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28 

Once a Month  

Repeat items 1 through 5 and continue with the 
following. 
 
6.

 

Check the Y strainer between the return 
connection and the evaporator inlet. Open the 
blow-down valve attached to the strainer to 
flush the screen free of debris. 

 
7.

 

Check the flow sensor tip visually for signs of 
build-up and clean with a soft cloth. Is there is 
some suborn calcium build-up that is not easily 
removed with a soft cloth use household vinegar 
as a cleaning agent to remove the deposit. 

 
8.

 

Shut off the power disconnect. Check the 
condition of electrical connections at all controls. 
Check for 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 amp draws to each leg of the 
compressor(s) to confirm that it is drawing the 
proper current. 

 
11.

 

Check the system superheat and sub-cooling. 
Normal superheat is approximately 10°F; 
however, it may be high but not more than 15°F. 
Normal sub-cooling ranges from 10°F to 20°F. 

 

Once Every 6 Months  

Repeat items 1 through 11 and continue with the 
following. 
 
12.

 

Check for visible mechanical damage to the 
compressor. 

 
13.

 

Check for excessive vibration from other rotating 
equipment. 

 
14.

 

Check for signs of hot spot/discoloration on 
power cables. 

 
15.

 

Check all communication cables are secure and 
tight. 

 
16.

 

Check all electrical modules are secure. 

 

17.

 

Check system refrigerant charge and verify the 
system is still full charged. 

 
18.

 

Check the operation of the compressor 
crankcase heater. Energize the heater while the 
compressor is off. Taking an amp reading of the 
heater leads is the best way to determine the 
correct operation. Another way is to feel if there 
is localized heat around the crankcase heater 
when the heater is on. 

 

Once a Year 

Repeat items 1 through 18 and continue with the 
following. 
 

19.

 

Check the condition of the chilled water for 
algae and particulate fouling. Back flush the 
evaporator with water or another suitable 
cleaning agent. The frequency at which this 
task is required depends on specific site 
conditions. 

 
20.

 

Check the condition of the air cooled 
condensers for dirt and debris. If the coils 
are dirty or clogged, use a compressed air 
source to blow the contaminants out of the 
air coil. The frequency at which this task is 
required depends on specific site conditions.  

 

21.

 

Have a qualified laboratory perform a 
compressor oil analysis to determine system 
moisture content and acid level. 

 

Cleaning the Operator Interface 

Use of abrasive cleaners or solvents may damage the 
window. Do not scrub or use brushes. To clean the 
display window: 
 
1.

 

Disconnect power from the terminal at the 
power source. 
 

2.

 

Using a clean sponge or a soft cloth, clean the 
display with a mild soap or detergent. If paint or 
grease splash is present, remove before drying 
by rubbing lightly with isopropyl alcohol. 
Afterward, provide a final wash using a mild 
soap or detergent solution. Rinse with clean 
water. 

3.

 

Dry the display with a chamois or moist cellulose 
sponge to avoid water spots. 

Summary of Contents for Accuchiller KSE

Page 1: ......

Page 2: ......

Page 3: ...reen Navigation 7 System Initialization 7 Figure 5 Start Up Splash Screen 7 Home Chiller Home Screen 8 System Overview 8 Figure 6 Chiller Home Screen 8 Table 1 System Overview Functions 8 Starting and...

Page 4: ...igital Outputs Screen 14 Menu 1 User Setup 14 Figure 33 User Setup Menu 1 Screen 14 Figure 34 User Setup Menu 2 Screen 14 Figure 35 User Setup Menu 3 Screen 14 User Setup Alarm Setup 15 Figure 36 User...

Page 5: ...ser Setup Primary Secondary Setup Screen 19 User Setup Chiller Capacity 20 Chiller Capacity Screen 20 Figure 50 User Setup Chiller Capacity Setup Screen 20 User Setup Date Time 20 Date Time Screen 20...

Page 6: ...erant Valves 26 Step 5 Check Low Temperature Alarm 26 Step 6 Turn On Control Power 26 Step 7 Establish Coolant Flow 26 Step 8 Initial Unit Operation 27 Preventive Maintenance 27 Once a Week 27 Once a...

Page 7: ...rant 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...

Page 8: ...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 9: ...e the clearance on the control panel side to 4 feet while still meeting NEC code and without impeding performance When installing multiple chillers in the same location the minimum separation between...

Page 10: ...4 Figure 3 Mounting Platform Figure 4 Rigging...

Page 11: ...e main terminal block energizes the entire electric circuitry of the unit A power supply provides 24 VDC control power Shut off the electric power at the main disconnect before opening access panels f...

