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

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Page 3: ...it 7 Figure 4 Condenser Located Above Chiller Unit 7 Determining Equivalent Line Length 7 Table 2 Equivalent Lengths of Elbows 7 Liquid Line Sizing 7 Table 3 Liquid Line Sizes for R410A 8 Discharge Ho...

Page 4: ...creen 19 Figure 22 Diagnostics Hardware Screen 19 Figure 23 Diagnostics Import Export Data Screen 20 Figure 24 Diagnostics Overview Screen 20 Figure 25 Diagnostics Import Export Data Screen 20 Menu 1...

Page 5: ...aging Setup Screen 26 Table 13 Compressor Staging Setup Parameters 26 User Setup Stage Order 26 Compressor Stage Order Screen 26 Figure 52 User Setup Stage Order Setup Screen 26 Table 14 Stage Order S...

Page 6: ...t 30 User Setup Miscellaneous Current Sensors 30 Figure 66 User Setup Miscellaneous Control Setup Screen 30 User Setup Chiller Tank and Water Makeup 31 Figure 67 User Setup Chiller Tank and Water Make...

Page 7: ...eventive Maintenance 38 Once a Week 38 Once a Month 39 Once Every 6 Months 39 Once a Year 39 Cleaning the Operator Interface 40 General Troubleshooting 41 Preventive Maintenance Checklist 42 Drawings...

Page 8: ...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...

Page 9: ...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 10: ...nts Avoid impact loading caused by sudden jerking when lifting or lowering the chiller Use pads where abrasive surface contact may occur Process Fluid Piping Proper insulation of chilled process fluid...

Page 11: ...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...

Page 12: ...ingle circuit flat coil 48 48 100 single circuit V coil 36 63 120 single circuit V coil 36 80 20 to 160 ton dual circuit flat coil 48 48 200 ton dual circuit V coil 36 47 240 ton dual circuit V coil 3...

Page 13: ...rrosive 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...

Page 14: ...actual equivalent length using the equivalent lengths as shown in Table 2 CAUTION When calculating the equivalent length do not include piping of the chiller unit Only field piping must be considered...

Page 15: ...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 20 Ton Circuit R410A Liquid Line Size Inch OD 25...

Page 16: ...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 50 Ton Circuit R410A Liquid Line Size Inch OD 60 Ton Circuit R410A Liquid Li...

Page 17: ...1 8 2 1 8 2 1 8 2 1 8 175 2 1 8 2 1 8 2 1 8 2 1 8 175 2 1 8 2 1 8 2 1 8 2 1 8 200 2 1 8 2 1 8 2 1 8 2 1 8 200 2 1 8 2 1 8 2 1 8 2 1 8 225 2 1 8 2 1 8 2 1 8 2 1 8 225 2 1 8 2 1 8 2 1 8 2 1 8 250 2 1 8...

Page 18: ...tions Figure 5 Vertical Riser Traps Figure 6 Double Discharge Riser Note Discharge line sizing shown in Table 4 and Table 5 are listed per circuit and applies where leaving water temperature LWT is 40...

Page 19: ...A 1 3 8 A 1 3 8 A 1 3 8 A 1 3 8 A 1 5 8 A 1 5 8 A 1 5 8 B 2 1 8 B 2 1 8 B 2 1 8 B 2 1 8 B 2 5 8 B 2 5 8 B 2 5 8 B 2 5 8 B 2 5 8 B 2 1 8 B 2 1 8 B 2 1 8 120 A 1 1 8 A 1 1 8 A 1 1 8 A 1 3 8 A 1 3 8 A 1...

Page 20: ...n power source Voltage must be within the voltage utilization range given on the drawings included with the unit If the measured voltage on any leg is not within the specified range notify the supplie...

Page 21: ...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 wh...

Page 22: ...ens 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...

Page 23: ...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 security level p...

Page 24: ...tem 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 area...

Page 25: ...shows there are no alarms in history if an alarm condition previously existed it would appear in this window Warning Glycol If the Chiller Setpoint goes below 45 F the Glycol Warning Screen will appe...

Page 26: ...he various portions of the system Figure 16 Diagnostics Menu Screen Figure 17 Diagnostics Circuit Details Screen Figure 18 Diagnostics Circuit Interlock Screen Figure 19 Diagnostics Pumps Screen Figur...

