Related Manuals for Conair ESEW-020D
Summary of Contents for Conair ESEW-020D
- Page 1 USER GUIDE UGH050-0816 www.conairgroup.com ESE Series Central Chillers ESE Series Scroll Central Chillers Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861...
- Page 2 Serial Number(s): Model Number(s) DISCLAIMER: Conair shall not be liable for errors contained in this User Guide or for incidental, consequential damages in connection with the furnishing, performance or use of this information. Conair makes no warranty of any kind with regard to this information, including, but not limited to the implied warranties of merchantability and fitness for a particular purpose.
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Page 4: Table Of Contents
Table of Contents Foreword ..................................... 1 Safety Guidelines ................................2 General Data ..................................3 Table 1 – ESEW Series Single-Circuit Water-Cooled Condenser Chiller General Data (60 Hz) ..........3 Table 2 – ESEW Series Dual-Circuit Water-Cooled Condenser Chiller General Data (60 Hz) ..........4 Table 3 –... - Page 5 Discharge (Hot Gas) Line Sizing ..................................32 Figure 16 – Vertical Riser Traps ..................................32 Figure 17 - Double Discharge Riser................................33 Table 8 – Discharge Line Sizes for Chiller (inches OD) ......................... 33 Table 9 - Upflow Discharge Line Sizes for R410A (inches OD) ......................34 Calculating System Refrigerant and Oil Charge ............................
- Page 6 Figure 27 – Alarm History ....................................51 Alarm Setup ..........................................52 Figure 28 – Alarm Setup ....................................52 Alarm Glycol ..........................................52 Figure 29 – Alarm Setup ....................................52 Menu 1 – Metric Units/Imperial Units ..........................53 Menu 1 - Compressor Data .............................. 53 Compressor Data Screen ......................................
- Page 7 Figure 47 – Analog Outputs Screen ................................63 Menu 1 – Temperature Offsets ............................64 RTD Temperature Offset Adjustment ................................64 Figure 48 – RTD Temperature Offsets Screen ............................64 Menu 1 – Process Control ..............................65 Leaving/Entering Sensor Selection ................................... 65 Figure 49 –...
- Page 8 Start-Up ....................................75 Step 1 - Connect Main Power ..................................... 75 Step 2 - Fill Coolant Circuit ....................................76 System Fill Water Chemistry Requirements .............................. 76 Table 33 – Fill Water Chemistry Requirements ............................77 Table 34 - Recommended Glycol Solutions .............................. 77 Step 3 - Check Condenser ....................................
- Page 9 Page Intentionally Blank Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861...
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Page 10: Foreword
Please supply life. If you should have any questions, please contact these instructions to your authorized refrigeration the Conair Service Department specifying the serial contractor. This manual is for our standard product number and model number of the unit as indicated line with supplements as required to accommodate on the nameplate. -
Page 11: Safety Guidelines
Safety Guidelines WARNING: Any use or misuse of this equipment outside of the design intent may cause injury or harm. Observe all safety precautions during installation, WARNING: Vent all refrigerant relief valves in start-up, and service of this equipment. The accordance to ANSI/ASHRAE Standard 15, Safety following is a list of symbols used in this manual and Code for Mechanical Refrigeration. -
