Thermal care Accuchiller eq series User manual

Installation & Operation Manual

EQ Series Portable and Remote Condenser Chillers

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Table of Contents

Foreword ...........................................................................................................................................................................1

Safety Guidelines .............................................................................................................................................................1

Pre-Installation.................................................................................................................................................................2

Receiving Inspection .......................................................................................................................................................................................2

Unit Storage........................................................................................................................................................................................................ 3

Installation - Chiller.........................................................................................................................................................3

Foundation..........................................................................................................................................................................................................3

Unit Location...................................................................................................................................................................................................... 3

Rigging ................................................................................................................................................................................................................. 3

Chilled Process Fluid Piping .........................................................................................................................................................................3

Condenser Water Piping................................................................................................................................................................................ 4

Installation –Remote Air-Cooled Condenser ..............................................................................................................4

Location................................................................................................................................................................................................................ 4

Lifting .................................................................................................................................................................................................................... 5

Mounting Legs ..................................................................................................................................................................................................5

Interconnecting Refrigerant Piping...........................................................................................................................................................5

Refrigeration Piping Design ......................................................................................................................................................................... 5

Determining Equivalent Line Length ........................................................................................................................................................ 7

Liquid Line Sizing.............................................................................................................................................................................................. 7

Discharge (Hot Gas) Line Sizing..................................................................................................................................................................7

Calculating Refrigerant and Oil Charge................................................................................................................................................... 8

Oil Charge Determination............................................................................................................................................................................. 8

Setting Condenser Fan Controls................................................................................................................................................................. 8

Installation - Electrical ....................................................................................................................................................9

Standard Controller Operation....................................................................................................................................10

Changing Temperature Display Scale ....................................................................................................................................................10

Diagnostic Error Codes.................................................................................................................................................................................12

SPI Communications Option......................................................................................................................................................................13

Start-Up...........................................................................................................................................................................15

Step 1 - Connect Main Power ...................................................................................................................................................................15

Step 2 - Fill Coolant Circuit.........................................................................................................................................................................15

Step 3 - Check Condenser ..........................................................................................................................................................................16

Step 4 –Check Refrigerant Valves...........................................................................................................................................................17

Step 5 –Verify Freezestat Setting ............................................................................................................................................................17

Step 6 –Turn On Control Power ..............................................................................................................................................................17

Step 7 –Establish Coolant Flow................................................................................................................................................................17

Step 8 –Intial Unit Operation....................................................................................................................................................................17

Preventive Maintenance ...............................................................................................................................................18

Once a Week ....................................................................................................................................................................................................18

Once a Month..................................................................................................................................................................................................18

Every Three Months.......................................................................................................................................................................................18

Preventive Maintenance Checklist ..............................................................................................................................19

General Troubleshooting..............................................................................................................................................20

Drawings .........................................................................................................................................................................20

Warranty .........................................................................................................................................................................21

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Foreword

The portable chiller is a packaged unit typically

consisting of a refrigeration circuit, coolant reservoir,

and pumping system in a cabinet. The purpose is to

provide cooling water or coolant for cooling an

industrial process.

This manual is to serve as a guide for installing,

operating, and maintaining the equipment. Improper

installation can lead to poor performance and/or

equipment damage. We recommend the use of

qualified installers and service technicians for all

installation and maintenance of this equipment.

This manual is for our standard product. The

information in this manual is general in nature. Unit-

specific drawings and supplemental documents are

included with the equipment as needed. Additional

copies of documents are available upon request. We

strive to maintain an accurate record of all

equipment during the course of its useful life.

Due to the ever-changing nature of applicable

codes, ordinances, and other local laws pertaining to

the use and operation of this equipment, we do not

reference them in this manual. There is no substitute

for common sense and good operating practices

when placing any mechanical equipment into

operation. We encourage all personnel to familiarize

themselves with this manual's contents. Failure to do

so may unnecessarily prolong equipment down time.

The equipment uses a hydro fluorocarbon (HFC),

trade named R-407c, as a chemical refrigerant for

heat transfer purposes. This chemical is sealed and

tested in a pressurized system containing ASME

coded vessels; however, a system failure will release

it. Refrigerant gas can cause toxic fumes if exposed

to fire. Place these units in a well-ventilated area,

especially if open flames are present. Failure to

follow these instructions could result in a hazardous

condition. We recommend the use of a refrigerant

management program to document the type and

quantity of refrigerant in the equipment. In addition,

we recommend only licensed and EPA certified

service technicians work on our refrigeration circuits.

Follow good piping practices and the information in

this manual to ensure successful installation and

operation of this equipment.

We trust your equipment will have a long and useful

life. If you should have any questions, please contact

our Customer Service Department specifying the

serial number and model number of the unit as

indicated on the nameplate.

