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Standing Vacuum Test
When performing the standing vacuum test, or machine dehydration, use a manometer or a
wet bulb indicator. Dial gages cannot indicate the small amount of acceptable leakage during a
short period of time.
1.
Attach an absolute pressure manometer or wet bulb indicator to the machine.
2.
Evacuate the vessel (see Pumpout and Refrigerant Transfer Procedures section) to at least
18 in. Hg vac, ref 30-in. bar (41 kPa), using a vacuum pump or the pump-out unit.
3.
Valve off the pump to hold the vacuum and record the manometer or indicator reading.
4.
a.
If the leakage rate is less than 0.05 in. Hg (.17 kPa)
in 24 hours, the machine is suffi-
ciently tight.
b.
If the leakage rate exceeds 0.05 in. Hg (.17 kPa)
in 24 hours, repressurize the vessel and
test for leaks. If refrigerant is available in the other vessel, pressurize by following Steps
2-10 of Return Refrigerant to Normal Operating Conditions section. If not, use nitrogen
and a refrigerant tracer. Raise the vessel pressure in increments until the leak is
detected. If refrigerant is used, the maximum gas pressure is approximately 70 psig
(483 kPa) at normal ambient temperature.
5.
Repair leak, retest, and proceed with dehydration.
- Definitions 8
- Contents 10
- Weekly Maintenance 22
- Scheduled Maintenance 22
- Troubleshooting Guide 24
- List of Tables 27
- List of Figures 31
- Introduction 36
- Abbreviations 38
- Machine Identification Label 39
- System Components 39
- Motor-Compressor 40
- Control Center 40
- Refrigeration Cycle ( 41
- Figure 4 41
- Summary 44
- Details 45
- (EX Compressor Shown) 47
- Details (See 48
- Figure 6 48
- Starters 50
- Controls 50
- Volatile Memory 51
- PIC System Components 52
- Processor Module (PSIO) 53
- Local Interface Device (LID) 54
- 6-Pack Relay Board 55
- 8-Input Modules 55
- Oil Heater Contactor (1C) 55
- Oil Pump Contactor (2C) 55
- Oil Auxiliary Relay (4C) 56
- Control Transformers (T1-T4) 56
- Figure 19, and Figure 20) 58
- Alarms and Alerts 59
- Menu Structure 61
- NEXT PREVIOUS SELECT EXIT 62
- Figure 18 63
- For Discrete Points 64
- Override Operations 65
- To Remove an Override 66
- Figure 19 67
- Figure 20 71
- PIC System Functions 74
- Deadband 75
- Proportional Bands and Gain 75
- Demand Limiting 76
- Machine Timers 76
- Occupancy Schedule 77
- Safety Controls 79
- Shunt Trip 80
- Default Screen Freeze 81
- Ramp Loading Control 82
- Capacity Override (See 83
- Oil Sump Temperature Control 85
- Oil Cooler 86
- Remote Start/Stop Controls 86
- Spare Safety Inputs 87
- Spare Alarm Contacts 87
- Condenser Pump Control 88
- Condenser Freeze Prevention 88
- Tower-Fan Relay 89
- Water/Brine Reset 91
- Surge Prevention Algorithm 93
- Surge Protection 95
- Lead/Lag Control 96
- Machine Communication Wiring 98
- Lead/Lag Operation 98
- Faulted Chiller Operation 102
- Load Balancing 103
- Ice Build Control 104
- Ice Build Initiation 105
- Start-Up/Recycle Operation 106
- Termination of Ice Build 107
- Service Operation 111
- To Log Off 112
- Holiday Scheduling ( 113
- Figure 24 113
- NEXT PREVIOUS SELECT EXIT 114
- INCREASE DECREASE QUIT ENTER 116
- Local Start-Up 118
- Shutdown Sequence 120
- COMPRESSOR MOTOR LOAD 121
- ENTERING CONDENSER WATER 121
- LEAVING CHILLED WATER 121
- CONTROL 121
- Chilled Water Recycle Mode 122
- Safety Shutdown 124
- Before Initial Start-Up 125
- Remove Shipping Packaging 126
- Open Oil Circuit Valves 129
- Torque All Gasketed Joints 129
- Check Machine Tightness 129
- Refrigerant Tracer 130
