Conair EP2 series User manual
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USER GUIDE
UGH041-1015-CE
EP2 Series Portable Chillers
Portable and Remote Condenser Chillers-CE Version
Original Instructions
Thank you for purchasing Conair equipment. This manual is addressed to operators and qualified technicians to
ensure correct use of this Conair equipment.
IMPORTANT: THIS MANUAL MUST BE READ BEFORE INSTALLATION. KEEP THIS MANUAL IN A PLACE
ACCESSIBLE FOR ALL OPERATORS.
It’s a good idea to record the model and serial number(s) of your equipment and the date you received it in the User Guide.
Our service department uses this information, along with the manual number, to provide help for the specific equipment you
installed.
Please keep this user guide and all manuals, engineering prints and parts lists together for documentation of your equipment.
Date:
Manual Number: UGH041-1015-CE_______
Serial Number(s):
Model Number(s):
Software Version:
Disclaimer: Conair shall not be liable for errors contained in this User Guide or for incidental, consequential damages in connection
with the furnishing, performance or use of this information. Conair makes no warranty of any kind with regard to this information,
including, but not limited to the implied warranties of merchantability and fitness for a particular purpose.
© Copyright 2016, Conair, all rights reserved.
EC Declaration of Conformity
We The Conair Group
Of 200 West Kensinger Drive, Cranberry Township, Pennsylvania 16066 - USA
+1 724 585 5500 phone, +1 724 584 5299 fax, www.conairgroup.com website
Hereby declare that:
Equipment Air Cooled Portable Industrial Chiller
Model number _______________________________________
Serial Number _______________________________________
In accordance with the following Legislation:
Machinery Directive (2006/42/EC) as amended
Low Voltage Directive (2006/95/EC) as amended
Electromagnetic Compatibility Directive (2004/108/EC) as amended
Has been designed and manufactured to the following standards:
Safety of Machines, Low voltage
EN 60204-01: 2006 +A1 + A2
Safety of Machines, Refrigeration
EN-378-01:2008+A2:2010, EN-378-02:2008+A2:2012
EMC Emissions
EN 55011:2009+A1:2010, EN61000-3-2:2006+A2:2009, EN61000-3-3:2013, EN61000-3-3:2013
EMC Immunity
EN61000-4-2:2009, EN61000—4-3:2006+A2:2010, EN61000-4-4:2012, EN61000-4-5:2006,
EN61000-4-6:2009, EN61000-4-8:2010, EN61000-4-11:2004
The authorized representative located within the Community is:
200 West Kensinger Drive,
Cranberry Township, Pennsylvania 16066 - USA
+1 724 585 5500 phone, +1 724 584 5299 fax, www.conairgroup.com website
I hereby declare that the equipment named above has been assessed and found to comply with the relevant
sections of the above referenced specifications. The unit complies with the relevant requirements of the applicable
Legislation.
Signed,
Name: RussPietryla Position: Acting Director of Engineering
Done at: Niles, IL - USA Date: _________________________
Doc # ____________________
Table of Contents
Foreword....................................................................................................................................................................... 8
Shipping, Operating, and Storage Ranges............................................................................................................................................. 8
Temperature Ranges.................................................................................................................................................................................. 8
Altitude Ranges............................................................................................................................................................................................ 2
Humidity Ranges ......................................................................................................................................................................................... 2
Safety Guidelines ......................................................................................................................................................... 3
Pre-Installation............................................................................................................................................................. 1
Receiving Inspection ....................................................................................................................................................................................... 1
Unit Storage........................................................................................................................................................................................................ 1
Storage Enviroment Ranges.................................................................................................................................................................... 1
Installation – Chiller Mechanical ................................................................................................................................ 2
Unit Location...................................................................................................................................................................................................... 2
Location Environment Ranges................................................................................................................................................................ 2
Rigging ................................................................................................................................................................................................................. 2
Chilled Water Piping ....................................................................................................................................................................................... 3
Figure 1 – Recommended Overhead Piping..................................................................................................................................... 3
Condenser Water Piping ............................................................................................................................................................................... 3
Installation – Remote Air-Cooled Condenser ........................................................................................................... 4
Location................................................................................................................................................................................................................ 4
Location Environment Ranges................................................................................................................................................................ 4
Rigging and Assembly.................................................................................................................................................................................... 4
Interconnecting Refrigerant Piping........................................................................................................................................................... 4
Refrigeration Piping Design ......................................................................................................................................................................... 5
Figure 2 – Condenser Located with No Elevation Difference .................................................................................................... 6
Figure 3 – Condenser Located above Chiller Unit.......................................................................................................................... 6
Figure 4 - Condenser Located Below Chiller Unit........................................................................................................................... 7
Determining Equivalent Line Length ........................................................................................................................................................ 7
Table 1 – Equivalent Lengths of Fittings............................................................................................................................................. 8
Liquid Line Sizing.............................................................................................................................................................................................. 8
Table 2 – Liquid Line Sizes for R410A.................................................................................................................................................. 9
Discharge (Hot Gas) Line Sizing................................................................................................................................................................11
Figure 5 – Vertical Riser Traps ..............................................................................................................................................................11
Figure 6 - Double Discharge Riser......................................................................................................................................................12
Table 3 - Horizontal or Downflow Discharge Line Sizes for R410A (inches OD)..............................................................12
Table 4 - Upflow Discharge Line Sizes for R410A (inches OD)................................................................................................12
Calculating System Refrigerant and Oil Charge.................................................................................................................................13
Table 5 – Combined Chiller and Remote Condenser Summer Refrigerant Charge........................................................13
Table 6 - Field Piping R-410A Refrigerant Charge per 100 Feet of Run (Lbs.)..................................................................13
Oil Charge Determination...........................................................................................................................................................................13
Setting Condenser Fan Controls...............................................................................................................................................................13
Table 7 - Condenser Fan Control Pressure Settings (psig) .......................................................................................................13
Installation - Electrical....................................................................................................Error! Bookmark not defined.
