Nibe CLIMACOOL UCR 30 Instruction manual

Remote Air Cooled Modular Chillers
Model UCR: 30, 50, and 70 tons
Installation, Operation & Maintenance Manual
• •

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Introduction ........................................1-2
Pre-Installation .......................................3
Model Key ...........................................4
Physical Data.......................................5-8
Dimensional Data and Piping Arrangement ..............9
Rigging and Lifting Procedures ........................10
Mounting Rail and Vibration Isolation .................. 11
Recommended Service Clearances ....................12
Unit Installation ...................................13-14
Electrical Connection.................................15
Communications Wiring ..............................16
Voltage/Phase Monitor Wiring Diagram ................17
Water Piping ......................................18-19
 ..........................20
Hydronic Refrigeration ...............................21
Part-Load Performance Advantage ....................22
Filling the Water System..............................23
Water Treatment ....................................24
Water Temperature Requirement......................25
Operating Limits.....................................26
Evaporator Water Pressure Drop Charts ................27
Glycol Performance Adjustment Factor Charts .......28-29
Power Distribution Drawing ..........................30
Remote Condenser ................................31-32
Head Pressure Control Valve Operation (LAC-10)...... 33-37
Remote Condenser Installation ....................38-45
Pre-Startup .........................................46
Pre-Startup Checklist.................................47
Startup..........................................48-49
Subcooling & Superheat Flow Chart....................50
Split System Startup .................................51
Startup and Warranty Registration Form ...............52
Remote Condenser Warranty Agreement...............53
Remote Air Cooled Chiller Operation and Maintenance ...54
Heat Exchangers ....................................55
Cleaning Arrangement ...............................56
Compressor Information .............................57
Refrigeration Circuit Diagram .........................58
Refrigeration Systems Re-Processing ..................59
Split System Interconnecting Piping....................60
Refrigerant Charging Procedure .................... 61-62
 ...................63-64
Options and Accessories..............................65
Stainless Steel Strainer Option .....................66-70
WYE Strainers .....................................71-72
Basket Strainers .................................. 73-74
Electrical Data UCR ..................................75
Wiring Diagrams..................................76-79
Troubleshooting Guide ...............................80
Warranty ...........................................81
Table of Contents

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Introduction
General Description
The ClimaCool®
cooled modular chiller is designed to provide the most

and serviceable modular chiller in the industry. The UCR
utilizes R-410A refrigerant.
Modules are available in 30, 50 and 70 tons, which when

capacity requirements from 30 to 400 tons per bank.
Safety
Throughout this manual, warning, danger, caution and
attention notices appear. Read these items carefully before
attempting any installation, service or troubleshooting
of the equipment. All labels on unit access panels must
be observed.
DANGER: Immediate hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING: Potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION: Potentially hazardous situation or an unsafe practice
which, if not avoided, could result in minor or moderate injury
or product or property damage.
ATTENTION: Notication of installed, operation or maintenance
information which is important, but not hazard related.
CAUTION/ATTENTION

installed wiring. Unit terminals are
not designed to accept other types of
conductors.
Utilisez uniquement des conducteurs en
cuivre pour le câblage. Bornes de l’unité
ne sont pas conçus pour accepter
d’autres types de conducteurs.
CAUTION/ATTENTION
3 PHASE SCROLL
COMPRESSOR UNIT
UNITÉ COMPRESSEUR
SCROLL 3-PHASE
If this unit uses a 3 Phase Scroll
Compressor, the following instructions
MUST BE followed:
• Unit power supply MUST BE wired
in the proper sequence to avoid
damage to the 3 Phase Scroll
Compressor;
• Scroll Compressors with
INCORRECT rotation show the
following characteristics:
- High sound level;
- High suction pressure and low
discharge pressure;
- Low current draw.
• If any of the three above
characteristsics exist, swap
two of the three supply wires
at the disconnect and recheck
compressor for incorrect rotation.
Si cet appareil utilise compresseur
scroll 3-Phase, les instructions
suivantes doivent être suivies:
• L’alimentation de l’appareil doit
être monté dans l’ordre correct
pour éviter endommager le
compresseur scroll 3-Phase;
• Compressuers scroll avec
rotation incorrecte montrent les
caractéristiques suivantes:
- Haut niveau de son;
- Pression d-aspiration élevée
et une faible pression de
décharge;
- Faible ampérage.
• Si l’un des trois éléments
mentionnés ci-dessus sont
remplies, échanger deux des trois
lignes électriques alimen tant la

la rotation du compresseur.
WARNING/ADVERTISSEMENT
To avoid possible injury or death
due to electrical shock, open the
power supply disconnect switch and
secure it in an open position during
installation.
Pour éviter les blessures ou la mort
par électrocution, ouvrir la interrupteur

ouverte lors de l’installation.
CAUTION/ATTENTION
Excessive Chlorine, undissolved
solids and other improper water
conditions WILL DAMAGE the
internal heat exchanger & WILL VOID
YOUR WARRANTY!
Chlore excessive, solides non dissous
et les autres impropre conditions de
l’eau ENDOMMAGERA l’échangeur
de chaleur interne et ANNULERA
VOTRE GARANTIE!
WARNING/ADVERTISSEMENT
WATER AND REFRIGERANT
SYSTEMSUNDERPRESSURE
EAU ET FRIGORIGÈNE
EQUIPEMENTS SOUS
PRESSION
• Isolate/Lockout source and relieve
pressure BEFORE servicing
equipment.
• Failure to relieve pressure may
result in property damage, serious
bodily injury or death!
• Isoler la source / de verrouillage
et de soulager la pression avant
entretien de l’équipement.
• Le défaut de soulager la pression
peut entraîner des dommages
matériels des blessures corporelles
graves ou la mort!
ATTENTION
To avoid the release of refrigerant into the atmosphere, the refrigerant circuit of
this unit must be serviced only by technicians who meet local, state and federal