Safety Guidelines

Observe all safety precautions during installation,

start-up, and service of this equipment. The

following is a list of symbols used in this manual and

their meaning.

General Warning

Electricity Warning

Sharp Element Warning

Hot Surface Warning

Flammable Material Warning

Explosive Material Warning

General Mandatory Action

Wear Eye Protection

Wear Protective Gloves

Wear Ear Protection

Disconnect Before Carrying Out Maintenance or

Repair

Connect an Earth Terminal to Ground

Only qualified personnel should install, start-up, and

service this equipment. When working on this

equipment, observe precautions in this manual as

well as tags, stickers, and labels on the equipment.

WARNING: Any use or misuse of this equipment

outside of the design intent may cause injury or

harm.

WARNING: Vent all refrigerant relief valves in

accordance to ANSI/ASHRAE Standard 15, Safety

Code for Mechanical Refrigeration. Locate this

equipment in a well-ventilated area. Inhalation

of refrigerant can be hazardous to your health

and the accumulation of refrigerant within an

enclosed space can displace oxygen and cause

suffocation.

WARNING: This equipment contains hazardous

voltages that can cause severe injury or death.

WARNING: This equipment contains refrigerant

under pressure. Accidental release of refrigerant

under pressure can cause personal injury and or

property damage.

WARNING: This equipment may contain fan

blades or other sharp edges. Make sure all fan

guards and other protective shields are securely

in place.

WARNING: The exposed surfaces of motors,

refrigerant piping, and other fluid circuit

components can be very hot and can cause burns

if touched with unprotected hands.

CAUTION: Disconnect and lock out incoming

power before installing, servicing, or

maintaining the equipment. Connecting power to

the main terminal block energizes the entire

electric circuitry of the unit. Shut off the electric

power at the main disconnect before opening

access panels for repair or maintenance.

CAUTION: Wear eye protection when installing,

maintaining, or repairing the equipment to

protect against any sparks, debris, or fluid leaks.

CAUTION: The equipment will exceed 70 dBA

sound pressure at 1 meter distance and 1 meter

elevation when operating. Wear ear protection

as required for personal comfort when operating

or working in close proximity to the chiller.

CAUTION: Wear protective gloves when

installing, maintaining, or repairing the

equipment to protect against any sparks, debris,

or fluid leaks.

Pre-Installation

Receiving Inspection

When the unit arrives, verify the information on the

unit nameplate agrees with the order

acknowledgement and shipping papers. Inspect the

equipment for any visible damage and verify all

items shown on the bill of lading are present. If

damage is evident, document it on the delivery

receipt by clearly marking any item with damage as

“unit damage” and notify the carrier. In addition,

notify our Customer Service Department and they

will provide assistance with preparing and filing

freight damage claims, including arranging for an

estimate on repair costs; however, filing the shipping

damage claim is the responsibility of the receiving

party. Do not install damaged equipment without

getting the equipment repaired.

Shipping damage is the responsibility of the carrier.

To protect against possible loss due to damage

incurred during shipping and to expedite payment

for damages, it is important to follow proper

procedures and keep records. Photographs of

damaged equipment are excellent documentation

for your records.

Start unpacking the unit, inspect for concealed

damage, and take photos of any damage found.

Once received, equipment owners have the

responsibility to provide reasonable evidence that

the damage did not occur after delivery. Photos of

the equipment damage while the equipment is still

partially packed will help in this regard. Refrigerant

lines can be susceptible to damage in transit. Check

for broken lines, oil leaks, damaged controls, or any

other major component torn loose from its

mounting point.

Record any signs of concealed damage and file a

shipping damage claim immediately with the

shipping company. Most carriers require concealed

damages be reported within 15 days of receipt of

the equipment. In addition, notify our Customer

Service Department and they will provide assistance

with preparing and filing freight damage claims,

including arranging for an estimate on repair costs;

however, filing the shipping damage claim is the

responsibility of the receiving party.

Chillers with an integral water-cooled or air-cooled

condenser ship with a full refrigerant charge. Chillers

designed for use with a remote air-cooled condenser

and the remote condensers themselves ship with a

nitrogen holding charge. Check the remote

condenser for signs of leaks prior to rigging. This will

ensure no coil damage has occurred after the unit

left the factory. The condenser ships with the legs

removed. Mount the legs to the condenser using the

provided nuts, bolts, and washers.

Unit Storage

If the chiller is stored prior to installation, it is

important to protect it from damage. Blow out any

water from the evaporator and water-cooled

condenser circuits to protect the unit from damage

from freezing. Close any open refrigerant valves.

