ClimaCool UCA 20 Installation, Operation And Maintenance Manual
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ClimaCool UCA 20 Installation, Operation And Maintenance Manual

Packaged air cooled modular chiller
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Packaged Air Cooled Modular Chiller
Water Cooled, Heat Pump, Heat Recovery and
Model UCA 20, 30, 50 & 70
on
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DEMAND
SIMULTANEOUS HEATING AND COOLING

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Summary of Contents for ClimaCool UCA 20

  • Page 1 Packaged Air Cooled Modular Chiller Water Cooled, Heat Pump, Heat Recovery and Model UCA 20, 30, 50 & 70 ® DEMAND SIMULTANEOUS HEATING AND COOLING...

  • Page 2: Table Of Contents

    Table of Contents Introduction ......... 1 Startup .

  • Page 3: Introduction

    Introduction General Description ATTENTION ClimaCool’s Air Cooled Packaged Modular Chiller, Model properly installed/sealed, including the condenser UCA, are available in 20, 30, 50 and 70 tons and can be fan motor cover. requirements from 20 to 420 tons. By simply adding...

  • Page 4: Pre-Installation

    9. Warranty To ensure proper equipment longevity, design performance and reliability, all ClimaCool chillers must be installed, operated and maintained in accordance with ClimaCool IO&M manuals. Water quality is of the utmost importance for the proper care and maintenance of your modular chiller system and regular treatment of the water will increase longevity of your system.

  • Page 5: Physical Data

    Physical Data Model UCA Cooling Only Heat Pump 18.4 27.5 17.9 26.7 17.9 26.7 Capacity (Tons) 10.3 10.3 9.97 9.97 9.97 9.97 Refrigerant Circuits (quantity) scroll scroll scroll scroll scroll scroll Compressor Type Compressor Quantity Compressor Nominal Hp (per circuit) Refrigerant Charge R-410A (lbs) 2,250 2,410...

  • Page 6: Condenser Fans

    Physical Data Model UCA Cooling Only Heat Pump 44.0 62.7 41.4 59.0 41.4 59.0 Capacity (Tons) 10.5 10.1 9.88 9.47 9.88 9.47 Efficincy (EER) Refrigerant Circuits (quantity) Scroll Scroll Scroll Scroll Scroll Scroll Compressor Type Compressor Quantity Compressor Nominal Hp (per circuit) Refrigerant Charge R-410A (lbs) (circuit 1/circuite2) 4,101 4,275...

  • Page 7: Physical Data

    Physical Data Free Cooling Free Cooling Fans T.E. T.E. Motor Type Quantity Axial Axial Fan Type 31.5 31.5 Diameter 20,000 40,000 Airflow (cfm per circuit) 1,100 1,100 Free Cooling Coils Aluminum Aluminum Fin Material Copper Copper Tube Material 20" x 78" (4) 20"...

  • Page 8: Dimensional Data And Drawings

    Dimensional Data and Drawings Figure 1 - Cooling Only, UCA 020 & 030 Discharge Discharge Air Intake Chilled Water Inlet Control Chilled Water Air Intake Outlet Header Model Header Header Voltage Connection Unit Width Unit Height Unit Depth Location Location (in.) (in.) (in.)
  • Page 9 Dimensional Data and Drawings Figure 3 - Simultaneous Heating & Cooling 020 & 030 Discharge Discharge Chilled Water Air Intake Inlet Chilled Water Outlet Water Outlet Control Water Air Intake Inlet Header Model Header Header Header Header Voltage Connection Unit Width Unit Height Unit Depth Location...

  • Page 10: Dimensional Data And Drawings

    Dimensional Data and Drawings Figure 5 - Free Cooling, UCF 030 Discharge Discharge Air Intake Chilled Water Inlet Control Chilled Water Air Intake Outlet Header Model Header Header Header Voltage Unit Width Unit Height Connection Unit Depth Location Location Location (in.) (in.) (in.)

