Northern Lights TECHNICOLD OTCW User manual

OTCW
For Chilled Water
Air Conditioning Systems
OPERATOR’S MANUAL
OPERATOR’S MANUAL
Technicold Marine Systems | www.technicold.com

Technicold by Northern Lights
1419 W. Newport Center Drive
Deereld Beach, FL 33442
Tel: [phone]
Fax: [phone]
Copyright ©2011, Northern Lights, Inc.
All rights reserved. Northern Lights, Technicold,
the Northern Lights logo, and the Technicold logo are
trademarks of Northern Lights, Inc.
Printed in U.S.A.
PART NO.: OTCW 4/11

1
Read this operator's manual thoroughly before starting to operate your equipment.
This manual contains information you will need to run and service your new unit.
OPERATOR'S MANUAL
for Chilled Water Air Conditioning
IMPORTANT SAFETY WARNINGS
Safety......................................................................................................... 2
Hazards................................................................................................... 2-4
PART 1: OPERATION, TROUBLESHOOTING, ELECTRICAL DRAWINGS,
VFD PROGRAMMING
Technicold Temperature Control ............................................................. 5-7
Chilled Water Troubleshooting Guide ................................................... 8-11
Electrical Drawings ............................................................................. 12-13
SMV Variable Frequency Drive........................................................... 14-17
PART 2: SERVICING - ADDING GLYCOL, FRESH WATER FILL ASSEMBLY,
IMMERSION HEAT CONVERSION
Adding Glycol to a Chilled Water System ........................................... 18-21
Fresh Water Fill Assembly .................................................................. 22-23
Fill Assembly Drawing.............................................................................. 24
Immersion Heaters.............................................................................. 25-27
Immersion Heater Drawings ............................................................... 28-30
PART 3: MAINTENANCE
Daily Maintenance ................................................................................... 31
Weekly Maintenance................................................................................ 32
Monthly Maintenance............................................................................... 33
Quarterly Maintenance........................................................................ 34-35
Annual Maintenance ................................................................................ 35
PART 4: APPENDIX
Fahrenheit/Celsius Conversion Chart ...................................................... 36
A/C Denitions and Facts ........................................................................ 37
Technicold air conditioning warranty statement ....................................... 38
Notes........................................................................................................ 39
Table of Contents
Proprietary Information
This publication is the property of Northern Lights, Inc.
It may not be reproduced in whole or in part without the written permission of Northern Lights, Inc.
© Northern Lights, Inc. All right reserved.
Every precaution has been taken in the preparation of this manual to insure its accuracy. However, Technicold by Northern Lights
assumes no responsibility for errors and omissions. Neither is any liability assumed for damages
resulting from the use of this product and information contained herein.
Litho U.S.A. Publication number OTCW 4/11

OTCW 4/11
SAFETY
General Overview
The installed Technicold equipment may be one component or a built-up system comprising of multiple
components. The equipment can present a hazard due to pressures, temperatures, chemicals, weight and
mass, moving parts, electrical components, and sharp or extruded edges. Only qualied service personnel
are to install, service or repair this equipment.
Technicold products are designed to be as safe as possible, and for the owner to be able to perform most
maintenance tasks. Nonetheless, some items require special equipment and knowledge. A qualied service
company should be hired to perform specialized maintenance tasks. Most service companies also o󰀨er
maintenance scheduling for routine maintenance in addition to seasonal or annual maintenance checks.
! Follow all safety instructions, regulations and signage on the equipment, in the manuals, on labels and
tags.
! Also use appropriate safety equipment.
! Use the correct tools for the task.
! Never work alone.
! Never attempt a task that exceeds your technical or physical capabilities.
HAZARDS
Chemical Burns
Chemicals used for cleaning internal and external components may cause a chemical burn if they make
contact with the skin. Follow product manufacturers' instructions for use and application of the product.
Read all safety and rst aid instructions prior to using any chemicals. Use protective clothing and equipment
to avoid skin contact. If contact should occur, follow the rst aid instructions provided by the product
manufacturer. If rst aid information is not available, seek medical attention immediately.
Chemicals used for cleaning can also cause damage to surrounding surfaces. Always protect surrounding
areas when using active chemicals.
To prevent accidental contact and injury do not transfer chemicals into unlabeled containers.
Do not apply, mix or store chemicals using containers or equipment that is not compatible with the product
used.
Dispose of spent or unused chemicals in a safe manner adhering to all regulations and guidelines.
IMPORTANT SAFETY WARNINGS - PLEASE READ
2