All refrigerant discharged from this unit must be recovered WITHOUT
EXCEPTION. Technicians must follow industry accepted guidelines and all
local, state and federal statues for the recovery and disposal of refrigerants.
If a compressor is removed from the unit, system refrigerant circuit oil will
remain in the compressor. To avoid leakage of compressor oil, the refrigerant
lines of the compressor must be sealed after it is removed.
WARNING/ADVERTISSEMENT
Disconnect power supply(ies)
before servicing. Refer servicing

Electric shock hazard. May
result in injury or death!
Debrancher avant d’entreprendre
le dépannage de l’appareil.

pour le dépannage. Risque de
choc électrique. Résiltat de mai
dans dommages ou la mort!
CAUTION/ATTENTION

personnel only. Refrigerant
system under pressure. Relieve
pressure before using torch.
Recover refrigerant and store or
dispose of properly.
Conifer la maintenance à un


Décomprimer avant d’exposer

frigorigene et le stocker ou le
détrulre correctement.

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Introduction
ATTENTION
Never dispense liquid refrigerant into the suction port of a compressor while it
is not running. If adding additional refrigerant is necessary, you must gradually
meter liquid refrigerant into suction port of the compressor ONLY WHILE THE
COMPRESSOR IS RUNNING and only through a metering valve.
WARNING/ADVERTISSEMENT
Cylinder pressures must be closely
monitored whenever a refrigerant
cylinder is being heated in ANY
manner. Allowing pressures to exceed
those for which the cylinder is rated
may result in cylinder rupturing,
personal injury and/or property
damage or even death.
Pression des cylindres doit être
surveillée étroitement chaque fois
qu’une bouteille de réfrigérant est
󰀨
des pressions supérieures à celles
pour lesquelles le cylindre est évalué
peut entraîner dans le cylindre une
rupture, des blessures corporelles ou
dommages matériels ou même la mort.
CAUTION/ATTENTION
Never dispense refrigerant amounts
into the receiver which may exceed
its liquid holding capacity. The
refrigeration system in our model
UCR030 is equipped with 72
pound receivers (at 80% full). Both
refrigeration systems in models
UCR050 and UCR070 are equipped
with 84 pound receivers (at 80% full).
Jamais distribuer montants réfrigérant
dans le récepteur, qui peut dépasser
sa capacité de rétention liquide.Le


livres récepteurs (à 80 % complet).


sont équipés de récepteurs de 84
livres (à 80 % complet).
WARNING/ADVERTISSEMENT
Unit charged with 50-psi Nitrogen
from factory. Pressure level should be
checked upon arrival to detect leaks
caused from shipping the unit.
Unité chargée avec 50-psi usine
d’azote. Le niveau de pression doit

causées par le transport.
CAUTION/ATTENTION
All pressure transducers should be
removed before evacuating or pressure
testing unit. Failure to do so will result
in damage to the transducers.
Tous les capteurs de pression doivent
être retirés avant l’évacuation ou de
test d’unité de pression. Faute de
quoi se traduira par des dommages à
des capteurs.
WARNING/ADVERTISSEMENT

communication wiring, installer must
use:
• 
• single-twisted pair
• shielded with drain
• 
• 22AWG
This conductor must be daisy chained
from the CoolLogic Controller to each
chiller module.
Maximum separation of low voltage
communication and high voltage
power wiring is required.
The communication cable must be
installed in its own conduit. Routing
must enter and exit the low voltage
section of the control box where the
controller is located and should not
be ran parallel to, or any closer than,

DC wiring either inside or outside of
the machinery compartment.
(See IOM or contact ClimaCool for

Pour l’installation sur place du

l’installateur doit utiliser:
• 
• Paire à simple torsion
• blindée avec drain
• 
• 22AWG
Ce conducteur doit être connecté en
guirlande du contrôleur CoolLogic à
chaque module de refroidissement.

conduit. L’acheminement doit entrer
et sortir de la section basse tension
du boîtier de commande où se trouve
le contrôleur et ne peut pas circuler

câblage de tension CA à l’intérieur
ou à l’extérieur du compartiment des
machines.
(Voir l’IOM ou contacter ClimaCool

CAUTION/ATTENTION
Never attempt to vapor charge into
the system high side, whether the
compressor is ON or OFF. This may

refrigeration system into the charging
cylinder. Cylinders can quickly be
over pressurized causing them
to rupture with resultant injury or
property damage.
Ne jamais essayer de vapeur frais

si le compresseur est ON ou
OFF. Cela peut entraîner dans le
réfrigérant qui se jettent dans le

cylindre de charge. Les bouteilles
peuvent être rapidement sursous la
pression obligeant à rompre avec
les blessures qui en résultent ou
dommages matériels.

