Redi Controls Redi-Purge PRG-113-C3 Instruction manual

Redi-Purge™
Model PRG-113-C3 & C4
MicroprocessorControlled
UltraHigh Efficiency
PurgeUnit
for
LowPressureChillers
Manufacturedinaccordancewith
ASHRAE Guidelines3-1990 Sec. 4.7and
Standard15-1992 Sec. 8.3, 8.7and 10.4
REDI CONTROLS, INC.
Installation, Operation &Maintenance Manual
LiteratureFile No. 1117-02
ETL Listed
3104248

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RevisedTechnicallyas of October11, 2013
© 1994 REDICONTROLS, INC., GREENWOOD, INDIANA

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GENERALINFORMATION
YOUAREURGED TOREAD THIS MANUALCOMPLETELY BEFORE
INSTALLINGAND/OR OPERATINGTHIS UNIT
Upon Receiving Your Unit
Inspect the unit forpossible damage caused during shipping. ContactEquipmentServicing
before attemptingto use a damagedunit.
Warningsand Cautions
NOTE: Warnings and Cautions appearin highlighted boxes as illustrated below at
appropriate points throughout this manual. Give special attention to these items.
Warnings:Providedto alertyouto potential hazards thatcouldresultinserious
personal injuryanddamage to your equipment. Warnings mayappearinthis manual or
onthe equipment. Heedall Warnings.
Cautions:Designedto alertyouto situations thatmayresultindamage to your
equipment.
Personalsafety and the properoperation of yourequipment require strict observance of these
precautions.
EQUIPMENTSHOULDBE INSTALLEDAND OPERATEDONLYBY
QUALIFIEDPERSONNEL
Warning: Certain servicingprocedures mayexpose youto harmful materials and
dangerous conditions. Tominimize the possibilityof injury, follow safetyprocedures
andinstructions describedinthis manual, onproductlabels andinmaterial safetydata
sheets provided.
NOTE: The manufacturerhas a continuous equipment improvement policy and reserves the
right to change specifications and design of its products without notice.

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Tabl eofC ontents
GENERALINFORMATION........................................................................................................3
UponReceivingYourUnit..........................................................................................................................................3
WarningsandCautions...............................................................................................................................................3
INSTALLATION .........................................................................................................................9
Before YouStart............................................................................................................................................................ 9
PurgeSpecifications..................................................................................................................................................10
Contentsof thePurgeInstallationKit ....................................................................................................................... 10
Field-ProvidedItems................................................................................................................................................. 10
Preliminary"Kit"Inspection.....................................................................................................................................10
RemovingOldPurge Unit ...........................................................................................................................................11
Preparation ...............................................................................................................................................................11
Removal Procedure...................................................................................................................................................11
Installingthe Unit........................................................................................................................................................ 12
Location....................................................................................................................................................................12
Mounting..................................................................................................................................................................12
Figure 1 - Connectionsizesandlocations.................................................................................................................12
Refrigerant LineConnections ...................................................................................................................................13
AuxiliaryCondenserandHeat RecoveryUnits.......................................................................................................... 13
PurgeVaporInlet Line .............................................................................................................................................13
LiquidRefrigerant Return Line.................................................................................................................................14
Refrigerant LineInstallationProcedure.....................................................................................................................14
Pumpout CompressorDischargeVent Line...............................................................................................................15
Electrical Connections..............................................................................................................................................15
Chiller“RunSignal” Wiring.....................................................................................................................................15
PreliminaryCheckout andPower-Up ........................................................................................................................15
SYSTEMCOMPONENTS........................................................................................................17
Figure 2. - MajorComponents .................................................................................................................................17
Figure 3. - Electrical Control Box Exterior..............................................................................................................17
Figure 4. - Electrical Control Box Interior..............................................................................................................17
Figure 5. - Flow Schematic andcomponent location................................................................................................18
OPERATIONALOVERVIEW....................................................................................................19
Air-CooledCondensingUnit.....................................................................................................................................19
Operatingcycle......................................................................................................................................................... 19
Figure 6. - Refrigerant Circuit Schematic ................................................................................................................ 19
PurgeTank...............................................................................................................................................................20
PurgeandRefrigerant DrainBackFunction..............................................................................................................20
Pumpout System .......................................................................................................................................................20
Security-Lock............................................................................................................................................................20
Optional Accessories.................................................................................................................................................... 21
1. EmissionCollectionCanistersaturationalarm (option).........................................................................................21

