Summary of Contents for Accu EQ Series
- Page 1 EQ Series Portable Chillers Installation, Operation and Maintenance Manual Copyright Thermal Care Inc. 2010...
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Page 2: Table Of Contents
Air Cooled Chillers Condenser Air ............................3 (Air Cooled Units Only) ................................3 Chilled Water Lines .................................. 3 Table 3 - EQ Series Chilled Water Flow Requirements ......................3 Figure 1 - Recommended Overhead Piping .......................... 4 Interconnecting Refrigerant Piping ............................4 Start-Up .................................... - Page 3 Chiller Construction ................................15 Compressor .................................... 15 Air Cooled Condenser................................15 (Air Cooled Units Only) ................................15 Water Cooled Condenser ............................... 15 (Water Cooled Units Only) ..............................15 Condenser Water Regulating Valve (Water Cooled Units Only) .................... 16 Condenser Remote Air-Cooled ............................... 16 Evaporator ....................................
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Page 4: Foreword
Foreword The intent of this manual is to serve as a guide for placing your portable chiller in service and operating and maintaining it properly. This manual is supplemented as required to accommodate any special items that may have been provided for a specific application. -
Page 5: Table 1 - Voltage Utilization Range
specific electrical schematic is shipped with the unit. Measure each leg of the main power supply voltage at the main power source. Voltage must be within the voltage utilization range given in Table 1. Table 1 - Voltage Utilization Range Rated Voltage Utilization Range 208 to 254... -
Page 6: Water Cooled Condenser Lines
Standard portable chillers have been designed to provide 50°F (10°C) coolant to the process. Under normal operating conditions there will be a 10°F (6°C) rise through the process resulting in 60°F (16°C) return coolant temperature to the chiller. Table 3 - EQ Series Chilled Water Flow Requirements Nominal Flow Pressure Drop... -
Page 7: Interconnecting Refrigerant Piping
unsatisfactory chiller performance is poorly designed piping. Avoid unnecessarily long lengths of hoses or quick disconnect fittings that offer high resistance to water flow. When manifolds are required for water distribution, they should be installed as close to the use point as possible. Provide flow-balancing valves at each machine to assure adequate water distribution in the entire system. -
Page 8: Table 4 - Recommended Glycol Solutions
Assure the main power source is connected properly, that it matches the voltage shown on the nameplate of the unit, and that it is within the voltage utilization range given in Table 1. Electrical phase sequence must be checked at installation and prior to start-up for three-phase systems. - Page 9 (EQ2 series only) Make sure the Freezestat is set appropriately for the operating conditions of the chiller. The Freezestat is located inside the main electrical control panel. It should be set at 10°F (5°C) below the minimum chilled water temperature setting that the chiller will be operating. Reference Table 4 to be sure the coolant solution has sufficient freeze protection (glycol) to handle at least 10°F (2.8°C) below the Freezestat setting.
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Page 10: Controller Operation
Once proper flow and temperature are achieved, press the Stop button. The unit is now ready to be placed into service. Controller Operation The chiller includes a microprocessor controller designed to perform all control functions directly from the front panel. When a button is depressed, a click will be felt and the corresponding LED will be energized. -
Page 11: Power
Power Depressing the Power button will switch the control power on or off. Control power must be initiated before either the Start button or remote on/off contacts can start the chiller. Start Depressing the Start button will start the pump and enable the compressor. The compressor (and condenser fans or blowers if the chiller is air cooled) will start only if the microprocessor is calling for cooling because the actual To Process temperature is higher than the Set Point temperature. -
Page 12: High Refrigerant Pressure
High Refrigerant Pressure If the compressor discharge refrigerant pressure exceeds the setting on the high refrigerant pressure safety, the compressor and pump will shut off and the High Refrigerant Pressure LED will be illuminated. Pressing the Alarm Reset button will reset the High Refrigerant Pressure fault, as long as the High Refrigerant Pressure switch located at the discharge of the compressor has been manually reset. -
Page 13: Partial Load
Note: During normal operation, the compressor may cycle on and off. An internal anti-cycle time delay will not allow the compressor to restart for 2.5 minutes after it has cycled off. For air cooled units the fans will cycle off with the compressor. Partial Load The Partial Load LED will be illuminated whenever the microprocessor energizes the hot gas bypass solenoid valve. - Page 14 Press and release the Start button to store the new selection into the controller memory. Press and release the Power button once to exit the function. Press and release the Power button again to restore controller power.
