Thermal Care Accuchiller NQ Series Operation, Installation, And Maintenance Manual
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Thermal Care Accuchiller NQ Series Operation, Installation, And Maintenance Manual

Portable chillers
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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 ........................................2   Installation - Chiller ......................................3   Foundation .......................................... 3   Unit Location ........................................3  ...
  • Page 4 Overview Screen 1 ..................................... 14   Overview Screen 2 ..................................... 14   Menu 1 - Alarms ......................................14   HMI Alarm Handler Screen ..................................14   Menu 1 – Diagnostics ....................................15   Main Diagnostics Screen ..................................15   Diagnostics Screen 1 - Circuit 1 Overview ............................15  ...
  • Page 5 Review System Build Screen .................................. 21   Communications ......................................22   Table 8 – Modbus Table ..................................22   Table 9 – BACNet Parameters ................................26   Start-Up ..........................................31   Step 1 - Connect Main Power ................................... 31   Step 2 - Fill Coolant Circuit ..................................
  • Page 6 Page Intentionally Blank...

  • Page 7: Foreword

    Foreword Safety Guidelines The portable chiller is a packaged unit that typically Observe all safety precautions during installation, includes a refrigeration circuit, coolant reservoir, and start-up, and service of this equipment. The pumping system in a cabinet. The purpose is to cool following is a list of symbols used in this manual and water or a process fluid.

  • 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 of this equipment outside of the acknowledgement and shipping papers.

  • Page 9: Installation - Chiller

    Installation - Chiller required, install them as close to the use point as possible. Provide flow-balancing valves at each machine to assure adequate water distribution in the Foundation entire system. When piping is overhead with a total Install the chiller on a rigid, non-warping mounting run over 90 feet, install a valve in the supply line and pad, concrete foundation, or level floor suitable to an inverted P trap with a vacuum break valve...

  • Page 10: Installation - Remote Condenser

    maintain proper flow through the condenser ensure chimneys. Fasten the mounting legs at their base to the condenser water pump supply provide at least the steel or concrete of the supporting structure. 25 psi at a flow of 3 gpm per ton of chiller capacity. Lifting The condenser has a two-way condenser water- Use qualified personnel when lifting and positioning...

  • Page 11: Refrigeration Piping Design

    piping should conform to the applicable local and chiller. Make the drop leg before any bends or state codes. angles connecting to the remainder of the liquid connection piping. CAUTION: Only use refrigerant grade copper tubing Figure 3 – Condenser Located at Chiller Level ASTM B280 and isolate the refrigeration lines from building structures to prevent transfer of vibration.

  • Page 12: Liquid Line Sizing

    the same pressure loss. See the ASHRAE Liquid Line Sizing Refrigeration Handbook for more information. To keep the system refrigerant charge at a minimum use the smallest acceptable line size possible. The Follow these steps when calculating line size: total length between the chiller and the condenser 1.
  • Page 13 Table 2 – Liquid Line Sizes for R410A 5 Ton Circuit (R410A) Liquid Line Size (Inch OD) 7½ Ton Circuit (R410A) Liquid Line Size (Inch OD) Up Flow (Feet of Run) Up Flow (Feet of Run) Equivalent Horizontal or Equivalent Horizontal or Length (Ft) Down Flow...
  • Page 14 Table 2 – Liquid Line Sizes for R410A (continued) 20 Ton Circuit (R410A) Liquid Line Size (Inch OD) 25 Ton Circuit (R410A) Liquid Line Size (Inch OD) Up Flow (Feet of Run) Up Flow (Feet of Run) Equivalent Horizontal or Equivalent Horizontal or Length (Ft)

  • Page 15: Discharge (Hot Gas) Line Sizing

    Table 2 – Liquid Line Sizes for R410A (continued) Figure 6 – Vertical Riser Traps 40 Ton Circuit (R410A) Liquid Line Size (Inch OD) Up Flow (Feet of Run) Equivalent Horizontal or Length (Ft) Down Flow 0 to 5 6 to 10 11 to 15 1 3/8 1 3/8...
  • Page 16 Table 3 - Horizontal or Downflow Discharge Line Sizes for R410A (inches OD) Total Equivalent Length (Ft) Circuit Tons 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8...

