Transcript
É n e r g i e
T r a n s f e r t
T h e r m i q u e
Technical instructions for Use & Maintenance Oil & Gas
A different climate Environmental control solutions
Version 04/2014
IMPORTANT The warranty of ETT units depends on the respect of these technical instructions as stipulated in ETT's General Terms of Sales. The maintenance shall be done by a specialized company. 3OHDVHFKDQJHDQGFOHDQÀOWHUVDVRIWHQDVSRVVLEOH Our equipments will surely meet your expectations. We hope you will enjoy using them.
Energie Transfert Thermique
ummary A. Maintenance and frequency.....................................................................................................................
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B. 6SHFLÀFPDLQWHQDQFHUHFRPPHQGDWLRQV...................................................................................
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C. 6SHFLÀFXVHUHFRPPHQGDWLRQV ...............................................................................................................
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D. Use of the controller ................................................................................................................................................
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E. Assistance for diagnostic and repairing ..........................................................................................
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Technical instructions for Use & Maintenance Oil & Gas
A. Maintenance and frequency Please remember: > ETT provides you the maintenance book of the unit to follow and organize maintenance operations described thereafter. > The use of ETT warranty necessitates a total respect of maintenance and use recommendations indicated in this document. > 8QLWVVHUYLFHOLIHDQGHIÀFLHQF\GHSHQGVRQWKHUHVSHFWRIDOOPDLQWHQDQFHDQGXVH recommendations.
Frequency: Q (Quarterly), H (Half-yearly), A (Annually) %HQHÀWV General control: Casing control Drainage and condensates evacuation cleaning Operating time report Securities control Ventilation: )LOWHUVUHSODFHPHQWRUFOHDQLQJ PPWKLFNQHVVÀOWHUV )LOWHUVUHSODFHPHQWRUFOHDQLQJ PPWKLFNQHVVÀOWHUV Servomotors and dampers control Control and cleaning of fans turbines Fans and motors pulleys control and tightening (if concerned) Fans bearings control (if concerned) )DQVURWDWLRQVSHHGDQGDLUÁRZUDWHVFRQWURO Ventilation motors control Control of belts and their tension (if unit with belts) Change of belts (if unit with belts) Fans motors intensities report Propellers fans control (if concerned) Propellers fans motors intensities report (if concerned) Refrigerant circuits: Circuit tightness control (Unit load >2kg ‘A’ >30kg ‘H’ >300kg ‘Q’ ) Refrigerant load control & adjustment if necessary Compressor control Compressor(s) parameters settings Compressor(s) intensities control Pressures control: HP and LP Temperatures control: gas and liquid Refrigerant to air exchangers cleaning and control Control of expansion valves 4-way valve(s) control (if concerned) Heating (if concerned) Hot water coil control Water quality in the hot water coil control 3-way valve operation control Electric heaters control Warm air heaters control (50 to 400 kW capacity) Warm air heaters control (more than 400 kW)
Q
H
A
X X X X X X X X X X X X X X X X X X
X X
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X X X X X X X X X X X X X
5 04/2014
Technical instructions for Use & Maintenance Oil & Gas Frequency: Q (Quarterly), H (Half-yearly), A (Annually) %HQHÀWV Electricity / Control: Controller control Clock hand settings Setpoints control Electrical connections tightening Temperature sensors control Gas probe Pressure probe &RDOHVFLQJÀOWHUVFOHDQLQJ &RQWURORIÀUHVWRSYDOYHV Ducts Control of ducts &RQWURORIVFUHZGRZQÁDQJHV Gaskets tightness control Check of the equipotential bondings Smoke detector head (DAD) cleaning Smoke detector head replacement Nota: This period is given as an example and can be shorter in case of polluted atmosphere.
