Manual

26
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PRE-START UP
Before the chiller is started, there are certain essential checks
which must be carried out Failure to carry out these checks could
result in damage to the chiller voiding the warranty
Electrical
It is imperative to turn off the main electrical power supply and
follow proper lock-out, tag-out procedures prior to servicing any
of the chiller’s electrical components The following procedures
can be performed only after the electrical power is conrmed to
be off:
1 The installation should have been inspected and approved by
the respective agent and found to be in compliance with all
local and national electrical codes
2 Check & tighten as required all electrical terminal connections
on each module Utilize lock-out/tag-out procedures for this
operation A systematic tightening of all terminals inside the
electrical control panel on each module should be carried
out This will include the compressor motor terminals, which
would require removal of the compressor terminal cover
Check connections at each safety and every termination in the
panel
3 There are approx (12) control wires which must be eld
connected from each module’s electrical panel back to the
“Master Control Panel” These control wires should be routed
using a series of twisted pair conductors having #18 AWG
minimum up to 50 ft, #16 AWG minimum up to 100 ft, and
#14 AWG min up to 250 ft All eld wiring must be identied
(tagged)
4 All eld connections should be checked for tightness
5 Check all fuses for proper sizing as indicated on the chiller
data plate and/or the electrical diagram on the inside door of
the electrical panel
Refrigeration
1 Remove the front and rear access covers from the top
compressor sound enclosure of each module
2 Refrigerant piping and components should be inspected for
damage
3 Check all refrigeration and water valves for proper
positioning; once completed mark refrigerant valves with
permanent marker Make sure all refrigerant valves are fully
opened and there are no visible signs of refrigerant leaks Pre-
Start Up
4 Place refrigerant gauges on the discharge and suction access
ports of each refrigerant circuit to ensure a refrigerant charge
is present Leave the gauges on for compressor rotation check
5 Conrm the settings on all pressure switches and thermostats
Water System
1 Conrm that leak testing has been carried out
2 Conrm that the system is clean
3 Conrm that necessary water treatment systems are in place
with both the evaporator and condenser water systems
4 Conrm that appropriate water analysis has been conducted
by the end-user
5 Conrm that the results of this water analysis does not conict
with the acceptable constituent ppm levels as indicated in
Table 1, page 16
6 Extract a water sample from both the evaporator and
condenser Conrm that the sample bottles are lled to the top
leaving no air in the bottles Both sample bottles must have
labels lled out per instructions included with bottles Mail
bottles immediately to the appropriate water testing laboratory
as per instructions included with bottles
7 Conrm that both the chilled water and condenser water
circulating pumps are operational and water is owing
through both exchangers
8 Shut entering water valve and blow out some water to check
for particles or coloration from suspended particles Record
the differential pressures across the chiller condenser water
header and across the condenser heat exchanger, measured at
the “Pete’s” ports at each module
9 Conrm correct water ow rates through the condenser
and evaporator Acquire the “predicted” ow rates from
the building’s “hydronics system balancer” Compare the
measured differential pressures from step 6 above with the
predicted ow rates to ensure proper correlation to the ow
results
Chiller Pre-Start-Up Procedures
1 Turn selector switches on module panel off Fill in circuit
# and power panel identication inside each Module cover
panel
2 Ensure the correct fuses are installed in the control
transformer fuse blocks inside each ClimaCool Module Turn
on the power to each module The “Power” light should be on
3 Override output with DX commissioning program or place
a jumper between compressor 1 start terminals on the “eld
wiring” terminal strip (terminals 8 &9) With jumper in
place, turn on the selector switch marked “compressor #1”
to bump the compressor and check for proper rotation
Use pressure gauges to verify proper rotation Once this is
complete and correct rotation is veried, override output
with DX commissioning program or place a jumper between
compressor 2 start terminals on the control terminal strip
(terminals 10 & 11) Turn on the switch marked “compressor
#2” to bump the compressor and verify that circuit #2
Pre-Start Up