KIRLOSKAR KAC Installation, Start-Up, Operation

KIRLOSKAR KAC Installation, Start-Up, Operation

Scroll liquid chillers
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KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company
Installation, Start-up, Operation &
Maintenance Manual
Scroll Liquid Chillers – KAC
DUAL COMPRESSOR
KAC 11 ~ 22 with HFC410A

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Summary of Contents for KIRLOSKAR KAC

  • Page 1 KIRLOSKAR CHILLERS PRIVATE LIMITED A Kirloskar Group Company Installation, Start-up, Operation & Maintenance Manual Scroll Liquid Chillers – KAC DUAL COMPRESSOR KAC 11 ~ 22 with HFC410A...
  • Page 2 FOREWORD At the outset, we thank you for purchasing chiller manufactured and supplied by KIRLOSKAR CHILLERS PRIVATE LIMITED. We are sure that our chiller will help you in satisfying your chilling requirement. This manual will guide you about the installation, Operation and maintenance of the system.
  • Page 3: Table Of Contents

    2.4.2. Anti-Vibration Mounts ……………………………………………………… 2.5. Water Treatment / Quality ………………………………………………………… 2.6. Installation of Flow Switch……………………………….……………………….. 2.7. Installation Check Report for KAC Chiller Units ………………………………… 3. Operation ………………………………………………………………………………. 3.1. Liquid Chilling Systems - Principle ………………………………………………. 3.2. Components and Their Functions ………………………………………………….
  • Page 4 3.8. Recommended Log Format for KAC Units ………………………………………. 3.9. Sequence of Operation for Packaged Chiller Units ……………………………….. 3.10. Standard Controls ………………………………………………………………… 3.10.1. High Pressure Control ………………………………………………………... 3.10.2. Low Pressure Control ………………………………………………………… 3.10.3. Voltage Protection Device …………………………………………………… 4. System Maintenance…………………………………………………………………… 4. Maintenance Instruction………………………………………………………………...
  • Page 5: Foreward

    Chiller Nomenclature KA C 011 . 2 0 0- R-410A No. of Compressors Nominal capacity, TR Scroll compressor KA – Kirloskar Air-cooled unit Operating Limits Description Unit R-410A Min leaving evaporator water ºC 3 ºC (ºF) ( 37.4 ºF) temperature (without glycol) Min leaving evaporator water ºC...
  • Page 6: Safety Considerations

    Installation, starting up and servicing packaged liquid chillers can be hazardous due to system pressures, electrical components and equipment location viz. roofs, elevated structures, etc. Kirloskar Chillers make liquid chillers are designed for safe and reliable operation, when operated within design limits. When operating this equipment, use good judgment and safety precautions to avoid damage to equipment, property or injury to personnel.
  • Page 7: Pressure Test

     HANDLE THE CYLINDERS carefully. Do not drop the cylinder.  NEVER EXCEED specified TEST PRESSURE; verify the allowable test pressure by checking the equipment nameplate. Contact Kirloskar Chillers if in doubt for further details. Refrigerant  Refrigerant R-134a, R-407C, R-410A is generally considered chemically non-toxic and non-inflammable;...
  • Page 8: Electrical

    The unit must not be operated outside the design parameters specified in this manual. KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 4 IOM-KAC-ENG...
  • Page 9: Introduction

    Chapter 1 Introduction 1.1. General Description Kirloskar Chillers hermetic scroll liquid chiller, type KAC (Air-cooled) comes complete, self- contained automatic refrigerating units and ready for installation. These units include the latest in engineered components arranged to provide a compact and efficient unit. Each unit is completely factory assembled, factory wired, pressure tested before evacuation, refrigerant and lubricating oil charged and factory run tested.
  • Page 10: Inspection

    NOTE: PHYSICAL DAMAGE TO UNIT AFTER ACCEPTANCE IS NOT THE RESPONSIBILITY OF KIRLOSKAR CHILLERS PRIVATE LIMITED. 1.4. Handling and Lifting Use spreader bars and suitable capacity crane & lifting cables. Refer Fig. 1.4a for details. Never allow any part of the unit to fall during unloading or moving as this may result in serious damage.
  • Page 11: Life Cycle Perspective And Disposal Of Product

    Carbon steel Hazardo √ √ √ √ √ √ √ √ √ Nitrile foam Hazardo insulation √ √ √ √ √ √ √ √ √ casting Hazardo componen KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 7 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 12: Instructions For Disposal After End Of Life Of Chiller

     Dispose all remaining non-hazardous waste like non-metallic parts, plastic as per Pollution control board norms.  Follow the legal norms for the waste disposal as per the local, state, national, international applicable legislation. KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 8 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 13: Installation