Replacement of the smoke detection box battery Hygrometry probes replacement (if concerned) CO2 probes replacement (if concerned)
Q
H
A
X X X X X
X Every 2 years Every 2 years Every 2 years Every 2 years
B.6SHFLÀFPDLQWHQDQFHUHFRPPHQGDWLRQV 1/ Exchangers cleaning Clean them using a bristle scrub brush, a vacuum or a compressed air jet if necessary. Rinse with cold DQGORZSUHVVXUHZDWHUDYRLGLQJVSDWWHUVRQWKHIDQPRWRU&OHDQLQFRXQWHUÁRZRIWKHDLUÁRZZD\
2/ Filtration %HFDUHIXODEDGÀOWUDWLRQRUDQLPSRUWDQWIRXOLQJFDQGDPDJHWKHXQLWHIÀFLHQF\DQGUHIULJHUDQWFLUFXLW
Nota:
7KRVHÀOWHUVFDQQRWEHFOHDQHGPRUHWKDQRUWLPHV$IWHUWKDWWKH\DUHOHVVHIÀFLHQW 'RQRWNHHSDÀOWHUDIWHUUHJHQHUDWLRQV ,IDÀOWHUFDQQRWEHUHJHQHUDWHGFKDQJHLW 0HWDOÀOWHUVUHJHQHUDWLRQ > Clean them with warm water and liquid detergent. > Rinse them after cleaning and dry them using compressed or current air. > &RDWDJDLQWKHÀOWHULQJHTXLSPHQWZLWKÀOWHUFRDWRUVRPHWKLQJVLPLODUWRJLYHLWVSURSHUWLHVEDFN > &KHFNWKDWÀOWHULQJHOHPHQWVDUHFRUUHFWO\LQVWDOOHGZKLOHUHDVVHPEOLQJWKHP 7LVVXHÀOWHUVUHJHQHUDWLRQ > 8VHWKHVDPHPHWKRGWKDQPHWDOÀOWHUVWRFOHDQDQGGU\WKHP > Reassemble them in the support frame.
6 04/2014
Technical instructions for Use & Maintenance Oil & Gas 3/ Fans bearings Many ETT units centrifugal fans have ball bearings, life-greased, without need of maintenance. However, a clearance control in bearings is necessary. > :HDGYLVH\RXWRFRQWURODQGDGGJUHDVHHDFKTXDUWHUO\SHULRGIRUIDQVZLWKJUHDVHÀWWLQJ > Our fans bearings have generally a 100.000 hours lifetime.
4/ Particularities of corrosive / salt areas > Bearings and fans shafts greasing each month (whatever the type). > Control and cleaning of fans each month. > Exchangers cleaning with clear water each month. > &RDOHVFLQJÀOWHUVFOHDQLQJ
5/ Cleaning of the DAD head It is necessary to control periodically the operation according to the regulation in force for the building. For W\SH'$' '$'6 DFRQWURORIWKHVHFRQGDU\VRXUFHPXVWEHGRQHPRQWKO\E\SUHVVLQJWKHVHFRQGDU\ VRXUFHWHVWEXWWRQGXULQJDWOHDVWVHFRQGV7KH8QGHUYROWDJHLQGLFDWRUPXVWVWD\VZLWFKHGRQ
&RDOHVFLQJÀOWHUVFOHDQLQJ '6+ 3OHDVHFRQVXOWWKHHTXLSPHQWVVSHFLÀFDWLRQV +9$
C.6SHFLÀFXVHUHFRPPHQGDWLRQV 1/ Cooling system register (EN 378-2) When there are more than 3 kg of refrigerant, a register concerning the cooling system must be created and updated by the concerned party. A register must be prepared during the installation of the system by the installer. As indicated in the EN 378-4, it must be constantly updated after maintenance. The register indicates those information: A. Details concerning all maintenance and repairing interventions B. Quantities and nature (new, reused, recycled) of the refrigerant loaded during each intervention. Refrigerant quantities transferred during each intervention (it is also possible to consult the EN 378-4) C. If the reused refrigerant is analysed, it is necessary to keep the results in the register D. The reused refrigerant origin E. The system components changes and replacements F. All routine periodic tests results G. Times during which it is not used.
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Technical instructions for Use & Maintenance Oil & Gas 2/ Use of refrigerant It is necessary to respect the EC No.842/2006 Directive while using refrigerants: - Operators must be trained and authorized to manipulate refrigerants. - 7KHFRPSDQ\HPSOR\LQJWKHRSHUDWRUPXVWKDYHDFHUWLÀFDWHRIFRPSHWHQF\JLYLQJWKHULJKWWRLWV staff to manipulate refrigerants. - It is important to control and declare refrigerants leakages according to the installation load.
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Warning: Please respect the security rules given by the refrigerant suppliers concerning the use of refrigerants.
3/ Unit temporary stop A. Stop the unit. B. Keep the evaporator reheater (air to water, water to water PAC (heat pump)) and the pipelines reheaters under voltage if it is not automatic and if the unit is in a place in which there might be temperatures under 0°C.