Cover the equipment to keep dirt and debris from

accumulating on it. Units charged with refrigerant

should not be stored in areas warmer than 145°F.

Installation - Chiller

Foundation

Install the chiller on a rigid, non-warping mounting

pad, concrete foundation, or level floor suitable to

support the full operating weight of the equipment.

When installed the equipment must be level within

¼ inch over its length and width.

Unit Location

The chiller is available in many different

configurations for various environments. Refer to the

proposal and order acknowledgement document for

the equipment to verify the specific design

conditions in which it can operate.

Allow a minimum of 48 inches of clearance between

the chiller and any walls or obstructions. For

installations with multiple chillers, allow a minimum

of 96 inches between chillers placed side-by-side or

48 inches for chillers placed end-to-end.

When locating the chiller it is important to consider

accessibility to the components to allow for proper

maintenance and servicing of the unit. In general,

allow a minimum of 36 inches of clearance around

and above the unit. Avoid locating piping or conduit

over the unit to ensure easy access with an overhead

crane or lift to lift out heavier components during

replacement or service.

Proper ventilation is another important

consideration when locating the chiller. In general,

locate the unit in an area that will not rise above

110°F. In addition, ensure the condenser and

evaporator refrigerant pressure relief valves can vent

in accordance with all local and national codes.

Chillers with an integral air-cooled condenser require

a minimum of 36 inches of clearance at both the

condenser air inlet and condenser air discharge, they

are not, as standard, designed to have the condenser

air discharge ducted. Improper clearance or poor

ventilation will reduce the cooling capacity of the

chiller and may cause high refrigerant pressure

problems. In order to avoid possible low refrigerant

pressure safety trips during start-up, maintain the

inlet air temperature above 50°F. If outside air is

ducted into an indoor chiller with an integral air-

cooled condenser, there is an option for low ambient

heat pressure controls which allow for incoming air

temperatures down to 0°F. Cooler temperatures than

this require custom modifications.

Rigging

The chiller has a frame to facilitate easy movement

and positioning with a crane or forklift. Follow

proper rigging methods to prevent damage to

components. Avoid impact loading caused by

sudden jerking when lifting or lowering the chiller.

Use pads where abrasive surface contact may occur.

Chilled Process Fluid Piping

Proper insulation of chilled process fluid piping is

crucial to prevent condensation. The formation of

condensation adds a substantial heat load to the

chiller.

The importance of properly sized piping between

the chiller and process cannot be overemphasized.

See the ASHRAE Handbook or other suitable design

guide for proper pipe sizing. In general, run full size

piping out to the process and reduce pipe size at

connections as needed. One of the most common

causes of unsatisfactory chiller performance is poor

piping system design. Avoid long lengths of hoses,

quick disconnect fittings, and manifolds wherever

possible as they offer high resistance to water flow.

When manifolds are required, install them as close to

the use point as possible. Provide flow-balancing

valves at each machine to assure adequate water

distribution in the entire system. Typically, when

piping is overhead with a total run length over 90

feet there should be a valve in the supply line and an

inverted P trap with a vacuum break valve installed

as shown in Figure 1.

Figure 1 –Recommended Overhead Piping

All standard portable chillers include an internal

coolant pump and reservoir. Nominal coolant flow

rates assume a 10°F rise across the evaporator at

50°F set point and 85°F entering condenser water for

water-cooled chillers or 95°F entering air for integral

air-cooled or remote air-cooled condenser chillers.

Condenser Water Piping

(Water-Cooled Condenser Units Only) The

performance of a water-cooled condenser is

dependent on the flow and temperature of the

cooling water used. Insufficient cooling of the

condenser will result in the reduction of cooling

capacity of the chiller and under extreme conditions

may result in the chiller shutting down due to high

refrigerant pressure. Allowing the condenser to plug

up from contaminants in the condenser water

stream adversely affects performance. In order to

reduce maintenance costs and chiller downtime, a

water treatment program is highly recommended for

the condenser cooling water. Contact our Customer

Service Department for assistance in the proper

procedure for cleaning out any plugged condenser.

The nominal water-cooled condenser is design for

85°F condenser cooling water supply. Under normal

operation there will be about a 10°F rise through the

condenser resulting in 95°F exiting water. To ensure

proper water flow through the condenser, ensure the

condenser water pump provides at least 25 psi or

water at a flow rate of 3 gpm per ton of chiller

capacity.

Each condenser has a two-way condenser water-

regulating valve. The condenser water-regulating

valve controls the amount of water allowed to pass

through the condenser in order to maintain proper

refrigeration pressures in the circuit.

To prevent damage to the condenser and/or water-

regulating valve, the water pressure should not

exceed 150 psig.