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HAZARDS
Electrical Shock
Disconnect voltage to equipment before opening any electrical panel or cover. Some equipment may have
two power sources; in this case, make sure both are turned o󰀨.
Tag, remove or lock-out any breaker, switch, fuse or disconnect that can be energized without the knowledge
of the user during service.
All electrical or electronic equipment should be adequately grounded. All ground wires should be point-to-
point and not "daisy chained". Ground wire connections should be tight on the posts/lugs for maximum safety
and to prevent electrical noise.
Ground wires should be of the correct gauge to protect the operator and equipment.
Fire
Electric motors and heaters have internal and/or external thermal protection. Never operate the equipment
with the thermal protective devices by-passed as this can create a re hazard. The thermal protection device
should be by-passed for troubleshooting purposes only. Upon completion of troubleshooting, replace the
defective device before the equipment is placed back into operation.
Loose electrical connections can cause overheating and burning of wires and components. High amperage
wires are especially susceptible to loosening; this is due to the heating and cooling of the wires and
terminations when current ows and stops. Periodically check electrical wiring terminations to ensure a tight
connection. With the power o󰀨, check wires for discoloration, inexibility or brittleness, as these can be an
indication of overheated wires. Fix the problem by replacing the wires and/or terminations.
Flooding
In most air conditioning, chilled water, refrigeration and load bank applications, water is a cooling or heating
media. Pipes and hoses transport the water throughout the boat to supply the equipment. Clamps, anges
or compression types connect the equipment, pumps, hoses, pipes and ttings. Should the integrity of these
components fail, localized ooding can occur. Periodic inspections can minimize the risk by identifying small
leaks, loose connections or deteriorated components allowing preventive measures.
Route the discharge hoses that connect to the pressure relief valves to a safe location. This will prevent
damage to equipment or injury should they discharge.
Some equipment, such as air handlers, produces condensate. Periodically check pans and drains to ensure
proper drainage.
3

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HAZARDS
Refrigerant
Chillers, refrigeration systems and direct expansion systems may contain pressurized refrigerant in liquid
and gas form. Refrigerant vapor reduces oxygen available for breathing, which can cause rapid su󰀨ocation.
Inhalation or misuse of the product can cause serious personal injury or death. Refrigerate may decompose
on ame or extremely hot surfaces to produce toxic or corrosive materials. Contact with liquid refrigerant to
skin or eyes can cause irritation or frostbite.
Wear proper eye and hand protection when handling components that carry refrigerant. Refer to the
manufacturers' instructions regarding transportation and storage of refrigerant cylinders.
By national and international law, only certied technicians can handle or work on refrigerants.
High Pressure
When operating, pumps can produce signicant high pressure. Do not disconnect hoses or open the system
when a pump in operation.
Refrigerant circuits are under high pressure even when the component is not in operation. Only qualied and
certied personnel should connect any equipment or gauge-set to the refrigerant circuit.
Rotating Machinery
Equipment such as pumps and blowers contain rotating parts that can cause serious injury upon bodily
contact. Always guard all moving parts to prevent incidental contact with ngers or foreign objects.
Wait for rotating parts to come to a complete stop after removing power. Even when de-energized other
external forces can cause fan blades and pumps to rotate. Lock blower wheels and isolate water ow to
pumps before working on equipment.
Never handle rotating equipment when connected to a power source.
Sharp Edges
Use caution and wear gloves when cleaning or installing equipment. Sharp edges can cause severe injuries.
4

