NANO NPC 280 Service Manual Download

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n-psi-C1-SM-02-01-US

NPC 280 - 400 60 Hz UL

SERVICE MANUAL

Summary of Contents for NPC 280

Page 1: ...n psi C1 SM 02 01 US NPC 280 400 60 Hz UL SERVICE MANUAL ...

Page 2: ......

Page 3: ...0 DESCRIPTION 11 4 1 Components 11 4 2 Cooling circuit 11 4 3 Compressors 11 4 4 Condenser 11 4 5 Evaporator 11 4 6 Tank 11 4 7 Pump 11 4 8 Fans 12 4 9 Casing 12 4 10 Materials in contact with the liquid to be cooled 12 4 11 Minimum distances from walls in the installation ambient 12 4 12 Electrical circuit 12 4 13 Negative ambient temperatures not present in models for 460 3 60 power supply 12 IN...

Page 4: ... 3 Display read out on unit stopped by remote control 28 7 14 Compressors unloading function 28 7 15 Probe key 28 OTHER COMPONENTS SETTING 29 8 1 Compressor integral protection PI 29 8 2 Refrigerant high and low pressure switches 29 8 3 Compressor operation 30 8 4 Pressure transducers 31 8 5 Fan regulation 31 8 6 Level sensor 32 OPERATION AND MAINTENANCE 33 9 1 Operation 33 9 2 Maintenance 33 9 3 ...

Page 5: ...sion drawing and refrigeration circuits in this manual Their meaning is the following The following warning symbols are shown on the stickers on the unit If requested the same stickers are available also in French Their meaning is the following Process water inlet Process water outlet Indications for lifting the unit Water drainage point from the machine Electric shock risk Risk of burns from cont...

Page 6: ...or to the nearest service centre providing the MODEL and MACHINE NUMBER shown on the machine data plate and on the first page of this manual Hazardous voltage All doors must be closed before energizing the panel Read and understand operator s manual before using this machine Failure to follow operating instructions could result in death or serious injury Moving parts can crush and cut Do not opera...

Page 7: ... item of equipment or a method of working which is not specifically recommended he must ensure that the unit and auxiliary equipment will not be damaged or made unsafe and that there is no risk to persons or property Any improper use of the machine will relieve the manufacturer from any liability for possible personal injury or property damage Arbitrary modifications made to the unit will automati...

Page 8: ...earthen and protected by fuses against short circuits and overloading When mains power is switched on lethal voltages are present in the electrical circuits and extreme caution must be exercised whenever it is necessary to carry out any work on the electrical system Do not open any electrical panels or cabinets or touch any electrical components or associated equipment while voltage is applied unl...

Page 9: ...ammable liquid to clean any component during operation If chlorinated hydrocarbon non flammable fluids are used for cleaning safety precautions must be taken against any toxic vapours which may be released ATTENTION Before removing any panels or dismantling any part of the unit carry out the following operations Isolate the unit from the main electrical power supply by disconnecting the cable from...

Page 10: ... cause suffocation reducing the oxygen available for breathing Protection of the eyes Safety goggles Protection of the hands Rubber gloves Hygiene measures Do not smoke PHYSICAL AND CHEMICAL PROPERTIES Colour Colourless Odour Similar to ether Boiling point 43 9 C at atm press Flammability point Non flammable Relative density 1 138 kg l at 25 C Solubility in water Negligible STABILITY AND REACTIVIT...

Page 11: ...As defined by the EN 60529 European standard NEMA 250 international standard WIRING DIAGRAM Number of wiring diagram REFRIGERANT This is the refrigerant fluid in the unit REFRIGERANT QUANTITY This is the quantity of refrigerant fluid contained in the unit MAX COOLING PRESSURE HP SIDE This is the design pressure of the refrigeration circuit of the high pressure side MAX COOLING PRESSURE LP SIDE Thi...

Page 12: ...unit and height of 1 6 m 5 2 FT from the ground Values tolerance 2 dB Sound power level in compliance with ISO 3744 Model 280 330 400 Tank capacity water volume litres galUS 500 132 500 132 500 132 PUMP P3 water flow rate m3 h gpm 7 7 48 17 6 211 3 8 2 48 17 6 211 3 10 4 48 17 6 211 3 pump head bar PSI 3 8 1 5 57 0 21 8 3 8 1 5 57 0 21 8 3 7 1 5 57 0 21 8 nominal power kW 4 4 4 nominal power 460 3...