Installation –Remote Air-

Cooled Condenser

Chillers designed for use with a remote air-cooled

condenser include a factory-selected remote

condenser. The remote air-cooled condenser

typically ships separately from a different location

than the chiller.

Location

The remote air-cooled condenser is for outdoor use.

Locate the remote condenser in an accessible area.

Allow a minimum of 48 inches of clearance between

the condenser and any walls or obstructions. For

installations with multiple condensers, allow a

minimum of 96 inches between condensers placed

side-by-side or 48 inches for condensers placed end-

to-end.

When locating the condenser it is important to

consider access to the components to allow for

proper maintenance and servicing of the unit. In

general, allow a minimum of 36 inches of clearance

around and above the unit. Avoid locating piping or

conduit over the unit to ensure easy access with an

overhead crane or lift to lift out heavier components

during replacement or service.

Proper ventilation is another important

consideration when locating the condenser. In

general, locate the unit in an area that will not rise

above 110°F.

Install the unit on a firm, level base no closer than its

width from walls or other condensers. Avoid

locations near exhaust fans, plumbing vents, flues, or

chimneys. Fasten the mounting legs at their base to

the steel or concrete of the supporting structure. For

units mounted on a roof structure, the steel support

base holding the condenser should be elevated

above the roof and attached to the building.

NOTE:

If piping is above chiller and exceeds 90 feet in total

length, install an inverted P-trap and vacuum break

valve in return line and add a check valve to the

supply line.

Check valve

1/2 inch vacum break valve

12 inches above highest

point in piping system

12 inches above highest point in

the piping system

½ inch vacuum

break valve

Check valve

Avoid areas that can create a “micro-climate” such as

an alcove with east, north, and west walls that can be

significantly warmer than surrounding areas. The

condenser needs to have unrestricted airways so it

can easily move cool air in and heated air away.

Consider locating the condenser where fan noise

and vibration transmission into nearby workspaces is

unlikely.

The unit ships on its side with the legs removed to

reduce shipping dimensions and provide more

protection to the coil from possible damage caused

by impact loading over rough roads and transit

conditions.

Lifting

Use only qualified personnel using the proper

equipment when lifting and positioning the

condenser. Lifting brackets or holes are at the

corners for attaching lifting slings. Use spreader bars

when lifting to apply the lifting force vertically.

Under no circumstances use the coil headers or

return bends in the lifting or moving of the

condenser.

Mounting Legs

Assemble the four corner legs to the bottom flanges

on the unit side panels and end panels using the

hardware provided and the matching mounting

hole-patterns. All corner legs are the same.

Figure 2 - Mounting Remote Condenser Legs

Interconnecting Refrigerant Piping

The chiller and remote condenser ship with a

nitrogen holding charge. Evacuation of this charge is

required before charging with refrigerant. The chiller

is for use only with the air-cooled condenser

provided with the unit. The following section covers

the required piping between the chiller and the

provided air-cooled condenser.

The discharge and liquid lines leaving the chiller

have caps. These line sizes do not necessarily reflect

the actual line sizes required for the piping between

the chiller and the air-cooled condenser.

Refrigerant piping size and piping design have a

significant impact on system performance and

reliability. All piping should conform to the

applicable local and state codes.

CAUTION: Use refrigerant grade copper tubing

ASTM B280 only and isolate the refrigeration

lines from building structures to prevent transfer

of vibration. All copper tubing must have a

pressure rating suitable for R-407c: tubing that is

¾” OD or larger must be Type K rigid tubing.

ACR annealed tubing coil may be used for sizes

⅝” ODS or smaller.

Do not use a saw to remove end caps. This might

allow copper chips to contaminate the system. Use a

tube cutter or heat to remove the caps. When

sweating copper joints it is important to evacuate all

refrigerant present and flow dry nitrogen through

the system. This prevents the formation of toxic

gases, corrosive acids, and scale.

CAUTION: Do not use soft solders. For copper-to-

copper joints use a copper-phosphorus braze

alloy (BCuP per the American Welding Society)

with 5% (BCuP-3) to 15% (BCuP-5) silver

content. Only use a high silver content brazing

alloy (BAg per AWS) for copper-to-brass or

copper-to-steel joints such as a 45% (BAg-5)

silver content. Only use oxy-acetylene brazing.

WARNING: The POE oil contained within the

compressor is hygroscopic and has the ability to

absorb water vapor from the atmosphere. Take

necessary steps to prevent an open system from

exposure to the atmosphere for extended periods

while installing the interconnecting refrigerant

tubing.

