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General Troubleshooting

Problem

Possible Cause

Remedy

Compressor
will not start

Compressor overload

Check supply voltage, amperage of each leg, contactor and
wiring, and overload set point

Compressor contactor

Replace if faulty

Compressor failure

Contact Customer Service for assistance

Pump will
not start

Pump overload

Check supply voltage, amperage of each leg, contactor and
wiring, and overload set point

Pump contactor

Replace if faulty

Pump failure

Replace if faulty

Low
refrigerant
pressure

Low refrigerant charge

Contact refrigeration service technician

Refrigerant leak

Contact refrigeration service technician

Low refrigeration pressure sensor

Check for proper range, replace if faulty

High
refrigerant
pressure

Dirty air filters (air-cooled units only)

Clean filters

Air flow obstruction (air-cooled units only)

Make sure chiller is installed in accordance with
recommendations in this manual

High ambient air temperature (air-cooled units only)

Ambient temperature must be reduced below 110°F

Condenser 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 out tubes

Insufficient condenser water flow (water-cooled units only)

Make sure chiller is installed in accordance with the
recommendations of this manual

High condenser water temperature (water-cooled units only) Condenser water temperature must be reduced below 100°F

Condenser water regulating valve

Check setting, replace if faulty

Refrigerant circuit overcharged

Contact 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

Replace if faulty

Excessive flow

Reduce flow

High pump
discharge
pressure

Closed valves in process piping

Open valves

Obstruction in piping or process

Remove obstruction

Clogged Y-strainer

Clean strainer

Pressure gauge

Replace if faulty

Erratic
temperature
control

Low coolant flow through evaporator

Adjust flow to proper level

Intermittent overloading of chiller capacity

Check to make sure chiller is properly sized for process load

Hot gas bypass valve

Contact refrigeration service technician

Temperature sensor

Replace if faulty

Содержание ACCUCHILLER EQ

Страница 1: ......

Страница 2: ......

Страница 3: ...ining Equivalent Line Length 6 Table 1 Equivalent Lengths of Elbows 6 Liquid Line Sizing 6 Table 2 Liquid Line Sizes for R407c 7 Discharge Hot Gas Line Sizing 7 Figure 5 Vertical Riser Traps 7 Figure 6 Double Discharge Riser 7 Table 3 Horizontal Downflow Discharge Line Sizes 7 Table 4 Upflow Discharge Line Sizes 7 Calculating Refrigerant and Oil Charge 8 Table 5 Field Piping R 407c Refrigerant Cha...

Страница 4: ... Water Chemistry Requirements 17 Table 12 Recommended Glycol Solutions 17 Step 3 Check Condenser 18 Integral Air Cooled Condenser Check 18 Water Cooled Condenser Check 18 Remote Air Cooled Condenser Check 18 Step 4 Check Refrigerant Valves 18 Step 5 Verify Freezestat Setting 18 Step 6 Turn On Control Power 18 Step 7 Establish Coolant Flow 18 Step 8 Intial Unit Operation 18 Preventive Maintenance 1...

Страница 5: ...arbon 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 instructions could result...

Страница 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...

Страница 7: ...ging The chiller has a frame to facilitate easy movement and positioning with a crane or forklift Follow proper rigging methods to prevent damage to components Avoid impact loading caused by sudden jerking when lifting or lowering the chiller Use pads where abrasive surface contact may occur Chilled Process Fluid Piping Proper insulation of chilled process fluid piping is crucial to prevent conden...

Страница 8: ...consider access to the components to allow for proper maintenance and servicing of the unit Avoid locating piping or conduit over the unit to ensure easy access with an overhead crane or lift to lift out heavier components during replacement or service Proper ventilation is another important consideration when locating the condenser In general locate the unit in an area that will not rise above 11...

Страница 9: ...per the American Welding Society with 5 BCuP 3 to 15 BCuP 5 silver content Only use a high silver content brazing alloy BAg per AWS for copper to brass or copper to steel joints such as a 45 BAg 5 silver content Only use oxy acetylene brazing WARNING The POE oil contained within the compressor is hygroscopic and has the ability to absorb water vapor from the atmosphere Take necessary steps to prev...

Страница 10: ... lengths as shown in Table 5 CAUTION When calculating the equivalent length do not include piping of the chiller unit Only field piping must be considered Table 1 Equivalent Lengths of Elbows Line Size OD in Equivalent Lengths of Refrigerant Pipe feet 90 Standard 90 Long Radius 90 Street 45 Standard 45 Street 1 2 1 4 0 9 2 3 0 7 1 1 5 8 1 6 1 0 2 5 0 8 1 3 7 8 2 0 1 4 3 2 0 9 1 6 Liquid Line Sizin...

Страница 11: ...ul consideration in the design of the discharge gas riser Check the oil level sight glass in the compressor to ensure it is at the appropriate level to verify there is no trapping of oil in the piping The chiller uses hot gas bypass for capacity control and when the chiller is fully unload the gas in the upflow discharge lines may have problems moving the oil against gravity if a single rise syste...