Page 13: ...sed sheet 4 5 E v a p o r a t o r The evaporator is a finned pack type the water flows in contact with the finned surface and at a speed that guarantees low pressure drops while the refrigerant fluid flows inside the tubes In the TAEevo models the exchanger is protected against the formation of ice caused by low evaporation temperatures through an anti freeze function in the electronic controller ...

Page 14: ... access to all machine components 4 1 0 M a t e r i a l s i n c o n t a c t w i t h t h e l i q u i d t o b e c o o l e d The chosen materials are evaporator with copper tubes aluminium fins and galvanized sheet metal shoulders carbon steel tank The pump mechanical seals are made of ceramics graphite and or EPDM 4 1 1 M i n i m u m d i s t a n c e s f r o m w a l l s i n t h e i n s t a l l a t i ...

Page 15: ...e metre around the unit to permit access during service operations 6 Do not obstruct or disturb the condenser s flow of thermal exchanging air 5 3 A n t i f r e e z e p r o t e c t i o n Even if the minimum working ambient temperature is above 0 C it is possible for the machine during stoppages in the cold seasons to find itself in an environment with a temperature below 0 C In these cases if the ...

Page 16: ...the manual valve If there are frequent air infiltrations into the water circuit it is advisable to install an automatic bleed valve 4 If the machine is supplied without a pump make sure that the pump installed by the user has the suction directly connected to the tank outlet NOTE The pump must never run dry ATTENTION If the unit is furnished without hydraulic group it is necessary to install a pum...

Page 17: ...es and contaminants If the pump runs noisily or emits anomalous noise it may be necessary to bleed the liquid circuit in order to prime the pump The procedure is as follows unscrew the filler breather plug at the top of the pump fill the hydraulic circuit until water starts to overflow from the filled hole refit the plug and tighten it Repeat the operation if the pump continues to run noisily in s...

Page 18: ...omply with the values indicated on the machine data plate Main distribution systems in United States Main distribution systems in Canada System Nominal Voltage Utilization Voltage 120 115 110 240 120 230 115 220 110 600 480 240 575 460 230 550 440 220 480 460 440 480 277 208 120 460 266 200 115 440 254 190 110 240 120 230 115 220 110 240 120 230 115 220 110 System Nominal Voltage Utilization Volta...

Page 19: ...iagram upline from the power cable For this purpose all protection devices must be homologated listed 4 Use conductors which can carry the maximum current required at the maximum ambient operating temperature according to the type of installation chosen seeindication in the electrical diagram Use only UL marked copper cables in conformity with NEC NATIONAL ELECTRICAL CODE and CEC CANADIAN ELECTRIC...

Page 21: ...city If this difference is lower it means that the water flow capacity is higher than the maximum value allowed In order not to damage the pump it is necessary to increase the pressure drop of the hydraulic circuit by for example partially closing a pump discharge cock 14 Models with centrifugal fans Check that the output of the centrifugal fans is correctly ducted and that the pressure drop of th...

Page 23: ...zone Signalling icons ICON ICON STATUS MEANING ON Celsius degrees If viewed OFF Fahrenheit degree If not viewed ON General alarm BLINKING Alarm without icon ON Bar pressure OFF PSI pressure ON it displays the size of circuit n 1 blinking with the led of circuit n 2 it means you are entering in programming mode ON it displays the size of circuit n 2 blinking with the led of circuit n 1 it means you...

Page 24: ...ress once With Cir1 on it shows on the display the values of the circuit n 1 probes With Cir2 on it shows on the display the values of the circuit n 2 During the programming press once It scrolls the parameter codes or increases their value F NOT ENABLED FUNCTION H Press once Turn the chiller on or off if the unit is on led is on The led is blinking if there is a POWER ON delay or during the pump ...

Page 25: ...and release I Defines if the parameter can be changed or not in the other levels Led n 1 and Led n 2 blinking the parameter is shown but not modifiable For the function of the buttons and of the led see 7 2 Display 7 3 Function of the buttons and 7 4 Symbols and leds of the display It is possible to connect 2 remote terminals The remote terminal can be interfaced with a shiels cable for a maximum ...

Page 26: ...er of the three levels are settled during the design phase ATTENTION All levels are protected by a password The USER password is 23 The parameters are so subdivided ATTENTION The parameters of the CF configuration can be modify only when the unit is in Stand by mode In the bottom of the display it will be viewed the alarm code while above you will see the temperature pressure blinking The icon of ...

Page 27: ...without pressing any button NOTE The new value is memorized even if you exit the programming because of the time out without pressing G 7 1 0 V a l u e s s h o w n o n t h e d i s p l a y As default in normal condition the display shows the circuit 1 information The displayed circuit is indicated from the corresponding LED Cir1 circuit n 1 on near the button C or Cir2 circuit n 2 on near the butto...