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TECHNICOLD TEMPERATURE CONTROL
Liquid Crystal Display (LCD)
The LCD display provides a constant readout of the sensor temperature if the control is
energized. During the operation the S1 annunciator is constantly illuminated when the
relay is energized. The display is also used in conjunction with the keypad to allow the
user to adjust the setpoint temperature, di󰀨erential and
heating/cooling modes.
Control Setup
The temperature setpoint refers to the temperature at which the normally open (NO) contacts of the output
relay will open. Determine the load(s) to be controlled and the operating mode required, cooling or heating
(Figure 1). When the cooling mode is chosen, the di󰀨erential is above the setpoint. The relay will de-energize
as the temperature falls below the setpoint. When the heating mode is chosen, the di󰀨erential is below the
setpoint. The relay will de-energize as the temperature rises to the setpoint .
Step 4 - Press the SET key again to access the cooling or heating mode. The LCD will display the current
mode, either C1 for cooling or H1 for heating. Press either the up 5key or down 6 key to toggle between the
C1 or H1 designation. Press the SET key once more and programming is complete.
Programming Steps and Display
The Technicold Temperature Control (TTC) can be programmed in four
simple steps using the LCD display and the three keys on the face of the
control.
Step 1 - To start programming, press the SET key once to access the
Fahrenheit/Celsius mode. The display will show the current status, in
either Fahrenheit (F) or Celsius (C). Press either the up 5key or down
6 key to toggle between the F or C designation.
Step 2 - Press the SET key again to access the setpoint. The LCD will
display the current setpoint and the S1 annunciator will blink on and o󰀨
to indicate setpoint mode. Press either the up 5 key to increase or the
down 6 key to decrease the setpoint to the desired temperature.
Step 3 - Press the SET key again to access the di󰀨erential. The LCD
will display the current di󰀨erential and the DIF1 annunciator will blink on
and o󰀨 to indicate that the control is in the di󰀨erential mode. Press either
the up 5 key to increase or the down 6 key to decrease the di󰀨erential
to the desired setting.
Note: The TTC will automatically end programming if no keys are
depressed for a period of 30 seconds. Any settings that have been input
to the control will be accepted at that point.
All control settings are retained in non-volatile memory if power to TTC
is interrupted for any reason. Re-programming is not necessary after
power outages or disconnects unless di󰀨erent control settings are
required.
SET POINT
COOLING
MODE
HEATING
MODE
ON
ON
OFF
OFF
ON = ENERGIZED
OFF = DE-ENERGIZED
(+)
(-)
TEMPERATURE
DIFFERENTIAL
DIFFERENTIAL
Figure 1: Setpoint and
Di󰀨erential Settings.
Diagram indicates relay on and
o󰀨 points in either the heating or
cooling modes.
S1
DIF1
Step Annun-
ciator
Description Display
1 F or C Fahrenheit or
Celsius
2S1
(blinking)
Setpoint
Temperature
3 DIF1
(blinking)
Di󰀨erential
Temperature
4 C1/H1 Cooling/
Heating Mode
PT 1: OPERATION, TROUBLESHOOTING, ELECTRICAL DRAWING, VFD PROGRAMMING
TEMPERATURE
5

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6
TECHNICOLD TEMPERATURE CONTROL
Troubleshooting Error Messages
Display Messages
E1 - Appears when either the up or down key is pressed when not in the programming mode.
To correct: If the E1 message appears when no keys are being pressed, replace the control.
E2 - Appears if the control settings are not properly stored in memory.
To correct: Check all settings and correct as needed.
EP - Appears when the probe is open, shorted or sensing a temperature that is out of range.
To correct: Check to see if the sensed temperature is out of range. If not, check for probe damage by
comparing it to a known ambient temperature between -30o F and 220o F. Replace the probe if neces-
sary.
Contact your Technicold representative for a replacement probe and installation instructions.
EE - Appears if the EEPROM data has been corrupted.
To correct: Replace the control.
CL - Appears if calibration mode has been entered.
To correct: Remove power to the control for at least 5 seconds. Reapply power. If the CL message still
appears, replace the control.
Installation Instructions - Important
1. All TTC series controls are designed as operating controls only. If an operating control failure could result
in personal injury or loss of property, a separate safety control and/or alarm should be installed.
2. The schematic drawings and other information included in these installation instructions are for purpose
of illustration and general reference only.
3. These instructions do not expand, reduce, modify or alter the Technicold Terms in any way; and no
warranty or remedy in favor of the customer or any other person arises our of these instructions.
4. Technicold TTC controls have been approved by Underwriter's Laboratories as UL listed; however,
approval does not extend to their use for any other purpose. Technicold assumes no responsibility for any
application of its control unless Technicold has approved such application in writing.
5. It is the responsibility of the installer and the user to assure that his or its application and use of all
Technicold products are in compliance with federal, state and local requirements, including, without any
limitation, all requirements imposed under the National Electric Code and any applicable codes and
regulations.
Lockout Switch
The TTC is provided with a lockout switch to prevent tampering by unauthorized
personnel. When placed in the LOCK position, the keypad is disabled and no
changes can be made. When placed in the UNLOCK position, the keypad will
function normally.
To access the lockout switch, disconnect the power supply and open the control.
The switch is located on the inside cover about 2 inches from the bottom (Figure
2). To disable the keypad, slide the switch to the left LOCK position. To enable
the keypad, slide the switch to the right UNLOCK position. All TTC controls are
shipped with this switch in the LOCK position.
Figure 2: Lockout Switch

