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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

Содержание NQ Series

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 75: ...Notes...

Страница 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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