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Inspection
Upon receipt of equipment, carefully check the shipment
against the bill of lading and inspect each chiller for any
damage incurred during shipment. Thoroughly check for
any visible damage of control panels and electrical and/
or refrigeration components or broken copper lines. The
carrier must make proper notation of any damages or
shortages on all copies of the bill of lading and complete a

of the shipment. Note: It is the responsibility of the

addition, please notify the ClimaCool Customer Service
Department at 405-815-3000 or customerservice@
climacoolcorp.com of all damage immediately.
Storage
Chillers should be stored in an upright position and kept in a
clean, dry area.
Handling of Modules
Carefully remove the module’s packaging. The chiller’s
steel base cut-outs provide maneuverability by fork lift or

Procedures Figures 3 - 5 on page 10). Verify that all header
grooved couplings and mounting hardware kits are on site
prior to connecting the modules. Note: Consult factory for
handling other than in the upright position.
Rigging and Lifting
Each module should be lifted by using a pallet jack or fork
lift. If it is necessary to utilize a crane for rigging or lifting,
each module shall be lifted by using lifting straps and

Rigging and Lifting Procedures.
Warranty
To ensure proper equipment longevity, design performance
and reliability, all ClimaCool modular chillers must be
installed, operated and maintained in accordance with
ClimaCool IO&M manuals. Water quality is of the utmost
importance for the proper care and maintenance of the
modular chiller system and regular treatment of the water
will increase longevity of the system. Failure to provide
adequate ltration or treatment of evaporator water
will void the ClimaCool module’s warranty. A factory
authorized technician is required to perform the start-
up of the ClimaCool chiller. Please contact the ClimaCool
Customer Service Department at 405.815.3000 or email
Technical Support at [email protected]
to schedule. There is a minimum of three (3) weeks notice
required to schedule the factory start-up.
Pre-Installation

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Model Key
Ul�mate Chiller Solu�on Model Key
REJECTION MEANS
R = Remote Condenser (Air Cooled)
030 E 0CASAR SAFCU
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
NOMINAL TONS
030 050 070
DESIGN SERIES A
VOLTAGE F = 460/3/60 H = 208-230/3/60 N = 575/03/60
CONTROLS & ELECTRICAL A = Standard (DDC)
COMPRESSOR TYPE S = Scroll
MODEL CONFIGURATION
S = Standard
REJECTION OPTIONS
0 = (None) B = Hot Gas Bypass - Both Circuits C = Compressor Isola�on Valves
WATER ISOLATION VALVES
E = Evap. Motorized Valves M = Manual Evap Valves
APPLICATION
C = Cooling
REFRIGERANT
A = R-410A

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Ul�mate Chiller Solu�on Model Key
REJECTION MEANS
R = Remote Condenser (Air Cooled)
030 E 0CASAR SAFCU
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
NOMINAL TONS
030 050 070
DESIGN SERIES A
VOLTAGE F = 460/3/60 H = 208-230/3/60 N = 575/03/60
CONTROLS & ELECTRICAL A = Standard (DDC)
COMPRESSOR TYPE S = Scroll
MODEL CONFIGURATION
S = Standard
REJECTION OPTIONS
0 = (None) B = Hot Gas Bypass - Both Circuits C = Compressor Isola�on Valves
WATER ISOLATION VALVES
E = Evap. Motorized Valves M = Manual Evap Valves
APPLICATION
C = Cooling
REFRIGERANT
A = R-410A
Physical Data
Model UCR Module and Compressor 30 50 70
Capacity (tons) 27.4 45 59
Refrigerant Circuits (quantity) 2 2 2
Compressor Type Scroll Scroll Scroll
Compressor Quantity 2 2 2
Compressor Nominal hp (per circuit)  25 35
Oil Factory Charge (per circuit) (oz.)  230 
Module Operating Weight w/Water (lbs.) 2  2085
Module Shipping Weight (lbs.) 3  
Model UCR Evaporator 30 50 70
Heat Exchanger Type Brazed Plate Brazed Plate Brazed Plate
Independent Refrigerant Circuits (quantity) 2 2 2
Water Storage Volume HX Only (gals.) 2.8  
   
Maximum Design Working Pressure - Water Side (PSI) 300 300 300
Header Water Connections - Inlet/Outlet (inches) 4
Notes:
 Unit tonnage ARI rating conditions: 44°F leaving chilled water temperature, and 2.4 GPM per ton through the evaporator; 95°F entering condenser air temperature

2. Module operational weight includes water, compressor oil, and refrigerant charge. Multiply times the number of modules for a total system operational weight.
3. Unit shipping weight includes compressor oil and packaging.
4. 
5. 󰀨
 Minimum chiller unloading percent can be as low as 4.8% of total systems. Calculate system unloading by dividing ½ of smallest module by total system tons.
7. 

