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Table of Contents
Related Manuals for Thermal Care Accuchiller MX Series
Summary of Contents for Thermal Care Accuchiller MX Series
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Page 3: Table Of Contents
Table of Contents Foreword ..........................................1 Safety Guidelines ........................................1 Pre-Installation ........................................2 Receiving Inspection ....................................... 2 Unit Storage ........................................3 Installation - Chiller ......................................3 Foundation .......................................... 3 Unit Location ........................................3 Rigging ..........................................3 Process Fluid Piping ......................................3 Condenser Water Piping.................................... - Page 4 Figure 9 – Full Screen ....................................12 Menu 1 - Overview ......................................13 Figure 10 – Menu 1 ....................................13 Table 8 – Menu 1 Functions ................................... 13 Menu 1 - Alarms........................................14 Alarms Active ........................................14 Figure 11 – HMI Alarm Handler ................................14 Alarm Setup ........................................
- Page 5 Menu 1 – Flow / Capacity ....................................20 Flow/Capacity Screen ....................................20 Figure 30 – Flow / Capacity Screen ..............................20 Menu 1 – Pump Control ....................................21 Pump Control Screen ....................................21 Figure 31 – Pump Control Screen ................................ 21 Table 13 –...
- Page 6 Checking Compressor Oil Level ................................29 Cleaning the Operator Interface ................................29 General Troubleshooting ....................................29 Preventive Maintenance Checklist ................................32 Drawings..........................................32...
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Page 7: Foreword
Foreword Safety Guidelines The central chiller consists of a refrigeration circuit to Observe all safety precautions during installation, provide cooling water to coolant. start-up, and service of this equipment. The following is a list of symbols used in this manual and This manual is to serve as a guide for installing, their meaning. -
Page 8: Pre-Installation
Only qualified personnel should install, start-up, and Pre-Installation service this equipment. When working on this equipment, observe precautions in this manual as Receiving Inspection well as tags, stickers, and labels on the equipment. When the unit arrives, verify the information on the unit nameplate agrees with the order WARNING: Any use or misuse of this equipment acknowledgement and shipping papers. -
Page 9: Unit Storage
Chillers with an integral water-cooled ship with a full sudden jerking when lifting or lowering the chiller. refrigerant charge. Chillers designed for use with a Use pads where abrasive surface contact may occur. remote air-cooled condenser and the remote condensers themselves ship with a nitrogen holding Process Fluid Piping charge. -
Page 10: Water Pressure Gauges
Each condenser has a two-way condenser water- CAUTION: Wear protective gloves when installing, maintaining, or repairing the equipment to protect against regulating valve. The condenser water-regulating any sparks, debris, or fluid leaks. valve controls the amount of water allowed to pass through the condenser in order to maintain proper Master Temperature Sensor refrigeration pressures in the circuit. -
Page 11: Lifting
Mounting Legs condensers placed side-by-side or 48 inches for condensers placed end-to-end. Before rigging the unit, install the legs using the hardware provided. The standard legs are 22 inches. When locating the condenser it is important to Optional 48 or 60 inches legs require a leg between consider accessibility to the components to allow for every fan section and gusset for stability. -
Page 12: Refrigeration Piping Design
the system. This prevents the formation of toxic Figure 2 – Condenser Located Above Chiller Unit gases, corrosive acids, and scale. CAUTION: Do not use soft solders. For copper-to- copper joints use a copper-phosphorus braze alloy (BCuP per the American Welding Society) with 5% (BCuP-3) to 15% (BCuP-5) silver content. -
Page 13: Liquid Line Sizing
Determine approximate line sizes by referring to effect on sub-cooling. In these situations, insulate Table 10 for liquid lines and Table 11 for the liquid lines. discharge lines. Check the line size by calculating the actual Table 2 – Liquid Line Size/Circuit (inches OD) equivalent length using the equivalent lengths Systems Designed for Systems Designed for... -
