Related Manuals for Unitrol PROCESS 8500
Summary of Contents for Unitrol PROCESS 8500
- Page 1 PROCESS WATER CHILLER MODELS 8500, 8501, 8550, 8551 Shown with option #8510 stacking stand. UNITROL ELECTRONICS, INC. 702 LANDWEHR ROAD NORTHBROOK, IL 60062 847-480-0115 info@unitrol-electronics.com...
- Page 2 1. Contact the Unitrol service department at 847-480-0115 to discuss the problem you are having with this chiller. 2. If Unitrol concurs that this is a warranty issue, and the chiller is more than 90 days from date of factory shipment, a Unitrol...
- Page 3 This Unitrol water chiller has been designed to operate under the most severe industrial conditions. Please observe the installation instructions to be sure that this chiller will provide years of superior service.
- Page 4 NOTES...
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Page 5: Table Of Contents
TABLE OF CONTENTS Installation……………………………………….…………………………… 1 Phase Sequence Test………………………………………………………. 2 Fuse and Wiring Chart……………………………………………………… 3 Inter-module Wiring…………………………………………………………. 4 Plumbing…………………………………………………………………..5 Inter-module Hose Connecting…………………………......7 First Power-up……………………………………………………………….. 8 Dew Point Protection System (Option 8001-03) ………………………… 9 Setting Temperature Controller……………………………………………. 10 Initial Startup…………………………………………………………………. 11 Temperature Sequence…………………………………………………….. -
Page 7: Installation
INSTALLATION UNITROL MODEL 8500, 8501, 8550, 8551 THIS CHILLER IS DESIGNED FOR INSIDE INSTALLATION. ONLY CHILLERS PURCHASED WITH THE –OS (OUTSIDE) KIT CAN BE INSTALLED OUTSIDE IN AREAS WHERE THE AIR TEMPERATURE CAN FALL BELOW 45ºF, AND SUCH INSTALLATION WILL VOID THE WARRANTY. -
Page 8: Phase Sequence Test
INSTALLATION UNITROL MODEL 8500, 8501, 8550, 8551 Note that a chiller marked 480V will operate on 430V – 500V. A chiller that is marked 230V will operate on 208V – 260V. 8. MODULE A: a. LINE VOLTAGE: Run a flexible cable (liquid tight) through one of the grommeted hole in the right side bottom of the base pan and up into the control panel. -
Page 9: Fuse And Wiring Chart
INSTALLATION UNITROL MODEL 8500, 8501, 8550, 8551 b. Install slow blow (time delay) fuses in the fused disconnect and use connecting wire per the FUSE AND WIRE CHART below. c. Connect the three line voltage wires to the L1, L2, L3 terminals on the contactor inside the black control boxes. -
Page 10: Inter-Module Wiring
INSTALLATION UNITROL MODEL 8500, 8501, 8550, 8551 INTER-MODULE WIRING 1. Route the interconnecting flexible cable (liquid tight) that comes from the MODULE A through the grommeted holes in the base pans near the black junction boxes. Be sure that you are running the cable marked MODULE B to MODULE B, and the cable marked MODULE C to MODULE C. -
Page 11: Plumbing
INSTALLATION UNITROL MODEL 8500, 8501, 8550, 8551 PLUMBING PIPE INSULATION ALL PIPES FROM THE CHILLER AND RETURNING TO THE CHILLER MUST BE INSULATED. COMMERCIAL SNAP-ON FOAM INSULATION IS SUFFICIENT FOR THIS PURPOSE. REASON #1: DURING WARM WEATHER THE INSULATION WILL PREVENT CONDENSATION FROM THE PIPES. - Page 12 INSTALLATION UNITROL MODEL 8500, 8501, 8550, 8551 Because this same pipe that feeds this makeup water line will be used to circulate water to the machinery if the chiller is taken out of service, the pipe size should be at least 1-1/2”.