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2. ChillermountedcondensertemperaturesensorTS3(option)................................................................................ 21
3. ChillerevaporatorpressurePre-Alarm PS1(option)............................................................................................. 21
SystemComponents .................................................................................................................................................... 21
PurgeControl Panel ................................................................................................................................................. 21
MicroprocessorCircuit Board................................................................................................................................... 22
Compressorunit (C1)............................................................................................................................................... 22
Pumpout Compressor(C2)........................................................................................................................................ 22
TemperatureSensor(TS1)........................................................................................................................................ 22
TemperatureSensor(TS2)........................................................................................................................................ 22
Pumpout SolenoidValves(L4&L5)........................................................................................................................ 22
Drainsolenoid(L3).................................................................................................................................................. 22
LiquidLevel Switch(LS1) - (see Figure5onpage18 forlocation)........................................................................... 22
Remote“PurgeFault” Alarm Relay(RY7)................................................................................................................ 23
AuxiliaryRelay(RY8).............................................................................................................................................. 23
Terminal Block(TB1).............................................................................................................................................. 23
Control Transformer(T1)......................................................................................................................................... 23
Constant pressureexpansionvalve............................................................................................................................ 23
6QUICK START 6- OPERATION..........................................................................................24
Quick StartIntroduction ............................................................................................................................................ 24
1. Press “SET CLOCK” KeypadSwitch .............................................................................................................. 24
2. Select DesiredOperatingMode ....................................................................................................................... 25
Security-Lock.............................................................................................................................................................. 25
SettingOperational Parameters................................................................................................................................. 26
PurgeFault setting.................................................................................................................................................... 26
Fault BYPASS setting.............................................................................................................................................. 26
DrainCyclesetting(setsLS1liquidlevel switchmake/breakhysterisis)................................................................... 27
DipSwitchS1Settings ................................................................................................................................................ 28
DipswitchS1SecurityLock..................................................................................................................................... 28
DipswitchS1CanisterAlarm.................................................................................................................................. 28
DipswitchS1CanisterAlarm (PurgeLock-Out Option) .......................................................................................... 28
DipswitchS1EvaporatorPressurePre-Alarm.......................................................................................................... 28
DipswitchS1CondensingTemperatureOption ....................................................................................................... 28
Microprocessor Overview........................................................................................................................................... 28
Introduction.............................................................................................................................................................. 28
SafetyFeatures ......................................................................................................................................................... 29
Maximum AllowablePumpout TimeExceeded(PURGE FAULT)....................................................................... 29
DrainOperation(DRAINFAULT) ...................................................................................................................... 29
SensorOperation(SENSORERROR).................................................................................................................. 29
OperatingModes(“Manual” - “Auto”&“Adaptive”) ............................................................................................. 29
Figure 7. - Purge Control Panel.............................................................................................................................. 30
LCD Display................................................................................................................................................................ 30
KeypadSwitches......................................................................................................................................................... 30
“SET CLOCK” KeypadSwitch ................................................................................................................................ 31
“STOP” Keypadswitch ............................................................................................................................................ 31
“MANUAL” Keypadswitch(foradditional informationsee “OperatingModes” page29)........................................ 31
“AUTO” KeypadSwitch........................................................................................................................................... 32
“ADAPTIVE” KeypadSwitch(foradditional informationsee “OperatingModes” page29)..................................... 32
“SENSORS” KeypadSwitch..................................................................................................................................... 33
“SETTINGS” KeypadSwitch ................................................................................................................................... 33

