Acuchiller Thermal Care AQ1W2504Z
Acuchiller Thermal Care AQ1W2504Z
Acuchiller Thermal Care AQ1W2504Z
Customer Service Phone (847) 966-2636 Fax (847) 966-2906 Parts Phone Fax
TABLE OF CONTENTS
Page No. Foreword 3 Pre-Installation 5 Receiving Inspection 5 Rigging, Handling & Locating Equipment 5 Installation 7 Electrical Power 7 Air Cooled Condenser (Air Cooled Chillers Only) 7 8 Condenser Water Lines (Water Cooled Chillers Only) Required Condenser Water Flow Table 9 Chilled Water Lines 9 Suggested Chilled Water Flow Table 10 Suggested Pipe Sizing Table 11 Overhead Piping Diagram 11 Chiller Start-Up 12 Recommended Glycol Mixtures Table 13 Control Panel Operation 15 Control Panel Diagram 15 Microprocessor Control Fault Logic Table 15 Control Buttons 16 Diagnostic LEDs 18 Diagnostic Error Codes 21 Control Options 22 Chiller Operation 26 Typical Piping Schematic Diagram 26 Coolant Circuit 27 Refrigerant Circuit 28 Chiller Construction 30 Refrigeration Components 30 Wet-Side Components 34 Operating and Safety Controls 36 Standard Options 38 Preventive Maintenance 40 Preventive Maintenance Checklist 42 Troubleshooting 43 Pump Curves 47 Diagrams 48 AQ0A0H Wiring Diagram 48 AQ0A01 Wiring Diagram 49 AQ0A02 - AQ0A10 Wiring Diagram 50 AQ0W02 - AQ0W05 Wiring Diagram 51 AQ0W08 - AQ0W10 Wiring Diagram 52 AQ1W05 - AQ1W15 Wiring Diagram 53 AQ1W20 - AQ1W30 Wiring Diagram 54 AQ1W35 - AQ1W40 Wiring Diagram 55 Air Cooled Dimensions 56 Page 2 Water Cooled Dimensions 57 Warranty 58
FOREWORD
The intent of this manual is to serve as a guide for placing your portable chiller in service, and operating and maintaining it properly. This manual will be supplemented as required to accommodate any special items which may have been provided for a specific application. The written information contained in this manual, as well as various drawings, are intended to be general in nature. The schematics included in this manual are typical only. Actual schematics are included in the electrical enclosure of the chiller and should be referred to for troubleshooting and servicing of the unit. Additional copies of wiring diagrams are available upon request. We strive to maintain an accurate record of all equipment during the course of its useful life. While every effort is made to standardize the design features of these chillers, the various options may make it necessary to rearrange some of the components; therefore, some of the general drawings in this manual may differ from your specific unit. Specific references to current applicable codes, ordinances, and other local laws pertaining to the use and operation of this equipment are avoided due to their ever changing nature. There is no substitute for common sense and good operating practices when placing any mechanical equipment into operation. We encourage all personnel to familiarize themselves with this manuals contents. Failure to do so may unnecessarily prolong equipment down time. Our chilling equipment uses chemical refrigerants for heat transfer purposes. This chemical is sealed and tested in a pressurized system containing ASME coded vessels; however, refrigerant gas can be released if there is a system failure. Refrigerant gas can cause toxic fumes if it is exposed to fire. These units must be placed in a well ventilated area, especially if open flames are present. Failure to follow these instructions could result in a hazardous condition. The standard refrigerant used in these units is a hydrochloro-fluorocarbon (HCFC) trade named R-22. The EPA has enacted laws regarding the handling of refrigerants and eventual phaseout of HCFC refrigerants. HCFC refrigerant production will continue until January 1, 2010 for new equipment and until January 1, 2020 for service purposes. Customers are advised to immediately implement a refrigerant management program including a survey of all equipment to document the type and quantity of refrigerant in each machine. All refrigeration service technicians must be certified by an EPA approved organization.
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It is recommended that good piping practices are followed and that the information in this manual is adhered to. We cannot be held responsible for liabilities created by substandard piping methods and installation practices external to the chiller. We trust your equipment will have a long and useful life. If you should have any questions, please contact our Customer Service Department specifying the serial number and model number of the unit as indicated on the nameplate.
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PRE-INSTALLATION
Receiving Inspection
Each unit is skid mounted and either boxed or crated prior to shipment. Before accepting delivery, check the overall equipment condition for any visible damage. If damage is evident, it should be properly documented on the delivery receipt. Shipping damage is the responsibility of the carrier. In order to expedite payment for damages, it is important that proper procedures be followed and records kept. Photographs of damaged equipment are excellent for your records. Once the unit is removed from the box or crate, it should be inspected for hidden damage. Refrigerant lines can be susceptible to damage in transit. Check for broken lines, oil leaks, damaged controls, or any other major component torn loose from its mounting point. Note: Any sign of damage should be recorded and a claim filed immediately with the shipping company. We will provide assistance in preparation and filing of your claims, including arranging for an estimate and quotation on repairs; however, filing the claim is the responsibility of the receiving party.
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! Ethylene Glycol
Warning: Ethylene glycol is harmful or fatal if swallowed or inhaled. Do not drink ethylene glycol solution. If swallowed, give two glasses of water and induce vomiting. Call a physician immediately. Avoid inhaling mist or hot vapors. If inhaled remove to fresh air. Do not store in open or unlabeled containers. Wash thoroughly after handling. Solution can be poisonous to animals.