4/ Starting after a temporary stop There is no particular precautions. The unit starts by reversing the actions in the paragraph:Unit temporary stop
5/ Unit seasonal stop A. If the heat pump has water circuits, drain them. If the unit is in a place in which there might be temperatures under 0°C, drain the connection pipelines. B. Open the main switch. Remove the fuse block or lock the main switch in opened position. C. If the heat pump is in an area in which there can be condensation, it is necessary to put oil on mechanical pieces that can become oxidized (fan bearings, rollings, pulleys, etc.).
6/ Seasonal start A. 5HVSHFWWKHDFWLRQVZULWWHQLQWKH$QQXDOO\SDUDJUDSKLQWKH0DLQWHQDQFHFKDSWHU B.,IQHFHVVDU\ÀOOXSWKHZDWHUFLUFXLWVDQGGUDLQWKHDLULQVLGHWKHP C.2SHQFRPSOHWHO\WKHFRPSUHVVRUEDFNÁRZYDOYH D. Open the stop valve of the liquid line (eventually). E. Check the whole refrigerant circuit tightness. F. Switch on the system main disconnector. G. Fix the control unit (if concerned). H. Wait for the compressor crankcase heaters preheating (72 hours). I. Start the system. J. Check the operation of the equipments connected together. K. Check the oil level and the service pressures after the operation of the system during 15 to 20 minutes. 7KHUHIULJHUDQWÁRZUDWHPXVWEHUHJXODU7KHUHPXVWQRWEHEXEEOHV
8 04/2014
Technical instructions for Use & Maintenance Oil & Gas 7. Generating sets $FOHDQVWRSRIWKHXQLWLVQHFHVVDU\LIWKHXQLWLVVXSSOLHGXVLQJDJHQHUDWLQJVHW SOHDVHFRQVXOW8QLW WHPSRUDU\VWRSIRUPRUHLQIRUPDWLRQ It can be managed manually or by programming a BMS according to the information given by the energy supplier, in case of peak-day load reductions. The unit can be damaged and components broken (electric components, compressors) in case of non respect of this point. In this case, the ETT warranty cannot be used.
D. Use of the controller 1/ Starting-up or stopping the unit 3UHVVENTERGXULQJVHFRQGV
)DXOWVÀ[LQJ ala alarm
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&RUUHFWWKHIDXOWRQWKHFRPSRQHQWFRQFHUQHG '$'UHVHWÀUHWKHUPRVWDWRUIUHH]HVWDWUHVHWVWDUWRI thermal protection, etc.) ala alarm
3UHVVALARMGXULQJVHFRQGVWRÀ[WKHIDXOW
3/ Access to level 0 - User settings Access to menus: - Setpoints - Operating hours - Clock settings Press the arrows simultaneously during 2 seconds Password = 0 Choose the desired menu by using the arrows 3UHVVENTERWRHQWHUWKHGHVLUHGPHQX Choose the desired mask by using the arrows 3UHVVENTERWRDFFHVVWRWKHVHWSRLQWV Choose the setpoint that needs to be changed by using the arrows 3UHVVENTERWRDFFHVVWRWKLVVHWSRLQW
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Technical instructions for Use & Maintenance Oil & Gas Set-up the setpoint by using the arrows Esc
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4/ Access to level 1 - Maintenance Access to menus:
- Maintenance - Communication - Alarm History - Energy meter - Inputs - Outputs - Counter reset
Press the arrows simultaneously during 2 seconds Password = 1 Choose the desired menu by using the arrows 3UHVVENTERWRHQWHUWKHGHVLUHGPHQX Choose the desired mask by using the arrows 3UHVVENTERWRDFFHVVWRWKHVHWSRLQWV Choose the setpoint that needs to be changed by using the arrows 3UHVVENTERWRDFFHVVWRWKLVVHWSRLQW Set-up the setpoint by using the arrows Esc
3UHVVESCWRFRPHEDFNWRWKHPDLQPDVN
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Technical instructions for Use & Maintenance Oil & Gas
E. Assistance for diagnostic and repairing 1/ Smoke fault Possible reasons of the fault
What should be done
Smoke detection
- Control of presence of smokes or dusts - Head cleaning - Change of head )DXOWÀ[LQJ &RQVXOW'
Detection head fouling
- Control of presence of smokes or dusts - Head cleaning - Change of head )DXOWÀ[LQJ &RQVXOW'
Saving battery out of service
- Change of battery
2/ Filter fault Possible reasons of the fault
What should be done
)RXOHGÀOWHUV
- Filters cleaning &KDQJHRIÀOWHUV
Fouled exchangers
- Exchangers cleaning according to the recommendations
$LUÁRZUDWHIDXOW Possible reasons of the fault
What should be done
)RXOHGÀOWHUV
- Filters cleaning &KDQJHRIÀOWHUV
Leakage on air network
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Transmissions problem