Standard Controller Operation.................................................................................................................................15
Start Button.......................................................................................................................................................................................................15
Stop Button.......................................................................................................................................................................................................15
Alarm Reset Button........................................................................................................................................................................................15
Compressor Hours Button ..........................................................................................................................................................................15
Pump Hours Button.......................................................................................................................................................................................16
Pump Test Button...........................................................................................................................................................................................16
Display/Program Button..............................................................................................................................................................................16
Up Button ..........................................................................................................................................................................................................16
Down Button ....................................................................................................................................................................................................16
Control Power On LED..................................................................................................................................................................................16
Autostart Signal LED......................................................................................................................................................................................16
Pump LED ..........................................................................................................................................................................................................17
Hot Gas Bypass LED.......................................................................................................................................................................................17
Compressor #1 LED.......................................................................................................................................................................................17
Compressor #2 LED.......................................................................................................................................................................................17
Temperature Limit LED.................................................................................................................................................................................17
Electrical Phase Error LED............................................................................................................................................................................17
Low Flow LED ...................................................................................................................................................................................................17
Freezestat LED .................................................................................................................................................................................................18
Low Reservoir Level LED ..............................................................................................................................................................................18
Compressor Recycle LED.............................................................................................................................................................................18
High Refrigerant Pressure LED..................................................................................................................................................................18
Low Refrigerant Pressure LED ...................................................................................................................................................................18
Program Mode LED .......................................................................................................................................................................................18
Set Point Temperature Display .................................................................................................................................................................18
Process Temperature Display ....................................................................................................................................................................18
Program Menu.................................................................................................................................................................................................19
Table 8 - Controller Program Menu...................................................................................................................................................20
Table 9 – Controller Control Fault Logic ..........................................................................................................................................21
SPI Communications (Optional) ...............................................................................................................................................................22
Table 10 - SPI Parameters ......................................................................................................................................................................22
Modbus RTU (Optional)...............................................................................................................................................................................23
Table 11 – ModBus RTU Option Parameters (Integer Values).................................................................................................23
Table 12 – ModBus RTU Option Parameters (Floating Point Values)...................................................................................24
Optional Controller Operation ................................................................................................................................. 26
Start-Up Screen & Contact Information................................................................................................................................................26
Main Screen......................................................................................................................................................................................................26
Local/ Remote Button (Press to Toggle) ..........................................................................................................................................26
Start Button..................................................................................................................................................................................................26
Stop Button..................................................................................................................................................................................................26
Set Point Temperature Display & Entry............................................................................................................................................26
Actual Supply Water Temperature Display .....................................................................................................................................26
Alarms Button .............................................................................................................................................................................................26
Setup Button ...............................................................................................................................................................................................26
Process Diagnostic Button.....................................................................................................................................................................26
Refrigereration Diagnostic Button......................................................................................................................................................26
Active Alarms Screen ....................................................................................................................................................................................27
Alarm Reset Button...................................................................................................................................................................................27
Alarm History Button ...............................................................................................................................................................................27
Main Button.................................................................................................................................................................................................27
Alarm History Screen ....................................................................................................................................................................................27
Up and Down Buttons .............................................................................................................................................................................27
Acknowledge Button................................................................................................................................................................................27
Alarms Button .............................................................................................................................................................................................27
Process Diagnostic Button.....................................................................................................................................................................27
Main Button.................................................................................................................................................................................................27
Compressor Setup Screen...........................................................................................................................................................................28
Process Setup Button...............................................................................................................................................................................28
PID Setup ......................................................................................................................................................................................................28
FreezeStat Setup Button.........................................................................................................................................................................28
Main Button.................................................................................................................................................................................................28
Process Setup Screen....................................................................................................................................................................................28
HGBP PID Button .......................................................................................................................................................................................28