! Propylene Glycol
Warning: Although propylene glycol is not "toxic," as defined by regulations of the Consumer Product Safety Commission, it is not intended for human or animal consumption.
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INSTALLATION
Electrical Power
Note: Main power to the chiller should remain connected during off hours to energize the compressor's crankcase heater. Disconnect main power only when servicing the chiller. The crankcase heater should remain on at all times to ensure liquid refrigerant does not accumulate in the compressor crankcase. A terminal block is provided for main power connection to the electric circuitry. An electrical knockout in the back panel for 1/2" conduit has been provided for main power wiring. This knockout may have to be enlarged for chillers with higher amp draws. All components requiring electric power are prewired at the factory. The main power source should be connected to the terminal block through an appropriate disconnect switch. A separate lug for grounding the unit is also provided in the main control panel. Note: All chillers should be properly grounded in compliance with local and national codes. The control panel and safeties are interwired such that connecting the appropriate power source to the main terminal block energizes the entire electric circuitry of a chiller. A control transformer has been factory wired to step down the incoming power to the 115 volt control power. Note: Electric power at the main disconnect should be shut off before opening access panels for repair or maintenance.
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The standard rated cooling capacity of our air cooled chiller is based upon 95F (35C) ambient air temperature. If the air temperature entering the condenser is above 95F (35C), the capacity will be reduced approximately 1% per 1F (0.5C). Entering air temperatures above 110F (43C) may result in high refrigerant pressure problems which would shut the unit down. For this reason, it is very important that the chiller be located where the warm discharge air will not be recirculated back into the condenser inlet. These chillers are designed for indoor usage with normal indoor ambient air temperature entering the condenser. Air temperatures below 60F (15C) entering the condenser may result in low refrigeration pressure "cold start-up" problems. Note: The condenser fans on these chillers are designed to pull the air through the condenser and discharge it out the side of the unit. Ductwork should not be installed on the intake or discharge of these units.
tain the refrigerant pressure at the factory set level. The condenser water regulating valve is standard on models AQ0W02 through AQ1W15 and optional on all other models. The following chart shows condenser water requirements and pipe sizing for the different size chillers. Please note that a condenser water supply temperature below 75F (24C) will not necessarily result in reduced flow requirements.
Model # AQ0W02 AQ0W03 AQ0W05 AQ0W08 AQ0W10 AQ1W15 AQ1W20 AQ1W25 AQ1W30 AQ1W35 AQ1W40
and water cooled models AQ0W02 through AQ0W05, the bypass line is fixed and requires no adjustment. On air cooled models AQ0A06 through AQ0A10 and water cooled models AQ0W08 through AQ1W40, there is a cock valve on the bypass line which may require adjustment if the chiller is not operated using the nominal flow rate. This valve is located where the bypass line enters the reservoir.
Model # AQ0A0H AQ0A01 AQ0A02 AQ0A03 AQ0A06 AQ0A08 AQ0A10 AQ0W02 AQ0W03 AQ0W05 AQ0W08 AQ0W10 AQ1W15 AQ1W20 AQ1W25 AQ1W30 AQ1W35 AQ1W40
*A throttling valve on the process supply line is provided to adjust the flow rate to process.
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The importance of properly sized piping between the chiller and process cannot be overemphasized. See the Suggested Pipe Sizing table for proper pipe sizing. In general, run full size piping out to the process and then reduce the pipe size to match the connections on the process equipment. One of the most common causes of unsatisfactory chiller performance is poorly designed piping. Avoid unnecessarily long lengths of hoses or quick disconnect fittings which offer high resistance to water flow. When manifolds are required for water distribution, they should be installed as close to the use point as possible. Provide flow balancing valves at each machine to assure adequate water distribution in the entire system. Typically, when piping is overhead with a total length of 90' or more, place a check valve in the supply line and trap the return line (see Overhead Piping Diagram).
Overhead Piping
SPA-0121
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CHILLER START-UP
All chillers are fully tested prior to shipping. Readings of voltage, amperage, compressor suction and discharge pressures, water inlet and outlet temperatures, water flow rates, etc., are recorded to make sure that all system components are performing up to their specifications. Every unit is factory set to deliver chilled water in accordance with the standard operating specifications for that particular chiller. Due to variables involved with different applications and different installations, minor adjustments may be required during the initial start-up to ensure proper operation. The following start-up procedure should be followed in sequence. If trouble is encountered in putting a chiller in operation, the fault can usually be traced to one of the control or safety devices. This outline can be used as a checklist for the initial start-up and for subsequent start-ups if the chiller is taken out of service for a prolonged period of time. 1. Assure the main power source is connected properly and that it matches the voltage shown on the nameplate of the unit. Once proper power connection and grounding have been confirmed, turn the main power on.
Note: The power must be on for 24 hours prior to starting the compressor to allow the crankcase heater to sufficiently vaporize any liquid refrigerant that may be present in the compressor. 2. Check to make sure that all process chilled water piping connections are secure. Remove the top panel from the chiller and the screw cap from the top of the reservoir. Fill the reservoir with the proper water or water/glycol solution. 3. (Water Cooled Units Only) Check the condenser water lines to make sure all connections are secure. Make sure sufficient condenser water flow and pressure are available (see Required Condenser Water Flow table), that the condenser water supply is turned on, and that all shut-off valves are opened. 4. Check to make sure that all process chilled water piping connections are secure. Remove the top panel from the chiller and the screw cap from the top of the reservoir. (On the AQ1W35 and AQ1W40, use the fill port that extends through the top of the cabinet.) Fill the reservoir with the proper water or water/glycol solution.