- Transmissions settings
Air network fouled
- Air distribution network cleaning
4/ Fire fault Possible reasons of the fault
What should be done
/DFNRIDLUÁRZUDWH
&KHFNÀOWHUV - Check the fan and its motor
Transmission problem
- Check the transmission
Thermostat problem
- Check the thermostat
11 04/2014
Technical instructions for Use & Maintenance Oil & Gas 5/ Antifrost fault Possible reasons of the fault
What should be done
/DFNRIDLUÁRZUDWH
&KHFNÀOWHUV - Check the fan and its motor
Transmission problem
- Check the transmission
Thermostat problem
- Check the thermostat
Lack of hot water
- Check the boiler house and the pump
6/ Inverters faults Possible reasons of the fault
What should be done
Fault with intensity
- Check the eventual presence of micro cuts on the power supply system
7/ Low pressure fault Possible reasons of the fault
What should be done
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&RQVXOWDLUÁRZUDWHIDXOWVDFWLRQV &RQVXOW(
Low pressure switch malfunction
- Pressure switch operation control - Pressure switch connections control
)RXOHGÀOWHUV
- Filters cleaning &KDQJHRIÀOWHUV
Expansion valve malfunction
- Expansion valve control (status, settings, operation)
Bad defrosting
- Check the refrigerant circuit probes - Check the 4-way valve - Check the defrosting settings
Problem of load of refrigerant
- Tightness control
8/ High pressure fault Possible reasons of the fault
What should be done
%DGDLUÁRZUDWH
&RQVXOWDLUÁRZUDWHIDXOWVDFWLRQV &RQVXOW(
High pressure switch malfunction
- Pressure switch operation control - Pressure switch connections control
)RXOHGÀOWHUV
- Filters cleaning &KDQJHRIÀOWHUV
Outside T° out of application range
- No action
Bad air distribution
- Air distribution network control
12 04/2014
Technical instructions for Use & Maintenance Oil & Gas 9/ Refrigerant circuit fault A. The compressor does not start. Possible reasons of the fault
What should be done
Electrical protection faults
- Protections control
Control security
- Control parameters control - Securities control - Controller reset if authorized
Abnormal supply voltage
- Phases control - Control of the voltage drop during the unit start-up - Control of the power supply chain (wire, connections, contactor, etc.)
Propeller fault
- Propellers control
B. The compressor stops. Possible reasons of the fault
What should be done
Low pressure faults
- Consult E.7
High pressure fault
- Consult E.8
Ipsotherm fault
- Control of the compressor cooling - Control of the ipsotherm probe - Filters fouling control
Thermal fault
- Compressor absorbed current control - Control of the starting voltage drop
Power supply chain broken
- Control of the power supply chain (wire, connections, contactors, etc.)
Propeller fault
- Propellers control
C. The compressor makes noise. Possible reasons of the fault Knocks Sluggings Grunts
What should be done - Control the compressor suction pressure - Control valves status - Overheating control &RQWURORIH[SDQVLRQYDOYHEXOEÀ[DWLRQ - Control of the supply voltage - Phases control - Galling => broken part
D. The compressor does not stop. Possible reasons of the fault
What should be done
Setpoint temperature too much different from the advised temperatures
- Setpoint temperatures control
Glued contactor
- Contactor control
13 04/2014
Technical instructions for Use & Maintenance Oil & Gas E. Lack of capacity. Possible reasons of the fault
What should be done
The expansion valve whistles
- Expansion valve settings control - Load control
Important overheating
- Expansion valve settings control - Load control
Pre-expansion
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- Flow rates control
10/ Please consult the unit FA for the other faults.
14 04/2014
T r a n s f e r t
T h e r m i q u e
Design: ETT - Document printed by an environmentally friendly printer using vegetable based ink on PEFC paper created from sustainably-managed forest.
É n e r g i e
A different climate Environmental control solutions
56 route de Brest - CS 93002 - 29830 Ploudalmézeau - France Phone number: +33 (0)2 98 48 14 22 - Fax: +33 (0)2 98 48 09 12 Export contact: +33 (0)2 98 48 00 70 - ETT Services: +33 (0)2 98 48 02 22
www.ett.fr
