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

RevisedTechnicallyas of October11, 2013

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.

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

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

“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

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

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.

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.

Removing Old PurgeUnit

Replacing the existing purge systemon oldercentrifugalchillers with the newPurge Unit

requires that the existing purge systembe completely disconnected and removed. Before

proceeding with the retrofit it is important that the installerthoroughly reviewand understand

the following instructions forpreparing the chillerto remove the old purge system.

Preparation

WARNING: Be sure to openandlock-outall electrical disconnects to prevent

possible injuryordeathcause byelectrical shock.

1. Terminate chilleroperation and disconnect all electricalpowerto the chillerand old

purge unit.

2. Turn off watersupply to purge system, where applicable.

3. Close the angle valve on the condenserto isolate inlet to purge system.

4. Close the liquid return angle valve on the evaporatorto isolate outlet of purge system.

NOTE: It is not necessary to remove chiller’s refrigerant charge to retrofit a new purge unit.

Removal Procedure

Disconnect and remove all existing purge unit electricalconnections fromboth the old purge

unit and chillercontrolpanel. Disconnect the waterlines to the old purge tank, if applicable,

and cap off orremove. These waterlines are no longerneeded since the newpurge system

does not require the use of water.

Disconnect the copperline fromthe purge solenoid valve (if present)on the condenser.

Temporarily cap off the flare fitting on solenoid valve. If there is no solenoid valve on the

condenser, remove copperline and cap off condenserfitting as quickly as possible to

minimize airleakage into chiller. This fitting will be used lateron. Also disconnect the copper

line fromthe purge compressorinlet, remove and discard tubing.

Disconnect the 1/4-inch copperliquid return line fromthe liquid return valve on the evaporator

and fromthe purge tank, remove and discard tubing. Also, if the purge tank relief is piped to

the rupture disc vent, disconnect and remove pipe. Unbolt old purge base fromits mounting

and remove.

WARNING Toavoidpossible injuryordamage to equipment, be sure to have

appropriate equipmentavailable to lowerthe purge unitfromthe chiller(ifnecessary).

Installing theUnit

Installation of the newpurge unit requires severalwiring and hardware modifications. To

insure properinstallation, it is important that the installerthoroughly read and understand the

following instructions.

NOTE: The installershould record all changes and modifications made to the chillerduring

installation and provide a copy forinclusion with the maintenance records of the

chiller.

Location

The purge unit is not location sensitive. The only limitation is that it must be higherthan the

liquid refrigerant levelin the chillerevaporator. The unit may be located at any convenient

location on ornearthe chiller. If you are replacing an old unit, it can be located in the same

place as the existing system.

Mounting

In a fewcases, some fabrication may be necessary to mount the newpurge. Since the purge

comes mounted on its own integralbase, field fabrication should be minimal.

WARNING: The purge weighs approximately110 lbs. Toavoidpossible injuryor

damage to equipment, be sure to have appropriate equipmentavailable to raise the unit

into place.

Figure 1 - Connection sizes and locations

1/2"PurgeLine

1/4"LiquidReturnLine

Temperature

Sensor

TS2

Moisture Indicator

Sensor TS1

Chiller

Evaporator

Condensor

Non-condensibles/Vapor

LS1

Filter-drier

Water

Drain

Sight

Glass

Purge

Tank

3/8"

VentLine

Atmosphere

RefrigerantLineConnections

The purge requires three separate refrigerant line connections (see Figure 1 on page 12):

1. A1/2"purge inlet line between the purge tank and the condenserpurge outlet. The

same condenseroutlet the old purge used.

2. A1/4"liquid return line fromthe purge tank drain solenoid valve to the liquid return angle

valve on the evaporator. (Can be same valve used by old purge unit drain back line

provided it enters Evaporatorabove liquid refrigerant level - see NOTE on next page).

3. A3/8"vent line fromthe discharge port on the pumpout compressorto the emission

collection canister, orthe rupture disc vent line ordirect to the outdooratmosphere.

AuxiliaryCondenserand Heat RecoveryUnits

When the purge is applied to a heat recovery unit ora unit with an auxiliary condenser, some

additionalpiping considerations are required:

1. The purge unit vaporinlet line must be connected toboththe cooling and auxiliaryheat recovery

condensers. The entirelengthofbothlinesmust slope towardeitherthe purge unit or

condensers. Avoidsagging ofthetubing wherepocketsofliquidrefrigerantcancondense

and accumulate.