Compressor Setup Button......................................................................................................................................................................28
Main................................................................................................................................................................................................................28
Hot Gas Bypass Screen PID Tuning Screen..........................................................................................................................................29
Refrigeration Diagnostic Button..........................................................................................................................................................29
Compressor Setup Button......................................................................................................................................................................29
Main Button.................................................................................................................................................................................................29
Freezestat Setup Screen...............................................................................................................................................................................29
HGBP PID Button .......................................................................................................................................................................................29
Compressor Setup Button......................................................................................................................................................................29
Main................................................................................................................................................................................................................29
Process Diagnostic Screen..........................................................................................................................................................................30
I/O Status Button.......................................................................................................................................................................................30
Alarms Button .............................................................................................................................................................................................30
Setup Button ...............................................................................................................................................................................................30
Main................................................................................................................................................................................................................30
I/O Status Screen............................................................................................................................................................................................30
Output Designation Button...................................................................................................................................................................30
Input Status Button...................................................................................................................................................................................30
Refrigeration Diagnostic Screen...............................................................................................................................................................31
I/O Status Button.......................................................................................................................................................................................31
Setup Button ...............................................................................................................................................................................................31
Process Diagnostic Button.....................................................................................................................................................................31
Main................................................................................................................................................................................................................31
Start-Up.......................................................................................................................................................................31
Step 1 - Connect Main Power ...................................................................................................................................................................32
Step 2 - Fill Coolant Circuit.........................................................................................................................................................................32
System Fill Water Chemistry Requirements....................................................................................................................................32
Table 13 – Fill Water Chemistry Requirements..............................................................................................................................33
Table 14 - Recommended Ethylene Glycol Solutions.................................................................................................................33
Step 3 - Check Condenser ..........................................................................................................................................................................34
Intergral Air-Cooled Condenser Check.............................................................................................................................................34
Water-Cooled Condenser Check.........................................................................................................................................................34
Remote Air-Cooled Condenser Check..............................................................................................................................................34
Step 4 – Check Refrigerant Valves...........................................................................................................................................................34
Step 5 – Verify Freezestat Setting............................................................................................................................................................34
Step 6 – Turn On Control Power ..............................................................................................................................................................34
Step 7 – Establish Coolant Flow................................................................................................................................................................34
Step 8 – Intial Unit Operation....................................................................................................................................................................34
Preventive Maintenance ...........................................................................................................................................35
Once a Week ....................................................................................................................................................................................................35
Once a Month..................................................................................................................................................................................................36
Every Three Months.......................................................................................................................................................................................36
Preventive Maintenance Checklist...........................................................................................................................37
Troubleshooting.........................................................................................................................................................38
Drawings .....................................................................................................................................................................39
Waste Disposal ...........................................................................................................................................................39
Refrigerant and Compressor Oil Disposal ............................................................................................................................................39
Disposal of Equipment .................................................................................................................................................................................40
Foreword
The portable chiller is a packaged unit typically consisting of a refrigeration circuit and a coolant reservoir and
pumping system in a compact packaged cabinet for easy location in industrial applications where chilled water is
required.
The intent of this manual is to serve as a guide for placing your portable chiller in service and operating and
maintaining it properly. Improper installation can lead to poor equipment performance or severe equipment
damage. Failure to follow the installation instructions may result in damage not covered by your warranty. It is
extremely important that a qualified refrigeration installation contractor perform all installation line sizing and
piping. Please supply these instructions to your authorized refrigeration contractor.
This manual is for our standard product line with supplements as required to accommodate any special items
provided for a specific application. The written information contained in this manual, as well as various drawings,
are intended to be general in nature. Unit specific drawings are included with the equipment for troubleshooting
and servicing of the unit. Additional copies of drawings are available upon request. We strive to maintain an
accurate record of all equipment during the course of its useful life.
Due to the ever-changing nature of applicable codes, ordinances, and other local laws pertaining to the use and
operation of this equipment we do not reference them in this manual. There is no substitute for common sense
and good operating practices when placing any mechanical equipment into operation. We encourage all
personnel to familiarize themselves with this manual's contents. Failure to do so may unnecessarily prolong
equipment down time.
The chilling equipment uses chemical refrigerants for heat transfer purposes. This chemical is sealed and tested in
a pressurized system containing ASME coded vessels; however, a system failure will release it. Refrigerant gas can
cause toxic fumes if exposed to fire. Place these units in a well-ventilated area, especially if open flames are
present.
Failure to follow these instructions could result in a hazardous condition. The standard refrigerant used in these
units is a hydro fluorocarbon (HFC) trade named R-410A. We strongly recommend a refrigerant management
program be implemented which includes a survey of all equipment to document the type and quantity of
refrigerant in each machine. In addition, we recommend only licensed and certified service technicians work on
our refrigeration circuits. Follow good piping practices and the information in this manual to ensure successful
installation and operation of this equipment. We are not responsible for liabilities created by substandard piping
methods and installation practices external to the chiller.
We trust your equipment will have a long and useful life. If you should have any questions, please contact our
Customer Service Department specifying the serial number and model number of the unit as indicated on the
nameplate.
Shipping, Operating, and Storage Ranges
The equipment is designed for a wide range of environments. Use care when planning for shipping, operating,
and storing the equipment to ensure the follow environmental conditions are met.
