Thermal Care Accuchiller NQ Series, Operation, Installation, And Maintenance Manual

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Page 3: ...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 Ris...

Page 4: ...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...

Page 5: ...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 Free...

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Page 7: ...at 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...

Page 8: ...t 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...

Page 9: ...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...

Page 10: ...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 Avo...

Page 11: ...igure 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...

Page 12: ...0 4 1 10 0 3 2 5 2 3 7 5 5 0 12 0 4 0 6 4 3 9 0 5 9 15 0 4 7 7 3 4 10 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 pos...

Page 13: ...50 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 Equivalen...

Page 14: ...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 Li...

Page 15: ...l 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 inch per e...

Page 16: ...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...

Page 17: ...l 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...

Page 18: ...nt 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 ed...

Page 19: ...nd 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 na...

Page 20: ...ing 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 Over...

Page 21: ...detailed information about the various portions of the system Main Diagnostics Screen Diagnostics Screen 1 Circuit 1 Overview Diagnostics Screen 2 Circuit 1 Interlocks Diagnostics Screen 3 Pumps Diagn...

Page 22: ...s of the control program and provide some level of supervisory control to some operating parameters the control system includes some security level protections Main Security Screen Security Log In Scr...

Page 23: ...ens 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 performance issues or alarms that a...

Page 24: ...al 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 parame...

Page 25: ...etup Screen User Setup Hot Gas Bypass Screen User Setup Pumps Screen User Setup Process Pump VFD Screen User Setup EEV Control Screen User Setup Staging User Setup Stage Order Screen User Setup Discha...

Page 26: ...er Setup Modbus RTU Screen User Setup Process Temperature Retransmit Screen User Setup Variable Speed Compressor Screen User Setup IP Address Screen User Setup Units Screen User Setup 3 Way Mod Valve...

Page 27: ...point of the system operation Menu 2 Full Screen Menu 2 System Build This menu allows configuration of the system Use this menu only with the assistances of someone from the Customer Service Departme...

Page 28: ...Coil 19 1 COND_FAN2_OVLD_OK Bool Coil 20 1 ENABLE_FAN_FS2 Bool Coil 21 1 COND_FAN3_EXISTS Bool Coil 22 1 COND_FAN3_OVLD_OK Bool Coil 23 1 ENABLE_FAN_FS3 Bool Coil 25 1 PULSE_2SEC Bool Coil 26 1 SYSTEM...

Page 29: ...T Active Bool Coil 94 1 AL_PRB_LIQUID_TEMP Active Bool Coil 95 1 AL_FLOW_SENSOR Active Bool Coil 96 1 AL_PRB_PUMP_PX Active Bool Coil 97 1 AL_CPCOE_COM_FAULT Active Bool Coil 110 1 HIGH_SUPPLY_WATER_T...

Page 30: ...URN_WATER_HIGH_WARNING_HMI Real HoldingRegister 60 1 WTR_TEMP_BYPASS_TIME_SECONDS Int HoldingRegister 61 1 NO_FLOW_TIME_DELAY_SEC Int HoldingRegister 62 2 FREEZESTAT_SETPOINT Real HoldingRegister 64 2...

Page 31: ...r 71 1 SUPPLY_WATER_BYPASS_REMIANING Int InputRegister 72 2 SUPPLY_WATER_HIGH_WARNING_HMI Real InputRegister 74 1 SUPPLY_WATER_HIGH_HIGH_FAULT_TIME Int InputRegister 75 2 SUPPLY_WATER_LOW_WARNING_HMI...

Page 32: ...206 1 RETRANSMIT_PERCENT Int InputRegister 226 1 CHILLER_STATUS UInt InputRegister 231 2 EVAP_IN_FLUID_HMI Real Table 9 BACNet Parameters Type Object Instance Variable Name Data Type BinaryValue 1 HM...

Page 33: ...PS Active Bool BinaryValue 57 AL_COND_FAN1_OVLD Active Bool BinaryValue 58 AL_COND_FAN2_OVLD Active Bool BinaryValue 59 AL_COND_FAN3_OVLD Active Bool BinaryValue 60 AL_FANS_ALL_FAULTED Active Bool Bin...

Page 34: ...ue 112 MASTER_SLAVE_ENA Bool BinaryValue 113 PROCESS_PUMP_MANUAL_MODE Bool BinaryValue 114 PROCESS_PUMP_MANUAL_MODE_ON Bool BinaryValue 115 AUTO_START_ENABLED Bool BinaryValue 116 REMOTE_START Bool Bi...

Page 35: ...ERCENT Int AnalogValue 166 PROCESS_PUMP_MANUAL_PERCENT Real AnalogValue 167 PROCESS_PUMP_SETPOINT_HMI Real PositiveIntegerValue 168 PROCESS_PUMP_HOURS_RETAIN UDInt PositiveIntegerValue 169 RECIRC_PUMP...

Page 36: ...IntegerValue 219 NQV_TRIP_LOCKOUT_NUMBER Int IntegerValue 220 NQV_SYSTEM_CONTROL_WORD Int IntegerValue 221 NQV_EV2_03_MAX_FREQUENCY Int IntegerValue 222 NQV_EV2_04_MIN_FREQUENCY Int IntegerValue 223...

Page 37: ...id refrigerant does not accumulate in the compressor crankcase Connect main power at least 24 hours prior to initial start up CAUTION Wire the unit ground in compliance with local and national codes S...

Page 38: ...haracteristic Quality Limitation Alkalinity HCO3 70 300 ppm Aluminum Al Less than 0 2 ppm Ammonium NH3 Less than 2 ppm Chlorides Cl Less than 300 ppm Electrical Conductivity 10 500 S cm Free aggressiv...

Page 39: ...the factory with the Freezestat set at 38 F CAUTION The manufacturer s warranty does not cover the evaporator from freezing It is vital that the Freezestat is set properly Step 6 Turn On Control Powe...

Page 40: ...uced potential downtime repair costs and extends the useful life of the chiller Once a Week 1 Air Cooled Units Only Check the surface of the air cooled condenser coil for dirt and debris To clean rins...

Page 41: ...ity Week Number 1 2 3 4 5 6 7 8 9 10 11 12 13 Date Clean Air Coils and Inlet Filters Temperature Control Pump Discharge Pressure Coolant Level Glycol Concentration Pump Seal Refrigerant Sight Glass El...

Page 42: ...10 F Condenser fan motor air cooled units only Replace if faulty Condenser fan cycling control air cooled units only Confirm proper operation replace if faulty Plugged condenser water cooled units onl...

Page 43: ...ontact refrigeration service technician Refrigeration circuit problem Contact refrigeration service technician Temperature sensor Replace if faulty Drawings Units ship from the factory with drawings i...

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Page 45: ...Customer Service Parts Department 847 966 2260 info thermalcare com 847 966 2260 847 966 9358 fax 847 966 2636 847 966 8560 847 966 9358 fax www thermalcare com sales thermalcare com service thermalc...