Thermal Care Accuchiller NQ Series Instruction Manual

Table of Contents
Foreword .................................................................................................................................................................................................................. 1
Safety Guidelines .................................................................................................................................................................................................. 1
Pre-Installation....................................................................................................................................................................................................... 2
Receiving Inspection ....................................................................................................................................................................................... 2
Unit Storage........................................................................................................................................................................................................ 2
Installation - Chiller.............................................................................................................................................................................................. 3
Foundation.......................................................................................................................................................................................................... 3
Unit Location...................................................................................................................................................................................................... 3
Rigging ................................................................................................................................................................................................................. 3
Chilled Process Fluid Piping ......................................................................................................................................................................... 3
Figure 1 – Recommended Overhead Piping..................................................................................................................................... 3
Condenser Water Piping ............................................................................................................................................................................... 3
Installation – Remote Condenser ................................................................................................................................................................... 4
Location................................................................................................................................................................................................................ 4
Lifting ............................................................................................................................................................................................................... 4
Mounting Legs .................................................................................................................................................................................................. 4
Figure 2 - Mounting Remote Condenser Legs ................................................................................................................................ 4
Interconnecting Refrigerant Piping........................................................................................................................................................... 4
Refrigeration Piping Design ......................................................................................................................................................................... 5
Figure 3 – Condenser Located at Chiller Level................................................................................................................................. 5
Figure 4 – Condenser Located Above Chiller Unit ......................................................................................................................... 5
Figure 5 - Condenser Located Below Chiller Unit........................................................................................................................... 5
Determining Equivalent Line Length ........................................................................................................................................................ 5
Table 1 – Equivalent Lengths of Elbows ............................................................................................................................................. 6
Liquid Line Sizing.............................................................................................................................................................................................. 6
Table 2 – Liquid Line Sizes for R410A.................................................................................................................................................. 7
Discharge (Hot Gas) Line Sizing.................................................................................................................................................................. 9
Figure 6 – Vertical Riser Traps ................................................................................................................................................................ 9
Figure 7 - Double Discharge Riser........................................................................................................................................................ 9
Table 3 - Horizontal or Downflow Discharge Line Sizes for R410A (inches OD)..............................................................10
Table 4 - Upflow Discharge Line Sizes for R410A (inches OD)................................................................................................10
Calculating Refrigerant and Oil Charge.................................................................................................................................................11
Table 5 – Chiller & Condenser Refrigerant Charge......................................................................................................................11
Table 6 - Field Piping R-410A Refrigerant Charges.....................................................................................................................11
Oil Charge Determination...........................................................................................................................................................................11
Setting Condenser Fan Controls...............................................................................................................................................................11
Table 7 - Condenser Fan Pressure Settings (psig)........................................................................................................................11
Figure 8 – Remote Condenser Fan Control Settings ...................................................................................................................11
Installation - Electrical.......................................................................................................................................................................................12
Control Operation ..............................................................................................................................................................................................13
Screen Navigation..........................................................................................................................................................................................13
System Initialization.......................................................................................................................................................................................13
Start-Up Screen..........................................................................................................................................................................................13
Home Screen....................................................................................................................................................................................................14
Home Overview Screen...........................................................................................................................................................................14
Menu 1 - Overview ........................................................................................................................................................................................14