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Note: Water quality can vary greatly in different areas of the country. Some water may require water treatment chemicals. A corrosion inhibitor can be added if necessary; however, make sure that it is compatible with ethylene glycol if there is glycol in the system. 5. Make sure that the Freezestat is set appropriately for the operating conditions of the chiller. The Freezestat is located inside the main electrical control panel. It should be set at 10F (5C) below the minimum chilled water temperature setting that the chiller will be operated at. Be sure that there is sufficient glycol in the system to handle at least 10F (5C) below the freezestat setting. All chillers are shipped from the factory with the Freezestat set at 40F (4C). This is done to protect against a possible freeze-up if no glycol has been added to the system. Once the proper glycol solution has been added, the freezestat can be adjusted to the appropriate setting. Note: Our warranty does not cover the evaporator from freezeups. It is vital that the freezestat is set properly. 6. Turn on the control power by pressing the Power button. The digital displays should now be illuminated. 7. Due to extreme temperatures during shipment, some of the safeties may have tripped. If this is the case, manually reset the Freezestat if necessary and then press the Reset button on the front panel. 8. Once all alarm conditions have been cleared, press the Start button. At this time, the pump should start running. If the controller is calling for cooling, the compressor may also start at this time.
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9.
Check the rotation of the pump. If the pump is running backwards, switch two of the main power leads, after shutting off the disconnect switch. The pressure gauge on the back of the unit should be reading at least 20 PSI.
10. The coolant flow out to process can be adjusted by using the cock valve on the supply line just inside the chiller cabinet. If the process does not create much of a pressure drop, the cock valve may have to be throttled in order to maintain the flow through the chiller at an acceptable level. If the flow is more than double the nominal flow rating, the cooling capacity of the chiller may be reduced. 11. Temperature adjustment is the next step in putting the chiller in operation. Adjust the controller set point to the desired temperature. The chiller should now be controlling to that temperature. Please note that if there is no load on the chiller, the compressor will cycle on and off causing swings in temperature of up to 10F (5C). 12. Once proper flow and temperature are achieved, press the Stop button and allow the water level in the tank to stabilize. Fill the tank, replace the screw cap, and replace the top panel on the cabinet. The unit is now ready to be placed into service.
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The chiller includes a microprocessor controller designed to perform all control functions directly from the front panel. When a button is depressed, a click will be felt and the corresponding LED will be energized. Only one button should be pressed at a time. The Microprocessor Control Fault Logic Table shown below provides the basic control fault logic for the microprocessor controller. The following section details each of these diagnostics and the control buttons.
Alarm Reset button or Stop button on control board must be pressed. Safety control must be manually reset before the controller can be reset. Activates the alarm horn (if included) and closes the alarms contacts (if included).
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Control Buttons
This unit was either shipped to display temperatures in F or C. Do the following to change the display. 1. With the power connected and the control power off, hold the Stop button. While holding the Stop button press the Power button. When the controller illuminates, release both buttons. 2. The To Process display will read "Unt". The Set Point display will show either "F" or "C" depending on the current display units selected. If the current selected units are "F" press the down key. If the current selected units are "C" press the up key. 3. The Set Point display should now indicate the desired display units. Press the Start button to store the new selection into the controller memory. 4. Press the Power button once to exit this function then press the Power button again to restore controller power.
! Power
Depressing the Power button will switch the control power on or off. Control power must be initiated before the chiller can be started by the Start button or by remote on/off contacts.
! Start
Depressing the Start button will start the pump and enable the compressor. The compressor will start only if the microprocessor is calling for cooling because the actual To Process temperature is higher than the Set Point temperature.
Note: Once the compressor has cycled off, it will not restart for two minutes because of an internal anti-cycle time delay.
! Stop
Depressing the Stop button will shut off the compressor and pump, and clear all fault signals.
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! Alarm Reset
Depressing the Alarm Reset button will reset any fault indicator that has been activated on the control board. This includes any LED indicators or alarm codes. The Freezestat, Low Oil Pressure, and Pump Overload require a mechanical safety to be manually reset before the control board can be reset. Note: If the condition still exists that originally caused the alarm indication, the alarm may be reactivated as soon as it is reset.
! Alarm Silence
The Alarm Silence button is not functional unless the Alarm Horn option or the Remote Alarm contacts option has been purchased. If the Alarm Horn option has been purchased, depressing the Alarm Silence button will disable the horn. The horn will not reactivate until the alarm has been reset and a subsequent alarm has been triggered. If the Remote Alarm contacts option has been purchased, depressing the Alarm Silence button will reopen the contacts which were closed when the alarm occurred. The contacts will not close again until the alarm has been reset and a subsequent alarm has been triggered.
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Diagnostic LEDs
! No Flow
The No Flow LED will be illuminated if the flow through the chiller is below the preset acceptable level. When the Start button is depressed, this safety is defeated for a period of 20 seconds in order for the pump to establish flow. The No Flow LED may remain illuminated during this 20 second period. This safety will shut off the pump and the compressor. If the chiller has been shut down by the No Flow safety, the Start button must be depressed in order to restart the pump and reset the 20 second time delay.
