KIRLOSKAR KAC User guide

Installation, Start-up, Operation &
Maintenance Manual
Scroll Liquid Chillers –KAC
DUAL COMPRESSOR
KAC 11 ~ 22 with HFC410A
KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company

FOREWORD
At the outset, we thank you for purchasing chiller manufactured and supplied by
KIRLOSKAR CHILLERS PRIVATE LIMITED. We are sure that our chiller will help you in
satisfying your chilling requirement.
This manual will guide you about the installation, Operation and maintenance of the system.
Please read this manual carefully and keep it in proper place in order to refer the same
whenever required. To prolong the life of your chiller and reduce maintenance cost, follow
the instructions given in this manual.
All information in this manual is based on the latest product information
available at the time of publication. Due to improvements or other changes,
there may be discrepancies between information in this manual and your
chiller. KIRLOSKAR CHILLERS PRIVATE LIMITED reserves the right to
make changes at any time without notice.

Table of Contents
FOREWARD ……………………………………………………………………………..
1
Chiller Nomenclature ……………………………………………………………………..
1
Operating Limits ………………………………………………………………………….
1
Safety considerations ……………………………………………………………………..
Some safety tips ………………………………………………………………………...
General ………………………………………………………………………………..
Pressure Test ………………………………………………………………………….
Refrigerant ……………………………………………………………………………
Electrical ……………………………………………………………………………...
Sharp edges …………………………………………………………………………...
Mechanical Strength …………………………………………………………………..
Suitability for Application …………………………………………………………….
2
2
3
3
4
4
4
4
4
1. Introduction ……………………………………………………………………………
1.1 General Description ………………………………………………………………...
1.2 Distinctive features …………………………………………………………………
1.2.1. Scroll Compressor ……………………………………………………………
1.2.2. Reliability Factory ……………………………………………………………
1.3. Inspection …………………………………………………………………………...
1.4. Handling and Lifting ………………………………………………………………..
1.5. Life Cycle Perspective and Disposal of Product ……………………………………
1.5.1. Instructions for Disposal after End of Life of Chiller ………………………….
5
5
5
5
5
6
6
7
8
2. Installation ……………………………………………………………………………...
2.1. Space Requirement for Servicing ………………………………………………….
2.2. Unit Location ………………………………………………………………………
2.3. Evaporator Water / Brine (Liquid) Piping …………………………………………
2.4. Foundation and Anti-Vibration Mounts ……………………………………………
2.4.1. Foundation ……………………………………………………………………
2.4.2. Anti-Vibration Mounts ………………………………………………………
2.5. Water Treatment / Quality …………………………………………………………
2.6. Installation of Flow Switch……………………………….………………………..
2.7. Installation Check Report for KAC Chiller Units …………………………………
9
9
9
10
11
11
12
12
14
14
3. Operation ……………………………………………………………………………….
3.1. Liquid Chilling Systems - Principle ……………………………………………….
3.2. Components and Their Functions ………………………………………………….
3.3. Equipment Description and Cycle Operation ………………………………………
3.3.1. Hermetic Type Scroll Compressor ……………………………………………..
3.3.2. Air Cooled Condenser ………………………………………………………….
3.3.3. Electronic Expansion Valve ……………………………………………………
3.3.4. Dry-Expansion Type Evaporator ………………………………………………
3.3.5. Control Center ………………………………………………………………….
3.3.6. System Accessories …………………………………………………………….
3.4. Preparing the System for Start-Up …………………………………………………
3.5. Startup and Operation ……………………………………………………………...
3.6. Stop or Weekend or Temporary Shutdown ……………………………………….
3.7. Extended Shutdown ……………………………………………………………….
16
16
17
18
19
20
21
21
21
22
22
23
24
24

