Conair ESEW-020D User manual

USER GUIDE
UGH050-0816
Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861
www.conairgroup.com
ESE Series Central Chillers
ESE Series Scroll Central Chillers

Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861
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: UGH050-0816
Serial Number(s):
Model Number(s)
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 l Conair l All rights reserved
Please record your equipment’s
model and serial number(s) and
the date you received it in the
spaces provided.

Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861
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Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861
Table of Contents
Foreword .............................................................................................................................................................................1
Safety Guidelines ...............................................................................................................................................................2
General Data .......................................................................................................................................................................3
Table 1 – ESEW Series Single-Circuit Water-Cooled Condenser Chiller General Data (60 Hz) ............................................3
Table 2 – ESEW Series Dual-Circuit Water-Cooled Condenser Chiller General Data (60 Hz)................................................4
Table 3 – ESER Series Single-Circuit Remote Air-Cooled Condenser Chiller General Data (60 Hz) ...................................5
Table 4 – ESER Series Dual-Circuit Remote Air-Cooled Condenser Chiller General Data (60 Hz).......................................6
Table 5 – Remote Air-Cooled Condenser General Data (60 Hz).......................................................................................................7
Pre-Installation...................................................................................................................................................................8
Receiving Inspection...............................................................................................................................................................................................8
Unit Storage...............................................................................................................................................................................................................8
Installation - Chiller Mechanical......................................................................................................................................9
Unit Location .............................................................................................................................................................................................................9
Rigging.........................................................................................................................................................................................................................9
Chilled Water Piping...............................................................................................................................................................................................9
Condenser Water Piping.......................................................................................................................................................................................9
Water Pressure Gauges .........................................................................................................................................................................................10
Master Temperature Sensor ................................................................................................................................................................................10
Figure 1 – Standard Flow Chiller Coolant Circuit Pressure Drop (10 through 30 Ton Single-Circuit Chillers) ...............11
Figure 2 – Standard Flow Chiller Coolant Circuit Pressure Drop (40 through 80 Ton Single-Circuit Chillers) ...............12
Figure 3 – Standard Flow Chiller Coolant Circuit Pressure Drop (20 through 160 ton Dual-Circuit Chillers).................13
Figure 4 – Standard Flow Chiller Coolant Circuit Pressure Drop (80 through 160 ton Dual-Circuit Chillers).................14
Figure 5 – High Flow Chiller Coolant Circuit Pressure Drop (10 through 25 ton Single-Circuit Chillers).........................15
Figure 6 – High Flow Chiller Coolant Pressure Drop (30 through 50 ton Single-Circuit Chillers) .......................................16
Figure 7 – High Flow Chiller Coolant Pressure Drop (20 through 50 ton Dual-Circuit Chillers) ..........................................17
Figure 8 – High Flow Chiller Coolant Pressure Drop (60 through 100 ton Dual-Circuit Chillers)........................................18
Figure 9 – Condenser Water Circuit Pressure Drop (10 through 30 ton Single-Circuit Chillers) .........................................19
Figure 10 – Condenser Water Circuit Pressure Drop (40 through 80 ton Single-Circuit Chillers).......................................20
Figure 11 – Condenser Water Circuit Pressure Drop (20 through 60 ton Dual-Circuit Chillers)..........................................21
Figure 12 – Condenser Water Circuit Pressure Drop (80 through 160 ton Dual-Circuit Chillers) .......................................22
Installation - Remote Air-Cooled Condenser ................................................................................................................23
Location .......................................................................................................................................................................................................................23
Mounted Legs and Lifting (10 ton Single-Circuit and 20-ton Dual-Circuit Units) .........................................................................24
Mounted Legs and Lifting (all except 10 ton Single-Circuit and 20-ton Dual-Circuit Units).....................................................25
Interconnecting Refrigerant Piping ..................................................................................................................................................................26
Refrigeration Piping Design ................................................................................................................................................................................26
Figure 13 – Condenser Located with No Elevation Difference..........................................................................................................27
Figure 14 – Condenser Located above Chiller Unit................................................................................................................................27
Figure 15 - Condenser Located Below Chiller Unit ................................................................................................................................28
Determining Equivalent Line Length................................................................................................................................................................28
Table 6 – Equivalent Lengths of Fittings.....................................................................................................................................................29
Liquid Line Sizing .....................................................................................................................................................................................................29
Table 7 – Liquid Line Sizes for R410A..........................................................................................................................................................30

Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861
Discharge (Hot Gas) Line Sizing.........................................................................................................................................................................32
Figure 16 – Vertical Riser Traps......................................................................................................................................................................32
Figure 17 - Double Discharge Riser..............................................................................................................................................................33
Table 8 – Discharge Line Sizes for Chiller (inches OD) .........................................................................................................................33
Table 9 - Upflow Discharge Line Sizes for R410A (inches OD)..........................................................................................................34
Calculating System Refrigerant and Oil Charge ..........................................................................................................................................34
Table 10 – Combined Chiller and Remote Condenser Summer Refrigerant Charge ...............................................................34
Table 11 - Field Piping R-410A Refrigerant Charge per 100 Feet of Run (Lbs.) .........................................................................34
Oil Charge Determination ....................................................................................................................................................................................35
Setting Condenser Fan Controls........................................................................................................................................................................35
Table 12 - Condenser Fan Pressure Settings (psig) ...............................................................................................................................35
Installation - Electrical ......................................................................................................................................................36
Table 13 – ESEW & ESER Single-Circuit Chiller Electrical Data (60 Hz) ..........................................................................................37
Table 14 – ESEW & ESER Single-Circuit Chiller with Standard Flow Pump Set Electrical Data (60 Hz).............................38
Table 15 – ESEW & ESER Single-Circuit Chiller with High Flow Pump Set 1 Electrical Data (60 Hz)..................................39
Table 16 – ESEW & ESER Single-Circuit Chiller with High Flow Pump Set 2 Electrical Data (60 Hz)..................................Error! Book
Table 17 – ESEW & ESER Dual-Circuit Chiller Electrical Data (60 Hz) .............................................................................................40
Table 18 – ESEW & ESER Dual-Circuit Chiller with Standard Flow Pump Set Electrical Data (60 Hz) ................................41
Table 19 – ESEW & ESER Dual-Circuit Chiller with High Flow Pump Set 1 Electrical Data (60 Hz).....................................42
Table 20 – ESEW & ESER Dual-Circuit Chiller with High Flow Pump Set 2 Electrical Data (60 Hz).....................................Error! Book
Table 21 – Single-Circuit Remote Condenser Electrical Data (60 Hz).............................................................................................43
Table 22 – Dual-Circuit Remote Condenser Electrical Data (60 Hz)................................................................................................44
General Control Operation ...............................................................................................................................................45
System Initialization................................................................................................................................................................................................45
Figure 18 – Start-Up Splash Screen..............................................................................................................................................................45
Home - System Overview .................................................................................................................................................46
System Overview......................................................................................................................................................................................................46
Figure 19 – ESEW System Overview .............................................................................................................................................................46
Figure 20 – ESER System Overview...............................................................................................................................................................46
Table 23 – System Overview Functions.......................................................................................................................................................46
Home – Full Screen ............................................................................................................................................................ 47
Figure 21 – Full Screen ......................................................................................................................................................................................47
Warnings .....................................................................................................................................................................................................................47
Figure 22 – Warning Screen ............................................................................................................................................................................47
Home – Pump Control (Optional) ...................................................................................................................................48
Pump Control Screen (Optional) .......................................................................................................................................................................48
Figure 23 – Pump Control Screen .................................................................................................................................................................48
Pump VFD Control Screen (Optional)..............................................................................................................................................................48
Figure 24 – Pump VFD Control Screen .......................................................................................................................................................48
Menu 1 - Overview ............................................................................................................................................................49
Figure 25 – Menu 1 Screen ..............................................................................................................................................................................49
Table 24 – Menu 1 Functions..........................................................................................................................................................................50
Menu 1 - Alarms.................................................................................................................................................................51
Alarms Active.............................................................................................................................................................................................................51
Figure 26 – HMI Alarm Handler .....................................................................................................................................................................51
Alarm History.............................................................................................................................................................................................................51

Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861
Figure 27 – Alarm History.................................................................................................................................................................................51
Alarm Setup ...............................................................................................................................................................................................................52
Figure 28 – Alarm Setup ...................................................................................................................................................................................52
Alarm Glycol...............................................................................................................................................................................................................52
Figure 29 – Alarm Setup ...................................................................................................................................................................................52
Menu 1 – Metric Units/Imperial Units ............................................................................................................................53
Menu 1 - Compressor Data ..............................................................................................................................................53
Compressor Data Screen ......................................................................................................................................................................................53
Figure 30 – Circuit Data Screen (Water-Cooled Condenser Chiller)................................................................................................53
Figure 31 – Circuit Data Screen (Remote Air-Cooled Condenser Chiller) .....................................................................................54
Compressor Data Screen – Interlocks..............................................................................................................................................................54
Figure 32 – Interlocks.........................................................................................................................................................................................54
Figure 33 – Critical Interlocks..........................................................................................................................................................................55
Figure 34 – Refrigeration Interlocks.............................................................................................................................................................55
Menu 1 – Modbus/BAS ..................................................................................................................................................... 56
Modbus RTU/BAS Setup Screen ........................................................................................................................................................................56
Figure 35 – Modbus Setup Screen................................................................................................................................................................56
Figure 36 – Modbus Word Data Screen .....................................................................................................................................................56
Figure 37 – Modbus Bit Data Screen ...........................................................................................................................................................56
Menu 1 – EXV1 Expansion Valve Setup ..........................................................................................................................57
EXV1 Expansion Valve Setup Screen ................................................................................................................................................................57
Figure 38 – EXV1 Expansion Valve Setup Screen....................................................................................................................................57
Table 25 – EXV1 Setup Parameters...............................................................................................................................................................57
Menu 1 – EXV2 Hot Gas Bypass Setup............................................................................................................................58
EXV2 Hot Gas Bypass Setup Screen (Optional)............................................................................................................................................58
Figure 39 – EXV2 Hot Gas Bypass Screen ..................................................................................................................................................58
Table 26 – EXV2 Setup Parameters...............................................................................................................................................................58
Menu 1 – Water Regulating Valve (WRV) Setup ..........................................................................................................59
WRV Water Regulating Valve Setup Screen .................................................................................................................................................59
Figure 40 – WRV Setup Screen.......................................................................................................................................................................59
Table 27 – WRV Setup Parameters ...............................................................................................................................................................59
Menu 1 – Compressor Staging/PID.................................................................................................................................60
Compressor Staging Setup Screen ...................................................................................................................................................................60
Figure 41 – Compressor Staging Setup Screen .......................................................................................................................................60
Table 28 – Compressor Staging Setup Parameters................................................................................................................................60
Compressor Staging Graph Screen ..................................................................................................................................................................61
Figure 42 – Compressor Staging Graph Screen ......................................................................................................................................61
Table 29 – Compressor Staging Graph Parameters...............................................................................................................................61
Compressor Staging Local Screen ....................................................................................................................................................................62
Figure 43 – Compressor Staging Local Screen ........................................................................................................................................62
Table 30 – Compressor Staging Local Parameters.................................................................................................................................62
Menu 1 – Inputs/Outputs .................................................................................................................................................63
Inputs / Outputs Screens......................................................................................................................................................................................63
Figure 44 – Digital Inputs Screen ..................................................................................................................................................................63
Figure 45 – Digital Outputs Screen ..............................................................................................................................................................63
Figure 46 – Analog Inputs Screen .................................................................................................................................................................63

Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861
Figure 47 – Analog Outputs Screen .............................................................................................................................................................63
Menu 1 – Temperature Offsets........................................................................................................................................64
RTD Temperature Offset Adjustment ..............................................................................................................................................................64
Figure 48 – RTD Temperature Offsets Screen ..........................................................................................................................................64
Menu 1 – Process Control................................................................................................................................................. 65
Leaving/Entering Sensor Selection ...................................................................................................................................................................65
Figure 49 – Process Control Screen..............................................................................................................................................................65
Menu 1 – Pumps Setup .....................................................................................................................................................66
Pump Setup Screen.................................................................................................................................................................................................66
Figure 50 – Pump Setup Screen.....................................................................................................................................................................66
Table 31 – Pump Setup Parameters .............................................................................................................................................................66
Menu 1 – Tank Setup.........................................................................................................................................................67
Tank Setup Screen...................................................................................................................................................................................................67
Figure 51 – Tank Setup Screen.......................................................................................................................................................................67
Menu 1 – Counters.............................................................................................................................................................68
Counters Screens .....................................................................................................................................................................................................68
Figure 52 – Counters 1 Screen .......................................................................................................................................................................68
Figure 53 – Counters 2 Screen .......................................................................................................................................................................68
Figure 54 – Counters 3 Screen .......................................................................................................................................................................68
Menu 2 - Overview ............................................................................................................................................................69
Figure 55 – Menu 2.............................................................................................................................................................................................69
Table 32 – Menu 2 Functions..........................................................................................................................................................................69
Menu 2 – Hardware Options Selected ............................................................................................................................70
Hardware Options Screen ....................................................................................................................................................................................70
Figure 56 – Hardware Options Screen ........................................................................................................................................................70
Menu 2 - Date/Time ..........................................................................................................................................................71
Menu 2 – System Menu ....................................................................................................................................................71
Menu 2 – Defaults..............................................................................................................................................................71
Figure 57 – Restore Factory Settings ...........................................................................................................................................................71
Figure 58 – Factory Settings Restored ........................................................................................................................................................72
Menu 2 – Remote Setpoint Setup ...................................................................................................................................72
Figure 59 – Remote Setpoint Setup Screen ..............................................................................................................................................72
Menu 2 – Remove SD Storage .........................................................................................................................................73
Menu 2 – Trending ............................................................................................................................................................73
Figure 60 – Trending Screen ...........................................................................................................................................................................73
Menu 2 – Remote Mode ...................................................................................................................................................73
Menu 2 – PLC Link Setup ..................................................................................................................................................74
PLC Link (Master/Slave) Setup Screen.............................................................................................................................................................74
Figure 61 – PLC Link Setup Screen ...............................................................................................................................................................74
Figure 62 – PLC Link Word Data Screen .....................................................................................................................................................74
Figure 63 – PLC Link Bit Data Screen ...........................................................................................................................................................74
Menu 2 – Touch Calibration .............................................................................................................................................75

Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861
Start-Up............................................................................................................................................................................... 75
Step 1 - Connect Main Power.............................................................................................................................................................................75
Step 2 - Fill Coolant Circuit ..................................................................................................................................................................................76
System Fill Water Chemistry Requirements ..............................................................................................................................................76
Table 33 – Fill Water Chemistry Requirements........................................................................................................................................77
Table 34 - Recommended Glycol Solutions..............................................................................................................................................77
Step 3 - Check Condenser....................................................................................................................................................................................77
Water-Cooled Condenser Check...................................................................................................................................................................77
Remote Air-Cooled Condenser Check ........................................................................................................................................................77
Step 4 – Check Refrigerant Valves ....................................................................................................................................................................77
Step 5 – Verify Freezestat Setting .....................................................................................................................................................................78
Step 6 – Turn On Control Power........................................................................................................................................................................78
Step 7 – Establish Coolant Flow.........................................................................................................................................................................78
Step 8 – Intial Unit Operation .............................................................................................................................................................................78
Low-Ambient Start-Up (Remote Condensers) .........................................................................................................................................78
Preventive Maintenance ...................................................................................................................................................79
Once a Week .............................................................................................................................................................................................................79
Once a Month ...........................................................................................................................................................................................................80
Once Every Three Months ....................................................................................................................................................................................80
Once a Year ................................................................................................................................................................................................................80
Cleaning the Operator Interface......................................................................................................................................81
General Troubleshooting..................................................................................................................................................82
Preventive Maintenance Checklist .................................................................................................................................. 83
Drawings .............................................................................................................................................................................83
Warranty Information.......................................................................................................................................................84

Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861
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Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861
1
Foreword
The central chiller contains on or more refrigeration
circuits intended to chiller or cool a process fluid. As
an option, a process fluid reservoir and pumping
system is available to create a complete packaged
chiller system.
The intent of this manual is to serve as a guide for
placing our central 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 chiller 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 EPA 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
the Conair Service Department specifying the serial
number and model number of the unit as indicated
on the nameplate.