    (depending on the model). 2.2. Unit Location 1. Minimum side clearance between two KAC chillers shall be 2000 mm. 2. Minimum top clearance for KAC shall be 10000 mm. 3. Over and above this, the side clearance around the chiller shall be maintained as shown in the Fig 2.2a...
  • Page 14: Evaporator Water / Brine (Liquid) Piping

    Entering evaporator liquid connection must always be to the nozzle near to the head cover having refrigerant liquid in and vapor out connections. Refer Fig. 2.3a for details Fig. 2.3a Typical Evaporator Water/ Brine (liquid) Piping KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 10 IOM-KAC-ENG...
  • Page 15: Foundation And Anti-Vibration Mounts

    2.4. Foundation and Anti-Vibration Mounts 2.4.1. Foundation Kirloskar Chillers make KAC units have very minimum vibrations and do not require any special type of mounts. These units can be set directly on the floor with the mounting pads supplied along with the unit. For further details refer Fig. 2.4.1a.
  • Page 16: Anti-Vibration Mounts

    Spring isolators 2.5. Water Treatment / Quality If the unit is operating with a cooling tower (KAC units), clean and flush the cooling tower. Make sure that the tower “blow-down” or “bleed-off” is operating. Atmospheric air contains many contaminants, which increases the need for water treatment. This is also applicable for liquid chiller / evaporator side.
  • Page 17 Slime and Algae formation and the growth of the bacterium Legionella pneumophila (Legionnaires Disease). NOTE: Kirloskar Chillers is not responsible for damage or under performance or faulty operation from untreated or improperly treated water It is therefore to the benefit of the end user to provide for proper water treatment to provide for longer and more economical life of the equipment.
  • Page 18: Installation Of Flow Switch

    / brine line. It may be a flow switch.  Flow switch installation: Mount individual flow switch in the leaving water line of the evaporator and condenser. Refer Fig. 2.3a for flow switch installation. 2.7. Installation Check Report for KAC Chiller Units Customer : ________________________________________________________...
  • Page 19 Use following Alpha Numeric symbols to answer above questions: : for YES, : for NO / NIL, NA: for NOT APPLICABLE KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 15 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 20: Operation

    Chapter 3 Operation 3.1. Liquid Chilling Systems - Principle Kirloskar Chillers make KAC liquid chilling package system shall be utilized for chilling water OR brine (for details please contact Kirloskar Chillers). These units work on vapor compression principle. The basic components of a vapor-compression liquid chilling system are as follows: ...
  • Page 21: Components And Their Functions

    Commonly used expansion devices in refrigeration industry are:  Capillary tubes  Thermostatic expansion valves / Electronic expansion valves KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 17 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 22: Equipment Description And Cycle Operation

    As the name implies, flooded evaporators have submerged liquid refrigerant coverage over the heat transfer surface. Dx type of evaporator are used in KAC chillers. Evaporator in liquid-chilling versions may be either tube-in-tube, shell and-coil, shell- and-tube or plate type heat exchangers.
  • Page 23: Hermetic Type Scroll Compressor

    Compression is a continuous process: the scroll movement is suction, compression and discharge all at the same time. KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 19 IOM-KAC-ENG...
  • Page 24: Air Cooled Condenser

    3.3.2. Air Cooled Condenser All KAC units are equipped with compactly packed air-cooled condensers. These air-cooled condensers are manufactured with the latest technology 9.53mm (3/8”) O.D internally enhanced seamless copper tubes and super-slit aluminum fins. The copper tubes are precisely expanded and brazed to the corresponding headers.
  • Page 25: Electronic Expansion Valve

    All blades are statically and dynamically balanced for vibration free operation. 3.3.3. Electronic Expansion Valve The KAC systems are equipped with Electronic expansion valve (EXV). Every EXV will:  Expand the high pressure, high temperature liquid refrigerant to low pressure, low temperature refrigerant and ...
  • Page 26: System Accessories

    Maximum deviation from average voltage: RY = 1.33V; YB = 7.67V; BR = 6.33V Hence, maximum deviation is 7.67V % Voltage Imbalance = 100 X 7.67 = 1.86 % 411.33 KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 22 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 27: Startup And Operation

    Make sure all interlock wiring is completed as per Kirloskar Chillers wiring diagram. d) Check compressor lubricating oil level. ‘Prior to startup, the oil level should cover at least half level of the oil sight glass. e) Turn the main power switch ON; this will energize the crankcase heaters of the compressor.
  • Page 28: Stop Or Weekend Or Temporary Shutdown

    5C is not recommended due to the risk of liquid flow back. j) Optimum operating characteristics are viewable on the controller display. NOTE: INITIAL START-UP IS TO BE PERFORMED ONLY BY KIRLOSKAR CHILLERS AUTHORIZED SERVICE TECHNICIAN. THIS IS A MUST TO OBTAIN THE COMPLETE WARRANTY BENEFITS 3.6.
  • Page 29: Recommended Log Format For Kac Units