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Remote Condenser Physical Data: 30°F TD & 110°F Maximum Ambient
Remote Condenser “H” Series Model UCR 30 50 70
Model RC (1140 RPM / 30°F TD / 110°F Max Ambient) RC1-008A*H20 RC2-026A*H48 RC2-031A*H48
Quantity of Remote Condensers Needed 2  
Heat Exchanger (Remote Air-Cooled Type)   
Fins per Inch (FPI)  8 8
Independent Refrigerant Circuits (Quantity) 2 2
Fan Motor Drive Type I Fan Dia. (in.)  Direct I 30” Direct I 30”
Total CFM   
Fan Speed   
Fan Motor Hp (ea)   
Quantity of Fan Motors 2 4 4
kW Input (ea.) Fan Motor I Total kW Input for All Motors   
   
 8.0 I 240  
Max. Design Working Pressure - Ref. side I Test Pressure (Psig.)   
Condenser Refrigerant Inlet Connection; Qty. @ Size O.D. (Inches)   
Condenser Refrigerant Outlet Connection; Qty. @ Size O.D. (Inches)   
 74.5 78.4 78.4
Dimensions: W x L x H (Inches) 43 X 97 X 40.5  
Net Weight I Shipping Weight (lbs)   
Remote Condenser “X” Series Model UCR 30 50 70
Model RC (830 RPM / 30°F TD / 110°F Max. Ambient) RC2-018A*X48 RC2-026A*X40 RC2-032A*X44
Quantity of Remote Condensers Needed 
Heat Exchanger (Remote Air-Cooled Type)   
Fins per Inch (FPI) 8 
Independent Refrigerant Circuits (Quantity) 222
Fan Motor Drive Type I Fan Dia. (in.) Direct I 30” Direct I 30” Direct I 30”
Total CFM  30,500 29,300
Fan Speed 830 830 830
Fan Motor Hp (ea)   
Quantity of Fan Motors 444
kW Input (ea.) Fan Motor I Total kW Input for All Motors   
   
   
Max. Design Working Pressure - Ref. side I Test Pressure (Psig.)   
Condenser Refrigerant Inlet Connection; Qty. @ Size O.D. (Inches)   
Condenser Refrigerant Outlet Connection; Qty. @ Size O.D. (Inches)   
   
Dimensions: W x L x H (Inches)   
Net Weight I Shipping Weight (lbs)   
Remote Condenser “Q” Series Model UCR 30 50 70
Model RC (540 RPM / 30°FTD / 110°F Max. Ambient) RC2-017A*Q42 RC2-025A*Q44 RC2-032A*Q62
Quantity of Remote Condensers Needed 
Heat Exchanger (Remote Air-Cooled Type)   
Fins per Inch (FPI)   
Independent Refrigerant Circuits (Quantity) 2 2 2
Fan Motor Drive Type I Fan Dia. (in.) Direct I 30” Direct I 30” Direct I 30”
Total CFM 22,300 20,800 32,300
Fan Speed 540 540 540
Fan Motor Hp (ea)   
Quantity of Fan Motors 4 4 
kW Input (ea.) Fan Motor I Total kW Input for All Motors   
   
  24.5 I 735 32.4 I 972
Max. Design Working Pressure - Ref. side I Test Pressure (Psig.)   
Condenser Refrigerant Inlet Connection; Qty. @ Size O.D. (Inches)   
Condenser Refrigerant Outlet Connection; Qty. @ Size O.D. (Inches)   
 55.7 55.7 57.3
Dimensions: W x L x H (Inches)   
Net Weight I Shipping Weight (lbs)   

7
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Remote Condenser Physical Data: 20°F TD & 120°F Maximum Ambient
Remote Condenser “H” Series Model UCR 30 50 70
Model RC (1140 RPM / 20°F TD / 120°F Max Ambient) RC2-026A*H48 RC2-038A*H44 RC2-047A*H62
Quantity of Remote Condensers Needed 
Heat Exchanger (Remote Air-Cooled Type)   
Fins per Inch (FPI) 8  
Independent Refrigerant Circuits (Quantity) 2 2 2
Fan Motor Drive Type I Fan Dia. (in.) Direct I 30” Direct I 30” Direct I 30”
Total CFM   59,400
Fan Speed   
Fan Motor Hp (ea)   
Quantity of Fan Motors 4 4 
kW Input (ea.) Fan Motor I Total kW Input for All Motors   
   
   
Max. Design Working Pressure - Ref. side I Test Pressure (Psig.)   
Condenser Refrigerant Inlet Connection; Qty. @ Size O.D. (Inches)   
Condenser Refrigerant Outlet Connection; Qty. @ Size O.D. (Inches)   
 78.4 78.4 80.0
Dimensions: W x L x H (Inches)   
Net Weight I Shipping Weight (lbs)   
Remote Condenser “X” Series Model UCR 30 50 70
Model RC (830 RPM / 20°F TD / 120°F Max. Ambient) RC2-026A*X40 RC2-039A*X60 RC2-047A*X62
Quantity of Remote Condensers Needed 
Heat Exchanger (Remote Air-Cooled Type)   
Fins per Inch (FPI)   
Independent Refrigerant Circuits (Quantity) 222
Fan Motor Drive Type I Fan Dia. (in.) Direct I 30” Direct I 30” Direct I 30”
Total CFM  45,700 44,000
Fan Speed 830 830 830
Fan Motor Hp (ea)   
Quantity of Fan Motors 4 
kW Input (ea.) Fan Motor I Total kW Input for All Motors   
   
  39.4 I 788 47.0 I 934
Max. Design Working Pressure - Ref. side I Test Pressure (Psig.)   
Condenser Refrigerant Inlet Connection; Qty. @ Size O.D. (Inches)   
Condenser Refrigerant Outlet Connection; Qty. @ Size O.D. (Inches)   
   