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“BYPASS” KeypadSwitch .......................................................................................................................................33
ExitingFault “BYPASS” Mode............................................................................................................................34
“DIAG.” KeypadSwitch...........................................................................................................................................34
“LOGs” KeypadSwitch ............................................................................................................................................36
Log1 - 30 day"slidingwindow"averagepurgepumpout time(chillerOFF)........................................................36
Log2 - 30 day"slidingwindow"averagepurgepumpout time(chilleron)...........................................................36
Log3 - Pumpout timethat hasoccurredduringlast 24 hour“slidingwindow” period ..........................................37
Log4 - Pumpout timeduringthe1st three(3) hoursfollowinglast chillershutdown.............................................37
Log5 - AveragedailychillerRUNtimeforlast 30-dayperiod .............................................................................37
Log6 - Total accumulatedpurgecondensingunit “RUN” timesince installed......................................................37
Log7 - Total accumulatedpurge“pumpout” timesince installed..........................................................................38
Log8 - Averagedailypumpout timeforlast 30 dayperiod...................................................................................38
Log9 - Numberof AdaptiveorAutoruncycles“ChillerON” (maximum 8cycles perday)..................................38
Log10 - Numberof Adaptiveonlyruncycles“ChillerOFF” (maximum 8cyclesperday) ...................................38
Log11 - Interval Log - Total chillerruntimesince loglast reset..........................................................................39
“CLEARLOGs” KeypadSwitch...............................................................................................................................39
“RESET” KeypadSwitch..........................................................................................................................................40
“STATUS” KeypadSwitch .......................................................................................................................................40
“<“or“>“ CURSORMOVEMENT KeypadSwitches..................................................................................................40
Informational Displays................................................................................................................................................40
STATUSDisplay...................................................................................................................................................... 40
LOGs Display........................................................................................................................................................... 41
Log1 - Purge30-dayaveragepumpout timewhilechillerisoff (Hrs&Min.)......................................................41
Log2 - Purge 30-dayaveragepumpout timewhilechillerison(Hrs&Min.).......................................................41
Log3 - PurgePumpout forLast 24 Hours(Hrs&Min.) .......................................................................................41
Log4 - Pumpout timefirst 3hoursafterlast chillershutdown(Hrs&Min.).........................................................42
Log5 - Last 30-DayChillerRunTime(dailyaverage)(inhours).........................................................................42
Log6 - Total PurgeCondensingUnit RunTime(inhours) ..................................................................................42
Log7 - Total CumulativePumpout Time(in hoursandminutes)..........................................................................42
Log8 - 30-DayAveragePumpout Timeperday(Hrs&Min.)..............................................................................42
Log9 - Numberof AdaptiveorAutoruncycles“ChillerON” (maximum 8cyclesperday)..................................42
Log10 - Numberof Adaptiveonlyruncycles“ChillerOFF” (maximum 8cyclesperday) ...................................43
Log11 - Interval log(indays, hoursandminutes)................................................................................................43
“SENSORS” Display................................................................................................................................................ 43
(Superheat)RefrigerationCompressorSuctionTemperature.................................................................................43
(Evaporator)PurgeTankEvaporatingTemperature..............................................................................................43
(LiquidLevel Status)DrainStatus........................................................................................................................43
“MISCELLANEOUS” - Informational Displays........................................................................................................44
Pump-out Display................................................................................................................................................. 44
DRAINBACKEQUALIZATION CYCLE...........................................................................................................44
SensorErrorDisplays...........................................................................................................................................45
Fault Indications ..................................................................................................................................................46
PURGE FAULT...............................................................................................................................................46
DRAINFAULT...............................................................................................................................................46
BATTERYFAULT .........................................................................................................................................46
MAINTENANCE .......................................................................................................................47
Periodic Maintenance.................................................................................................................................................. 47
Weekly ..................................................................................................................................................................... 47
Semi-Annually.......................................................................................................................................................... 47
MoistureMonitoring.................................................................................................................................................47
Table 1 - DeterminingRefrigerant Moisture Content................................................................................................48
Filter-Drier Replacement............................................................................................................................................49
Optional liquidreturn linefilter-drier: (ifused) ........................................................................................................49