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7
TECHNICOLD TEMPERATURE CONTROL
Caution
To prevent possible electrical shock or equipment damage, disconnect electrical power to the unit before and
during installation. DO NOT restore electrical power to unit until the control is properly installed and the cover
is assembled. DO NOT locate the control in an explosive atmosphere as a safety hazard can result due to pos-
sible spark generation in the control. Controls are not to be located in areas of signicant moisture, dirt or dust or
in a corrosive explosive atmosphere. Use of control in such environments may result in injury or damage to the
persons or property (or both) and are likely to shorten the control life; Technicold assumes no responsibility for any
such use.
Control Remote Mounting
Mount the TTC to a bulkhead or other at surface using a combination of two or more of the slotted holes
located on the back of the control case. CAUTION: Do not damage circuit board when using the upper
mounting holes for installation. Remove the circuit board to access the holes. The control's components are
not position sensitive, but should be mounted so that they can be easily wired and adjusted. Do not mount in
an environment of excessive of moisture, dirt and corrosive atmosphere.
The TTC has provisions for 1/2-inch conduit connections. The conduit hub should be secured to the conduit
before securing the hub to the plastic housing of the control. When using the conduit entry in the rear of the
case, a standard plug should be inserted into the conduit hold in the bottom. Caution should be exercised not
to damage the control conduit board or wiring when installing a conduit connector.
Specications
Input Voltage 120 or 208/240 VAC (24 VAC optional) 50/60 Hz
Temperature Range -30o F to 220o F
Di󰀨erential Range 1o F to 30o F
Switch Action SPDT
Probe/Sensor Thermistor, 2 in. long x 0.25 in. diameter with 8 ft. cable

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8
CHILLED WATER TROUBLESHOOTING GUIDE
The following troubleshooting guide should be used in conjunction with the Chillers' Electrical Schematic.
On the top of the chiller evaporator plate there is a terminal strip protected by a stainless steel cover. All of
the control and safety circuits are placed in a series along this terminal strip. Should the chiller go o󰀪ine, the
device that has stopped the chiller from running can be found by troubleshooting the terminal strip.
Once you have determined the device that has stopped the chiller from running, further investigation is needed
to nd out why it has shut the chiller down. Steps should be taken to rectify the problem so that the chiller can
be brought back to normal operating status.
The following is a designation of the terminal strip connections as determined by wire colors:
Terminal Strip Position Device Wire Colors Device
1 (Flow Switch) White/Black (VFD Trigger)
2 (Freeze Stat) Brown/Red (Flow Switch)
3 (Low Pressure) Yellow/Brown (Freeze Stat)
4 (High Pressure) Black/Yellow (Low Pressure)
5 (High Pressure) Black/Orange (Thermostat)
6 (Thermostat) Orange/Black (VFD Trigger)
Place a wire with terminal ends or an alligator jumper across the following terminals. Use the following
sequence to nd which control or safety device has shut o󰀨 the chiller.
Jump TS1 to TS2 Comes on - Tripped on Flow Switch.
Jump TS2 to TS3 Comes on - Tripped on Freeze Thermostat.
Jump TS3 to TS4 Comes on - Tripped on Low Pressure Switch.
Jump TS4 to TS5 Comes on - Tripped on High Pressure Switch.
Jump TS5 to TS6 Comes on - Cycled on the Thermostat.
Jump TS6 to TS1 Comes on - Triggers the VFD by sending a signal to Terminals 1 and 11, indicating
that more than one safety device has opened.

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9
Possible Causes and Remedies for the Chiller Cycling O󰀨
Fault Cause Remedy
Tripped on Flow
Switch
Flow switch opened due to:
1. Loss of circulation water pressure.
2. Loss of circulation water ow.
3. Reed moved to the Normally Closed
(NC) position.
4. Failed Reed.
5. Loose or broken wire between reed
and terminal strip.
6. Flow switch paddle stuck due to
particulate or has been eld
adjusted.
Note: When the problem has been
cleared the ow switch will
automatically return to normal
operation. No manual resetting
is required.
• Check pressure gauge on suction side of the
pump, ll as needed.
• Check for leaks on circulation loop and x.
• Purge air from loop and equipment.
• Check circulation pump for normal operation.
• Check the pumps' rotation.
• Make sure all service/shut-o󰀨 valves are in the
fully open position.
• Loosen the two small screws holding the silver
disc on top of the ow switch body. Slide the
reed to the Normally Open (NO) position then
tighten them back down.
• Check for continuity.
• If none then the reed has failed. Fully remove
the two small screws and silver disc from the ow
switch body to replace the reed.
• The new reed wires can be butt-spliced or
soldered to the existing wires.
• Check wiring for signs of damage for loose
connections. Ohm out the wires to verify continuity.
• Isolate the loop where the ow switch is located.
Remove the reed. Place a mark where the
threads of the body enter the pipe. Relieve the
loop pressure and back out the ow switch body
taking note of the directional arrow on the body
and how many full turns it was inserted into the
pipe. Check for damage or particulate on the
paddle. Measure the distance from the back of
the pipe to the top of the threads. Measure the
length of the paddle to the mark on the threads.
Insert back into the pipe ensuring that the paddle
does not touch the back of the pipe and the
directional arrow is pointing the correct way.
Install reed.
Tripped on Freeze
Thermostat
The freeze thermostat has opened at
38o F due to:
1. Low Water Pressure.
2. Restricted water ow.
• Check pressure gauge on suction side of pump,
ll system as needed.
• Check for leaks on circulation loop and x.
• Purge air from loop and equipment.
• Check circulation pump for normal operation.
• Check the pumps' rotation.
• Make sure that all service/shut-o󰀨 valves are in
the fully open position.
CHILLED WATER TROUBLESHOOTING GUIDE