Overview Screen 1.....................................................................................................................................................................................14
Overview Screen 2.....................................................................................................................................................................................14
Menu 1 - Alarms .............................................................................................................................................................................................14
HMI Alarm Handler Screen....................................................................................................................................................................14
Menu 1 – Diagnostics ...................................................................................................................................................................................15
Main Diagnostics Screen ........................................................................................................................................................................15
Diagnostics Screen 1 - Circuit 1 Overview.......................................................................................................................................15
Diagnostics Screen 2 – Circuit 1 Interlocks .....................................................................................................................................15
Diagnostics Screen 3 - Pumps..............................................................................................................................................................15
Diagnostics Screen 4 - Process ............................................................................................................................................................15
Diagnostics Screen 5 - Hardware........................................................................................................................................................15
Menu 1 – Security...........................................................................................................................................................................................16
Main Security Screen................................................................................................................................................................................16
Security – Log In Screen..........................................................................................................................................................................16
Security – Add User Screen ...................................................................................................................................................................16
Security - Edit User Screen.....................................................................................................................................................................16
Security - Delete User Screen...............................................................................................................................................................17
Security - Change Password Screen...................................................................................................................................................17
Menu 1 – Input/Output................................................................................................................................................................................17
Main Inputs/Outputs Screen.................................................................................................................................................................17
Inputs/Outputs – Temperature Inputs Screen ...............................................................................................................................17
Inputs/Outputs – Pressure Inputs .......................................................................................................................................................17
Inputs/Outputs – Analog Inputs Screen...........................................................................................................................................18
Inputs/Outputs – Digital Inputs Screen............................................................................................................................................18
Inputs/Outputs – Analog Outputs Screen.......................................................................................................................................18
Inputs/Outputs – Digital Outputs Screen ........................................................................................................................................18
Menu 1 – User Setup.....................................................................................................................................................................................18
User Setup Menu - Screen 1.................................................................................................................................................................18
User Setup Menu - Screen 2.................................................................................................................................................................18
User Setup Menu - Screen 3.................................................................................................................................................................18
User Setup – Alarm Setup Screen .......................................................................................................................................................19
User Setup – Hot Gas Bypass Screen.................................................................................................................................................19
User Setup – Pumps Screen ..................................................................................................................................................................19
User Setup – Process Pump VFD Screen..........................................................................................................................................19
User Setup – EEV Control Screen ........................................................................................................................................................19
User Setup - Staging................................................................................................................................................................................19
User Setup – Stage Order Screen........................................................................................................................................................19
User Setup – Discharge Control Screen 1........................................................................................................................................19
User Setup – Discharge Control Screen 2........................................................................................................................................20
User Setup – Modbus RTU Screen......................................................................................................................................................20
User Setup – Process Temperature Retransmit Screen ..............................................................................................................20
User Setup – Variable Speed Compressor Screen........................................................................................................................20
User Setup – IP Address Screen...........................................................................................................................................................20
User Setup – Units Screen......................................................................................................................................................................20
User Setup – 3-Way Mod Valve Screen............................................................................................................................................20
User Setup – Miscellaneous Menu Screen ......................................................................................................................................20
Menu 1 – Trending ........................................................................................................................................................................................21
System Trending Screen .........................................................................................................................................................................21
Menu 2 – Full Screen.....................................................................................................................................................................................21
Menu 2 – Full Screen................................................................................................................................................................................21
Menu 2 – System Build.................................................................................................................................................................................21

Review System Build Screen..................................................................................................................................................................21
Communications.............................................................................................................................................................................................22
Table 8 – Modbus Table .........................................................................................................................................................................22
Table 9 – BACNet Parameters ..............................................................................................................................................................26
Start-Up ..................................................................................................................................................................................................................31
Step 1 - Connect Main Power ...................................................................................................................................................................31
Step 2 - Fill Coolant Circuit.........................................................................................................................................................................31
System Fill Water Chemistry Requirements....................................................................................................................................31
Table 10 – Fill Water Chemistry Requirements..............................................................................................................................32
Table 11 - Recommended Glycol Solutions....................................................................................................................................32
Step 3 - Check Condenser ..........................................................................................................................................................................33
Integral Air-Cooled Condenser Check ..............................................................................................................................................33
Water-Cooled Condenser Check.........................................................................................................................................................33
Remote Air-Cooled Condenser Check..............................................................................................................................................33
Step 4 – Check Refrigerant Valves...........................................................................................................................................................33
Step 5 – Verify Freezestat Setting............................................................................................................................................................33
Step 6 – Turn On Control Power ..............................................................................................................................................................33
Step 7 – Establish Coolant Flow................................................................................................................................................................33
Step 8 – Intial Unit Operation....................................................................................................................................................................33
Preventive Maintenance...................................................................................................................................................................................34
Once a Week ....................................................................................................................................................................................................34
Once a Month..................................................................................................................................................................................................34
Every Three Months.......................................................................................................................................................................................34
Preventive Maintenance Checklist ...............................................................................................................................................................35
General Troubleshooting.................................................................................................................................................................................36
Drawings.................................................................................................................................................................................................................37
AHRI Certification ...............................................................................................................................................................................................37

