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Periodic Maintenance
• Possible low discharge superheat at high loads
• High condenser + Subcooler pressure drop
Some of the symptoms of a refrigerant over-charged unit
• Condenser Pressure Limit
FWD
• High –Pressure Cutout diagnostic
Power supply
• More-than-normal number of fans running
Capacities
Cooling capacity on water (1)
• Erratic fan control
Heating capacity on water (2)
Fan motor
• Higher-than-normal compressor power
Fan power input (3)
• Very low discharge superheat at start up if the refrigerant
Current amps (3)
Start-up amps
charge is correct the discharge superheat is between 10°C
Air flow
and 15°C when the unit is running at full load
minimum
nominal
• Compressor rattle or grinding sound at start up
maximum
Some of the symptoms of an oil over-charged unit
Main coil
Water entering/leaving connections
• Larger-than-normal evaporator approach temperatures
(Leaving-water-temperature – Saturated Evaporator
Electric heater (accessory for blower only)
Electric power supply
Temperature)
Heating capacity
• Low Evaporator-refrigerant Temperature limit
Hot water coil (accessory for blower only)
Heating capacity (4)
• Low Refrigerant – Temperature Cutout diagnostic
G2 filter (filter box accessory)
Quantity
• Low unit capacity
Dimensions ( LxWxth)
• Low discharge superheat (specially at high loads)
G4 filter (filter box accessory)
Quantity
• Compressor rattle or grinding sound
Dimensions ( LxWxth)
• High oil-sump level after normal shutdown
Condensate pump (accessory)
Water flow - lift height
Some of the symptoms of an oil under-charged unit
Not available for FWD30 and FWD45
Sound level (L/M/H speed)
• Compressor rattling or grinding sound
Sound pressure level (5)
Sound power level (5)
• Lower-than-normal pressure drop through oil system
Unit dimensions
• Seized or Welded compressors
Width x Depth
Height
• Low oil-sump level after normal shutdown
Shipped unit dimensions
• Lower-than-normal oil concentrations in the evaporator
Width x Depth
Height
Weight
R134a/R513A Field – Charging
Colour
Recommended fuse size
Procedure
Unit alone (aM/gI)
Unit with electric heater (gI)
This procedure should be followed when the unit is
(1) Conditions: Water entering/leaving temperature: 7/12 °C, Air inlet temperature 27/19°C DB/WB - Nominal air flow
empty of all refrigerant and under vacuum. Add the
(2) Conditions: Water entering/leaving temperature: 50/45 °C, Air inlet temperature 20°C DB - Nominal air flow
charge through the evaporator service valve.
(3) At high speed with nominal air flow.
(4) Water entering/leaving temperature 90/70 °C, air inlet temperature 20 °C DB, Nominal air flow.
(5) A rectangular glass wool duct 1m50 long is placed on the blower.The measurement is taken in the room containing the blower unit.
1.
Respect refrigerant type on the nameplate and do not
mix R134a with R513A
Heat exchanger operating limits:
FWD:
2.
Note the weight of the amount of charge removed.
*water temperature: max 100° C
Compare it to the nameplate value. A difference in
*absolute service pressure: min 1 bar/max 11 bars
charge may indicate a leak.
Accessories - Hot water coil:
3.
Attach the charging hose to the evaporator service
*water temperature: min. +2° C/max. 100° C
*absolute service pressure: min 1 bar/max 11 bars
valve (9mm [3/8inch] flare). Open the service valve.
4.
Add charge to the evaporator to bring the total
circuit charge up to the level indicated in the unit
nameplate.
5.
Close the service valve and disconnect the charging
hose.
Chiller settings
Prior starting refrigerant charge optimization, the
technician must insure the following chiller conditions:
• Constant water flow on a air purged circuit is strictly
necessary during the whole operation (water fl ow to be
within allowed operating range)
• A fully loaded chiller is highly recommended for a
successful operation. In case the technician is not able to
116
4
Technical Data
ensure a 2 circuit fully loaded chiller then he must lockout
one circuit and perform charge optimization for
1 circuit at a time
• When the refrigerant charge optimization is done per
circuit the chiller load must not be lower than 60%
08
(V/Ph/Hz)
This procedure should be followed when adding
(kW)
5,2
refrigerant to an undercharged unit:
(kW)
6,3
(type)
1.
