Baltimore Aircoil Company ICE CHILLER TSU-M Manual

TSU-M ICECHILLER® Thermal Storage Unit
for internal melt
OPERATING AND MAINTENANCE INSTRUCTIONS
MTSU-Mv06EN

Recommended maintenance and
monitoring programme
Baltimore Aircoil Company's Ice Chiller®Thermal Storage Units and Thermal Storage Coils have been developed
for long, trouble-free service when installed, operated and maintained properly. To ensure optimal performance and
maximum equipment life for your Ice Chiller®Thermal Storage Unit, it is important that a regular
inspection/maintenance program be developed and implemented. This manual is provided as a guide to unit
operation and establishing an effective maintenance program for Ice Thermal Storage systems.
Included in the manual are start-up and shutdown procedures, maintenance procedures and a schedule of
maintenance items and their recommended frequency for the Ice Chiller®Thermal Storage Unit and its related
components. An illustration of the Thermal Storage Unit, with its major components identified, is provided in "Ice
Chiller®" on page4. All inspections, maintenance and monitoring actions should be recorded in a cooling system
logbook.
As part of your maintenance record, it is advisable to have a copy of the unit's certified drawing available for
reference during inspection and maintenance. If you do not have a copy of this drawing, or need further information
about the unit, contact your local BAC Service provider. You can find name, e-mail and phone number on the
website www.BACService.eu.
Checks and adjustments Start-Up Monthly Quarterly Every 6 months Annually Shutdown
Operating level X X
System charging X
Inspections and monitoring Start-Up Monthly Quarterly Every 6 months Annually Shutdown
General condition X X
Ice Chiller®tank X X
Ice Chiller®water (1)
- Quality
- Level
X
X X
X
Ice thickness X X
Coil X X
Ice Logic™ Ice Quantity controller:
- condition of sensor X X
Refrigerant:
- Glycol quality X
Cleaning procedures Start-Up Monthly Quarterly Every 6 months Annually Shutdown
Disinfection X X X
Notes
1. Water treatment and auxiliary equipment integrated in the cooling system may require additions to the table
above. Contact suppliers for recommended actions and their required frequency.
2. Recommended service intervals are for typical installations. Different environmental conditions may dictate
more frequent servicing.
3. When operating in ambient temperatures below freezing, the unit should be inspected more frequently.
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Table of contents
OPERATING AND MAINTENANCE INSTRUCTIONS
1 Construction details 4
Ice Chiller® 4
2 General information 5
Operating conditions 5
Connecting pipework 5
Safety precautions 6
Disposal requirements 6
Non-walking surfaces 7
Modifications by others 7
Warranty 7
3 Operating instructions 8
General Information 8
Start-up and commissioning procedures 8
Daily Operating Guidelines 10
Seasonal Shutdown 10
Ice LogicTM Ice Quantity Controller 10
4 Water Care 21
About water care 21
Passivation 21
Special water treatment considerations 22
5 Cold Weather Operations 23
About cold weather operation 23
Protection of operating control assembly 23
Insulation of piping 23
Protection against coil freezing 23
Ice due to subfreezing ambients 24
6 Maintenance Procedure 25
General 25
Checks and adjustments 25
Inspections and corrective actions 27
7 Comprehensive Maintenance 30
About comprehensive maintenance 30
Prolonged outdoor stay 30
8 Further Assistance & Information 31
Assistance 31
More information 31
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CONSTRUCTION DETAILS
Ice Chiller®
INTERNAL MELT APPLICATION
1. Wall panel
2. Coil support beams
3. Glycol connections
4. Galvanised steel coil
5. Watertight covers
6. Primary liner
7. Extruded polystyrene insulation
8. Secondary liner/Vapor barrier
9. Sight tube
Not shown: Ice Inventory Sensor - Ice Logic™ Ice Quantity Controller – Air pump
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1 Construction details
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2 General information
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GENERAL INFORMATION
Operating conditions
BAC cooling equipment is designed for the operating conditions specified below, which must not be exceeded
during operation.
•Wind Load: For safe operation of unshielded equipment exposed to wind speeds above 120 km/h installed at a
height above 30 m from the ground, contact your local BAC-Balticare representative.
•Seismic Risk: For safe operation of equipment installed in moderate and high hazard area's contact your local
BAC-Balticare representative.