Temperature Ranges
Transportation.................................................-30°F to 145°F
Operation
Standard Units ..............................................60°F to 110°F
2
Low Ambient Indoor Units.........................0°F to 110°F
Outdoor-Duty Units..................................-20°F to 110°F
Storage.................................................................32°F to 145°F
Altitude Ranges
Transportation.......................................-100 to 26,350 feet
Operation...................................................-100 to 3,280 feet
Storage........................................................-100 to 9,840 feet
Humidity Ranges
Transportation.............0% to 95% RH, non-condensing
Operation......................0% to 95% RH, non-condensing
Storage...........................0% to 95% RH, non-condensing
3
Safety Guidelines
Observe all safety precautions during installation, start-up, and service of this equipment. The following is a list of
symbols used in this manual and their meaning.
General Warning
Electricity Warning
Hot Surface Warning
Flammable Material Warning
Explosive Material Warning
General Mandatory Action
Wear Eye Protection
Wear Protective Gloves
Wear Ear Protection
Disconnect Before Carrying Out Maintenance or
Repair
Connect an Earth Terminal to Ground
Only qualified personnel should install, start-up, and service this equipment. When working on this equipment,
observe precautions in literature, and on tags, stickers, and labels located on the equipment.
WARNING: Any use or misused of this equipment
outside of the design intent may cause injury or
harm.
WARNING: Vent all refrigerant relief valves in
accordance to ANSI/ASHRAE Standard 15, Safety
Code for Mechanical Refrigeration. This
equipment should be located within a well-
ventilated area. Inhalation of refrigerant can be
hazardous to your health and the accumulation
of refrigerant within an enclosed space can
displace oxygen and cause suffocation.
WARNING: This equipment contains hazardous
voltages that can cause severe injury or death.
WARNING: This equipment contains refrigerant
under pressure. Accidental release of refrigerant
under pressure can cause personal injury and or
property damage.
WARNING: The exposed surfaces of motors,
refrigerant piping, and other fluid circuit
components can be very hot and can cause burns
if touched with unprotected hands.
WARNING: Authorized personnel only, only
qualified service technicians or operators are to
access this part of the equipment.
CAUTION: Disconnect and lock out incoming
power before installing, servicing, or
maintaining the equipment. Connecting power to
the main terminal block energizes the entire
electric circuitry of the unit. A power supply
provides 24 VDC control power. Electric power at
the main disconnect should be shut off before
opening access panels for repair or maintenance.
CAUTION: Wear eye protection when installing,
maintaining, or repairing the equipment to
protect against any sparks, debris, or fluid leaks.
CAUTION: The chiller will exceed 70 dBA sound
pressure at 1 meter distance and 1 meter
elevation when operating. Wear ear protection
as required for personnel comfort when
operating or working in close proximity to the
chiller.
CAUTION: Wear protective gloves when
installing, maintaining, or repairing the
equipment to protect against any sparks, debris,
or fluid leaks.
1
Pre-Installation
Receiving Inspection
When the unit arrives, verify it is the correct unit by comparing the information that appears on the unit
nameplate with that which appears on the order acknowledgement and shipping papers. Inspect the equipment
condition for any visible damage and verify all items shown on the bill of lading are present. If damage is evident,
properly document it on the delivery receipt and clearly mark any item with damage as “unit damage” and notify
the carrier. In addition, make note of the specific damage and notify our Customer Service Department and they
will provide assistance in preparation and filing of your claims, including arranging for an estimate and quotation
on repairs; however, filing the claim is the responsibility of the receiving party. Do not install damaged equipment
without getting the equipment repaired.
Shipping damage is the responsibility of the carrier. To protect against possible loss due to damage incurred
during shipping and to expedite payment for damages, it is important to follow proper procedures and keep
records. Photographs of damaged equipment are excellent documentation for your records.
Start unpacking the unit, inspect for concealed damages, and take photos of any damages found. Once received,
equipment owners have the responsibility to provide reasonable evidence that the damage did not occur after
delivery. Photos of the equipment damage while the equipment is still partially packed will help in this regard.
Refrigerant lines can be susceptible to damage in transit. Check for broken lines, oil leaks, damaged controls, or
any other major component torn loose from its mounting point.
Record any signs of concealed damage and file a shipping damage claim immediately with the shipping company.
Most carriers require concealed damages be reported within 15 days of receipt of the equipment. In addition to
notifying the carrier, notify our Customer Service Department and they will provide assistance in preparation and
filing of your claims, including arranging for an estimate and quotation on repairs; however, filing the claim is the
responsibility of the receiving party.
Water-cooled chillers ship with a full refrigerant charge while remote condenser chillers ship with a nitrogen
holding charge. Remote air-cooled condenses ship separately typically with a 25 psi dry nitrogen gas charge.
Check the remote condenser for signs of leaks prior to rigging. This will ensure no coil damage has occurred after
the unit left the factory. The remote condensers typically ship with the legs removed. Mount the legs to the
condenser using the provided nuts, bolts, and washers per the remote condenser manufacturer’s installation
instructions.
Unit Storage
If the chiller is stored prior to installation, it is important to protect it from damage. Blow out any water from the
evaporator and water-cooled condenser circuits to protect the unit from damage from freezing. Close any open
refrigerant valves. Cover the equipment to keep dirt and debris from accumulating on it. Store the equipment in
an area that remains within the following limits.