Page Intentionally Blank

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 cool
water or a process fluid.
This manual is a guide for installing, operating, and
maintaining the equipment. Improper installation,
operation, and maintenance can lead to poor
performance and/or equipment damage.
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-410A, 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. Use a refrigerant management program
to document the type and quantity of refrigerant in
the equipment. Only allow licensed and EPA certified
service technicians to work on 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

2
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 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 all
items for visible damage. If damage is evident,
document it on the delivery receipt by marking any
item with damage as “unit damage” and notify the
carrier and our Customer Service Department. Do
not install damaged equipment without approval
from our Customer Service Department.
To protect against loss due to damage incurred
during shipping it is important to follow proper
procedures and keep records. When unpacking
equipment inspect for concealed damage and take
pictures 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 damage while the
equipment is still partially packed helps in this
regard.
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.
Unit Storage
When storing the unit it is important to protect it
from damage. Blow out any water from the unit;
cover it to keep dirt and debris from accumulating or
getting in, and store in an indoor sheltered area that
remains between 40°F and 140°F.

3
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
To ensure proper airflow and space for maintenance
allow a minimum of 36 inches of clearance between
the sides of the equipment and any walls or
obstructions. Avoid locating piping or conduit over
the unit to ensure easy crane access of heavier
components during replacement or service. Make
sure all refrigerant pressure relief valves can vent in
accordance with all local and national codes.
Air-cooled chillers use the surrounding air for
cooling the condenser and require free passage of
air in and out of the chiller. Locate the chiller in an
area that allows for removal of the warm air from the
area.
Rigging
The chiller has a cabinet with casters or feet and 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 cannot be
overemphasized. See the ASHRAE Handbook or
other suitable design guide for proper pipe sizing. In
general, run full size pipe to the process and only
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. When piping is overhead with a total
run over 90 feet, install 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
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.
Install a throttling valve or flow control valve on the
discharge line to allow for adjustment of the flow of
process fluid through the chiller. The valve should be
the same size as the To Process connection of the
chiller.
Condenser Water Piping
(Water-Cooled Condenser Chillers Only)
The performance of a water-cooled condenser chiller
depends on proper flow and temperature of the
condenser cooling water. Insufficient cooling of the
condenser will result in the reduction of cooling
capacity and under extreme conditions could result
in a high refrigerant pressure alarm. Contaminants in
the condenser water stream or scale formation will
lead to poor performance and the potential for
unwanted downtime.
The nominal water-cooled condenser requires 85°F
condenser water supply. Under normal operation
there will be about a 10°F rise through the
condenser resulting in 95°F exiting water. To
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

4
maintain proper flow through the condenser ensure
the condenser water pump supply provide at least
25 psi at a flow of 3 gpm per ton of chiller capacity.
The condenser has a two-way condenser water-
regulating valve to control the amount of water
passing through the condenser, which in turn
maintains the 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 Condenser
Chillers 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.
The condenser 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.
Location
The condenser is for outdoor use. Locate the remote
condenser in an accessible area with enough space
to allow for easy maintenance and operation. 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.
The vertical air discharge must be unobstructed.
Allow a minimum of 48 inches of clearance on all
sides of the condenser. 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.
Proper ventilation is important. Locate the condenser
in an area that will not rise above 110°F. Avoid areas
such as an alcove with east, north, and west walls
that can be significantly warmer than surrounding
areas. Locate the condenser where fan noise and
vibration transmission into nearby workspaces is
unlikely.
Install the condenser on a firm, level surface. 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.
Lifting
Use qualified personnel 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 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. For units
that are longer than three fans, assemble the center
leg. Remove two bolts from the bottom flange of the
unit side panels that match the hole-pattern on the
top flanges of both legs. Attached the center legs
using the hardware provided at the center-divider
panel location. Replace the bolts removed from the
side panels to secure the leg assembly to the bottom
flanges of the condenser side panels.
Figure 2 - Mounting Remote Condenser Legs
Interconnecting Refrigerant Piping
The chiller and remote condenser ship with a
nitrogen holding charge. Evacuate this charge before
charging with refrigerant.
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
Corner Le
g
Center Leg
(Ri
g
ht-hand Side Facin
g
Header)