  • Page 17: Calculating Refrigerant And Oil Charge

    Calculating Refrigerant and Oil Charge Setting Condenser Fan Controls To estimate the total amount of refrigerant required The remote condenser has a controller that cycles to charge the system combine the charges from the the fans as needed to maintain the proper below two tables for the size system and line sizes refrigerant pressure.

  • Page 18: Installation - Electrical

    Installation - Electrical CAUTION: Wear eye protection when installing, maintaining, or repairing the equipment to protect against any sparks, debris, or fluid leaks. Install all wiring in compliance to all applicable local and national codes. Minimum circuit amps (MCA) CAUTION: Wear protective gloves when installing, and other unit electrical data are on the unit maintaining, or repairing the equipment to protect against any sparks, debris, or fluid leaks.

  • Page 19: Control Operation

    Control Operation The user-level password allows access to the most common functions; however, there are a few screens protected with a Supervisor-level password. The units uses a Programmable Logic Controller Changing items in Supervisor-level menus without (PLC) and color touch-screen operator interface fully understanding the impact can lead to improper display that serves as the Human to Machine or poor performance of the unit.

  • Page 20: Home Screen

    Home Screen Overview Screen 2 This screen provides an overall synopsis of the system, quick links to other views, as well as other additional information. Home Overview Screen To return to the Home screen simply touch the Home button. Some screens have links to sub- screens or menus but all have a Home button to allow you to return to the Home screen.
  • Page 21 Menu 1 – Diagnostics Diagnostics Screen 3 - Pumps The diagnostics screens provide detailed information about the various portions of the system. Main Diagnostics Screen Diagnostics Screen 4 - Process Diagnostics Screen 1 - Circuit 1 Overview Diagnostics Screen 5 - Hardware Diagnostics Screen 2 –...
  • Page 22 Menu 1 – Security Security – Add User Screen To add protection to sensitive areas of the control program and provide some level of supervisory control to some operating parameters, the control system includes some security level protections. Main Security Screen Security –...
  • Page 23 Security - Delete User Screen Menu 1 – Input/Output The Input/Output screens display the status of the various system inputs and outputs. This provides a detailed level of information for monitoring system operation and for diagnosing any performance issues or alarms that arise. Main Inputs/Outputs Screen Security - Change Password Screen Inputs/Outputs –...
  • Page 24 Inputs/Outputs – Analog Inputs Screen Menu 1 – User Setup The control system allows for customization and adjustment of many parameters. In most cases, the factory default settings are sufficient; however, adjustment of parameters and settings is possible through the User Setup menus. User Setup Menu - Screen 1 Inputs/Outputs –...
  • Page 25 User Setup – Alarm Setup Screen User Setup – EEV Control Screen User Setup - Staging User Setup – Hot Gas Bypass Screen User Setup – Stage Order Screen User Setup – Pumps Screen User Setup – Discharge Control Screen 1 User Setup –...
  • Page 26 User Setup – Discharge Control Screen 2 User Setup – IP Address Screen User Setup – Units Screen User Setup – Modbus RTU Screen User Setup – 3-Way Mod Valve Screen User Setup – Process Temperature Retransmit Screen User Setup – Miscellaneous Menu Screen User Setup –...

  • Page 27: Review System Build Screen

    Menu 1 – Trending Menu 2 – System Build A graphical representation of the core operating This menu allows configuration of the system. Use parameters of the system is in the trending screen. this menu only with the assistances of someone from The trending screen displays the setpoint the Customer Service Department.

