Commissioning and Start Up Form

Commissioning and Start Up Form

Chiller Start Up Procedure Form Doc. N°061103
To enable warranty this form must be filled out.

The warranty starts on the date of initial startup if startup or 30 days after delivery whichever occurs first.

Refer to unit installation and user manual.
Job Name:
Job Address:
Distributor:
Installation Contractor:
Commissioning Agent / Factory Rep / Technician Name:
Commissioning Agent / Factory Rep / Technician Email:
Email Address of Person Who Requires a Copy of this Report:
Enter the email address of the individual that requires a copy
Commission Date:

MonthDayYear
Accessories Installed:
General points for attention concerning installation and commissioning practice:
Check all that apply:
Any additional specific notes concerning the unit or the system where the unit is operating:
Check:
Check:
Unit Information
- Number of Units:
- Unit #1
- Model Number:
- Configuration Number / Version / Comm:
- Serial Number:
- Unit #2
- Model Number:
- Configuration Number / Version / Comm:
- Serial Number:
- Unit #3
- Model Number:
- Configuration Number / Version / Comm:
- Serial Number:
- Unit #4
- Model Number:
- Configuration Number / Version / Comm:
- Serial Number:
- Unit #5
- Model Number:
- Configuration Number / Version / Comm:
- Serial Number:
- Unit #6
- Model Number:
- Configuration Number / Version / Comm:
- Serial Number:
- Unit #7
- Model Number:
- Configuration Number / Version / Comm:
- Serial Number:
- Unit #8
- Model Number:
- Configuration Number / Version / Comm:
- Serial Number:
- Unit #9
- Model Number:
- Configuration Number / Version / Comm:
- Serial Number:
- Unit #10
- Model Number:
- Configuration Number / Version / Comm:
- Serial Number:
- 1. Preliminary Operation
- WARNING: The following operation must be done without the power supply (unit with the main switch in the OFF position).
  
  WARNING: Before the following operations, disconnect the unit from the power supply. The main switch must be in the OFF position. Please check with a voltmeter on each phase in order to be sure of the absence of voltage. Apply a label to the unit if required by the safety procedure of the country.
- 1.1. Cables Section: Check the section of the power supply cables and verify that they are correct (insulation and size) for the nominal current of the unit (check the rating in the Technical Manual section electrical data.).
- Notes for Parameter 1.1:
- 1.2. Ground connection (Earthing): Check the connection to the ground and test it. (see the Technical Manual). Check each unit individually.
- Notes for Parameter 1.2:
- Checked the following unit:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- 1.3. Cable tightness / good electrical contact: Check the cable termination tightness and good electrical contact of all the cables. Tighten all the bolts and screws of the terminals.
- Notes for Parameter 1.3:
- 1.4. Voltage sequence check. In some units it is installed the automatic check. If the automatic check is not installed please check carefully the correct sequence of the three phases. High noise of the compressors means that the sequence is wrong.
- Notes for Parameter 1.4:
- The following operation must be done with the power supply connected. The unit must not be switched ON until check 1.4 has been made.
- 1.5. Nominal Voltage: Check the nominal voltage of the unit 208V or 230V or 460V or 575V on the nameplate. Verify with the voltmeter that the nominal voltage corresponds to the voltage at the terminals. WARNING: If the voltage measured does not correspond you must stop the start up operation. The Voltage should be within ±10% of the nominal voltage (ex. for 575V ±10% should be between 632V and 518V). The difference across the phases should not be more than 3%. If the voltage difference is above the 3% limit DO NOT START THE UNIT and call the technical service.
- Notes for Parameter 1.5:
- L1-L2 (V):
  Enter the Voltage (V)
- L1-L3 (V):
  Enter the Voltage (V)
- L2-L3 (V):
  Enter the Voltage (V)
- L1-GND (V):
  Enter the Voltage (V)
- L2-GND (V):
  Enter the Voltage (V)
- L3-GND (V):
  Enter the Voltage (V)
- 1.6. Switch the main switch ON: Place the main switch in the ON position with the unit control in the off position.
- Notes for Parameter 1.6:
- 1.7. Display activation: The display of the unit will be activated a few seconds after the main switch has been turned to the ON position.