Page 12: General Data
General Data Table 1 – ESEW Series Single-Circuit Water-Cooled Condenser Chiller General Data (60 Hz) ESEW- ESEW- ESEW- ESEW- ESEW- ESEW- ESEW- ESEW- ESEW- Model 010S 015S 020S 025S 030S 040S 050S 060S 080S General Cooling Capacity tons 10.9 16.1 22.1 27.3 32.6... -
Page 13: Table 2 – Esew Series Dual-Circuit Water-Cooled Condenser Chiller General Data (60 Hz)
Table 2 – ESEW Series Dual-Circuit Water-Cooled Condenser Chiller General Data (60 Hz) ESEW- ESEW- ESEW- ESEW- ESEW- ESEW- ESEW- ESEW- ESEW- 020D 030D 040D 050D 060D 080D 0100D 0120D 0160D General Cooling Capacity tons 21.7 32.1 44.3 54.7 65.2 84.5 106.7 136.9... -
Page 14: Table 3 – Eser Series Single-Circuit Remote Air-Cooled Condenser Chiller General Data (60 Hz)
Table 3 – ESER Series Single-Circuit Remote Air-Cooled Condenser Chiller General Data (60 Hz) ESER- ESER- ESER- ESER- ESER- ESER- ESER- ESER- ESER- 010S 015S 020S 025S 030S 040S 050S 060S 080S General Cooling Capacity tons 14.9 20.4 25.2 30.1 38.9 48.9 63.6... -
Page 15: Table 4 – Eser Series Dual-Circuit Remote Air-Cooled Condenser Chiller General Data (60 Hz)
Table 4 – ESER Series Dual-Circuit Remote Air-Cooled Condenser Chiller General Data (60 Hz) ESER- ESER- ESER- ESER- ESER- ESER- ESER- ESER- ESER- 020D 030D 040D 050D 060D 080D 0100D 0120D 0160D General Cooling Capacity tons 20.4 29.9 40.7 50.5 60.2 77.8 97.7... -
Page 16: Table 5 – Remote Air-Cooled Condenser General Data (60 Hz)
Table 5 – Remote Air-Cooled Condenser General Data (60 Hz) Chiller Dimensions inches {mm} Weights lbs {kg} Total Sound MCA @ Refrig Lines Model Model Pressure 460/3/60 (in) Used Flow Level (amps) Inlet Outlet With (cfm) (dBA) Ship Oper Circuit Circuit KCM014 14,400... -
Page 17: Pre-Installation
In addition, make note of the specific damage and 145°F (62.8°C). notify Conair’s Service Department. Shipping damage is the responsibility of the carrier. To protect against possible loss due to damage incurred during shipping and to expedite payment for damages, it is important to follow proper procedures and keep records. -
Page 18: Installation - Chiller Mechanical
Installation - Chiller sudden jerking when lifting or lowering the chiller. Use pads where abrasive surface contact may occur. Mechanical Use the frame supporting the unit for positioning it with a crane or a forklift. Unit Location Chilled Water Piping The chiller is available in many different configurations to meet various environments. -
Page 19: Water Pressure Gauges
The nominal chiller design is for 85°F (38.6°C) Mount the sensor in a ½” NPT coupling in a condenser cooling water supply. Under normal minimum pipe size of 3”. The probe sheath is ¼” OD operation under full load there will be about a 10°F x 3”... -
Page 20: Figure 1 – Standard Flow Chiller Coolant Circuit Pressure Drop (10 Through 30 Ton Single-Circuit Chillers)
Figure 1 – Standard Flow Chiller Coolant Circuit Pressure Drop (10 through 30 Ton Single-Circuit Chillers) Standard Flow Chiller Coolant Circuit Pressure Drop (Water at 50°F) TSEW15S ESEW-015S ESER-015S & TSER15S TSEW25S ESEW-025S & TSER25S ESER-025S TSEW20S ESEW-020S TSEW30S ESEW-030S &... -
Page 21: Figure 2 – Standard Flow Chiller Coolant Circuit Pressure Drop (40 Through 80 Ton Single-Circuit Chillers)
Figure 2 – Standard Flow Chiller Coolant Circuit Pressure Drop (40 through 80 Ton Single-Circuit Chillers) Standard Flow Chiller Coolant Circuit Pressure Drop (Water at 50°F) TSEW40S ESEW-040S ESER-040S & TSER40S TSEW80S ESEW-080S ESEW-050S TSEW50S & TSER80S ESER-080S ESER-050S & TSER50S TSEW60S ESEW-060S &... -