  • Page 28: Communications

    Communications All standard control systems have Modbus RTU. The Premium control option includes Modbus RTU and TCP/IP and is available with options for BACnet, LonWorks, or OPC/UA communications. The Modbus RTU default set up uses a Baud Rate: 57,600, Data Length: 8 bits, Parity: Odd, Stop Bit: 1 and Station ID: 1. The default IP address of Modbus TCP/IP is 192.168.1.1.
  • Page 29 Table 8 – Modbus Parameters (continued) Types Index Size Variable Name Data Type Coil AL_PRB_EVAP_OUT_FLUID.Active Bool Coil AL_PRB_SUCTION_TEMP.Active Bool Coil AL_SUCTION_PX_SENSOR.Active Bool Coil AL_LPS.Active Bool Coil AL_LLPS.Active Bool Coil AL_PRB_DISCHARGE_TEMP.Active Bool Coil AL_DISCHARGE_PX_SENSOR.Active Bool Coil AL_DISCHARGE_PX_SOFT_FAULT.Active Bool Coil AL_HPS.Active Bool Coil AL_COND_FAN1_OVLD.Active Bool...
  • Page 30 Table 8 – Modbus Parameters (continued) Types Index Size Variable Name Data Type Coil COMPRESSOR_STAGING_MANUAL Bool Coil STAGE_ERROR Bool Coil STAGE1_TRIGGER_ON Bool Coil STAGE1_TRIGGER_OFF Bool Coil STAGE2_TRIGGER_ON Bool Coil STAGE2_TRIGGER_OFF Bool Coil SLAVE_MODE Bool Coil MASTER_SLAVE_ENA Bool Coil PROCESS_PUMP_MANUAL_MODE Bool Coil PROCESS_PUMP_MANUAL_MODE_ON Bool...
  • Page 31 Table 8 – Modbus Parameters (continued) Types Index Size Variable Name Data Type HoldingRegister MOD_VALVE_MANUAL_PERCENT Real HoldingRegister MOD_VALVE_SETPOINT Real HoldingRegister COMPRESSOR_STAGE_ORDER_C1 HoldingRegister COMPRESSOR_STAGE_ORDER_C2 HoldingRegister COMP1_HOURS_RETAIN UDInt HoldingRegister COMP2_HOURS_RETAIN UDInt InputRegister PLC_VERSION Real InputRegister CAREL_TEMP_HMI Real InputRegister AUTOSTART_REMAINING InputRegister ANALOG_IN.RFRG_SUCTION_TEMP_HMI Real InputRegister SUCTION_PRESSURE_HMI Real...
  • Page 32 Table 8 – Modbus Parameters (continued) Types Index Size Variable Name Data Type InputRegister NQV_EV2_50_AC_INPUT_CURRENT_FOLDBACK_STATUS InputRegister NQV_EV2_59_POWERUP_STATUS InputRegister NQV_EV2_POWER_MODULE_TEMP Real InputRegister NQV_EV2_DLT Real InputRegister NQV_EV2_78_1ST_FAULT_OCCURRED InputRegister NQV_EV2_79_1ST_FAULT_OCCURRED InputRegister COMP1_ANTI_CYCLE_TIME InputRegister COMP2_ANTI_CYCLE_TIME InputRegister PUMP_PRESSURE_HMI Real InputRegister PROCESS_PUMP_PID_PERCENT Real InputRegister MOD_VALVE_CTRL_TEMP_HMI Real InputRegister MOD_VALVE_PERCENT Real...
  • Page 33 Table 9 – BACNet Parameters (continued) Type Object Instance Variable Name Data Type BinaryValue COMP2_OVLD_INTERNAL Bool BinaryValue COMPRESSOR_2_DISABLED Bool BinaryValue COMP2_REQUEST Bool BinaryValue COMP2_STATUS_OK Bool BinaryValue COMP2_OK Bool BinaryValue COMP2_ANTICYCLE_TIMER_DONE Bool BinaryValue COMP2_ENABLE Bool BinaryValue AL_ALARMS_PRESENT Bool BinaryValue AL_GENERAL_ALARMS Bool BinaryValue AL_RFRG_ALARM Bool...
  • Page 34 Table 9 – BACNet Parameters (continued) Type Object Instance Variable Name Data Type BinaryValue NQV_DRIVE_108 Bool BinaryValue NQV_DRIVE_110 Bool BinaryValue NQV_DRV_MANUAL_ENABLE Bool BinaryValue NQV_DRV_STARTUP_DELAY_DONE Bool BinaryValue NQV_DRV_PID_ENABLE Bool BinaryValue PROCESS_PUMP_ON Bool BinaryValue PROCESS_PUMP_OVLD_OK Bool BinaryValue PROCESS_PUMP_VFD_CTRL Bool BinaryValue PUMP_VFD_AUTO Bool BinaryValue PUMP_VFD_ON Bool...
  • Page 35 Table 9 – BACNet Parameters (continued) Type Object Instance Variable Name Data Type AnalogValue RETURN_WATER_HIGH_WARNING_HMI Real IntegerValue WTR_TEMP_BYPASS_TIME_SECONDS IntegerValue NO_FLOW_TIME_DELAY_SEC AnalogValue FREEZESTAT_SETPOINT Real IntegerValue SUCTION_PRESSURE_BYPASS_TIMER DInt IntegerValue CONDENSER_FAN_COUNT IntegerValue FAN1_CUTIN_PSIG IntegerValue FAN1_CUTOUT_PSIG PositiveIntegerValue FAN1_HOURS_RETAIN UDInt IntegerValue FAN2_CUTIN_PSIG IntegerValue FAN2_CUTOUT_PSIG PositiveIntegerValue FAN2_HOURS_RETAIN UDInt IntegerValue...
  • Page 36 Table 9 – BACNet Parameters (continued) Type Object Instance Variable Name Data Type IntegerValue SUPPLY_WATER_BYPASS_REMIANING AnalogValue SUPPLY_WATER_HIGH_WARNING_HMI Real IntegerValue SUPPLY_WATER_HIGH_HIGH_FAULT_TIME AnalogValue SUPPLY_WATER_LOW_WARNING_HMI Real IntegerValue RETURN_WATER_HIGH_HIGH_FAULT_TIME AnalogValue DISCHARGE_PERCENT Real AnalogValue HGBP_PERCENT Real AnalogValue HGBP_SETPOINT_HMI Real AnalogValue EXV_PERCENT Real IntegerValue NQV_DRV_SPEED_FEEDBACK_INT IntegerValue NQV_DRV_PID_RPM IntegerValue NQV_DRV_DEMAND_PERCENT...