! Freezestat
If the coolant temperature being delivered to the process drops below the setting on the Freezestat, the compressor will shut off, the pump will remain running, and the Freezestat LED will be illuminated. The Freezestat should be set 10F (5C) above the freezing point of the glycol solution and 10F (5C) below the minimum operating temperature. The Freezestat is factory set at 40F (4C). In order to reset the Freezestat fault, press the Alarm Reset button after resetting the mechanical thermostat (labeled Freezestat) inside the electrical enclosure. Page 18
! Pump On
The Pump On LED will be illuminated whenever the pump is running. If the pump is shut off due to a safety, the Pump On LED will turn off. The Start button must be pressed in order to restart the pump.
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! Compressor On
The Compressor On LED will be illuminated whenever the compressor is running. The Compressor On LED will cycle on and off with the compressor. The compressor will not come on unless the pump is already running and the To Process temperature is above the Set Point temperature.
Note: During normal operation, the compressor may cycle on and off. An internal anti-cycle time delay will not allow the compressor to restart for two minutes after it has cycled off.
! Partial Load
The Partial Load LED will be illuminated whenever the microprocessor energizes the hot gas bypass solenoid valve. This valve is cycled in order for the chiller to maintain a constant To Process temperature even when there is only a partial load. The longer that this LED stays on, the more unused excess capacity is available from the chiller. If the Partial Load LED stays off, the chiller is fully loaded by the heat from the process. If the Partial Load LED stays on, the chiller has a very small load on it from the process. If this low load condition persists, the To Process temperature may begin to drop below the Set Point temperature, and when it reaches 7F (or 4C) below the Set Point temperature, the compressor will cycle off. The compressor will come back on when the To Process temperature rises back up to the Set Point temperature and the anti-cycle two minute time delay relay has timed out.
! Water Make-Up
The Water Make-Up LED is only functional if the Water Make-Up option is purchased with the chiller. When the water level in the reservoir drops below the lower limit of the float switch, the water make-up solenoid valve is opened and the Water Make-Up LED is illuminated. When the water level rises to the upper limit of the float switch, the water make-up solenoid is closed and the Water Make-Up LED turns off. The microprocessor will also close the water make-up solenoid valve if it has been open for a period of ten minutes. This is done to help prevent further problems if a water leak has developed in the system. If this occurs, the Water Make-Up LED will turn off, but the Low Water Level LED will remain illuminated.
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! Probe Fault
The Probe Fault LED will illuminate if the signal from the thermocouple is out of tolerance. This fault will also shut off the compressor and the pump. It can be reset by pressing the Alarm Reset button.
! Pr Off
If the chiller is running and main power is discontinued or drops more than 10% below the normal operating voltage, the unit will shut down and the Pr OFF fault will be indicated on the digital displays. This fault condition can be cleared by pressing the Stop button.
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! Err 126
The Err 126 fault code will be indicated on the digital displays if the pump has gone off due to the pump overload. In order to reset this fault, press the Alarm Reset button after resetting the pump overload inside the electrical enclosure.
! Err 127
Some units equipped with a semi-hermetic compressor include this function. The Err 127 fault code will be indicated on the digital displays if the compressor has gone off due to the internal compressor thermal overload. This fault will also shut off the pump. The thermal overload will automatically reset when the compressor motor winding temperature drops back into the normal operating range. Once this occurs, the fault can be reset by pressing the Alarm Reset button.
Note: Units equipped with a scroll compressor will require manual reset of the compressor motor overload module.
! Err 128
The Err 128 fault code will be indicated on the digital displays if the chiller has been shut off due to the high temperature safety. This safety will shut off both the pump and compressor. This safety is triggered if the To Process temperature rises more than 10F (or 5C) above the maximum operating temperature for that particular chiller. The maximum operating temperature for each chiller is noted on the nameplate. The To Process temperature must be over the limit for three minutes before this safety will be triggered, and the fault is defeated for a period of 30 minutes from the time the Start button is pressed or the Set Point temperature is changed. This fault can be reset by pressing the Alarm Reset button.
Control Options
! Return Water Temperature Display
If the Return Water temperature display option is purchased, the To Process digital display can be used to view To Process temperature or Return Water temperature. To view the Return Water temperature, hold down the ! and # buttons simultaneously. Once the buttons are released, the display will return to To Process temperature. Page 22
! Alarm Horn
If the Alarm Horn option is purchased, the control panel will be fitted with an alarm horn which will be activated by certain faults. Reference the Microprocessor Control Fault Logic table to determine which faults will trigger the horn. The horn can be silenced by clearing the
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fault or by pressing the Alarm Silence button. If this option is selected in conjunction with the remote control panel, the horn will be mounted on the chiller and not the panel.
! SPI Communications
If the SPI Communications option is included, an RS-485 communication port will be located below the control panel on the front of the chiller. The serial communications will be multi-drop, half duplex, SPI 3.01 compatible. This option allows the chiller to communicate with another piece of equipment that also has SPI protocol capabilities. The following SPI communications are supported by the microprocessor.