Page 22: Figure 3 – Standard Flow Chiller Coolant Circuit Pressure Drop (20 Through 160 Ton Dual-Circuit Chillers)
ESEW-050D & TSER40D ESER-040D ESER-050D & TSER50D TSEW30D TSEW60D ESEW-030D ESEW-060D ESER-030D ESER-060D & TSER30D & TSER60D TSEW20D ESEW-020D & TSER20D ESER-020D Flow (gpm) Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861... -
Page 23: Figure 4 – Standard Flow Chiller Coolant Circuit Pressure Drop (80 Through 160 Ton Dual-Circuit Chillers)
Figure 4 – Standard Flow Chiller Coolant Circuit Pressure Drop (80 through 160 ton Dual-Circuit Chillers) Standard Flow Chiller Coolant Circuit Pressure Drop (Water at 50°F) TSEW120D ESEW-0120D TSEW100D TSEW80D & ESEW-0100D ESEW-080D ESER-0120D & TSER120D & TSER100D ESER-0100D TSER80D ESER-080D TSEW160D ESEW-0160D... -
Page 24: Figure 5 – High Flow Chiller Coolant Circuit Pressure Drop (10 Through 25 Ton Single-Circuit Chillers)
Figure 5 – High Flow Chiller Coolant Circuit Pressure Drop (10 through 25 ton Single-Circuit Chillers) High Flow Chiller Coolant Circuit Pressure Drop (Water at 50°F) TSEW10S & ESEW-010S TSEW20S & ESEW-020S ESER-010S TSER10S ESER-020S TSER20S TSEW15S & ESEW-015S TSEW25S & ESEW-025S ESER-015S TSER15S... -
Page 25: Figure 6 – High Flow Chiller Coolant Pressure Drop (30 Through 50 Ton Single-Circuit Chillers)
Figure 6 – High Flow Chiller Coolant Pressure Drop (30 through 50 ton Single-Circuit Chillers) High Flow Chiller Coolant Circuit Pressure Drop (Water at 50°F) TSEW50S ESEW-050S TSEW30S ESEW-030S ESER-050S & TSER50S & TSER30S ESER-030S ESEW-040S TSEW40S ESER-040S & TSER40S Flow (gpm) Corporate Office: 724.584.5500 ... -
Page 26: Figure 7 – High Flow Chiller Coolant Pressure Drop (20 Through 50 Ton Dual-Circuit Chillers)
Figure 7 – High Flow Chiller Coolant Pressure Drop (20 through 50 ton Dual-Circuit Chillers) High Flow Chiller Coolant Circuit Pressure Drop (Water at 50°F) TSEW20D ESEW-020D TSEW40D ESEW-040D & TSER20D ESER-020D ESER-040D & TSER40D TSEW50D ESEW-050D ESER-050D & TSER50D... -
Page 27: Figure 8 – High Flow Chiller Coolant Pressure Drop (60 Through 100 Ton Dual-Circuit Chillers)
Figure 8 – High Flow Chiller Coolant Pressure Drop (60 through 100 ton Dual-Circuit Chillers) High Flow Chiller Coolant Circuit Pressure Drop (Water at 50°F) TSEW100D ESEW-0100D TSEW60D ESEW-060D & TSER100D ESER-0100D & TSER60D ESER-060D TSEW80D ESEW-080D ESER-080D & TSER80D Flow (gpm) Corporate Office: 724.584.5500 ... -
Page 28: Figure 9 – Condenser Water Circuit Pressure Drop (10 Through 30 Ton Single-Circuit Chillers)
Figure 9 – Condenser Water Circuit Pressure Drop (10 through 30 ton Single-Circuit Chillers) Condenser Water Circuit Pressure Drop (Water at 85°F with Condenser Water Regulating Valve 100% Open) ESEW-010S TSEW10S TSEW15S ESEW-015S TSEW25S ESEW-025S TSEW20S ESEW-020S ESEW-030S TSEW30S Flow (gpm) Corporate Office: 724.584.5500 ... -
Page 29: Figure 10 – Condenser Water Circuit Pressure Drop (40 Through 80 Ton Single-Circuit Chillers)
Figure 10 – Condenser Water Circuit Pressure Drop (40 through 80 ton Single-Circuit Chillers) Condenser Water Cicuit Pressure Drop Water at 85°F with Condenser Water Regulating Valve 100% Open) TSEW50S ESEW-050S TSEW80S ESEW-080S ESEW-040S TSEW40S TSEW60S ESEW-060S Flow (gpm) Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861... -
Page 30: Figure 11 – Condenser Water Circuit Pressure Drop (20 Through 60 Ton Dual-Circuit Chillers)
Condenser Water Circuit Pressure Drop (Water at 85°F with Condenser Water Regulating Valve 100% Open) TSEW30D ESEW-030D TSEW40D ESEW-040D TSEW20D ESEW-020D TSEW50D ESEW-050D TSEW60D ESEW-060D Flow (gpm) Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861... -
Page 31: Figure 12 – Condenser Water Circuit Pressure Drop (80 Through 160 Ton Dual-Circuit Chillers)