  • Page 11: Rigging And Lifting Procedures

    Rigging and Lifting Procedures Rigging Lifting and Transporting Modules Each module should be lifted by using lift straps threaded Forklifts are required for lifting and transporting the through the steel base cutouts and a spreader bar. module. Each module has base cutouts provided Note: If no spreader bar is used, damage to the module for ease of maneuverability.

  • Page 12: Mounting Rail And Vibration Isolation

    Mounting Rail and Vibration Isolation ClimaCool recommends locking down the chiller to a concrete base or to two (2) 4” base mounting rails using the six bolt holes provided in each base pan (see Figure 10). Due to the low vibration of the modules, ClimaCool does not require the application of spring isolators or pads.

  • Page 13: Recommended Service Clearances

    Recommended Service Clearances Top View 36” 36” Rear Service Access See Note See Note 4 for side 4 for side clearance clearance Air Intake Air Intake 42” Service and Air Intake Clearance Service and Air Intake Clearance 42” 42” Air Intake See Note See Note 4 for side...

  • Page 14: Model Key

    Model Key www.climacoolcorp.com...

  • Page 15: Unit Installation

    (the part that goes into the groove), are engaged into the grooves. Insert the bolts and install ClimaCool recommends locking down the chiller to a nuts to hand tight. Make sure that the oval neck of the bolt concrete base, or to two (2) 4”...

  • Page 16: Unit Installation

    Unit Installation Figure 15 - Hardware Kit Figure 17 - Back to Back Header Insulation Chilled water piping is pre-insulated on each module at the factory with 3/4” closed cell insulation. After bolting all modules together and leak testing, the entire coupling connection will need to be insulated by the installing contractor.

  • Page 17: Electrical Connection

    Proper clockwise rotation for scroll compressor motors is line voltage wiring or with wires that switch highly inductive important to prevent damaging the compressors. ClimaCool loads such as contactor and relay coils. Note: It is mandatory recommends the use of a phase sequence indicating to install one (1) monitor per bank at main power instrument following the manufactures directions.

  • Page 18: Wiring Diagram-Voltage/Phase Monitor

    Wiring Diagram-Voltage/Phase Monitor www.climacoolcorp.com...

  • Page 19: Water Piping

    316 stainless steel prior to making The strainer must be installed as shown in the Water Piping connections to the ClimaCool chiller. There are certain necessary components that should always be installed in when the chiller is operating. ClimaCool’s warranty does the chilled water system.
  • Page 20 CoolLogic software. Installation location can be found on page 19 – Water The design piping must accommodate one module’s worth controlled by others. There are system communication the use of ClimaCool sensors and controls for control heating water systems. www.climacoolcorp.com...
  • Page 21 www.climacoolcorp.com...

  • Page 22: Hydronic Refrigeration

    Service Ports (3/4”) Refrigerant Circuit #2 Isolation Ball Valves Leaving Chilled Water (2 or 2-1/2”) Temperature Sensor Pete’s Ports Heat Exchanger Note: Figure 23 depicts hydroponic piping in each ClimaCool chiller module and is shown with water isolation valves. www.climacoolcorp.com...

  • Page 23: Part Load Performance Advantage

    Refrigerant Refrigerant Circuit 1 Circuit 2 Water Out (Cold) Refrigerant Circuit 2 Only If circuit 1 is cut, the unique ClimaCool modular chillers employ reliable and highly channel to remain in water water water water Refrigerant Circuits 1 and 2...

  • Page 24: Filling The Water System

    Filling the Water System It is imperative that the water systems are free from Cleaning the System debris prior to initial operation. See Water Treatment The following method is recommended to properly clean for a comprehensive list of precautions on page 22. the water systems: Filling, Purging and Leak Testing the System Before cleaning the system, install a temporary...

  • Page 25: Water Treatment

    Table 1. The materials exposed to the water are type 316 stainless steel, pure copper and carbon steel. Other materials may exist external to the ClimaCool chiller. It is the user’s responsibility to ensure these materials are compatible with the treated water. Regular treatment of the water will increase longevity of your system.

