Thermal Care NQ Series Installation & Operation Manual Download

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Installation & Operation Manual

NQ Series Portable and Remote Condenser Chillers

Summary of Contents for NQ Series

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

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

Page 3: ...formances 60 Hz 12 Figure 12 15 Ton Chiller Net Pump Performances 60 Hz 12 Figure 13 15 Ton High Flow Chiller Net Pump Performances 60 Hz 13 Figure 14 20 Ton Chiller Net Pump Performances 60 Hz 13 Fig...

Page 4: ...OD 31 Calculating System Refrigerant and Oil Charge 32 Table 9 Combined Chiller and Remote Condenser Summer Refrigerant Charge 32 Table 10 Field Piping R 410A Refrigerant Charge per 100 Feet of Run Lb...

Page 5: ...Button Press to Toggle 54 Start Button 54 Stop Button 54 Set Point Temperature Display Entry 54 Actual Supply Water Temperature Display 54 Alarms Button 54 Setup Button 54 Process Diagnostic Button 54...

Page 6: ...try Requirements 60 Table 20 Fill Water Chemistry Requirements 61 Table 21 Recommended Glycol Solutions 61 Step 3 Check Condenser 61 Intergral Air Cooled Condenser Check 61 Water Cooled Condenser Chec...

Page 7: ...of this equipment we do not reference them in this manual There is no substitute for common sense and good operating practices when placing any mechanical equipment into operation We encourage all per...

Page 8: ...zardous voltages that can cause severe injury or death WARNING This equipment contains refrigerant under pressure Accidental release of refrigerant under pressure can cause personal injury and or prop...

Page 9: ...75 for NQA08 10 82 for NQA15 84 for NQA20 85 for NQA25 and 82 for NQA30 3 Net available pressure at outlet of chiller is pump discharge pressure less the internal coolant circuit pressure loss 4 MCA...

Page 10: ...ons based on 12 000 BTU Hr ton with 50 F leaving coolant and 95 F ambient air 2 Sound pressure is for chiller unit only see the Remote Air Cooled Condenser table for condenser sound pressures 3 Net av...

Page 11: ...mage while the equipment is still partially packed will help in this regard Refrigerant lines can be susceptible to damage in transit Check for broken lines oil leaks damaged controls or any other maj...

Page 12: ...d condenser air discharge They are not designed to have the condenser air discharge ducted Improper clearance or poor ventilation will reduce the cooling capacity of the chiller and may cause high ref...

Page 13: ...erence one of the following net pump pressure drop curves to determine actual pumping capabilities for your process If you have ordered the chiller less pump use the following coolant circuit pressure...

Page 14: ...igh Flow Chiller Net Pump Performance Pump Discharge Pressure Less Coolant Circuit Pressure Loss Based on Water at 50 F 60 Hz 1 hp 3 hp 3 hp 2 stage 5 hp 2 stage 0 10 20 30 40 50 60 70 80 90 0 5 10 15...

Page 15: ...on High Flow Chiller Net Pump Performance Pump Discharge Pressure Less Coolant Circuit Pressure Loss Based on Water at 50 F 60 Hz 1 hp 3 hp 3 hp 2 stage 5 hp 2 stage 0 10 20 30 40 50 60 70 80 90 0 10...

Page 16: ...ow gpm 7 Ton High Flow Chiller Net Pump Performance Pump Discharge Pressure Less Coolant Circuit Pressure Loss Based on Water at 50 F 60 Hz 1 hp 3 hp 5 hp 7 hp 0 10 20 30 40 50 60 70 80 90 0 10 20 30...

Page 17: ...i Flow gpm 10 Ton High Flow Chiller Net Pump Performance Pump Discharge Pressure Less Coolant Circuit Pressure Loss Based on Water at 50 F 60 Hz 1 hp 3 hp 7 hp 5 hp 0 10 20 30 40 50 60 70 80 90 0 10 2...

Page 18: ...gpm 13 Ton High Flow Chiller Net Pump Performance Pump Discharge Pressure Less Coolant Circuit Pressure Loss Based on Water at 50 F 60 Hz 1 hp 3 hp 7 hp 5 hp 0 10 20 30 40 50 60 70 80 90 0 10 20 30 4...

Page 19: ...si Flow gpm 15 Ton High Flow Chiller Net Pump Performance Pump Discharge Pressure Less Coolant Circuit Pressure Loss Based on Water at 50 F 60 Hz 3 hp 7 hp 5 hp 0 20 40 60 80 100 120 0 20 40 60 80 100...

