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KKT Training Series: The ECO PM Guide

The document provides instructions for performing preventative maintenance on a chiller. The procedure involves shutting down the chiller, checking and adjusting various components like the buffer tank, expansion tanks, filters, and coils. Glycol concentration is tested and the system is refilled before starting up the chiller. Electrical readings like voltages, amperages, pressures and temperatures are checked using an Eco Tool device. The checklist is submitted for review upon completion.

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Daniel Martinez Collazo
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296 views

KKT Training Series: The ECO PM Guide

The document provides instructions for performing preventative maintenance on a chiller. The procedure involves shutting down the chiller, checking and adjusting various components like the buffer tank, expansion tanks, filters, and coils. Glycol concentration is tested and the system is refilled before starting up the chiller. Electrical readings like voltages, amperages, pressures and temperatures are checked using an Eco Tool device. The checklist is submitted for review upon completion.

Uploaded by

Daniel Martinez Collazo
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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KKT Training Series

The ECO PM Guide


eco series overview

Electrical Cabinet

Compressor
Compartment

Pump Compartment

Front Side Back Side

10/30/2017 KKT Training Series, Eco PM Guide 2


p.m. process
The preventative maintenance is a scheduled event with one hour of downtime. A Not to Exceed of 4 Labor hours is permitted for the Preventative Maintenance. Approval by KKT is required if exceeding the 4 hours.

We must ensure the following procedure is performed:

 Shut down chiller


 Check buffer tank operation(adjustment of pressure regulator may be needed)
 Drain glycol mixture into a 5 gallon bucket (should only relieve 3.5 gallons)
 Check expansion tank nitrogen pressure on both tanks (set to 0.6 bar of nitrogen)
 Clean filter strainers on the chiller/IFP, Glycol check
 Re-fill system with external pump
 Top off buffer tank pressure (3-6 Bar)
 Clean condenser coils with water or non-acidic solution
 Check for loose wires and prepare wiring for amp / voltage checks
 Run the chiller, bleed air out of the system
 Connect KKT Eco Tool
 Check electrical
 Amps draws
 Voltages
 Pressures and temperatures
 Water
 Refrigeration
After completion of the above, we finalize the checklist and make sure every reading requested is filled out on the checklist. The checklist needs to be sent back to [email protected]
ASAP for review by our TSG department.

10/30/2017 KKT Training Series, Eco PM Guide 3


buffer tank operation
During the scheduled PM, when we are draining the
chiller (chiller off). We can check the operation of the
Pressure Regulator.
1. Fill the buffer tank, if it isn’t between the
allowed range (3.0 to 6.0 Bar)
2. Drain the main line to 0.5 Bar (For verification of
the settings of the Pressure Regulator). If the
Pressure Regulator is set correctly. The main line 1
should begin to fill and increase the return 2
pressure to the pump.
3. If the main line doesn’t begin to fill, follow the
procedure on the next slide to adjust Main Line
Pressure.

10/30/2017 4
buffer tank operation
Adjusting the Pressure Regulator!
Adjust (drain/fill) the main line until the return
pressure gauge to the pump is reading 0.6 bar.
1. Remove the cap on the Pressure
Regulator.
2. With a flat head screw driver, turn the
valve (Clockwise) keeping an eye on the
buffer tank gauge. When the gauge starts
dropping in pressure you will see your
return pressure increase.

NOTE: DO NOT continue to rotate the


Pressure Regulator.

10/30/2017 5
draining the chiller for expansion tank check
The draining/filling of the chiller is done at the port
before the pump.

A five gallon bucket is used to collect the glycol fluid


for re-filling. Approx. 3.5 gallons is what is usually
recovered.

The red-handle ball valve is opened to drain/fill.

10/30/2017 KKT Training Series, Eco PM Guide 6


expansion tank
• The reserve and operating tank should be pressurized to 0.6 - 0.8 Bar (depending on the chiller location, if chiller is higher
than 21 feet from the scanner set to 0.6 Bar).
• Remove cap and check with a pressure gauge.
• No fluid should be in the system while checking pressure.