Refrigeration Piping Design

The system is configurable in any of the

arrangements as shown in Figure 3, Figure 4 and

Figure 5. The configuration and its associated

elevation, along with the total distance between the

chiller and the air-cooled condenser are important

factors in determining the liquid line and discharge

line sizes. This will also affect the field refrigerant

charges. Consequently, it is important to adhere to

certain physical limitations to ensure the system

operates as designed.

General design considerations are:

1. The total distance between the chiller and the

air-cooled condenser must not exceed 200

actual feet or 300 equivalent feet. Keep the

distance as short as possible.

2. Liquid line risers must not exceed 15 feet in

height from the condenser liquid line

connection.

3. Discharge line risers cannot exceed an elevation

difference greater than 100 actual feet without a

minimum of 2% efficiency decrease.

4. To form a proper liquid seal at the condenser,

immediately drop at least 15 inches down from

the liquid outlet before routing the piping to the

chiller. Make the drop leg before any bends or

angles connecting to the remainder of the liquid

connection piping.

Figure 3 –Condenser Located at Chiller Level

Figure 4 –Condenser Located Above Chiller Unit

Figure 5 - Condenser Located Below Chiller Unit

Caution: Liquid line sizing for each chiller

capacity are in Table 6. These line sizes are listed

per circuit and apply where leaving water

temperature (LWT) is 40°F or higher. For

applications where the LWT is below 40°F, size

lines using the ASHRAE Refrigeration Handbook

or other suitable design guide.

Determining Equivalent Line Length

To determine the appropriate size for field installed

liquid and discharge lines, it is first necessary to

establish the equivalent length of pipe for each line.

The equivalent length is the approximate friction loss

from the combined linear run of pipe and the

equivalent feet of elbows, valves, and other

components in the refrigeration piping. The sum

total is the equivalent length of pipe that would have

the same pressure loss. See the ASHRAE

Refrigeration Handbook for more information.

Follow these steps when calculating line size:

1. Start with an initial approximation of equivalent

length by assuming that the equivalent length of

pipe is 1.5 times the actual pipe length.

2. Determine approximate line sizes by referring to

Table 2 for liquid lines, Table 3 and Table 4 for

the discharge lines.

3. Check the line size by calculating the actual

equivalent length using the equivalent lengths

as shown in Table 5.

CAUTION: When calculating the equivalent

length, do not include piping of the chiller unit.

Only field piping must be considered.

Table 1 –Equivalent Lengths of Elbows

Line

Size

(in)

Equivalent Lengths of Refrigerant Pipe (feet)

90°

Standard

90°

Long

Radius

90°

Street

45°

Standard

45°

Street

1.4

0.9

2.3

0.7

1.1

⅝

1.6

1.0

2.5

0.8

1.3

⅞

2.0

1.4

3.2

0.9

1.6

Liquid Line Sizing

The liquid line diameter should be as small as

possible while maintaining acceptable pressure drop.

This is necessary to minimize refrigerant charge. The

total length between the chiller unit and the air-

cooled condenser must not exceed 200 actual feet

or 300 equivalent feet. It is best to pipe the liquid

line so that there is an immediate drop of at least 15

inches at the condenser outlets to make a liquid seal.

Liquid line risers in the system will require an

additional 0.5 psig pressure drop per foot of vertical

rise. When it is necessary to have a liquid line riser,

make the vertical run immediately after the

condenser before any additional restrictions. The

liquid line risers must not exceed 10 feet in height

from the condenser liquid line connection. The liquid

line does not require pitching. Install a pressure tap

valve at the condenser to facilitate measuring

pressure for service.

Liquid lines do not typically require insulation.

However, if exposing the lines to solar heat gain or

temperatures exceeding 110 °F, there is a negative

effect on sub-cooling. In these situations, insulate

the liquid lines.

Table 2 –Liquid Line Sizes for R407c

3 Ton Circuit (R407c) Liquid Line Size (Inch OD)

Equivalent

Length (Ft)

Horizontal

Down Flow

Up Flow (Feet of Run)

0 to 5

6 to 10

11 to 15

100

125

⅝

150

⅝

175

⅝

200

⅝

225

⅝

250

⅝

275

⅝

300

⅝

Discharge (Hot Gas) Line Sizing

The discharge line sizes depend on the velocity

needed to obtain sufficient oil return. It is very

important to minimize line length and restrictions to

reduce pressure drop and maximize capacity.

Upflow hot gas risers need to have a trap at the

bottom and reverse trap at the top. In addition, a

trap and reverse trap arrangement needs to be

spaced every 15 feet in the rise for oil management

(see Figure 5).

The discharge lines should pitch downward, in the

direction of the hot gas flow, at the rate of ½ inch

per each 10 foot of horizontal run. If the chiller unit

is below the condenser, loop the discharge line to at

least 1 inch above the top of the condenser. Install a

pressure tap valve at the condenser to facilitate

measuring pressure for service. Take careful

consideration in the design of the discharge gas

riser.