Страница 12: ...power source Voltage must be within the voltage utilization range given on the drawings included with the unit If the measured voltage on any leg is not within the specified range notify the supplier and correct before operating the unit Voltage imbalance must not exceed 2 When installing any unit to 3 phase power check the electrical phase sequence at installation and prior to start up Operation ...

Страница 13: ... controller boots up The controller then displays the software version and after 10 seconds the controller is ready for operation After power is applied and the controller has gone through its initial start up the default main screen will look similar to the screen shown below The interface has six buttons that allow for various functions and adjustments See Table 6 for details of the button funct...

Страница 14: ...emperature shows on the screen Once the desired temperature shows press the enter button to enter the new set point temperature the value should match with the Actual Setpoint If the Modbus control is enabled the septoint can be written only through communication Main Menu The main menu access is through the PRG Button and depending of the password level is it possible to change the different sett...

Страница 15: ...r the below defines all I O possible ID1 Fan Overload ID2 Pump Overload NO1 Compressor Enable NO2 Process Pump Enable NO3 Condenser Fan Enable NO4 Fluid Makeup Valve Liquid Line Solenoid Valve NO5 Alarm Horn NO NC6 Remote alarm contacts Normally open normally close contacts This screen also shows the analog outputs Y1 EC fan control 0 10V Y2 Supply Fluid Temperature retransmit 0 10V Running Hours ...

Страница 16: ...p Control No or Yes No If the Return Fluid sensor is an option this feature allows to change the process temperature control using the Return Fluid Temperature Manufacturer Remote Setpoint No or Yes No This allows for enabling or disabling of the Remote Setpoint option Service Supply Fluid High Fault 20 to 140 F 100 This is the setpoint for the Supply High Temperature Alarm High Fault Delay 0 to 6...

Страница 17: ... screen allows reset the run hours counter this screen also shows the current run hours and status B HGBP Service Hot Gas Bypass Manual or Automatic Automatic This allows for changing the mode of Hot Gas Bypass control from automatic to manual mode Position 0 to 480 steps 0 When in the Manual mode it is possible to change the valve position 0 step is equal to 0 minimum valve percent and 480 steps ...

Страница 18: ...M BIT R 10012 BOOL LOW FLOW ALARM BIT R 10013 BOOL HIGH SUPPLY FLUID TEMPERATURE ALARM BIT R 10014 BOOL HIGH RETURN FLUID TEMPERATURE WARNING BIT R 10015 BOOL LOW SUPPLY FLUID TEMPERATURE ALARM BIT R 10016 BOOL LOW RETURN FLUID TEMPERATURE WARNING BIT R 10017 BOOL SUPPLY FLUID TEMPERATURE SENSOR ALARM BIT R 10018 BOOL RETURN FLUID TEMPERATURE SENSOR ALARM BIT R 10019 BOOL FREEZESTAT ALARM BIT R 10...

Страница 19: ...ult Controller User Reset Low Flow Critical Fault Controller User Reset Tank Low Water Level Critical Fault Controller User Reset Fan Motor Overload Critical Fault Controller User Reset Phase Loss Critical Fault Controller User Reset High Supply Fluid Temperature Warning Controller User Reset Low Supply Fluid Temperature Critical Fault Controller User Reset Tank Low Water Level Warning Auto Reset ...

Страница 20: ...he 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 CAUTION Wire the unit ground in compliance with local and national codes Step 1 Connect Main Power Connect main power properly ensuring it matches the voltage shown on the nameplate of the unit Check the electrical phase sequence prior to ...

Страница 21: ...ble 11 shows the list of water characteristics and quality limitations Table 11 Fill 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...

Страница 22: ...eeze up if no glycol is in the coolant Once the proper glycol solution is present adjust the Freezestat to the appropriate setting CAUTION The manufacturer s warranty does not cover the evaporator from freezing It is vital 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...

Страница 23: ...record to log and keep track of maintenance and repairs 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 reasonably close to the Set Point temperature If the temperature stays more than 5...

Страница 24: ...ty Plugged condenser water cooled units only Clean out tubes Insufficient condenser water flow water cooled units only Make sure chiller is installed in accordance with the recommendations of this manual High condenser water temperature water cooled units only Condenser water temperature must be reduced below 100 F Condenser water regulating valve Check setting replace if faulty Refrigerant circui...

Страница 25: ...re Hot gas bypass valve stuck open Contact refrigeration service technician Refrigeration circuit problem Contact refrigeration service technician Temperature sensor Replace if faulty Drawings We have prepared a custom set of drawings for your unit and placed them inside the control panel prior to shipment Please refer to these drawings when troubleshooting servicing and installing the unit If you...

Страница 26: ...22 Notes ...

Страница 27: ......

Страница 28: ...t Sales Customer Service Parts Department 847 966 2260 info thermalcare com 847 966 2260 847 966 9358 fax 847 966 2636 847 966 8560 847 966 9358 fax www thermalcare com info thermalcare com service thermalcare com tcparts thermalcare com EQ IOM 03 ...

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