10/30/2017 KKT Training Series, Eco PM Guide 7


strainers
The filter strainers on the chiller and IFP are isolated from the system when it is in
the closed position. Only a cup of glycol mixture is loss during the cleaning of the
filter strainer.
Snap ring pliers are required for the removal of the strainer basket in the ball
valve.
Reminder: Chiller must be in the off position to avoid “dead-head” of the pump!

10/30/2017 KKT Training Series, Eco PM Guide 8


glycol, rule of thumb
After the strainer is cleaned, the glycol we have collected is
tested for concentration with a refractometer.

35-38% No samples
In range
Ethylene Glycol needed

No samples needed. Top-off

21-34% Out of immediately or at the next


scheduled event. Note: glycol may
be mixed with other brand(s) when
Ethylene Glycol range glycol percentage is 29% or higher
to top-off, same type must be used
(ethylene).

20% or lower Sample


Critical
Ethylene Glycol needed

10/30/2017 KKT Training Series, Eco PM Guide 9


chiller filling
The filling of the chiller is done at the port before the
pump.

We will re-use the recovered glycol mixture to put


back into the system.

The red-handle ball valve is opened to fill.

Verify static pressure of the system based on chiller


height from scanner. Below is our guidelines. On
longer runs with higher diameter runs we may need
to static fill higher.

Chiller lower than the IFP panel or on the same level


→ 1.1–1.5bar,

Read at the IFP


Limitation: 25m below IFP

Chiller higher than the IFP panel → 1.7–1.9bar, Read


at the IFP
Limitation: 10m above IFP

10/30/2017 10
buffer tank filling
The filling of the buffer tank is done at the
port near the pressure gauge.

The buffer tank glycol pressure must be 3 - 6


Bar.

10/30/2017 11
condenser coil cleaning
Clean the condenser coil with water or non-acidic solution. The unit should be powered off, be sure to use
non-acidic solution when cleaning the coil. On condenser coils with excessive dirt build up you may have
to use a brush. If a water source isn’t available, you may use a shop vacuum or compressed air.

CAUTION: High pressure water flow may damage/bend fins when cleaning!

10/30/2017 12
system start-up and air bleeding
• Allow the pump to run for 15 seconds and turn it off again
• Open the air vents, purge the remaining air
• If the pressure drops. Fill again until the pressure with the pump OFF reaches the desired static fill at the IFP.
• Clean the filter strainer during the next-to last pass
If the pressure remains constant for 60 – 90 minutes of operation, proceed with chiller operation.

10/30/2017 KKT Training Series, Eco PM Guide 13


eco tool
The Eco Tool is an important factor during
the PM process. We can pull both past and
current data. A review of the system is
essential in diagnosing issues found during
the PM. All pressure and temperature
readings are displayed in real-time and can
be submitted to techsupport@kkt-
chillers.com if findings are troubling.

10/30/2017 KKT Training Series, Eco PM Guide 14


chiller operation
Operating Pressures (Glycol Circuit)
Chiller 1-2 Bar
(Day Mode) IFP 5-6 Bar
(Night Mode) IFP 4-5 Bar

Operating Pressures (Refrigeration Circuit)


Low Pressure: 7-11 Bar
High Pressure: 19-22 Bar
Chiller Set Point
(Day Mode) 20 C
(Night Mode) 26 C to 19 C

10/30/2017 KKT Training Series, Eco PM Guide 15


amperage
Amperage checks are done at the electrical cabinet (please use wiring diagram to identify the circuit).

Tip: For checking the second compressor during day mode, please remove the fuses on 18F1 (compressor 1) while the unit is off
and power on chiller to check operation!
Pump Amperage Average
Note: any noises, excessive vibrations or leaks!
(Day Mode) 2.8 - 3.5 A
(Night Mode) 0.5 - 1.0 A
Big Compressor Amperage Average
13.0 - 27.0 A
Small Compressor Amperage Average
10.0 - 17.0 A
Big Fan Amperage Average
1.0 - 4.0 A
Small Fan Amperage Average
1.7 - 2.2 A

10/30/2017 KKT Training Series, Eco PM Guide 16


checklist
After verifying chiller operation, a checklist is completed (see following pages).

10/30/2017 KKT Training Series, Eco PM Guide 17

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