Page 14: Calculating Refrigerant Charge
The discharge lines should pitch downward, in the Table 4 – Upflow Discharge Line Size direction of the hot gas flow, at the rate of ½ inch Line Size/Circuit (inches OD) per each 10 foot of horizontal run. If the chiller unit Total Systems Designed for Systems Designed for... -
Page 15: Installation - Electrical
charge may nearly double. The best way to assure percent. Excessive voltage imbalance between the proper charging is, on the coldest day of the year phases of a three-phase system can cause motors to under full load, the charge should be up to the overheat and eventually fail. -
Page 16: Compressor Control Logic
WARNING: The exposed surfaces of motors, refrigerant approximately two minutes after which it will piping, and other fluid circuit components can be very load/unload as required to maintain the fluid set hot and can cause burns if touched with unprotected point temperature. -
Page 17: General Control Operation
General Control Operation Home - System Overview Graphical representations presented in this manual System Overview may vary slightly based on special unit customization The System Overview Screen provides an overall or modification; however, the operation of the chiller synopsis of the chiller system. It also provides quick is consistent and the principles presented are links to other views as well as additional useful applicable to all chillers. -
Page 18: Home - Full Screen
Table 7 – System Overview Functions Home – Full Screen Screen Function Description Reference The Full Screen Display Screen provides a simplified Provides information about any view of the chiller. The SETPOINT and PROCESS Alarm warnings or alarms which may temperatures display in a large font easily seen from Messaging have occurred. -
Page 19: Menu 1 - Overview
Menu 1 - Overview Table 8 – Menu 1 Functions Screen Function Description Reference Menu 1 provides a common location for most adjustments or settings. A listing of all active, history, and Figure 8 Alarms frequency of system alarms. Figure 12 Figure 13 Figure 10 –... -
Page 20: Menu 1 - Alarms
Alarm Glycol Menu 1 - Alarms If the Chiller set point goes below 40°F (4.4°C), the Alarms Active Glycol Warning screen will appear. The amount of antifreeze will vary depending on the actual desired When a critical system fault occurs, the controller operating conditions and should be enough to activates the HMI alarm handler. -
Page 21: Menu 1 - Circuit Details
Menu 1 – Circuit Details Touching the CRITICAL button opens the Critical Interlocks Screen (Figure 17). A critical interlock fault shuts down the entire system and must be resolved Circuit Details Screen prior to a restart. The Circuit Details Screen can be accessed directly from Menu 1 or by touching the option. -
Page 22: Menu 1 - Trending
Menu 1 – Trending Menu 1 – Inputs / Outputs The trending screen (Figure 19) displays the setpoint Inputs / Outputs Screens temperature, process temperature, demand, The Inputs/Outputs screens provide the status of all expansion valve, and optional hot gas bypass valve digital inputs, digital outputs, analog inputs, and (if present) resisters for easy analysis of the system outputs. -
Page 23: Menu 1 - Hot Gas Bypass
Figure 23 – Analog Outputs Screen Menu 1 – Hot Gas Bypass Hot Gas Bypass Setup Screen Figure 25 – Hot Gas Bypass Screen Figure 24 – RTD Inputs Screen Table 9 – Hot Gas Bypass Valve Setup Parameters Menu Item Description Default Value AUTO MODE: The valve will... -
Page 24: Menu 1 - Expansion Valve Setup
Menu 1 – Expansion Valve Setup Table 10 – EXV Setup Parameters Menu Item Description Default Value EXV Control Setup Screen In Auto Mode, the control system AUTO MODE adjusts the valve to maintain discharge pressure. In manual Figure 26 – EXV Control Screen Mode Control mode, the system drives the valve to a fixed position and holds it... -
Page 25: Menu 1 - Discharge Control Setup
Menu 1 – Discharge Control Table 11 – Discharge Control Setup Parameters Default Menu Item Description Setup Value In Auto Mode, the valve adjusts to AUTOMATIC Discharge Control Setup Screen maintain optimum performance. In Mode manual mode, it holds to the input An electric condenser water-regulating valve is valve. -
Page 26: Menu 1 - Capacity Control Setup
Menu 1 – Capacity Control Setup Menu 1 – Flow / Capacity Capacity Control Screen Flow/Capacity Screen The compressor is equipped with four solenoid The graph displays trend data for the process fluid valves flange mounted to the compressor. These flow rate measured at the outlet of the evaporator solenoid valves control the location of the slide on each chiller circuit. -