Page 28: ...or outlet COdt function when the compressor outlet temperature probe is present 8 Display and reset the hours of operation of controlled loads Hour function 9 Display and reset the starting number of each compressor COSn function 10 Display the operation percentage of the 4 proportional exits 0 10 Volt Pout function 11 Display the temperature of the probes that check the auxiliary exits uS functio...

Page 29: ...PAS and the top display 0 flashing If the password is not inserted again within 5 sec the label CO1r is automatically displayed again 7 To exit the function COtr and return in normal displaying press I button or wait for time out 8 Repeat the operations 2 5 with all compressor thermal protection alarms ATTENTION The password for resetting the compressor thermal protection alarm corresponds to the ...

Page 30: ...s be subject to dangerous overheating which would cause the activation of the thermal protections or the pressure of the refrigerant gas could reach alarm levels which would cause the machine to shut down This function enables the machine to run through the switch off or capacity step operation of the compressors even when the temperature of the water at the evaporator s inlet is high summer start...

Page 31: ...02 see chapter 12 1 Alarm codes and actions band will stop the compressor s while the pump if it is installed will continue to operate After the alarm tripping if the compressor intake pressure increases and exceeds the pressure switch tripping value it will restart It will be possible to start up the unit again following the alarm reset procedure described in Chapter 7 Electronic control If the c...

Page 32: ... further variable the time The starting of compressors depends on the temperature value during a certain time If during a certain time the temperature measured increases the compressors will start with a delayed sequence In this way the number of compressors in operation is always optimal ST07 TEMPERATURE ST01 COMPRESSORS OFF Compr n 1 Compr n 2 Compr n 3 Compr n 4 Compr n 5 Compr n 6 ST01 Chiller...

Page 33: ...d on the refrigerant compressor outlet pipeline According to the pressure detected by the transducer the electronic control switches on or off the fans 2 Units configured with fan speed regulator NOT present with 460 3 60 Hz supply The unit is furnished with a speed regulator of fan rotation which operates to maintain the condensing pressure within a pre fixed value These units are furnished with ...

Page 34: ...on solutions Service Centre NOTE If the electrical resistance of the liquid is outside the maximum range of the control device green LED 3 will flash rapidly for 2 seconds while amber LED 2 remains off thus signalling a teach in error ATTENTION The level sensor has been calibrated by QDQR SXULILFDWLRQ VROXWLRQV to operate at maximum sensitivity admissible on the instrument 220kOhm Modifications to...

Page 35: ... concerned have read and understood the Chapter 2 Safety 9 3 U n i t a c c e s s ATTENTION Everytime the panels must be removed the unit must be switched off and disconnected from power supply To access the components of the refrigerant circuit use an appropriate key furnished with the unit and operate on the closing bolts of the front panel A The access to the evaporator and to the components of ...

Page 36: ... 5 bar with the circuit closed x In units with hydraulic group check that the difference between the discharge and the suction pressure of the pump measured on the manometer with the pump stopped is within expected limits and in particular that it is not lower than the value corresponding to the maximum flow capacity x Clean the water filter We recommend to clean the filter after a week from the u...

Page 37: ... with pump installed on the machine pressure difference read on the machine pressure gauge too low with pump stopped and pump running possible tripping of pump thermal protection Reduce water flow to within the preset limits for example by closing partially a pump outlet cock Reset the pump thermal protection and check the electrical absorption B2 See point C B2 1 See point C See point C B3 Evapor...

Page 38: ...ter Electronic control D6 Thermal load too high D6 1 Water outlet temperature too high refrigerant compressor stops main alarm relay tripped If possible reduce the thermal load to within the design limits Follow the alarm reset procedure to star up the unit again chapter Electronic control E Low pressure switch tripped LP Alarm displayed B_LP E1 Lack of refrigerant see also A5 E1 1 Refrigerant com...

Page 39: ... tripped because the water flow is too high J1 1 See problem main alarm relay tripped the refrigerant compressor and pump stop the indication AtE appears on the display alternated to BTWOT value the pressure difference read on the machine gauge with the pump stopped and pump running is lower than the available head with maximum pump flow Reset the thermal protection device Increase the pressure dr...

Page 41: ...e r s e t t i n g To modify the following parameters follow the procedure illustrated in chapters 7 9 1 Access to the parameters and 7 9 2 How to change the value of a parameter 11 1 1 Thermoregulation parameters 11 1 2 Displaying parameters 11 1 3 Configuration parameters Parameter Description Min Max Udm Resolution Factory setting ST01 Chiller set point It allows to fix the operating set point d...

