Nibe CLIMACOOL UCR 30, Installation, Operation & Maintenance Manual

Page 1: ...Remote Air Cooled Modular Chillers Model UCR 30 50 and 70 tons Installation Operation Maintenance Manual...

Page 2: ...9 Power Distribution Drawing 30 Remote Condenser 31 32 Head Pressure Control Valve Operation LAC 10 33 37 Remote Condenser Installation 38 45 Pre Startup 46 Pre Startup Checklist 47 Startup 48 49 Subc...

Page 3: ...l un des trois l ments mentionn s ci dessus sont remplies changer deux des trois lignes lectriques alimen tant la interrupteur de s curit et v rifier la rotation du compresseur WARNING ADVERTISSEMENT...

Page 4: ...s Tous les capteurs de pression doivent tre retir s avant l vacuation ou de test d unit de pression Faute de quoi se traduira par des dommages des capteurs WARNING ADVERTISSEMENT For field installatio...

Page 5: ...ooved couplings and mounting hardware kits are on site prior to connecting the modules Note Consult factory for handling other than in the upright position Rigging and Lifting Each module should be li...

Page 6: ...5 NOMINAL TONS 030 050 070 DESIGN SERIES A VOLTAGE F 460 3 60 H 208 230 3 60 N 575 03 60 CONTROLS ELECTRICAL A Standard DDC COMPRESSOR TYPE S Scroll MODEL CONFIGURATION S Standard REJECTION OPTIONS 0...

Page 7: ...6 6 Notes 1 Unit tonnage ARI rating conditions 44 F leaving chilled water temperature and 2 4 GPM per ton through the evaporator 95 F entering condenser air temperature dry bulb 30 F condenser TD and...

Page 8: ...n Motor Hp ea 1 0 hp 1 0 hp 1 0 hp Quantity of Fan Motors 4 4 4 kW Input ea Fan Motor I Total kW Input for All Motors 1 1 I 4 4 1 1 I 4 4 1 1 I 4 4 FLA per Fan Motor 460V 3 60 I Total FLA 460V 3 60 2...

Page 9: ...Fan Motor Hp ea 1 0 hp 1 0 hp 1 0 hp Quantity of Fan Motors 4 6 6 kW Input ea Fan Motor I Total kW Input for All Motors 1 1 I 4 4 1 1 I 6 6 1 1 I 6 6 FLA per Fan Motor 460V 3 60 I Total FLA 460V 3 60...

Page 10: ...RPM db 10 46 5 I 73 1 46 5 I 73 1 46 5 I 73 1 Dimensions W x L x H Inches 88 X 127 X 49 88 X 127 X 49 88 X 127 X 49 Net Weight I Shipping Weight lbs 1290 I 1510 1290 I 1510 1390 I 1610 Remote Condense...

Page 11: ...ection Size Inches Unit Weight1 Pounds Operating Weight2 Pounds 030 208 230 460 575 3 60 337 8 651 8 34 1 4 41 1 4 27 1 2 58 47 1 2 55 1 2 6 1170 1265 050 208 230 460 575 3 60 337 8 651 8 34 1 4 41 1...

Page 12: ...e to the unit may occur Figure 5 Lifting and Transporting Modules Pallet jacks or fork lifts are required for lifting and transporting the module Each module has base cutouts provided for ease of mane...

Page 13: ...e determined by a qualified structural engineer per individual job requirements ClimaCool recommends locking down the chiller to a concrete base or to three 3 4 base mounting rails using the six 6 bol...

Page 14: ...anels and 30 clearance for rear access to modules 2 Allow a minimum of 18 height clearance for service 3 Local building or electrical codes may require additional clearance Consult applicable codes To...

Page 15: ...hiller from the structure is recommended by installing vibration eliminating springs or pads under the base rails on which the chiller will rest see page 10 Mounting Rail and Vibration Isolation One e...

Page 16: ...he installing contractor Sound Attenuation Panels and Gasket Attenuation panels are enclosures made of 18 gauge galvanized steel with powder coat paint finish and fiberglass insulation Field Installed...

Page 17: ...be reversed by opening the main electrical disconnect and switching any two of the main power supply leads feeding that compressor s contactor Proper Voltage Balance Occasionally in three phase circu...