    NOTE: CRANKCASE HEATERS SHOULD BE OPERATED AT LEAST 24 HOURS PRIOR TO START- UP. CRANKCASE SHOULD BE WARM. OPEN ALL THE CLOSED VALVES BEFORE STARTING. 3.8. Recommended Log Format for KAC Units Unit ↓ Sr no. Description Date of Log : Compressor run hours No.
  • Page 30: Sequence Of Operation For Packaged Chiller Units

    It is customer’s responsibility to send the log readings once in fortnight to Kirloskar Chillers Pvt. Ltd., Service department at Head Office. This may help KCPL to keep continuous monitoring of unit for its trouble free operation 3.9.
  • Page 31 Stop the evaporator liquid Step-IV Stopping pump(s) c. Check that oil return to crank case is in order and the heater comes on. d. If required, close the compressor isolation valve KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 27 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 32: Standard Controls

    NOTE: ‘DO NOT RESET’ THE CONTROL UNLESS THE CAUSE FOR TRIPPING DUE TO HIGH PRESSURE IS ASCERTAINED. Checking Control Operation - (This test has to be performed only in presence of Kirloskar Chillers authorized service personal) a) Observe the discharge pressure on the panel.
  • Page 33: Voltage Protection Device

    3.10.3. Voltage Protection Device The KAC liquid chilling package unit comes along with voltage protection device, having manual reset. The VPD is incorporated in the unit to safe-guard the hermetic compressor motor failure from:  Single phasing, phase reversing & Voltage imbalance ...
  • Page 34: System Maintenance

    PLEASE BE AWARE THAT ALL REFRIGERANT PIPING MATERIAL IS COPPER. h) Use correct chiller parts as per our recommendation. Always mention correct part number / description, refer spare part manual for details. KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 30 IOM-KAC-ENG...
  • Page 35 √ Check refrigerant suction superheat temperature. √ Check setting and operation of safety devices. √ Check lubricating oil quality and level. √ Check setting and proper operation of KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 31 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 36: System Service

    Inspect the contacts of the motor starters and controls. WARNING:  The warranty becomes void if the wiring is not in accordance with Kirloskar Chillers specifications.  The warranty is void if the settings on any of the protection devices are altered.
  • Page 37: Evaporator

    CAUTION: THE BOND PRODUCED BY EXPANSION MUST BE REFRIGERANT TIGHT. THIS BOND SHALL BE PRODUCED BY APPLYING LOCKTITE (GRADE 638) OVER THE OUTER SURFACE OF THE TUBE AND ROLLING IT INTO THE TUBE SHEET. KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 33 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 38: Liquid Refrigerant Drier Replacement

    4.2.2. Liquid Refrigerant Filter Drier Replacement KAC units are equipped with high capacity replaceable filter drier in liquid line. The purpose of the filter drier is to keep the refrigeration circuit clean of solid contaminants, water and acid. Contamination can cause corrosion and ice building as well as malfunction of the unit. The filter drier cartridge is specially made out of Molecular sieves and Activated alumina.
  • Page 39: Refrigerant Properties

    BEFORE MAKING THE FIRM CONNECTION TO THE CHARGING VALVE. b) Open the valves and allow the refrigerant to flow into the refrigeration system. Refrigerant will get charged till the pressures are equalized. KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 35 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 40: Adjusting The Refrigerant Charge

    Pressurize the system with dry nitrogen and use a soap solution to determine if leaks are present. The leak test has to be performed only after evacuating the complete refrigerant from the part OR equipment OR chiller. KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 36 IOM-KAC-ENG...
  • Page 41 Refer recommended leak pressure test values mentioned in technical specification of chillers or concern Kirloskar Chillers Pvt. Ltd. e) Close the charging valve on the chiller OR part OR the equipment. Remove the copper tube if no longer required.
  • Page 42: Chapter 5 Troubleshooting

    Wait until unit calls for cooling / No Load. load. Liquid line expansion valve has Repair or replace motor. not operated. Check all wire junctions. Tighten Loose wiring. terminal screws. KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 38 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 43 Reduce load or add additional Excessive load. equipment Check remote bulb / check HIGH SUCTION Expansion valve overfeeding. superheat setting. Regulate PRESSURE superheat. High return water temperature. Reduce load or add additional KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 39 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 44 Expansion valve not opening / LOW SUCTION Check wiring connections of EXV. malfunctioning. PRESSURE Condensing temperature too Check cooling water flow and low. entering water temperature. Insufficient water flow. Adjust water flow. KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 40 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 45: Controls And Settings