Page 42: ...assword 0 999 Parameter Description Min Max Udm Resolution Factory setting Pr1 Password 0 999 023 Pr2 Password 0 999 Pr3 Password 0 999 Parameter Description Min Max Udm Resolution Factory setting Capacity controls NOT ENABLED FUNCTION Compressor start up Compressor rotation balancing thermoregulation Evaporator water pump NOT ENABLED FUNCTION Condenser water pump NOT ENABLED FUNCTION Load mainten...

Page 43: ...Udm Resolution Factory setting Boiler function NOT ENABLED FUNCTION Boiler function in chiller modality NOT ENABLED FUNCTION Boiler function in heat pump modality NOT ENABLED FUNCTION Tank resistance Antifreeze alarm Pump for antifreeze Pr1 Password 0 999 023 Pr2 Password 0 999 Pr3 Password 0 999 Parameter Description Min Max Udm Resolution Factory setting Forced defrosting Defrosting modality t d...

Page 44: ...the antifreeze alarm is enabled ambient air low temperature air air units outlet air low temperature air air units from AL23 to AL24 AL24 AL25 C F Dec int 37 0 F Antifreeze alarm in heat pump High temperature at compressor outlet Unit block general alarm Alarm relay Password for alarm history reset compressor thermal protection alarm Pr1 Password 0 999 023 Pr2 Password 0 999 Pr3 Password 0 999 Par...

Page 45: ...16 tripping per hour reset procedure in functions menu Flashing Alarm relay buzzer enabled AtE1 Evaporator 1 water pump thermal protection ID configured as evaporator 1 water pump thermal protection With ID not enabled Manual reset procedure in functions menu E Flashing Alarm relay buzzer enabled AtE2 Support evaporator 2 water pump thermal protection ID configured as support evaporator 2 water pu...

Page 46: ... FA18 FA19 If a condensation evaporation probe per circuit is not present when the pump and defrost are enabled When triac regulation is enabled CF68 CF69 2 and the continuous power supply has been selected CF83 0 Incorrect programming Correct programming Auto E Flashing Alarm relay buzzer enabled ACF3 Two digital analogue inputs configured with the same function or without the necessary resources...

Page 47: ...or not even the low pressure pressure switch is configured Incorrect programming Correct programming Auto E Flashing Alarm relay buzzer enabled ACF6 The compressor has been configured with CF04 and CF05 parameters but the related relays have not been foreseen Main Intermittent valve when enabled by the ON OFF times different than 0 Neither the capacity control nor the by pass gas when the by pass ...

Page 48: ... is configured not defined CO16 0 but a relay is defined Condenser pump defined CO21 different from 0 but no relay is configured not defined CO21 0 but a relay is defined Incorrect programming Correct programming Auto E Flashing Alarm relay buzzer enabled ACF8 Thermoregulation probe configuration a thermoregulation probe in chiller ST09 in pump when enabled ST10 is not correctly configured it does...

Page 49: ...ser 1 water pump maintenance request Compressor operating time than the set counter Reset operating time in functions menu Hour function Manual E Flashing Alarm relay buzzer enabled ACP2 Condenser 2 water pump maintenance request AELt Evaporator water outlet low temperature With unit operation selected probe configured in evaporator outlet if temperature detected by temperature control probe AL48 ...

Page 50: ...With the ID configured as antifreeze alarm and active Antifreeze regulation probe Pbr measures a temp than the set A33 differential AL34 With ID inactive Auto becomes manual after AL37 tripping per hour reset procedure in functions menu E Flashing If AL38 0 only the comp are turned off the alarm label b1Ah b2Ah is signalled but the alarm relay and buzzer are not activated If AL38 1 the comp are tu...

Page 51: ...t CO37 time is not reached and the pump down stops for the CO39 time From thermoregulation start up and ID not active From thermoregulation start up with evaporating pressure than the set CO37 CO38 differential Auto becomes manual after AL21 tripping per hour reset procedure in functions menu Logged only with manual restart E Flashing Alarm relay buzzer enabled only when the alarm becomes manual r...

Page 52: ...larm relay buzzer enabled C1tr C6tr Compressor 1 6 relay alarm The alarm is not detected for AL19 after the starting of the compressor with ID active If ID is not active Manual If more than AL20 tripping per hour Of the compressor to reset the alarm go to functions menu see COtr function in functions menu E Flashing Alarm relay buzzer enabled Compressor involved If parameter AL47 0 or 1 Off Compre...

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