  • Page 26: Water Temperature Requirements

    Water Temperature Requirements Table 2 - Water Temperature Requirements Chilled Water 20°F 62°F Hot Water 80°F 135°F Notes: Operating in ambient temperatures below 40°F requires a suitable antifreeze solution. All modules can operate in this range without the need of special controls. A glycol solution additive is required at a lower operating suction temperatures in order to pro- tect the evaporator from freeze-ups.

  • Page 27: Evaporator Water Pressure Drop Charts

    Evaporator Water Pressure Drop Charts www.climacoolcorp.com...

  • Page 28: Evaporator Water Pressure Drop Charts

    Evaporator Water Pressure Drop Charts Table 3 - Performance Adjustment Factors vs. Altitude vs. Chiller Temperature Drop www.climacoolcorp.com...

  • Page 29: Operational Limitations

    Operational Limitations Table 4 - Voltage Limitations Table 5 - Compressor Operating Limitations Compressor Operating Limitations Voltage Limitations The following voltage limitations are absolute and operation beyond these limitations may cause serious damage to the compressor. Nominal Voltage Minimum Voltage Maximum Voltage 208/230/3/60 460/3/60...

  • Page 30: Pre-Startup

    Pre-Startup compressor rotation check. All startups must be performed by ClimaCool factory trained personnel. Prior to chiller startup, there are certain essential checks which must be completed. Failure to carry Water System out these checks could result in damage to the chiller voiding the modules warranty.

  • Page 31: Pre-Startup Check List

    *This form must be completed and submitted to ClimaCool Corp. three (3) weeks prior to final scheduling of any Start-up. Note: If any of the above items are not complete at time of start-up, backcharges will be assessed for additional costs.

  • Page 32: Startup

    Startup All startups must be performed by ClimaCool factory and that all VFD’s are controlling the pump speeds to trained personnel. Review all items are complete from the Pre Startup the chiller bank headers, measured precisely at the Checklist. Cross reference model number with submittal sheet to verify that the units are the correct model type and 10 psid.

  • Page 33: Startup

    Startup 18. Use refrigerant gauge set suitable for the high pressure is 5-15°F, BUT for total accuracy please follow the charge R-410A, and hook up to the suction and discharge recommendations found in the selection program. If ports of each module’s compressor stages separately. subcooling is too low, then refrigerant must be added to the Bump start the compressors either by depressing the contactor manually, or by using the manual run...

  • Page 34: Superheat & Subcooling Flow Chart

    Startup Documentation All startup paperwork and documentation must be submitted to ClimaCool. Future warranty claims cannot be processed Form and page 89 for Warranty).

  • Page 35: Startup And Warranty Form

    Startup and Warranty Registration Form (Pkg Air-Cooled UCA) Sign, date and E-mail to: technicalsupport@climacoolcorp.com or Ambient Page: Fax: 405.815.3052 Attn: Technical Support Temp: 1 of 1 Project Name: Contractor Name: Address: Address: City/State/Zip: City/State/Zip: Startup Date: Phone No.: Module Compressor Model No.: Model No.: Serial No.:...

  • Page 36: Operation And Maintenance

    As with any mechanical system, it is necessary to conduct a series of checks to the ClimaCool chiller to strainer may need to be cleaned. Visually inspect inner and outer condenser coil slab and Maintaining a Daily Log cleaner.

  • Page 37: Condenser Fans

    Condenser Fans • Check the impeller, in particular the weld-seams, for integral head pressure control are provided as standard. possible cracks. Any repairs by welding is prohibited. • Fans include electronically switched external rotor motors The fan or motor is maintenance free due to the use of with permanent magnets and a speed that is controlled by ball bearings with “life-long lubrication”.

  • Page 38: Heat Exchangers

    Heat Exchangers Draining of a module, proceed to isolate a second module separately from the bank and repeat the cleaning process. When performing standard maintenance procedures Chemical Clean In Place Washing With Water if factory mounted water isolation valves are provided. Isolation Valves Chemical Clean in place washing will typically provide maintenance procedures.