Figure 12 – Condenser Water Circuit Pressure Drop (80 through 160 ton Dual-Circuit Chillers) Condenser Water Circuit Pressure Drop (Water at 85°F with Condenser Water Regulating valve 100% Open) TSEW80D ESEW-080D TSEW100D ESEW-0100D TSEW160D ESEW-0160D TSEW120D ESEW-0120D 1000 Flow (gpm) Corporate Office: 724.584.5500 ... -
Page 32: Installation - Remote Air-Cooled Condenser
Installation - Remote Air- Avoid areas that can create a “micro-climate” such as an alcove with east, north, and west walls that can be Cooled Condenser significantly warmer than surrounding areas. The condenser needs to have unrestricted airways so it The remote condenser usually ships separately and can easily move cool air in and heated air away. -
Page 33: Mounted Legs And Lifting (10 Ton Single-Circuit And 20-Ton Dual-Circuit Units)
Mounted Legs and Lifting (10 ton Single-Circuit and 20-ton Dual-Circuit Units) The unit ships on its side with the legs removed to reduce shipping dimensions and provide more protection to the coil from possible damaged caused by impact loading over rough roads and transit conditions. Follow the below for mounting of the legs and lifting into position. -
Page 34: Mounted Legs And Lifting (All Except 10 Ton Single-Circuit And 20-Ton Dual-Circuit Units)
Mounted Legs and Lifting (all except 10 ton Single-Circuit and 20-ton Dual-Circuit Units) The unit ships on its side with the legs removed to reduce shipping dimensions and provide more protection to the coil from possible damaged caused by impact loading over rough roads and transit conditions. Follow the below for mounting of the legs and lifting into position. -
Page 35: Interconnecting Refrigerant Piping
Interconnecting Refrigerant Piping Note: Do not use soft solders. For copper-to- copper joints use a copper-phosphorus braze The chiller and remote condenser ship with a alloy (BCuP per the American Welding Society) nitrogen holding charge. Evacuation of this charge is with 5% (BCuP-3) to 15% (BCuP-5) silver required before charging with refrigerant. -
Page 36: Figure 13 – Condenser Located With No Elevation Difference
Figure 13 – Condenser Located with No Elevation Difference Chiller 15" minimum at liquid exit from condenser. Condenser Width To be same as condenser width Figure 14 – Condenser Located above Chiller Unit Locate condenser so condenser liquid turns down right away. Chiller Corporate Office: 724.584.5500 ... -
Page 37: Determining Equivalent Line Length
Figure 15 - Condenser Located Below Chiller Unit Chiller 10' MAX Note: Liquid line sizing for each chiller capacity is in Table 7. These line sizes are listed per circuit and apply where leaving water temperature (LWT) is 40°F or higher. For applications where the LWT is below 40°F, size lines using the ASHRAE Refrigeration Handbook or other suitable design guide. -
Page 38: Liquid Line Sizing
Table 6 – Equivalent Lengths of Fittings Equivalent Lengths of Refrigerant Pipe (feet) Line Size Elbow Elbow 90° Elbow 90° Elbow 45° Elbow 45° 90° Long Street Standard Street inches Standard Radius ⅞ 1⅛ 1⅜ 1⅝ 2⅛ 2⅝ 10.0 3⅛ 12.0 3⅝... -
Page 39: Table 7 – Liquid Line Sizes For R410A
Table 7 – Liquid Line Sizes for R410A 10 Ton Circuit (R410A) 15 Ton Circuit (R410A) Liquid Line Size (Inch OD) Liquid Line Size (Inch OD) Total Total Equivalent Horizontal Horizontal Equivalent Upflow Upflow Upflow Upflow Upflow Upflow Length (ft) Length (ft) 1 to 5 ft 6 to 10 ft... - Page 40 Table 7 – Liquid Line Sizes for R410A (continued) 30 Ton Circuit (R410A) 40 Ton Circuit (R410A) Liquid Line Size (Inch OD) Liquid Line Size (Inch OD) Total Total Equivalent Horizontal Horizontal Equivalent Upflow Upflow Upflow Upflow Upflow Upflow Length (ft) Length (ft) 1 to 5 ft 6 to 10 ft...