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10
CHILLED WATER TROUBLESHOOTING GUIDE
Fault Cause Remedy
Tripped on Freeze
Thermostat
(Continued)
3. Low load on circulation water
NOTE: The freeze thermostat will
reset at 48o F
4. TTC has been set too low
• Turn on Immersion or Parastic Load Bank
Heater to add load to cirulation water.
• Turn on air handlers in high load areas.
• Check setting and adjust as needed
Tripped on Low
Pressure Switch
Unit is o󰀨 on the low pressure switch:
1. Refrigerant (FREON®) loss.
2. Low load on circulation water loop.
3. Too large of a glycol to water ratio.
4. Extremely cold ambient
temperatures at chiller location
during the initial start up or after the
systems have been o󰀨 for an
extended period of time.
NOTE: The low pressure switch will trip
at 40 PSIG and automatically
reset at 80 PSIG.
• During normal operation the sight glass should
be full of liquid refrigerant. If there is an excess
of bubbles or only vapor in the sight glass then
this can be an indication of a refrigerant loss. The
chiller evaporator plate must not be frozen when
using the sight glass for a refrigerant level check.
Visually check the chiller for signs of damage on
the refrigerant circuit or oil traces.
• Pay close attention to ttings (low pressure
control, service ports, pressure switched, TXV,
etc.) for oil traces. If any tting is loose, tighten
using a back up wrench. If the refrigerant circuit
has been breached and requires brazing or
soldering. Consult a qualied refrigeration
or air-conditioning tech.
• Turn on Immersion or Parasitic Load Bank
Heaters to add additional load to the circulation
water.
• Turn on air handlers in high load areas.
• Too high of a glycol percentage will not pump
and a󰀨ects the heat transfer of the evaporator.
Drain o󰀨 some of the Glycol/Water mixture and
add additional water to dilute.
• Turn on heaters in the area where the chillers
are located. Or, allow the compressor to start and
trip two or three times. This will allow the
compressor's shell to warm up enough that the
back pressure will rise above the switch cut-out
setting.
Tripped on High
Pressure Switch
Unit is o󰀨 on the high pressure switch:
1. Raw water ow is restricted.
2. Raw water condenser is dirty.
• Check raw water strainer and thru-hull tting and
clean as needed.
• Make sure all shut-o󰀨 valves are fully open.
• Inspect pump impeller for wear.
• Back ush or chemically clean as needed.

