TC Manual Air Cooled Chillers PDF

Page 1 of 26
Temperature Control Manual Version 0.1

Date: 1/02/2007
Air Cooled Chillers Prepared By: Justin Day
Engineering Department
Temperature Control Manual
AIR COOLED CHILLERS
TC Manual Air Cooled Chillers.doc Aggreko Australia Pacific

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Date: 1/02/2007
TABLE OF CONTENTS
Section Page
IMPORTANT INFORMATION.............................................................................................................3
SERVICE BULLETIN.............................................................................................................................4
1 INTRODUCTION................................................................................................................5
1.1 Description........................................................................................................................5
1.3 Equipment .........................................................................................................................5
1.3.1 Compressor ..................................................................................................................5
1.3.2 Oil Separator ................................................................................................................6
1.3.3 Condenser ....................................................................................................................6
1.3.4 Expansion Valve ..........................................................................................................7
1.3.5 Evaporator....................................................................................................................7
1.3.6 Control Devices ...........................................................................................................7
1.4 Applications ......................................................................................................................7
1.5 Process ..............................................................................................................................8
1.5.1 Refrigerant Cycle.........................................................................................................8
1.5.2 Oil Cycle ......................................................................................................................8
2 TECHNICAL DATA ...........................................................................................................9
3 INSTALLATION, OPERATION AND MAINTENANCE (IOM)................................15
3.1 Installation.......................................................................................................................15
3.1.1 Handling.....................................................................................................................15
3.1.2 Foundation .................................................................................................................15
3.1.3 Water Drain Hole.......................................................................................................15
3.1.4 Clearances..................................................................................................................15
3.1.5 Water to Evaporator Connection ...............................................................................15
3.3 Commissioning ...............................................................................................................16
3.3.1 Starting the Unit.........................................................................................................16
3.4 Operation.........................................................................................................................16
3.4.1 Temporary Shut Down and Restart............................................................................16
3.4.2 Emergency Stop.........................................................................................................16
3.4.3 Final Check ................................................................................................................17
3.4.2 Principal of Operation................................................................................................17
3.5 Decommissioning ...........................................................................................................17
3.6 Maintenance Procedures .................................................................................................18
3.6.1 Condenser ..................................................................................................................18
3.6.2 Refrigerant Charge.....................................................................................................18
3.6.3 Weekly Maintenance and Checks..............................................................................18
3.6.4 Monthly Maintenance and Checks.............................................................................18
3.6.5 Annual Maintenance ..................................................................................................18
3.6.9 Maintenance Schedules..............................................................................................19
1.6 Troubleshooting ..............................................................................................................22
4 ELECTRICAL ...................................................................................................................25

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Date: 1/02/2007
IMPORTANT INFORMATION
Fluid Flow through the chiller:
Fluid pump MUST always feed into the Chiller
Proper flow MUST be established for optimum operation
The pressure across the chiller barrel is set to 40kPa delta p
(delta p = fluid press entering the chiller minus fluid leaving the chiller)
Correct Pump size
Installation:
Have technical information with you at all times to refer to
Position equipment on a level surface and leave room for air intake and room to work
Keep hosing lengths as short as possible and tidy
Complete a commissioning report
Chiller Settings:
Leaving fluid temperature setting (Set Point)
Cut in / Cut out temperature settings (Range / Dead Band)
Low water temperature cut out setting
Low refrigerant cut out setting
Fluid Flow (delta p)
Chiller Safety:
Contamination of chiller barrels
Proper fluid flow
Correct Power Supply
Correct Phase Rotation
PRE HEAT CHILLERS (minimum 24 hrs)
Service valves
Follow manufacturers recommendations
Install strainers

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Date: 1/02/2007
SERVICE BULLETIN
BULLETIN NUMBER ASB0088A ISSUE DATE 4th September 2006
REFERENCE
SUBJECT YCAS chillers supplied to Aggreko
WITHDRAWAL DATE N/A
Re: YCAS0623 chillers supplied to Aggreko for the chiller rental market
A number of YCAS chillers have been supplied to Aggreko for use as rental chillers. These machines have been
especially modified so that they will operate on normal air conditioning duty down to 4oC, low temperature glycol
duty down to -12oC and ultra low temperature glycol duty down to -19oC.
As for a standard machine, for air conditioning duty dip switch number one must be in the open position. For
normal glycol mode (down to -12oC) dip switch number one must be in the closed position. If ultra low
temperature glycol is required (down to -19oC) a special procedure is required.
Procedure for ultra low temperature glycol operation (down to -19oC).