Storage Enviroment Ranges
Temperature ......................................................32°F to 145°F
Elevation.....................................................-100 to 9,840 feet
Humidity........................0% to 95% RH, non-condensing
2
Installation – Chiller Mechanical
Unit Location
The chiller is available in many different configurations to allow each unit to meet the environment in which used.
Please refer to the proposal and order acknowledgement for this equipment to verify the specific design
conditions in which your chiller is to operate. The following are the standard location environment ranges for this
product line. Locate the chiller and components on a rigid, solid, level surface with casters locked before operating
the equipment in an area that remains in the following ranges unless your unit has been specifically build for a
custom application.
Location Environment Ranges
Temperature
Standard Units ..............................................60°F to 110°F
Low Ambient Indoor Units.........................0°F to 110°F
Outdoor-Duty Units..................................-20°F to 110°F
Elevation.....................................................-100 to 3,280 feet
Humidity........................0% to 95% RH, non-condensing
Allow a minimum of 48 inches of clearance between the remote condenser and any walls or obstructions. For
installations with multiple condensers, allow a minimum of 96 inches between condensers placed side-by-side or
48 inches for condensers placed end-to-end. In all cases, install the equipment on a rigid surface suitable to
support the full operating weight of the unit. Level all equipment to ensure proper operation.
Serviceability was an important factor in the design of our equipment. Do not compromise this feature by locating
the chiller in an inaccessible area. When locating the chiller it is important to consider accessibility to the
components to allow for proper maintenance and servicing of the unit. In general, allow a minimum of 36 inches
of clearance around all sides and above the unit. Avoid locating piping or conduit over the unit. This ensures easy
access with an overhead crane or lift to lift out heavier components.
Proper ventilation is another important consideration when locating the unit. In general, locate the unit in an area
that will not rise above 110°F unless your unit includes modification for high temperature ambient conditions. In
addition, ensure the condenser and evaporator refrigerant pressure relief valves can vent in accordance with all
local and national codes.
Chillers with an integral air-cooled condenser require a minimum of 36 inches of clearance at both the condenser
air inlet and condenser air discharge. They are not designed to have the condenser air discharge ducted. Improper
clearance or poor ventilation will reduce the cooling capacity of the chiller and may cause high refrigerant
pressure problems. In order to avoid possible low refrigerant pressure safety trips during start-up, maintain the
inlet air temperature above 50°F. If outside air is ducted into an indoor chiller with integral air-cooled condenser
there is an option for low ambient heat pressure controls which allow for incoming air temperatures down to 0°F.
Cooler temperatures than this require custom modifications.
Rigging
The chiller has a structural steel frame to facilitate easy movement and positioning. Follow proper rigging
methods to prevent damage to components. Avoid impact loading caused by sudden jerking when lifting or
lowering the chiller. Use pads where abrasive surface contact may occur. Use the frame supporting the unit for
positioning it with a crane or a forklift.
3
Chilled Water Piping
Proper insulation of chilled water piping is crucial to prevent condensation. The formation of condensation on
chiller water piping, the state change of the water from gas to liquid, adds a substantial heat load to the system
and becomes an additional burden for the chiller.
The importance of properly sized piping between the chiller and process cannot be overemphasized. See the
ASHRAE Handbook or other suitable design guide for proper pipe sizing. In general, run full size piping out to the
process and then reduce the pipe size to match the connections on the process equipment. One of the most
common causes of unsatisfactory chiller performance is poor piping system design. Avoid long lengths of hoses,
quick disconnect fittings, and manifolds wherever possible as they offer high resistance to water flow. When
manifolds are required, install them as close to the use point as possible. Provide flow-balancing valves at each
machine to assure adequate water distribution in the entire system.
The connection labeled “Chilled Water Supply” delivers fluid to the process and the connection labeled “Chilled
Water Return” receives water back from the process. Typically, when piping is overhead with a total run length
over 90 feet there should be a valve in the supply line and an inverted P trap with a vacuum break valve installed
as shown in Figure 1.
Figure 1 – Recommended Overhead Piping
NOTE:
If piping is above chiller and exceeds 90 feet in total
length, install an inverted P-trap and vacuum break
valve in return line and add a check valve to the
supply line.
Check valve
1/2 inch vacum break valve
12 inches above highest
point in piping system
All standard portable chillers include an internal coolant pump and reservoir. Nominal coolant flow rate calculates
use a 10°F rise across the evaporator at 50°F set point and 85°F entering condenser water for water-cooled chillers
or 95°F entering air for integral air-cooled or remote air-cooled condenser chillers.
Condenser Water Piping
(Water-Cooled Condenser Units Only) The performance of a condenser is dependent on maintaining the proper
flow and temperature of water through the heat exchanger. Insufficient water flow or high condenser water supply
temperature will result in the reduction of cooling capacity of the chiller. Extreme conditions will eventually result
in the chiller shutting down due to high refrigerant pressure. Allowing the condenser to plug up from
contaminants in the condenser water stream adversely affects performance. In order to reduce maintenance costs
and chiller downtime, a water treatment program is highly recommended for the condenser cooling water.
