Thermal Care Accuchiller KSE, Operation, Installation, And Maintenance Manual

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Page 3: ...reen Navigation 7 System Initialization 7 Figure 5 Start Up Splash Screen 7 Home Chiller Home Screen 8 System Overview 8 Figure 6 Chiller Home Screen 8 Table 1 System Overview Functions 8 Starting and...

Page 4: ...igital Outputs Screen 14 Menu 1 User Setup 14 Figure 33 User Setup Menu 1 Screen 14 Figure 34 User Setup Menu 2 Screen 14 Figure 35 User Setup Menu 3 Screen 14 User Setup Alarm Setup 15 Figure 36 User...

Page 5: ...ser Setup Primary Secondary Setup Screen 19 User Setup Chiller Capacity 20 Chiller Capacity Screen 20 Figure 50 User Setup Chiller Capacity Setup Screen 20 User Setup Date Time 20 Date Time Screen 20...

Page 6: ...erant Valves 26 Step 5 Check Low Temperature Alarm 26 Step 6 Turn On Control Power 26 Step 7 Establish Coolant Flow 26 Step 8 Initial Unit Operation 27 Preventive Maintenance 27 Once a Week 27 Once a...

Page 7: ...rant 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...

Page 8: ...aining 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 wi...

Page 9: ...e the clearance on the control panel side to 4 feet while still meeting NEC code and without impeding performance When installing multiple chillers in the same location the minimum separation between...

Page 10: ...4 Figure 3 Mounting Platform Figure 4 Rigging...

Page 11: ...e main terminal block energizes the entire electric circuitry of the unit A power supply provides 24 VDC control power Shut off the electric power at the main disconnect before opening access panels f...

Page 12: ...f 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 sequenc...

Page 13: ...assword 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 adj...

Page 14: ...h circuit None Status Messaging Provides information about any warnings or alarms which may have occurred None Setpoint Modify the Setpoint by touching the current Setpoint on the HMI An authorized se...

Page 15: ...em 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...

Page 16: ...uld appear in this window Warning Glycol If the Chiller Setpoint goes below 45 F the Glycol Warning Screen will appear as in Figure 12 The amount of antifreeze will vary depending on the actual desire...

Page 17: ...rious portions of the system Figure 13 Diagnostics Menu Screen Figure 14 Diagnostics Circuit Details Screen Figure 15 Diagnostics Circuit Interlock Screen Figure 16 Diagnostics Pumps Screen Figure 17...

Page 18: ...ontrol program and provide some level of supervisory control to some operating parameters the control system includes some security level protections Figure 20 Security Menu Figure 21 Security Log In...

Page 19: ...ts Outputs The Input Output screens display the status of the various system inputs and outputs This provides a detailed level of information for monitoring system operation and for diagnosing any per...

Page 20: ...Digital Outputs Screen Menu 1 User Setup The control system allows for customization and adjustment of many parameters In most cases the factory default settings are sufficient however adjustment of p...

Page 21: ...he fault trigger will occur Supply 0 0 F Evap 38 0 F Startup Bypass Delay time once the system has started before monitoring High and Low temperature Alarms 1200 sec Flow Delay Flow Sensor fault delay...

Page 22: ...line temperature is the superheat Figure 39 User Setup EEV Control Setup Screen Table 4 EEV Control Setup Parameters Menu Item Description Default Value Mode Selection In Auto Mode the control system...

Page 23: ...cess value drops below the set point by this differential all compressors turn off 5 F Stage to Stage Delay This is the minimum delay duration between stages on multiple compressors During this time d...

Page 24: ...setpoint relating to low percent setpoint During the start sequence 45 F 7 C User Setup Dynmic Lift Setup Dynamic Lift Setup Screen The Dynamic Lift control logic adjusts the chiller head pressure to...

Page 25: ...its Setup Screen User Setup Remote Setpoint When the remote setpoint option is active an incoming 4 20mA or 0 10VDC signal controls the setpoint of the master chiller The signal will span from the MIN...

Page 26: ...e fields for adjustment The time is automaticity saved Figure 51 User Setup Date Time Setup Screen User Setup Pump Down Pump Down Screen This screen allows for adjustments to the pump down sequence Th...

Page 27: ...y start if a power outage has occurred during a run state When active the Automatic Start toggle will indicate Automatic Start Enabled and when not active it will indicate Automatic Start Disabled Fig...

Page 28: ...AL_CKT2_RFRG_ALARM Bool Coil 32 1 AL_CKT1_CRITICAL_ALARM Bool Coil 33 1 AL_CKT2_CRITICAL_ALARM Bool Coil 34 1 AL_PROCESS_PUMP_OVLD Active Bool Coil 35 1 AL_STANDBY_PUMP_OVLD Active Bool Coil 36 1 AL_C...

Page 29: ...eal InputRegister 32 2 CKT2_EXV_PERCENT Real InputRegister 34 2 CKT1_RFRG_SUCTION_TEMP_HMI Real InputRegister 36 2 CKT2_RFRG_SUCTION_TEMP_HMI Real InputRegister 38 2 CKT1_SUCTION_PRESSURE_HMI Real Inp...

Page 30: ...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 i...

Page 31: ...0 2 ppm Ammonium NH3 Less than 2 ppm Chlorides Cl Less than 300 ppm Electrical Conductivity 10 500 S cm Free aggressive Carbon Dioxide CO2 Less than 5 ppm Free Chlorine Cl2 Less than 1 PPM HCO3 SO4 2...

Page 32: ...will be operating Also ensure the process coolant has sufficient freeze protection glycol to handle at least 5 F below the Low Temperature Alarm setting All chillers are shipped from the factory with...

Page 33: ...e procedures as closely as possible Specific site conditions may require repeating certain tasks more frequently The importance of a properly established preventive maintenance program cannot be overe...

Page 34: ...tem refrigerant charge and verify the system is still full charged 18 Check the operation of the compressor crankcase heater Energize the heater while the compressor is off Taking an amp reading of th...

Page 35: ...ge service valve is fully or partially closed Open valve all the way Refrigerant circuit overcharged Contact refrigeration service technician High refrigerant pressure sensor Replace if faulty PLC inp...

Page 36: ...s Compressor 2 L2 Amps Compressor 2 L3 Amps Compressor 3 L1 Amps Compressor 3 L2 Amps Compressor 3 L3 Amps Compressor 4 L1 Amps Compressor 4 L2 Amps Compressor 4 L3 Amps Refrigerant Circuit 1 Superhea...

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