Thermal Care ACCUCHILLER EQ Instruction Manual

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................................................................................................................................................................................ 3
Installation –Remote Condenser ................................................................................................................................................................... 4
Location................................................................................................................................................................................................................ 4
Lifting .................................................................................................................................................................................................................... 4
Mounting Legs .................................................................................................................................................................................................. 4
Figure 1 - Mounting Remote Condenser Legs ................................................................................................................................. 5
Interconnecting Refrigerant Piping........................................................................................................................................................... 5
Refrigeration Piping Design ......................................................................................................................................................................... 5
Figure 2 –Condenser Located at Chiller Level.................................................................................................................................. 5
Figure 3 –Condenser Located Above Chiller Unit .......................................................................................................................... 6
Figure 4 - Condenser Located Below Chiller Unit............................................................................................................................ 6
Determining Equivalent Line Length ........................................................................................................................................................ 6
Table 1 –Equivalent Lengths of Elbows .............................................................................................................................................. 6
Liquid Line Sizing.............................................................................................................................................................................................. 6
Table 2 –Liquid Line Sizes for R407c ................................................................................................................................................... 7
Discharge (Hot Gas) Line Sizing.................................................................................................................................................................. 7
Figure 5 –Vertical Riser Traps ................................................................................................................................................................. 7
Figure 6 - Double Discharge Riser......................................................................................................................................................... 7
Table 3 –Horizontal/Downflow Discharge Line Sizes.................................................................................................................... 7
Table 4 - Upflow Discharge Line Sizes ................................................................................................................................................. 7
Calculating Refrigerant and Oil Charge................................................................................................................................................... 8
Table 5 - Field Piping R-407c Refrigerant Charges......................................................................................................................... 8
Oil Charge Determination............................................................................................................................................................................. 8
Setting Condenser Fan Controls................................................................................................................................................................. 8
Installation - Electrical......................................................................................................................................................................................... 8
Standard Controller Operation........................................................................................................................................................................ 9
Table 6 - Operating Buttons –Soft Buttons ...................................................................................................................................... 9
User Menu.........................................................................................................................................................................................................10
User Menu –ON-OFF ...................................................................................................................................................................................10
User Menu –Info............................................................................................................................................................................................10
User Menu –SET.............................................................................................................................................................................................10
Changing Setpoint Temperature..............................................................................................................................................................10
Main Menu –Process....................................................................................................................................................................................10
Main Menu –HGBP .......................................................................................................................................................................................10
Main Menu –Alarm Logs ............................................................................................................................................................................10
Main Menu –Settings...................................................................................................................................................................................10

Table 7 –User Menu Parameters .........................................................................................................................................................11
Table 8 - Main Menu Setup....................................................................................................................................................................12
Modbus RTU Communications.................................................................................................................................................................14
Table 9 –Modbus Parameters ..............................................................................................................................................................14
Alarms .................................................................................................................................................................................................................15
Table 10 –Alarms and Fault Logic.......................................................................................................................................................15
Start-Up ..................................................................................................................................................................................................................16
Step 1 - Connect Main Power ...................................................................................................................................................................16
Step 2 - Fill Coolant Circuit.........................................................................................................................................................................16
System Fill Water Chemistry Requirements.....................................................................................................................................16
Table 11 –Fill Water Chemistry Requirements...............................................................................................................................17
Table 12 - Recommended Glycol Solutions.....................................................................................................................................17
Step 3 - Check Condenser ..........................................................................................................................................................................18
Integral Air-Cooled Condenser Check ...............................................................................................................................................18
Water-Cooled Condenser Check..........................................................................................................................................................18
Remote Air-Cooled Condenser Check ...............................................................................................................................................18
Step 4 –Check Refrigerant Valves...........................................................................................................................................................18
Step 5 –Verify Freezestat Setting ............................................................................................................................................................18
Step 6 –Turn On Control Power ..............................................................................................................................................................18
Step 7 –Establish Coolant Flow................................................................................................................................................................18
Step 8 –Intial Unit Operation....................................................................................................................................................................18
Preventive Maintenance...................................................................................................................................................................................19
Once a Week ....................................................................................................................................................................................................19
Once a Month..................................................................................................................................................................................................19
Every Three Months.......................................................................................................................................................................................19
General Troubleshooting.................................................................................................................................................................................20
Drawings.................................................................................................................................................................................................................21

1
Foreword
The portable chiller is a packaged unit that typically
includes a refrigeration circuit, coolant reservoir, and
pumping system in a cabinet. The purpose is to
provide cooling water or coolant.
This manual is to serve as a guide for installing,
operating, and maintaining the equipment. Improper
installation, operation, and maintenance can lead to
poor performance and/or equipment damage. Use
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.
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.
The equipment uses a hydrofluorocarbon (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.
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