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11
CHILLED WATER TROUBLESHOOTING GUIDE
Fault Cause Remedy
Tripped on High
Pressure Switch
(Continued)
3. Unit has been serviced and now
has an overcharge.
4. Non-condensables have been
introduced into the system.
NOTE: The high pressure switch
must be manually reset by
depressing the red button
on the switch body.
• Recover the refrigerant charge and recycle if
needed. Evacuate the system and weigh-in the
charge, or charge until the sight glass has cleared.
If the system charge is a blend, there may be
occasional bubbles in the sight glass. Charge
blends as a liquid.
• Recover and reclaim the refrigerant charge.
Evacuate the system. Using virgin refrigerant,
weigh-in the charge, or charge until the sight glass
has cleared at design conditions. If the system
charge is a blend, there may be occasional
bubbles in the sight glass. Charge blends as
a liquid.
Cycled on the
Thermostat
Cycling on the thermostat is normal.
However, if the thermostat is cycling
prematurely, check to see if the set
points have been adjusted. The
factory settings are shown in the
remedy column.
NOTE: If the thermostat is displaying
a fault code then refer to the
controls instruction sheet on
page 3 for a detailed
description and remedy.
Remove the cover of the thermostat by loosening
the four screws on each corner. On the back of
the cover there is a Lock/Unlock switch.
Turn this to Unlock (See page 3). Adjust the
temperature settings and di󰀨erential by following
the instructions on Page 5. The settings are:
Stage 1: 44
o F set point, 8o F di󰀨erential.
Stage 2: 46o F set point, 8o F di󰀨erential.
Stage 3: 48o F set point, 8o F di󰀨erential.
Stage 4: 50o F set point, 8o F di󰀨erential.
Stage 5: 52o F set point, 8o F di󰀨erential.
The switch should be moved back to Lock when
programming has been completed and before
the cover is put back on.
VFD Trigger Signal 1. No drive fault - This is normal. This
is the trigger signal to tell the
Variable Frequency Drive (VFD)
to start. If one of the above safety
devices opens, the signal to the
drive is broken and the device
stops. When the fault has cleared
the circuit is complete and the drive
is triggered to start.
2. If the thermostat is calling for
cooling and the system will only
come on when the VFD signal is
jumped then this could indicate that
two or more safety devices are open.
• Even though the trigger signal is present, the
drive may still be locked out on a fault code.
Fault codes for the drive will be displayed on
the drives' LED and a list of these codes and
remedies can be found in the drives' manual.
Once the faults have been cleared the lock-out
can be reset by pressing the Stop button on
the front of the drive.
• To nd out which of the multiple devices are
open, remove one of the wires from the
terminal strip for each device.
• Connect an ohm meter between the open wire
and the one attached to the terminal strip for
that device and check for continuity.
• No continuity indicates an open device.
• Continue this process for all of the devices.

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12

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13

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14
SMVector VARIABLE FREQUENCY DRIVE (VFD)
VFD Compressor Re-Programming Instructions
(Congured for Optional TB-16 & TB-17 Normally Open Relay Operations)
Most drives provided by Technicold leave the factory pre-programmed for their intended application. In the
event that the customer receives a drive that has not been programmed the following steps will guide you
through the process. Sometimes electrical disturbances or faulty programming may require resetting of the
device back to default settings. The following instructions include that procedure as well.
When programming your drive the power must be applied without the start signal. At this time do not
apply power to the drive. To disable the start signal, turn o󰀨 the control circuit breaker feeding the ETC digital
thermostat. This will turn o󰀨 the thermostat and de-energize the trigger signal from its relay.
*Note - Some applications use a single circuit breaker to feed the digital controls of multiple chillers. In these
applications, turn o󰀨 the breaker to disable all controls. Then remove the control wire from either terminal 1 or
11 on the terminal strip located inside the front access cover of the drive. Cover the loose wire with electrical
tape and turn the control breaker back on to power up all digital controls. The other chillers will now be back in
service. Turn on the power supply circuit breaker for the drive. The drive is now ready for programming.
Upon completion of programming the power supply circuit breaker should be turned o󰀨. The control circuit
breaker should also be turned o󰀨 and the wire connected back onto terminal 1 or 11. Place the terminal cover
back on drive. Turn the power circuit breaker back on, then the control circuit breaker. When the control ther-
mostat calls for cooling the drive ramps up to run the compressor.
NOTE: It is important that the VFD power supply breaker is turned on before the control breaker. Failure to
comply will cause the drive to short cycle and trip the fault alarm.
NOTE: Once the power supply circuit breaker for the drive has been turned o󰀨, make sure that at least three
minutes has elapsed before applying power back on the drive. This will prevent damage to the DC Bus
capacitors inside the drive.
1256 25 411 13A 13B 13C 14 30 2 TXA TXB 16 17
Trigger
Signal
Trigger
Signal
Form C
2 amp
N.O. Relay
Control terminal strip found inside the cover of the drive.
These terminals used on
15HP or larger drives