ICE THERMAL STORAGE UNIT
1. For units designed to work with secondary coolants:
- Fluid compatibility: Fluids circulated through the coil(s) must be compatible with the coil construction
material. Standard coils are constructed of black steel.
- Coil design pressure: max. 10 bar
- Max. temperature of fluid: +50°C
- Min. temperature of fluid: -20°C
• The coils are manufactured from black steel and hot dip galvanised after fabrication and may contain certain
contaminants, such as carbon, iron oxide or welding particles.
• The installer must take the necessary precautions on site to safeguard the operation of sensitive components
in conjunction with the coils.
PURGE REQUIREMENTS
The installer of BAC equipment must ensure proper system purging of air prior to operation. Entrained air can
obstruct the proper flow of glycol solution, resulting in higher operating pressures than design and reduced thermal
storage capacity.
Connecting pipework
All piping external to BAC cooling equipment must be supported separately.
In case the equipment is installed on vibration rails or springs, the piping must contain compensators to eliminate
vibrations carried through the external pipework.
The equipment outlet piping must be installed under the operating level of the equipment to prevent air suction and
pump cavitation.
All connections in the external pipework (installed by others) must be leak free and tested accordingly.
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Safety precautions
All electrical, mechanical and rotating machinery constitutes a potential hazard, particularly for those not familiar
with its design, construction and operation. Accordingly, adequate safeguards (including use of protective
enclosures where necessary) should be taken with this equipment both to safeguard the public (including minors)
from injury and to prevent damage to the equipment, its associated system and the premises.
If there is doubt about safe and proper rigging, installation, operation or maintenance procedures, contact the
equipment manufacturer or his representative for advice.
When working on operating equipment, be aware that some parts may have an elevated temperature. Any
operations on elevated level have to be executed with extra care to prevent accidents.
AUTHORIZED PERSONNEL
The operation, maintenance and repair of this equipment should be undertaken only by personnel authorized and
qualified to do so. All such personnel should be thoroughly familiar with the equipment, the associated systems
and controls and the procedures set forth in this and other relevant manuals. Proper care, personal protective
equipment, procedures and tools must be used in handling, lifting, installing, operating, maintaining and repairing
this equipment to prevent personal injury and/or property damage. Personnel must use personal protective
equipment where necessary (gloves, ear plugs, etc...)
MECHANICAL SAFETY
Mechanical safety of the equipment is in accordance with the requirements of the EU machinery directive.
Depending upon site conditions it also may be necessary to install items such as bottom screens, ladders, safety
cages, stairways, access platforms, handrails and toe boards for the safety and convenience of the authorized
service and maintenance personnel.
At no time this equipment should be operated without all access cover panels and access doors in place.
For more information consult your local BAC Balticare representative.
ELECTRICAL SAFETY
All electrical components associated with this equipment should be installed with a lockable disconnect switch
located within sight of the equipment.
In the event of multiple components, these can be installed after a single disconnect switch but multiple switches
or a combination thereof are also allowed.
No service work should be performed on or near electrical components unless adequate safety measures are
taken. These include, but are not limited to the following:
• Isolate the component electrically
• Lock the isolation switch in order to prevent unintentional restart
• Measure that no electrical voltage is present anymore
• If parts of the installation remain energized, make sure to properly demarcate these in order to avoid confusion
Fan motor terminals and connections may have residual voltage after unit shut-down. Wait five minutes after
disconnecting the voltage at all poles before opening the fan motor terminal box.
LOCAL REGULATIONS
Installation and operation of cooling equipment may be subject to local regulations, such as establishment of risk
analysis. Ensure regulatory requirements are consistently met.
Disposal requirements
Dismantling of the unit and treatment of refrigerants (if applicable), oil and other parts must be done with respect to
the environment whilst protecting workers from potential risks related to exposure to harmful substances.
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National and regional legislation for material disposal and protection of workers should be taken into account with
regard to:
• Appropriate handling of construction and maintenance materials when dismantling the unit. In particular when
dealing with materials that contain harmful substances, such as asbestos or carcinogenic substances.
• Appropriate disposal of the construction and maintenance materials and components such as steel, plastics,
refrigerants and waste water according to local and national requirements for waste management, recycling
and disposal.
Non-walking surfaces
Access to and maintenance of any component needs to be performed in accordance with all local applicable laws
and regulations. If the proper and required access means are not present, temporary structures need to be
foreseen. Under no circumstance can one use parts of the unit, that are not designed as an access mean, unless
measures can be taken to mitigate any risks that might occur from doing so.