Page 18: ...0 254 mm wall 0 144 in 3 6576 mm O D DC resistance 15 2 Ohms 1000 feet 50 Ohms km nominal Capacitance 12 5 pF ft 41 pF meter nominal conductor to conductor Characteristic impedance 100 Ohms nominal We...

Page 19: ...17 www climacoolcorp com Voltage Phase Monitor Wiring Diagram...

Page 20: ...em for a total of four 4 taps If a port is shared by the pressure differential flow sensor and the pressure gauge it will require two 2 1 2 taps See Water Piping Configurations page 20 Water Isolation...

Page 21: ...f ClimaCool sensors and controls for control of field supplied bypasses or other field supplied items The recommended method is to control via differential pressure or gpm flow meters across the chill...

Page 22: ...awings 5 A pressure differential flow sensor is a required safety device for ClimaCool modular chillers on the chilled water circuits 6 A strainer with a minimum of 60 mesh stainless steel screen is a...

Page 23: ...te s Ports Heat Exchanger Leaving Chilled Water Temperature Sensor Refrigerant Circuit 1 Refrigerant Circuit 2 Hydronic Refrigeration Figure 15 Chilled Water Circuit Note Figure 15 depicts hydronic pi...

Page 24: ...mpact exchangers are true dual circuit heat exchangers in which each water channel is anked by two refrigerant circuits This design gives maximum performance even at part load Of course full performan...

Page 25: ...stem The following method is recommended to properly clean the water systems 1 Before cleaning the system install a temporary bypass line between the main supply and return water headers of both chill...

Page 26: ...recommended to install an intermediate plate and frame heat exchanger to isolate the ClimaCool chiller from the building water system Cooling Tower The cooling tower should be located away from source...

Page 27: ...ed of special controls or glycol additives Leaving water temperatures below 40 F can result in evaporator suction temperatures below the freezing point of water Therefore a glycol solution additive is...

Page 28: ...mum Entering Condenser Air Temperature 20FTD F 120 120 120 Maximum Entering Condenser Air Temperature 30FTD F 110 110 110 Minimum Condenser Temperature Differential TD F 20 20 20 Maximum Condenser Tem...

Page 29: ...27 www climacoolcorp com Evaporator Water Pressure Drop Charts...

Page 30: ...28 www climacoolcorp com Glycol Performance Adjustments Factor Charts...

Page 31: ...kW Power Multplier Capacity Multplier Flow gpm Multplier kW Power Multplier Capacity Multplier Flow gpm Multplier kW Power Multplier Capacity Multplier Flow gpm Multplier kW Power Multplier 8 1 00 1...

Page 32: ...hielded cable daisy chain from the master controller to the modules see Figure 18 Figure 17 Specifications for ARC156 Wiring Description Single twisted pair low capacitance CL2P TC foam FEP plenum rat...

Page 33: ...ow and access all sides of the unit should be a minimum of W away from any wall or obstruction It is preferred that this distance be increased whenever possible Care should be taken to see that ample...

Page 34: ...nal 20 F Variable speed control furnished for lead fans Mechanical head pressure fan cycling control provided for on all others Optional 20 F Factory furnished field installed LAC 10 flooded head pres...

Page 35: ...hot gas raises liquid pressure in the receiver allowing the system to operate normally Figure 23 LAC 10 Valve Operation The valve designation LAC stands for Low Ambient Control The LAC 10 is a three w...

Page 36: ...od the condenser coil at the appropriate ambient The factors involved in calculating the extra pounds of refrigerant are 1 Length of tubing and return bends in condenser 2 Minimum ambient temperature...

Page 37: ...80 0 0 0 0 70 0 0 0 0 60 26 20 10 4 50 45 40 33 28 40 56 42 46 42 30 64 60 55 51 20 69 66 62 59 0 76 73 70 68 20 80 79 76 73 Refrigerant Charging Procedures for Head Pressure Control Valve Once the am...

Page 38: ...nt will be backed up into the condenser and the sight glass will indicate bubbles in the liquid line 3 Add more refrigerant while allowing sufficient time for the refrigerant to stabilize and clear th...

Page 39: ...AC Discharge line to LAC restricted Remove restriction in fitting s or line Malfunction High Head Pressure Chart Possible Cause Remedy Dirty condenser coil Clean coil Air on condenser blocked off Clea...