1. Program chiller panel for “imperial” units mode (ultra low temperature duty will not operate in SI units
mode).
2. Enter special password code “7522”. The display will indicate “standard’ mode.
3. Using the scroll buttons select “low temperature” mode.
4. Once “low temperature” mode is selected the desired leaving liquid control temperature, leaving liquid
temperature cut out and suction pressure cut out can be programmed in the usual manner (settings must
be in Fahrenheit for temperature and PSIG for pressure).
CAUTION
Do not operate the chiller in a lower temperature mode than is required for a particular application. Low
temperature operation does require close attention to glycol concentration so only ever select glycol mode or ultra
low temperature mode when absolutely necessary.
Graham Parry
Technical support.
PLEASE FILE THIS BULLETIN IN YOUR APPLIED BULLETIN BINDER AND POST ON THE APPLIED SECTION OF
YOUR BULLETIN NOTICE BOARD.
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Date: 1/02/2007
1 INTRODUCTION
This manual contains directions regarding the descriptions, installation, and operations
of the Aggreko Air Cooled Fluid Chillers.
1.1 Description
The units are intended for the cooling of water or non corrosive fluids. They are
designed to be located outside (rooftop or ground), not in an enclosed plant room or
sealed building.
They are used for a wide variety of applications in the mining, process, HVAC, Food,
Industrial, and Manufacturing industries.
The outlet temperatures for the chillers vary from our standard 6°C water mixture to
the lower temperatures of -19°C (50% water / glycol mixture).
1.3 Equipment
1.3.1 Compressor
The air cooled chiller consists of two distinct components; motor and rotor.
A two pole, hermetic, squirrel cage induction motor directly drives the compressor
rotors. The motor is cooled by suction refrigerant gas from the evaporator, entering the
end of the motor housing through the suction line.
The compressor is a semi-hermetic direct drive helical rotor compressor. Each

compressor has only 3 moving parts, 2 rotors and a slide valve to control the capacity.
The male rotor is attached to, and driven by the motor.
The refrigerant from the evaporator is drawn into the suction opening at the end of the
motor barrel, through a suction strainer screen, across the motor, and into the intake of
the compressor rotor section. The gas is then compressed and discharged directly into
the discharge line.

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Date: 1/02/2007
1.3.2 Oil Separator
The oil leaves the compressor entrained within the discharged refrigerant vapour, and it
is the oil separator that recovers this oil.
The separator consists of a vertical cylinder surrounding an exit passageway. As the

refrigerant and oil mixture is discharged into this passageway the oil is forced outward
by centrifugal force, collects on the walls of the cylinder and drains to the bottom. This
accumulated oil drains out of the cylinder and collects in the oil sump located near the
bottom of the chiller.
The oil sump is heated to ensure proper lubrication and minimise refrigerant
condensation in the sump.
1.3.3 Condenser
The air cooled condenser coils have aluminium fins mechanically bonded to internally
finned seamless copper tubing. The condenser coil has an integral sub cooling circuit.
Direct drive vertical discharge airfoil condenser fans are dynamically balanced.
The water is pumped through the tubes of the shell and tube heat exchanger while
refrigerant vapour fills the shell space surrounding the tubes. The condenser has a
baffle plate that helps distribute the refrigerant evenly within the shell. As heat is
transferred from hot, high pressure refrigerant vapour to the water, refrigerant
condenses on the tube surfaces.

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Date: 1/02/2007
1.3.4 Expansion Valve
The expansion valve is used to maintain the pressure difference between the high-
pressure (condenser) and the low pressure (evaporator) sides of the system, as
established by the compressor. This pressure difference allows the evaporator
temperature to be low enough to absorb heat from the water being cooled, whilst
allowing the refrigerant to be at high enough temperature in the condenser to reject heat
to water at normally available temperatures.
High pressure liquid refrigerant flows through the expansion device, causing a large
pressure drop that reduces the refrigerant pressure to that of the evaporator. This
pressure reduction causes a small portion of the liquid to boil off, or flash, cooling the
remaining refrigerant to the desired temperature.
1.3.5 Evaporator
The evaporator is a tube in shell heat exchanger design, with internally finned copper
tubes roller expanded into the tube sheet.
The evaporator is designed for a waterside working pressure of 14 bar. Water

connections are grooved pipe for victaulic couplings. Each shell includes a vent, a
drain, and fitting for temperature control sensors, and is insulated.
Evaporator heaters with thermostats provide protection to the evaporator from freezing
at ambient temperatures of -29°C.
1.3.6 Control Devices
The unit controls are housed in a weather tight enclosure with removable plates to
allow for connection of power wiring and remote interlocks.
Microcomputer controls provide all control functions including startup and shutdown,
leaving chilled water temperature control, compressor and electronic expansion valve
modulation, fan sequencing, anti-recycle logic, automatic lead/lag compressor starting
and load limiting.
The controls also automatically take action to avoid unit shutdown due to abnormal
operating conditions associated with low refrigerant pressure, high condensing
pressure, and motor current overload. Unit protective functions include loss of chilled
water flow, evaporator freezing, loss of refrigerant, low/high refrigerant pressure, phase
reversal, and loss of oil flow.
1.4 Applications
The air cooled chiller can be used in a wide variety of applications in various
industries. The chiller is often used in conjunction with other Aggreko equipment such
as cooling towers, fluid pumps, and heat exchangers.