3.8. Recommended Log Format for KAC Units ……………………………………….
3.9. Sequence of Operation for Packaged Chiller Units ………………………………..
3.10. Standard Controls …………………………………………………………………
3.10.1. High Pressure Control ………………………………………………………...
3.10.2. Low Pressure Control …………………………………………………………
3.10.3. Voltage Protection Device ……………………………………………………
25
26
28
28
28
29
4. System Maintenance……………………………………………………………………
4. Maintenance Instruction………………………………………………………………
4.1. Tips for Preventive Maintenance……………………………………………………
4.2. System Service………………………………………………………………………
4.2.1. Condenser and Evaporator………………………………………………………
4.2.1.1. Air-Cooled Condensers ……………………………………………………..
4.2.1.2. Evaporator …………………………………………………………………..
4.2.1.3. Testing Of Condenser and Evaporator Tube Leaks…………………………
4.2.2. Liquid Refrigerant Drier Replacement …………………………………………
4.2.3. Refrigerants ……………………………………………………………………..
4.2.4. Vacuum / Dehydration Procedure ………………………………………………
4.2.5. Refrigerant Properties ………………………………………………………….
4.2.5.1. Charging the Refrigerant……………………………………………………
4.2.5.2. Adjusting the Refrigerant Charge………………………………………….
4.2.5.3. Pressure Testing After Service or Repair or Major Leak …………………..
30
30
30
32
32
32
33
33
34
34
34
35
35
36
36
Chapter 5 Troubleshooting
38
6. Controls and settings …………………………………………………………………...
6.1. About the controller ………………………………………………………………...
6.2. PCOOEM+ Board Carel Controller ……………………………………………….
6.2.1. Features of K-smart Controller …………………………………………………
6.2.2. Connector Details ………………………………………………………………
6.3. K-Smart Inputs/Outputs …………………………………………………………….
6.4. PCO OEM+ Technical specification ………………………………………………..
6.5 pLDPRO Carel Keypad/Display ……………………………………………………
6.5.1. Keys and display functions ……………………………………………………..
6.6. Troubleshooting …………………………………………………………………….
41
41
41
42
44
45
47
49
51
53
7. Technical Data …………………………………………………………………………
7.1. Refrigerant Pressure –Temperature Chart …………………………………………
7.2. Useful Conversion Factors ………………………………………………………….
56
56
57
8. Annexures ……………………………………………………………………………...
8.1. Start-Up and Check Form ………………………………………………………….
58
58

KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company IOM-KAC-ENG - Page 1
Chiller Nomenclature
KA C 011 . 2 0
0- R-410A
No. of Compressors
Nominal capacity, TR
Scroll compressor
KA –Kirloskar Air-cooled unit
Operating Limits
Description
Unit
R-410A
KAC
Min leaving evaporator water
temperature (without glycol)
ºC
(ºF)
3 ºC
( 37.4 ºF)
Min leaving evaporator water
temperature (with glycol)
ºC
(ºF)
-10 ºC
( 14 ºF)
Min ambient temperature
ºC
(ºF)
13 ºC
( 55.4 ºF)
Max ambient temperature for
standard ambient units
ºC
(ºF)
46 ºC
( 114.8 ºF)

KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company IOM-KAC-ENG - Page 2
Safety Considerations
Installation, starting up and servicing packaged liquid chillers can be hazardous due to system
pressures, electrical components and equipment location viz. roofs, elevated structures, etc.
Kirloskar Chillers make liquid chillers are designed for safe and reliable operation, when
operated within design limits. When operating this equipment, use good judgment and safety
precautions to avoid damage to equipment, property or injury to personnel. Be sure that you
understand and follow the procedure and safety precautions.
When working on the equipment, observe precautions in the literature, tags, stickers attached to
the equipment.
Some of the Safety Tips:
General
DO NOT CLIMB over the chiller or DO NOT STEP on refrigerant lines. Broken lines
can bang and release high-pressure refrigerant, causing personal injury.
USE platform, catwalk or staging. Follow safe practices when using ladders.
NEVER SHORT CIRCUIT any safety controls in the system.
Care in HANDLING & RIGGING; check weight before rigging any item. Always use
lifting hooks provided in the unit. Use suitable capacity crane to lift the unit
DO NOT ATTEMPT TO REMOVE pipefitting, flanges, covers etc., while chiller is
under pressure OR chiller is running. Ensure the pressure is at 0 kg/cm2g (0 psig) before
opening any refrigerant line OR connection.
WORK CAREFULLY, when working near OR in line with a compressed spring. Sudden
release of the spring can cause it and objects in its path to act as projectiles.
PERIODICALLY INSPECT all valves, fittings and piping for corrosion, rust, leaks OR
damages.
DRAIN WATER completely before loosening the bolts of water box / heat exchanger
dish ends.
NOTE: ONLY TRAINED, QUALIFIED INSTALLERS AND SERVICE
MECHANICS SHOULD INSTALL, START AND SERVICE THIS
EQUIPMENT.

KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company IOM-KAC-ENG - Page 3
Pressure Test
USE ONLY DRY NITROGEN for pressure test. Use a regulating valve between the
Nitrogen cylinder and the system to regulate the pressure.
DO NOT USE OXYGEN or ACETYLENE to pressurize the refrigeration system.
Oxygen may react with oil and form an explosive chemical compound. Acetylene is an
explosive gas.
HANDLE THE CYLINDERS carefully. Do not drop the cylinder.
NEVER EXCEED specified TEST PRESSURE; verify the allowable test pressure by
checking the equipment nameplate. Contact Kirloskar Chillers if in doubt for further
details.
Refrigerant
Refrigerant R-134a, R-407C, R-410A is generally considered chemically non-toxic and
non-inflammable; however, any refrigerant vapor UNDER PRESSURE CAN BE
HAZARDOUS. AVOID SPILLING liquid refrigerant on skin or getting it into the eyes.
USE SAFETY GOGGLES. A sudden release of refrigerant liquid sprayed on the skin can
cause serious damage to skin tissues. Keep eyes and exposed skin areas away from any
potential refrigerant discharge. If such refrigerant burn occurs flush it immediately with
cold water, apply ice packs. If liquid refrigerant enters the eyes, IMMEDIATELY
FLUSH EYES with water. Consult a physician immediately.
DO NOT VENT refrigerant directly within the plant room. Refrigerant must be vented to
outdoor. The accumulation of refrigerant in an enclosed space can displace Oxygen and
cause asphyxiation. Also, PROVIDE adequate VENTILATION for enclosed plant room.
DO NOT WELD or FLAMECUT any refrigerant line or vessel until complete refrigerant
has been removed from chiller. Traces of vapor should be displaced with dry Nitrogen
and the work area should be well ventilated. Refrigerant in contact with an open flame
produces toxic gases.
CHECK THE REFRIGERANT TYPE before adding refrigerant to the chiller package.
Usage of wrong refrigerant can cause damage to OR malfunction of chiller package.
Contact KCPL for further information for using other refrigerant in the chiller package.
NEVER HEAT refrigerant cylinder WITH AN OPEN FLAME, to remove the refrigerant
vapor. When it is necessary to heat the refrigerant cylinder, use only warm water {43C
(109.4F) maximum}.

KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company IOM-KAC-ENG - Page 4
Electrical
DO NOT WORK ON HIGH-VOLTAGE equipment unless you are a qualified
electrician.
DO NOT WORK ON electrical components, including controls panels, switches, starters
OR oil heater until you are sure ALL POWER IS OFF and NO RESIDUAL VOLTAGE
can leak from capacitors OR solid state components.
LOCK OPEN & TAG electrical circuits during servicing. IF WORK IS INTERRUPTED,
confirm that all circuits are de-energized before resuming work.
Sharp Edges
The fins on the air-cooled condenser coils have sharp metal edges. Reasonable care should be
taken when working in contact with the coils to avoid the risk of minor abrasions and lacerations.
The use of gloves is recommended. Frame rails, brakes, and other components may also have
sharp edges. Reasonable care should be taken when working in contact with any components to
avoid risk of minor abrasions and lacerations.
Mechanical Strength
The unit is not designed to withstand loads or stresses from adjacent equipment, pipework or
structures. Additional components must not be mounted on the unit. Any such extraneous loads
may cause structural failure and may result in injury to the operator, or damage to the equipment.
Suitability for Application
The unit is intended for cooling water and is not suitable for purposes other than those specified
in these instructions. Any use of the equipment other than its intended use, or operation of the
equipment contrary to the relevant procedures may result in injury to the operator, or damage to
the equipment. The unit must not be operated outside the design parameters specified in this
manual.

KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company IOM-KAC-ENG - Page 5
Chapter 1 Introduction
1.1. General Description
Kirloskar Chillers hermetic scroll liquid chiller, type KAC (Air-cooled) comes complete, self-
contained automatic refrigerating units and ready for installation. These units include the latest in
engineered components arranged to provide a compact and efficient unit. Each unit is completely
factory assembled, factory wired, pressure tested before evacuation, refrigerant and lubricating
oil charged and factory run tested. Run test can be witnessed at an extra cost.
Each KAC unit consists of air-cooled condensers with integral sub-cooler sections, multiple
hermetic compressors, direct expansion (Dx) type shell-and-tube evaporator, complete
refrigerant piping and control panel.
Refrigerant piping components include compressor suction and discharge, main liquid line, main
liquid line filter driers, electronic expansion valves. The control panel includes all safety and
operating controls necessary for dependable automatic operation. Compressors are fused in all
three phases and started by respective three-pole contactors.
1.2. Distinctive Features
1.2.1. Scroll Compressor
A scroll compressor actually consists of two scrolls or spirals. One scroll is moving, whereas
the second one is fixed (attached to the compressor body). The first scroll orbits (rotates) in a
path defined by fixed scroll. The orbiting scroll is connected to the compressor's crankshaft. As a
result of the scroll's movement, gas pockets are formed between the two scrolls. At the outer part
of the scrolls, the pockets suck in gas and then move towards the center of the scroll, where the
compressed gas is discharged. As the gas moves into the continuously smaller internal pockets,
both its temperature and pressure are increased. Thus a desirable discharge pressure is achieved
by the motion of the compressor scrolls.
1.2.2. Reliability
Testing of all units ensures a trouble free start-up. Extensive tests make sure that all safety
controls are adjusted properly and operate correctly.

KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company IOM-KAC-ENG - Page 6
1.3. Inspection
Upon receipt of the units at site, ensure the complete shipment against delivery note OR bill of
lading / bill of entry invoice / packing list and also inspect the units for any transit damage. If any
transit damage is found, report the shipping damage to the transporter and file the insurance
claim.
1.4. Handling and Lifting
Use spreader bars and suitable capacity crane & lifting cables. Refer Fig. 1.4a for details. Never
allow any part of the unit to fall during unloading or moving as this may result in serious
damage. Lifting rope hole on spreader bars shall be minimum 300mm more than the width of the
unit.
Refer lifting diagram instruction pasted on unit.
Fig 1.4a : Lifting diagram for scroll chiller
NOTE: PHYSICAL DAMAGE TO UNIT AFTER ACCEPTANCE IS NOT THE
RESPONSIBILITY OF KIRLOSKAR CHILLERS PRIVATE LIMITED.
CAUTION: SHARP EDGES AND IMPROPER BALANCING DURING HANDLING
AND LIFTING ARE POSSIBLE INJURY HAZARDS.
NOTE: DO THE UNIT HANDLING ONLY WITH QUALIFIED PERSONNEL WHO
ARE FAMILIAR AND EXPERIENCED WITH THIS TYPE OF EQUIPMENT.