Thermal Care Accuchiller EQ Series Installation & Operation Manual Download Page 28

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Thermal Care, Inc.

New Equipment Sales

Customer Service

Parts

5680 W. Jarvis Ave.

Phone

(847) 966-2260

Phone (847) 966-2636

Phone

(847) 966-8560

Niles, IL 60714-3491

Fax

(847) 966-9358

Fax

(847) 966-2906

Fax

(847) 966-6065

www.thermalcare.com

[email protected]

EQ Series IOM 2-313.25
December 2016

Summary of Contents for Accuchiller EQ Series

Page 1: ...Installation Operation Manual EQ Series Portable and Remote Condenser Chillers ...

Page 2: ...Page Intentionally Blank ...

Page 3: ... Refrigerant and Oil Charge 8 Oil Charge Determination 8 Setting Condenser Fan Controls 8 Installation Electrical 9 Standard Controller Operation 10 Changing Temperature Display Scale 10 Diagnostic Error Codes 12 SPI Communications Option 13 Start Up 15 Step 1 Connect Main Power 15 Step 2 Fill Coolant Circuit 15 Step 3 Check Condenser 16 Step 4 Check Refrigerant Valves 17 Step 5 Verify Freezestat ...

Page 4: ...Page Intentionally Blank ...

Page 5: ...s a hydro fluorocarbon HFC trade named R 407c as a chemical refrigerant 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 if exposed to fire Place these units in a well ventilated area especially if open flames are present Failure to follow these instruct...

Page 6: ...taining 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 with the order acknowledgement and shipping papers Inspect the equipment for any visible damage and verify all items shown on the bill of lading are present If damage is evident document it on the deli...

Page 7: ...vice Proper ventilation is another important consideration when locating the chiller In general locate the unit in an area that will not rise above 110 F In addition ensure the condenser and evaporator refrigerant pressure relief valves can vent in accordance with all local and national codes Chillers with an integral air cooled condenser require a minimum of 36 inches of clearance at both the con...

Page 8: ...geration pressures in the circuit To prevent damage to the condenser and or water regulating valve the water pressure should not exceed 150 psig Installation Remote Air Cooled Condenser Chillers designed for use with a remote air cooled condenser include a factory selected remote condenser The remote air cooled condenser typically ships separately from a different location than the chiller Locatio...

Page 9: ...ing size and piping design have a significant impact on system performance and reliability All piping should conform to the applicable local and state codes CAUTION Use refrigerant grade copper tubing ASTM B280 only and isolate the refrigeration lines from building structures to prevent transfer of vibration All copper tubing must have a pressure rating suitable for R 407c tubing that is OD or lar...

Page 10: ... at the condenser immediately drop at least 15 inches down from the liquid outlet before routing the piping to the chiller Make the drop leg before any bends or angles connecting to the remainder of the liquid connection piping Figure 3 Condenser Located at Chiller Level Figure 4 Condenser Located Above Chiller Unit Figure 5 Condenser Located Below Chiller Unit Caution Liquid line sizing for each ...

Page 11: ...immediate drop of at least 15 inches at the condenser outlets to make a liquid seal Liquid line risers in the system will require an additional 0 5 psig pressure drop per foot of vertical rise When it is necessary to have a liquid line riser make the vertical run immediately after the condenser before any additional restrictions The liquid line risers must not exceed 10 feet in height from the con...

Page 12: ...25 250 275 300 A A A A A A A A A A A A B B B B B B B B B B B B Calculating Refrigerant and Oil Charge To determine the approximate charge assume a combined chiller and remote condenser summer refrigerant charge of 4 6 Lbs of R 407c then refer to Table 5 to determine the charge required for the field installed piping per circuit The approximate charge per circuit is therefore the sum 4 6 and the va...

Page 13: ...ter If the meter reads CBA open the main power disconnect and switch two line leads on the line power terminal blocks or the unit mounted disconnect Do not interchange any load leads that are from the unit contactors or the motor terminals WARNING This equipment contains hazardous voltages that can cause severe injury or death WARNING This equipment contains refrigerant under pressure Accidental r...

Page 14: ...de If C is displayed the temperature display is in C mode To change from F to C press the Lower Set Point Temperature button down arrow To change from C to F press the Raise Set Point Temperature button up arrow After changing to the desired temperature scale the Set Point display shows the desired display units Press and release the Start button to store the new selection into the controller memo...