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Date: 1/02/2007
1.5 Process
1.5.1 Refrigerant Cycle
Saturated refrigerant vapour from the evaporator is drawn into the suction opening of
the screw compressor. The gas is compressed and discharged through a check valve
into the discharge line.
An oil separator removes the oil from the refrigerant going to the air cooled condenser,
where the heat of compression and cooling load are rejected, (the refrigerant
condenses). In the sub-cooler, which is a part of the condenser, the refrigerant is
cooled down further. The refrigerant passes through the expansion valve, where the
pressure is dropped, which results in vaporisation of some of the refrigerant.
The liquid vapour refrigerant mixture enters the liquid vapour separator where liquid
and gas are separated, the vapour is directed to the evaporator suction. The liquid is
evenly distributed over the length of the evaporator by the distribution liquid system.
Heat is transferred from the water inside the tubes to the refrigerant as the film of
refrigerant evaporates on the surface of the tube, refrigerant vapour exits the evaporator
through the suction baffle where is mixes with the vapour from the liquid vapour
separator.
1.5.2 Oil Cycle
The compressor oil supply is obtained from the oil separator. Due to the pressure
differential between discharge and suction pressure, oil is injected via the oil cooler
into the compression chamber and the bearings of the compressor from where it is
returned together with the compressed gas to the oil separator.
The oil and gas are separated, oil flows down to the bottom of the separator, from
where it again flows to the compressor.
Oil that gets past the oil separator flows through the condenser, sub-cooler and
expansion valve into the evaporator. This oil is collected in the pool of refrigerant that
is maintained in the bottom of the evaporator. A small amount of oil and refrigerant
from this pool is returned through a line that is connected to the compressor down
stream of the motor.
This oil and refrigerant mixes with the refrigerant vapour that was drawn out of the
evaporator.

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Date: 1/02/2007
2 TECHNICAL DATA
aggreko
Prepared by: Adam Hentschel Date: 17.12.2002 Revision: A Page 9 of 26
Discipline: Fluid Chillers Document number
Section:
AIR COOLED SCROLL FC50A au.1.3
1. INTRODUCTION
The Aggreko -C- range air cooled fluid chillers are designed for water or water-Glycol cooling. All units
are designed to be located outside. The units are completely assembled with all interconnecting
refrigerant piping and internal wiring, ready for installation.
The unit base and frame is of heavy-gauge steel and is fully tested and certified
2. KEY-DATA
Cooling Capacity 52 kW at 6 degrees leaving water temperature

Absorbed Power 19 kW
Temperature Range +15 ºC to -12 ºC
Maximum ambient temp. 43ºC
Dimensions
length 2.36 metres
width 1.20 metres
height 2.11 metres
Weight 1250 kg
3. LAYOUT

Page 10 of 26

Date: 1/02/2007
aggreko
Section:
4. TECHNICAL SPECIFICATIONS
ITEM UNITS VALUE

Performance Data
Design Capacity kW 52
Design Operation Fluid Temperature IN / OUT ºC / ºC 12 / 6
Minimum / Maximum Outlet Fluid Temperature ºC / ºC -12 / +15
Minimum / Maximum Chilled Liquid Temperature Difference ºC / ºC 3.5 / 10.2
Design Ambient Temperature ºC 35
Minimum / Maximum Ambient Temperature ºC / ºC 3 / +43
Compressor
Compressor Type Semi Hermetic Scroll
Number Of Compressors 2
Number Of Capacity Steps No. / % 2/ 50
Evaporator Data
Evaporator Type Plate
Evaporator Material S.Steel & Copper
Design Flow l/s 2.07
Minimum / Maximum Flow l/s / l/s 1/4
Evaporator Capacity litres 4
Evaporator Maximum Working Pressure kPa 1000
Design Chiller Barrel Pressure Drop kPa 30
Recommended System Fluid Volume litres 315
Condenser Data
Number Of Condenser Fans 1
kW per Fan kW 1.2
Total Air Volume m³/s 5.5
External Static Pressure Pa 0
Refrigerant Data
Refrigerant Type R22
Number of Circuits 1
Refrigerant Charge circuit 1 / 2 kg 9
Type Of Compressor Oil 025E
Oil Charge circuit 1 / 2 litres 7.6
Electrical Data
Design Electrical Supply Voltage Volts 440 3ph / 50/60hz
Design Electrical Rating kVA / kW 22 / 19.1
Design / Maximum Operating Current Ampere 30 / 45
Starting Current Ampere 107
Pre-Heating Supply Volts / VA N/a
Recommended Generator Set kVA 30
Required Cable Size per Phase mm² 10
Electrical Connection 40A Clipsal Plug
Noise Data
Sound Pressure Level at 10 metres - Lp(A) dB(A) 54
Sound Power Level - Lw(A) dB(A) 82
Physical Data
Overall Length metres 2.30
Overall Width metres 1.20
Overall Height metres 2.11
Weight kg 1250
Fluid Coupling Size mm / inch 50 / 2" Camlock
NOTE: Contact Technical Department If Application Conditions Differs From Design Conditions

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Date: 1/02/2007
aggreko
Section:
1. INTRODUCTION
The unit base and frame is of heavy-gauge steel and is fully tested and certified
2. KEY-DATA

Maximum ambient temp. 43ºC
Dimensions
length 2.80 metres
width 2.20 metres
height 2.08 metres
Weight 2400 kg
3. LAYOUT

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Date: 1/02/2007
aggreko
Section:
ITEM UNITS VALUE