  • Page 39: Cleaning Arrangement

    Cleaning Arrangement Figure 26 - City Water Cleaning Arrangement Isolation Ball Valve (2, 2-1/2 or 3”) Connected to City Water Refrigerant Circuit #1 Service Port (3/4”) To Cooling Tower Header Refrigerant Circuit #2 From Cooling Tower Header Service Port (3/4”) To Drain Isolation Ball Valve (2, 2-1/2 or 3”) Heat Exchanger...

  • Page 40: Compressor Information

    Compressor Information Adding Oil are used on Model UCA. The information contained in this The compressor must never be ran in a vacuum. A suitable manual will be useful for their care. hydraulic pump should be used to add oil and reserved for this process.

  • Page 41: Refrigeration Circuit Diagram

    "TEE" SOLDER JOINT REFRIGERANT FLOW PATH PRESSURE ACCESS FITTING THERMAL EXPANSION VALVE REFRIGERATION CIRCUIT DIAGRAM TITLE (CIRCUIT #1 OF 2 SHOWN) PACKAGE AIR-COOLED MODULAR CHILLER DESCRIPTION CLIMACOOL Model # UCA020,030,070 REVISED SIZE REVISED DWG NO ClimaCool Corp. RefrigDiag-UCA RefriDiag-UCA APPROVED...
  • Page 42 THERMAL EXPANSION VALVE REFRIGERATION CIRCUIT DIAGRAM TITLE (CIRCUIT #1 OF 2 SHOWN) PACKAGE AIR-COOLED MODULAR CHILLER -20°F LOW AMBIENT CONTROL DESCRIPTION REVISED CLIMACOOL Model # UCA020,030,070 SIZE REVISED DWG NO ClimaCool Corp. RefriDiag-UCA (-20°F Ambient) RefriDiag-UCA (-20°F Ambient) APPROVED DATE...

  • Page 43: Refrigeration Circuit Diagram

    PRESSURE ACCESS FITTING THERMAL EXPANSION VALVE BRAZED CAP REFRIGERATION CIRCUIT DIAGRAM TITLE (CIRCUIT #1 OF 2 SHOWN) PACKAGE AIR-COOLED MODULAR HEAT PUMP CHILLER DESCRIPTION REVISED CLIMACOOL Model # UCA020,030,070 SIZE REVISED DWG NO ClimaCool Corp. RefrigDiag-UCA-HP RefrigDiag-UCA-HP APPROVED DATE FILENAME...

  • Page 44: Head Pressure Control Valve Operation (Lac)

    Head Pressure Control Valve Operation (LAC) Figure 28 - LAC-10 Valve High and Low Ambient Stability The design of air conditioning systems, utilizing air cooled condensing units, involves two main problems that must be solved if the system is to operate reliably and economically during high ambient and low ambient operation.

  • Page 45: Refrigeration Systems Re-Processing And Charging

    It is necessary to use a micron meter equipped with an absolute pressure gauge (or transducer) to take this reading. ClimaCool recommends the double evacuation process to ensure the proper removal of moisture and contaminants from the refrigeration system.
  • Page 46 General Compressors Factory-assembled and wired remote air cooled chiller. Each module shall contain two scroll compressors Chiller consists of two compressors, one evaporator, safety independently circuited for redundancy. Each compressor and operational controls. The modular remote air cooled shall be mounted with rubber isolated compressor mounts chiller shall incorporate one or more modules with two to the module base and each shall include compressor independent refrigerant circuits.
  • Page 47 distribution of compressor run time. A load limit control are operated above the freeze point shall be available to limit the number of compressors that for part load operation. can be energized at one time. Factory Testing Starter/Control Panel Each remote air cooled chiller module shall be pressure- tested, evacuated and charged with nitrogen.