- Notes for Parameter 1.7:
- Main Transformer - Primary / Secondary (V):
  Enter the voltage (V)
- Control Transformer #1 - Primary / Secondary (V):
  Enter the voltage (V)
- Control Transformer #2 - Primary / Secondary (V):
  Enter the voltage (V)
- 1.8. Connection: Check that the connections done on the unit are in accordance with the Technical Manual supplied with the unit.
- Notes for Parameter 1.8:
- 1.9. Compressor heater: Check the correct functioning of the crank case heater of each compressor. Check the increase of the temperature of the oil. The heater must be activated at least 12 hours before the start up of the compressor. The temperature of the oil should be at least 10-15°C more than the ambient temperature.
- Notes for Parameter 1.9:
- 2. Hydraulic Circuit
- 2.1. Hydraulic connections: Check all the hydraulic connections and verify their correctness.
- Notes for Parameter 2.1:
- 2.2. Filter: Check a mechanical filter is installed at the entry of the evaporator. (compulsory; if the mechanical filter is not installed any warranty is immediately voided). Check each unit individually.
- Notes for Parameter 2.2:
- Checked the following unit:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- 2.3. Hydraulic circuit: The hydraulic circuit must be filled with water (glycol if necessary) and it should have the right pressure. Vent all the air in the circuit.
- Notes for Parameter 2.3:
- Pressure Load (psi):
  Enter the psi
- 2.4. Valves: Verify that all the valves in the hydraulic circuit are open.
- Notes for Parameter 2.4:
- 2.5. Pumps: Check and verify the functioning of the water pump. It must be in operation. Verify that there is enough water flow to close the contact of the flow switch.
- Notes for Parameter 2.5:
- Unit #1 - Pump(s)
- Unit #2 - Pump(s)
- Unit #3 - Pump(s)
- Unit #4 - Pump(s)
- Unit #5 - Pump(s)
- Unit #6 - Pump(s)
- Unit #7 - Pump(s)
- Unit #8 - Pump(s)
- Unit #9 - Pump(s)
- Unit #10 - Pump(s)
- 2.6. Water flow: Check and verify the water flow by measuring the pressure difference between water in and water out of the evaporator. In order to calculate the water flow please refer to the pressure drop of the evaporator and use the table / chart in the technical manual to determine the water flow.
- Notes for Parameter 2.6:
- Water Flow Common to All Units (gpm):
  Enter (gpm) gallons per minute
- Water Flow Through Each Unit (gpm):
  Enter (gpm) gallons per minute
- Number of Compressors in Operation:
- Supply Water Temperature:
  Enter Temperature
- Select metric:
- Return Water Temperature:
  Enter Temperature
- Select metric:
- Delta T Across Unit:
  Enter Temperature
- Select metric:
- Outdoor Air Temperature:
  Enter Temperature
- Select metric:
- 2.7. Flow Switch: Check and verify the correct functioning of the flow switch. Closing the water valve of the hydraulic circuit slowly, you should cause an Alarm that will be shown on the unit display. Once this check has been done please open the valve again and reset the alarm. (compulsory; if the mechanical filter is not installed any warranty is immediately voided). Check each unit individually.
- Notes for Parameter 2.7:
- Checked the following unit:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- 2.8. Cleaning: The hydraulic circuit of the plant must be vented (several times) in order to eliminate all the air and dirty particles that are present in the circuit. The mechanical filter must be cleaned until all the dirty particles are completely removed.
- Notes for Parameter 2.8:
- 2.9. Glycol: In case of usage with glycol, check that the percentage of glycol is correct
- Notes for Parameter 2.9:
- 3. Start Up
- 3.1. Start up the unit: Once all the above checks have been done it is possible to start up the unit pressing the ON button. Check each unit individually.
- Notes for Parameter 3.1:
- Checked the following unit:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- 3.2. Set Points: Check all the set points of the unit and verify that they are within the operating limits of the unit. Reset any possible alarms. After some minutes the unit will start.