5
piping should conform to the applicable local and
state codes.
CAUTION: Only use refrigerant grade copper tubing
ASTM B280 and isolate the refrigeration lines from
building structures to prevent transfer of vibration. All
copper tubing must have a pressure rating suitable for
R-410A: tubing that is 3/4” OD or larger must be Type
K rigid tubing. ACR annealed tubing coil may be used
for sizes 5/8” ODS or smaller.
Use a tube cutter or heat to remove the caps. When
sweating copper joints 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 condenser are important factors in
determining the liquid line and discharge line sizes
and refrigerant charge.
General design considerations:
1. The total distance between the chiller and the
condenser must not exceed 200 actual feet or
300 equivalent feet.
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 is
in Table 2. 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
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

6
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 1.
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 OD
(in)
Equivalent Lengths of Refrigerant Pipe (feet)
90°
Standard
90°Long
Radius
90°
Street
45°
Standard
45°
Street
⅞2.0 1.4 3.2 0.9 1.6
1⅛2.6 1.7 4.1 1.3 2.1
1⅜3.3 2.3 5.6 1.7 3.0
1⅝4.0 2.6 6.3 2.1 3.4
2⅛5.0 3.3 8.2 2.6 4.5
2⅝6.0 4.1 10.0 3.2 5.2
3⅛7.5 5.0 12.0 4.0 6.4
3⅝9.0 5.9 15.0 4.7 7.3
4⅛10.0 6.7 17.0 5.2 8.5
Liquid Line Sizing
To keep the system refrigerant charge at a minimum
use the smallest acceptable line size possible. The
total length between the chiller and the condenser
must not exceed 200 actual feet or 300 equivalent
feet. Pipe the liquid line so 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 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, insulate the lines to
avoid a negative effect on sub-cooling.

7
Table 2 – Liquid Line Sizes for R410A
5 Ton Circuit (R410A) Liquid Line Size (Inch OD) 7½ Ton Circuit (R410A) Liquid Line Size (Inch OD)
Equivalent
Length (Ft)
Horizontal or
Down Flow
Up Flow (Feet of Run) Equivalent
Length (Ft)
Horizontal or
Down Flow
Up Flow (Feet of Run)
0 to 5 6 to 10 11 to 15 0 to 5 6 to 10 11 to 15
25 1/2 1/2 1/2 1/2 25 5/8 5/8 5/8 5/8
50 1/2 1/2 1/2 5/8 50 5/8 5/8 5/8 5/8
75 1/2 1/2 1/2 5/8 75 5/8 5/8 5/8 3/4
100 1/2 1/2 5/8 5/8 100 5/8 5/8 5/8 3/4
125 1/2 1/2 5/8 3/4 125 5/8 5/8 3/4 3/4
150 1/2 5/8 5/8 3/4 150 5/8 5/8 3/4 7/8
175 5/8 5/8 5/8 3/4 175 5/8 5/8 3/4 7/8
200 5/8 5/8 5/8 3/4 200 5/8 3/4 3/4 7/8
225 5/8 5/8 5/8 3/4 225 5/8 3/4 3/4 7/8
250 5/8 5/8 5/8 3/4 250 5/8 3/4 3/4 7/8
275 5/8 5/8 3/4 3/4 275 3/4 3/4 3/4 7/8
300 5/8 5/8 3/4 7/8 300 3/4 3/4 3/4 7/8
10 Ton Circuit (R410A) Liquid Line Size (Inch OD) 15 Ton Circuit (R410A) Liquid Line Size (Inch OD)
Equivalent
Length (Ft)
Horizontal or
Down Flow
Up Flow (Feet of Run) Equivalent
Length (Ft)
Horizontal or
Down Flow
Up Flow (Feet of Run)
0 to 5 6 to 10 11 to 15 0 to 5 6 to 10 11 to 15
25 3/4 3/4 3/4 3/4 25 7/8 7/8 7/8 7/8
50 3/4 3/4 3/4 3/4 50 7/8 7/8 7/8 7/8
75 3/4 3/4 3/4 3/4 75 7/8 7/8 7/8 7/8
100 3/4 3/4 3/4 7/8 100 7/8 7/8 7/8 1 1/8
125 3/4 3/4 3/4 7/8 125 7/8 7/8 7/8 1 1/8
150 3/4 3/4 3/4 7/8 150 7/8 7/8 7/8 1 1/8
175 3/4 3/4 3/4 7/8 175 7/8 7/8 7/8 1 1/8
200 3/4 3/4 7/8 1 1/8 200 7/8 7/8 1 1/8 1 1/8
225 3/4 3/4 7/8 1 1/8 225 7/8 7/8 1 1/8 1 1/8
250 3/4 3/4 7/8 1 1/8 250 7/8 7/8 1 1/8 1 1/8
275 3/4 3/4 7/8 1 1/8 275 7/8 7/8 1 1/8 1 1/8
300 3/4 7/8 7/8 1 1/8 300 7/8 7/8 1 1/8 1 1/8