Dimensions: W x L x H (Inches)   
Net Weight I Shipping Weight (lbs)   
Remote Condenser “Q” Series Model UCR 30 50 70
Model RC (540 RPM / 20°FTD / 120°F Max. Ambient) RC2-025A*Q44 RC2-039A*Q64 RC2-048A*Q82
Quantity of Remote Condensers Needed 
Heat Exchanger (Remote Air-Cooled Type)   
Fins per Inch (FPI)   
Independent Refrigerant Circuits (Quantity) 2 2 2
Fan Motor Drive Type I Fan Dia. (in.) Direct I 30” Direct I 30” Direct I 30”
Total CFM 20,800  
Fan Speed 540 540 540
Fan Motor Hp (ea)   
Quantity of Fan Motors 4 8
kW Input (ea.) Fan Motor I Total kW Input for All Motors  0.43 I 2.58 0.43 I 3.44
   
 24.5 I 490 39.5 I 790 
Max. Design Working Pressure - Ref. side I Test Pressure (Psig.)   
Condenser Refrigerant Inlet Connection; Qty. @ Size O.D. (Inches)   
Condenser Refrigerant Outlet Connection; Qty. @ Size O.D. (Inches)   
 55.7 57.3 
Dimensions: W x L x H (Inches)   88 X 233 X 49
Net Weight I Shipping Weight (lbs)   

8
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Variable Speed Remote Condenser Physical Data: 30°F TD & 110°F
Maximum Ambient
Variable Speed Remote Condenser Physical Data: 20°F TD & 120°F
Maximum Ambient
Remote Condenser “V” Series Model UCR 30 50 70
Model RC (Variable Spd / 30°F TD / 110°F Max Amb.) RC2-020A*V48 RC2-025A*V42 RC2-033A*V42
Quantity of Remote Condensers Needed 
Heat Exchanger (Remote Air-Cooled Type)   
Fins per Inch (FPI) 8  
Independent Refrigerant Circuits (Quantity) 2 2 2
Fan Motor Drive Type I Fan Dia. (in.) Var Spd I 30.5 Var Spd I 30.5 Var Spd I 30.5
Total CFM   
Fan Speed   
Fan Motor Hp (ea)   
Quantity of Fan Motors 4 4 4
kW Input (ea.) Fan Motor I Total kW Input for All Motors 2.2 I 8.8 2.2 I 8.8 2.2 I 8.8
   
  24.8 I 744 
Max. Design Working Pressure - Ref. side I Test Pressure (Psig.)   
Condenser Refrigerant Inlet Connection; Qty. @ Size O.D. (Inches)   
Condenser Refrigerant Outlet Connection; Qty. @ Size O.D. (Inches)   
   
Dimensions: W x L x H (Inches)   
Net Weight I Shipping Weight (lbs)   
Remote Condenser “V” Series Model UCR 30 50 70
Model RC (Variable Spd / 20°F TD / 120°F Max Ambient) RC2-025A*V42 RC2-038A*V42 RC2-046A*V60
Quantity of Remote Condensers Needed 
Heat Exchanger (Remote Air-Cooled Type)   
Fins per Inch (FPI)   
Independent Refrigerant Circuits (Quantity) 2 2 2
Fan Motor Drive Type I Fan Dia. (in.) Var Spd I 30.5 Var Spd I 30.5 Var Spd I 30.5
Total CFM   
Fan Speed   
Fan Motor Hp (ea)   
Quantity of Fan Motors 4 4 
kW Input (ea.) Fan Motor I Total kW Input for All Motors 2.2 I 8.8 2.2 I 8.8 
   
   
Max. Design Working Pressure - Ref. side I Test Pressure (Psig.)   
Condenser Refrigerant Inlet Connection; Qty. @ Size O.D. (Inches)   
Condenser Refrigerant Outlet Connection; Qty. @ Size O.D. (Inches)   
   48.0 I 74.7
Dimensions: W x L x H (Inches)   
Net Weight I Shipping Weight (lbs)   

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Dimensional Data and Piping Arrangement
Figure 1 - Dimensional Drawings
Figure 2 - Refrigerant Piping Arrangement
Table 1 - Dimensional Data
Table 2 - Refrigerant Piping Data
Header Width
Chilled Water
Outlet
Chilled Water
Inlet
Control Box
Unit Width
Front View
C
B
AH
G F
D
E
Unit Dimensions (in inches)
Model
UCR Voltage
A
Unit
Width
Inches
B
Unit
Height
Inches
C
Header
Width
Inches
D
Header
Location
Inches
E
Header
Location
Inches
F
Header
Location
Inches
G
Header
Location
Inches
H
Unit
Depth
Inches
Header
Connection
Size
Inches
Unit
Weight1
Pounds
Operating
Weight2
Pounds
030       58     
050       58     
070       58     2085
Note:
 
2. Operational weight includes refrigerant charge, compressor oil and water.
Right Side
View
TOP VIEW
FRONT
Circuit 1
Discharge Line
Circuit 1
Liquid Line
Circuit 1
Liquid Line
Circuit 1
Discharge Line
EDC
B A
Unit Dimensions (in inches)
Model
UCR A B C D E
030 4 8-7/8   
050 4 8-7/8   
070 4 8-7/8   