Page 15: ...ssure is less than the setting of the high refrigerant pressure safety Low Refrig The Low Refrigerant Pressure light is red when the compressor suction pressure drops below the setting on the low refrigerant pressure safety This safety stops all compressors but allows pumps to continue running Pressing the Alarm Reset button resets the fault if the compressor suction pressure is above the setting ...

Page 16: ...2 A D Converter Failure Controller requires servicing Contact Manufacturer for repair or replacement 103 Controller serial bus failure Controller requires servicing Contact Manufacturer for repair or replacement 105 CJC Error Controller requires servicing Contact Manufacturer for repair or replacement 109 Unused memory byte changed Controller requires servicing Contact Manufacturer for repair or r...

Page 17: ...pt the Serial Peripheral Interface bus SPI bus which coincidently has the same abbreviation as the trade association To allow our unit to operate as a slave unit in a plastic processing system using this protocol we offer an option that includes an expansion module for the control board and a RS 485 communication port on the unit The communication hardware firmware is SPI 3 01 standard compliant U...

Page 18: ...as occurred high or low temperature deviation 3 An alarm affecting the machine has occurred probe fault or pump fault 4 The controller has exceeded its over setpoint deviation 5 The controller has exceeded its below setpoint deviation Status Machine 1 20 42 This is the machine status in a 16 bit format as follows 0 Controlling 1 An alarm is present 2 An alarm affecting the process has occurred hig...

Page 19: ... the 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 in the compressor crankcase Connect main power at least 24 hours prior to initial start up Step 1 Connect Main Power Connect main power properly ensuring it matches the voltage shown on the namepla...

Page 20: ... Water Chemistry Requirements Water Characteristic 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 500µS cm Free aggressive Carbon Dioxide CO2 Less than 5 ppm Free Chlorine Cl2 Less than 1 PPM HCO3 SO4 2 Greater than 1 0 Hydrogen Sulfide H2S Less than 0 05 ppm Iron Fe Less than 0 2 pp...

Page 21: ...l that the Freezestat is set properly Step 6 Turn On Control Power Some chillers may have a control power switch If present turn the control power switch on If not present turning the main power on should turn the control power on When the control power is on the panel displays are illuminated Due to extreme ambient temperatures that may occur during shipment the High Refrigerant Pressure switch m...

Page 22: ...ly more than pay for it The preventative maintenance checklist in this manual is a great way to log and keep track of maintenance Once a Week 1 Air Cooled Units Only Check the surface of the air cooled condenser coil for dirt and debris To clean rinse thoroughly with water and use a mild detergent to remove smoke and or grease stains 2 Check to make sure that the To Process temperature is reasonab...

Page 23: ...erature Control Pump Discharge Pressure Coolant Level Glycol Concentration Pump Seal Refrigerant Sight Glass Electrical Connections Incoming Voltage Compressor 1 L1 Amps Compressor 1 L2 Amps Compressor 1 L3 Amps Pump L1 Amps Pump L2 Amps Pump L3 Amps Fan 1 L1 Amps Fan 1 L1 Amps Fan 1 L3 Amps Clean Y Strainer Refrigerant Circuit Check Refrigerant Suction Pressure Refrigerant Discharge Pressure Refr...

Page 24: ...t refrigeration service technician High refrigerant pressure sensor Replace if faulty Freezestat Low flow through evaporator Adjust flow to proper level Freezestat control module Check for proper setting Protected Setting Freezestat sensor Replace if faulty Low pump discharge pressure Pump running backwards Switch 2 legs of the incoming power Pump pressure gauge Replace if faulty Pump failure Repl...

Page 25: ...e 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 All lab...

Page 26: ...ponsible 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 Care s 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 This warranty s...

Page 27: ...Notes ...

Page 28: ...W Jarvis Ave Phone 847 966 2260 Phone 847 966 2636 Phone 847 966 8560 Niles IL 60714 3491 Fax 847 966 9358 Fax 847 966 2906 Fax 847 966 6065 www thermalcare com info thermalcare com service thermalcare com tcparts thermalcare com EQ Series IOM 2 313 25 December 2016 ...

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