Performance Data
Compressor
Compressor Type Semi Hermetic Scroll
Number Of Capacity Steps No. / % 4/ 25
Evaporator Data
Evaporator Type Plate
Evaporator Material Steel & Copper
Minimum / Maximum Flow l/s / l/s 1 / 10
Evaporator Capacity litres
Evaporator Maximum Working Pressure kPa 1400
Recommended System Fluid Volume litres
208
Condenser Data
kW per Fan kW 1.2
Total Air Volume m³/s 16.2
Refrigerant Data
Refrigerant Charge circuit 1 / 2 kg / kg 14.45/14.45
Type Of Compressor Oil 025E
Oil Charge circuit 1 / 2 litres 11 / 11
Electrical Data
Design Electrical Supply Voltage Volts 440 3ph / 50/60hz
Design Electrical Rating kVA / kW 88 / 71
Design / Maximum Operating Current Ampere 116
Pre-Heating Supply Volts / VA N/a
Electrical Connection M12
Noise Data
Physical Data
Weight kg 2400
Fluid Coupling Size mm / inch 100 / 4"
NOTE: Contact Technical Department If Application Conditions Differs From Design Conditions

Page 13 of 26

Date: 1/02/2007
aggreko
Section:
AIR COOLED SCREW FC600A au.1.1
1. INTRODUCTION
The unit base and frame is of heavy-gauge steel with the dimensions of a standard 20 ft container
tested and certified .
2. KEY-DATA

Maximum ambient temp. 40 ºC
Dimensions standard ISO 20ft. Container.
length 6.05 metres
width 2.43 metres
height 2.59 metres
Weight 6820 kg
3. LAYOUT

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Date: 1/02/2007
aggreko
Section:
AIR COOLED SCREW FC600A au.1.1
ITEM UNITS VALUE
Performance Data
Compressor
Compressor Type Semi Hermetic Screw
Number Of Capacity Steps % 12.5 thru 100
Evaporator Data
Evaporator Type Shell & Tube
Evaporator Material Steel & Copper
Minimum / Maximum Flow l/s / l/s 15 / 44
Chiller Barrel Capacity litres 204
Chiller Barrel Maximum Working Pressure kPa 1000
Chiller Barrel Pressure Drop Factor p.u. 5.66
Recommended System Water Volume litres 2520
Condenser Data
kW per Fan kW 0.85
Total Air Volume m³/h 139
Refrigerant Data
Refrigerant Charge circuit 1 / 2 kg / kg 62 / 62
Type Of Compressor Oil ISO 68
Oil Charge circuit 1 / 2 litres 17 / 17
Electrical Data
Design Electrical Supply Voltage Volts 400 3ph / 50 Hz
Design Electrical Rating kVA / kW 213 / 182
Design / Maximum Operating Current Ampere 308 / 443
Pre-Heating Supply Volts / VA 220 / 600
Electrical Connection Busbar M12
Noise Data
Physical Data
Weight kg 6820
Fluid Coupling Size mm / inch 100 / 4"
NOTE: Contact Technical Department If application conditions differ from design conditions

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Date: 1/02/2007
3 INSTALLATION, OPERATION AND MAINTENANCE (IOM)
3.1 Installation
Installation of the Chillers is of utmost importance. The operating life will be

improved with the correct installation of the equipment.
3.1.1 Handling
The fluid chiller can be handled by a forklift or slings. Ensure that the weight of the
fluid chiller does not exceed the maximum allowable lifting capacity of the crane,
slings or forklift. Ensure all doors are closed and locked before moving.
3.1.2 Foundation
A solid foundation is required for the positioning of the unit, and must be flat, level and
able to withstand the weight of the unit.
3.1.3 Water Drain Hole
Ensure that there is a drain hole wide enough to drain any water from the unit in the
event of shutdown or repair.
Note: Chemicals added to the chilled water system can affect the environment if
drained. Ensure water is free of these before draining.
3.1.4 Clearances
Ensure there are sufficient clearances around the unit to allow maintenance operations
to take place without obstruction. The following minimum distances are required to
prevent condenser air recirculation and faulty operation:
a. Front clearance of 1.5m
b. Side and rear clearance of 1.5m
c. Clearance above unit of 10m
d. Distance between adjacent units of 3m.
3.1.5 Water to Evaporator Connection
Install the water circulation pump upstream of the evaporator, making sure that the
evaporator is under positive pressure. The water must enter the evaporator by the inlet
connection.
Pipe work and fittings must be separately supported to prevent any loading on the
evaporator. Flexible connections or hoses are recommended.

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Date: 1/02/2007
3.3 Commissioning
Before starting up the system, the following should be checked;

a. Connect 32A auxiliary supply, min preheating time is 4hrs
b. Chilled water circuits ready to operate, filled with water, pressure and leak tests
have been carried out and purging has taken place
c. Ensure that all water and refrigerant valves are in the service position
d. Where mechanical guards are provided these must be in position when the unit is
running
e. Check that all electrical connections are clean
f. Close all panel doors
e. Switch on supply circuit breaker
3.3.1 Starting the Unit

a. Switch on the main circuit breaker
b. Start water pump, adjust flow rate with flow valve if necessary
c. Reset alarm (if any) by pressing “Reset all active Diagnostics” in alarm tab
d. To start the unit, press the “Auto” tab on the unit control module
NOTE: The unit will automatically start and try to maintain the set temperatures if the
following conditions are met:
a. Supply voltages are within operating parameters
b. Preheating time elapsed and oil temperature within parameters
c. All anti-recycle timers are timed out
d. All safety systems are within operating parameters
e. Sufficient fluid flow
f. Cooling demand exists
3.4 Operation
3.4.1 Temporary Shut Down and Restart

a. Press the “stop” tab on the control panel, compressors will stop
b. To restart the unit, press the “Auto Tab”
3.4.2 Emergency Stop
A push button located on the unit causes the unit to stop immediately. To restart the
unit after an emergency stop, pull out the stop button and reset the alarm on the touch
screen.