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15
SMVector VARIABLE FREQUENCY DRIVE (VFD)
VFD Compressor Re-Programming Instructions - Continued
(Congured for Optional TB-16 & TB-17 Normally Open Relay Operations)
The programmable parameters for the Compressor VFD are as follows:
Default New
Parameter Name Value Setting Selection
P199 = Program Selection (60 Hz) 0 3 Reset to 60Hz default settings
Program Selection (50 Hz) 0 4Reset to 50Hz default settings
P194 = Password Protection (60 Hz) 0 225 Enable password protection
Password Protection (50 Hz) 0 225 Enable password protection
P100 = Start Control Source (60 Hz) 0 1Terminal Strip
Start Control Source (50 Hz) 0 1Terminal Strip
P101 = Standard Ref Source (60 Hz) 0 3Preset #1
Standard Ref Source (50 Hz) 0 3Preset #1
P102 = Minimum Frequency (60 Hz) 0 60 Match Compressor Hz
Minimum Frequency (50 Hz) 0 50 Match Compressor Hz
P104 = Acceleration Time #1 (60 Hz) 20 5.0 Ramp Time from 0 Hz to 60 Hz
Acceleration Time #1 (50 Hz) 20 5.0 Ramp Time from 0 Hz to 50 Hz
P107 = Line Volts Selection (60 Hz) 1 1 Leave at 1 for 60 Hz
Line Volts Selection (50 Hz) 1 0 Set to 0 for 50 Hz
P110 = Start Method (60 Hz) 0 5Flying Start/Restart #1
Start Method (50 Hz) 0 5Flying Start/Restart #1
P131 = Preset Speed #1 (60 Hz) 0 60 Match Compressor Hz
Preset Speed #1 (50 Hz) 0 50 Match Compressor Hz
P140 = Relay Output (60 Hz) 0 0None
0 1 Run
0 3 Fault
0 4 Inverse Fault
0 5 Fault Lockout
Relay Output (50 Hz) 0 0None
0 1Run
0 3Fault
0 4Inverse Fault
0 5Fault Lockout
P140 Parameter Options
Setting Selection Function of T16 & T17 Normally Open Relay
0 None Disables the relay output
1 Run Relay closes when the drive is running
3 Fault Relay opens when the drive trips, or when power is removed
4 Inverse Fault Relay closes when the drive trips
5 Fault Lockout Relay opens when the drive locks-out after restart attempts
Use selection #1 (RUN) for the trigger signal on a pump relay. It can also be used to power an LED, lamp or
relay to indicate that the compressor is running.
Use selection #3, 4 or 5 (FAULTS) to power an LED, lamp or relay to indicate that there is a fault condition or
that the drive has locked-out. It can also be used to show that the circuit breaker has tripped or is turned o󰀨.

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16
SMVector VARIABLE FREQUENCY DRIVE (VFD)
1. Press Mode and the word PASS will be
displayed for one second then 0000.
2. Use 5to scroll up to 225 (Security Code).
3. Press Mode and P100 will be displayed.
4. Use 5to scroll to P199.
5. Press Mode and 00 will be displayed.
6. Use5to change it to 03 or 04 depending
on the application.
7. Press Mode twice to return to P199.
8. Use 6to scroll to P194.
9. Press Mode and 0000 will be displayed.
10. Use 5to change to 225.
11. Press Mode twice to return to P194.
12. Use 6to scroll to P100.
13. Press Mode and 00 will be displayed.
14. Use 5to change to 01.
15. Press Mode twice to return to P100.
16. Use 5to scroll to P101.
17. Press Mode and 00 will be displayed.
18. Use 5to change to 03.
19. Press Mode twice to return to P101.
20. Use 5to scroll to P102.
21. Press Mode and 0.0 will be displayed.
22. Use 5to change to 60.0/50.0 (depending on
compressor Hz),
VFD Compressor Re-Programming Instructions - Continued
(Congured for Optional TB-16 & TB-17 Normally Open Relay Operations)
There are six buttons on the front of the drive 5(Up), 6(Down), (Mode), (Rotation),
(Stop), & | (Run).
Use only the Up 5, Down 6, and Mode buttons to program the drive.
If you scroll past a setting use the 5or6to go back to the desired setting.
Once power is applied to the VFD the two-part Software Code is displayed for two seconds followed by the
word STOP.
U
23. Press Mode twice to return to P102.
24. Use 5to scroll to P104.
25. Press Mode and 20.0 will be displayed.
26. Use 6to change to 5.0.
27. Press Mode Twice to return to P104.
28. Use 5to scroll to P107 .
29. Press Mode and 01 will be displayed (for
60 Hz applications).
30. Use 6to change to 00 if unit is a
50 Hz application).
31. Press Mode twice to return to P107.
32. Use 5to scroll to P110.
33. Press Mode and 00 will be displayed.
34. Use 5to change to 05.
35. Press Mode twice to return to P110.
36. Use 5to scroll to P131.
37. Press Mode and 0.0 will be displayed.
38. Use 5to change to 50.0/60.0 (depending
on compressor Hz).
39. Press Mode twice to return to P131.
40. Use 5to scroll to P140.
41. Press Mode and 00 will be displayed.
42. Use 5to change to 01, 03, 04, 05 or
leave at 00.
43. Press Mode once to return to STOP.
After re-programming your VFD, apply the start signal. This can be done by turning on the
control circuit breaker feeding the ETC, or re-connecting the control wire removed from either terminal 1 or 11
on the small terminal strip located inside the front access cover of the drive.