    Chapter 6 Controls and settings 6.1. About the controller The Kirloskar “PRODIGYTM SERIES” Scroll Chillers have a state of the art control system ‘K – Smart’ which consists of main controller, the temperature and pressure transducers, expansion boards, and a backlit LCD display. The K-Smart controller is a rugged microprocessor based controller.
  • Page 46: Features Of K-Smart Controller

    3) Chilled Water Inlet Temp 4) Chilled Water Outlet Temp 5) Liquid Line Refrigerant Temp 6) Suction Line Ref. Temp. 7) Sat. Suction Temp. 8) Suction Super Heat KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 42 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 47 1) Battery backup for memory and clock to take care of power failures 2) Automatic startup on resumption of power after power failure. 3) Compressor lead-lag and sequencing facility for multi compressor units KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 43 IOM-KAC-ENG...
  • Page 48: Connector Details

    10. Connector for all standard PCO series terminals and for downloading the application program; 11. Relay digital outputs; 12. Connector for connection to the I/O expansion board; 13. PLAN network connector; 14. Cover for inserting the supervisor (Modbus) card option KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 44 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 49: K-Smart Inputs/Outputs

    Voltage free contact - digital input 3 J7-4 Voltage free contact - digital input 4 J7-5 Common for voltage free contact - digital inputs 1, 2, 3, 4 Connector for unipolar valve 2 KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 45 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 50 Relay 8, common J25-1 * DI7H Digital input 7, at voltage B(**) J25-2 * Digital input 7, at voltage A(*) J25-3 * DI7C Common for digital inputs 7, 8 KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 46 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 51: Pco Oem+ Technical Specification

    (**): voltage B: 230 Vac - 50/60 Hz. 6.4. PCO OEM+ Technical specification: Analog input: Analogue conversion: 10-bit A/D converter embedded in CPU Maximum number 10 Nos •NTC probes (-50T90°C; R/T 10 kΩ•}1% at Type: KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 47 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 52 T memory, buffer (EEPROM) 13 kB P memory, parameters (EEPROM) 32 kB (not visible from pLAN) Working cycle duration 0.2 s (typical) Clock with battery Supplied, accuracy 100 ppm Other features: KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 48 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 53: Pldpro Carel Keypad/Display

    Maximum distances: Maximum pLAN length: 500 m with AWG22 twisted pair cable pCO terminal distance: 50m with telephone cable 500m with AWG22 twisted pair cable and TCONN6J000 Note: to KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 49 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 54 RJ12 telephone jack (the factory default value is 32). To access configuration mode, press the buttons together and hold them for at least 5seconds; the screen shown in Fig below will displayed. KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 50 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 55: Keys And Display Functions

    Descriptions for the display This is the main screen displayed on display when we power on the machine. This is main menu from where you need to navigate. KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 51 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 56 Only after entering the proper password the controller will allow the parameters which are in user level. For enter the password we can use keys. KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 52 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 57: Troubleshooting

    2. 24 Vac/Vdc is available downstream of the power The unit does not start (power transformer; LED off) 3. The 24 Vac/Vdc power connecter is plugged in correctly; KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 53 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 58 “IDn”, in Doubtful alarm signal from digital input the following conditions: 1. If there is voltage (24 Vdc, depending on the power KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 54 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 59 PCO off and on again with the terminal The user terminal is blocked (it connected does not respond to the buttons) 2. The software on the PCO has been corrupt. (contact to KCPL service) KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 55 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 60: Technical Data

    46.96 122.0 0.09562 0.2322 310.0 309.1 62.95 5.513 49.06 122.0 0.09932 0.2308 332.0 331.1 61.95 5.990 51.21 121.8 0.1030 0.2293 355.3 354.3 60.90 6.513 53.39 121.6 0.1068 0.2277 KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 56 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 61: Useful Conversion Factors

    C = {(5/9) x (F-32)} F = {((9/5) x C) + 32}, 1 bar = 105 Pascal = 105 N/mm2 = 14.504 psi 1 psi = 0.68948 x 105 N/m2 = 68.948 mbar = 2.0360” Hg = 51.7149 torr (mmHg) KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 57...
  • Page 62: Annexures

    YES/NO properly? Do the condenser fans rotate in proper YES/NO direction? REFRIGERANT TYPE R-410A Is there a remote unit control? YES/NO Are all electrical connections tightness YES/NO checked? KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 58 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 63 C (F) Saturated condensing temperature C (F) Suction line refrigerant temperature C (F) Saturated Suction temperature C (F) Suction superheat Compressor amps Air-cooled condenser motors amps KIRLOSKAR CHILLERS PRIVATE LIMITED - Page 59 IOM-KAC-ENG A Kirloskar Group Company...
  • Page 64 REMARKS (if any) After start-up :  Keep one copy inside the control panel door.  Send one copy to ‘Kirloskar Chillers Head Office’ within one week from the date of commissioning; otherwise warranty claim may not be applicable. Contact Details...

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