- Notes for Parameter 3.2:
- Setpoint:
  Enter temperature
- Select metric:
- Differential:
  Enter temperature
- Select metric:
- Integral Time (s):
  Enter (s) seconds
- Regulation:
- 3.3. Phase rotation: Check the phase rotation. If the rotation is not correct disconnect the main switch from the power supply and change over two phases of the incoming triple main supply to reverse motor rotation. Do not alter the internal wiring of the unit otherwise the warranty will terminate with immediate effect.
- Notes for Parameter 3.3:
- 3.4. Input current: Check the fans and compressor input current and verify it with the technical data. Check each unit individually.
- Notes for Parameter 3.4:
- Checked the following unit:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Unit #1
- How Many Circuits on Unit #1?
- Compressor(s) on Unit #1 / Circuit 1:
- Compressor(s) on Unit #1 / Circuit 2:
- Compressor(s) on Unit #1 / Circuit 3:
- Compressor(s) on Unit #1 / Circuit 4:
- Fan(s) on Unit #1:
- Unit #2
- How Many Circuits on Unit #2?
- Compressor(s) on Unit #2 / Circuit 1:
- Compressor(s) on Unit #2 / Circuit 2:
- Compressor(s) on Unit #2 / Circuit 3:
- Compressor(s) on Unit #2 / Circuit 4:
- Fan(s) on Unit #2:
- Unit #3
- How Many Circuits on Unit #3?
- Compressor(s) on Unit #3 / Circuit 1:
- Compressor(s) on Unit #3 / Circuit 2:
- Compressor(s) on Unit #3 / Circuit 3:
- Compressor(s) on Unit #3 / Circuit 4:
- Fan(s) on Unit #3:
- Unit #4
- How Many Circuits on Unit #4?
- Compressor(s) on Unit #4 / Circuit 1:
- Compressor(s) on Unit #4 / Circuit 2:
- Compressor(s) on Unit #4 / Circuit 3:
- Compressor(s) on Unit #4 / Circuit 4:
- Fan(s) on Unit #4:
- Unit #5
- How Many Circuits on Unit #5?
- Compressor(s) on Unit #5 / Circuit 1:
- Compressor(s) on Unit #5 / Circuit 2:
- Compressor(s) on Unit #5 / Circuit 3:
- Compressor(s) on Unit #5 / Circuit 4:
- Fan(s) on Unit #5:
- Unit #6
- How Many Circuits on Unit #6?
- Compressor(s) on Unit #6 / Circuit 1:
- Compressor(s) on Unit #6 / Circuit 2:
- Compressor(s) on Unit #6 / Circuit 3:
- Compressor(s) on Unit #6 / Circuit 4:
- Fan(s) on Unit #6:
- Unit #7
- How Many Circuits on Unit #7?
- Compressor(s) on Unit #7 / Circuit 1:
- Compressor(s) on Unit #7 / Circuit 2:
- Compressor(s) on Unit #7 / Circuit 3:
- Compressor(s) on Unit #7 / Circuit 4:
- Fan(s) on Unit #7:
- Unit #8
- How Many Circuits on Unit #8?
- Compressor(s) on Unit #8 / Circuit 1:
- Compressor(s) on Unit #8 / Circuit 2:
- Compressor(s) on Unit #8 / Circuit 3:
- Compressor(s) on Unit #8 / Circuit 4:
- Fan(s) on Unit #8:
- Unit #9
- How Many Circuits on Unit #9?
- Compressor(s) on Unit #9 / Circuit 1:
- Compressor(s) on Unit #9 / Circuit 2:
- Compressor(s) on Unit #9 / Circuit 3:
- Compressor(s) on Unit #9 / Circuit 4:
- Fan(s) on Unit #9:
- Unit #10
- How Many Circuits on Unit #10?
- Compressor(s) on Unit #10 / Circuit 1:
- Compressor(s) on Unit #10 / Circuit 2:
- Compressor(s) on Unit #10 / Circuit 3:
- Compressor(s) on Unit #10 / Circuit 4:
- Fan(s) on Unit #10:
- 4. Refrigeration Circuit
- 4.1. Leaks: Check and verify that there are no refrigerant leaks by using a leak detector. In particular you must check all the pressure plugs (manometers, transducers, pressure switches); The vibration during transport could have caused plugs to loosen.
