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Liquid Chillers Grasso Ingenium Compact Plus Commissioning checklist (Translation of the original text) L_126111_2

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Page 1: Liquid Chillers Grasso Ingenium Compact Plus Documents/Grasso... · Liquid Chillers Grasso Ingenium Compact Plus 12 GEA Refrigeration Germany GmbH | L_126111_2 | Generated 03.12.2014

Liquid Chillers Grasso Ingenium Compact Plus

Commissioning checklist (Translation of the original text)L_126111_2

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COPYRIGHTAll Rights reserved.No part of this publication may be copied or pub-lished by means of printing, photocopying, microfilmor otherwise without prior written consent of

• GEA Refrigeration Germany GmbHherein after called manufacturer. This restrictionalso applies to the corresponding drawings and dia-grams.

LEGAL NOTICEThis documentation has been written in all con-science. However, the manufacturer cannot be heldresponsible, neither for any errors occurring in thisdocumentation nor for their consequences.

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SYMBOLS USED IN THIS MANUALDanger!

Stands for an immediate danger whichleads to heavy physical injuries or tothe death.

Warning!

Stands for a possibly dangerous situa-tion which leads to heavy physicalinjuries or to the death.

Caution!

Stands for a possibly dangerous situa-tion which could lead to light physicalinjuries or to damages to property.

Hint!

Stands for an important tip whoseattention is important for the designa-ted use and function of the device.

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PREFACEGENERAL INFORMATION

Hint!

Before commissioning the unit andputting it into service, carefully readthe operating manual of the liquidchiller of the Ingenium series as wellas the user handbook of the GrassoSystem Control and proceed inaccordance with the instructions givenin them. The instructions in the "SafetyInstructions Refrigerant Ammonia"brochure must be followed.

Tools and accessories required for commission-ing the unit and putting it into service are:

– Filling tube with connecting fittings

– Refrigerant cylinder

– Scales for refrigerant cylinder

– Vacuum pump

– Calibrated test pressure gaugePrerequisites for commissioning the unit andputting it into service are:

– Installation space around the chiller (see infor-mation about installation in the product informa-tion or operating manual)

– Cooling load of approx. 70% of project values

– Closed wiring and power supply

– Closed piping

– Cooling agent filled and vented, set volume flowsin accordance with the project values (see alsooperating manual: Chapter 2 Commissioning/Operation, Section 2.2)

It must be possible to contact the appropriate contactpartners of the electrical installation and operatingcompany. After the unit has been commissioned andput into service, this is followed by training of theoperating company and handover to the client.

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TABLE OF CONTENTS1 CHECKLIST 72 MEASUREMENT SHEET 11

2.1 Operating parameters for refrigerant circuit (template) 12

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1 CHECKLIST

Liquid Type: ……………Reg. no.: ……………Year of construction: ……………Date: ……………

Steps OK / completed Not OK / measure, com-ment

Check the status on delivery

– Protective gas filling (connect check manometer to serv-ice valve, item 2505)

– Insulation

– Painting

– Sealing of safety pressure switch (set to 22 bar in thefactory)

– Inspection of glycol circuit filling (the compressor oftypes 100 to 180 are standard with liquid cooled cylinderheads. The refrigerant circuit come factory filled with34% ethyl glycol

Check installation(see operating manual - start-up)

– Spring elements (optional)

– Water piping, (for installation on spring elements, con-nection must be made using compensators; Installationof dirt filter)

– Inspection of the refrigerant flow direction in accorand-ance with the P+I diagram and overall view.

– Sequence of the scheduled temperature sensors or theflow switch; (see operating manual - start-up - coolingagent system)

– Check the valve positions

– E-connection (inlcluding control cables)

Leak test(see operating manual - start-up- leak tightness test)

– Only necessary if protective gas filling is leaking

System evacuation(see operating manual - start-up- system evacuation)

– Refrigerant circuit incl. refrigerant filling tube

Commissioning checklist |Liquid Chillers Grasso Ingenium Compact Plus

Checklist

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Steps OK / completed Not OK / measure, com-ment

First refrigerating machine oil fill(see operating manual - start-up- first oil filling)

– Always use fresh oil from sealed containers

– Always use oil permitted under the operating manual

– Use the refrigerant circuit vacuum for the first oil fill

– Inject oil using the oil filling hose via the oil inlet valveitem 90 in the crankcase of the compressor

– Oil fill amount corresponds to the information in theappropriate installation and operating manual for thecompressor

– Grasso V compressors need to have the oil lubrication ofthe oil filter, oil pump and drive shaft seals carried out inaccordance with the compressor operating manual.