(kW)
0,23
(A)
1,1
2.
(A)
3,2
(m
/h)
490
3
3.
(m
/h)
820
3
(m
/h)
980
3
(type)
(Dia)
3/4"
(V/Ph/Hz)
230/1/50
(kW)
2/4
(kW)
6,3
2
(mm)
386x221x8
-
This procedure should be followed when removing
(mm)
-
refrigerant to an overcharged unit:
(type)
(l/h - mm)
1.
(dB(A))
36/40/43
2. Adjust water flow within operating range and keep it
(dB(A))
46/50/53
(mm)
890 x 600
(mm)
250
(mm)
933 x 644
(mm)
260
(kg)
32
(A)
8/16
(A)
16 (2kW),25 (4kW)
Isolation of the Refrigerant Charge
on the Low side of the System
By closing the suction-line service valve, refrigerant
charge can be isolated in the evaporator for maintenance
on the compressor.
Returning the unit to running conditions:
1.
2.
3.
4.
12
230/1/50
8,3
11,9
2 x direct drive centrifugal
Attach the charging hose to the evaporator service
0,46
valve (9mm [3/8inch] flare). Open the service valve.
2,2
Fix the leaving water set point (water temperature to
5,5
be steady as much as possible).
980
1400
Adjust water flow within operating range and keep it
1650
2300
1970
2600
steady.
a) Note approach temperature T1
ISO R7 rotating female
3/4"
1 1/2"
b) Add 2kg of R134a or R513A refrigerant
c) Note approach temperature T2
230/1/50 or 400/3/50
400/3/50
8
d) If Tn - Tn+1 < 0.2 (with n=1 → charge addition
count) then charge is good and optimization is done
12
e) If Tn - Tn+1 > 0.2 (with n=1 → charge addition
2
count) then perform steps b) to e) if needed
486x271x8
586x321x8
2
486x264x48
586x314x48
Centrifugal
24 - 500
Fix the leaving water set point (water temperature to
be steady as much as possible)
38/41/44
46/50/53
48/51/54
56/60/63
steady
1090 x 710
1290 x 820
a) Note approach temperature T1
300
b) Add 2kg of R134a or R513A refrigerant
1133 x 754
1333 x 864
c) Note approach temperature T2
310
d) Keep performing step b until Tm+1
46
galvanised steel
- Tm > 0.5 (with m = 1 > charge removal count)
e) Once step d) is confirmed add 4kg of R134a or
8/16
40 (230V),3*16 (400V)
3*20
R513A refrigerant and note T3
f) If T1-Tn < 0.2 (with n = 3 → charge addition count)
then charge is good and optimization is done
g) If T1-Tn > (with n = 3 → charge addition count) then
perform step e) to f) if needed
Open all the valves.
Manually Open EXV for 15 minutes to allow the
refrigerant drain to the evaporator by gravity.
Let the unit sit with heaters on to drive refrigerant
out of the oil and warm up the compressor bearings.
Depending upon ambient conditions, this may take
up to 24 hours.
After the oil level has returned to normal, the unit
can be put back into operation.
20
30
15
18,8
30,1
18,9
20,9
38,2
0,65
1,04
1,51
3,1
4,7
9,3
14,1
16,5
1800
2700
3000
4500
3600
5400
1 1/2"
1 1/2"
400/3/50
400/3/50
10
12
17,4
22,4
34,5
2
2
586*421*8
586*621*8
2
2
586*414*48
586*614*48
47/52/57
47/52/58
57/62/67
57/62/68
1290 x 970
1290 x 1090
350
450
1333 x 1008
1333*1133
360
460
61
76
8/16
8/25
8/25
3*25
3*25
RLC-SVX19E-GB
UNT-PRC002-GB
45
5,5
12
2
2
650
660
118
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