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Page 41: Discharge (Hot Gas) Line Sizing
Table 7 – Liquid Line Sizes for R410A (continued) Figure 16 – Vertical Riser Traps 80 Ton Circuit (R410A) VERTICLE UPFLOW DISCHARGE RISER Liquid Line Size (Inch OD) Total Equivalent Horizontal Upflow Upflow Upflow REVERSE Length 11 to 15 TRAP 1 to 5 ft 6 to 10 ft (ft) -
Page 42: Figure 17 - Double Discharge Riser
Figure 17 - Double Discharge Riser PITCH TO CONDENSER REDUCING FROM CHILLER 90 DEGREE 45 DEGREE STREET ELBOWS STREET ELBOWS Note: Discharge line sizing shown in Table 8 and Table 9 are listed per circuit and applies where leaving water temperature (LWT) is 40°F or higher. -
Page 43: Calculating System Refrigerant And Oil Charge
Table 9 - Upflow Discharge Line Sizes for R410A (inches OD) Total Equivalent Length (ft) Circuit Tons A - ⅜ A - ⅜ A - ⅜ A - ⅜ A - ⅜ A - ⅜ A - ⅜ A - ⅜ A - ⅜... -
Page 44: Oil Charge Determination
Oil Charge Determination The chiller is factory charged with 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. -
Page 45: Installation - Electrical
Installation - Electrical WARNING: This equipment contains hazardous voltages that can cause severe injury or death. All wiring must comply with local codes and the WARNING: This equipment contains refrigerant National Electric Code. Minimum Circuit Amps (MCA) under pressure. Accidental release of refrigerant and other unit electrical data are on the unit under pressure can cause personal injury and or nameplate. -
Page 46: Table 13 – Esew & Eser Single-Circuit Chiller Electrical Data (60 Hz)
Table 13 – ESEW & ESER Single-Circuit Chiller Electrical Data (60 Hz) Main Power (3-phase, 60 Hz) Compressors Chiller Model Allowable Rated MOPD (each) (each) 19.0 ESEW-010S 19.0 & ESER-010S 29.5 ESEW-015S 29.5 & ESER-015S 14.7 12.2 33.3 ESEW-020S 33.3 &... -
Page 47: Table 14 – Esew & Eser Single-Circuit Chiller With Standard Flow Pump Set Electrical Data (60 Hz)
Table 14 – ESEW & ESER Single-Circuit Chiller with Standard Flow Pump Set Electrical Data (60 Hz) Main Power Compressors Pumps Chiller (3-phase, 60 Hz) Model Process Allowable Chiller Pump Pump Rated MOPD (ea) (ea) 19.0 16.6 ESEW-010S 19.0 15.0 &... -
Page 48: Table 15 – Esew & Eser Single-Circuit Chiller With High Flow Pump Set 1 Electrical Data (60 Hz)
Table 15 – ESEW & ESER Single-Circuit Chiller with High Flow Pump Set 1 Electrical Data (60 Hz) Main Power Compressors Pumps Chiller (3-phase, 60 Hz) Model Process Allowable Chiller Pump Pump Rated MOPD (ea) (ea) 19.0 16.6 ESEW-010S 19.0 15.0 &... - Page 49 Table 17 – ESEW & ESER Dual-Circuit Chiller Electrical Data (60 Hz) Main Power (3-phase, 60 Hz) Compressors Chiller Model Allowable Rated MOPD (each) (each) 19.0 ESEW-020D & 19.0 ESER-020D 29.5 ESEW-030D & 29.5 ESER-030D 14.7 12.2 33.3 ESEW-040D &...
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Page 50: Table 18 – Esew & Eser Dual-Circuit Chiller With Standard Flow Pump Set Electrical Data (60 Hz)
Main Power Compressors Pumps Chiller (3-phase, 60 Hz) Model Process Allowable Chiller Pump Pump Rated MOPD (ea) (ea) 19.0 16.6 ESEW-020D & 19.0 15.0 ESER-020D 29.5 24.3 ESEW-030D & 29.5 22.0 ESER-030D 14.7 11.0 12.2 33.3 31.0 ESEW-040D & 33.3 28.0... - Page 51 Main Power Compressors Pumps Chiller (3-phase, 60 Hz) Model Process Allowable Chiller Pump Pump Rated MOPD (ea) (ea) 19.0 31.0 ESEW-020D & 19.0 28.0 ESER-020D 14.0 29.5 31.0 ESEW-030D & 29.5 28.0 ESER-030D 14.7 14.0 12.2 33.3 42.0 ESEW-040D &...
- Page 52 Table 21 – Single-Circuit Remote Condenser Electrical Data (60 Hz) Main Power Variable-Speed Fan Constant Speed Fans (3-phase, 60 Hz) (1-phase) (3-phase) Total Model Allowable Motor Motor Rated (hp) Each (hp) Each ½ ¾ ½ ¾ KCM014 ½ ¾ ½ ¾...
