SCOPE OF WORK

Testing and Commissioning of Chillers as per specification, and in accordance with the
manufacturer’s instructions.
SYSTEM COMPONENT
Part I Mechanical Systems
Part II Electrical Systems
TECHNICAL SECTION
Testing Tools / Equipment Clamp on Meter
Amp Meter
Electronic Leak detector
Electronic Thermometer
(All test equipment should be with valid calibration certificates)
Part I Mechanical Systems:
Pre-start up
1. Inspect all water piping for flow direction and correct connections at the evaporator.
2. See that all auxiliary control equipment is operative and that an adequate cooling load
is available for initial startup.
3. Check all compressor valve connections for tightness to avoid refrigerant loss at
startup.
Open the compressor suction and discharge shut off valves until back seated. Open the
liquid line shut off valves until back seated. Always replace valve seal caps.
4. Make sure system switch S1 is in the “Stop” position and pumpdown
switches PS1, PS2, PS3 and PS4 are set to “Pumpdown and Stop”, throw the main power
and control disconnect switches to “ON”. This will energize crankcase heaters. Wait a
minimum of 12 hours before starting up unit. Turn compressor unit breakers to ”OFF”
position until ready to start unit.
5. Vent the air from the evaporator as well as from the system piping. Open all water
flow valves and start the chilled water pump. Check all piping for leaks. Flush the
evaporator and system piping to obtain clean / noncorrosive water in the evaporator
unit.
Start-up.
1. Double check that the compressor suction and discharge shut off valves is
backseated. Always replace valve seal caps.
2. Ensure that the ball valves are open on the lines entering the evaporator.
3. Ensure that the manual liquid line shut off valve at the outlet of the subcooler is open.
4. Adjust the leaving chilled water temperature set point on the MicroTech Controller to
the desired chilled water temperature.
5. Start the auxiliary equipment for the installation by turning on the time clock, and/or
remote ON/OFF switch, and chilled water pump after checking that all procedures
mentioned in Part II Electrical sitemaps are completed.
6. Check to see that pumpdown switches PS1, PS2,PS3 and PS4 are in the “Pumpdown
and Stop” (open) position. Throw the S1 switch to the “Auto” position.
7. Under the “Control Mode” menu of the keypad place the unit into the automatic cool
mode.
8. Start the system by moving pumpdown switch PS1 to the “Auto” position.
9. After running circuit 1 for a short time, check the rotation of the condenser fans.
(Proper rotation
will have air being drawn into the vertical coils and discharged out from the top of the
unit). Check for flashing in the refrigerant sight glass under stable conditions.
10. Repeat steps 8 and 9 for PS2, PS3 and PS4 and the second, third and fourth
refrigerant circuits.
11. Check the superheat should be between 8 and 12 F, with the liquid line sightglass
full, once the system temperatures have stabilized at the Micro Tech set point
temperatures.
Part II Electrical Systems:
1. To assure correct compressor rotation, field power supply leads must be properly
phased prior to startup.
2. With all electric disconnects open, check all screw or lug type electrical connections to
be sure they are tight for good electrical contact.
3. Using a phase tester, check that electrical phasing to each compressor circuit is ABC
for phases L1, L2 & L3 respectively.
4. Check the voltage of the unit power supply and see that it is within the ± 10%
tolerance that is allowed. Voltage unbalance between phases must be within ± 3%.
5. Verify that all mechanical and electrical inspection has been completed as per local
codes.
BMS hook-up
These sections are covered under Method Statement for Building Management system.
MANUFACTURER’S/OTHER’S SPECIAL RECOMMENDATIONS:
For further recommendations, please refer to the manufacturer’s manual.
RECORD AND REPORT DATA
1. Prepare report of recommendations for correcting unsatisfactory performance, if any.
2. All test data to be recorded in forms, which are enclosed for reference.
SAFETY
Only competent personnel will be present in vicinity of the testing area while carrying out
the test.
TRAINING
Train the Owner’s maintenance personnel for Operation and Preventative maintenance
as per specification clauses.
WORK DURATION
The procedure will take 1 day per chiller.
RELATED EQUIPMENT
Prior to starting the Chiller all electrical works related to supply of power to the
equipment should be tested and energized. Furthermore, chemical treatment of chilled
water pipes and circulating pumps should be commissioned. In addition, all AHUs should
be operational to provide load for the Chiller.
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Checklist For Testing & Commissioning Of Chillers:

MECHANICAL SYSTEMS :
1 Check water piping connections at the evaporator.
2 See that all auxiliary control equipment is operative and that an adequate cooling load
is available for initial startup.
3 Check all compressor valve connections for tightness. Open suction & discharge shutt
off valves and liquid line shut off valve.
4 Make sure that system switch S1 is in the “stop” position and pumpdown switches are
set to “pumpdown and stop” and control disconnect switches to “on”. Wait a minimum
of 12 hours before starting up of unit. Turn compressor unit breakers to “off” position
until ready to start the unit.
5 Vent the air from the evaporator as well as from the system. Start the chilled water
pump after opening all water flow valves.
6 Ensure that the ball valves are open on the refrigerant lines entering the evaporator.
7 Ensure that liquid line shut off valve at the outlet of the subcooler is open.
8 Adjust the leaving chilled water temperature set point on the controller to the desired
chilled water temperature.
9 Start the auxiliary equipment for the installation by turning on the time clock, and/or
remote ON/OFF switch and chilled water pump after completing all Electrical checkups.
10 Throw the S1 switch to the auto position.
11 Under the “control mode” menu of the keypad place the unit into the automatic cool
mode.
12 Start the system by moving pumpdown switch to PS1 to the “auto” position.
13 After running circuit 1 for a short time, check the rotation of the condenser fans.
Check for flashing in the refrigerant sight glass under stable conditions.
14 Repeat steps 12 & 13 for PS2, PS3 and PS4 and the second, third and fourth
refreigerant
circuits.
15 Check that the superheat should be between 8 and 12 deg. F, with the liquid line
sight glass full, once the system temperatures have stabilized at the MicroTech set point
temperatures.
ELECTRICAL SYSTEMS :
1 With the electric disconnects open, check all screw or lug type electrical connections to
be sure that they are tight for good electrical contact.
2 Using a phase tester, check that electrical phasing to each compressor circuit is ABC
for phases L1, L2 & L3 respectively.
3 Check the voltage of the unit power supply and see that it is within the +/10%
tolerance that is allowed. Voltage unbalance between phases must be within +/3%.
4 Verify that all mechanical and electrical inspections have been completed as per local
codes.