8
Table 2 – Liquid Line Sizes for R410A (continued)
20 Ton Circuit (R410A) Liquid Line Size (Inch OD) 25 Ton Circuit (R410A) Liquid Line Size (Inch OD)
Equivalent
Length (Ft)
Horizontal or
Down Flow
Up Flow (Feet of Run) Equivalent
Length (Ft)
Horizontal or
Down Flow
Up Flow (Feet of Run)
0 to 5 6 to 10 11 to 15 0 to 5 6 to 10 11 to 15
25 1 1/8 1 1/8 1 1/8 1 1/8 25 1 1/8 1 1/8 1 1/8 1 1/8
50 1 1/8 1 1/8 1 1/8 1 1/8 50 1 1/8 1 1/8 1 1/8 1 1/8
75 1 1/8 1 1/8 1 1/8 1 1/8 75 1 1/8 1 1/8 1 1/8 1 1/8
100 1 1/8 1 1/8 1 1/8 1 1/8 100 1 1/8 1 1/8 1 1/8 1 1/8
125 1 1/8 1 1/8 1 1/8 1 1/8 125 1 1/8 1 1/8 1 1/8 1 1/8
150 1 1/8 1 1/8 1 1/8 1 1/8 150 1 1/8 1 1/8 1 1/8 1 3/8
175 1 1/8 1 1/8 1 1/8 1 1/8 175 1 1/8 1 1/8 1 1/8 1 3/8
200 1 1/8 1 1/8 1 1/8 1 3/8 200 1 1/8 1 1/8 1 1/8 1 3/8
225 1 1/8 1 1/8 1 1/8 1 3/8 225 1 1/8 1 1/8 1 1/8 1 3/8
250 1 1/8 1 1/8 1 1/8 1 3/8 250 1 1/8 1 1/8 1 1/8 1 3/8
275 1 1/8 1 1/8 1 1/8 1 3/8 275 1 1/8 1 1/8 1 1/8 1 3/8
300 1 1/8 1 1/8 1 1/8 1 3/8 300 1 1/8 1 1/8 1 3/8 1 3/8
30 Ton Circuit (R410A) Liquid Line Size (Inch OD) 35 Ton Circuit (R410A) Liquid Line Size (Inch OD)
Equivalent
Length (Ft)
Horizontal or
Down Flow
Up Flow (Feet of Run) Equivalent
Length (Ft)
Horizontal or
Down Flow
Up Flow (Feet of Run)
0 to 5 6 to 10 11 to 15 0 to 5 6 to 10 11 to 15
25 1 1/8 1 1/8 1 1/8 1 1/8 25 1 3/8 1 3/8 1 3/8 1 3/8
50 1 1/8 1 1/8 1 1/8 1 1/8 50 1 3/8 1 3/8 1 3/8 1 3/8
75 1 1/8 1 1/8 1 1/8 1 1/8 75 1 3/8 1 3/8 1 3/8 1 3/8
100 1 1/8 1 1/8 1 1/8 1 3/8 100 1 3/8 1 3/8 1 3/8 1 3/8
125 1 1/8 1 1/8 1 1/8 1 3/8 125 1 3/8 1 3/8 1 3/8 1 3/8
150 1 1/8 1 1/8 1 1/8 1 3/8 150 1 3/8 1 3/8 1 3/8 1 3/8
175 1 1/8 1 1/8 1 1/8 1 3/8 175 1 3/8 1 3/8 1 3/8 1 3/8
200 1 1/8 1 1/8 1 1/8 1 3/8 200 1 3/8 1 3/8 1 3/8 1 5/8
225 1 1/8 1 1/8 1 3/8 1 3/8 225 1 3/8 1 3/8 1 3/8 1 5/8
250 1 1/8 1 1/8 1 3/8 1 5/8 250 1 3/8 1 3/8 1 3/8 1 5/8
275 1 1/8 1 1/8 1 3/8 1 5/8 275 1 3/8 1 3/8 1 3/8 1 5/8
300 1 1/8 1 1/8 1 3/8 1 5/8 300 1 3/8 1 3/8 1 3/8 1 5/8