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Rigging
Each module should be lifted by using lift straps threaded through the steel base cut outs and the use of a spreader bar.
Note: If no spreader bar is used, damage to the unit may occur.
Figure 5
Lifting and Transporting Modules
Pallet jacks or fork lifts are required for lifting and transporting the module. Each module has base cutouts provided for ease
of maneuverability. 60” forks are recommended to prevent damage to the chiller base.
Rigging and Lifting Procedures
Lifting Strap
Spreader Bar
Spreader Bar
Spreader Bar
Lifting Strap
Figure 3 Figure 4

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Spring Vibration
Isolators (by others)
4” Rail Minimum
Recommended
(by others)
Spring Vibration
Isolators (by others)
4” Rail Minimum
Recommended
(by others)
Mounting Rail and Vibration Isolation
Figure 6 - Spring Vibration Isolators Option
Figure 7 – Vibration Isolation Pads Option
Note: 
ClimaCool recommends locking down the chiller to a concrete base or to three (3) 4” base mounting rails using the six (6)
bolt holes provided in each base pan. Due to the low vibration of the modules, the application of spring isolators or pads is
not required. Should isolators or pads be desired, install in accordance with Figures 6 and 7.
4” Rail Minimum
Recommended
(by others) Vibration Pads (by others)
4” Rail Minimum
Recommended
(by others) Vibration Pads (by others)

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Recommended Service Clearances
Notes:
1. Allow 36” clearance for electrical panels and 30” clearance for rear access to modules.
2. Allow a minimum of 18” height clearance for service.
3. Local building or electrical codes may require additional clearance. Consult applicable codes.
Top View
Rear Service Access
Front Service Access
CoolLogic
Control Panel
(Wall Mounted)
30” 30”
36”36”
12”

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Unit Placement
ClimaCool modular chillers must be installed in a

foundation requirement for the ClimaCool chiller is a level
surface capable of bearing the combined operating weight
of the modules (see Physical Data - page 5).
Service Access
The recommended service clearances are 36” for front
service access, 18” height clearance for service and 30” for

Clearances on page 11. Local building or electrical codes may
require additional clearance – consult applicable codes.
Draining
When performing standard maintenance procedures such


optional water isolation valves for this purpose. Access

maintenance procedures. Warning: Water valves must be
reopened after ushing is complete.
Assembling Modules
ClimaCool recommends locking down the chiller to a
concrete base, or to three (3) 4” base mounting rails, using
the six (6) bolt holes provided in each base pan. Although
the compressors are installed on anti-vibration mountings,
further isolation of the chiller from the structure is
recommended by installing vibration — eliminating springs
or pads under the base rails on which the chiller will rest
(see page 10 – Mounting Rail and Vibration Isolation). One
end of the modules should be chosen as the reference
module and carefully located.
Field installed mounting accessories are provided for
adjoining each module.
• Header grooved coupling kits containing two (2) grooved
couplings with gaskets.
• Mounting hardware kit containing necessary bolts,
spacers, nuts and washers.
• Header bank end cap kit containing two (2) grooved
couplings with gaskets and two (2) end caps.
Unit Installation
Field installing the mounting hardware kit will assist with



set the adjacent unit on mounting surface roughly aligned


a washer and insert bolt through front mounting hole and
spacer. Repeat the process for the rear mounting hole. Line
up mounting hole of adjacent module with bolt from previous
module. Work through adjacent modules front base cutout
by placing a washer, split lock washer and nut. Using the
appropriate tools, tighten hardware assembly until seated.
Figure 8 - Hardware Kit
Figure 9 - Spacer Holes
END TO END SPACER HOLES

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Unit Installation
Inspect the pipe ends to ensure they are free from any
indentations, projections, roll marks or other harmful
surface defects such as loose paint, scale, dirt, chips,
grease and rust. Inspect the grooved coupling gasket for
any defects. Apply a thin layer of silicone or other non-
petroleum lubricant to the sealing lips of the gasket as well
as to the exterior of the gasket. Install gaskets on the pipe
ends of one of the two modules to be mated. Be sure the
gasket is completely on the pipe to avoid damage in the
next step. Move the second module into position and line
up the piping. Ensure the operator is maintaining alignment
for any additional modules to be added. When pipe ends
are aligned, slide the gasket over the ends and center it
between the grooves. No part of the gasket should protrude
into the groove of either pipe end. Place the coupling halves
over the gasket and make sure that the coupling keys
(the part that goes into the groove) are engaged into the
grooves. Insert the bolts and install nuts to hand tighten.
Ensure the oval neck of the bolt engages into the bolt hole
of the housing. Tighten nuts alternately and equally until
the bolt pads meet and make metal to metal contact.
Tighten nuts by another quarter to half turn to make sure
the nuts and bolts are snug and secure. The use of a torque
wrench is usually not required. Uneven tightening of bolts
may cause the gasket to be pinched resulting in immediate
or delayed leaks.
Header Insulation
Chilled water piping is pre-insulated on each module

bolting all modules together and leak testing, the entire
coupling connection will need to be insulated by the
installing contractor.
Sound Attenuation Panels and Gasket
Attenuation panels are enclosures made of 18 gauge

insulation. Field Installed panel package includes one (1)
upper panel made out of two (2) sections and one (1) lower