Page 20: ...Flow gpm 20 Ton High Flow Chiller Net Pump Performance Pump Discharge Pressure Less Coolant Circuit Pressure Loss Based on Water at 50 F 60 Hz 3 hp 7 hp 5 hp 10 hp 0 20 40 60 80 100 120 0 20 40 60 80...

Page 21: ...Flow gpm 25 Ton High Flow Chiller Net Pump Performance Pump Discharge Pressure Less Coolant Circuit Pressure Loss Based on Water at 50 F 60 Hz 7 hp 5 hp 10 hp 0 20 40 60 80 100 120 0 20 40 60 80 100...

Page 22: ...Flow gpm 30 Ton High Flow Chiller Net Pump Performance Pump Discharge Pressure Less Coolant Circuit Pressure Loss Based on Water at 50 F 60 Hz 7 hp 5 hp 10 hp 0 20 40 60 80 100 120 0 20 40 60 80 100...

Page 23: ...Flow gpm 35 Ton High Flow Chiller Net Pump Performance Pump Discharge Pressure Less Coolant Circuit Pressure Loss Based on Water at 50 F 60 Hz 7 hp 5 hp 10 hp 0 20 40 60 80 100 120 0 20 40 60 80 100...

Page 24: ...Flow gpm 40 Ton High Flow Chiller Net Pump Performance Pump Discharge Pressure Less Coolant Circuit Pressure Loss Based on Water at 50 F 60 Hz 7 hp 5 hp 10 hp 0 0 5 0 10 0 15 0 20 0 25 0 30 0 5 0 10 0...

Page 25: ...rop psi Flow gpm 7 Ton and 10 Ton Chiller Coolant Circuit PressureDrop Based on Water at 50 F 7 ton Std Flow 10 ton Std Flow 7 Ton High Flow 10 Ton High Flow 0 0 5 0 10 0 15 0 20 0 25 0 30 0 10 0 20 0...

Page 26: ...Drop psi Flow gpm 20 Ton and 25 Ton Chiller CoolantCircuit PressureDrop Based on Water at 50 F 20 ton Std Flow 25 ton Std Flow 20 Ton High Flow 25 Ton High Flow 0 0 5 0 10 0 15 0 20 0 25 0 30 0 30 0...

Page 27: ...hrough the condenser resulting in 95 F exiting water temperature from the condenser To ensure proper water flow through the condenser the condenser water pump should be able to provide at least 25 psi...

Page 28: ...5 0 15 0 25 0 35 0 45 0 55 0 65 0 Pressure Drop psi Condenser Water Flow gpm Condenser Water Circuit Pressure Drop Based on Water 85 F 5 Ton 7 Ton 10 Ton 15 Ton 0 0 5 0 10 0 15 0 20 0 25 0 30 0 35 0...

Page 29: ...an create a micro climate such as an alcove with east north and west walls that can be significantly warmer than surrounding areas The condenser needs to have unrestricted airways so it can easily mov...

Page 30: ...rant 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 410A...

Page 31: ...tion difference greater than 100 actual feet without a minimum of 2 efficiency decrease 4 To form a proper liquid seal at the condenser immediately drop at least 15 inches down from the liquid outlet...

Page 32: ...inear run of pipe and the equivalent feet of elbows valves and other components in the refrigeration piping The sum total is the equivalent length of pipe that would have the same pressure loss See th...

Page 33: ...it and the air cooled condenser must not exceed 200 actual feet or 300 equivalent feet Liquid line risers in the system will require an additional 0 5 psig pressure drop per foot of vertical rise When...

Page 34: ...low 11 to 15 Feet 25 25 50 50 75 75 100 100 125 125 150 150 175 175 200 200 225 225 250 250 275 275 300 300 10 Ton Circuit R410A 15 Ton Circuit R410A Total Equivalent Length Ft Liquid Line Size Inch O...

Page 35: ...1 200 1 1 1 1 225 1 1 1 1 225 1 1 1 1 250 1 1 1 1 250 1 1 1 1 275 1 1 1 1 275 1 1 1 1 300 1 1 1 1 300 1 1 1 1 30 Ton Circuit R410A 35 Ton Circuit R410A Total Equivalent Length Ft Liquid Line Size Inch...

Page 36: ...h downward in the direction of the hot gas flow at the rate of inch per each 10 foot of horizontal run If the chiller unit is below the condenser loop the discharge line to at least 1 inch above the t...

Page 37: ...1 1 2 2 2 2 2 2 Table 8 Upflow Discharge Line Sizes for R410A inches OD Circuit Tons Total Equivalent Length Ft 25 50 75 100 125 150 175 200 225 250 275 300 5 A A A A A A A A A A A A B B B B B B B B...