9
Table 2 – Liquid Line Sizes for R410A (continued)
40 Ton Circuit (R410A) Liquid Line Size (Inch OD)
Equivalent
Length (Ft)
Horizontal or
Down Flow
Up Flow (Feet of Run)
0 to 5 6 to 10 11 to 15
25 1 3/8 1 3/8 1 3/8 1 3/8
50 1 3/8 1 3/8 1 3/8 1 3/8
75 1 3/8 1 3/8 1 3/8 1 3/8
100 1 3/8 1 3/8 1 3/8 1 3/8
125 1 3/8 1 3/8 1 3/8 1 3/8
150 1 3/8 1 3/8 1 3/8 1 5/8
175 1 3/8 1 3/8 1 3/8 1 5/8
200 1 3/8 1 3/8 1 3/8 1 5/8
225 1 3/8 1 3/8 1 3/8 1 5/8
250 1 3/8 1 3/8 1 3/8 1 5/8
275 1 3/8 1 3/8 1 3/8 1 5/8
300 1 3/8 1 3/8 1 3/8 1 5/8
Discharge (Hot Gas) Line Sizing
The discharge line size depends 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 require a trap at the bottom
and reverse trap at the top. In addition, install a trap
and reverse trap arrangement spaced every 15 feet
in the rise for oil management (see Figure 6).
Pitch the discharge lines 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 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.
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. Use a double riser
system to ensure proper oil return under low load
operation. See Figure 7 and Table 4 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 are listed per circuit and apply where 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.