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Page 13: Inter-Module Hose Connecting
INSTALLATION UNITROL MODEL 8500, 8501, 8550, 8551 INTER-MODULE HOSE CONNECTION HOSE CONNECTION HINT: Put a little grease or oil on the tip of the hose barbs to make installation of hoses easier. 1. Install the four 1-1/4” hose supplied with this chiller from MODULE A to MODULE B and MODULE C. -
Page 14: First Power-Up
2. The water pump pressure gauge should be showing pressures between 35 - 55psi. If lower or higher pressures are shown, turn chiller off and contact the Unitrol service department at 847-480-0115 to discuss this problem. -
Page 15: Dew Point Protection System Option 8001-03
INITIAL STARTUP UNITROL MODEL 8500, 8501, 8550, 8551 DEW POINT PROTECTION SYSTEM OPTION 8001-03 FUNCTION: When this option is installed, this option prevents the tank temperature from being chiller below the DEW POINT of the factory air. Water that is below the dew point can cause condensation inside water-cooled welding transformers that can, over time, damage or destroy the welding transformer. -
Page 16: Setting Temperature Controller
INITIAL STARTUP UNITROL MODEL 8500, 8501, 8550, 8551 FIRST TURN ON: When the chiller is first turned on, the display will briefly show: then Then for about 30 seconds Then then and finally the tank water temperature Once this initial procedure has been completed, the compressor in MODULE A will turn on if the temperature is at least 3°F above the SP number as customer-set in the next section. -
Page 17: Initial Startup
INITIAL STARTUP UNITROL MODEL 8500, 8501, 8550, 8551 (t t), push the ▼button until you see the symbol for the value you want to view. Then push the SEL button. When you are finished, push the ▲or ▼button at the same time twice and the tank water temperature will be displayed. -
Page 18: Temperature Sequence
INITIAL STARTUP UNITROL MODEL 8500, 8501, 8550, 8551 TEMPERATURE SEQUENCE The chart below shows the operation of the three modules in response to the tank water temperature and the customer-set SP (SV) temperature. FOR CHILLERS WITH OPTIONAL DEW POINT CONTROL: IN ALL CASES BELOW, IF THE TANK WATER TEMPERATURE IS BELOW THE DEW POINT, NO COMPRESSORS WILL OPERATE. -
Page 19: Control Panel And Fault Lights
INITIAL STARTUP UNITROL MODEL 8500, 8501, 8550, 8551 CONTROL PANEL OPERATION AND FAULT INDICATOR LIGHTS ON TEMPERATURE CONTROLLER SV = Customer-set temperature target A = Glows when controller turns on compressor #1 in MODULE A B = Glows when controller turns on... -
Page 20: Low Water Flow
INITIAL STARTUP UNITROL MODEL 8500, 8501, 8550, 8551 MODULE A, MODULE B, and MODULE C: LOW WATER FLOW: Each module has a separate WATER FLOW switch. WHY THE LOW WATER FLOW SAFETY SWITCHES ARE IMPORTANT If the water flowing through the evaporators (chilling component) of either refrigeration system is too low, the water deep in that evaporator can easily reach temperatures below freezing. -
Page 21: Low Freon Fault
INITIAL STARTUP UNITROL MODEL 8500, 8501, 8550, 8551 ii. The setting on the overload is too low. Check the pump motor nameplate for amperage and set the rotary switch on the overload to a value about 25% higher. iii. Contacts on contactor K1 are arched causing an imbalance of voltage, especially for 3Ø... - Page 22 This can be done using a commercial fan blowing air into the front of the coil (where air filter is located), or by installing a factory fan booster kit. Consult the Unitrol service department on this.
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Page 23: Dew Point Control Faults, Option 8001-03
INITIAL STARTUP UNITROL MODEL 8500, 8501, 8550, 8551 DEW POINT CONTROL FAULTS, OPTION 8001-03 This OPTIONAL DEW POINT controller monitors four measurements and responds as follows when a fault is detected: 1. TANK WATER SENSOR FAILURE: If the control detects temperature, as sampled by the thermister sensor in the water tank, that is below 20°F or above 100°F, the display... -
Page 24: Bypass Chiller During Service
CONNECTING LOAD TO CHILLER: TURN ON VALVES #3, #4, and M TURN OFF VALVES: #1, and #2 If any problems are incurred during this installation, contact the Unitrol service department at 847-480-0115. Please have the model number and serial number ready. -
Page 25: Preventative Maintenance
PREVENTIVE MAINTENANCE UNITROL MODEL 8500, 8501, 8550, 8551 PREVENTATIVE MAINTENANCE ONLY A CERTIFIED REFRIGERATION TECHNICIAN SHOULD BE ALLOWED TO SERVICE THE SEALED REFRIGERATION SECTION OF THIS CHILLER CLEAN THE CONDENSER: Inspect the evaporator coil fins (behind the air intake filter) every 3 months of operation. -
Page 26: Outside Plumbing Connection
DOCUMENTS UNITROL MODEL 8500, 8501, 8550, 8551 OUTSIDE PLUMBING CONNECTION Plumb chiller to city water and load as shown below. Valves are installed to allow fast switchover to city water and drain if needed. TO OPERATE ON CHILLER: Open valves 1, 4, and M... -
Page 27: Wiring Schematic
DOCUMENTS UNITROL MODEL 8500, 8501, 8550, 8551... -
Page 28: Dew Point Schematic (Option 8001-03)
DOCUMENTS UNITROL MODEL 8500, 8501, 8550, 8551... -
Page 29: Assembly Of Optional Mounting Stand 8510
DOCUMENTS UNITROL MODEL 8500, 8501, 8550, 8551 OPTIONAL MOUNTING STAND MODEL 8510 Assemble mounting stand as shown above using the 20 = ½-13 X 1” hex head cap screws, lock washers, and flat washers supplied with this stand as shown in the photo inset below. - Page 30 Install the module without the water tank on top of the stand and place the chiller foot pads between the front and rear top braces. There should be about ½” space all around. It is not necessary to bolt the chiller since it will be locked in place. MAINTENANCE RECORD DATE PROBLEM...
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Page 31: Maintenance Record Sheet
UNITROL ELECTRONICS, INC. 702 LANDWEHR ROAD NORTHBROOK, ILLINOIS 60062 847-480-0115 techsupport@unitrol-electronics.com...