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.

KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company IOM-KAC-ENG - Page 7
1.5. Life Cycle Perspective and Disposal of Product:
Sr.
no.
Raw
Material
Category
KSC/
KDC
KAS
KA
A
KW
S
KWE
KWK
KWI
KCM
KAC
1
Refrigeran
t (R134a,
R407C
and
R410A)
Hazardo
us
√
√
√
√
√
√
√
√
√
2
Refrigeran
t(R1234ze
)
Hazardo
us
NA
NA
NA
NA
NA
NA
√
NA
NA
3
Lubricatin
g Oil
Hazardo
us
√
√
√
√
√
√
√
NA
√
4
Electronic
-Waste
Hazardo
us
√
√
√
√
√
√
√
√
√
5
Brass
Hazardo
us
√
√
√
√
√
√
√
√
√
6
Copper
Hazardo
us
√
√
√
√
√
√
√
√
√
7
Plastic
Hazardo
us
√
√
√
√
√
√
√
√
√
8
Stainless
steel
Non
Hazardo
us
√
√
√
√
√
√
√
√
√
9
Cast iron
Non
Hazardo
us
√
√
√
√
√
√
√
√
√
10
Carbon
steel
Non
Hazardo
us
√
√
√
√
√
√
√
√
√
11
Nitrile
foam for
insulation
Non
Hazardo
us
√
√
√
√
√
√
√
√
√
12
All
casting
componen
t
Non
Hazardo
us
√
√
√
√
√
√
√
√
√

KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company IOM-KAC-ENG - Page 8
1.5.1. Instructions for Disposal after End of Life of Chiller
Isolate chiller from location.
Take out refrigerant and oil separately and store in different containers.
Dismantle all components/sub-components of chiller.
Segregate all metallic, non-metallic parts and plastic material.
Collect hazardous material like E-waste, oil and refrigerant separately.
Store all scrap material at proper place.
Refrigerant can be disposed either by reuse as per the purity or handing over to specialized
disposal agencies.
Oil can be disposed by authorized disposal agencies.
Dispose the metal scrap to the authorized recycler.
Handle all hazardous materials by using PPE (for any additional information regarding PPE,
please contact our service engineer) and follow all safety norms.
Dispose it with Pollution control approved hazardous waste disposal agencies.
Dispose all remaining non-hazardous waste like non-metallic parts, plastic as per Pollution
control board norms.
Follow the legal norms for the waste disposal as per the local, state, national, international
applicable legislation.

KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company IOM-KAC-ENG - Page 9
Chapter 2 Installation
2.1. Space Requirement for Servicing
Each side of the unit must be accessible for periodic service work. Servicing needs to be done
on system components like compressor(s), shut off valves, filter drier(s) etc. Compressor(s),
compressor suction and discharge isolation valves are accessible from the side(s) of the unit.
Typical location of control panel for air-cooled chillers is shown in Fig. 2.2a. The panel has
power and control section. The power section includes the required switchgear components. The
control section includes the state of art dedicated Microprocessor ‘K-smart’ controller for the
efficient operation of the chiller. Other refrigerant controls and valves are main liquid line and
liquid injection line shut-off valves, liquid line and injection line filter driers, Electronic
expansion valve that are accessible from the back end of the unit OR from side(s) of the unit
(depending on the model).
2.2. Unit Location
1. Minimum side clearance between two KAC chillers shall be 2000 mm.
2. Minimum top clearance for KAC shall be 10000 mm.
3. Over and above this, the side clearance around the chiller shall be maintained as shown in the
Fig 2.2a
Fig. 2.2a : Typical fan arrangement and minimum clearances required

KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company IOM-KAC-ENG -Page 10
4. Failure to pay heed to recommended clearances may result in reduced system performance,
nuisance shutdown & / or servicing problems.
In all air-cooled units, condenser air inlet and condenser fan air discharge must be free from
obstruction. Unit installed less than the minimum recommended clearance to a wall OR top
clearance OR between units may experience a combination of coil starvation and warm air re-
circulation. Warm air re-circulation occurs when the discharge air from condenser fan is recycled
back to the condenser coil inlet. Coil starvation occurs when free airflow to the condenser is
restricted. Both warm air recirculation and coil starvation reduces the unit capacity and operating
efficiency because of the high head pressure. Hence, unit must be located at a place where it gets
free air supply.
2.3. Evaporator Water / Brine (Liquid) Piping
All Evaporator water nozzles come with standard grooved neck type nozzles for Flexible
couplings (Victaulic couplings). Victaulic coupling is in customers scope.
a) Isolation valves shall be provided at evaporator water / brine (liquid) inlet and outlet
connections. This helps in accomplishing the normal servicing without draining the liquid in total
system.
b) It is recommended to use flexible connections between the evaporator liquid nozzle
connection and the system OR process piping, suitable for the system liquid pressure to eliminate
vibration transformation either from system to unit OR vice versa.
c) Although evaporator has an air vent on shell side, it is recommended that the main chilled
liquid header shall have vent valve at the top most point in the header to facilitate purging on
evaporator liquid headers.
d) Entering evaporator liquid connection must always be to the nozzle near to the head cover
having refrigerant liquid in and vapor out connections. Refer Fig. 2.3a for details
Fig. 2.3a Typical Evaporator Water/ Brine (liquid) Piping

KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company IOM-KAC-ENG -Page 11
e) It is recommended that thermometers and pressure gauges be installed at the evaporator inlet
and outlet. This will aid to check the liquid temperature.
f) It is recommended that installation of a wire mesh strainer at the pump suction to protect the
pump and the exchanger from foreign matter; otherwise provide a strainer as shown in Fig. 2.3a.
This prevents damage to control valves and evaporator tubes.
g) All chilled liquid piping should be insulated to prevent condensation over the chilled liquid
pipelines. If insulation is not of the self-contained vapor barrier type, it should be covered with a
vapor seal. Vent and drain connections must extend beyond proposed insulation thickness for
accessibility.
NOTE: DO THE LEAK CHECK BEFORE INSULATING THE CHILLED LIQUID PIPE.
h) Flow control devices such as balancing valves shall be mounted in the chilled liquid piping to
have the controlled and constant liquid flow. Refer design data sheet for the evaporator liquid
flow rate data.
2.4. Foundation and Anti-Vibration Mounts
2.4.1. Foundation
Kirloskar Chillers make KAC units have very minimum vibrations and do not require any special
type of mounts. These units can be set directly on the floor with the mounting pads supplied
along with the unit. For further details refer Fig. 2.4.1a.
a) Unit must be mounted on flat and level foundation, floor capable of supporting the entire
operating weight of the equipment. Refer the enclosed unit general arrangement drawing OR
physical data sheet for operating weight.
b) When floors are weak or of inadequate strength, supplementary structural OR concrete
supports must be provided. Such kind of supplementary supports must be designed to distribute /
transfer the unit weight to the nearest stronger beams.
REMOVE THE TEMPERATURE SENSORS FROM THERMOWELLS TO
PREVENT DAMAGE TO THE SENSORS WHEN WELDING THE FLANGE
CONNECTIONS.

KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company IOM-KAC-ENG -Page 12
Fig. 2.4.1a Typical Unit Mounting Arrangement
NOTES:
a) Standard Neoprene Rubber Pads are supplied along with the chiller.
b) For KAC chillers, Anchoring / Foundation bolts are not required.
2.4.2. Anti-Vibration Mounts
If minimum vibration is an important consideration, it is recommended that vibration isolators of
a suitable type be installed under the base. The isolators must be designed for the operating
weight of the unit and can be supplied by Kirloskar Chillers as an OPTIONAL ACCESSORY at
an extra cost. To further reduce the transmission of vibrations it is recommended to use flexible
connections, suitable for the system water pressure, be installed on the water connections, refer
water piping, section 2.3 for further details.
Sr.no.
Type of Installation
Recommended type of Isolator
1
Floor mounting
Rubber-in-shear isolators
2
Supplementary support mounting
Spring isolators
2.5. Water Treatment / Quality
If the unit is operating with a cooling tower (KAC units), clean and flush the cooling tower.
Make sure that the tower “blow-down” or “bleed-off” is operating. Atmospheric air contains
many contaminants, which increases the need for water treatment. This is also applicable for
liquid chiller / evaporator side.
The use of untreated water in cooling towers, closed water systems etc. frequently results in one
or more of the following:

KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company IOM-KAC-ENG -Page 13
a) Scale formation
b) Corrosion or erosion
c) Slime and Algae formation and the growth of the bacterium Legionella pneumophila
(Legionnaires Disease).
It is therefore to the benefit of the end user to provide for proper water treatment to provide for
longer and more economical life of the equipment. The following recommendation is to
understand the condition of the water.
Recommended water quality standard for KAC liquid chillers
Test Item
Chilled water line
Tendency if the conditions are
not met
Circulation
Make up
Corrosion
Scale
pH (@ 25C)
-
6.8 ~ 8.0
6.8 ~ 8.0
√
√
Chloride Ion
Ppm
below 50
below 50
√
Sulphuric
Acid Ion
Ppm
below 50
below 50
√
Total
Hardness
Ppm
below 70
below 70
√
Calcium
Hardness
Ppm
below 50
below 50
√
Silica Ion
Ppm
below 30
below 30
√
Iron
Ppm
below 1.0
below 0.3
√
√
Copper
Ppm
below 1.0
below 0.3
√
Sulphide Ion
Ppm
Should not be
detected
√
Ammonium
Ion
Ppm
below 1.0
below 0.1
√
Residual
Chlorine
Ppm
below 0.3
below 0.3
√
Free Carbon-
dioxide
Ppm
below 4.0
below 4.0
√
Ryzner
Stability
Index
RSI
---
---
√
√
NOTE: Kirloskar Chillers is not responsible for damage or under performance or
faulty operation from untreated or improperly treated water

KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company IOM-KAC-ENG -Page 14
2.6. Installation of Flow Switch
For the safety of the unit, install flow-sensing instrument (shall be supplied at extra cost) in each
evaporator water / brine line. It may be a flow switch.
Flow switch installation: Mount individual flow switch in the leaving water line of the
evaporator and condenser. Refer Fig. 2.3a for flow switch installation.
2.7. Installation Check Report for KAC Chiller Units
Customer : ________________________________________________________
End User Consultant : __________________________________________________________
Unit model : ________________________________________________________
Unit serial # : _________________________________________________________
SR
No
PARTICULARS
1
UNIT:
1. In case of transit damage, has it been attended completely?
2. Is there any damage during installation?
3. If any damage as per #2, has it been attended?
4. Whether unit is mounted as per recommendations?
5. Is there free space available to attend compressor(s)?
3
AIR-COOLED CONDENSERS:
1. Sufficient space allowed for cleaning and replacing tubes.
2. Air vent and Water drain valves are provided.
3. Flow switch is mounted in the leaving water line
4. Service valves are provided for de-scaling / servicing
4
EVAPORATOR / CHILLER:
1. Sufficient space allowed for air entry & service facilities?
2. Coil guard provided
5
POWER AND CONTROL PANEL:
Sufficient space allowed for accessing and servicing the panel.
6
MISCELLANEOUS:
Sufficient space allowed to access and attend refrigerant liquid line valves,
Electronic expansion valves and moisture & liquid flow indicator.

KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company IOM-KAC-ENG -Page 15
Use following Alpha Numeric symbols to answer above questions:
: for YES, : for NO / NIL, NA: for NOT APPLICABLE

KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company IOM-KAC-ENG -Page 16
Chapter 3 Operation
3.1. Liquid Chilling Systems - Principle
Kirloskar Chillers make KAC liquid chilling package system shall be utilized for chilling water
OR brine (for details please contact Kirloskar Chillers). These units work on vapor compression
principle. The basic components of a vapor-compression liquid chilling system are as follows:
Compressor
Condenser,
Liquid refrigerant expansion or flow control device
Evaporator
Refrigerant and
Power and Control Panel.
The basic vapor compression refrigeration cycle is explained in Fig. 3.1a.
Fig. 3.1a Vapor Compression system
In cooler / evaporator, entering hot liquid (usually water) is cooled by the evaporating refrigerant
which is at a lower pressure and lower temperature. The evaporated refrigerant is drawn by the
compressor, which increases the temperature and pressure of the gas above ambient temperature