Page 38: ...ith the amount of oil required by the chiller only and not the total system The amount of oil required is dependent upon the amount of refrigerant added to the system for the field installed piping Us...

Page 39: ...A 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 m...

Page 40: ...1 27 9 3 HP 460 3 60 414 506 9 7 62 0 1 8 4 8 19 9 29 7 5 HP 460 3 60 414 506 9 7 62 0 1 8 7 6 22 7 32 5 None 575 3 60 518 633 7 4 50 0 1 4 0 0 11 6 19 0 1 5 HP 575 3 60 518 633 7 4 50 0 1 4 2 4 14 0...

Page 41: ...40 7 5 HP 575 3 60 518 633 14 7 100 0 1 4 1 4 6 1 28 2 42 9 7 5 HP 575 3 60 518 633 14 7 100 0 1 4 1 4 8 8 30 9 45 6 NQA13 None 230 3 60 207 253 51 3 300 0 2 9 2 9 0 0 72 4 123 7 1 5 HP 230 3 60 207...

Page 42: ...3 3 HP 230 3 60 207 253 33 3 239 0 33 3 239 0 8 3 8 3 9 6 103 6 136 9 5 HP 230 3 60 207 253 33 3 239 0 33 3 239 0 8 3 8 3 15 2 109 2 142 5 7 5 HP 230 3 60 207 253 33 3 239 0 33 3 239 0 8 3 8 3 22 0 11...

Page 43: ...3 7 3 7 8 8 61 9 81 8 10 HP 575 3 60 518 633 19 9 109 0 19 9 109 0 3 7 3 7 11 2 64 3 84 2 NQA30 None 230 3 60 207 253 55 8 340 0 55 8 340 0 8 3 8 3 8 3 0 0 153 0 208 8 5 HP 230 3 60 207 253 55 8 340...

Page 44: ...33 7 4 50 0 6 1 16 3 23 7 NQW08 NQR08 None 230 3 60 187 253 29 5 195 0 0 0 39 4 68 9 1 5 HP 230 3 60 187 253 29 5 195 0 6 0 45 4 74 9 3 HP 230 3 60 187 253 29 5 195 0 9 6 49 0 78 5 5 HP 230 3 60 187 2...

Page 45: ...5 3 60 518 633 14 7 100 0 2 4 21 7 36 4 3 HP 575 3 60 518 633 14 7 100 0 3 8 23 2 37 9 5 HP 575 3 60 518 633 14 7 100 0 6 1 25 4 40 1 7 5 HP 575 3 60 518 633 14 7 100 0 8 8 28 1 42 8 NQW15 NQR15 None...

Page 46: ...0 0 3 8 33 6 46 4 5 HP 575 3 60 518 633 12 8 80 0 12 8 80 0 6 1 35 8 48 6 7 5 HP 575 3 60 518 633 12 8 80 0 12 8 80 0 8 8 38 6 51 4 10 HP 575 3 60 518 633 12 8 80 0 12 8 80 0 11 2 41 0 53 8 NQW25 NQR2...

Page 47: ...one 460 3 60 414 506 26 9 173 0 30 4 225 0 0 0 66 1 92 1 5 HP 460 3 60 414 506 26 9 173 0 30 4 225 0 7 6 73 7 99 7 7 5 HP 460 3 60 414 506 26 9 173 0 30 4 225 0 11 0 77 1 103 1 10 HP 460 3 60 414 506...

Page 48: ...6 15 KCL030 NQR20 230 187 253 1 3 6 1 2 6 6 13 2 16 0 20 460 414 508 1 1 7 1 2 3 1 6 2 7 0 15 575 518 632 1 1 4 1 2 2 5 5 0 5 6 15 KCL037 NQR25 230 187 253 1 3 6 1 2 6 6 13 2 16 0 20 460 414 508 1 1 7...

Page 49: ...ee the Program Menu section for instructions on how to enable or disable the Autostart feature This button also performs a Cancel function while in the programming menu Alarm Silence Alarm Reset Butto...

Page 50: ...ore detail Up Button The Up Arrow button raises the set point temperature Pressing the Up Arrow and releasing it increases the set point temperature by one degree Pressing the Up Arrow button and hold...

Page 51: ...ressor cycling the control board has a compressor anti cycle delay timer built in Any time a compressor is prevented from turning on by the anti cycle timer the Compressor Recycle LED will be lit Comp...

Page 52: ...Reset button will reset the Low Refrigerant Pressure fault as long as the refrigerant pressure has risen back up above the safety s cutout level Program Mode LED The Program Mode LED will flash yello...