Page 40: ...35 TON CIRCUIT W HOT GAS BYPASS 1 1 8 1 1 8 1 5 8 1 1 8 REF UCR070 42 1 2 TON CIRCUIT W OUT HOT GAS BYPASS NOT 2 1 8 2 1 8 1 3 8 REF UCR085 USED 42 1 2 TON CIRCUIT W HOT GAS BYPASS 1 3 8 1 3 8 1 5 8 1...

Page 41: ...39 www climacoolcorp com Condenser Layout for RC1 007A H24 and RC1 008A H24 1 Row 2 Fan 1140RPM...

Page 42: ...40 www climacoolcorp com Condenser Layout for RC2 019A 026A and 31A H48 and RC2 038A H44 2 Row 4 Fan 1140RPM...

Page 43: ...41 www climacoolcorp com Condenser Layout for RC2 018A X48 RC2 026A X40 and RC2 032A X44 2 Row 4 Fan 830 RPM...

Page 44: ...42 www climacoolcorp com Condenser Layout for RC2 014A Q48 RC2 017A Q42 RC2 021A Q48 and RC2 025A Q44 2 Row 4 Fan 540 RPM...

Page 45: ...43 www climacoolcorp com Condenser Layout for RC2 020A V48 RC2 025A V42 RC2 033A V42 and RC2 038A V42 2 Row 4 Fan Variable Speed...

Page 46: ...44 www climacoolcorp com Condenser Layout for RC2 047A H62 RC2 046A V60 RC2 032A Q62 RC2 039A Q64 RC2 039A X60 and RC2 047A X62 2 Row 6 Fan...

Page 47: ...45 www climacoolcorp com 45 www climacoolcorp com Condenser Layout for RC2 048A Q82 2 Row 8 Fan 540RPM...

Page 48: ...lace 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 3 Confirm the...

Page 49: ...lled and wired to the CoolLogic controller 7 Have all chiller coupling connections been leak tested 8 Is water presently circulating through chiller 9 Veri ed that temperature sensors and voltage phas...

Page 50: ...0 psid 10 Confirm the jumper locations for all master controller and module controllers as shown on the wiring diagrams provided on the inside electrical door panels Set the rotary switches for the MA...

Page 51: ...temperature The saturated condensing temperature is found by converting the liquid line pressure reading on the manifold gauge to the related temperature The normal subcooling temperature range at the...

Page 52: ...ersion of the startup forms are available on www climacoolcorp com in the Service page Water Testing Extract three water samples from each water loop Hot Water Condenser Chilled Water Evaporator using...

Page 53: ...it is usually safe to allow the compressor to run Step 4 After starting the compressor listen for unusual sounds such as knocking If heard immediately stop the compressor Do not restart until the pro...

Page 54: ...re Verify Safety Setting Limits Low Temp High Pressure Low Pressure Rep Signature Print Name E Signature Check Box Authorized Signature All wiring terminations in module panel safeties and compressors...

Page 55: ...er is located Less than 30 feet Higher Eleva on relative to chiller module 5 Refrigerant Piping Geometry to Remote A C Condenser Horizontal Distance A C Condenser is located at an aggregate total dist...

Page 56: ...l data taken The temperature drop rise on a fully loaded both compressors heat exchanger is generally 10 F If only one compressor is running the temperature drop rise will be approximately 5 F Some pr...

Page 57: ...he 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 each heat exchanger The cleaning solution use...

Page 58: ...cuit Service Port 3 4 Refrigerant Circuit Header Header To Cooling Tower From Cooling Tower Cleaning Tank Cleaning Pump Pete s Ports Isolation Ball Valves 2 2 or 3 Heat Exchanger Figure 2 In Place Cle...

Page 59: ...acuum A suitable hydraulic pump should be used to add oil and reserved for this process It is imperative that oil type be verified prior to adding to a compressor Oil should only be added to a compres...

Page 60: ...QUID RECEIVER 14 PRESSURE RELIEF VALVE 15 FILTER DRIER 16 SIGHT GLASS MOISTURE INDICATOR 17 LIQUID LINE SOLENOID VALVE 18 THERMAL EXPANSION VALVE 19 CHILLER EVAPORATOR BPHX S1 DISCHARGE TEMPERATURE SE...