Check the oil-level sight glass in the compressor to

ensure it is at the appropriate level to verify there is

no trapping of oil in the piping. The chiller is

equipped with hot-gas bypass capacity control and

the gas in the upflow discharge lines may have

problems moving the oil against gravity when

completely unloaded if a single rise system is used.

We recommend a double riser system to ensure

proper oil return under low load operation. See

Figure 6 and Table 8 for double riser constructions.

Figure 6 –Vertical Riser Traps

Figure 7 - Double Discharge Riser

Note: Discharge line sizing shown in Table 3

and Table 4 apply when leaving water

temperature (LWT) is 40°F or higher. For

applications where LWT is below 40°F, size

lines using the ASHRAE Refrigeration

Handbook or other suitable design guide.

Table 3 - Horizontal or Downflow Discharge Line

Sizes for 3-ton R407c Circuit (inches OD)

Total Equivalent Length (Ft)

100

125

150

175

200

225

250

275

300

⅝

⅞

Table 4 - Upflow Discharge Line Sizes for 3-ton

R407c Circuit (inches OD)

Total Equivalent Length (Ft)

100

125

150

175

200

225

250

275

300

A-⅜

B-½

B-⅝

B-¾

Calculating Refrigerant and Oil Charge

To determine the approximate charge, assume a

combined chiller and remote condenser summer

refrigerant charge of 4.6 Lbs. of R-407c then refer to

Table 5 to determine the charge required for the

field-installed piping per circuit. The approximate

charge per circuit is therefore the sum 4.6 and the

value from Table 5.

Table 5 - Field Piping R-407c Refrigerant Charges

Line Size OD

(inches)

Discharge Line

(Lbs/100’ run)

Liquid Line

(Lbs/100’ run)

⅜

0.4

3.7

0.7

6.8

⅝

1.1

11.0

1.6

16.4

⅞

2.2

22.8

Oil Charge Determination

The chiller is factory charged with the amount of oil

required by the chiller only and not the total system.

The amount of oil required is dependent upon the

amount of refrigerant added to the system for the

field-installed piping. Use the following to determine

the amount of oil needed for the system.

Pints of Oil = Pounds of refrigerant in system / 100

Check the oil level after the chiller has run for 15

minutes.

Setting Condenser Fan Controls

The remote condenser has one fan and the fan

pressure setting should be set to turn on at 220 psig

and off at 180 psig. It is important that these settings

be correct in order to maintain proper capacity

control and operation of the system.

Installation - Electrical

All wiring must comply with local codes and the

National Electric Code. Minimum circuit amps (MCA)

and other unit electrical data are on the unit

nameplate. A unit specific electrical schematic ships

with the unit. Measure each leg of the main power

supply voltage at the main power source. Voltage

must be within the voltage utilization range given on

the drawings included with the unit. If the measured

voltage on any leg is not within the specified range,

notify the supplier and correct before operating the

unit. Voltage imbalance must not exceed two

percent. Excessive voltage imbalance between the

phases of a three-phase system can cause motors to

overheat and eventually fail. Voltage imbalance is

determined using the following calculations.

%Imbalance = (Vavg –Vx) x 100 / Vavg

Vavg = (V1 + V2 + V3) / 3

Vx = phase with greatest difference from Vavg

For example, if the three measured voltages were

442, 460, and 454 volts, the average would be:

(442 + 460 + 454) / 3 = 452

The percentage of imbalance is then:

(452 –442) x 100 / 452 = 2.2 %

This exceeds the maximum allowable of 2%.

There is a terminal block for main power connection

to the main power source. The main power source

should be connected to the terminal block through

an appropriate disconnect switch. There is a separate

lug in the main control panel for grounding the unit.

Check the electrical phase sequence at installation

and prior to start-up. Operation of the compressor

with incorrect electrical phase sequencing will result

in mechanical damage to the compressors. Check

the phasing with a phase sequence meter prior to

applying power. The proper sequence should read

“ABC” on the meter. If the meter reads “CBA”, open

the main power disconnect and switch two line leads

on the line power terminal blocks (or the unit

mounted disconnect). Do not interchange any load

leads that are from the unit contactors or the motor

terminals.

WARNING: This equipment contains hazardous

voltages that can cause severe injury or death.

WARNING: This equipment contains refrigerant

under pressure. Accidental release of refrigerant

under pressure can cause personal injury and or

property damage.

WARNING: This equipment may contain fan

blades or other sharp edges. Make sure all fan

guards and other protective shields are securely

in place.