Page 27: ...ta Screen Menu 1 Security Security Menu To add protection to sensitive areas of the control program and provide some level of supervisory control to some operating parameters the control system includ...

Page 28: ...ame Password Screen Reference User 9999 None Supervisor 7720 None Admin None Menu 1 Inputs Outputs The Input Output screens display the status of the various system inputs and outputs This provides a...

Page 29: ...Figure 36 Inputs Outputs Digital Inputs Screen Figure 37 Inputs Outputs Analog Outputs Screen Figure 38 Inputs Outputs Digital Outputs Screen Figure 39 Inputs Outputs Digital Outputs Screen Note This...

Page 30: ...are sufficient however adjustment of parameters and settings is possible through the User Setup menus Figure 40 User Setup Menu 1 Screen Figure 41 User Setup Menu 2 Screen Figure 42 User Setup Menu 3...

Page 31: ...ly 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 timer 5 sec User Setup Hot Gas...

Page 32: ...ntain superheat The difference between the saturated suction temperature and the suction line temperature is the superheat Figure 50 User Setup EEV Control Setup Screen Table 12 EEV Control Setup Para...

Page 33: ...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 delay...

Page 34: ...eters Menu Item Description Default Value Mode In Auto Mode the fans adjusts to maintain optimum performance In manual mode it holds to the Manual Mode Position input valve AUTO Kp Proportional PID va...

Page 35: ...lue 300 000 Td Derivative PID value 0 000 EXV Setpoint Optimal EXV target position 95 User Setup Serial Communications Setup Modbus RTU Setup Screen This Modbus RTU Setup Screen provides the ability t...

Page 36: ...tpoint Setup Screen User Setup Primary Secondary Figure 61 User Setup Primary Secondary Setup Screen User Setup Chiller Capacity Chiller Capacity Screen This screen is necessary to adjust the nominal...

Page 37: ...control via process return User Setup Miscellaneous Local Mode The Local Remote Mode toggle indicates if the chiller is set to use a remote contact closure for remote start stop When active the Local...

Page 38: ...raphical representation of the core operating parameters of the system are in the trending screens The trending screen displays the setpoint temperature evaporator fluid out process supply and return...

Page 39: ...Full Screen This screen provide a simple large font display of the process supply temperature for users who are primarily concerned only with this data point of the system operation Figure 72 Menu 2 F...

Page 40: ...1 AL_PRB_PROCESS_RETURN_FLUID Active Bool Coil 26 1 AL_PRB_PROCESS_SUPPLY_FLUID Active Bool Coil 27 1 AL_CKT1_RFRG_ALARM Bool Coil 28 1 AL_CKT2_RFRG_ALARM Bool Coil 29 1 AL_CKT1_CRITICAL_ALARM Bool Co...

Page 41: ...TEMP_HMI Real InputRegister 40 2 CKT2_LIQUID_TEMP_HMI Real InputRegister 42 2 CKT1_EVAP_OUT_FLUID_HMI Real InputRegister 44 2 CKT2_EVAP_OUT_FLUID_HMI Real InputRegister 46 2 CKT1_EVAP_DELTA_T_HMI Real...

Page 42: ...ssor is off to ensure liquid refrigerant does not accumulate in the compressor crankcase Connect main power at least 24 hours prior to initial startup Step 1 Connect Main Power Connect main power prop...

Page 43: ...and treatment chemicals the information is usually up to date when a specialist in the industry is involved Table 19 shows the list of water characteristics and quality limitations Table 19 Fill Wate...

Page 44: ...ons are secure and the refrigeration is as described in the installation section of this manual Check the remote condenser main power and control wiring to ensure all connections are secure Step 4 Che...

Page 45: ...indicate a refrigerant shortage charge refrigerant as required With the unit running add refrigerant using industry best practices until operating conditions become normal CAUTION A clear sight glass...

Page 46: ...r loose or frayed wires 9 Check the main power supply to ensure it is acceptable connected properly and the unit has a proper ground see Installation section of this manual for details 10 Check the am...

Page 47: ...to blow the contaminants out of the air coil The frequency at which this task is required depends on specific site conditions 22 Have a qualified laboratory perform a compressor oil analysis to deter...

Page 48: ...temperature TSEW only Maximum temperature is 95 F Condenser water regulating valve TSEW only Replace if faulty Compressor discharge service valve is fully or partially closed Open valve all the way Re...

Page 49: ...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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