$ $ $ $ $
Process Temperature Setpoint High Deviation Low Deviation Process Status To Process Temperature
The microprocessor is designed to accept inputs and deliver outputs according to SPI protocol. There must also be a computer or another piece of equipment which is equipped with the SPI protocol in order for the communications from the chiller to be of any use. The programming of this computer and/or other equipment is not the responsibility of the manufacturer. Note: The manufacturer is not responsible for SPI protocol programming beyond what is included in the microprocessor controller. When the SPI option is included, there is a second set of DIP switches included on the back of the main control panel. This set of DIP switches is labeled COMM. All DIP switch adjustments that follow are to be made on the COMM set. Do not adjust any DIP switches on the CONFIG set. Page 24
Note: All DIP switch changes must be made with power disconnected. In order to activate the SPI protocol, DIP switch #8 must be set to the On position. To deactivate the SPI communication, set DIP switch #8 to the Off position. If more than one piece of equipment is going to be on the same communications network, the base address will have to be changed so that each unit has a unique address. This is done by changing one or more of the DIP switches to the Off position. The base address is 32 decimal. Changing these switches causes the following address change. DIP Switch 1 OFF DIP Switch 2 OFF DIP Switch 3 OFF DIP Switch 4 OFF DIP Switch 5 OFF Add one to base address Add two to base address Add four to base address Add eight to base address Add sixteen to base address
The BAUD rate can be adjusted to the appropriate setting by using the following chart. BAUD Rate 1,200 2,400 4,800 9,600 DIP Switch #6 ON OFF ON OFF DIP Switch #7 ON ON OFF OFF
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CHILLER OPERATION
The following diagram illustrates the basic operation of a water cooled portable chiller. There is a brief description of the coolant circuit and the refrigerant circuit. Keep in mind that this drawing is general in nature and that some of the components and piping may change depending on which options have been selected.
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Coolant Circuit
The pump draws coolant from the reservoir and circulates it through the evaporator. It is in the evaporator where the heat is transferred from the coolant to the refrigerant. The temperature of the coolant being delivered to the process is controlled by adjusting the amount of heat transferred in the evaporator. After leaving the evaporator, the coolant passes through a manifold which includes a freezestat sensing bulb, flow switch (or pressure switch), thermocouple and process supply throttling valve. The freezestat sensing bulb, flow switch and pressure switch are safety controls that are connected to the microprocessor. The thermocouple senses the temperature of the coolant being delivered to process and communicates this temperature to the microprocessor. The process supply throttling valve can be used to adjust the flow out to process. Opening this valve will increase the flow to process while closing it will result in a reduction of flow. This manifold is connected directly to the process water supply connection on the back of the chiller. Once the coolant passes through this manifold, it is delivered out to process where it picks up the process heat before returning to the process water return connection. From this connection, the coolant returns directly to the reservoir where the whole sequence starts over. A small coolant bypass line tees off of the manifold between the thermocouple and the supply throttling valve. This line allows the chiller to operate with sufficient flow through the evaporator even if the flow is restricted or completely shut off through the process. On air cooled models AQ0A0H through AQ0A03 and water cooled models AQ0W02 through AQ0W05 chillers, the bypass is a small copper line running from the process supply manifold to the process return line. On air cooled models AQ0A06 through AQ0A10 and water cooled models AQ0W08 through AQ1W40, the bypass is a hose that runs from the process supply manifold directly back into the reservoir. There is a cock valve located in this line right where it connects to the reservoir. This valve can be adjusted depending on how much flow is required by the process. Note: Closing this valve off too far may result in a situation that could damage components in the chiller. The main purpose of the bypass line is to avoid deadheading of the pump and reduce the possibility of a freeze-up.
!
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Refrigerant Circuit
The heat that is transferred in the evaporator from the coolant to the refrigerant is used to change the state of the refrigerant from a liquid to a gas. After leaving the evaporator, the refrigerant passes through the suction accumulator. The purpose of the suction accumulator is to trap any liquid refrigerant that may exit the evaporator during startup. The refrigerant gas passes through to the compressor. The trapped liquid in the suction accumulator will eventually boil off and move on to the compressor. The compressor is the heart of the refrigeration circuit. It takes the cool, low pressure gas entering the compressor and compresses it which creates the hot, high pressure gas that exits the compressor. Since the compressor is not 100% efficient, some extra heat is added to the refrigerant as it is being compressed. The hot, high pressure gas that exits the compressor is delivered to the condenser. In the condenser, the heat is transferred from the refrigerant into the air stream or water stream that is passing through in the opposite direction. As the heat is transferred, the refrigerant changes from a gas to a liquid. The condenser has been sized to remove the heat from the process load and the heat that was added by the compressor. After leaving the condenser, the liquid refrigerant passes through the receiver (air cooled units only), the filter drier and sight glass. The filter drier filters out any particles and/or moisture from the refrigerant. The sight glass is used to monitor the stream of liquid refrigerant. The liquid refrigerant then passes through the thermal expansion valve (TXV) which meters the flow into the evaporator where the process starts all over again. Capacity and temperature control is accomplished with a hot gas bypass system on these chillers. If the chiller is catering to a partial load from the process, the coolant supply temperature would normally tend to drop. The microprocessor senses this drop in temperature, and opens the hot gas bypass solenoid valve. When this valve is open, some of the hot compressor discharge gas is directed to the inlet of the evaporator instead of going through the condenser. This puts an additional heat load on the evaporator which brings the coolant temperature back up to set point. With PID control from the microprocessor and the solenoid cycling as much as once every ten seconds, coolant temperature is usually controlled within 1F (0.5C) of set point even with loads as low as 10% - 25% of full capacity. Page 28
If the process heat load is extremely low, or even nonexistent, the hot gas bypass system may not be able to put enough of a false load on the evaporator, and the coolant temperature will begin to drop. When the coolant temperature drops to 7F (4C) below the set point temperature, the controller will shut the compressor off. When the coolant temperature rises back to the set point temperature, the compressor comes back on. The compressor will remain off for at least two minutes to prevent short cycling.