  • Page 37: Start-Up

    Start-Up Step 1 - Connect Main Power Before connecting main power, ensuring it matches The unit is factory set to standard operating the voltage shown on the nameplate of the unit. specifications. Use a qualified refrigeration Check the phasing prior to applying power. The technician to perform the start-up procedure in proper sequence is “ABC.”...
  • Page 38 To avoid the unwanted side effects associated with Table 10 – Fill Water Chemistry Requirements water cooling, proper chemical treatment and Water Characteristic Quality Limitation preventive maintenance is required for continuous Alkalinity (HCO 70-300 ppm plant productivity. Aluminum (Al) Less than 0.2 ppm Ammonium (NH Less than 2 ppm Unwanted Side Effects of Improper Water Quality...

  • Page 39: Step 3 - Check Condenser

    Step 3 - Check Condenser CAUTION: The manufacturer’s warranty does not cover the evaporator from freezing. It is vital that the There are three possible types of condensers present Freezestat is set properly. in the chiller: Integral air-cooled, water-cooled, or remote air-cooled.

  • Page 40: Preventive Maintenance

    WARNING: Never deactivate the High Refrigerant temperature stays more than 5°F away from the Pressure Switch or the Low Compressor Pressure set point, there may be a problem with the Switch. Failure to heed this warning can cause serious chiller. If this is the case, refer to the compressor damage, severe personal injury, or death.

  • Page 41: Preventive Maintenance Checklist

    11. Have a qualified refrigeration technician inspect 12. (Units with a Variable-Speed compressor) Ensure the operation of the entire unit to ensure the variable speed drive remains dust-free. everything is operating properly. Have the Check the heat sink of the drive and make sure it condenser cleaned out if necessary.

  • Page 42: General Troubleshooting

    General Troubleshooting Problem Possible Cause Remedy Compressor will not Compressor overload Check supply voltage, amperage of each leg, contactor start 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...

  • Page 43: Drawings

    General Troubleshooting (continued) Problem Possible Cause Remedy Insufficient cooling Process load too high Check to make sure chiller is properly sized for process (temperature continues load to rise above set point) Coolant flow through evaporator too high or low Adjust flow to proper level Insufficient condenser cooling See “High Refrigerant Pressure”...
  • Page 45 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 sales@thermalcare.com service@thermalcare.com tcparts@thermalcare.com March 2021 NQ IOM 03...

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