Contact our Customer Service Department for assistance in the proper procedure for cleaning out any plugged
condenser.
The nominal chiller design is for 85°F condenser cooling water supply. Under normal operation under full load
there will be about a 10°F rise through the condenser resulting in 95°F exiting water temperature from the
4
condenser. To ensure proper water flow through the condenser, the condenser water pump should be able to
provide at least 25 psi.
Each condenser has a two-way condenser water-regulating valve. Under varying loads and condenser inlet water
temperatures the amount of cooling water needed varies. The condenser water-regulating valve controls the
amount of water allowed to pass through the condenser in order to maintain proper refrigeration pressures in the
circuit.
To prevent damage to the condenser or regulating valve, the condenser water pressure should not exceed 150
psig. The condenser water-regulating valve controls the condenser water flow in order to maintain the pressure
set point. The chiller load, condenser-water inlet temperature, and pressure set point determine the actual flow.
Installation – Remote Air-Cooled Condenser
Chillers designed for use with a remote air-cooled condenser typically come with a factory-selected remote
condenser. The remote air-cooled condenser ships separately and in most cases will ship from a different location
than the chiller so it will most likely be on a separate truck shipment from the chiller.
Location
The remote air-cooled condenser is for outdoor use. A primary concern when designing your unit was
serviceability; therefore, the condenser should be located in an accessible area. Install the unit on a firm, level base
no closer than their width from walls or other condensers. Avoid locations near exhaust fans, plumbing vents,
flues, or chimneys. Fasten the mounting legs at their base to the steel or concrete of the supporting structure. For
units mounted on a roof structure, the steel support base holding the condenser should be elevated above the
roof and attached to the building.
Location Environment Ranges
Temperature ....................................................-20°F to 110°F
Elevation.....................................................-100 to 3,280 feet
Humidity........................0% to 95% RH, non-condensing
Whenever possible locate the remote condenser away from occupied spaces and above or outside of utility areas,
corridors, and auxiliary spaces to reduce the transmission of sound and vibration to occupied spaces. If the
refrigerant lines are suspended from the structure of the building, use isolation hangers to prevent the
transmission of vibration. Where refrigeration piping passed through a wait it is highly recommended to pack
fiberglass and sealing compound around the lines to minimize vibration and retain flexibility in the lines.
Rigging and Assembly
Follow the remote condenser manufacturer’s recommendations for locating and installing the remote condenser.
Interconnecting Refrigerant Piping
The chiller ships with a nitrogen holding charge. Evacuation of this charge is required before charging with
refrigerant. Use a qualified refrigeration contractor to design and install the refrigeration piping system between
the chiller and the remote condenser.
The discharge and liquid lines leaving the chiller have caps. These line sizes do not necessarily reflect the actual
line sizes required for the piping between the chiller and the air-cooled condenser. The installing contractor need
only provide the interconnecting piping between the chiller and the air-cooled condenser.
Refrigerant piping size and piping design have a significant effect on system performance and reliability. All piping
should conform to the applicable local and state codes.
5
CAUTION: Use refrigerant grade copper tubing
ASTM B280 only and isolate the refrigeration
lines from building structures to prevent transfer
of vibration. All copper tubing must have a
pressure rating suitable for R-410A: tubing that
is ¾” OD or larger must be Type K rigid tubing.
ACR annealed tubing coil may be used for sizes
⅝” ODS or smaller.
Do not use a saw to remove end caps. This might allow copper chips to contaminate the system. Use a tube cutter
or heat to remove the caps. When sweating copper joints it is important to evacuate all refrigerant present if any
and flow dry nitrogen through the system. This prevents the formation of toxic gases, corrosive acids, and the
formation of scale within the copper tube.
CAUTION: Do not use soft solders. For copper-to-
copper joints use a copper-phosphorus braze
alloy (BCuP per the American Welding Society)
with 5% (BCuP-3) to 15% (BCuP-5) silver
content. Only use a high silver content brazing
alloy (BAg per AWS) for copper-to-brass or
copper-to-steel joints such as a 45% (BAg-5)
silver content. Only use oxy-acetylene brazing.
CAUTION: The POE oil contained within the
compressor is hygroscopic and has the ability to
absorb water vapor from the atmosphere. Take
necessary steps to prevent an open system from
exposure to the atmosphere for extended periods
while installing the interconnecting refrigerant
tubing.
Refrigeration Piping Design
The system is configurable in any of the arrangements as shown in Figure 2, Figure 3, and Figure 4. The
configuration and its associated elevation, along with the total distance between the chiller and the air-cooled
condenser are important factors in determining the liquid line and discharge line sizes. This will also affect the
field refrigerant charges. Consequently, it is important to adhere to certain physical limitations to ensure the
system operates as designed.
General design considerations are:
1. The total distance between the chiller and the air-cooled condenser must not exceed 200 actual feet or 300
equivalent feet. Keep the distance as short as possible.