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CHILLER CONSTRUCTION
Refrigeration Components
! Compressor
Hermetic
If the model number of the chiller begins with AQ0, then the chiller is equipped with a hermetically sealed compressor. Both the compressor and the motor are encased together in the enclosure. Inside the casing, the compressor is spring mounted which extends compressor life and provides quiet operation. The motor windings are cooled by the cool refrigerant suction gas, and there is an internal thermal overload to protect the windings from overheating. The compressor also includes a crankcase heater which will boil off any liquid refrigerant that may have migrated into the compressor crankcase while the chiller was shut off. The compressor is lubricated with oil that travels throughout the system with the refrigerant. Semi-Hermetic If the model number of the chiller begins with AQ1, then the chiller is equipped with a semi-hermetic compressor. A semi-hermetic compressor has all of the features of the hermetic compressor except that the semi-hermetic compressor has removable heads so that it can be taken apart to be serviced or rebuilt. The semi-hermetic compressor is not internally spring mounted like the hermetic compressor, so it tends to run a little louder. Scroll If the model number of the chiller begins with AQ2, then the chiller is equipped with a scroll compressor(s). Both the compressor and the motor are encased together and solidly mounted in the enclosure. The compressor is unidirectional and will only pump refrigerant when properly phased. The motor windings are cooled by the cool refrigerant suctions gas, and there is an internal thermal overload to protect the windings from overheating. The compressor is lubricated with oil that travels throughout the system with the refrigerant.
approximately 1% of its cooling capacity per 1F (0.5C) above 95F (35C). The chiller should be able to operate with ambient temperatures of up to 110F (43C). The fan(s) draw the air flow through the condenser and blows the warm discharge air through the chiller cabinet and out the other side. The fan(s) are designed to draw sufficient air flow through the chiller as long as there are no obstructions. The fan(s) are not capable of drawing air in through ductwork on the intake or discharging air through ductwork on the exhaust. The discharge air will be approximately 35F (20C) warmer than the intake air.
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Note: The condenser water regulating valve may not completely shut-off water flow when the chiller is not operating. If flow must be completely stopped for any reason, a shut-off valve must be used. Make sure the shut-off valve is reopened before restarting the chiller.
! Evaporator
There are three different types of evaporators used in these chillers. Air cooled models AQ0A0H through AQ0A03 and water cooled models AQ0W02 and AQ0W03 use a tube-in-tube style evaporator. Air cooled models AQ0A06 through AQ0A10 and water cooled models AQ0W05 through AQ1W30 use a brazed plate style evaporator. Water cooled models AQ1W35 and AQ1W40 use a shell-and-tube evaporator. The tube-in-tube evaporators have a steel outer tube with a copper inner tube. The refrigerant passes between the steel and the copper, while the coolant flows through the copper tube in the opposite direction from the refrigerant. The brazed plate evaporators are constructed with stainless steel plates and copper brazing. The refrigerant passes between every other set of plates, while the coolant flows on the other side of the plates in the opposite direction. The shell-and-tube evaporators are constructed with a steel shell around a bundle of copper tubes. The refrigerant passes through the copper tubes, while the coolant passes in the opposite direction around the tubes.
conditions. It is located in the liquid line directly after the condenser. The receiver is supplied with a shut-off valve on the outlet which enable pump-down of the refrigeration circuit for servicing.
! Suction Accumulator
The suction accumulator is the refrigerant vessel located in the suction line between the evaporator and the compressor. The purpose of the suction accumulator is to trap any liquid refrigerant before it can enter the compressor. The refrigerant gas is allowed to pass through, while the liquid will remain in the bottom of the vessel. The trapped liquid will eventually boil off and move on to the compressor.
Wet-Side Components
! Reservoir
On chillers up to 30 HP, the coolant reservoir is mounted on top of the shelf in the chiller and is easily accessible by removing the top panel. The reservoir is made of polyethylene and is fully insulated. A slot has been made in the insulation so that the coolant level can be observed without removing any panels. There is a six inch screw cap on the top of the reservoir that can be used for filling and cleaning. There is a small hole in this cap so that air can vent to the atmosphere.
!
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Note: These reservoirs are not designed to be pressurized. Modifications to the chiller that would result in pressurization of the reservoir will void the warranty.
Air cooled models AQ0A0H through AQ0A03 and water cooled models AQ0W02 through AQ0W05 are equipped with an eight gallon reservoir, air cooled models AQ0A06 through AQ0A10 have a 20 gallon reservoir, while water cooled models AQ0W08 through AQ1W30 have a 45 gallon reservoir. During chiller operation, these reservoirs should be at least half full. For most installations, these tanks have sufficient capacity to handle the coolant that drains back from the piping when the chiller is shut off. For overhead piping runs of more than 50 feet, special precautions will have to be made during installation. See details on Overhead Piping diagram for overhead piping installations. Water cooled models AQ1W35 and AQ1W40 are equipped with a 40 gallon cylindrical galvanized steel reservoir mounted inside the cabinetry above the pump. This reservoir is filled using the fill-port that extends through the top of the cabinet. There is a sight glass located at one end of the tank. These tanks cannot be pressurized, and it is very likely that overhead piping will require the special precautions illustrated on the Overhead Piping Diagram.
! Coolant Pump
The close-coupled centrifugal pump is equipped with a mechanical seal. The 1 HP pumps are constructed of bronze, while all other sizes are bronze-fitted cast iron construction. Each pump is factory tested for the specified operating conditions. The ODP motor meets NEMA specifications and industry standards.