2. Shutoff valves(½ inchball valves)must be provided at bothcondenserssothe non-operating

condensercan be isolated.

PurgeVapor Inlet Line

The purge vaporinlet line runs between the originalpurge pickup point on the condensershell

(this point is typically beneath an internalbaffle plate inside the condenser), and the purge

inlet connection on the purge tank. This line must be 1/2-inch refrigeration-grade copper

tubing.

The existing shutoff valve, orsolenoid valve must be removed and discarded, and the 1/2-inch

line adapted to connect direct to the condenserpurge pickup fitting. Chillermanufacturers

have generally utilized three different size purge connections, 1/2-inch NPT, 3/8-inch NPT,

and 1/4-inch NPT. In any case, the 1/2-inch line can be easily adapted to connect to any of

the three connections.

LiquidRefrigerantReturn Line

The liquid refrigerant return line runs between the evaporator's originalliquid return angle

valve and drain back solenoid valve L3 (see Figure 1 on page 12)orthe outlet of the optional

liquid line filter-drier, if used. Use 1/4"refrigerant-grade coppertubing.

NOTE: The Liquid Refrigerant Return Line MUST connect

to the chillerevaporator ABOVE the Liquid Level. THE

PURGEUNITWILL NOTDRAIN PROPERLY if the line is

connected to a point below the liquid refrigerant level (see

illustration to the right).

RefrigerantLineInstallation Procedure

It is recommended that the following procedures be followed when making the purge

refrigerant line connections.

Caution: Federal RefrigerantRecyclingRegulations require thatthe chiller, during

servicing, be eithercompletelyevacuatedorpressurizedto atmospheric pressure (0

psig) priorto openingthe refrigerantcircuitto the atmosphere. Failure to comply, or

usingmeans otherthanheatto elevate refrigerantpressure, violates Section608 of the

CleanAiract.

1. First, install the 1/4-inchliquidrefrigerant returnline. DoNot open the liquidreturnvalveon the

evaporatorat thistime.

NOTE: Avoid sagging of the tubing to insure free gravity flow of liquid refrigerant back to the

chiller.

2. Ifused, install the optionalliquidline filter-drier and the moistureindicating sight glass asshown

inFigure5on page 18. The sight glass shouldbe installed sothe viewing area istilted slightly

downwardjust enough toassureliquidcontact withthe moisturesensing element. Ifnot used,

connect returnline direct todrainback solenoidvalveL3.

3. Install the 1/2-inchpurge line (see Figure5on page 18)fromthe purge unit tothe condenser

purge fitting. Start bymaking the connection at the purge first. Next, determine what fitting will

be used tomakethe connection at the condenser. Cap off the flareend offitting withaflare

cap.

4. Removethe existing purge solenoidvalveoranglevalvefromthe condenserpurge fitting and as

quicklyaspossiblescrewinthe newfitting withcap.

5. Finally, cut the 1/2-inchpurge line tothe properlength. Install the 1/2-inchODball valveinthe

1/2-inchline asclosetothe condenserconnection aspossible. Cut and flareashort section of

1/2-inchtube (approx. 4to6incheslong). Slipon the flarenut and sweat tube toinlet end ofthe

ball valve. Nowagain, asquicklyaspossibleremovethe flarecap fromthe purge outlet fitting

and connect the 1/2-inchline withball valve.

6. Open purge isolation valvesat thistime.

Liquid Level

Chiller

Purger

Purge Line

Liquid ReturnLine

Evaporator

Condensor

NOTE: The entire length of the vaporline, including the in-line filter-drierset, must slope

toward eitherthe purge inlet orthe chillercondenser. Avoid sagging of the tubing

where pockets of liquid refrigerant can condense and accumulate.

PumpoutCompressor DischargeVent Line

When venting the pumpout compressorto the emission collection canister, orto the outdoor

atmosphere, orthe chillerrupture disc vent line, it is important to use 3/8-inch line size to

minimize pressure drop. Forproperoperation the pumpout compressordischarge must be at

atmospheric.

Electrical Connections

WARNING: Be sure to openandlock-outall electrical disconnects to prevent

possible injuryordeathcausedbyelectrical shock.