Modifications by others
Whenever modifications or changes are made by others to the BAC equipment without written permission of BAC,
the party who has done the modification becomes responsible for all consequences of this change and BAC
declines all liability for the product.
Warranty
BAC will guarantee all products to be free from manufactured defects in materials and workmanship for a period of
24 months from the date of shipment. In the event of any such defect, BAC will repair or provide a replacement.
For more details, please refer to the Limitation of Warranties applicable to and in effect at the time of the
sale/purchase of these products. You can find these terms and conditions on the reverse side of your order
acknowledgement form and your invoice.
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2 General information
2 General information

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OPERATING INSTRUCTIONS
General Information
To ensure dependable, trouble-free, efficient operation of the thermal storage units, each system is provided with
factory installed, operating control assemblies. During normal operation a solid layer of ice at the top of the tank
will not form. However, should such a layer form due to unforeseen and unwanted operational circumstances, the
low level alarm can be activated. In such case melt out the ice completely.
Start-up and commissioning procedures
For internal melt applications (TSU-M), the ice quantity is measured by measuring the difference in water level in
the tank that occurs due to ice build-up. Ice has a lower density than water, and therefore the water level increase
will be proportioned to the ice quantity inside the tank. The Analogue Ice Thickness Transmitter is factory installed
on the tank and consists of two major components:
- Transmitter box, for power supply and passive analogue 4-20 mA output signal.
- A guided wave radar sensor installed in a PVC tube.
In case the sensor is exposed to subfreezing temperatures (outside installation), the sensor and connected PVC
piping must be heat traced.
TANK FILLING AND ICE LOGIC CALIBRATION
The sensor is factory mounted and wired to the transmitter box, which is located at the connection end of the tank.
A “zero level” adjustment (=calibration) is needed at start-up. To follow the procedure for the correct calibration,
please refer to chapter: “Ice Logic™ Ice Quantity Controller”.
Make sure there is no ice left in the tank. Fill the ice thermal storage unit according to following instructions:
1. Open the ball valve so that the water can enter the water level sensor. The water level in the sight tube must be
below the 0% level.
2. Use a hose through the hatch opening to fill the tank to the top of the coil. Water level must remain below 0%
level indicated on the label.
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Ice LogicTM with radar sensor
CAUTION
Do not overfill!
Overflowing the tank may damage the insulation and/or cause the operating controls to
malfunction.
3. Continue to fill the tank slowly with a minimum of water turbulence until the water level in the sight tube
corresponds with the zero water level indicated on the label.
CAUTION
Make sure no more water is added to the tank.
4. If necessary, move the sensor upwards until the water level (0% ice) falls between the minimum and maximum
calibration lines indicated on the sensor tube.
SYSTEM CHECKS
Before initiating the first ice build cycle, check the following points:
1. Verify the system has been charged with a glycol solution of the type and concentration specified.
2. Confirm all circulating pumps are rotating in the proper direction.
3. Confirm there is sufficient load to discharge the tanks.
4. If any of the units are equipped with a heated enclosure around the operating control and sight tube, check to
ensure the heater and thermostat are wired and operational.
Once the checks are completed, start the initial ice build cycle and monitor the system throughout the cycle,
recording glycol temperatures and noting the duration of the build. Confirm the operating controls function properly
to terminate the build cycle and that once the build cycle is completed, the chiller is shut down and locked out until
the cooling cycle is initiated.
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On multiple unit installations, once the initial ice build cycle has been completed, check all the sight tubes to verify
the water levels in each tank are equal. If the inventories are significantly out of balance, the flow rates of the
glycol solution to each of the thermal storage units should be checked and balanced. Then, after the next ice build
cycle, check the sight tubes once again to ensure balance has been achieved
Daily Operating Guidelines
BUILD CYCLE
For the most energy-efficient operation of the system, the controls should be designed to operate the build cycle as
follows:
Once the ice build cycle has been initiated, the glycol chiller(s) should run at full capacity without cycling or
unloading until the storage device is fully charged (recharged). At that point, the chiller and the glycol circulating
pump should be turned off and not allowed to restart until the discharge (cooling) cycle is initiated. Additionally, a
build cycle should not be re-initiated until approximately 15% of the ice has been melted.
DISCHARGE (COOLING) CYCLE
Ice Chiller®Thermal Storage Units can be discharged in a variety of ways depending upon the system
configuration and objectives of the system designer. Consult the project drawings and specifications for direction
on how the system is to operate during the discharge (cooling) cycle.