Page 27: Menu 1 - Pump Control
Menu 1 – Pump Control Menu 1 – Staging Pump Control Screen Compressor Staging Setup Screen This screen displays pertinent pump status information for a system with the optional integral Figure 32 – Compressor Staging Screen pump controls and provides the ability to change mode selection. -
Page 28: Menu 1 - Stage Order
Menu 1 – Stage Order Menu 2 – Overview Compressor Staging Setup Screen Figure 34 – Menu 2 Screen Figure 33 – Compressor Stage Order Screen Table 16 – Menu 2 Functions Screen Function Description Reference Table 15 – Compressor Staging Local Parameters Provides the ability to restore the Default Menu Item... -
Page 29: Menu 2 - Defaults
Menu 2 – Defaults Menu 2 – Backup Chiller CAUTION: The Defaults screen provides the ability to If this feature has been enabled from the factory, the restore the control system back to factory defaults in the system has the capability of enabling a backup case that an unknown setting modification occurred and chiller in the event that the primary chiller has a fault the system now behaves unexpectedly. -
Page 30: Start-Up
Start-Up CAUTION: The unit requires the main power to remain connected during off-hours to energize the compressor’s crankcase heater. Disconnect main Every unit is factory set to deliver chilled water in power only when servicing the chiller. The crankcase accordance with the standard operating heater should remain on when the compressor is off to ensure liquid refrigerant does not accumulate in the specifications for that particular chiller. - Page 31 water can also encourage biological growth that can Table 17 – Fill Water Chemistry Requirements foul heat transfer surfaces. Water Characteristic Quality Limitation Alkalinity (HCO 70-300 ppm To avoid the unwanted side effects associated with Aluminum (Al) Less than 0.2 ppm water cooling, proper chemical treatment and Ammonium (NH Less than 2 ppm...
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Page 32: Step 3 - Check Condenser
Step 3 - Check Condenser Step 6 – Turn On Control Power There are two possible types of condensers present Turn on the control power by turning the control in the chiller: water-cooled and remote air-cooled. It power switch to "On". The panel displays should now is important to verify the chiller will have adequate be illuminated. -
Page 33: Preventive Maintenance
Once a Week ranges are from 10°F to 20°F. If subcooling is not within this range, check the superheat and adjust if Check to make sure the To Process temperature required. The superheat should be approximately is close to the Set Point temperature. If the 10°F. -
Page 34: Once Every 6 Months
Once a Year Check the amp draws to each leg of the compressor(s) to confirm that it is drawing the Repeat items 1 through 17 land continue with the proper current. following. 10. Check the system superheat and sub-cooling. 18. Check the condition of the chilled water for The normal superheat is approximately 10°F and algae and particulate fouling. -
Page 35: Maintenance
Maintenance Disconnect power from the terminal at the power source. Checking Compressor Oil Level Using a clean sponge or a soft cloth, clean the The oil level should be visible in the sight glass while display with a mild soap or detergent. If paint or the compressor is running. - Page 36 General Troubleshooting (continued) Problem Possible Cause Remedy Low refrigerant charge Contact refrigeration service technician Refrigerant leak Contact refrigeration service technician Low flow through evaporator Adjust flow to proper level Clogged Y-strainer Clean Y-strainer Clogged evaporator Back flush / clean evaporator Check start-up settings Check control power to IB board, check fuse Expansion valve...
- Page 37 General Troubleshooting (continued) Problem Possible Cause Remedy Process load too high Check to make sure chiller is properly sized for process load Coolant flow through evaporator out of range Adjust flow to proper level Insufficient condenser cooling See high refrigerant pressure Insufficient cooling Check microprocessor output...
- Page 38 Preventive Maintenance Checklist Week Number Maintenance Activity Date Chilled Water Set Point Temperature Control Chiller % Loading Condenser Water Temperature Condenser Ambient Temperature Refrigerant Suction Pressure Refrigerant Discharge Pressure Refrigerant Sight Glass Compressor Oil Level Electrical Connections Incoming Voltage Compressor L1 Amps Compressor L2 Amps Compressor L3 Amps Refrigerant Superheat...
- Page 40 New Equipment Sales Customer Service Parts Department 5680 W. Jarvis Ave. Niles, IL 60714 • 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 MX IOM 00...
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