  • Page 48: Options & Accessories

    Options and Accessories Free Cooling Modules Directly couples to chiller bank. Includes: glycol free cooling Field installed to prevent operation of chiller without integral head pressure control with acoustical airfoil blade Pump Module design providing low operating sound levels, two position motorized water isolation valve, 3-way bypass valves and Module includes primary and standby centrifugal pumps in a fully integrated controls.

  • Page 49: Stainless Steel Strainer Option

    After unpacking your strainer, carefully inspect your “over-center latch clamp” lid designs. The over-center strainer housing, lid assembly and screen for damaged or missing parts. Contact ClimaCool’s customer service removing the lid. The lock washer is set at the factory for department for any replacement parts.
  • Page 50 Stainless Steel Strainer Option Table 8 - Bolt Size and Recommended Torque Figure 30 - Recommended Torquing Sequence Recommended Strainer Bolt Size Torque (inches) 5/16 - 18 60 - 80 3/8 - 16 15 - 25 1/2 - 13 45 - 55 1/2 - 13 45 - 55 10CS...

  • Page 51: System Components

    Stainless Steel Strainer Option What is Water Hammer? Figure 31 - Timer Based Valve Controller RED POINTER systems with long pipes. Water hammer is a rapid change OUTER RING (TIME BETWEEN FLUSHES) entire system is raised very quickly. (FACTORY SET AT 24-HOURS) What Causes Water Hammer? GREEN POINTER...
  • Page 52 Stainless Steel Strainer Option Operation Instructions Water Resistance Flush valve line must be piped to atmospheric pressure such The valve and controller are water-resistant, not water- any changes in elevation and should be sloped downward in proof. Do not install below ground level where the the direction of drainage.
  • Page 53 Stainless Steel Strainer Option and visual alarms will be triggered and will remain engaged until both the alarm condition is corrected and the alarm-reset button is pressed (if the alarm-reset button is the alarms will re-engage immediately). After the strainer should return to 1 psi.

  • Page 54: Wye Strainers

    WYE Strainers Installation Procedure: fuction, not by the size of the pipeline. Pre Installation Checklist: pressure gauge at inlet and outlet connections or at the strainer gauge tap (if provided). WYE strainers must be positioned in the pipeline ahead Ensure working conditions (pressure/temperature) of the equipment requiring protection.
  • Page 55 WYE Strainers Note: Remove screen and clean. Do not permit screed to than water or when the working temperature is above hardened. Avoid banding or hitting the screen to remove stubborn debris. appropriate equipment (goggles, gloves, vests etc.) Inspect screen and cover gasket for damage. If either is when venting or servicing is performed.

  • Page 56: Basket Strainers

    Basket Strainers function, not by the size of the pipeline. tighten. Flange bolts should then be tightened, using Pre Installation Checklist: a star or crisscross pattern to evenly load the bolts, in accordance with established piping standards. This is free of defects. The pipeline should also be checked for proper alignment.

  • Page 57: Basket Strainers

    Basket Strainers Maintenance Replace clean basket into its original position, enrusing it is squarely positioned on the screen seat. Replace cover gasket and replace and tighten cover. Basket strainers require little monitoring once they are Follow the Start-up precedure outlines within the Operation strainer should be checked periodically to determine if the Instructions.

  • Page 58: Electrical Data

    Electrical Data - UCA, Cooling Only and Heat Pump www.climacoolcorp.com...
  • Page 59 Electrical Data - Model UCF, Free Cooling www.climacoolcorp.com...