2. Liquid line risers must not exceed 15 feet in height from the condenser liquid line connection.
3. Discharge line risers cannot exceed an elevation difference greater than 100 actual feet without a minimum of
2% efficiency decrease.
6
4. To form a proper liquid seal at the condenser, immediately drop at least 15 inches down from the liquid outlet
before routing the piping to the chiller. Make the drop leg before any bends or angles connecting to the
remainder of the liquid connection piping.
Figure 2 – Condenser Located with No Elevation Difference
CondenserWidth
Tobesameas
condenserwidth
Chiller
15"minimumatliquid
exitfromcondenser.
W W
Figure 3 – Condenser Located above Chiller Unit
Chiller
Locatecondenserso
condenserliquidturns
downrightaway.
7
Figure 4 - Condenser Located Below Chiller Unit
Chiller
10'MAX
CAUTION: Liquid line sizing for each chiller capacity is in Table 6. These line sizes are listed per circuit and apply where
leaving water temperature (LWT) is 40°F or higher. For applications where the LWT is below 40°F, size lines using the
ASHRAE Refrigeration Handbook or other suitable design guide.
Determining Equivalent Line Length
To determine the appropriate size for field installed
liquid and discharge lines, it is first necessary to
establish the equivalent length of pipe for each line.
The equivalent length is the approximate friction loss
from the combined linear run of pipe and the
equivalent feet of elbows, valves, and other
components in the refrigeration piping. The sum
total is the equivalent length of pipe that would have
the same pressure loss. See the ASHRAE
Refrigeration Handbook for more information.
Follow these steps when calculating line size:
1. Start with an initial approximation of equivalent
length by assuming that the equivalent length of
pipe is 1.5 times the actual pipe length.
2. Determine approximate line sizes by referring to
Table 6 for liquid lines, Table 7 and Table 8 for
the discharge lines.
3. Check the line size by calculating the actual
equivalent length using the equivalent lengths
as shown in Table 5.
CAUTION: When calculating the equivalent
length, do not include piping of the chiller unit.
Only field piping must be considered.
8
Table 1 – Equivalent Lengths of Fittings
Equivalent Lengths of Refrigerant Pipe (feet)
Line Size OD (in) Elbow 90°
Standard
Elbow 90°
Long Radius
Elbow 90°
Street
Elbow 45°
Standard
Elbow 45°
Street
⅞2.0 1.4 3.2 0.9 1.6
1⅛2.6 1.7 4.1 1.3 2.1
1⅜3.3 2.3 5.6 1.7 3.0
1⅝4.0 2.6 6.3 2.1 3.4
2⅛5.0 3.3 8.2 2.6 4.5
2⅝6.0 4.1 10.0 3.2 5.2
3⅛7.5 5.0 12.0 4.0 6.4
3⅝9.0 5.9 15.0 4.7 7.3
4⅛10.0 6.7 17.0 5.2 8.5
Liquid Line Sizing
The liquid line diameter should be as small as
possible while maintaining acceptable pressure drop.
This is necessary to minimize refrigerant charge. The
total length between the chiller unit and the air-
cooled condenser must not exceed 200 actual feet
or 300 equivalent feet.
Liquid line risers in the system will require an
additional 0.5 psig pressure drop per foot of vertical
rise. When it is necessary to have a liquid line riser,
make the vertical run immediately after the
condenser before any additional restrictions. The
liquid line risers must not exceed 15 feet in height
from the condenser liquid line connection (see
Figure 5). The liquid line does not require pitching.
Install a pressure tap valve at the condenser to
facilitate measuring pressure for service.
Liquid lines do not typically require insulation.
However, if exposing the lines to solar heat gain or
temperatures exceeding 110 °F, there is a negative
effect on sub-cooling. In these situations, insulate
the liquid lines.
