Sp9907-A - Chiller Statup Procedures

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Service
Procedure
SP Number:SP-9907-A
Originator: RDH
Supersedes: NONE
Date: 12/03/99
CHILLER START-UP PROCEDURES

Proper unit start-ups are critical to insuring unit performance and reliability. This includes understanding
the system loads and the system / unit controls. It is critical to select the proper control settings in order
to provide stable system operations. The correct settings will limit temperature swings, compressor
cycling, and excessive control staging. Modifications to system controls or design may be necessary to
insure stable operations. Potential problems should always be noted on start-up reports. The
information below is for all types of chillers.
The following settings should be verified to match the application. Other settings may also need to be
reviewed and adjusted.
ITEM
Leaving
Evap Spt
DESCRIPTION
Desired leaving fluid
temperature.
Control
Band
Total range of leaving fluid

temperature
Start-up
T
Temperature above Leaving

Evap Spt plus Control
band before staging on
compressor.
Shut-down Temperature below Leaving

Evap Spt plus Control
T
band before staging off
compressor.
1999 McQuay International
SETPOINT
Settings below 44F may require the addition of a glycol solution,
depending on control band, shutdown T, system load, and other
variables.
Setting should be high enough to prevent excessive staging due to
load variations or reaction to compressor capacity steps. For example:
(Screw, Scroll, or Recip unit) The control band setting should be set in
excess of the largest capacity step of the unit, at nominal water flow.
This will vary from 2.0- 5.0 F. Any decrease in flow rates will require a
higher control band setting, proportional to the flow reduction. The
full load operating T across the evaporator should never exceed 16F.
Flow or load variations should be limited to a maximum of 10% of full
load rating within a one-minute period.
Setting should be as high as possible for the application. For example:
In a comfort cooling application, the machine should rarely cycle
during periods of high ambient and during periods of lower ambient.
Higher swings in supply water temperature are not as critical so a
setting of 5-10 F would be practical.
Setting will depend on the leaving chill water setpoint and control
band setting. For example: (The LWT setpoint is 44 F and the control
band is 4 F) The Shutdown T would be set at 1-2 F maximum to
prevent low-pressure safety trip. Higher Shutdown T setpoint is
practical with lower loads, higher LWT setpoint, and lower control
band setting.
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MaxChw
Pulldown
Rate
Prevents additional staging

if temperature drop rate per
minute equals or exceeds
setting.
Chill
Water
Reset
Hot Gas
Bypass
Start to
Start
Timer
InterStage
Timer
Maximum temperature base

change on input signal.
Ramp
Time
Only incorporated during

initial pulldown to the
Leaving Evap Spt.
Used only for thermal
storage systems. NOT to
be used for low
temperature applications.
Ice Mode
Setting will depend on the system water volume, startup heat load, and
type of operation. A setting of 0.5 F or less is normally more than
adequate for comfort cooling due to high loop water temperatures and
moderate building loads. Settings should be low to prevent peak
demand charges and to prevent excessive staging. Setting should also
prevent compressor cycling or safety trips due to rapid pull down
rates. Settings of 1.0 F or greater should only be used in cases of
critical process systems, or large water volume/high load applications.
Control points should be verified to provide required
cooling/dehumidification and confirm that remote reset signals are
stable.
Confirm & Set at minimum

loading.
Chill water T should not be less than 1F with hot gas operating and
minimum loading.
Minimum time delay

between starts.
Settings may be increased based on the job site operating conditions

and requirements.
Minimum time between

steps of increased capacity.
Set timers to react to changes in chill water temperatures. Load

changes greater than 10% of full load within one minute should be
corrected. Any changes in load should be minimized for best
performance.
Use the same considerations as listed under Max Chw Pulldown Rate
above.
Confirm water flow rates in different operating modes. Reset
temperature should be based on storage vessels approach and
manufacturers recommendations.
If you have any specific questions regarding control functions or set-up,