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Purge Tank Service..................................................................................................................................................... 49
WaterRemoval......................................................................................................................................................... 49
PurgeTankat a PositivePressure......................................................................................................................... 49
PurgeTankat a NegativePressure....................................................................................................................... 50
Figure 8. - Electrical Schematic (for York Chillerssee Figure 8A)........................................................................ 51
Figure 8A. – WiringFor YORK “Optiview”and “MicroPanel”controls............................................................... 52
Trouble Shooting......................................................................................................................................................... 53
TroubleshootingChart.............................................................................................................................................. 53
TroubleshootingChart (continued)........................................................................................................................... 54
Purge RefrigerationSystemDiagnostic Procedure.................................................................................................... 55
EvaporatorPressureCPEV....................................................................................................................................... 55
TemperatureSensorTS1 .......................................................................................................................................... 55
TemperatureSensorTS2 .......................................................................................................................................... 56
Optional TemperatureSensorTS3............................................................................................................................ 56
CheckingforCalibration .......................................................................................................................................... 57
Table 2. - SensorTemperature -vs- Resistance........................................................................................................ 57
SERVICETIPS.........................................................................................................................58
Purgingafter Internal Chiller Repairsor Servicing.................................................................................................. 58
BypassingPumpout FlowRestrictor........................................................................................................................... 59
Moisture monitor......................................................................................................................................................... 59
Air-Leak Rate ............................................................................................................................................................. 59
Locatingaleak............................................................................................................................................................ 60
Usingthe "Interval Log"............................................................................................................................................ 60
Data Logging (see Graph/LogChartsforcopyingonpages62-66).............................................................................. 61
3Graph &Log - Purge PumpoutTime Last24 Hours............................................................................................ 62
3Graph &Log - 30-Day Average Purge PumpoutTime Per Day........................................................................... 63
3Graph &Log - 30-Day Average Purge PumpoutTime - Chiller running ............................................................ 64
3Graph &Log - 30-Day Average Purge PumpoutTime- Chiller Off..................................................................... 65
3Graph &Log - First3HoursPurge PumpoutTime after Chiller Shutdown....................................................... 66
EquipmentWarranty.................................................................................................................................................. 68

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INSTALLATION
BeforeYou Start
Caution: Federal RefrigerantRecyclingRegulations require thatthe chiller, during
servicing, be eithercompletelyevacuated orpressurizedto atmospheric pressure (0
psig) priorto openingthe refrigerantcircuitto the atmosphere. Failure to comply, or
usingmeans otherthanheatto elevate refrigerantpressure, violates Section608 of the
CleanAiract.
The purge systemis designed to automatically remove non-condensables fromlowpressure
centrifugalchillers using CFC orHCFC refrigerants. The Purge, togetherwith the emission
collection canister, is designed to assure the highest efficiency in preventing refrigerant from
escaping to the atmosphere.
This section discusses the properprocedures forreplacing the purge unit on an R-113 low
pressure centrifugalchiller. This purge unit is designed forapplication on watercooled
centrifugalchillers, eitherpneumatically orelectrically controlled.
NOTE: The Purge Unit is not designed forapplication on aircooled chillers.
Warning: Installingorservicingrefrigerantsupportequipmentcanbe hazardous due
to systempressures anddangerous voltages. Onlyqualifiedservice personnel should
work onsuchequipment.

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PurgeSpecifications
Electrical PowerRequirements: 103-127 VAC, 50/60 Hz., 1-Phase, 15 Amp Fused Circuit
Remote Alarm Relay(RY7)ContactRating: (FormC) 120 VAC; 15 Amp
OperatingEnvironment: 40°Fto 120°F, 5%to 95%relative humidity
Storage Environment: -20°Fto 120°F
Dimensions (approximate): 19"height x25"length x14"depth
RefrigerantCharge: 0.5 lbs R-134a orR404a (check CDU)
Weight(approximate): 110 pounds
Shippingweight(approximate): 120 pounds
NOTE: The purge unit comes equipped with a RS232C communication interface.
Contents ofthePurgeInstallation Kit
Each"kit" includes: One Purge Unit;
One Installation, Operation and Maintenance Manual;
One 1/2-inch ball valve;
Field-ProvidedItems
Tobe furnishedby Purge Unit mounting hardware;
the installer: Electricalconduit and wiring materials;
1/4-inch copperrefrigerant tubing;
1/2-inch copperrefrigerant tubing;
3/8-inch copperrefrigerant tubing;
Fittings.
Preliminary"Kit" Inspection
Before installing the Purge Unit check the data on the purge unit nameplate and verify that the
modelnumberand voltage are correct forthe application.
It is recommended that the sealed refrigeration section of the newpurge unit be verified for
properoperation priorto actualinstallation. The unit can be easily bench-tested utilizing a
temporary 110 VAC powerconnection.