It is recommended to completely melt-out the ice during each cooling cycle by pumping the warm glycol solution
through the coils. If complete melt-out cannot be accomplished, try to melt out as much ice as possible.
CAUTION
Unmelted ice is wasted energy.
Seasonal Shutdown
Ice Chiller® Thermal Storage Units installed indoors in a heated space (or outdoors where subfreezing
temperatures do not occur) do not require special attention or preparation for a seasonal or winter shutdown.
However, if subfreezing conditions do occur, please refer to section "About cold weather operation" on page23
Ice LogicTM Ice Quantity Controller
ANALOGUE ICE THICKNESS TRANSMITTER AITT-420-R (RADAR TYPE SENSOR)
When ice is build in the TSU the water level will increase in the tank. The water level rise is proportional to the % of
ice present in the tank. The new radar type Ice Logic measures the water level by the principle of guided wave
radar. It measures the level using electromagnetic pulses. The pulses are transmitted by the sensor head and
guided along a rod. When they hit the medium to be detected (in our case water), they are reflected and guided
back to the sensor. The time between transmitting and receiving the pulse directly relates to the travelled distance
and the current level.
The sensor has no moving parts, is not sensitive to pollution and is independent of the fluid properties.
Prior to setting the controller, make sure the ice tank is filled with water and the radar type sensor in connected to
the control box according to the wiring diagram below and the 230V supply voltage is present. The zero level
markings on the sensor should correspond with the zero level (water without ice) in the tank.
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When properly set, the control box will provide a passive 4-20 mA output signal where 0 mA stands for 0% ice and
20mA corresponds with 100% ice (full ice build).
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WIRING SPECIFICATION
Terminal Fuse Description
LN L-N220VAC / max 10VA supply
Max. cable section is 2.5 mm2
1, 2, 3, 4 Sensor terminals (Wiring done by BAC). Wiring details see wiring diagram.
9, 10 4-20mA passive current loop output.
External voltage: max. 24VDC / %o, 12VDC
Max. loop resistance at 24VDC: 600 Ohm.
Max. cable section 1.5 mm2
9 = negative, 10 = Positive
11, 12, 13 High level alarm contacts.
380VAC/10A - 24VDC/10A
Max. cable section is 2.5 mm2
- 11,13 = normally closed (NC)
- 12,13 = normally open (NO)
14, 15, 16 Low level alarm contacts.
380VAC/10A – 24VDC/10A
Mac cable section is 2.5mm2
- 14, 16 = normally closed (NC)
- 15,16 = normally open (NO)
Wiring specification
OUTPUT SIGNAL GRAPHICS
Output signal graphic
1. Output signal (mA)
2. % Ice
START UP
At initial start up the range of the water level rise must be entered into the controller and the zero ice (water) level
must be set. Make sure no ice is present in the tank and the water level is at zero level from the sight glass. Put the
power supply at least 15 minutes on prior to commissioning of the controller to allow the radar sensor to warm up.
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CAUTION
Never operate the black control knob whenever the protective cover above the supply terminals is
not properly installed.
At initial start up the following screen is shown:
In the terminal box of the controller, you can find a black knob. Pressing this knob or button results in activating a
menu, a selected line or confirming your choice.Rotating the button allow to change values (dial) or navigate
through the menu.The active line has a ">" mark in front of it.
Press the black button to continue. Following screen appears:
For standardTSU-M models the range setting is 117 mm. For TSU-ML models (low height) the standard setting is
92 mm.Dial the correct setting for the model at hand (check the unit name plate) by rotating the black knob.
Confirm your selection by pressing the black know. The next screen appears:
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Rotate the black button to dial 7 and press to confirm. The display indicates 'Range successfully changed'. In
case the button is pressed without dialing 7 you return to the previous menu and values are not stored.
After the range is entered, the following screen appears for a few seconds, followed by the next screen:
Now follow the procedure to set the zero level. When pressing the black button you enter the screen below. Rotate
the black button to select 'Set Zero Level' and press to activate. Make sure you only do this when no ice is present
in the ice tank and when the water level is at the zero level of the sight glass. (For concrete tank applications make
sure the water level is just above the coil header.)
Select 'Set Zero Level' by rotating the black button and press to confirm.