- Leak Test Machine 130
- Standing Vacuum Test 134
- Machine Dehydration 135
- Inspect Water Piping 137
- Check Relief Devices 138
- Inspect Wiring 139
- 0- 900 500 142
- 901- 7000 1000 142
- 7001-14500 2500 142
- Check Starter 147
- Mechanical-Type Starters 148
- Solid-State Starters 149
- Oil Charge 150
- Software Version 151
- Input the Design Set Points 152
- Input Service Configurations 153
- At low loads (<50%) 159
- At high loads (>50%) 159
- Check Voltage Supply 160
- High Altitude Locations 163
- Trimming Refrigerant Charge 165
- Initial Start-Up 166
- TARGET GUIDE 167
- VANE POSITION 167
- TARGET GUIDE VANE POSITION 167
- If Rotation Is Proper 174
- Cooler-Condenser 178
- Utility Vessel 178
- Pumpout System 178
- Operating Instructions 180
- To Start the Machine 181
- Check the Running System 181
- To Stop the Machine 183
- After Limited Shutdown 184
- Extended Shutdown 184
- After Extended Shutdown 184
- Cold Weather Operation 185
- Manual Guide Vane Operation 185
- Refrigeration Log 186
- Preparation 187
- To Read Refrigerant Pressures 188
- (12-ft Vessel Shown) 188
- 1 2 3 4 5 6 7 8 9 10 11 189
- C C CCCCC 190
- Compressor Section 191
- CC CCCCC 192
- C CC CCCC C 193
- Condition 194
- General Maintenance 195
- Adding Refrigerant 196
- Removing Refrigerant 196
- Refrigerant Leak Testing 197
- Leak Rate 197
- Figure 35 199
- Seal Disassembly ( 201
- Figure 36 201
- Handle carefully 202
- Protect seal faces of ring 202
- Seal Reassembly ( 203
- Alignment Methods 205
- Preliminary Alignment 207
- Near Final Alignment 208
- Measurement 211
- Adjustment 213
- Final Alignment 217
- Hot Alignment Check 217
- Doweling 220
- Changing Oil Filter 224
- FA Style Compressors 225
- Oil Changes 226
- Oil Specification 226
- Refrigerant Filter 227
- Oil Reclaim Filter 228
- Procedure 229
- Cleanliness 231
- Sleeve Bearings 235
- Open-Drive Motor Storage 244
- Condenser 247
- Check Pressure Transducers 251
- Pumpout System Maintenance 251
- Figure 47 252
- Checking Temperature Sensors 255
- Resistance Check 256
- Voltage Drop 256
- Check Sensor Accuracy 257
- Dual Temperature Sensors 257
- Checking Pressure Transducers 258
- Figure 48 261
- Troubleshooting Transducers 262
- Transducer Replacement 262
- Control Test 264
- Control Modules 267
- Green LEDs 268
- Other Green LED 269
- Green LED 269
- Notes on Module Operation 270
- Options Modules (8-Input) 274
- Table 2 — LID Screens 284
- Table 4 — Capacity Overrides 302
- Table 6 — Recommended Torque 307
- B. Timing Out or Timed Out 311
- C. In Recycle Shutdown 312
- D. Pre-Start Alerts: 313
- E. Normal or AUTO.-RESTART 314
- F. Start-Up Failures: 315
- (Continued) 316
- L. Machine Alerts 324
- L. Machine Alerts (Continued) 325
- (Page 1 of 2) 333
- (English) 336
- 150 1034 2236 1015 1275 579 338
- 300 2068 3060 1389 1660 754 338
- 150 1034 – – 1643 746 338
- 300 2068 – – 2243 1018 338
- Compressor End View 353
- Machine Front View 354
- Motor End View 355
- Machine Rear View 359
- (Open-Drive Machine Shown) 365
- (Status01) 371
- Figure 25 — Control Sequence 378
- Figure 31 — Refrigeration Log 384
- Figure 40 — Alignment Formula 394
- To Check Angular Alignment 399
- To Check Parallel Alignment 400
- Figure 53 — Options Module 410
- Size (See Figure 1 Also) 411
- Note: See Table 17 414
- Open Drive Machine 420
- (Remove and use for job file.) 426
- MACHINE INFORMATION: 426
- INSTRUCTIONS 426
- CENTRIFUGAL LIQUID CHILLER 428
- CONFIGURATION SETTINGS LOG 428
- MACHINE ALIGNMENT REPORT 437
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