Maintenance manual

Absorption chillers

November 99 ABS-SVD01A-EN
 Dear customer,

Thank you for your confidence in choosing TRANE.

The commissioning of your TRANE equipment has been completed in accordance

with our standard start-up procedures.

We confirm that the machine run log has been completed and registered with our
factory under our ISO 9001 Quality Management System.
The first stage of your warranty has been validated.
To keep your TRANE equipment operating at peak efficiency during the warranty
period and to extend its life we recommend that regular maintenance procedures as
detailed in the timetable contained within this maintenance guide must be carried out.

To guarantee that the service your receive is efficient, reliable and carried out by
technically competent factory trained technicians certificated to the refrigerant
handing standard, we strongly recommend that you enroll in one of our
”SécuriTrane” Maintenance Programs.

As a commitment to our customers, we have created a nationwide service division

called Trane ServiceFirst. At Trane ServiceFirst we offer all the benefits of after
sales service direct from the manufacturer and we are committed to our mission
statement to provide customer Care second to none.

We would be delighted to discuss your individual requirement with you. For further
information regarding SécuriTrane please contact your local TRANE ServiceFirst
Center.

We at Trane ServiceFirst look forward to providing you with Customer care

second to none and again thank you for your confidence in choosing Trane.

©American Standard Inc. 1999 ABS-SVD01A-EN

 Contents

Manufacturer visit 4
Recommended yearly service
Routine frequencies

Maintenance routine 5
Commissioning
Inspection visit
Seasonal shut down
Seasonal start up
Preventive maintenance
Annual maintenance

Optionnal services 7
System upgrade
Annual operator training
Water treatment
Refrigerant analysis
Annual cooling tower maintenance
24hours duty
Training
Tube cleaning / coil cleaning
ESP (Extended Service Programs)
Remote monitoring service
Tube analysis

Scope of coverage 9

Table

Notes 11

ABS-SVD01A-EN 3
 Recommended yearly service
routine frequencies

Inspection Seasonal Seasonal Annual Preventive

Year Commissioning Tube Analysis
visit shut-down start-up maintenance maintenance

1 X X X X XX

2 X X X XXX

3 X X X XXX

4 X X XXX X

5 X X X XXX X (1)

6 X X X XXX

7 X X X XXX

8 X X X XXX

9 X X X XXX

10 X X XXX X

+10 Every Every Every 3 every Every

year year year year 3 years

This timetable is applicable to for units operating in normal conditions with an average of 4000 hours per year. If
operating conditions are abnormally severe, an individual timetable must be made for that unit.

(1) Tube testing required if aggressive water conditions exist. Applies to condensers only on water cooled units.

Seasonal start up and shut down are mainly recommended for Comfort Air Conditioning and annual and preventive
maintenance are mainly recommended for Process Application

4 ABS-SVD01A-EN
 Maintenance routine

Commissioning Seasonal shut down

- Check installation of equipment/ - Visually inspect the machine for
pre-commission refrigerant and water leaks
- Check water flows and interlocks - Pressure test the machine as
- Check steam or hot water circuits required to identify leaks
- Check all valves - Clean pump cooling water filter
- Check the chiller for proper - Inspect condenser and absorber
vacuum tubes
- Check operation of all safety - Check operation of
devices machines/compare conditions of
- Check configuration of unit control operation against original
module (if applicable) commissioning data
- Inspect the purge pump - Fill the Start up Log Sheet and
- Lithium bromide and refrigerant review with the operator
charge - Provide a written report of work
- Meg test on solution pump performed and indicate all
- Burner installation and adjustment detected deficiencies.
(when available)
- Check the sensors (when
available)
- Start the unit
- Check and calibrate all modulating
controls and actuators
- Measure and record operating
conditions
- Stop the unit and check for proper
dilution cycle
- Start the unit again
- Check the refrigerant for salt
- Train the operator for unit
operation
- Fill the Start up Log Sheet and
review with the operator.

Inspection visit
- Take a bromide sample for
analysis
- Clean the magnetic filter
- Measure and record :concentrate
and dilute solution, refrigerant
- Change the vacuum pump oil
- Check the UCP2 control module
- Check the operation of
machine/compare conditions of
operation against original
commissioning data
- Fill the Inspection visit Log Sheet
and review with the operator.

ABS-SVD01A-EN 5
 Maintenance routine

Seasonal start-up Annual Maintenance

- Check water flows and interlocks - Inspection visit plus
- Check operation of all safety - Meg solution pump motor
devices - Measure voltage and amperage of
- Check the unit for proper vacuum the pumps and motors
- Check oil level and operation of - Check the lithium bromide
the purge pump solution to adjust inhibitors
- Check configuration of unit control - Test for hydrogen
module (if applicable) - Clean pump cooling water filter
- Measure voltage and amperage of - Check solution pump seals for
the pumps and motors leakage
- Check operation of - Inspect concentrator steam traps
machines/compare conditions of - Check condition of all valve
operation against original diaphragm
commissioning data - Check valves operation and
- Fill the Start up Log Sheet and calibration
review with the operator - Clean absorption pump strainer
- Provide a written report of work - Tension any drive belts replace as
performed and indicate all required (where applicable)
detected deficiencies. - Check and adjust burner and his
peripheries
- Check operation of
machines/compare conditions of
Preventive Maintenance operation against original
commissioning data
- Check the level of vacuum in the
- Fill the Maintenance Log Sheet
unit
and review with the operator
- Check operation of purge system
- Provide a written report of work
- Change oil in purge vacuum pump
performed and indicate all
- Check operation of solution
detected deficiencies.
pump (s)
- Check the safety controls for
proper operation
- Check configuration of unit control
module (If applicable)
- Visually inspect chiller for
refrigerant and water leak
- Check the refrigerant for salt
- Check operation of
machines/compare conditions of
operation against original
commissioning data
- Fill the Inspection visit Log Sheet
and review with the operator
- Provide a written report of work
performed and indicate all
detected deficiencies.