Rotate the black know to change 'No' to 'Yes' and press to confirm your choice. When choosing 'No', you return to
the previous menu.When pressing 'Yes' you access the screen below:
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The sample counter moves from 1 to 16 and then the next screen is shown:
Rotate the black know to dial 7 and press to confirm the zero setting.The display shows 'Zero Level successfully
changed' to confirm the setting. If the black button is pressed without dialing 7, the zero level is not stored.
In case the sensor is not in the correct position (sensor too high or too low) to allow a correct full range
measurement, the display will indicate an error first and the position of the sensor must be modified after
which the procedure must be repeated. Examples of possible alarm messages in case of false sensor
position are shown below.
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START SCREEN / SCREEN AT NORMAL OPERATION
The display shows the measured water level in mm and the percentage versus the range that was set to
correspond with 100% ice.
On line 2 and 3 the status of the low and high level alarm is shown. 'OK' means there is no alarm.
If the water level is below the minimum level, the Low LevelAlarm is activated and 'Alarm' is displayed on the
screen.The output contact for low alarm (13/14/15) is also activated and the red LEDfor low alarm lights up. The
4-20mA output signal is set at 3.5mA to indicate a low level alarm.
If the water level rises above the maximum level, the High Level Alarm is activated and 'Alarm' is displayed on the
screen. The output contact (11/12/13) for high alarm is also activated and the red LED for high alarm lights up.The
4-20mA output signal is set at 24mA to indicate a high level alarm.
The bottom line shows when the next measurement will be done (Waiting and counting down) or if the value is
being updated (Updating) at the end of the count down.
CONTROLLER SET UP MENU
By pressing the black button, you get in the following screen.On the screen you see 4 lines.You can scroll down
by rotating the black button.
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By scrolling down you can see following additional lines:
The '->' sign in front of the lines indicates which line is selected.The arrow up or down at the right of the screen
indicates that more lines are available in the upper or lower area of the screen.
To select or activate a line, press the black button. If you want to navigate through the menu or change values or
settings, rotate the black button to dial and press to confirm.
DETAILS OF EACH LINE
Quit
Activate to return to the previous menu.
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Set Zero Level
Activate to set the zero ice level value. Make sure you only do this when no ice is present in the ice tank and when
the water level is at zero level of the sight glass. (For concrete tank applications make sure the water level is just
above the coil header.)
Rotate the black knob to change 'No' to 'Yes' and press to confirm your choice. When choosing 'No', you return to
the previous menu.When pressing 'Yes' you access the screen below:
The sample counter moves from 1 to 16 and then the next screen is shown.
Rotate the black knob to dial 7 and press to confirm the zero setting. The display shows 'Zero Level succesfully
changed' to confirm the setting. If the black button is pressed without dialing 7, the zero level is not stored.
In case sensor position is no good to allow a full range measurement, an alarm message is shown on the
display. Modify sensor position and start over.
Set Update Period
This allows you to determine how often a measurement will be updated by the controller.Typically 120 seconds is
set.During commissioning or testing periods the sample time can be reduced to obtain quicker response. Make
sure to put this time long enough to get a stable output signal.
Rotate the black button to dial different value. Press button to confirm or leave the menu.
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Show Range
This allows you to see the range which corresponds to 100% ice level rise. For TSU-M models the range is
typically 117 mm, for TSU-ML models this is typically 92 mm. This menu is only to view the range. Setting the
range is another menu (Set Range).
Press button to confirm or leave the menu.
Set Range
This allows you to set the range which corresponds to 100% ice level rise. For TSU-Models this range is typically
117 mm, to TSU-ML models this is typically 92 mm. This menu can only be accessed after dialing the access
code 2220 preventing unwanted change of settings. (During initial start up the access code is not asked for.)
Rotate the black button to select 2, press to confirm.Press 2 more times to confrim next 2 digits. Dial then to
select 0 and press to confirm.You have now entered access code 2220.
For standard TSU-M models the range setting is 117mm. For TSU-ML models (low height) the range setting is 92
mm. Dial the correct setting for the model at hand by rotating the black knob. Confirm your selection by pressing
the black knob.
Rotate the black button to dial 7 and press to conirm.The display indicates 'Range successfully changed'.In case
the button is pressed without dialing 7, you return to the previous menu.
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Service Menu
This menu allows to do additional factory settings which are not accessible by the standard user. If you enter the
menu you get the following screen.Keep pressing the black button to exit. You can only enter with the correct
code.
Software Version
Press black button to see which software version is installed on the controller.
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