The unit requires three powerconnections to the chiller's controlcircuit. The electrical

requirement is:

103-127 VAC, 50/60 Hz., 1-Phase 15 AmpFusedCircuit

NOTE: Use Class 1, 14 AWG copperwire and metal conduit. All field installed wiring must

comply with all applicable NEC and local electrical codes.

Chiller“Run Signal” Wiring

1. Forthe typical purge unitinstallation referto ElectricalSchematic (Figure8) for

appropriate chiller “Run Signal” wiring.

2. However,ifthe purge unitisbeing installed on a YORK chillerwith eithera “Micro-Panel”

or “Optiview” panel you MUST wirethechiller“Run Signal” to the purge unit according

to ElectricalSchematic (Figure 8A).

3. This"Run"signal can be obtained by tapping into the chiller'shourmeterpowersource, or

any othersource that can provide a115 VACsignalwheneverthe chillerisrunning. This

signaltriggers the Circuit Board run input opto-isolatorwhich enables purge operation.

WARNING:Failure to properlywire the chiller“Run Signal” onYORK chillers with

“Optiview” and“Micro-Panel” controllers couldresultinserious damage to the chiller.

PreliminaryCheckoutand Power-Up

1. Connect the 115 VAC main “hot line”fromthe fused purge output in the chillercontrol

panelto TB1-1 in the purge unit electricalbox, and the 115 VAC “neutral”to TB1-6 (see

Figures 8 and 8Aon pages 51 and 52 forlocation of terminalconnections). This power

line provides 115 volt powerto the purge condensing unit, pumpout compressor, pumpout

solenoid valves and the controltransformer.

PreliminaryCheckout and Power-Up (continued)

2. Check the Unit fuse (F1)to insure that it is properly installed (see Figure 4 on page 17).

3. Check to make sure that all internalconnections are secure.

4. Apply powerto purge unit and measure voltages at TB1-1 &TB1-6 and TB1-3 &TB1-6

(see figures 8 and 8Aon pages 51 and 52).

5. The voltage between TB1-1 &TB1-6 should be 103 to 127 VAC, and between TB1-3 &

TB1-6 should be 0 volts with chiller"OFF" and 103 to 127 VAC when chilleris ”ON”.

6. Check purge controlpanelLCD display, the display should be displaying:

SystemReady

Select Mode:

Alternating with:

SystemReady

00:00 AM (current clocktime)

NOTE: Upon initial power-up the purge display may read BATTERYFAULT PRESS RESET

KEY. Simply press the RESETkeypad switch to reset the purge unit and begin the

QUICKSTARTprogram. (See “QUICK START” startingonpage 24.)

7. Preliminary Checkout is complete.

SYSTEM COMPONENTS

Figure 2. - Major Components

Purge operation is controlled via the 16 keypad switches and display located on the

front of the unit controlbox(see figure 3 and 4 below).

Figure 3. -

ElectricalControlBoxExterior

(Control Panel)

(See Figure7on page 30 forlargerviewof keypad)

Figure 4. -

ElectricalControlBoxInterior

DISPLAY

BYPASS

Fault

Toggle On/Off

Scroll

ENTER

Display

SENSORS LOGs

Display

AUXValve

CLEAR

LOGs

STOP

Mode

Compressor

ADAPTIVE

RESET

Function

SETTINGS

STATUS

Display

CLOCK

Alarm

SET

Mode

DIAG.

MANUAL

Mode

Pump

AUTO

Drain

Mode

FAULT

Dip Switch

(S1) è

Fault indication

çlight

Control

Transformer

(T1) è

Remotealarm

Relay

(RY7) è

1Amp Fuse

(F1) è

Terminalstrip

(TB1) è

TB1

Ground Lug

42 3 5 6

J2J1

Microprocessor Board

RY7

DISPLAY

KEYPAD

Pump-out Compressor

(BehindPurgeTank)

Air Cooled

Condensing Unit

Sight

Glass Electrical

Control

Box

Figure 5. - Flow Schematicand componentlocation

High EfficiencyPurge with optional Emission Collection Canister

(Together, systemexpels .0049 lbs CFC's orless perlb of airremoved)

Atmosphere

OPERATIONALOVERVIEW

Air-CooledCondensing Unit

The air-cooled condenseron the purge unit provides the necessary cooling source to

condense and separate refrigerant fromnon-condensables in the purge tank. The unit

operates most efficiently within an ambient temperature range of 40° to 120°F. The rate at

which the purge removes airfromthe chilleris proportionate to the ambient temperature. The

higherthe ambient temperature the slowerthe purge rate. Conversely, purge efficiency is

proportionate to chillersaturated condensing temperature. The higherthe chillersaturated

condensing temperature the greaterthe purge efficiency.