! Pressure Gauge
A pressure gauge is mounted on the back panel of the chiller. This gauge displays the pressure of the coolant at the discharge of the pump. It can be used to determine the approximate point on the pump curve in which the pump is operating.
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Note: Although partially closing this valve will raise the pressure reading on the pressure gauge, the pressure being delivered to the process will actually be reduced. Throttling this valve will always reduce the flow out to process.
The fan cycling controls are designed to turn the condenser fans on and off in order to maintain a constant compressor discharge refrigerant pressure. During normal operation, the fans will cycle on and off based upon the process heat load and ambient air conditions.
Note: It is possible that a condenser fan will continue to operate after the chiller has been shut-off. This fan will automatically shut off as soon as the refrigerant pressure drops below the preset level on the fan cycling control.
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! Freezestat
The freezestat control is a mechanical thermostat which senses the coolant temperature separately from the microprocessor controller. This safety is designed to limit the temperature of the coolant leaving the evaporator and prevent any possible freeze-up situations. This control should be set 10F (5C) below the minimum coolant supply temperature, and there should be a sufficient glycol concentration for 10F (5C) below the freezestat setting. Manual reset is required. Note: It is critical that the freezestat is set properly and that there is sufficient glycol in the system to correspond with the freezestat setting. Freeze-ups can cause extensive damage to several components in the chiller, and the warranty does not cover repairs required due to a freeze-up.
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STANDARD OPTIONS
There are many different combinations of options available on portable chillers. Many special options are provided so that the chiller can meet the special requirements of a particular process. It is not practical to include all of the special options in this manual; therefore, in instances where these options have been included, it may be necessary to refer to separate documentation for the specifics of the special features. The following are the most common standard options.
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! Nonferrous Construction
Standard chillers have several components in contact with the coolant that are made of mild steel. This is acceptable for most applications; however, for applications that require extremely clean water, distilled water, or deionized water, the nonferrous construction option is strongly recommended. With this option, all components in contact with the process fluid are constructed of nonferrous materials. These materials include stainless steel, bronze, brass, copper, plastic and rubber.
! Upgraded Pumps
The standard pumps that have been selected for each size chiller will meet the requirements of most applications; however, in certain instances, larger pumps may be required to provide the desired flow and pressure for a specific application. The horsepower of the pump will be indicated on the nameplate on the chiller.
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PREVENTIVE MAINTENANCE
Once your portable chiller has been placed into service, the following maintenance procedures should be adhered to as closely as possible. The importance of a properly established preventive maintenance program cannot be overemphasized. Taking the time to follow these simple procedures will result in substantially reduced downtime, reduced repair costs, and an extended useful lifetime for the chiller. Any monetary costs of implementing these procedures will almost always more than pay for itself. To make this as simple as possible, a checklist should be prepared which lists the recommended service operations and the times at which they are to be performed. On the following page, we have included a checklist that can be used for this purpose. Notice that there are locations for voltage readings, amperages, etc. so that they can be monitored over time. With this information, maintenance personnel may be able to correct a potential problem before it causes any downtime. For best results, these readings should be taken with a full heat load from process, preferably with similar operating conditions each time. The following is a list of suggested periodic maintenance.
! Once a Week
1. (Air Cooled Units Only) Check the surface of the air cooled condenser coil for dirt and debris. Clean out with compressed air if necessary. 2. Check to make sure that the To Process temperature is maintained reasonably close to the Set Point temperature. If the temperature stays more than 5F (3C) away from the set point, there may be a problem with the chiller. If this is the case, refer to the Troubleshooting Chart or contact the Service Department. 3. Check the pump discharge pressure on the gauge on the back panel of the chiller. Investigate further if the pressure starts to stray away from the normal operating pressure. 4. Check the coolant level in the reservoir. Replenish if necessary making sure to take proper precautions to maintain the appropriate glycol concentration. 5. Check coolant circulation pump for leaks in the seal area. Replace pump seal if necessary. Page 40
6. Check refrigerant sight glass for air bubbles or moisture indication. If the sight glass indicates that there is a refrigeration problem, have the unit serviced as soon as possible. Repeat items 1 through 6 as listed above and continue with the following.
! Once a Month
7. With the main disconnect shut off, check the condition of electrical connections at all contactors, starters and controls. Check for loose or frayed wires. 8. Check the incoming voltage to make sure it is within 10% of the design voltage for the chiller. 9. Check the amp draws to each leg of the compressor and pump to confirm that they are drawing the proper current. Repeat items 1 through 9 listed above and continue with the following.
