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Manual Guide Vane Operation . . . . . . . . . . . . . . . . . 39
Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
TRANSFER PROCEDURES . . . . . . . . . . . . . . . . . 39
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Operating the Optional Pumpout Unit . . . . . . . . . . . 41
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . 44
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . 44
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . 44
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . 44
Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Test After Service, Repair, or Major Leak . . . . . . . . 44
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . 44
Checking Guide Vanes . . . . . . . . . . . . . . . . . . . . . . . 44
Trim Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . 44
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 47
Check the Lubrication System . . . . . . . . . . . . . . . . . 47
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . 47
Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . 47
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
VFD Refrigerant Strainer (if equipped) . . . . . . . . . . 48
Oil Reclaim Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Inspect Refrigerant Float System . . . . . . . . . . . . . . 48
Inspect Relief Valves and Piping . . . . . . . . . . . . . . . 49
Compressor Bearing and Gear Maintenance . . . . . 49
Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Inspect the Starting Equipment or VFD . . . . . . . . . 50
Recalibrate Pressure Transducers . . . . . . . . . . . . . 50
Optional Pumpout System Maintenance . . . . . . . . . 50
Ordering Replacement Chiller Parts . . . . . . . . . . . . 50
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . 51
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Checking Display Messages . . . . . . . . . . . . . . . . . . 51
Checking Temperature Sensors . . . . . . . . . . . . . . . 51
Checking Pressure Transducers . . . . . . . . . . . . . . . 56
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . 56
Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
End of Life and Equipment Disposal . . . . . . . . . . . . 56
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
MULTIPLE CHILLERS (TYPICAL) . . . . . . . . . . . . 107
LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
SAFETY CONSIDERATIONS
Centrifugal liquid chillers are designed to provide safe and reliable
service when operated within design specifications. When operat-
ing this equipment, use good judgment and safety precautions to
avoid damage to equipment and property or injury to personnel.
Be sure you understand and follow the procedures and safety pre-
cautions contained in the chiller instructions as well as those listed
in this guide.
Failure to follow these procedures will result in severe person-
al injury or death.
DO NOT VENT refrigerant relief valves within a building.
Outlet from rupture disc or relief valve must be vented out-
doors in accordance with the latest edition of ANSI/ASHRAE
15 (American National Standards Institute/American Society
of Heating, Refrigerating, and Air-Conditioning Engineers).
The accumulation of refrigerant in an enclosed space can dis-
place oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/
ASHRAE 15, especially for enclosed and low overhead spac-
es. Inhalation of high concentrations of vapor is harmful and
may cause heart irregularities, unconsciousness, or death. Mis-
use can be fatal. Vapor is heavier than air and reduces the
amount of oxygen available for breathing. Product causes eye
and skin irritation. Decomposition products are hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a
chiller for any purpose. Oxygen gas reacts violently with oil,
grease, and other common substances.
NEVER EXCEED specified test pressures; VERIFY the al-
lowable test pressure by checking the instruction literature
and the design pressures on the equipment nameplate.
DO NOT USE air for leak testing. Use only refrigerant or dry
nitrogen.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed
and functioning before operating any chiller.
RISK OF INJURY OR DEATH by electrocution. High volt-
age is present on motor leads even though the motor is not run-
ning when a solid-state or wye-delta mechanical starter is
used. Open the power supply disconnect before touching mo-
tor leads or terminals.
2
DANGER
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