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Page 53: Table 22 – Dual-Circuit Remote Condenser Electrical Data (60 Hz)
Table 22 – Dual-Circuit Remote Condenser Electrical Data (60 Hz) Main Power Variable-Speed Fan Constant Speed Fans (3-phase, 60 Hz) (1-phase) (3-phase) Total Model Allowable Motor Motor Rated (hp) Each (hp) Each ½ ¾ ½ ¾ KCM034 ½ ¾ ½ ¾... -
Page 54: General Control Operation
General Control Operation System Initialization Upon power-up, the first screen to appear is the Start-Up Screen as shown in Figure 18. This screen will display while the Programmable Logic Controller (PLC) and Human Machine Interface (HMI) establish communications. The PLC/HMI version is located in the lower right hand corner of the screen. Figure 18 –... -
Page 55: Home - System Overview
Home - System Overview System Overview The System Overview Screen (Home Screen) provides an overall synopsis of the chiller system. It also provides quick links to other views as well as additional information. Figure 19 – ESEW System Overview Figure 20 – ESER System Overview Table 23 –... -
Page 56: Home - Full Screen
Home – Full Screen The Full Screen (Figure 21) provides a simplified view of the ESE Chiller. The SETPOINT and PROCESS temperatures appear in a large font easily seen from a distance, providing a “quick glance” look to validate proper operation. Figure 21 –... -
Page 57: Home - Pump Control (Optional)
Home – Pump Control (Optional) Pump Control Screen (Optional) The Pump Control Screen (Figure 23) displays pertinent pump status information for a system with integral pump controls. The Pump Control Screen also provides the ability to change mode selection. Figure 23 – Pump Control Screen Pump VFD Control Screen (Optional) The Pump VFD Screen (Figure 24) displays pertinent pump VFD status information for system with integral pump controls with pump VFDs. -
Page 58: Menu 1 - Overview
Menu 1 - Overview Menu 1 (Figure 25) provides a common location for most adjustments and settings. Descriptions of each section are in detail within this manual. Access to some of the parameters is password protected. The main user-level password is 9999 used for gaining access to changing the main system set point and various other warning and alarm settings. -
Page 59: Table 24 – Menu 1 Functions
Table 24 – Menu 1 Functions Function Description Screen Reference A listing of all active, history, and frequency of system alarms. Figure 26, Figure 27, Alarms Figure 28, Figure 29 Imperial or Metric units can be selected directly from this screen. Touch the Units UNITS button to toggle the selection between Imperial or Metric units Compressor Data... -
Page 60: Menu 1 - Alarms
Menu 1 - Alarms Alarms Active When a critical system fault occurs, the controller activates the HMI alarm handler (Figure 26). This forces the alarm screen to appear and will display the current faults. To silence this alarm, press the ALARM SILENT button. If multiple alarms are active at once, use the DOWN and UP buttons to view all alarms. -
Page 61: Alarm Setup
Alarm Setup Alarm set points and timers are modifiable on the Alarm Setup Screen (Figure 28). Figure 28 – Alarm Setup Alarm Glycol If the Chiller Setpoint goes below 45°F {7°C}, the Glycol Warning Screen will appear as in Figure 29. The amount of antifreeze will vary depending on the actual desired operating conditions and should be enough to provide freeze protection to temperatures 15°F {-9°C} colder than the coldest temperature anticipated. -
Page 62: Menu 1 - Metric Units/Imperial Units
Menu 1 – Metric Units/Imperial Units All units of measures within all menus and screens can be changed from Metric to Imperial and back again using this button. The units of measure indicated on this button are the active units. Menu 1 - Compressor Data Compressor Data Screen The Compressor Data Screen (Figure 30 and Figure 31) is accessible directly from Menu 1 (Figure 25) or by... -
Page 63: Compressor Data Screen - Interlocks
Figure 31 – Circuit Data Screen (Remote Air-Cooled Condenser Chiller) Compressor Data Screen – Interlocks Touching the INTERLOCK button on the bottom of the Compressor Data Screen (Figure 30 or Figure 31) will display the Interlock Screen shown in Figure 32. If the compressor is not starting, the reason for the fault will clearly be visible on this screen. -
Page 64: Figure 33 – Critical Interlocks
Figure 33 – Critical Interlocks Figure 34 – Refrigeration Interlocks Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861... -
Page 65: Menu 1 - Modbus/Bas
Menu 1 – Modbus/BAS Modbus RTU/BAS Setup Screen This Modbus BAS Setup Screen (Figure 35) can enable or disable the Modbus RTU capability. It also displays the current Modbus data and its associated Modbus registers as shown in the following figures. Default Modbus Settings: Baud-19200, Data Length-8, Parity-Odd, Stop Bits-1. -
Page 66: Menu 1 - Exv1 Expansion Valve Setup
Menu 1 – EXV1 Expansion Valve Setup EXV1 Expansion Valve Setup Screen Figure 38 – EXV1 Expansion Valve Setup Screen Table 25 – EXV1 Setup Parameters Default Menu Item Description Value In Auto Mode, the control system adjusts the valve to maintain discharge pressure AUTO MODE Mode Control (Super Heat Mode or Suction Pressure Mode). -