Page 12: ...f the compressor with incorrect electrical phase sequencing will result in mechanical damage to the compressors Check the phasing with a phase sequence meter prior to applying power The proper sequenc...

Page 13: ...assword 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 user adj...

Page 14: ...h circuit None 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 se...

Page 15: ...em 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 areas...

Page 16: ...uld appear in this window Warning Glycol If the Chiller Setpoint goes below 45 F the Glycol Warning Screen will appear as in Figure 12 The amount of antifreeze will vary depending on the actual desire...

Page 17: ...rious portions of the system Figure 13 Diagnostics Menu Screen Figure 14 Diagnostics Circuit Details Screen Figure 15 Diagnostics Circuit Interlock Screen Figure 16 Diagnostics Pumps Screen Figure 17...

Page 18: ...ontrol program and provide some level of supervisory control to some operating parameters the control system includes some security level protections Figure 20 Security Menu Figure 21 Security Log In...

Page 19: ...ts Outputs The Input Output screens display the status of the various system inputs and outputs This provides a detailed level of information for monitoring system operation and for diagnosing any per...

Page 20: ...Digital Outputs Screen Menu 1 User Setup The control system allows for customization and adjustment of many parameters In most cases the factory default settings are sufficient however adjustment of p...

Page 21: ...he fault trigger will occur Supply 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...

Page 22: ...line temperature is the superheat Figure 39 User Setup EEV Control Setup Screen Table 4 EEV Control Setup Parameters Menu Item Description Default Value Mode Selection In Auto Mode the control system...

Page 23: ...cess 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 d...

Page 24: ...setpoint relating to low percent setpoint During the start sequence 45 F 7 C User Setup Dynmic Lift Setup Dynamic Lift Setup Screen The Dynamic Lift control logic adjusts the chiller head pressure to...

Page 25: ...its Setup Screen User Setup Remote Setpoint When the remote setpoint option is active an incoming 4 20mA or 0 10VDC signal controls the setpoint of the master chiller The signal will span from the MIN...

Page 26: ...e fields for adjustment The time is automaticity saved Figure 51 User Setup Date Time Setup Screen User Setup Pump Down Pump Down Screen This screen allows for adjustments to the pump down sequence Th...

Page 27: ...y start if a power outage has occurred during a run state When active the Automatic Start toggle will indicate Automatic Start Enabled and when not active it will indicate Automatic Start Disabled Fig...

Page 28: ...AL_CKT2_RFRG_ALARM Bool Coil 32 1 AL_CKT1_CRITICAL_ALARM Bool Coil 33 1 AL_CKT2_CRITICAL_ALARM Bool Coil 34 1 AL_PROCESS_PUMP_OVLD Active Bool Coil 35 1 AL_STANDBY_PUMP_OVLD Active Bool Coil 36 1 AL_C...

Page 29: ...eal InputRegister 32 2 CKT2_EXV_PERCENT Real InputRegister 34 2 CKT1_RFRG_SUCTION_TEMP_HMI Real InputRegister 36 2 CKT2_RFRG_SUCTION_TEMP_HMI Real InputRegister 38 2 CKT1_SUCTION_PRESSURE_HMI Real Inp...

Page 30: ...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 i...

Page 31: ...0 2 ppm Ammonium NH3 Less than 2 ppm Chlorides Cl Less than 300 ppm Electrical Conductivity 10 500 S cm Free aggressive Carbon Dioxide CO2 Less than 5 ppm Free Chlorine Cl2 Less than 1 PPM HCO3 SO4 2...

Page 32: ...will be operating Also ensure the process coolant has sufficient freeze protection glycol to handle at least 5 F below the Low Temperature Alarm setting All chillers are shipped from the factory with...

Page 33: ...e procedures as closely as possible Specific site conditions may require repeating certain tasks more frequently The importance of a properly established preventive maintenance program cannot be overe...

Page 34: ...tem refrigerant charge and verify the system is still full charged 18 Check the operation of the compressor crankcase heater Energize the heater while the compressor is off Taking an amp reading of th...

Page 35: ...ge service valve is fully or partially closed Open valve all the way Refrigerant circuit overcharged Contact refrigeration service technician High refrigerant pressure sensor Replace if faulty PLC inp...

Page 36: ...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...

Page 37: ...31 Notes...

Page 38: ...32...

Page 39: ......

Page 40: ...t Sales Customer Service Parts Department 847 966 2260 info thermalcare com 847 966 2260 847 966 2636 847 966 8560 847 966 9358 fax www thermalcare com sales thermalcare com service thermalcare com tc...

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