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Date: 1/02/2007
3.4.3 Final Check
After start up, leave the unit in operation for at least 15 minutes, to ensure that the
refrigerant pressures are stabilised. The following must then be checked:
a. Both suction and pressure / temperature gauges must show approx 2 - 5°C below
leaving liquid temperature. (When running at low temp applications, this value can
be higher)
b. Both discharge pressure / temperature gauges must be approx 15°C above ambient
air temperature
c. The sight glass in expansion valve must be clear
d. Check for any noise and vibrations
3.4.2 Principal of Operation
3.5 Decommissioning
The decommissioning procedure is as follows:

a. Press the “stop” tab on the control panel, compressors will stop
b. Stop all fluid pumps
c. Switch off unit power supplies
d. Disconnect supply cable, lock access panel
e. Drain the chilled water system
f. Disconnect fluid hoses (water circuit to evaporator might be under pressure.
Reduce before opening up the system

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Date: 1/02/2007
3.6 Maintenance Procedures
3.6.1 Condenser
In some environments the condenser coils may get dirty and shutdown due to high
condensing pressure. If this happens, clean condenser coils with a brush or jet of
water. Note: Fins of condenser coils may be sharp, use appropriate PPE.
3.6.2 Refrigerant Charge
The amount and type of refrigerant charge is listed on the unit name plate. Check
monthly for unit leaks. Oil marks can be symptoms of refrigerant leaks.
3.6.3 Weekly Maintenance and Checks
After the unit has operated for approx 30 minutes and the system has stabilised, check
the operating conditions and complete the following:
a. Log the chiller
b. Check evaporator and condenser pressures with gauges and compare to the
reading on the display. Pressure readings should fall within the operating ranges.
3.6.4 Monthly Maintenance and Checks
On a monthly basis, the following should be done:

a. Review the operating log
b. Clean all water strainers in both chilled and condensing water piping system
c. Measure the oil filter pressure drop. Replace oil filter if required
d. Measure and log the sub-cooling and superheat
e. If operating conditions indicate a refrigerant shortage, leak check the unit using
soap bubbles and repair all leaks
f. Trim refrigerant charge until the unit operates in accordance with settings.
3.6.5 Annual Maintenance
Shut down the chiller once per year to check the following:
a. Perform all weekly and monthly maintenance procedures;
b. Check refrigerant charge and oil level;
c. Perform oil analysis;
d. Check pressure drop across the oil filter;
e. Inspect all piping for leakage and damage. Clean strainers;
f. Clean and repaint;
g. Test vent piping of all relief valves for presence of refrigerant to detect
improperly sealed relief valves. Replace any leaking relief valves; and
h. Inspect condenser tubes for fouling; clean if necessary.

Page 19 of 26

Date: 1/02/2007
3.6.9 Maintenance Schedules
The following are the Maintenance Schedules for the Aggreko Fluid Pumps:
Maintenance Schedule for Aggreko's Water-Cooled Liquid Chiller Fleet Series No: FC1200
(RTHA), FC1300 (RTHB), and FC1500 (RTHC) with Helical Rotary (Screw) Compressors:
Monthly Completion At 36
On Hire 6-Monthly
Item or at of Hiring Cumulative
No. Installation, Operation, and Maintenance Instructions and
750
or at 4300
and Months of
Installation Hours
Hours Decomm. Operation
General:
Check and record the following operational data, as much

as possible, on Commissioning and Start-up Report Sheet and
check monthly and at decommissioning time:
o
1. ambient air dry bulb and wet bulb temperatures ( C)
2. compressor suction and discharge pressures (kPa)
o
3. compressor suction and discharge temperatures ( C)
o
4. compressor suction superheat temperature ( C)
o
5. low refrigerant temp safety cut out set point ( C)
o
6. chilled water leaving temperature set point value ( C)
1 o
7. chilled water return temperature ( C) X X X
o
8. low chilled water temp. safety cut out set point ( C)
o
9. condenser water leaving temperature ( C)
o
10. condenser water return temperature ( C)
11. condenser water return limit set point value (%)
12. power supply Voltage (V) and frequency (Hz)
13. FLC: full load current (Amps)
14. phase currents (Amps)
15. current limit set point value (%)
Check and record pressure drops through chilled water

recirculation system and condenser water recirculation, and
2 X X
compare with design specifications and the job site-specific
chiller selection/ rating data.
3 Check and record sump heater operation when unit is off. X X
Check and expedite any undue vibrations on the chiller unit.

4 X X
Seek for solution(s) to rectify.
Check and record oil pressure. Compare with the operating
5 X X X
range in chiller manufacturer's IOM manual.
Check liquid refrigerant flow in sight glass for presence of
6 X X X
moisture or any shortage of refrigerant.
Check the settings of the HP and LP safety switches and oil
7 control functions and compare with the allowable limit values X X X
in the manufacturer's IOM Manual. Reset if necessary.
Check motor and drive and record the rated running load
8 X X
current in Amps.
Check the existence of any refrigerant leaks. Report the
9 X X X
leaks for rectification.
10 Prove solenoid operation, as applicable. X X X
Check the functionality of the flow switches on chilled water

11 X X
system and condenser water system, as applicable.

Page 20 of 26

Date: 1/02/2007
On Hire 6-Monthly
No. Maintenance and Servicing Instructions and
750
or at 4300
and Months of
Installation Hours
Check the TX valve or electronic expansion valve and

12 X X
superheat, as applicable.
Check operation and calibration of chilled water temperature
13 X X
controller to maintain the intended design temperature.
Check setting and operation of chilled water, low
14 X X
temperature safety thermostat, and record trip temperature.
Check the thermal insulation over the chiller components.
15 Replace or repair if necessary. Re-establish vapour seal X X X
around the chiller unit.
16 Inspect corrosion protection device, as applicable. X X
Remove insulation and water boxes. Clean and fit new
17 X
gaskets.
Clean chilled water tubes, plates, bolts, grease threads, and
18 X
reassemble.
Slug dose chilled water upon refilling or replenishing CHW
19 X
in the recirculation system.
Check and clean in-line strainers and scale traps on both
the chilled water and condenser water recirculation systems,
20 X X
as necessary, depending on the type of cooling application
and quality of the chilled water.
21 Check oil level and top up if necessary. X X X
22 Test oil for acidity. X X
23 Flush oil sump and change oil, if necessary. X
24 Check driers and change if necessary. X X
25 Check oil filters and change if necessary. X X
26 Check and align coupling and report on rubber wear. X X
27 Set unit to work, prove operation. X X X
28 Lubricate and grease all points and linkages. X X
29 Repair and paint any corrosion, clean generally. X X
Electrical:
Check for signs of burnt, hot connections and burnt contacts
1 X X
on starters and relays. Clean, rectify, and tighten.
2 Replace any faulty indicator lights. X X X
Examine general condition of conduits, connectors,
3 switches, and wiring, especially when chiller installed in damp X
and outdoor areas.
4 Check operation of each item of equipment. X X X X
Check for proper operation of Voltmeter and Ammeter as
5 X X X
applicable. Replace faulty meters.
6 Inspect, clean, and replace contacts, as necessary. X
7 Inspect relays. Replace faulty relays, as necessary. X
8 Check overload ratings against motor nameplate. X X
Check connections to compressor motors, control panel/
9 MCCB (Motor Control Centre Board), and at points where the X X
equipment is subjected to vibrations.
10 Examine external switches for possible damages to seals. X X
11 Check all time delays. X X
12 Check all fuses for correct rating. X X
Replace any safety warning, instructional, and operational
13 X X X X
labels that have fallen off, damaged, or removed.
Check and rectify condition of exposed cable insulation.
14 Strictly follow safe power isolation procedures prior to cable X X X
repair works.

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Date: 1/02/2007
On Hire 6-Monthly
No. Maintenance and Servicing Instructions and
750
or at 4300
and Months of
Installation Hours
15 Vacuum clean interior of the control panel/ MCCB. X X
16 Check and ensure that conduits are securely fixed. X X
17 Examine and rectify the seals on the control panel/ MCCB. X X
Check for the existence of electrical wiring diagram inside

18 X X X X
the control panel/ MCCB.
Check the consistency of the electrical wiring diagram with
19 the actual wiring and the components of the chiller. Ensure X X
that it is 'as-installed'. Report any inconsistencies.
Report any required revisions on the electrical diagram as
20 X X
per electrical modifications done or planned.
21 Lubricate all pivot points. Use pure petroleum jelly. X X
Piping and Fittings Associated with Chiller Installation:
Check rigid and flexible CHW and CDW pipework and valve
1 X X
glands for leaks, and repair leaks.
Clean rigid and flexible pipework, wipe flexible pipe
2 X
connections with grease, as applicable.
Check and ensure that all valves are in correct position and
3 X
orientation.
4 Check proper functioning/ operation of all valves. X X X X
5 Check strainers and clean, as necessary, as applicable. X X X
6 Vent all high points in the system, as applicable. X

Check all vents or scale pockets, vent or drain as
7 X
necessary.
Check condition of pipe insulation, test pipe insulation, as
8 X X X
applicable.

