STEP-BY-STEP GUIDE TO OPERATE THE XXXXXXXXXXXXX TEST STAND

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A. Pre-check 0 Secure area with chain A1. Check system for leaks: 1.1 Water/Glycol loop 1.2 Refrigeration cycle A2. Check standstill pressures: 2.1 Refrigeration cycle: approx 220 PSI 2.2 Water loop: approx 15 PSI A3. Check initial position of switches and valves 3.1 Check if 3 phase switch S1, 110 V switch S2 and motor starter S3 are switched off. 3.2 Water inlet valve W1.0 and water outlet valve W4.1 are closed 3.3 Shut off valves R1.1a and R2.2b are fully open 3.4 Flow adjustment valves W3.4 and G2.1 and

shutoff-valves for the hose connections between the tables are fully open 3.5 Bypass valves W3.3 and G3.1 are fully closed B. Start-Up B1. Measurement equipment: 1.1 Set output voltage at the adjustable power supply to 0V (turn voltage dial counterclockwise to mechanical limit). 1.2 Cold start: Plug in cables: EXV, Q 15, Q 0-15, Mr12; switch on extension cord. Warm start: make sure that all cables are plugged in and extension cord is

Name 08f2c947feab70c4c440b4bd688035a5.docx 4/21/2010 switched on. 1.3 Cold start: Switch on data acquisition computer and DAQ-box; Warm start: start LabVIEW program, click and hold the “manual reset valves” button until the LED’s turn red (mark in this checklist with C or W and tick, if done). Wait for the valves to reach their position. 1.4 Check readings of pressure transducers/temperature sensors. B2. Switch on main switch #3 at the wall. B3. Prepare water- and glycol cycle, EXV R2.2: 3.1 Open the valve connected to the red hose at the supply pipe 1 turn, check for leaks. 3.2 Open water inlet valve W1.0, check pressure on MW3.1 (<30PSI), open water outlet valve W4.1 to get a noticeable flow rate, wait until water temperature W3.4 gets down to supply temperature. Reduce flow rate to 1.3 GPM. 3.4 Switch on 110 V S2 at the control box, check flow rate on MW3.4 and MG3.2(both 3 GPM). 3.5 Wait for EXV R2.2 to finish startup, check function. 3.6 Adjust temperature on Condenser PID 2 to 35°C, Temperature on Evaporator PID 1 to 5°C 3.4 Set condenser PID 2 to standby mode. 3.7 Check temperatures and pressures in LabVIEW program. Water cycle ≤ 45°C, Glycol ≤30°C // ≥ -30°C. Compressor ≤140°C. Evaporation and condensation temperatures within compressor operating envelope. Evaporation//condensation pressure ≥ 180 PSI//≤ 240 PSI. B4. Prepare refrigeration cycle: 4.1 Close needle valves R4.1 and R4.2, set opening of EXV R1.1 to 500 and EXV R1.4 to xxx steps in LabVIEW program. 4.2 Adjust control voltage for EXV R2.2 to 0V to fully close this valve. 4.3 Wait for all electronic valves to reach their position. 4.4 Switch on 3 phase switch S1. 4.5 Switch on motor starter S3 to startup compressor. 4.6 At all times, check temperatures and pressures. Water cycle ≤ 45°C, Glycol ≤30°C // ≥ -30°C. Compressor ≤140°C. Evaporation and condensation temperatures within compressor operating envelope. Evaporation pressure ≥ 50 PSI//≤ 171 PSI, condensation pressure ≥ 272 PSI//≤ 450 PSI. 4.7 Check system for abnormal vibration 4.7 Set condenser PID 2 to operating mode again. 4.8 Adjust water flow rate//PID set points to keep refrigeration cycle inside of the specified operating range. Adjust R1.4 to reach a superheat > 3°C. 4.9 Wait for system to stabilize. C. Running//taking data C1. Adjust temperatures of water respectively glycol cycle: 1.1 Adjust mass flow rate, using valves EXV R1.1, EXV R1.3, EXV R2.2, needle valve R4.1 and R4.2 and R2.2b to reach a reasonable superheat at the compressor inlet (3…20°C). ). If using R2.2b or R2.2, first close them fully, the open the upstream shut off valves and then open them to the required degree. 1.2 At all times, check temperatures and pressures in LabVIEW program. Water cycle ≤ 45°C, Glycol ≤30°C //≥ -30°C. Compressor ≤140°C. Evaporation and condensation temperatures within compressor operating envelope. Evaporation pressure ≥ 50 PSI//≤ 171 PSI, condensation pressure ≥ 272 PSI//≤ 450 PSI. 1.3 If condensing temperature rises/falls above/below the set point of condenser PID 2, increase/reduce water flow rate at W4.1. 1.4 Wait for the system to get to stable conditions before setting the “steady flag”. 1.5 Remove the “steady flag” before approaching the next data point. D. Shut Down 1. Switch off motor starter S3 to shut down compressor. 2. At all times, check temperatures and pressures in LabVIEW program. Water cycle ≤ 45°C, Glycol ≤30°C //≥ -30°C. Compressor ≤140°C. Evaporation and condensation pressures should approach the standstill pressure of ~220PSI (use HP/LP gauge to check). 3. Set both PID controllers on standby. 4. Switch of 3 phase switch S1, then switch of switch #3 at the wall. 5. Wait for 1 minute to remove all heat from the heater coils, and then switch off 110 V S2. 6. Close water outlet valve W4.1, then close water inlet valve W1.0 and then close the faucet at the sink. 7. Open stepper valves R1.1 and R1.3 200 Steps. 8. Open valves R2.2b (needle~).and R2.2(EXV) by adjusting the control voltage to 5 V. Close the upstream shutoff valves. 9. Switch of the power supplies and the data acquisition (order not important). E. Cool Down 1. Secure area around compressor. 2. Attach warning sign to chain. 3. Wait for cool down, and then remove chain and warning sign. F. Emergency Shut Down Switch off motor starter S2, and then switch off 3 Phase switch S1. Switch off main switch #3 at wall, and then switch off 110 V extension cord at back of table 1.

Name 08f2c947feab70c4c440b4bd688035a5.docx 4/21/2010