  • Page 60: Power Distribution Drawing

    Power Distribution Drawing Figure 40 - Power Distribution Drawing Notes: chiller system. your local ClimaCool representative. Control wiring is by others. the modules. • Description - Single twisted pair, low capacitance, CL2P, shield becomes too great relative to the earth ground, then TC foam FEP, plenum rated cable •...
  • Page 61 Wiring Diagram - UCA020, Cooling Only, 208/230v, 460v www.climacoolcorp.com...
  • Page 62 Wiring Diagram - UCA020, Cooling Only, 208/230v, 460V www.climacoolcorp.com...
  • Page 63 Wiring Diagram - UCA020, HeatPump, 208/230v, 460v www.climacoolcorp.com...
  • Page 64 Wiring Diagram - UCA020, HeatPump, 208/230v, 460v www.climacoolcorp.com...
  • Page 65 Wiring Diagram - UCA020, Heat Pump, 575v www.climacoolcorp.com...
  • Page 66 Wiring Diagram - UCA020, Heat Pump, 575v www.climacoolcorp.com...
  • Page 67 Wiring Diagram - UCA020, SHC Heat Pump, 208/230v, 460v www.climacoolcorp.com...
  • Page 68 Wiring Diagram - UCA020, SHC Heat Pump, 208/230v, 460v www.climacoolcorp.com...
  • Page 69 Wiring Diagram - UCA030, Cooling Only, 208/230v, 460v www.climacoolcorp.com...
  • Page 70 Wiring Diagram - UCA030, Cooling Only, 208/230v, 460v www.climacoolcorp.com...
  • Page 71 Wiring Diagram - UCA030, Cooling Only, 575v www.climacoolcorp.com...
  • Page 72 Wiring Diagram - UCA030, Cooling Only, 575v www.climacoolcorp.com...
  • Page 73 Wiring Diagram - UCA030, Heat Pump, 208/230v, 460v www.climacoolcorp.com...
  • Page 74 Wiring Diagram - UCA030, Heat Pump, 208/230v, 460v www.climacoolcorp.com...
  • Page 75 Wiring Diagram - UCA030, Heat Pump, 575v www.climacoolcorp.com...
  • Page 76 Wiring Diagram - UCA030, Heat Pump, 575v www.climacoolcorp.com...
  • Page 77 Wiring Diagram - UCA030, SHC Heat Pump, 208/230v, 460v www.climacoolcorp.com...
  • Page 78 Wiring Diagram - UCA030, SHC Heat Pump, 208/230v, 460v www.climacoolcorp.com...
  • Page 79 Wiring Diagram - UCA030, SHC Heat Pump, 575v www.climacoolcorp.com...
  • Page 80 Wiring Diagram - UCA030, SHC Heat Pump, 575v www.climacoolcorp.com...
  • Page 81 Wiring Diagram - UCF030, Free Cooling, 208/230v , 460v www.climacoolcorp.com...
  • Page 82 Wiring Diagram - UCF030, Free Cooling, 208/230v, 460v www.climacoolcorp.com...
  • Page 83 Wiring Diagram - UCF030, Free Cooling, 575v www.climacoolcorp.com...
  • Page 84 Wiring Diagram - UCF030, Free Cooling, 575v www.climacoolcorp.com...

  • Page 85: Wiring Diagrams

    Wiring Diagrams - UCA070, Cooling Only, 208/230v, 460v www.climacoolcorp.com...
  • Page 86 Wiring Diagrams - UCA070, Cooling Only, 208/230v, 460v www.climacoolcorp.com...
  • Page 87 Wiring Diagrams - Master Control Panel www.climacoolcorp.com...
  • Page 88 Wiring Diagrams - Master Control Panel www.climacoolcorp.com...
  • Page 89 Wiring Diagrams - Expansion Board, SHC Heat Pump www.climacoolcorp.com...

  • Page 90: Troubleshooting Guide

    Troubleshooting Guide WARNING! disconnects before servicing. Follow proper lockout-tagout The troubleshooting guidelines recommended in this trained to handle live electrical components should be section could result in exposure to electrical safety hazards. Please refer to the safety warnings provided in this manual. allowed to work with energized electrical components.

  • Page 91: Warranty

    Warranty www.climacoolcorp.com...
  • Page 92 Fax: 405.815.3052 www.climacoolcorp.com for order may be changed without notice and may not be as described herein. Please contact ClimaCool’s Customer Service Department at 405-815-3000 contained herein are not express warranties and do not form the basis of any bargain between the parties, but are merely ClimaCool’s opinion or commendation of its products.

This manual is also suitable for:

Uca 50Uca 30Uca 70

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