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Sintesis™ Air-Cooled Chiller: Annual Maintenance

This procedure is the recommended annual maintenance of your equipment. You need to contact a qualified service provider to leak test the chiller, check operating and safety controls, and to inspect electrical components for proper operation. Leak testing my be accomplished using soap solution or with electronic or ultrasonic leak detectors.
MaintainX
10/24/2021

Sintesis™ Air-Cooled Chiller: Annual Maintenance

6 steps
This procedure is the recommended annual maintenance of your equipment. You need to contact a qualified service provider to leak test the chiller, check operating and safety controls, and to inspect electrical components for proper operation. Leak testing my be accomplished using soap solution or with electronic or ultrasonic leak detectors.
  • Maintenance

  • ! WARNING

  • Hazardous Voltage w/Capacitors!

  • Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s literature for allowable waiting periods for dis

  • This section describes the basic chiller preventive maintenance procedures, and recommends the intervals at which these procedures should be performed. Use of a periodic maintenance program is important to ensure the best possible performance and efficiency from a Sintesis™ chiller.

  • Use Operator Log in Log and Check Sheet chapter to record an operating history for unit. The log serves as a valuable diagnostic tool for service personnel. By observing trends in operating conditions, an operator can anticipate and prevent problem situations.

  • If unit does not operate properly during inspections, see Diagnostics chapter.

  • Perform all maintenance procedures and inspections at the recommended intervals. This will increase the life of the chiller and minimize the possibility of costly failures.

  • Recommended Maintenance

  • Annual:

  • NOTICE:

  • Coil Damage! Do not use detergents to clean coils. Use clean water only. Use of detergents on coils could cause damage to coils

  • Important: Panel cooling air lets must be regularly inspected and kept clean and free of debris. Failure to do so can cause reduced cooling to drives, resulting in unit trips on drive over-temperature.

  • Refrigerant and Oil Charge Management

  • Proper oil and refrigerant charge is essential for proper unit operation, unit performances, and environmental protection. Only trained and licensed service personnel should service the chiller.

  • Table below lists baseline measurements for Sintesis™ units running at AHRI standard operating conditions. If chiller measurements vary significantly from values listed below, problems may exist with refrigerant and oil charge levels. Contact your local Trane office.

  • Note: Low temperature applications units will have values that vary from the table below. Contact your local Trane office for more information.

  • Table 41. Typical Sintesis baselines (AHRI conditions)

  • Lubrication System

  • Oil Sump Level Check

  • Figure 80. Oil sump level check

  • Important: Do not operate the unit with the sight glass service valves opened. Close the valves while running before and after checking the oil level. Oil system function may be affected and level reading will not be accurate during operation if valves are opened during operation.

  • The oil level in the sump can be measured to give an indication of the system oil charge. Follow the procedures below to measure the level.

  • Table 42. Nominal oil levels

  • Travel Restraint

  • ! WARNING

  • Falling Off Equipment!

  • Failure to use travel restraint slots and equipment could result in individual falling off the unit which could result in death or serious injury.This unit is built with travel restraint slots located on unit top that MUST be used during servicing. These slots are to be used with travel restraint equipment that will not allow an individual to reach the unit edge. However such equipment will NOT prevent falling to the ground, for they are NOT designed to withstand the force of a falling individual.

  • Microchannel Condenser Coils

  • For proper operation, microchannel condenser coils must be cleaned regularly. Eliminate pollution and other residual material help to extend the life of the coils and the unit.

  • Regular coil maintenance, including annual cleaning, enhances the unit’s operating efficiency by minimizing compressor head pressure and amperage draw. The condenser coil should be cleaned at minimum once each year, or more if the unit is located in a “dirty” or corrosive environment.

  • NOTICE:

  • Coil Damage! Do not use detergents to clean coils. Use clean water only. Use of detergents on coils could cause damage to coils

  • Cleaning with cleansers or detergents is strongly discouraged due to the all-aluminum construction. Water should prove sufficient. Any breach in the tubes can result in refrigerant leaks.

  • ! WARNING

  • Hazardous Voltage w/Capacitors!

  • Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s literature for allowable waiting periods for dis

  • Coil Cleaning:

  • Figure 81. Sprayer source angle

  • Note: To avoid damage from the spray wand contacting the coil, make sure the 90º attachment does not come in contact with the tube and fin as abrasion to the coil could result.

  • Free-Cooling Option Maintenance

  • Free-Cooling Coil Cleaning

  • Follow coil cleaning procedures found in Figure , p. 92 for free-cooling microchannel coils.

  • Free-Cooling By-Pass Valve Adjustment

  • To change the bypass percentage, follow procedure below:

  • Figure 82. Belimo operating controls and indicators

  • Table 43. Belimo operating controls descriptions

  • Figure 83. By-pass valve setting

  • Figure 84. By-pass valve setting photo

  • If the minimum opening is modified after unit start-up, motor recalibration is needed to validate new operating range. When motor is powered, push green LED button (2). Motor memorizes the new reference of end of travel position on its signal (2-10 VDC).

  • Water Strainer

  • Figure 85. In-line strainer

  • The water strainer is factory-installed with taps for pressure gauges on the inlet and outlet. For maximum efficiency, a differential pressure gauge installed across the inlet and outlet will indicate pressure loss due to clogging and may be used as a guide to determine when cleaning is required.

  • To determine if strainer requires cleaning, install pressure gauges across inlet and outlet of strainer, and measure pressure differential.

  • Normally, when differential pressure reaches 5-10 psi, the screen must be cleaned as follows:

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