– Inspection of the correct filling level using the sight glasson the compressor crankcase or in the sight glass of theoil level regulator on chiller with compressors in in theType F series (2/3 of sight glass level)

– IN the Grasso Ingenium Compact Plus 100, 120, 150and 180 chillers an initial filling of the oil receiver, Item2390 needs to be carried out.To do so close the valve item 2393, connect the oil fillinghose on to valve item 2355.2 and fill the oil receiver withsix liters of oil until the oil filling level on the upper edgeof the upper sight glass can be seen.

First refrigerant fill(see operating manual - start-up- first refrigerant filling)

– Connection of the refrigerant cylinder to the filling valveof the chiller with filling tube

– Fill amount of refrigerant according to weight

– If necessary, top up last amount of refrigerant after thecompressor is switched on

– Observe filling criteria:

1. Net weight based information in the technical specifi-cations

2. After the initial start-up:

– Refrigerant level in the evaporator sight glass1/2 to 2/3

– No amount of gas in sight glass of liquid line

– At minimal part-load the liquid level in the sightglass of the liquid collection tube discernable

Checklist Commissioning checklist |Liquid Chillers Grasso Ingenium Compact Plus

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Steps OK / completed Not OK / measure, com-ment

Initial startup(see operating manual - operation - Initial start and operatingmanual GSC TP)

– Check external locking mechanisms

– Voltage connection

– Release emergency stop button and acknowledge ondisplay with ACK button

– Select the control variable in Operating modes menu:Cooling agent inlet/ outlet, heating agent inlet/ outlet

– Input of the setpoint temperature in accordance with theproject value

– Switch to "MANUAL" mode

– Switch "Compressor on"

– Increase output

– Check the refrigerant filling,

Chiller shut-down(see operating manual - start-up)

– Switch to "MANUAL" mode

– Switch "Reduce output"

– Switch "Compressor off"

– Close stop valves if necessary

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Checklist

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Steps OK / completed Not OK / measure, com-ment

Shut down in the event of dangerous situations(see operating manual - taking out of service - shut down inhazardous situations)

– Emergency stop button function

Automatic drive(see operating manual - operation - operation type "auto+auto")Check the prerequisites:

– There is an enable signal from the Central I&C

– Switch-on conditions for compressor fulfilled

– There are no queued faults

– System signals output requirement (temperature set-point is lower than actual value)

Switching sequence:

– Select operation mode "auto + auto"

– Run project values, if possible to steady state, check tk2- to< 5K

– Read operating parameters in steady state (with Serv-icelab after approx. 20min).

Checklist Commissioning checklist |Liquid Chillers Grasso Ingenium Compact Plus

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2 MEASUREMENT SHEET

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Measurement sheet

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2.1 Operating parameters for refrigerant circuit (template)

User

Refrigerant

Type of oil

Chiller - Type / ManufacturerSerial No. / Year

Compressor - Type / ManufacturerSerial No. / Year

Date / Time

Operating hours OH

Rating class %

Speed min-

1

Psuc suction pressure bar

t0 evaporating temperature °C

Pdis discharge pressure bar

tC condensation temperature °C

Tdis compression end temperature °C

Tsuc-t0 overheating K

Poil oil difference pressure bar

Toil oil temperature (piston housing) °C

Imot compression motor current A

tLE air temperature °C

t K1 Cooling agent inlet temperature °C

tK2 Cooling agent outlet temperature °C

Oil level in compressor 1)

Measurement sheet Commissioning checklist |Liquid Chillers Grasso Ingenium Compact Plus

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Refrigerant status in 2)the sight glasses

Remarks

Service technician

Notes:

1) Oil level must be visible2) Normal condition: clear and free of bubbles

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Measurement sheet

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