After many months of planning, March 2015 marked a monumental moment in the history of Whaley Products, Inc. A new era of Whaley equipment quality and consistency emerges as WHALE-SOFT™ Testing Software was launched and became a standard manufacturing procedure.
Whaley describes its new testing system to include the following procedures:
- Each chiller system receives the following tests to ensure quality & consistency:
o Test #1: The chiller system’s refrigerant circuit is vacuum tested for 4 hours to negative PSIG pressure.
o Test #2: The chiller system’s refrigerant circuit is nitrogen tested to a minimum of 40psi for at least 30 minutes to confirm it is leak-free.
- If a leak is found, the leak is repaired, and a new 30 minute nitrogen leak test is completed until a successful 30 minute nitrogen leak test is achieved.
o Test #3: The chiller system’s hydronic circuit is ran through a simulated WATER ONLY circulation loop at its rated flow rate for 5 minutes.
- If a leak is found, the leak is repaired, and a new 5 minute leak test is completed until a successful 5 minute leak test is achieved.
o Test #4: The complete chiller system is ran through a simulated heat load circulation loop for 10 minutes to confirm the chiller system cools the loop sufficiently. If the chiller system is a dual circuit system (20ton chiller with 2each 10ton refrigerant circuits), then each refrigerant circuit is tested for 10 minutes independently to confirm that each of the refrigerant circuits are functioning properly.
- There are two separate heat load run testing stations. The difference in the two is the type of heat transfer fluid the client’s chiller system will utilize. The first is for straight-water applications only, and the second is for glycol applications. A food-grade propylene glycol is utilized in the glycol testing station, and is maintained at 45% to 50% at all times. If a client desires for their unit to be tested down to a specific fluid temperature, Whaley runs the chiller system or longer than 10minutes (if necessary), to achieve the lower fluid temperature. The minimum for water is 40 degF, and the minimum for glycol is 10 degF, for standard R-410A refrigeration systems. Whaley also offers alternative refrigerant systems for lower than 5F leaving glycol temperature.
A microprocessor interface is utilized in order to receive test data from a variety of sensor input from the simulation circulation test loops. The test data streams live in the WHALE-SOFT™ Testing Software environment, and testing certificates in addition to start/end image screen shots of the software showing time stamps are provided to the customer for proof that their equipment was fully tested, demonstrating its full functional operation.
Below you will see an example of the WHALE-SOFT™ Testing Software interface.