Page 53: ...wn in Table 15 To change an item press the Display Program button until the item code displays in the Process display Pressing the Alarm Reset button and Display Program button at the same time will r...

Page 54: ...DIS or Enabled EnA Compressor 2 Negative Spread nS2 5 1 to 10 Compressor 2 Positive Spread PS2 3 1 to 10 Derivative dEr 3 0 to 200 Display Units Unt F F to C Freezestat Limit FSL 40 50 to 40 High Dev...

Page 55: ...es No Yes Supply Probe Fault Lo The Set Point Temperature Display shows PRS and the Process Temperature Display shows ELo Yes Yes Yes No Yes Return Probe Fault Hi The Set Point Temperature Display sho...

Page 56: ...ers Command Poll Select Description Echo 20 20 20 21 This is the controller integrity command used to accept and retain data and provide it in response to a poll inquiry This is an open 4 byte ASCII f...

Page 57: ...upply 20 70 Returns the process supply temperature This is a numeric format in F Temperature To Process Return 20 72 Returns the process return temperature This is a numeric format in F Modbus RTU Opt...

Page 58: ...DISPLAY 4033 COMP 2 ENABLED R 0 DISABLED 1 ENABLED 4034 HEAT COOL SWITCH DELAY R 4035 DAC OUTPUT SPI0 R 16 bit value being sent to DAC card 4036 DAC OUTPUT SPI1 R 16 bit value being sent to DAC card...

Page 59: ...R 8066 POS COMP 2 SPREAD C R 8068 FREEZESTAT LIMIT C R 8070 SUPPLY TEMP INPUT OFFSET R 8072 RETURN TEMP INPUT OFFSET R 8074 REMOTE SP INPUT OFFSET R 8076 FLOW INPUT OFFSET R 8078 FREEZESTAT INPUT OFFS...

Page 60: ...Local Control is ON If Start shows the chiller is OFF If Running shows the chiller is ON Stop Button Pressing this button will stop the chiller if Local Control is ON If Stopped shows the chiller is...

Page 61: ...ill reappear immediately Alarm History Button Touching this button navigates to the Alarm History screen Main Button Touching this button navigates to the Main screen Alarm History Screen This screen...

Page 62: ...navigates to the Main screen Process Setup Screen The process setup screen displays and allows adjustment of the temperature alarms The Process Setup Screen displays and allows for the adjustment of t...

Page 63: ...c screen Compressor Setup Button Touching this button navigates to the Compressor Setup screen Main Button Touching this button navigates to the Main screen Freezestat Setup Screen This screen display...

Page 64: ...r Setup screen is password protected so navigating to this screen shows a prompt for a password The Password is 9999 Main Touching this button navigates to the Main screen I O Status Screen This scree...

Page 65: ...dous voltages that can cause severe injury or death WARNING This equipment contains refrigerant under pressure Accidental release of refrigerant under pressure can cause personal injury and or propert...

Page 66: ...tower As the concentration exceeds the solubility of some minerals scale forms The life giving properties of water can also encourage biological growth that can foul heat transfer surfaces Sometimes t...

Page 67: ...C Not required 45 F 7 2 C 5 40 F 4 4 C 10 35 F 1 7 C 15 30 F 1 1 C 20 25 F 3 9 C 25 20 F 6 7 C 30 CAUTION When your application requires the use of glycol use industrial grade glycol specifically desi...

Page 68: ...p should be energized to establish flow through the chiller Note The compressor will not start as long as the flow switch is open A positive flow must be established through the evaporator before the...

Page 69: ...led condenser coil for dirt and debris To clean rinse thoroughly with water Mild detergent can be used to remove smoke and or grease stains 2 Check to make sure that the To Process temperature is main...

Page 70: ...t Glass Electrical Connections Incoming Voltage Compressor 1 L1 Amps Compressor 1 L2 Amps Compressor 1 L3 Amps Compressor 2 L1 Amps Compressor 2 L2 Amps Compressor 2 L3 Amps Pump L1 Amps Pump L2 Amps...

Page 71: ...enser fan motor air cooled units only Replace if faulty Condenser fan cycling control air cooled units only Confirm proper operation replace if faulty Plugged condenser water cooled units only Clean o...

Page 72: ...lant flow through evaporator too high or low Adjust flow to proper level Insufficient condenser cooling See High Refrigerant Pressure Hot gas bypass valve stuck open Contact refrigeration service tech...

Page 73: ...ipment 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...

Page 74: ...ble 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 sys...

Page 75: ...Notes...

Page 76: ...North Lehigh 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 therma...

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