Beruflich Dokumente
Kultur Dokumente
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
IMPORTANT INFORMATION
(delta p = fluid press entering the chiller minus fluid leaving the chiller)
Installation:
Position equipment on a level surface and leave room for air intake and room to work
Chiller Settings:
Chiller Safety:
Service valves
Install strainers
SERVICE BULLETIN
REFERENCE
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.
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.
TC Manual Air Cooled Chillers.doc Aggreko Australia Pacific
Page 5 of 26
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 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.
The oil leaves the compressor entrained within the discharged refrigerant vapour, and it
is the oil separator that recovers this oil.
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.
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.
Evaporator heaters with thermostats provide protection to the evaporator from freezing
at ambient temperatures of -29°C.
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.
1.5 Process
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.
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.
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
3. LAYOUT
aggreko
Prepared by: Adam Hentschel Date: 17.12.2002 Revision: A Page 10 of 26
Discipline: Fluid Chillers Document number
Section:
AIR COOLED SCROLL FC50A au.1.3
4. TECHNICAL SPECIFICATIONS
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
aggreko
Prepared by: Adam Hentschel Date: 14.04.1999 Revision: A Page 11 of 26
Discipline: Fluid Chillers Document number
Section:
AIR COOLED SCROLL FC160A au.1.2
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
3. LAYOUT
aggreko
Prepared by: Adam Hentschel Date: 14.04.1999 Revision: A Page 12 of 26
Discipline: Fluid Chillers Document number
Section:
AIR COOLED SCROLL FC160A au.1.2
4. TECHNICAL SPECIFICATIONS
NOTE: Contact Technical Department If Application Conditions Differs From Design Conditions
aggreko
Prepared by: Adam Hentschel Date: 14.04.1999 Revision: A Page 13 of 26
Discipline: Fluid Chillers Document number
Section:
AIR COOLED SCREW FC600A au.1.1
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 with the dimensions of a standard 20 ft container
tested and certified .
2. KEY-DATA
3. LAYOUT
aggreko
Prepared by: Adam Hentschel Date: 14.04.1999 Revision: A Page 14 of 26
Discipline: Fluid Chillers Document number
Section:
AIR COOLED SCREW FC600A au.1.1
4. TECHNICAL SPECIFICATIONS
ITEM UNITS VALUE
Performance Data
Design Capacity kW 612
Design Operation Fluid Temperature IN / OUT ºC / ºC 12 / 6
Minimum / Maximum Outlet Fluid Temperature ºC / ºC -18 / +30
Minimum / Maximum Chilled Liquid Temperature Difference ºC / ºC 3.5 / 10.2
Design Ambient Temperature ºC 30
Minimum / Maximum Ambient Temperature ºC / ºC 0 / +40
Compressor
Compressor Type Semi Hermetic Screw
Number Of Compressors 2
Number Of Capacity Steps % 12.5 thru 100
Evaporator Data
Evaporator Type Shell & Tube
Evaporator Material Steel & Copper
Design Flow l/s 24.5
Minimum / Maximum Flow l/s / l/s 15 / 44
Chiller Barrel Capacity litres 204
Chiller Barrel Maximum Working Pressure kPa 1000
Design Chiller Barrel Pressure Drop kPa 34
Chiller Barrel Pressure Drop Factor p.u. 5.66
Recommended System Water Volume litres 2520
Condenser Data
Number Of Condenser Fans 10
kW per Fan kW 0.85
Total Air Volume m³/h 139
External Static Pressure Pa 0
Refrigerant Data
Refrigerant Type R22
Number of Circuits 2
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
Starting Current Ampere 543
Pre-Heating Supply Volts / VA 220 / 600
Recommended Generator Set kVA 350
Required Cable Size per Phase mm² 240
Electrical Connection Busbar M12
Noise Data
Sound Pressure Level at 10 metres - Lp(A) dB(A) 66
Sound Power Level - Lw(A) dB(A) 94
Physical Data
Overall Length metres 6.0
Overall Width metres 2.4
Overall Height metres 2.6
Weight kg 6820
Fluid Coupling Size mm / inch 100 / 4"
NOTE: Contact Technical Department If application conditions differ from design conditions
3.1 Installation
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.
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.
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.
3.3 Commissioning
3.4 Operation
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.
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
3.5 Decommissioning
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.
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.
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.
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.
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:
Monthly Completion At 36
On Hire 6-Monthly
Item or at of Hiring Cumulative
No. Maintenance and Servicing Instructions and
750
or at 4300
and Months of
Installation Hours
Hours Decomm. Operation
Monthly Completion At 36
On Hire 6-Monthly
Item or at of Hiring Cumulative
No. Maintenance and Servicing Instructions and
750
or at 4300
and Months of
Installation Hours
Hours Decomm. Operation
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.
1.6 Troubleshooting
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)
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