is available and is in working order e Ensure that all communication links to higher level control systems and process control systems have been connected e Ensure that the cold water brine circuit has been filled and is operational e Ensure that the refrig
36. s intended that this document be used with the applicable installation and wiring drawings The water cooled centrifugal chiller consists of an evaporator condenser twin turbine centrifugal compressor compressor controller and interconnecting refrigerant piping The chiller set is a packaged unit requiring connection to the condenser and chilled water circuits as well as the main electrical supply and control wiring Safety precautions must be observed during installation start up and service of the chiller due to the presence of refrigerant charge and low voltage hazards Only qualified personnel should install start up and service this equipment Ensure that relief valves vent outside the building in accordance with safety regulations Concentrations of refrigerant in enclosed spaces can displace oxygen and cause asphyxiation Do not disable any safety devices This instruction manual contains the generally valid safety regulations that are of the most importance to the operator of refrigeration units e Always ensure that the Smardt chiller is operated by qualified staff only e Provide suitable fully operational fire extinguishing equipment Environmentally friendly handling e Observe the instructions on handling and storing refrigerant see safety data sheet e Ensure that refrigerant does not escape into the air the ground or the sewage system e Ensure that installation set up maintenance and cleaning are only carri
37. soj 5 uedo AjjewoN Indu ejqeu3 sva L 10 10 140 ejBurs duie jueeBujes pnb S L C D 8 ATH D LAT D 9 ATH diay 104 je peuoees Ajoeder uielw G A TH JEM J8suapuo2 p A TH Ieufis ejqeu3 G4A Jesuepuo deng Jo ue Jamo Z ATH Aejay xoopieju 10ssaJduio2 L A TH el ve asn4 vov o vov e cov e cov e zov e zov e vov o vov o duie 19j amp M puoo umea p 1 CJ duie jeje A puo Buusqu3 E L dwa Jojem p dway J9jeM paruo Buueju3 1 1 C 9 Bunea z Canty nez Is nez lo papunos9 JON OvAbe vo asna A Pt LAA OWA OLL Controller Default and Custom Settings SETTING DESCRIPTION COMMENT Foaeramaesapm 4 Teaving or entering airfaater wmm Leaving Desa 9E OS Rpw m
38. ternal pipe work during the soldering process This keeps the internal pipe work clean and free of contamination 1 Connect the gauge manifold set as per procedure 4 2 2 Connect the common gauge line yellow hose to the nitrogen regulator 3 Set the regulator to provide a positive pressure of 5 psig 4 Open the nitrogen cylinder and manifold set to purge the area to be soldered Nitrogen displaces any oxygen present in the pipe work During the soldering process be sure that any component that may be affected by the addition of heat to the area be cooled by means of a wet rag wrapped around the component 5 Once the soldering process is complete cool down the pipe work and shut off the nitrogen supply Once cool the system can be reassembled and tested for leaks Checking IGV operation During compressor ramp up the inlet guide vanes open depending on load conditions as indicated by the ball bearing on the outside of the IGV housing refer to Figure 4 If the ball does not move further testing will be required refer to the Compressor Service Manual When the Turbocor compressor is not in operation the Inlet Guide Vanes wil move to the closed position Checking Electronic Expansion Valve operation During operation the EXV modulates maintaining the pre set liquid level in the evaporator The EXV responds to the liquid level sensor via the chiller controller Refer to procedure 4 12 to verify the operation of the
39. the compressor strip down and analysis procedures Compressor installation Install new o rings only when reattaching the ball valves to the compressor 1 Remove the blanking plates provided with the new compressor 2 Connect an approved lifting device such as a mobile hydraulic lifter to the eyebolts provided on each end of the compressor 3 Position and align the compressor over the mounting base 4 Insert the four compressor mounting bolts that secure the compressor to the chiller Tighten the screws using a 16mm socket 5 Attach the motor cooling connection at the front of the compressor 6 Using a 8 mm hex key tighten the inter stage valve bolts 27 7 Using a 8mm hex key tighten the discharge service valve bolts 8 Using a 14mm hex key tighten the suction service valve bolts 9 Connect the communication interlock cables to the compressor I O connector module 10 Using a 25 bit remove the four Torx screws that secure the main input cover Lift away cover Make sure that electrical power is isolated from the AC mains cables before handling them 11 Route the power cable through the opening in the mains input bracket 12 Attach the AC mains cables to the terminals and the grounding cable to the grounding lug 13 Attach the terminal nuts to the terminal block using a 16mm socket and wrench 14 Tighten the gland nut on the mains input bracket 15 Replace the main input cover and secure it using Torx screws
40. val procedures 1 Remove the terminal nuts from the terminal block using a 16mm socket and wrench 2 Remove the AC mains cables from the terminals 3 Loosen the gland nut on the mains input bracket and pull the power cable through the opening until it is completely detached from the compressor 4 Disconnect the communication interlock cables from the compressor I O connector module Make sure that there is no secondary power source connected to the terminal block before disconnecting any sensors or relay inputs outputs Once the transfer of refrigerant is complete disconnect the service isolation valves 5 Using a 24mm wrench remove the suction ball valve bolts 6 Using a 8mm hex key remove the discharge ball valve bolts 7 Using a 8 mm hex key remove the inter stage ball valve bolts 8 Remove the motor cooling connection at the rear of the compressor 9 Replace the top cover and secure it using Torx screws 10 Replace the main input cover and secure it using Torx screws 11 Remove the four compressor mounting bolts using a 9 16 socket 12 Connect an approved lifting device such as a mobile hydraulic lifter to the eyebolts provided on each side of the compressor 13 Remove the compressor 14 Using the blanking plates provided with the new compressor seal up the compressor in preparation for shipment to the supplier this will prevent moisture and foreign material from entering the compressor possibly affecting
41. y apply ensure clearances comply with local codes standaras amp CTRL CONNECR NS ELECTRICAL CABINET ELECTRICAL CABINET Figure 2 Dimensions and Clearances The condenser and evaporator connections are grooved type stubs Victaulic Shurjoint or other equivalent for interconnection to the external water circuits All external piping must be adequately supported and aligned to prevent strain and distortion on the chiller headers and couplings Pressure drops and flows Table 2 Pressure drops and Flows Design flow Pressure drop No of Conn Size nominal GPM PSI Passes inch Evaporator 957 3 3 2 8 Condenser 1153 5 9 2 8 NOTE Values shown are typical Refer to Smaradt for product specific values The chiller set performance and efficiency can be adversely affected by contaminants in the water circuits Such contaminants may impede or block the flow of water through the circuits or reduce heat exchanger performance Strainers should be located on the inlet side of the evaporator and condenser Water inlets to the chiller must be connected to the lower headers of the evaporator and condenser All external water piping must be cleaned or flushed before being connected to the chiller set The water circuits should be arranged so that the pumps discharge through the evaporat
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