OTCW 4/11
17
SMVector VARIABLE FREQUENCY DRIVE (VFD)
Troubleshooting Guides
The SMV variable frequency drive provides for surge less starting of the Chiller Compressor and inherent
circuit/fault protection. See the VFD manual for a complete description of the drives operation and
functionality, including programmable parameters. There are 18 Status/Warning, 2 Conguration and 25 Fault
Messages. Sections 5.1, 5.2 and 5.3 provide a complete listing of these messages, their cause and remedy.
A summary of the most common fault trips, their implications and remedies are listed below. Programmable
Parameter, P500 - Fault History will log the last 8 fault trips.
Code on
LED Display
Reason Solution
E r r When entering the program mode an
incorrect password has been entered,
or an invalid command was attempted.
• The default password is "225."
• Refer to the programming section or the VFD
manual for programming instructions.
S P When the drive is in fault condition this
code (Start Pending) will ash between
the restarts
• Fix fault condition.
L C After ve automatic restarts the drive
will lockout (Lockout Condition) if the
problem still exists.
• Manually reset the drive once the fault condition
has been xed.
• Reset it by pressing the STOP button. If that does
not unlock the fault condition turn o󰀨 the power
supply. Wait 3 minutes and then apply power back
to the drive.
F _ A F High Temperature Fault • Check that the drives' cooling fan is running.
• Check the cabinet cooling fan for operation and
direction of ow.
• If a lter is installed make sure it is clean.
• If ambient conditions are too high relocate the
drive to a cooler location.
F _ F1 The EPM chip to the left of the LED
display is missing or damaged.
• If the EPM is missing replace with a new one
and program per the instruction sheet. If EPM is in
place then gently push down on it to ensure a rm
seating.
• Replace the EPM if it is in place and will not hold
the programming.
F _ H F High DC Bus Voltage. • Line voltage is too high - check power supply to
the drive.
F _ L F Low DC Bus Voltage. • Line voltage is too low - check power supply to
the drive.
F _ U F Start Command Fault. Power turned on to drive with the start signal
applied. Turn o󰀨 the control circuit breaker for the
chiller before applying power to the drive. Then turn
the control circuit breaker back on.
NOTE 1: Wait two minutes after power is applied
to the drive before turning on the control circuit
breaker.
NOTE 2: When power is removed from the drive
wait three minutes for the DC Bus Capacitors to
discharge before applying power back to the drive.

OTCW 4/11
18
WARNINGS
! Over the course of time, any product under pressure may corrode, weaken and burst or explode, causing
serious or fatal personal injury, leaking or ooding and/or property damage. To minimize this risk, a licensed
professional or experienced technician must install, periodically inspect and service the product.
General Information
In cooler operating climates it may be necessary to add glycol to the circulation water circuit. The following
is a general guideline for the mixing the glycol/water solution. It is recommended that you consult with the
manufacturer of the glycol solution for their mix rates to achieve the desired temperature.
Propylene Glycol (monopropylene glycol) also uses the acronym PG or MPG.
Ethylene Glycol (monoethylene glycol) also uses the acronym MEG.
The industry norm is to use Propylene Glycol rather than Ethylene Glycol as it is lower in toxicity. It is
colorless, nearly odorless, clear, viscous liquid hygroscopic and miscible with water. Some manufacturers
add non-toxic inhibitors, performance additives and tracer dyes. Select a type that best ts your application.
The freezing points of both glycols are depressed when mixed with water due to the disruption of hydrogen
bonding.
The percentage of glycol by weight will di󰀨er for each type of glycol to obtain the same freeze point. Virgin
glycol can be purchased at di󰀨erent concentrations (35%, 40%, 70%, 76%, 96% are common percentages)
which will also vary the mix rates. Again, consult with the manufacturer to obtain the desired temperature.
Mixing to a 20°F temperature is su󰀩cient for most systems.
Freezing Points of Propylene Glycol – Water Mixtures
@ ARI 590 Standard Conditions
Percent Propylene Glycol (wt. %) Freezing Point (°F) Freezing Point (°C)
0 32 0
10 26 -3
20 20 -7
30 10 -12
36 0 -18
40 -5 -20
43 -10 -23
48 -20 -29
PART 2: SERVICING - ADDING GLYCOL, FRESH WATER FILL ASSEMBLY, IMMERSION
HEAT CONVERSION
ADDING GLYCOL TO A CHILLED WATER SYSTEM