Page 67: Menu 1 - Exv2 Hot Gas Bypass Setup
Menu 1 – EXV2 Hot Gas Bypass Setup EXV2 Hot Gas Bypass Setup Screen (Optional) Figure 39 – EXV2 Hot Gas Bypass Screen Table 26 – EXV2 Setup Parameters Default Menu Item Description Value OFF: The valve will always be closed (zero output) AUTO AUTO-LAST COMP ONLY: The valve will only respond relative to the demand PID ALWAYS ON... -
Page 68: Menu 1 - Water Regulating Valve (Wrv) Setup
Menu 1 – Water Regulating Valve (WRV) Setup WRV Water Regulating Valve Setup Screen An electric condenser water-regulating valve is standard on all chillers with a water-cooled condenser. The valve is a butterfly type valve with a modulating actuator and is located in the condenser water piping at the outlet of the condenser. -
Page 69: Menu 1 - Compressor Staging/Pid
Menu 1 – Compressor Staging/PID Compressor Staging Setup Screen Figure 41 – Compressor Staging Setup Screen Table 28 – Compressor Staging Setup Parameters Default Menu Item Description Value In Auto Mode, the control system adjusts the number of staged compressors AUTOMATIC relative to the demand and available compressors. -
Page 70: Compressor Staging Graph Screen
Compressor Staging Graph Screen The Staging Graph Screen (Figure 42) depicts the process value versus the process setpoint. As the process value increases above the setpoint, the system demand will increase. This increase in system demand will stage compressors on as needed to maintain setpoint. As the process value decreases, compressors will de-stage trying to maintain process setpoint. -
Page 71: Compressor Staging Local Screen
Compressor Staging Local Screen The Compressor Staging Local Screen (Figure 43) depicts the stage order of the local chiller. The stage order will auto calculate based off of the hours entered in the auto stage hours parameter. The intent is to run the compressors with the least amount of hours first to help equalize the run hours of all the compressors. -
Page 72: Menu 1 - Inputs/Outputs
Menu 1 – Inputs/Outputs Inputs / Outputs Screens The Inputs/Outputs screens provide the status of all digital inputs, digital outputs, analog inputs and outputs. X’s are discrete inputs and Y’s are discrete outputs. When the PLC input LED is illuminated (ON), the corresponding input or output is on. -
Page 73: Menu 1 - Temperature Offsets
Menu 1 – Temperature Offsets RTD Temperature Offset Adjustment The Entering Water RTD and LWT Manifold RTD (Dual Circuits or Master/Slave Systems only) are adjustable. To change, enter a temperature offset into the RTD Temperature Offset Screen. Only change the offset if there is a discrepancy between the sensor reading and the actual temperature. -
Page 74: Menu 1 - Process Control
Menu 1 – Process Control Leaving/Entering Sensor Selection There are two selections for the temperature control mode, Leaving Water Control or Entering Water Control. To make a change from the current selection, simply press the mode of operation button. This will toggle between the two options (Master Only). -
Page 75: Menu 1 - Pumps Setup
Menu 1 – Pumps Setup Pump Setup Screen Figure 50 – Pump Setup Screen Table 31 – Pump Setup Parameters Default Menu Item Description Value AUTOMATIC: Allows for automatic timer enable of the pumps. AUTOMATIC Mode MANUAL: Requires manual enable of the pumps. Recirc On Delay Delay duration before the Recirc Pump starts. -
Page 76: Menu 1 - Tank Setup
Menu 1 – Tank Setup Tank Setup Screen The Tank Setup Screen (Figure 51) displays tank options, inputs and outputs. The tank ENABLE/DISABLE option is located in the lower right hand corner of the screen. Touch this button to toggle its state. If the tank mid/high sensors are enabled their status will be indicated. -
Page 77: Menu 1 - Counters
Menu 1 – Counters Counters Screens Once powered up, the control system keeps track of certain inputs and outputs. Every time an input or output is activated a counter will record this state change. This is useful in troubleshooting the system. Also recorded are minimum and maximum pressure levels. -
Page 78: Menu 2 - Overview
Menu 2 - Overview Figure 55 – Menu 2 Table 32 – Menu 2 Functions Function Description Screen Reference Hardware Options Displays the current Hardware configuration Figure 56 Selected Date/Time Date and Time for the HMI (Used for logging alarms) Display the HMI system menu. -
Page 79: Menu 2 - Hardware Options Selected
Menu 2 – Hardware Options Selected Hardware Options Screen The Hardware Options Screen (Figure 56) shows an overall status view of the current hardware options enabled. This is a read only screen. Make all adjustments on their appropriate screens. Figure 56 – Hardware Options Screen Corporate Office: 724.584.5500 ... -
Page 80: Menu 2 - Date/Time
Menu 2 - Date/Time The Date/Time screen is where the system date and time is set. The system date and time stamps any alarms. Menu 2 – System Menu This menu is part of the HMI manufacturer’s firmware and is for high-level setup of the HMI hardware. This menu is password protected to prevent unintended adjustments that may impair proper functioning of the system. -
Page 81: Menu 2 - Remote Setpoint Setup