Page 22 of 26

Date: 1/02/2007
1.6 Troubleshooting
Problem Possible Cause Action

No lights on panel Switch on main supply if safe to do so
Mains supply to control system not on
1Q5-2 tripped (380V)
Display A53 not on Reset if safe to do so
1Q5-2 tripped (24V)
Reset if safe to do so
Power Supply Module A10
Check fuse
Check Phase Rotation, correct if req
Incorrect Phase Rotation
Unit will not
Check voltage according to name
operate Supply Fault Lit Voltage outside operating parameters
plate data
1U1 faulty
Check / Replace 1U1
Emergency Stop Reset
Emergency Stop input is open
Main supply 1Q531 tripped Reset if safe to do so

1Q532 tripped Reset if safe to do so
K8 faulty Check / Replace
D20-3 faulty Check / Replace
K9 faulty Check / Replace
1Q4 tripped Reset if safe to do so
Auxiliary Supply 1Q3 tripped Reset if safe to do so
Preheating 1Q5-33 tripped Reset if safe to do so
not D20-4 faulty Check / Replace
operational K10 faulty Check / Replace
No display 1T71 fuse blown Check / Replace
1Q5-31 tripped (main supply) Reset if safe to do so
1Q5-32 tripped (main supply) Reset if safe to do so
1Q3 tripped (auxiliary supply) Reset if safe to do so
1Q5-33 tripped (aux supply) Reset if safe to do so
B31 faulty Check / Replace
Temperature reading Faulty sensor Check / Replace
Oil heat delay light on/ Oil temp has not reached working Check display on B31 module to
compressor lockout temp following power up / or still in 4 hr confirm oil temp is slowly rising,
time delay cycle check time remaining
Compressor Set up not correct Check setting on dyna view module
will not start Compressor locked out Unit held off by timers Wait until timers are timed out
Run inhibit No heat load Check setting temp controller
Temp Control Mod. “Auto” Incorrect temp reading Check calibration temp sensors
display Incorrect temp setting Check set point
Discharge high pressure trip due to Check for airflow restrictions caused
poor air flow through the condenser by blockage
coil Check for fouling of condenser coils
Check for damaged fins/return bends
Check for correct fan operation
High Check for recirculation of ejected air
Pressure Unit operating above load limit Check ambient temp is above design
Alarm conditions
Check leaving water temp is below
max operating limits
Service valve closed Open service valves
Excessive refrigerant charge Check for signs of air in refrig. system
Check sub-cooling is correct
Filter Iced up Refrigerant filter blocked Check filter
Temperature sensor fault Bad sensor or LLID Check / Replace
Pressure transducer fault Bad sensor or LLID Check / Replace
Communication loss Faulty LLid Check / Replace

Page 23 of 26

Date: 1/02/2007

Starter did not transition
Starter module didn’t receive a
(Compressor)
transition complete signal in
designated time.
180FO 182 Phase reversal (compressor) Check power supply
A phase reversal was detected on the
incoming current, on a compressor
startup
No current sensed on one or two of the
current-transformer inputs while
running or starting.
19C If phase reversal protection is enabled
Phase loss (compressor) Check power supply
19E and current is not sensed on one or
both current transformer inputs, logic
will detect and trip in a max of 0.3 sec
after compressor start
Compressor previously established
1A0
Power loss (compressor) currents while running, and then all Check power supply
1A2
three phases of current were lost
A 40% phase current balance is
1B2 Severe Phase Unbalance
detected on one phase, relative to all 3 Check power supply
1B4 (compressor)
phases (for 90 sec)
Currents detected when only 1MI is
1E9 Starter fault type 1
closed, one of the other contactors is Check contactors
1EB (compressor)
shorted
1ED Starter fault type 2 Currents detected with only 1K3
Check contactors
1EF (compressor) closed. 1M contactor is shorted
1F1 Starter fault type 3 No currents detected within 1.6 sec
Check contactors
1F3 (compressor) during startup sequence
5AC Transition complete input The transition complete input found to
5AE shorted (compressor) be shorted before compressor started
B
Compressor current exceeded
EC Overload trip (compressor) Check compressor
overload time
BC
D7 Over voltage Line voltage above 10% of nominal Check power supply
D8 Under voltage Line voltage below 10% of nominal Check power supply
Intermediate oil pressure transducer
198 out of acceptable range for 15 sec,
Low oil flow (compressor) Check pressure transducers
19B while delta pressure greater then
2.45bar.
System differential pressure for
1AE Low differential refrigerant
respective circuit below 2.45 bar for
1AF pressure
more than 140 bar-sec
System differential pressure for
1C6 High differential refrigerant
respective circuit was above 19.25 bar
1C7 pressure
for two consecutive
Oil temp of respective circuit, as
1DD supplied to compressors exceeded
High oil temperature
1DF 93°C for 2 consecutive samples or for
more then 10 seconds
MP received fault signal from

2A1 Check speed inverter
Condenser fan VSD fault condenser fan Variable speed inverter
5B5 Check fans
drive and can’t clear the fault
The liquid level sensor is near low end Check refrigerant

583
Low evaporator liquid level of range for 80 continuous minutes Check expansion valve operation
5B6
while compressor is running Check liquid level sensor