- Notes for Parameter 4.1:
- 4.2. Oil Level: Check and verify that after a few hours of operation of the unit, the oil level of the compressor is correct.
- Notes for Parameter 4.2:
- 4.3. Refrigerant circuit: Check and verify after a few hours of operation of the unit, that there are no vapour bubbles at the sight glass. If there are a lot of bubbles you must charge refrigerant or adjust the thermostatic valve. If there are a few bubbles the unit could operate but after the approval of the technical service, nevertheless the presence of bubbles for a short period is possible.
- Notes for Parameter 4.3:
- High Pressure (HP):
  Enter value (bar)
- Low Pressure (LP):
  Enter value (bar)
- Hot Gas Discharge Temperature:
  Enter temperature
- Select metric:
- Suction Temperature:
  Enter temperature
- Select metric:
- Liquid Line Temperature:
  Enter temperature
- Select metric:
- 4.4. Superheat: Check and verify that the refrigerant superheat is between 4 and 8°C. This operation to be done comparing the temperature measured with a contact thermometer located on the compressor suction, with the temperature shown in the manometer (if not present on the unit you need to install one for the check) set on the suction side (the saturated temperature corresponding to the suction pressure). The difference between the two values gives the superheat value). Check each unit individually.
- Notes for Parameter 4.4:
- Checked the following unit:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Superheat Value Measured:
  Enter temperature
- Notes for Parameter 4.5:
- 4.5. Subcooling: Check and verify that the refrigerant subcooling is between 4 and 6°C. This operation can be done comparing the temperature measured with a contact thermometer located on the outlet pipe of condenser, with the temperature shown in the manometer (if not present on the unit you need to install one for the check) set on the outlet of the condenser (saturated temperature corresponding to the condenser outlet pressure). The difference between the two values gives the subcooling value). Check each unit individually.
- Notes for Parameter 4.5:
- Checked the following unit:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Subcooling Value:
  Enter temperature
- Notes for Parameter 4.6:
- 4.6. Discharge Temperature: Check the Discharge Temperature of the compressor. If the subcooling and the superheat values are correct the temperature measured at the discharge line of the compressor must be 30 to 40°C above the condensing temperature. Check each unit individually.
- Notes for Parameter 4.6:
- Checked the following unit:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- Checked each of the following units:
- 5. Safety and Control Devices
- 5.1. General: The unit is set and tested in the factory before delivery. It is, however, advisable to check all these devices after a reasonable period of working time. All maintenance and service operations must be carried out by qualified persons. Incorrect setting values of the safety devices could cause serious damage of the unit:
- Notes for Parameter 5.1:
- 5.2. High pressure switch: Check and verify that the high pressure switch is working. This device must stop the unit, generating the appropriate Alarm, once the discharge pressure exceeds the setting value. In order to check the correct operation, stop the condenser air flow (in cooling mode) and verify with the manometer the pressure that the unit stops. WARNING: in case the value measured exceeds the setting value given STOP THE COMPRESSOR IMMEDIATELY, and verify the reasons. The reset of this device is manual and it can be reactivated once the pressure value drops by the differential value. In order to check the setting and the differential value refer to the technical manual.
- Notes for Parameter 5.2:
- 5.3. Low pressure switch: Check and verify that the low pressure switch is working. This device stops the unit, generating the appropriate Alarm, once the suction pressure drops below the set value. In order to check the correct operation, after about 5 minutes with the compressor in operation, close the liquid line slowly (in cooling mode) and verify with the manometer the pressure when the unit stops. The reset of this device is manual and it can be reactivated once the pressure value drops by the differential value. In order to check the setting and the differential value refer to the technical manual.
- Notes for Parameter 5.3:
- 5.4. Antifreeze system: Check the antifreeze system. The antifreeze control is managed by the electronic control board with the water outlet sensor in order to prevent the water freezing if the water flow temperature is too low. To check the correct operation of this control, increase the set point gradually in the electronic board parameters until the value is equal to the water out temperature constantly measured with a high quality contact thermometer, and verify that the unit stops. The appropriate Alarm will appear on the unit display. After this check RESET THE ANTIFREEZE ORIGINAL VALUE.
- Notes for Parameter 5.4:
- If changed, record new setting:
  Enter temperature
- Select metric: