ClimaCool FLEX 30, Installation, Operation & Maintenance Manual

Page 1: ... Installation Operation Maintenance Manual ClimaCool IOM FLEX SERIES Water Cooled Modular Chillers ...

Page 2: ... described herein Please contact ClimaCool s Customer Service Department at 405 745 3185 for specific information on the current design and specifications Statements and other information contained herein are not express warranties and do not form the basis of any bargain between the parties but are merely ClimaCool s opinion or commendation of its products Refer to www climacoolcorp com for complet...

Page 3: ...c Timer Flush Package Option 18 Pressure Differential Alarm Package 21 Y Type and Basket Type Strainers 23 Pre Start Up 24 Start Up 25 Pre Start Up Check List 26 Start Up and Warranty Registration Form 27 Chiller Operation and Maintenance 28 Heat Exchangers Drawings 29 Operation Limitations 30 Physical Data 31 Application Parameters 32 Compressor Information 33 Refrigeration Circuit Drawings 34 Re...

Page 4: ...f all damage immediately Refer to the back cover for the Customer Service Department phone number Storage Equipment should be stored as shipped in a clean dry area Store modules in an upright position at all times Plastic wrap should be left on until the module is ready to be installed Handling of Modules The packaging allows for handling by fork lift or pallet jack only lift the module from the s...

Page 5: ...quipped with isolation valves for this purpose Access to a floor drain is helpful when performing standard maintenance procedures INSTALLATION Assembling Modules Use of 2 4 rails minimum size is required for ease of installation One of the end modules should be chosen as the reference module and carefully located Site Preparation Installation A factory supplied fastener kit is provided for the adjo...

Page 6: ...th Height Height w covers Weight1 Oper Weight2 FLEX inches inches inches inches lbs lbs 30 208 230 3 60 41 7 8 29 1 2 72 7 8 77 1 669 1 825 30 460 3 60 41 7 8 29 1 2 72 7 8 77 1 669 1 825 30 575 3 60 41 7 8 29 1 2 72 7 8 77 1 669 1 825 50 208 230 3 60 41 7 8 33 1 2 76 5 8 78 3 8 1 873 2 163 50 460 3 60 41 7 8 33 1 2 76 5 8 78 3 8 1 873 2 163 50 575 3 60 41 7 8 33 1 2 76 5 8 78 3 8 1 873 2 163 65 2...

Page 7: ...TION Units are top heavy Please use caution when rigging or moving When lifting and transporting the module it is very im s n a e m r e h t o y n a f o e s U t h g i r t a n w o h s s a d e e c o r p o t t n a t r o p for lifting and transporting may damage the module and void the warranty Lifting and Transporting Modules Figure 3 A spreader bar should be utilized when rigging with ClimaCool Riggi...

Page 8: ... minimum of 18 height clearance for service and 12 for side clerances 3 Local building or electrical codes may require additional clearance Consult applicable codes Modular Chiller Bank Dimensions w Connnection Flange Gaskets and Blank Off Plates Model Dimensions FLEX Width ft inches Depth Height w o panels Height w panels 30 50 65 30 50 65 30 50 65 30 50 65 1 module 2 7 1 8 2 11 1 8 2 11 1 8 41 7...

Page 9: ...or pads Should isolators or pads be desired install in accordance with Figs 1 and 2 Figure 1 Spring Vibration Isolators Option Figure 2 Vibration Isolation Pads Option NOTE l a u d i v i d n i r e p r e e n i g n e l a r u t c u r t s d e fi i l a u q a y b d e n i m r e t e d e b o t s i n o i t u b i r t s i d t h g i e w d n a e z i S job requirements 4 Rail Minimum Required by others 4 Rail Min...

Page 10: ... Proper clockwise rotation for scroll compressor motors is important to prevent damaging the compressors If you have access to a phase sequence indicating instrument it is recommended to use this following the manufactures directions If not you may bump test the compressors one at a time with pressure gauges attached to the high and low gauge ports of the compressors to check for proper rotation E...

Page 11: ...10 Water Piping Configurations Temperature Sensor Wells Four temperature sensors and wells are provided with each ClimaCool chiller system chilled water inlet chilled water outlet condenser water inlet condenser water outlet The installing contractor must install these temperature sensor wells as shown in figures 1 and 2 on page 10 Strainers Minimum 60 Mesh Screen Required ClimaCool chillers employ ...

Page 12: ...tribution through ClimaCool modular chillers 2 Module order and incoming outgoing water flow as shown in both Figure 1 and 2 can be set up as either a left to right or right to left configuration 3 Condenser Hydronic Circuit shown Piping configurations are similar for the chilled water hydronic circuit 4 For condenser and chilled water evaporator inlet outlet location dimensions refer to Module Dimen...

Page 13: ...ircuit 2 Service Port 3 4 Pete s Port Pete s Port Service Port 3 4 From Cooling Tower To Cooling Tower Header Header Isolation Ball Valve 2 or 2 1 2 Isolation Ball Valve 2 or 2 1 2 Heat Exchanger Refrigerant Circuit 1 Refrigerant Circuit 2 Service Port 3 4 Pete s Port Service Port 3 4 Chilled Water Outlet Chilled Water Inlet Sensor Well internal Cap Tube to Low Limit Protection Thermostat Header H...

Page 14: ...ce to properly clean the water systems 1 If possible install a temporary bypass line between the supply and return water lines of both water systems prior to cleaning the system 2 Close all isolation valves inside each modular chiller before engaging the main water pumps 3 The pumps should be run with the strainer in place see the Starting the Pumps section for proper pump startup All external hyd...

Page 15: ...wer the freezing point Heavily Contaminated Water In such instances whereby the particulates in the water are excessive it is recommended to install an intermediate plate frame heat exchanger to isolate the ClimaCool chiller from the building water system Water Treatment Other Considerations The following considerations are listed to help achieve system longevity Cooling Tower The cooling tower sh...

Page 16: ...perature in the evaporator This pressure differential is most commonly ensured by cycling the fans on the cooling tower to maintain the entering condenser water temperature above the minimum temperature of 65 F An alternate method to maintain the minimum entering condenser water temperature above 65 F is to employ a bypass arrangement as show in Fig 1 below This valve is an automatic 3 way bypass ...

Page 17: ...ner s maximum operating pressure not to exceed the maximum rated pressure Consult your local dealer or pressure relief valve manufacturer to obtain properly sized valves for your application Note At No Time Should The Internal Pressure Exceed The Maximum Rated Pressure For Your Strainer Strainer Installation Recommendations We recommend following the guidelines below when installing your strainer ...

Page 18: ...ire higher inlet water pressures in order to achieve a complete flushing For example the CS 4 model can be flushed with inlet water pressures as low as 15 PSI while the CS 6 can be flushed with 30 PSI The CS 8 and CS 10 models should be flushed with inlet water pressures greater than 40 PSI Stainless Steel Strainer Option Note When shutting down the chiller for extended periods of time the strainer sh...

Page 19: ...change in velocity If the flow has been abruptly shut off downstream the pressure in the entire system is raised very quickly What Causes Water Hammer Any action that can cause a rapid change in the velocity of the flow can set off a water hammer such as closing a downstream valve pump stoppage etc Typically for short lengths of pipe below 500 feet downstream valves that are closed within 1 10th of ...

Page 20: ... controller s settings refer to your specific strainer manual To program the ATF Controller Plug the transformer into a 120 VAC outlet Insert the 12 VDC plug coming from the transformer into the jack on the underside of the ATF box Test for power by pressing the manual flush side of the control switch lower switch light should come on and the valve will start to open Adjust the ON TIME Valve Open by...

Page 21: ...amaged or worn out Install repair kit Valve is not stopping at proper Adjust limit switches closed position Valve stem leaks Worn stem seals On metal valves tighten stem packing nut 1 2 turn CAUTION Over tightening stem nut could cause drag on motor and trip internal circuit breaker May require repair kit or new valve Valve body leaks Loose body bolts or excessive operating Check bolts and observe...

Page 22: ...ess than 90 days old needing repair under warranty conditions must be returned to ClimaCool and must be accompanied by a Return Material Authorization RMA Number To request a RMA Number call 405 745 3185 then enter this number on the RMA form available from the ClimaCool web site Please Follow Environmental Note All ATF valves sent to ClimaCool for repair must be cleaned and the valve rinsed and d...

Page 23: ...l Strainer operates at a pressure differential slightly less than 1 PSI during maximum flow when the strainer screen is clean By the time this differential pressure reaches 7 8 PSI the strainer element will be significantly clogged and require immediate removal and cleaning To adjust the pressure differential switch gauge setting insert a 1 16 allen wrench and rotate the differential set point conta...

Page 24: ... cover plate If you have any additional questions please contact a ClimaCool technical representative at 405 745 3185 Water Resistance The Pressure Differential Alarm Controller is water resistant but not water proof Do not install below ground level where the box can be submerged in water DO NOT REMOVE the cover plate from the PDA Controller Keep the cover tightly sealed on the module during norm...

Page 25: ... F Tighten cover The strainer is ready for line start up For Basket Strainers Follow Steps G through L G Drain piping H Vent line to relieve pressure 1 Loosen cover and open to access basket J Remove clean and replace basket in original position Note In some instances a high pressure water jet or steam may be required for effective cleaning K Inspect cover gasket for damage If necessary replace No...

Page 26: ...e no visible signs of refrigerant leaks Pre Start Up 4 Place refrigerant gauges on the discharge and suction access ports of each refrigerant circuit to ensure a refrigerant charge is present Leave the gauges on for compressor rotation check 5 Confirm the settings on all pressure switches and thermostats Water System 1 Confirm that leak testing has been carried out 2 Confirm that the system is clean ...

Page 27: ...er water temperature is below the normal operating level ensure that the condenser water temperature control is in the correct position 3 Re install all fuses and set the controller 4 When all temperatures are within operating limits all Start Up high and low pressure safety switches should be tested for each refrigeration system 5 The condenser temperature controller should be checked Once stable...

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Page 30: ...r oil level Check and test all safeties Check water flow rates and pressure drops across evaporator and condenser Properly document all data taken Annual Isolate chiller drain all water circuits Back flush all heat exchangers use only ClimaCool recommended de scalers Remove and clean all waterside strainers Perform leak test on all refrigerant circuits Check all interconnecting flanges for proper tig...

Page 31: ...ergoes the Clean In Place Washing The rest of the chiller modules can continue to operate to satisfy the cooling load required The cleaning tank pump and pump strainer should be arranged in the manner shown in Fig 2 In Place Cleaning Arrangement The flow of the cleaning is arranged in the opposite flow to the normal operational direction Connection points are provided using the 3 4 service ports at ...

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Page 33: ... 8 43 5 8 Width 29 1 2 33 1 2 33 1 2 Denotes unit with covers Height 77 78 3 8 78 3 8 Height 72 7 8 76 5 8 76 5 8 Module Operating Weight w Water Lbs 3 1825 2163 2280 Module Shipping Weight Lbs 4 1669 1873 1990 p y yp g Q y g Q y g Q y p yp p Q y p p g g g g g g g g g g g g g g g g p g g p g g p g g g s r o s s e r p m o C d n a e l u d o M Model FLEX 30 50 65 pp g g Heat Exchanger Type Brazed Pla...

Page 34: ...pplication Parameters 3UHVVXUH URS W RI DWHU ORZ 30 YDSRUDWRU DWHU 3UHVVXUH URS 7RQ 6HULHV 0RGHO 0 0 0RGHO 0 0RGHO 0 3UHVVXUH URS 36 3UHVVXUH URS W RI DWHU ORZ 30 RQGHQVHU DWHU 3UHVVXUH URS 7RQ 6HULHV 0RGHO 0 0 0RGHO 0 0RGHO 0 3UHVVXUH URS 36 ...

Page 35: ...il level should be between 1 3 and 1 2 of the sight glass During operation a certain amount of oil is carried out into the refrigeration system The system has been designed to bring the oil back to the compressor If the level in the sight glass falls it may be due to the operating conditions and enough time should be given to allow the oil to return before more oil is added This could take up to 6...

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Page 38: ... the following codes ASHRAE Standard Safety Code for Mechanical Refrigeration ANSI ASHRAE 15 1978 American National Standard Code for Pressure Piping ANSI B31 5 1974 Factory Tested ClimaCool modular chillers have been leak tested fully charged and factory run tested before shipment In the unlikely event that a refrigerant leak is detected at start up the following guidelines should be consulted be...

Page 39: ...r is above 65 F Each module of the chiller has 2 compressors Stage 1 compressors shall be started first on lead week and stage 2 compressors shall be started first on lag weeks to equalize run hours between compressors 1 and 2 of the modules automatically Compressors shall be staged with a single compressor per module as required until all available modules of the chiller have one compressor running...

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Page 42: ... JSPTHJVVSJVYW JVT JSPTHJVVSJVYW JVT 40 Module Power Control Circuit T H E U L T I M A T E C H I L L E R S O L U T I O N ...

Page 43: ... JSPTHJVVSJVYW JVT 41 Module Power Control Circuit T H E U L T I M A T E C H I L L E R S O L U T I O N ...

Page 44: ... JSPTHJVVSJVYW JVT JSPTHJVVSJVYW JVT 42 Module Power Control Circuit T H E U L T I M A T E C H I L L E R S O L U T I O N ...

Page 45: ... power 6 Change any 2 of 3 phases of main power COMPRESSOR HUMS BUT DOES NOT START Possible Cause Remedy 1 Low voltage 1 Check at main power entry and power entry at unit consult power company if low COMPRESSOR RUNS BUT DOES NOT COOL Possible Cause Remedy 1 Improper phasing of main power 1 Change any 2 of 3 phases of main power 2 Refrigeration service valves closed 2 Open all refrigeration system ...

Page 46: ...cient water flow through the condenser 8 Check water flow thru condenser against design requirements 9 Fouled condenser brazed plate heat exchanger 9 Clean in place heat exchanger as described in previous section 10 Defective high pressure switch 10 Replace high pressure switch CAUSES AND PREVENTION OF FREEZE UP Possible Cause Prevention 1 Improper charging 1 Charge per ClimaCool s data plate info...

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Page 50: ...ific information on the current design and specifications Statements and other information contained herein are not express warranties and do not form the basis of any bargain between the parties but are merely ClimaCool s opinion or commendation of its products For the most current version of this document please visit www climacoolcorp com The management system governing the manufacture of ClimaCo...