Page 24 of 26

Date: 1/02/2007

The liquid level sensor is near high
584 Check expansion valve operation
High evaporator liquid level end of range for 80 continuous
5B7 Check liquid level sensor
minutes while compressor is running
This info diagnostic will auto reset if
Input signal out of range (low / high or input returns to normal range
87 External chilled water set point
bad LLID) Check signal
Change setting to front panel setpoint
This info diagnostic will auto reset if
Input signal out of range (low / high or input returns to normal range
89 External current limit set point
bad LLID) Check signal
Change setting to front panel setpoint
Leaving chilled water temp fell below
Run water pump until the diagnostic
C5 Low chilled water temp: unit off leaving water temp cutout set point
Auto resets
(chiller stopped)
Chilled water temp fell below cutout Auto reset occurs when temp rises
C6 Low chilled water temp: unit on
set point while compressor running 1.1°C above cutout for 2 mins.
Evaporator water flow was not
Check flow
384 Evaporator water flow overdue detected within 4.25 mins of unit being
Check flow safety
started
Chilled water flow switch input open for Check flow
ED Evaporator water flow lost
more than 6-10 continuous seconds Check flow safety
Reset the clock
2E6 Check Clock The real time clock had an error
Check battery

Page 25 of 26

Date: 1/02/2007
4 ELECTRICAL
The following schematics are based on the latest supply of the fluid pumps (3l/s, 10l/s,
30l/s, 50l/s, 75l/s and 100l/s)

Page 26 of 26

Date: 1/02/2007
Chiller capacity Fluid pump
50 kw 3 l/s
157 kw 10 l/s
200 kw 10 l/s
500 kw 30 l/s
600 kw 30 l/s
1300 kw 75 l/s
1500 kw 75 l/s

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Page 1 of 26

Temperature Control Manual Version 0.1

Temperature Control Manual

AIR COOLED CHILLERS

TC Manual Air Cooled Chillers.doc Aggreko Australia Pacific

Temperature Control Manual Version 0.1

TC Manual Air Cooled Chillers.doc Aggreko Australia Pacific

Temperature Control Manual Version 0.1

Fluid Flow through the chiller:

 Fluid pump MUST always feed into the Chiller

 Proper flow MUST be established for optimum operation

 The pressure across the chiller barrel is set to 40kPa delta p

 Correct Pump size

 Have technical information with you at all times to refer to

 Keep hosing lengths as short as possible and tidy

 Complete a commissioning report

 Leaving fluid temperature setting (Set Point)

 Cut in / Cut out temperature settings (Range / Dead Band)

 Low water temperature cut out setting

 Low refrigerant cut out setting

 Fluid Flow (delta p)

 Contamination of chiller barrels

 Proper fluid flow

 Correct Power Supply

 Correct Phase Rotation

 PRE HEAT CHILLERS (minimum 24 hrs)

 Follow manufacturers recommendations

TC Manual Air Cooled Chillers.doc Aggreko Australia Pacific

Temperature Control Manual Version 0.1

BULLETIN NUMBER ASB0088A ISSUE DATE 4th September 2006

SUBJECT YCAS chillers supplied to Aggreko

WITHDRAWAL DATE N/A

Procedure for ultra low temperature glycol operation (down to -19oC).

Temperature Control Manual Version 0.1

The compressor is a semi-hermetic direct drive helical rotor compressor. Each

TC Manual Air Cooled Chillers.doc Aggreko Australia Pacific

Temperature Control Manual Version 0.1

1.3.2 Oil Separator

The separator consists of a vertical cylinder surrounding an exit passageway. As the

TC Manual Air Cooled Chillers.doc Aggreko Australia Pacific

Temperature Control Manual Version 0.1

1.3.4 Expansion Valve

The evaporator is designed for a waterside working pressure of 14 bar. Water

1.3.6 Control Devices

TC Manual Air Cooled Chillers.doc Aggreko Australia Pacific

Temperature Control Manual Version 0.1

1.5.1 Refrigerant Cycle

1.5.2 Oil Cycle

TC Manual Air Cooled Chillers.doc Aggreko Australia Pacific

Temperature Control Manual Version 0.1

Cooling Capacity 52 kW at 6 degrees leaving water temperature

TC Manual Air Cooled Chillers.doc Aggreko Australia Pacific

Temperature Control Manual Version 0.1

ITEM UNITS VALUE

TC Manual Air Cooled Chillers.doc Aggreko Australia Pacific

Temperature Control Manual Version 0.1

Cooling Capacity 157 kW at 7 degrees leaving water temperature

TC Manual Air Cooled Chillers.doc Aggreko Australia Pacific

Temperature Control Manual Version 0.1

ITEM UNITS VALUE

TC Manual Air Cooled Chillers.doc Aggreko Australia Pacific

Temperature Control Manual Version 0.1

Cooling Capacity 612 kW at 6 degrees leaving water temperature

Fluid pump MUST always feed into the Chiller

Proper flow MUST be established for optimum operation

The pressure across the chiller barrel is set to 40kPa delta p

Correct Pump size

Have technical information with you at all times to refer to

Keep hosing lengths as short as possible and tidy

Complete a commissioning report

Leaving fluid temperature setting (Set Point)

Cut in / Cut out temperature settings (Range / Dead Band)

Low water temperature cut out setting

Low refrigerant cut out setting

Fluid Flow (delta p)

Contamination of chiller barrels

Proper fluid flow

Correct Power Supply

Correct Phase Rotation

PRE HEAT CHILLERS (minimum 24 hrs)

Follow manufacturers recommendations