9
Table 2 – Liquid Line Sizes for R410A
5 Ton Circuit (R410A) 7½ Ton Circuit (R410A)
Liquid Line Size (Inch OD) Liquid Line Size (Inch OD)
Total
Equivalent
Length
(Ft)
Horizont
al
or
Downflo
w
Upflow
1 to 5
Feet
Upflow
6 to 10
Feet
Upflow
11 to 15
Feet
Total
Equivalent
Length
(Ft)
Horizontal
or
Downflow
Upflow
1 to 5
Feet
Upflow
6 to 10
Feet
Upflow
11 to 15
Feet
25 ½ ½ ½ ½ 25 ⅝⅝⅝⅝
50 ½ ½ ½ ½ 50 ⅝⅝⅝⅝
75 ½ ½ ½ ½ 75 ⅝⅝⅝⅝
100 ½ ½ ½ ¾ 100 ⅝⅝⅝⅝
125 ½ ½ ½ ⅝125 ⅝⅝⅝¾
150 ½ ½ ⅝⅝150 ⅝⅝⅝¾
175 ½ ⅝⅝⅝175 ⅝⅝⅝¾
200 ½ ⅝⅝⅝200 ⅝⅝⅝¾
225 ⅝⅝⅝⅝225 ⅝⅝⅝¾
250 ⅝⅝⅝⅝250 ⅝⅝¾ ¾
275 ⅝⅝⅝⅝275 ⅝⅝¾ ¾
300 ⅝⅝⅝⅝300 ⅝⅝¾ ¾
10 Ton Circuit (R410A) 15 Ton Circuit (R410A)
Liquid Line Size (Inch OD) Liquid Line Size (Inch OD)
Total
Equivalent
Length
(Ft)
Horizont
al
or
Downflo
w
Upflow
1 to 5
Feet
Upflow
6 to 10
Feet
Upflow
11 to 15
Feet
Total
Equivalent
Length
(Ft)
Horizontal
or
Downflow
Upflow
1 to 5
Feet
Upflow
6 to 10
Feet
Upflow
11 to 15
Feet
25 ⅝⅝⅝¾ 25 ⅞⅞⅞⅞
50 ⅝⅝¾ ¾ 50 ⅞⅞⅞⅞
75 ⅝⅝¾ ¾ 75 ⅞⅞⅞⅞
100 ⅝¾ ¾ ¾ 100 ⅞⅞⅞1⅛
125 ¾ ¾ ¾ ⅞125 ⅞⅞⅞1⅛
150 ¾ ¾ ¾ ⅞150 ⅞⅞⅞1⅛
175 ¾ ¾ ¾ ⅞175 ⅞⅞⅞1⅛
200 ¾ ¾ ¾ ⅞200 ⅞⅞⅞1⅛
225 ¾ ¾ ¾ ⅞225 ⅞⅞⅞1⅜
250 ¾ ¾ ¾ ⅞250 ⅞⅞⅞1⅜
275 ¾ ¾ ¾ 1⅛275 ⅞⅞⅞1⅜
300 ⅞⅞⅞1⅛300 ⅞⅞⅞1⅜
10
Table 2 – Liquid Line Sizes for R410A (continued)
20 Ton Circuit (R410A) 25 Ton Circuit (R410A)
Liquid Line Size (Inch OD) Liquid Line Size (Inch OD)
Total
Equivalent
Length
(Ft)
Horizont
al
or
Downflo
w
Upflow
1 to 5
Feet
Upflow
6 to 10
Feet
Upflow
11 to 15
Feet
Total
Equivalent
Length
(Ft)
Horizontal
or
Downflow
Upflow
1 to 5
Feet
Upflow
6 to 10
Feet
Upflow
11 to 15
Feet
25 ⅞⅞⅞1⅛25 1⅛1⅛1⅛1⅛
50 ⅞⅞⅞1⅛50 1⅛1⅛1⅛1⅛
75 ⅞⅞⅞1⅛75 1⅛1⅛1⅛1⅛
100 ⅞⅞1⅛1⅛100 1⅛1⅛1⅛1⅜
125 ⅞⅞1⅛1⅛125 1⅛1⅛1⅛1⅜
150 ⅞1⅛1⅛1⅜150 1⅛1⅛1⅛1⅜
175 ⅞1⅛1⅛1⅜175 1⅛1⅛1⅛1⅜
200 1⅛1⅛1⅛1⅜200 1⅛1⅛1⅛1⅜
225 1⅛1⅛1⅛1⅜225 1⅛1⅛1⅜1⅜
250 1⅛1⅛1⅛1⅜250 1⅛1⅛1⅜1⅜
275 1⅛1⅛1⅛1⅜275 1⅛1⅛1⅜1⅜
300 1⅛1⅛1⅛1⅜300 1⅛1⅛1⅜1⅜
30 Ton Circuit (R410A) 35 Ton Circuit (R410A)
Liquid Line Size (Inch OD) Liquid Line Size (Inch OD)
Total
Equivalent
Length
(Ft)
Horizont
al
or
Downflo
w
Upflow
1 to 5
Feet
Upflow
6 to 10
Feet
Upflow
11 to 15
Feet
Total
Equivalent
Length
(Ft)
Horizontal
or
Downflow
Upflow
1 to 5
Feet
Upflow
6 to 10
Feet
Upflow
11 to 15
Feet
25 1⅛1⅛1⅛1⅛25 1⅛1⅛1⅛1⅛
50 1⅛1⅛1⅛1⅛50 1⅛1⅛1⅛1⅛
75 1⅛1⅛1⅛1⅛75 1⅛1⅛1⅛1⅛
100 1⅛1⅛1⅛1⅛100 1⅛1⅛1⅛1⅛
125 1⅛1⅛1⅛1⅛125 1⅛1⅛1⅛1⅛
150 1⅛1⅛1⅛1⅛150 1⅛1⅛1⅛1⅛
175 1⅛1⅛1⅛1⅛175 1⅛1⅛1⅛1⅜
200 1⅛1⅛1⅛1⅛200 1⅛1⅛1⅛1⅜
225 1⅛1⅛1⅛1⅛225 1⅛1⅛1⅛1⅜
250 1⅛1⅛1⅛1⅛250 1⅛1⅛1⅜1⅜
275 1⅛1⅛1⅛1⅛275 1⅛1⅛1⅜1⅜
300 1⅛1⅛1⅛1⅜300 1⅛1⅛1⅜1⅜
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