ClimaCool IOM FLEX SERIES - Manual (Page 26)

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®
24
Pre-Start Up
Prior to chiller start up, there are certain essential checks
which must be carried out. Failure to carry out these checks
could result in damage to the chiller voiding the warranty.
Electrical
It is imperative to turn off the main electrical power supply
and follow proper lock-out, tag-out procedures prior to
servicing any of the chiller's electrical components. The
following procedures can be performed only after the
electrical power is confirmed to be off:
1. The installation must be inspected and approved by the
respective agent and be in compliance with all local and
national electrical codes.
2. Check and tighten as required all electrical terminal
connections on each module. Utilize lock-out/tag-out
procedures for this operation. A systematic tightening
of all terminals inside the electrical control panel on
each module should be carried out. This will include
the compressor motor terminals, which would require
removal of the compressor terminal cover. Check
connections at each safety and every termination in the
panel.
3. There are approx. (12) control wires which must be field
connected from each module's electrical panel back to
the "Master Control Panel". These control wires should
be routed using a series of twisted pair conductors having
#18 AWG minimum up to 50 ft., #16 AWG minimum
up to 100 ft., and #14 AWG min. up to 250 ft. All field
wiring must be identified (tagged).
4. All field connections should be checked for tightness.
5. Check all fuses for proper sizing as indicated on the
chiller data plate and/or the electrical diagram on the
inside door of the electrical panel.
Refrigeration
1. Remove the front and rear access covers from the top
compressor sound enclosure of each module.
2. Refrigerant piping and components should be inspected
for damage.
3. Check all refrigeration and water valves for proper
positioning; once completed mark refrigerant valves with
permanent marker. Make sure all refrigerant valves are
fully opened and there are no visible signs of refrigerant
leaks.
Pre-Start Up
4. Place refrigerant gauges on the discharge and suction
access ports of each refrigerant circuit to ensure a
refrigerant charge is present. Leave the gauges on for
compressor rotation check.
5. Confirm the settings on all pressure switches and
thermostats.
Water System
1. Confirm that leak testing has been carried out.
2. Confirm that the system is clean.
3. Confirm that necessary water treatment systems are
in place with both the evaporator and condenser water
systems.
4. Confirm that appropriate water analysis has been
conducted by the end-user or facility manager.
5. Confirm that the results of this water analysis does not
conflict with the acceptable constituent ppm levels as
indicated in Table 1, page 15.
6. Extract a water sample from both the evaporator and
condenser. Confirm that the sample bottles are filled to the
top leaving no air in the bottles. Both sample bottles must
have labels filled out per instructions included with bottles.
Mail bottles immediately to the appropriate water testing
laboratory as per instructions included with bottles.
7. Confirm that both the chilled water and condenser water
circulating pumps are operational and water is flowing
through both exchangers.
8. Shut entering water valve and blow out some water to
check for particles or coloration from suspended particles.
Record the differential pressures across the chiller and
condenser, measured at the "Pete's ports at each module.
9. Confirm correct water flow rates through the condenser
and evaporator. Acquire the "predicted" flow rates from
the building's "hydronics system balancer". Compare the
measured differential pressures from step 6 above with
the predicted flow rates to ensure proper correlation to the
flow results.
Chiller Pre-Start-Up Procedures
1. Turn selector switches on module front panel to
off position. Fill in circuit number and power panel
identification inside each module cover panel.
2. Ensure the correct fuses are installed in the control
transformer fuse blocks inside each ClimaCool Module.
Turn on the power to each module. The "Power" light
should be on.
3. Override output with DX commissioning program or
place a jumper between compressor 1 start terminals on