10
Table 3 - Horizontal or Downflow Discharge Line Sizes for R410A (inches OD)
Circuit
Tons
Total Equivalent Length (Ft)
25 50 75 100 125 150 175 200 225 250 275 300
5 5/8 5/8 5/8 5/8 3/4 3/4 3/4 3/4 3/4 3/4 3/4 7/8
7.5 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8
10 7/8 7/8 7/8 7/8 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8
15 7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8
20 7/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8
25 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8
30 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8
35 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8
40 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8
Table 4 - Upflow Discharge Line Sizes for R410A (inches OD)
Circuit
Tons
Total Equivalent Length (Ft)
25 50 75 100 125 150 175 200 225 250 275 300
5 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8
B – 1/2 B – 1/2 B – 1/2 B – 1/2 B – 5/8 B – 5/8 B – 5/8 B – 5/8 B – 5/8 B – 5/8 B – 5/8 B – 3/4
7.5 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8
B – 3/4 B – 3/4 B – 3/4 B – 3/4 B – 3/4 B – 3/4 B – 3/4 B – 3/4 B – 3/4 B – 3/4 B – 3/4 B – 3/4
10 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8
B – 3/4 B – 3/4 B – 3/4 B – 3/4 B – 3/4 B – 3/4 B – 3/4 B – 7/8 B – 7/8 B – 7/8 B – 7/8 B – 7/8
15 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 1/2 A – 1/2
B – 3/4 B – 3/4 B – 7/8 B – 7/8 B – 7/8 B – 7/8 B – 7/8 B – 7/8 B – 7/8 B – 7/8 B – 1 1/8 B – 1 1/8
20 A – 3/8 A – 3/8 A – 3/8 A – 1/2 A – 1/2 A – 1/2 A – 1/2 A – 1/2 A – 1/2 A – 1/2 A – 5/8 A – 5/8
B – 3/4 B – 7/8 B – 7/8 B – 1 1/8 B – 1 1/8 B – 1 1/8 B – 1 1/8 B – 1 1/8 B – 1 1/8 B – 1 1/8 B – 1 3/8 B – 1 3/8
25 A – 3/8 A – 3/8 A – 3/8 A – 1/2 A – 1/2 A – 1/2 A – 1/2 A – 1/2 A – 1/2 A – 1/2 A – 5/8 A – 5/8
B – 7/8 B – 7/8 B – 7/8 B – 1 1/8 B – 1 1/8 B – 1 1/8 B – 1 1/8 B – 1 1/8 B – 1 1/8 B – 1 1/8 B – 1 3/8 B – 1 3/8
30 A – 1/2 A – 1/2 A – 1/2 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4
B – 7/8 B – 7/8 B – 7/8 B – 1 1/8 B – 1 1/8 B – 1 1/8 B – 1 1/8 B – 1 1/8 B – 1 1/8 B – 1 3/8 B – 1 3/8 B – 1 3/8
35 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4
B – 1 1/8 B – 1 1/8 B – 1 1/8 B – 1 3/8 B – 1 3/8 B – 1 3/8 B – 1 3/8 B – 1 5/8 B – 1 5/8 B – 1 5/8 B – 1 5/8 B – 1 5/8
40 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4 A – 3/4
B – 1 3/8 B – 1 3/8 B – 1 3/8 B – 1 3/8 B – 1 3/8 B – 1 3/8 B – 1 5/8 B – 1 5/8 B – 1 5/8 B – 1 5/8 B – 1 5/8 B – 1 5/8

11
Calculating Refrigerant and Oil Charge
To estimate the total amount of refrigerant required
to charge the system combine the charges from the
below two tables for the size system and line sizes
used..
Table 5 – Chiller & Condenser Refrigerant Charge
Circuit Capacity
(tons)
Chiller and Condenser Combined Summertime
Refrigerant Charge (lbs of R410A)
5 7.6
7.5 11.1
10 15.3
15 22.2
20 30.2
25 37.2
30 44.3
35 51.9
40 59.4
Table 6 - Field Piping R-410A Refrigerant Charges
Line Size OD
(inches)
Lbs of R410A per 100 Foot of Line Length
Discharge Line Liquid Line
3/8 0.4 3.7
1/2 0.7 6.8
5/8 1.1 11
3/4 1.6 16.4
7/8 2.2 22.8
1 1/8 3.6 36.7
1 3/8 5.6 57.4
1 5/8 7.9 81.2
2 1/8 13.9 142.1
2 5/8 21.4 219.5
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
Oil level should be checked after the chiller has run
for 15 minutes.
Setting Condenser Fan Controls
The remote condenser has a controller that cycles
the fans as needed to maintain the proper
refrigerant pressure. The settings change based on
the number of fans in the remote condenser. Refer
to Table 7 for the proper pressure settings.
Table 7 - Condenser Fan Pressure Settings (psig)
Stage
Number Setting Number of Fan Stages
1 2 3 4
Stage 1 Max Speed 410 410 410 410
Min Speed 320 320 320 320
Stage 2 Fan On 400 400 370
Fan Off 340 340 305
Stage 3 Fan On 435 385
Fan Off 375 325
Stage 4 Fan On 400
Fan Off 340
To change the settings open the remote condenser
control panel, remove the cover from the pressure
control module, and make sure everything is set as
shown below.
Figure 8 – Remote Condenser Fan Control Settings

12
Installation - Electrical
Install all wiring in compliance to all applicable local
and national codes. Minimum circuit amps (MCA)
and other unit electrical data are on the unit
nameplate. An 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 shown 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 2%.
Excessive voltage imbalance between the phases of a
three-phase system can cause motors to overheat
and eventually fail.
Check the main power 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. Operation of the
compressor with incorrect electrical phase
sequencing will result in mechanical damage to the
compressors.
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 startup.