WARNING: The exposed surfaces of motors,

refrigerant piping, and other fluid circuit

components can be very hot and can cause burns

if touched with unprotected hands.

CAUTION: Disconnect and lock out incoming

power before installing, servicing, or

maintaining the equipment. Connecting power to

the main terminal block energizes the entire

electric circuitry of the unit. Electric power at the

main disconnect should be shut off before

opening access panels for repair or maintenance.

CAUTION: Wear eye protection when installing,

maintaining, or repairing the equipment to

protect against any sparks, debris, or fluid leaks.

CAUTION: Wear protective gloves when

installing, maintaining, or repairing the

equipment to protect against any sparks, debris,

or fluid leaks.

CAUTION: Wire the unit ground in compliance

with local and national codes.

CAUTION: The unit requires the main power to

remain connected during off-hours to energize

the compressor’s crankcase heater. Disconnect

main power only when servicing the chiller. The

crankcase heater should remain on when the

compressor is off to ensure liquid refrigerant

does not accumulate in the compressor

crankcase. Connect main power at least 24 hours

prior to initial start-up.

Standard Controller Operation

The chiller includes a controller to perform all

control functions directly from the front panel. When

Control Power is applied, the controller initiates a

diagnostic test of each indicating light and display

segment by briefly lighting each sequentially. As part

of this initial diagnostic test, the revision level of the

control program displays for a moment. After the

initial diagnostic sequence is completed, the

controller is ready for operation.

Changing Temperature Display Scale

The chiller is able to display temperatures in either °F

or °C. To determine which temperature is in use and

to change the temperature scale used stop the unit

and press the Power button to turn off the

controller. Press and hold the Stop Button and then

press the Power Button. When the controller

illuminates, release both buttons. The To Process

display will read "Unt". The Set Point display will

show either "F" or "C" depending on the current

display units selected. If "F" is displayed the

temperature display is in °F mode. If "C" is displayed

the temperature display is in °C mode. To change

from °F to °C press the Lower Set Point Temperature

button (down arrow). To change from °C to °F press

the Raise Set Point Temperature button (up arrow).

After changing to the desired temperature scale the

Set Point display shows the desired display units.

Press and release the Start button to store the new

selection into the controller memory then press and

release the Power button to exit the function. Press

and release the Power button again to restore

controller power. The unit is now ready for

operation.

Table 6 -Temperature Displays

Display

Description of Operation

Set Point

The Set Point display shows the set point temperature. This display also shows alarm codes and programming

information.

To Process

The To Process display normally shows supply temperature. If the return temperature display option is purchased this

display is also used for the return fluid temperature. To toggle this display between supply and return temperatures,

depress and hold down the Down and Up button at the same time. The return temperature shows as long as the Down

and Up button are depressed. Release the Down and Up buttons to return the display to show the supply temperature.

Table 7 - Operating Buttons

Button

Description of Operation

Power

Depressing the Power button switches the control power on or off. The control power must be on before the Start

button or remote on/off contact can start the chiller. The light above this button is one when the power is on.

Start

Depressing the Start button starts the pump and enables the compressor. The compressor (and condenser fans if the

chiller is air-cooled) will start if cooling is required. The light above this button is on when the chiller is running.

Stop

Depressing the Stop button shuts off the compressor, pump, condenser fans (if the chiller is air-cooled), and clears all

fault signals. The light above this button is on when the chiller stops.

Alarm Reset

Depressing the Alarm Reset button resets the alarm, silences the optional alarm horn, and opens the optional remote

alarm contact. The light above this button is on if an alarm is present. The High Refrigerant Pressure and Pump

Overload require a mechanical safety manual reset before the control board reset. If the fault is still present, the unit

will immediately go into a new alarm state.

Alarm Silence

Depressing the Alarm Reset button silences the optional alarm horn, and opens the optional remote alarm contact.

The light above this button is on when the alarm horn is on or the remote alarm contact is closed. The High

Refrigerant Pressure and Pump Overload require a mechanical safety manual reset before the control board reset. If

the fault is still present, the unit will immediately go into a new alarm state.

The Up Arrow button raises the set point temperature. Pressing the Up Arrow and releasing it increases the set point

temperature by one degree. Pressing the Up Arrow button and holding it increases the set point temperature until

reaching the maximum allowable set point temperature.

Down

The Down Arrow button decreases the set point temperature. Pressing the Down Arrow and releasing it decreases the

set point temperature by one degree. Pressing the Down Arrow button and holding it decreases the set point

temperature until reaching the minimum allowable set point temperature.

Table 8 - Operating Lights

Light

Description of Operation

No Flow

The No Flow light is red if the flow through the chiller is too low. This safety is defeated for 20 seconds after

starting the chiller to allow the pump to establish flow. This safety stops all compressors and pumps. Pressing the

Start button resets the safety and restarts the chiller.