contact your area manager or TRC for assistance.
An efficient and complete startup requires preparation. Use the following checklist as a general
guideline and make any improvements or changes to suit your applications. Some of the items are
requirements and others are recommendations. Any deficiencies should be noted in the start-up report
and should have the customers signature indicating they are aware of and may be responsible for
consequences based on the noted deficiencies.
NOTE:
This is not a replacement for the unit startup sheet. It is intended to be a minimum checklist for all
models of chillers. All checks and information needed for the individual chillers must be completed.
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Before beginning work: Is a confirmation of job site conditions that may prevent or
delay start-up completion and should be verified first. This section is generally
completed prior to scheduled start-up. It may require a Purchase Order or authorization
for additional services. Typically, this requires a visual review of installation, literature,
and drawings.
____ Must have Chiller Passport and completed Request for Start-up form for Category one products.
____ Verify items signed off on the Request for Start-up form.
____ Inspect the chiller for damage and appearance.
____ Inspect for moisture damage in the control panels.
____ Minimum clearances for air flow and services, per IM.
____ Equipment level and properly supported per IM.
____ ALS unit with remote evaporator, piping has been approved by TRC and meets SB 37-9951 specs.
____ Pumps, piping and direction of flow are correct per specifications and properly supported.
____ Vent, gauge, and drain connections provided per IM.
____ Verify water systems have been flushed, cleaned, and strainers provided for new systems.
____ Per code requirements, relief valves should be vented to outdoors, properly supported, & terminations
protected from weather and insects.
____ All power wiring is copper gauge and insulation rating per NEC.
____ Over current protection per specifications.
____ Load available for adequate testing under stable conditions.
____ Paddle type flow switch (or approved DP) in leaving water piping per specifications.
____ Spring isolators require flex connections in all piping and conduit (36 min. flex conduit). Unit
should have springs installed. The weight load should be carried by shims or blocks at free height until all
piping, water, and refrigerant charging is complete.
Check first: Items may require services which may delay unit start-up.
____ Control power on, compressor oil temperature at recommended range.
____ Leak test unit (insure all required valves are open and pressure adequate).
____ Check water boxes for construction debris and piping stress.
____ Verify pump and flow (calibrate flow / p switch to trip at 50% rated flow) interlocks are per specs.
____ Customer interlocks only as indicated on wiring diagrams (shielded cable as required).
____ Customer has Site License for open protocol, if used.
____ Glycol solutions correct type and % mixture.
____ Water treatment services have been performed and auto feed equipment has flow interlocks.
____ Primary/secondary pump interlocks operate properly (sequence to confirm).
____ Condenser and chill water controls provide stable water supply.
____ BAS operational for chiller support (tower fans, pumps, etc.)
Before starting: Complete or confirm prior to starting equipment.

____ Temperature sensors, txv bulbs, and gauges are installed properly. Heat conductive compound
is used as required.
____ Wiring is visually inspected and connections checked for torque and proper termination.
____ Mechanical interlocks function properly.
____ Voltage, phasing, and phase imbalances are within specs.
____ Verify correct position of all valves.
____ Check all setpoints per McQuay specs and job requirements.
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____ Controller displays correct readings. Verified by mechanical gauges. Calibrate as necessary.
____ Oil level and temperature correct.
____ Drives have proper alignment, tension, and rotation. Mounting bolts and setscrews torqued.
____ Tubing, capillary tubing, wiring, and conduit properly routed and secured.
Once started: Test and confirm operations.

____ Verified overcurrent set points.
____ Controls sequence tested.
____ Safety set points properly set and calibrated.
____ Unloader needle valves adjusted. Unloader operation tested.
____ Conditions and operations verified under full load and minimum loads.
____ Modem operational.
____ Note any repairs or deficiencies needed, including repairs to insulation and paint, or if freeze protection may
be required.
____ All log sheets and start-up reports must be complete and signed by the customer.
It is extremely important that any items not meeting installation

requirements or that may cause potential operating problems are
noted to prevent any future dispute of liabilities. Stable operating
conditions must be available for testing and start-up and some test
may require full design load to insure proper set-up and
verifications. Review all start-up forms for correct and complete
data before sending in for registration. Current Start-up forms
should be used and are available from McQuay-on-Line.

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Page 1 of 4

CHILLER START-UP PROCEDURES

Total range of leaving fluid

Temperature above Leaving

Shut-down Temperature below Leaving

1999 McQuay International

Prevents additional staging

Maximum temperature base

Only incorporated during

Confirm & Set at minimum

Minimum time delay

Settings may be increased based on the job site operating conditions

Minimum time between

Set timers to react to changes in chill water temperatures. Load

If you have any specific questions regarding control functions or set-up,

1999 McQuay International

Before starting: Complete or confirm prior to starting equipment.

1999 McQuay International

Once started: Test and confirm operations.

It is extremely important that any items not meeting installation

1999 McQuay International

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