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Maintenance Activity
Date Temperature Control Pump Discharge Pressure Coolant Level Glycol Concentration Pump Seal Refrigerant Sight Glass Electrical Connections Incoming Voltage Compressor L1 Amps Compressor L2 Amps Compressor L3 Amps Pump L1 Amps Pump L2 Amps Pump L3 Amps Clean Y-strainer Refrigerant Circuit Check Refrigerant Suction Pressure Refrigerant Discharge Pressure Refrigerant Superheat Clean Out Condenser
10
11
12
13
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TROUBLESHOOTING
Problem
Compressor will not start
Possible Cause
Compressor internal thermal overload
Remedy
Check supply voltage Check amperages of each line Check compressor contactor and wiring Replace if faulty Replace if faulty Contact refrigeration service technician
Problem
Pump will not start
Possible Cause
Pump overload
Remedy
Check supply voltage Check amperages of each line Check overload setting Replace overload if faulty Replace if faulty Replace if faulty Replace if faulty
Problem
Low refrigerant pressure
Possible Cause
Low refrigerant charge
Remedy
Contact refrigeration service technician Contact refrigeration service technician Open valve all the way Check for proper setting Replace if faulty Replace if faulty
Refrigerant leak Compressor suction service valve partially closed Low refrigerant pressure control Microprocessor control board
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Problem
High refrigerant pressure
Possible Cause
Dirty condenser coil (air cooled units only) Air flow obstruction (air cooled units only)
Remedy
Clean out with compressed air
Make sure chiller is installed in accordance with recommendations in this manual Maximum temperature is 110F (43C) Replace if faulty
High ambient air temperature (air cooled units only) Condenser fan (air cooled units only) Condenser fan cycling controls (air cooled units only) Plugged condenser (water cooled units only) Insufficient condenser water flow High condenser water temperature Condenser water regulating valve Compressor discharge service valve partially closed Refrigerant circuit overcharged High refrigerant pressure control Microprocessor control board
Make sure chiller is installed in accordance with recommendations in this manual Maximum temperature is 100F (38C) Replace if faulty Open valve all the way Contact refrigeration service technician Replace if faulty Replace if faulty
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Problem
Freezestat
Possible Cause
Low flow through evaporator Freezestat control Microprocessor control board Thermocouple
Remedy
Adjust flow to proper level Check for proper setting Replace if faulty Replace if faulty Replace if faulty
Problem
Low pump discharge pressure
Possible Cause
Pump running backwards
Remedy
Switch two legs of the incoming power Slightly close off To Process throttling valve Replace if faulty Replace if faulty
Problem
High pump discharge pressure
Possible Cause
Closed valves in process piping Closed To Process throttling valve Obstruction in piping or process Clogged Y-strainer Pressure gauge
Remedy
Open valves Open valve Clear obstruction Clean strainer Replace if faulty
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Problem
Insufficient cooling (temperature continues to rise above set point)
Possible Cause
Process load too high Coolant flow through evaporator too high or too low Insufficient condenser cooling Hot gas bypass valve stuck open Refrigeration circuit problem Microprocessor control board Thermocouple
Remedy
Check to make sure chiller is properly sized for process load Adjust flow to proper level See High Refrigerant Pressure Contact refrigeration service technician Contact refrigeration service technician Replace if faulty Replace if faulty
Problem
Erratic temperature control
Possible Cause
Low coolant flow through evaporator Intermittent overloading of chiller capacity Hot gas bypass valve Microprocessor control board Thermocouple
Remedy
Adjust flow to proper level
Check to make sure chiller is properly sized for process load Contact refrigeration service technician Replace if faulty Replace if faulty
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PUMP CURVES
Portable Chiller Pump Curves
Flow (GPM)
3500 RPM pumps. Curves represent pump discharge. Correct for unit discharge. SPA-1791
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DIAGRAMS
AQ0A0H Electrical Wiring Diagram
EWC-0767
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EWC-0771
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EWC-0731
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DIAGRAMS
AQ0W02 - AQ0W05 Electrical Wiring Diagram
EWC-0751
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EWC-0755
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EWC-0763
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EWC-0884
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EWC-0894
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SPA-2537
SPB-2439
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Pressure Gauge Electrical Knock-Out Sight Glass Chilled Water Return Chilled Water Supply
SPA-2549
Chilled Water Supply Chilled Water Return Pressure Gauge Condenser Water Out Condenser Water In
SPB-2550
SPD-1780
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WARRANTY
Thermal Care warrants its equipment to be free from defects in material and workmanship when used under recommended operating conditions. Thermal Care's obligation is limited to repair (i.e. rewind a motor) or replacement (not adjustment or maintenance), F.O.B. the factory of any parts supplied by Thermal Care for a period of eighteen months (twelve months for 1/2 and 1 HP compressor units) from date of shipment to the original purchaser. The microprocessor is provided with a five year parts warranty. All units with 2 HP or larger compressors include a labor warranty in the continental United States, Canada, Puerto Rico and select portions of Mexico. Refrigerant and any labor associated with its evacuation or replacement are not covered by this warranty. This warranty does not cover the cost of labor during overtime hours (after normal working hours or during weekends and holidays). Any cost differential for overtime labor will be the responsibility of the customer. Thermal Care is not responsible for any sales, use, excise or other applicable taxes associated with the replacement of parts under this warranty. This warranty will be voided when, in Thermal Cares opinion, the equipment and/or system has been subject to misuse, negligence or operation in excess of recommended limits, including freezing, or has been altered, and/or repaired without express factory authorization. If equipment is installed in hostile environments, unless such conditions were specified at the time of purchase; or the serial number has been removed or defaced this warranty shall not apply. This warranty is not transferrable. Under no circumstances shall Thermal Care be liable for loss of prospective or speculative profits, or special, indirect, incidental or consequential damages. All warranty service must be authorized by Thermal Care prior to work being performed and have a Thermal Care purchase order issued. All defective parts become the property of Thermal Care and must be returned as advised by Thermal Care. Thermal Care neither assumes, nor authorizes any person to assume for it, any liability not expressed in this warranty. There is an implied warranty of merchantability and of fitness for particular purpose; all other implied warranties, and any liability not based upon contract are hereby disclaimed and excluded by this warranty. This warranty is part of the standard conditions and terms of sale of Thermal Care. Form 1-407
7720 N. Lehigh Ave. Niles, IL 60714-3491 Phone: 847-966-2260, ext. 2900 e-mail: info@thermalcare.com www.thermalcare.com Fax: 847-966-9358
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