13
Control Operation
The units uses a Programmable Logic Controller
(PLC) and color touch-screen operator interface
display that serves as the Human to Machine
Interface (HMI).
Screen Navigation
The overall menus structure allows for quick access
and navigation to each section of the control
monitoring and control system. The following are
the main buttons used to navigate through the
various screens.
Menu Button – This button is located on the top left
of the screen. Touch this button to go to Menu 1.
Home Button – This button is located on the bottom
of the screen. Touch this button to go to the Home
Overview Screen.
Alarm Button – This button is located on the bottom
of the screen. This button shows the number of alarms
active. Touch this button to go to the HMI Alarm
Handler Screen.
Alarm Reset Button – This button is located on the
bottom of the screen. Touch this button to
acknowledge and silence active alarms.
Start/Stop Button – This button is located at the
bottom right of the screen. Touch this button to start
and stop the chiller. When stopped, the button outline
is red, when running the button outline is green.
Arrow Button – These buttons appear in multiple
areas of the screen. Touch these buttons to navigate
forward, back, up or down in menus and screens.
Some screens are password protected to prevent
unintended changes. There are two levels of security
(Username is case sensitive):
“User” Level Password = 9999
“Supervisor” Level Password = 7720
When navigating screens any user adjustable areas
appear in a slightly different color. Touching one of
these areas brings up a keypad. Use the keypad to
enter the appropriate user and password to gain
access.
The user-level password allows access to the most
common functions; however, there are a few screens
protected with a Supervisor-level password.
Changing items in Supervisor-level menus without
fully understanding the impact can lead to improper
or poor performance of the unit. Contact our
Customer Service department for assistance with any
questions before making changes.
There is a master reset function to restore the
factory default settings. When this is done you will
need to follow the on-screen prompts to reconfigure
the chiller based on the options present. For
assistance with this process, please contact our
Customer Service Department and have the unit
Serial Number ready for reference.
System Initialization
When power is initially applied, the first screen to
appear is the Start-Up Screen. This screen displays
while the PLC and HMI establish communications.
The PLC and HMI version shows on the screen and
must match.
Start-Up Screen
Once control communication is established, the HMI
screen automatically switches to the Home Screen.

14
Home Screen
This screen provides an overall synopsis of the
system, quick links to other views, as well as other
additional information.
Home Overview Screen
Note: This is an example of a chiller with the most extensive set of
options; your screen may appear slightly differently based on your
actual chiller configuration.
Use the main screen to navigate to other screens
and menus. The menu and screen buttons are
located at the bottom of all screens. Touch any one
of these to navigate to that menu or screen.
Menu 1 - Overview
The Menu 1 Screen contains buttons to allow
navigation to various sections of the control system.
Some parameters are password protected. The main
User level password is for gaining access to
changing the main system set point and various
other warning and alarm settings. A few higher-level
areas require a high-level “Supervisor” password.
Contact our Customer Service Department for
assistance in accessing any restricted menus.
Overview Screen 1
Overview Screen 2
To return to the Home screen simply touch the
Home button. Some screens have links to sub-
screens or menus but all have a Home button to
allow you to return to the Home screen.
Menu 1 - Alarms
When a critical system fault occurs, the controller
activates the HMI alarm handler. This forces the
alarm screen to appear and will display the current
faults. To silence this alarm, press the ALARM
SILENCE button. If multiple alarms are active at once,
use the DOWN and UP buttons to view all alarms.
When no alarms are active, the white portion of the
display will be blank. All alarms must be resolved
and reset using the RESET ALARM button.
HMI Alarm Handler Screen
Note: The above shows there are no alarms; if an alarm condition
was present, it would appear in this window.