Page 61: ...ough heated spaces which may result in undesirable flash gas generated at the TXV inlet Avoid insulating liquid lines Conforming to local and national codes is the responsibility of the service techni...

Page 62: ...tion and potentially cause nuisance head pressure trips Moisture in the system can cause chemical reactions with many POE oil additives resulting in the formation of undesirable acids which corrode th...

Page 63: ...refrigerant cylinder tank pressures have equalized it will be necessary to finish the refrigerant charging process by gradually metering small bursts of liquid refrigerant into the suction line of the...

Page 64: ...40 100 80 9 25F 1140 100 87 9 20F 1140 100 94 9 45F 1140 125 119 1 25F 1140 125 122 2 20F 1140 125 125 2 45F 1140 150 130 8 25F 1140 150 133 8 20F 1140 150 136 9 Model Minimum Outdoor Temp Condenser F...

Page 65: ...ulation shall be provided on suction side refrigerant tubing including refrigerant to chiller heat exchanger to prevent condensation Compressors Each module shall contain two scroll compressors indepe...

Page 66: ...itor and report the following system parameters for the chiller system Chilled water entering and leaving temperature Evaporator water flow availability Any module failure condition shall cause a faul...

Page 67: ...ts Factory installed water isolation valves and flush ports shall provide isolation to the module for maintenance and cleaning of evaporator heat exchangers while adjacent modules continue normal oper...

Page 68: ...elow for the strainer installation 1 The carbon steel CS strainer should be placed on a firm supporting surface Failure to do so can cause stress on the weld joints It is recommended a concrete pad be...

Page 69: ...sure differential reaches 5 10 psi the strainer element may require cleaning Caution Prior to dismantling the strainer for cleaning it is imperative that the strainer assembly is isolated and complete...

Page 70: ...tor fitted with a suitable pressure relief valve strategically located within the water system may provide adequate protection against the effects from water hammer Careful attention should be given t...

Page 71: ...n the moving parts The electric motor supplied a sufficient amount of power to cause personal injury Take precaution when handling Water Resistance The valve and controller are water resistant but not...

Page 72: ...matic inside the PDA box by removing the four screws on the cover plate Water Resistance The Pressure Differential Alarm Controller is water resistant but not water proof Do not install below ground l...

Page 73: ...if provided 2 WYE strainers must be positioned in the pipeline ahead of the equipment requiring protection 3 To provide for easier maintenance the WYE strainer should be located where the drain plug...

Page 74: ...odically checking for leaks During normal use the screen will become clogged with foreign matter causing the differential pressure to increase Once the differential pressure has increased to an unacce...

Page 75: ...to place using slings positioned underneath the inlet and outlet connections 4 Install a standard ANSI 1 8 thick flange gasket between the basket strainer and pipeline flanges on both sides Install lu...

Page 76: ...ay to determine when the screen needs to be replaced is to install pressure gauges on the inlet and outlet sides of the strainer The maximum acceptable pressure drop across the strainer will indicate...

Page 77: ...R070AFASAC00S 575V 3PH 60HZ 89 100 125 125 150 44 5 55 7 239 100 70 Notes 1 RLA Rated Load Amps are calculated as per UL1995 2 MCA Minimum Circuit Ampacity is 125 of the RLA of the largest compressor...

Page 78: ...76 www climacoolcorp com Wiring Diagram...

Page 79: ...77 www climacoolcorp com Wiring Diagram...

Page 80: ...78 www climacoolcorp com Wiring Diagram CoolLogic Control Panel...

Page 81: ...79 www climacoolcorp com Wiring Diagram CoolLogic Control Panel...

Page 82: ...azed plate heat exchanger Clean in place heat exchanger as described on page 54 Improper chilled water circulation Use an ample sized cleanable strainer in the chilled water circuit make certain the s...

Page 83: ...damages due to freezing of the water supply an inadequate or interrupted water supply corrosives or abrasives in the water supply or improper or inadequate ltration or treatment of the water or air s...

Page 84: ...es but are merely ClimaCool s opinion or commendation of its products USGBC and related logo is a trademark owned by the U S Green Building Council and is used with permission Modbus is a registered t...