NOTE: Because the purge utilizes its own self-contained cooling source, it is capable of

operating whetherthe chilleris running ornot. No waterconnections are required.

Operating cycle

Refrigerant vaporfromthe chillercondenserpasses through a 1/2-inch line, then through an

inlet filter-drierinto the top of the purge tank. The purge tank is cooled by the purge’s air

cooled condensing unit. As the chiller’s refrigerant condenses the pressure in the purge tank

lowers, drawing in additionalvaporalong with any airand moisture that may be present from

the chiller’s condenser(see Figure 6 belowand flowschematic Figure 5 on page 18).

Underconditions of no airpresent in the system, the purge condensing unit compressor

suction temperature will be at 22°Forabove. As airaccumulates within the purge tank the

available condensing surface area of the condensing coil decreases, causing the condensing

unit compressorsuction temperature to drop due to decreasing load. When the suction

temperature (Superheat)drops to 18°Findicating the presence of air, Temperature Sensor

TS1 initiates a pumpout cycle. The airin the purge tank is then vented by the pumpout

compressor. As airis removed fromthe chillersystemto the point where only refrigerant

vaporis drawn into the purge tank, the purge condensing unit compressorsuction

temperature will rise above 22°F, at which point Temperature SensorTS1 terminates the

pumpout cycle. The pumpout cycle is typically 30 to 90 seconds.

Figure 6. -

RefrigerantCircuit

Schematic

PurgeTank

The purge tank consists of a refrigerated cooling coil, liquid levelswitch, liquid levelsight

glass, waterbleed-off valve, and a non-condensables exhaust port. The non-condensables

are removed fromthe purge tank via pumpout solenoid valve L4 and the pumpout

compressor. The condensed refrigerant accumulates in the bottomof the purge tank (see

Figure 5 on page 18).

Purgeand RefrigerantDrainBack Function

Purge activity is continuous while the purge condensing unit is operating. The purge

condensing unit provides the cooling source to condense the refrigerant vaporas it enters the

purge tank. Accumulation of non-condensables in the purge tank is dependent upon the

presence orabsence of airin the chillercondenser. If there is no airin the chillercondenser,

non-condensables will not accumulate in the purge tank. All condensed refrigerant falls to the

bottomof the purge tank where a levelof liquid refrigerant is maintained during purge

operation. When the purge condensing unit is operating, liquid is visible in the purge tank

sight glass. The liquid refrigerant levelis controlled by liquid levelswitch LS1 and liquid return

solenoid valve L3 (see Figure 5 on page 18).

PumpoutSystem

The pumpout systemconsists of a 1/20 H.P. diaphragmpumpout compressor, two pumpout

solenoid valves and a flowrestrictordevice. When sufficient airhas accumulated in the purge

tank the purge controlenergizes and opens the pumpout solenoid valves and starts the

pumpout compressor. Airis slowly pumped fromthe purge tank through the flowrestrictorand

discharged to an emission collection canister, vent line, orthe atmosphere. Removing the air

slowly via the restrictordevice improves the efficiency of the purge cycle.

Security-Lock

The purge unit is equipped with a simple security lock systemthat prevents unauthorized

personnelfromtampering with certain functions. The purge unit comes fromthe factory

with the security lock enabled (see Dip switch S1 settings starting on page 28).

One example of why the operatormay wish to use the “Security Lock”function is that the

purge unit in the ADAPTIVE mode acquires a certain amount of historicaldata in it’s LOGs

which it then uses to determine when and howoften the purge needs to run to purge non -

condensables fromthe systemefficiently. If an unauthorized person were to inadvertently

clearthe LOGs the purge unit would then have to run many days to re-acquire historical

data. When the “Security Lock”is activated unauthorized entry cannot be made.

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