6 ABS-SVD01A-EN
 Additionnal services

System upgrade Refrigerant analysis

This Service provides a consulting This Service includes a thorough
service. analysis for contamination and
Up grating your equipment will solution upgrade
increase the unit reliability and can It is recommended that this analysis
reduce the functioning costs by is performed every six months.
optimizing the controls.
A list of solutions /
recommendations to the system will
be explained to the customer. Annual cooling tower
Actual upgrade for the system will maintenance
be under different quotation.
This Service includes the inspection
and maintenance of the cooling
tower at least once a year.
Operator training This involves checking the motor.
This service includes one day of
training for the system operators or 24 hours duty
building engineers for unit on site.
They will gain overall understanding This service includes emergency
and improve the ability to operate calls outside of the office normal
and maintain the chiller. working hours.
This Service is only available with
our Ally Maintenance Contract,
where available.
Water treatment
This Service provides all of the
necessary chemicals to properly treat
each water system for the period
designated.
The inspections will be conducted at
agreed upon intervals and will
submit a written report to the
customer after each inspection.
These reports will indicate the
conditions of corrosion, scaling, and
algae growth of the system.

ABS-SVD01A-EN 7
 Additionnal services

Training Remote monitoring service

Our Trane Training Center, is able to This Service will require Trane
support all your training needs, technicians to log onto the
about the refrigeration, theoretical, customer’s system.
practical, general and specific It is used within the maintenance
trainings dedicated for our units. contract to optimize the maintenance
These trainings can be done in our and repair.
Training Center or in a area defined A diagnosis log report with the
by you. following information will be
provided to the customer on a
scheduled basis.
Tube cleaning/coil cleaning
This Service includes mechanical or
Tube analysis
chemical cleaning of the tubes or - Eddy Current Tube Testing for
coils. prediction of tube failure/ wear.
- Frequency-every 5 years for first
10 years (depending on the water
ESP (Extended Service quality), then every 3 years
Programs) thereafter.

This Service, only available within a

Maintenance contract, provides three
different warranty levels

ESP one Parts only

ESP two Parts and Labor
ESP three Parts, Labor
and refrigerant

8 ABS-SVD01A-EN
 Scope of coverage

Inspection Seasonal Seasonal Preventive Annual

Description Startup
visit shut-down start-up maintenance maintenance

Check installation of equipment/ pre-commission.

Check water flows and interlocks.
Check steam or hot water circuits.
Check all valves
Check the chiller (unit) for proper vacuum.
Check operation of all safety devices.
Check configuration of unit
control module.(if applicable)
Inspect the purge pump
Lithium bromide and refrigerant charge
Meg test on solution pump
Burner installation and adjustment. ( when available )
Check the sensors ( when available )
Start the unit
Check and calibrate all modulating
controls and actuators
Measure and record operating conditions
Stop the unit and check for proper dilution cycle
Start the unit again
Check the refrigerant for salt
Train the operator for unit operation
Fill the Start up Log Sheet and review
with the operator
Check oil level/Change the vacuum pump oil
Inspect the unit for refrigerant and water leak
Check operation of solution pump
Check operation of purge pump
Measure voltage and amperage
of the pumps and motors
Check the lithium bromide solution
to adjust inhibitors/Bromide analyses
Clean the magnetic filter
Test for hydrogen
Provide a written report of work performed
and indicate all detected deficiencies
Inspect condenser and absorber tubes
Clean pump cooling water filter
Check solution pump seals for leakage
Inspect concentrator steam traps
Check condition of all valve diaphragm
Check valves operation and calibration
Clean absorption pump strainer.
Tension any drive belts replace as required (if applicable)
Check and adjust burner and his peripheries
Check operation of machines/ Compare operation
against original commissioning data 9
Fill the Log Sheet and review with the operator

ABS-SVD01A-EN
 Recommended yearly service
routine frequencies

Inspection Seasonal Seasonal Annual Preventive

Year Commissioning Tube Analysis
visit shut-down start-up maintenance maintenance

10

+10

This timetable is applicable to for units operating in normal conditions with an average of 4000 hours per year. If
operating conditions are abnormally severe, an individual timetable must be made for that unit.

Seasonal start up and shut down are mainly recommended for Comfort Air Conditioning and annual and preventive
maintenance are mainly recommended for Process Application

10 ABS-SVD01A-EN
 Notes

ABS-SVD01A-EN 11
 ABS-SVD01A-EN - 1199

New
Société Trane
Route de Chamagne Literature stocking location in Europe
88130 Charmes Trane reserves the right alter any information without prior notice.
Cedex, France

http : // www.trane.com
Société Trane - Société Anonyme au capital de 41 500 000 F - Siège Social : 1, rue des Amériques - 88190 Golbey - France -
An American Standard Company Siret 306 050 188-00011 - RCS Epinal B 306 050 188 - Numéro d’identification taxe intracommunautaire : FR 83 306050188