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Page 15: Diagnostic Error Codes
Diagnostic Error Codes Several different error codes may be displayed on the digital readouts labeled To Process and Set Point. Most of the possible error codes indicate some type of failure in the microprocessor controller. Below is a list of the error codes. If there are any error codes other than the one listed below, try to reset the unit by shutting the power off and then turning it back on. -
Page 16: Control Options
Control Options Return Water Temperature Display This option allows the To Process digital display to indicate To Process or Return Water Temperatures. To view the Return Water Temperature, hold down the Lower Set Point Temperature and Raise Set Point Temperature buttons simultaneously. Once the buttons are released, the display will return to the To Process temperature. -
Page 17: Chiller Operation
When the SPI option is purchased, there is a second set of DIP switches included on the back of the main control panel. This set of DIP switches is labeled "COMM". All DIP switch adjustments that follow are to be made on the COMM set. Do not adjust any DIP switches on the CONFIG set. -
Page 18: Chiller Construction
The compressor is the heart of the refrigeration circuit. It takes the cool, low-pressure gas entering the compressor and compresses it, which creates the hot, high-pressure gas that exits the compressor. Since the compressor is not 100% efficient, some extra heat is added to the refrigerant as it is being compressed. The hot, high-pressure gas that exits the compressor is delivered to the condenser. -
Page 19: Condenser Water Regulating Valve (Water Cooled Units Only)
Condenser Water Regulating Valve (Water Cooled Units Only) A condenser water regulating valve is provided as standard. This valve is located in the condenser water piping at the outlet of the condenser. It regulates the flow of water through the condenser in order to maintain the high-pressure side of the refrigeration circuit. -
Page 20: Reservoir
microprocessor controller controls the amount of hot gas used. Eliminating cycling of the compressor is extremely desirable as it significantly extends its lifetime expectancy. Reservoir The reservoir is mounted to the inside of the cabinet. The reservoir is made of polyethylene and is fully insulated. A sight glass is included so the coolant level can be observed from the back of the chiller. -
Page 21: Coolant Pressure Switch
Coolant Pressure Switch This switch is located in the water piping at the inlet of the evaporator. It is designed to shut the unit down if there is insufficient coolant pressure at the evaporator and hence coolant flow through the evaporator. The switch is adjustable; however, no adjustments should be made without prior approval from the factory. -
Page 22: Every Three Months
With the main disconnect shut off and locked out, check the condition of electrical connections at all contactors, starters and controls. Check for loose or frayed wires. Check the incoming voltage to make sure it is within 10% of the design voltage for the chiller. Check the amp draws to each leg of the compressor (fans or blowers on air cooled units) and pump to confirm that they are drawing the proper current. -
Page 23: Preventive Maintenance Checklist
Preventive Maintenance Checklist Model # ___________________________ Serial # ___________________________ Week Number Maintenance Activity Date Clean Condenser Coil and Inlet Filter (air cooled units) Temperature Control Pump Discharge Pressure Coolant Level Glycol Concentration Pump Seal Refrigerant Sight Glass Electrical Connections Incoming Voltage Compressor L1 Amps Compressor L2 Amps Compressor L3 Amps... -
Page 24: Troubleshooting
Troubleshooting Problem Possible Cause Remedy Check supply voltage, start components (single phase), and Compressor overload wiring Run capacitor (single phase units only) Measure capacitance and replace if faulty Start capacitor (single phase units only) Measure capacitance and replace if faulty Check for contiuity between 2,5 and 1,2. - Page 25 Problem Possible Cause Remedy Low flow through evaporator Adjust flow to proper level Freezestat control module Check for proper setting, replace if faulty Freezestat Microprocessor control board Replace if faulty Freezestat sensor Replace if faulty Pump running backwards (three-phase pumps Switch two legs of the incoming power only) Pump pressure gauge...
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Page 26: Charts And Drawings
Charts and Drawings Table 8 - EQ Air Cooled Chiller Electrical Specifications Compressor Pump Condenser Fan Control Circuit Model Voltage Unit MCA Power (HP) Power (HP) 208/1/60 0.24 12.8 EQ3A01 ¼ (.186 kW) (.186 kW) 230/1/60 0.22 11.8 208/3/60 0.24 18.5 230/3/60 1 (.745 kW) -
Page 27: Table 9 - Eq Water Cooled Chiller Electrical Specifications
Table 9 - EQ Water Cooled Chiller Electrical Specifications Compressor Pump Control Circuit Model Voltage Unit MCA Power (HP) 208/3/60 0.24 16.8 230/3/60 1 (.745 kW) 0.22 15.4 460/3/60 0.11 208/3/60 0.24 20.4 230/3/60 2 (1.49 kW) 0.22 18.6 460/3/60 0.11 EQ2W02 208/3/60... -
Page 28: Figure 2 - 60 Hz Pump Curves (Water)
Figure 2 - 60 Hz Pump Curves (water) Pump Curves (60 Hz) PUMP FLOW (L/MIN) ¼ HP positive discplacement pump (EQ3A01 2 HP 2-stage 3 HP 2 HP 1 HP PUMP FLOW (GPM) -
Page 29: Figure 3 - 50 Hz Pump Curves (Water)
Figure 3 - 50 Hz Pump Curves (water) Pump Curves (50 Hz) PUMP FLOW (L/MIN) ¼ HP positive discplacement pump (EQ3A01 2 HP 2-stage 3 HP 2 HP 1 HP PUMP FLOW (GPM)