High Refrig

The High Refrigerant Pressure light is red when the compressor discharge refrigerant pressure exceeds the setting

of the high refrigerant pressure safety. This safety stops all compressors but allows pumps to continue running.

Pressing the Alarm Reset button resets the fault if the high refrigerant switch resets and the compressor discharge

refrigerant pressure is less than the setting of the high refrigerant pressure safety.

Low Refrig

The Low Refrigerant Pressure light is red when the compressor suction pressure drops below the setting on the

low refrigerant pressure safety. This safety stops all compressors but allows pumps to continue running. Pressing

the Alarm Reset button resets the fault if the compressor suction pressure is above the setting of the low

refrigerant pressure safety.

Freezestat

The Freezstat light is red if the coolant leaving the chiller drops below the Freezestat thermostat setting. This safety

stops all compressors but allows pumps to continue running. Set the Freezestat 10°F above the freezing point of

the coolant in the chiller. The Freezestat is factory set at 38°F. Pressing the Alarm Reset button resets the

Freezestat fault if the coolant temperature has risen above the Freezestat thermostat setting.

Low Oil Press

The Low Oil Pressure light is only active on custom units with a semi-hermetic compressor that has an oil pressure

switch and lights if the oil pressure in the compressor drops below the setting of the oil pressure switch.

Over Set Pt

The Over Set Point light is on if the To Process temperature exceeds the Set Point temperature by more than 5°F.

To avoid nuisance trips this feature has a 30-minute delay after the unit starts before it is active.

Under Set Pt

The Under Set Point light is on if the To Process temperature drops below the Set Point temperature by more than

5°F. To avoid nuisance trips this feature has a 30-minute delay after the unit starts before it is active.

Pump On

The Pump light is solid green when the pump is running. The light is off if the pump is off or if motor overload

trips.

Comp On

The Compressor On light is solid green when the Compressor is running. The light is off if the compressor is off or

if a overload or fault occurs.

Partial Load

The Partial Load light will pulse or light solidly when the chiller is operating at partial load and the hot gas bypass

valve opens. The light stays on for longer periods of time when the chiller is under smaller loads. If the light stays

off the chiller is under full load. If the light stays on the chiller is fully unloaded. If this condition persists, the To

Process temperature may begin to drop below the Set Point temperature, eventually cycling off the compressor.

Water Make-up

The Water Make-up light is on when the make-up solenoid valve is open.

Low Wtr Level

The Low Water Level light is on when the water level in the reservoir drops below the lower limit of the optional

low water level switch. Pressing the Alarm Reset button resets the Low Water Level fault if the coolant level in the

reservoir has risen about the lower limit of the float switch.

Hi Wtr Temp

The High Water Temperature light is on if the To Process temperature is 10°F above the Set Point temperature.

This light is off if the To Process temperature is less than 10°F above the Set Point temperature.

Probe Fault

The Probe Fault light is on if the signal from a thermocouple is out of tolerance.

Table 9 –Controller Control Fault Logic

Fault

Alarm

Indication

Compressor

Shutdown

Pump

Shut Off

Alarm

Reset

Required1

Manual

Reset

Required2

Remote

Alarm

Activated3

No Flow

LED

Yes

High Refrigerant Pressure

LED

Yes

Low Refrigerant Pressure

LED

Yes

Freezestat

LED

Yes

Low Oil Pressure

LED

Yes

Over Set Point

LED

Yes

Under Set Point

LED

Yes

Low Water Level

LED

High Water Temperature

LED

Probe Fault

LED

Yes

Low Power

Pr OFF

Yes

Pump Overload

Err 126

Yes

Compressor Overload

Err 127

Yes

High Temperature Safety

Err 128

Yes

1 Alarm Reset button or Stop button on control panel must be pressed.

2 Safety control must be manually reset before the controller can be reset.

3 Activates the alarm horn (if included) and closes the alarm contact (if included).

Diagnostic Error Codes

Several different error codes may show on the digital readouts labeled To Process and Set Point. Most of the

possible error codes indicate some type of failure in the microprocessor controller. If any error codes other than

the ones listed below occur, try to reset the unit by shutting the power off and then turning it back on. If this does

not work, make a note of the error code and contact our Customer Service Department for further assistance.

Table 10 - Diagnostic Error Codes

Error

Code

Description

Cause/Corrective Action

Pr Off

Brown Out Indication

Indicates the chiller is running and main power is disconnected or drops more

than 10% below the normal operating voltage, the unit will shut down and the

Pr OFF fault will show on the digital displays. Pressing the Power button will

clear this fault condition.

101

EEPROM Failure