for each module in the bank (factory installed) and gasket
sealant tape for installation between modules. Install panels
by setting in place and locking down with the half turn
latches or self tapping screws. Note: Panel package includes
a compressed 1” x 1” gasket sealant tape for installation
between modules. Install the tape on the outer frame on
the side of one module prior to installing the adjacent
modules.
CAUTION/ATTENTION
3 PHASE SCROLL
COMPRESSOR UNIT
UNITÉ COMPRESSEUR
SCROLL 3-PHASE
If this unit uses a 3 Phase Scroll
Compressor, the following instructions
MUST BE followed:
• Unit power supply MUST BE wired
in the proper sequence to avoid
damage to the 3 Phase Scroll
Compressor;
• Scroll Compressors with
INCORRECT rotation show the
following characteristics:
- High sound level;
- High suction pressure and low
discharge pressure;
- Low current draw.
• If any of the three above
characteristsics exist, swap
two of the three supply wires
at the disconnect and recheck
compressor for incorrect rotation.
Si cet appareil utilise compresseur
scroll 3-Phase, les instructions
suivantes doivent être suivies:
• L’alimentation de l’appareil doit
être monté dans l’ordre correct
pour éviter endommager le
compresseur scroll 3-Phase;
• Compressuers scroll avec
rotation incorrecte montrent les
caractéristiques suivantes:
- Haut niveau de son;
- Pression d-aspiration élevée
et une faible pression de
décharge;
- Faible ampérage.
• Si l’un des trois éléments
mentionnés ci-dessus sont
remplies, échanger deux des trois
lignes électriques alimen tant la

la rotation du compresseur.

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The power for all modules is taken from a suitable circuit
breaker/fused disconnect power supply within the main
panel. The electrical service enters the individual modules
through the top into the module’s control panel enclosure.
Proper grounding of the module is mandatory. Before

supply is isolated. A typical power wiring is located on page
28 – Power Distribution Drawing. Knockouts are provided.
Do not drill into cabinet as shavings can damage electronic
components. The power for all individual modules must be
in compliance with all local and national codes.
CoolLogic Control System Wiring
A separate 115 volt power supply is required to power the
CoolLogic master control panel. Communication between
the master control panel and chiller modules requires a
simple two-conductor 22 AWG shielded cable rated at 60°C
minimum, daisy chain connection. Control wiring cannot be
installed in the same conduit as line voltage wiring or with
wires that switch highly inductive loads such as contactor
and relay coils. Refer to the Power Distribution Drawing on
page 28 of this manual for more information. All wiring must
be in compliance with all local and national codes.
ARC156 Wiring Specications

ARC156 wiring. The wire jacket and UL temperature rating

has a higher temperature rating and a tougher outer jacket
than SmokeGard, and it is appropriate for use in applications
where there are concerns about abrasion. Halar is also less
likely to crack in extremely low temperatures.
NOTE: 
maximum signal integrity.
Electrical Phase Sequencing
Proper clockwise rotation for scroll compressor motors
is important to prevent damage to the compressors.
ClimaCool recommends the use of a phase sequence
indicating instrument following the manufacturers
directions. An alternative is to “bump test” the compressors
one at a time with pressure gauges attached to the high and
low gauge ports of the compressors to check for proper
rotation. Energize the compressor for a few seconds to

If the discharge pressure does not increase, proper
rotation is reversed. Compressor rotation can be reversed
by opening the main electrical disconnect and switching
any two of the main power supply leads feeding that
compressor’s contactor.
Proper Voltage Balance
Occasionally, in three phase circuits, a voltage imbalance
occurs between phases. It is not recommended to operate
equipment when an imbalance greater that 2% occurs. This

their longevity. The following example describes how to
calculate the average voltage of the three phases to see if
the imbalance is greater than 2%.
Example: Line 1 = 226v Line 2 = 230v Line 3 = 228v
The average is: (226+230+228) / 3 = 228v
Next, [100(228-226)] / 228 = 0.9%
The voltage imbalance of the three phase circuit is 0.9%.
This is well under the 2% range.
Voltage/Phase Monitor

installation with the CoolLogic Master Control Panel. The
voltage/phase monitor helps guard the chiller bank against

conditions which could void the warranty. The voltage/
phase monitor has three wires that connect to the main
three phase power chiller bank input. Two low voltage
control wires are connected to the CoolLogic Master Control
Panel. Do not install control wiring in the same conduit
as line voltage wiring or with wires that switch highly
inductive loads such as contactor and relay coils. Note: It
is mandatory to install one (1) monitor per bank at main
power distribution panel to monitor voltage and phasing of
power to the modules. See Wiring Diagram on page 17.
Electrical Connection
CAUTION/ATTENTION

installed wiring. Unit terminals are
not designed to accept other types of
conductors.
Utilisez uniquement des conducteurs en
cuivre pour le câblage. Bornes de l’unité
ne sont pas conçus pour accepter
d’autres types de conducteurs.
WARNING/ADVERTISSEMENT
Disconnect power supply(ies)
before servicing. Refer servicing

Electric shock hazard. May
result in injury or death!
Debrancher avant d’entreprendre
le dépannage de l’appareil.

pour le dépannage. Risque de
choc électrique. Résiltat de mai
dans dommages ou la mort!
CAUTION/ATTENTION

personnel only. Refrigerant
system under pressure. Relieve
pressure before using torch.
Recover refrigerant and store or
dispose of properly.
Conifer la maintenance à un


Décomprimer avant d’exposer

frigorigene et le stocker ou le
détrulre correctement.