Figure 58 – Factory Settings Restored Menu 2 – Remote Setpoint Setup When the remote setpoint option is enabled, an incoming 4-20mA signal controls the setpoint of the master chiller. The 4- 20mA signal will span from the MINIMUM SETPOINT to the MAXIMUM SETPOINT as defined in Figure 59. -
Page 82: Menu 2 - Remove Sd Storage
Menu 2 – Remove SD Storage This is an optional feature and is only active if programmed as such from the factory. This feature allows data logging to an SD storage card. When activated data is automatically data logged to the SD storage card. When the SD storage feature is active, this function stops writing data to the SD storage card to allow for safe removal. -
Page 83: Menu 2 - Plc Link Setup
Menu 2 – PLC Link Setup PLC Link (Master/Slave) Setup Screen This screen can enable or disable the Master/Slave Capability. It also displays the current linked data. Each chiller is capable of being a Master or a Slave. To do this, toggle the MASTER MODE to SLAVE MODE. Figure 61 –... -
Page 84: Menu 2 - Touch Calibration
Menu 2 – Touch Calibration CAUTION: Disconnect and lock out incoming power before installing, servicing, or This is a firmware menu provided by the HMI maintaining the equipment. Connecting power to manufacturer to allow the touch sensitivity and the main terminal block energizes the entire electric circuitry of the unit. -
Page 85: Step 2 - Fill Coolant Circuit
Step 2 - Fill Coolant Circuit • Electrical Conductivity • pH Check to make sure all process chilled-water piping • Alkalinity connections are secure. Fill the chilled water • Total Hardness reservoir with the proper water or water/glycol • Dissolved gases solution following the guidelines shown below. -
Page 86: Step 3 - Check Condenser
Table 33 – Fill Water Chemistry Requirements CAUTION: When your application requires the use of glycol, use industrial grade glycol Water Characteristic Quality Limitation specifically designed for heat transfer systems Alkalinity (HCO 70-300 ppm and equipment. Never use glycol designed for Aluminum (Al) Less than 0.2 ppm automotive applications. -
Page 87: Step 5 - Verify Freezestat Setting
Step 5 – Verify Freezestat Setting Step 8 – Intial Unit Operation Make sure the Freezestat is set appropriately for the Enter the desired leaving fluid temperature on the operating conditions of the chiller. The Freezestat is control panel. Unless otherwise specified, the chiller in a password-protected menu of the chiller is factory set to deliver coolant at 50°F . -
Page 88: Preventive Maintenance
safety is the absolute lowest pressure allowed for Once proper flow and temperature are achieved, operation. At start-up, the control system ignores press the Stop button. The unit is now ready to be the low refrigerant pressure alarm for a period of 2 placed into service. -
Page 89: Once A Month
4. Check each refrigerant sight glass for air bubbles 11. (Remote Air-Cooled Condenser Chillers Only) or moisture indication. Bubbles in the refrigerant Check the condition of the air coils of the indicate either low refrigerant charge or remote condensers for dirt and debris. If the excessive pressure drop in the liquid line. -
Page 90: Cleaning The Operator Interface
Compressor contactor Replace if faulty start PLC output card Replace if faulty Compressor failure Contact Conair’s Service Department for assistance Low refrigerant charge Contact refrigeration service technician Refrigerant leak Contact refrigeration service technician Compressor suction service valve partially or fully... - Page 91 PLC input card Replace if faulty Evaporator Y-strainer clogged or dirty Clean Y-strainer Process load too high Check to make sure chiller is properly sized for process load Insufficient cooling Coolant flow outside of normal operating range Adjust flow to proper level (temperature Insufficient condenser cooling See high refrigerant pressure...
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Page 92: Preventive Maintenance Checklist
Preventive Maintenance Checklist The following is a sample of a typical dual-circuit chiller checklist. Week Number Maintenance Activity Date Temperature Control Pump Discharge Pressure Refrigerant Suction Pressure #1 Refrigerant Suction Pressure #2 Refrigerant Discharge Pressure #1 Refrigerant Discharge Pressure #2 Refrigerant Sight Glass #1 Refrigerant Sight Glass #2 Check and clean evaporator Y-strainer... -
Page 93: Warranty Information
We’re Here to Help Conair has made the largest investment in customer support in the plastics industry. Our service experts are available to help with any problem you might have installing and operating your equipment. Your Conair sales representative also can help analyze the nature of your problem, assuring that it did not result from misapplication or improper use. - Page 94 (except for parts that are typically replaced after normal usage, such as filters, liner plates, etc.). Conair’s guarantee is limited to replacing, at our option, the part or parts determined by us to be defective after examination. The customer assumes the cost of transportation of the part or parts to and from the factory.
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