16
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Avoiding Noise
Avoid running communication wires or sensor input wires
next to AC power wires or the controller’s relay output

quality. Common sources of noise are:
Spark igniters
Radio transmiers
Variable speed drives
Electric motors (> 1hp)
Generators
Relays
Transformers
Other electronic modules
Inducon heaters
Video display devices
Lamp dimmers
Fluorescent lights
Parallel runs with power lines
Large contactors,
(i.e., motor starters)
ARC156 Wiring Specications


acceptable alternatives. Halar has a higher temperature
rating and a tougher outer jacket than SmokeGard, and it is
appropriate for use in applications where you are concerned
about abrasion. Halar is also less likely to crack in extremely
low temperatures. NOTE: 
cable for maximum signal integrity.
Communications Wiring
ARC156 Specications
Description 
Conductor 22 AWG (7x30) stranded copper (tin plated)

NOTE:
Insulation Foamed FEP


Color code Black/white
Twist lay 2 in. (50.8 mm) lay on pair

Shielding Aluminum/Mylar shield with 24 AWG (7x32) TC drain wire
Jacket SmokeGard (SmokeGard PVC)


Halar®(ECTFE)


DC resistance 
Capacitance 
Characteristic impedance 
Weight 
UL temperature rating SmokeGard

Halar

Voltage 300 Vac, power limited
Listing UL: NEC CL2P, or better
WARNING/ADVERTISSEMENT

communication wiring, installer must
use:
• 
• single-twisted pair
• shielded with drain
• 
• 22AWG
This conductor must be daisy chained
from the CoolLogic Controller to each
chiller module.
Maximum separation of low voltage
communication and high voltage
power wiring is required.
The communication cable must be
installed in its own conduit. Routing
must enter and exit the low voltage
section of the control box where the
controller is located and should not
be ran parallel to, or any closer than,

DC wiring either inside or outside of
the machinery compartment.
(See IOM or contact ClimaCool for

Pour l’installation sur place du

l’installateur doit utiliser:
• 
• Paire à simple torsion
• blindée avec drain
• 
• 22AWG
Ce conducteur doit être connecté en
guirlande du contrôleur CoolLogic à
chaque module de refroidissement.

conduit. L’acheminement doit entrer
et sortir de la section basse tension
du boîtier de commande où se trouve
le contrôleur et ne peut pas circuler

câblage de tension CA à l’intérieur
ou à l’extérieur du compartiment des
machines.
(Voir l’IOM ou contacter ClimaCool


17
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Voltage/Phase Monitor Wiring Diagram
®

18
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As with any water system, it is important that the system
be clean. If care is taken during installation, the possibility
of dirt related problems are avoided in future operation
of the chiller. The pipe work installer must remove weld
scale, rust and contamination during pipe work fabrication.


are compatible with 316 stainless steel, prior to making
connections to the ClimaCool chiller. There are certain
necessary components that should always be installed in
the chilled water system. (See Figures 13 and 14 on page

multiple modules may also be found on page 20. All water
piping must be installed in accordance with applicable codes
and standards.
Temperature Sensor and Wells
ClimaCool provides two (2) temperature sensors and wells
with each chiller system programmed by the CoolLogic
Control System. The temperature sensor and wells must be

from the bank and before the strainer, on the chilled water

on page 20). Note: Sensors must be fully inserted into
the well to obtain proper readings and must be 2 ½ pipe
diameter minimum before or after an elbow.
Pressure Dierential Flow Sensor


page 56, are not exceeded. To prevent operation of the


chilled water circuit, downstream of the strainer on the
inlet and outlet of a straight pipe as close to the module as
possible. Do not put in an elbow on the outlet. (See Water

Pressure Taps
The installing contractor must provide access ports for


tap is required on the inlet and the outlet of the chilled
water system for a total of four (4) taps. If a port is shared



Water Isolation Valves
It is recommended to provide bank water isolation valves for
proper isolation and maintenance of the chiller, pump and

Strainers – Minimum 60 Mesh Screen Required
ClimaCool chillers employ brazed plate heat exchangers
which are extremely sensitive to debris. Therefore, it is
mandatory that all chilled water systems include a strainer
with a minimum of 60 mesh screen for proper ltration
and be in place at all times while chillers are in operation.
The strainers must be installed as shown in the Water Piping

ClimaCool’s warranty does not cover and does not apply to
products which have defects or damages due to freezing
of the water supply, an inadequate or interrupted water
supply, corrosives or abrasives in the water supply, or
improper or inadequate ltration or treatment of the
water supply.
Chiller System Water Header Bypass
A bypass is required for any chilled water/evaporator,
hot water/condenser and source water side (geothermal,
cooling tower or closed circuit cooler) with variable
pumping. The bypass must be piped in such a way that


11 on page 19). The purpose of the chiller system bypass
is to prevent deadheading of the pumps when all of the
internal unit valves go closed as well as allow temperature

The bypass should be sized for an absolute minimum of


Modules can also be designated for use as an internal
bypass, however, use of a module acting as a bypass can
cause increased wear of heat exchangers due to abrasion


direct return (Figure 10 on page 19) and reverse return
(Figure 11 on page 19). The bypass kits must be installed on
each water source loop and controls are integrated with the
CoolLogic software. Installation location can be found on

Water Piping