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Cold Shot Chillers ACWC-024-E-DR-LT-0-2 Installation, Operation And Maintenance Instructions

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INSTALLATION, OPERATION, AND
MAINTENANCE INSTRUCTIONS
(ACWC-024-E-RF and ACWC-240-E outdoor models shown)
AIR-COOLED, WATER CHILLERS
UP TO 240 kBTU/HR CAPACITY
Model#: ACWC-024-E-DR-LT-0-2
Serial#: MXXXXXX-X
Marrone & Co., Inc.
Houston, Texas 77032 • Phone (800) 473-9178, (281) 227-8400
Fax (800) 473-9175, (281) 227-8404 • www.waterchillers.com

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Summary of Contents for Cold Shot Chillers ACWC-024-E-DR-LT-0-2

  • Page 1 MAINTENANCE INSTRUCTIONS (ACWC-024-E-RF and ACWC-240-E outdoor models shown) AIR-COOLED, WATER CHILLERS UP TO 240 kBTU/HR CAPACITY Model#: ACWC-024-E-DR-LT-0-2 Serial#: MXXXXXX-X Marrone & Co., Inc. Houston, Texas 77032 • Phone (800) 473-9178, (281) 227-8400 Fax (800) 473-9175, (281) 227-8404 • www.waterchillers.com...

  • Page 2: Table Of Contents

    MODEL NUMBER NOMENCLATURE ACWC Example Model#: Position: Position-Description 1. Model Type: ACWC: Air Cooled Water Chiller 2. Nominal Capacity in kBtu/hr 3. Series System 4. Flow Design: (_=Portable, ST=Stationary, RF=ReverseFlow, EXCH=HeatExchanger, DP=DualPump, DR=DualReturn) 5. Leaving Fluid Temperature (_=Standard, LT=LowTemperature-specify lowest temperature in °F) 6.

  • Page 3: Important

    Inspect carton’s exterior for evidence of rough handling in shipment. Carefully remove protective wrap and all banding to uncrate, for inspection; if damage is found, report immediately to the transportation agency and Cold Shot Chillers. Provide a report and photographs (highly recommended), if possible.

  • Page 4: Installation

    II. INSTALLATION A. MOVEMENT/RIGGING 1. The preferred method for movement of the chiller while on the pallet is with forklift or pallet jack. 2. For rigging, overhead rigging with spreader bars above the unit is preferred. Protect unit from being crushed. CAUTION! All panels must be in place when rigging.

  • Page 5: Split Systems (Remote Condenser Or Condensing Unit)

    National Electrical Code (NEC), Section 440-14. b) Verify electrical power on the Cold Shot Chillers label plate with actual voltage. c) Connect line power supply to terminal block or as noted in machine; typically, connect power leads to terminals L1, L2 and L3 on compressor contactor.

  • Page 6: Freeze Protection

    IMPORTANT!! DO NOT BYPASS OR ADJUST ANY SAFETY DEVICES OR PARAMETERS WITHOUT FIRST CONTACTING COLD SHOT CHILLERS. ANY MODIFICATIONS OF THE CHILLER SYSTEM FROM THE MANUFACTURER’S DESIGN WILL REQUIRE PRIOR WRITTEN APPROVAL FROM COLD SHOT CHILLER’S, OTHERWISE ALL WARRANTIES WILL BECOME VOID.

  • Page 7: Performance

    2. Automatic/Manual refill or change over systems should be cautious and attentive to the specific concentration of mixtures dilution over time. Measure the system’s concentration regularly. 3. Glycol concentrations affect cooling performance. As the temperature reduces, the fluid becomes thicker which may reduce heat transfer capabilities and reduces the circulating pump performance.

  • Page 8: Pre-Startup

    III. PRE-STARTUP 1. STARTUP CHECKLIST - Review and use. (Typically located at end of this manual.) 2. COMPRESSOR MOUNTS a) As shipped, the compressor(s) is held down by mounting bolts with vibration rubber grommets. b) Verify bolts are tight to base and that the compressor is able to move on the rubber grommets. (1) Single Compressor units: Verify that the shipping spacers (if installed) are removed from between the compressor bottom (or compressor plate) and the base of the unit.

  • Page 9: Startup

    IV. STARTUP 1. Verify installation is complete and all Pre-Startup steps are completed. 2. STARTUP CHECKLIST - Review and use. (Typically, located at end of this manual) 3. Attach refrigerant gauges to the appropriate service ports. 4. PUMP ONLY: Turn switch to Pump Only (or use local system pump) and operate for at least 15 minutes.

  • Page 10: System Components: (See Your Chiller's Specification For Details.)

    clear sight glass for optimum performance. Returning fluid temperature should not exceed 90°F on standard units or the chiller will cycle off on high head pressure and not run. Should this occur, allow water to cool down and restarting chiller once water is below 90°F. e) If sight glass is bubbly add to charge.
  • Page 11 8. FLOW SAFETY THERMOSTAT (FS): when the pressure drops below the set point and will automatically reset when pressure is above the non-adjustable reset setting. (See specifications for Figure 1 Low Flow details) / Freeze Safety 12. REFRIGERANT HIGH PRESSURE SAFETY (HPS) a) Monitors the pressure of the refrigerant and will automatically open when the pressure rises above the sensor fixed set...
  • Page 12 Also, some temperature thermostats may supplied with a makeup water source of need to be adjusted. fluid for the tank. 17. PUMP (Depending on design) b) The makeup water (such as city water Systems with integral pump are typically supply) is connected the pipe setup to provide recirculating fluid for the...

  • Page 13: Maintenance (Basic Guide)

    If any questions regarding the equipment, please contact Cold Shot Chillers for assistance. NOTE: Not performing the following will cause early unit failure and considered abuse which is not covered by warranty.
  • Page 14 Replace any wiring parameters. Contact Cold Shot Chillers for that could cause problems with shorting or assistance. unintentional grounds.

  • Page 15: Troubleshooting (Basic Guide)

    VII. TROUBLESHOOTING (BASIC GUIDE) • The Troubleshooting Guide below is to be used as a guide only. All work should be performed by a trained technician and only with proper understanding of the system. Contact manufacturer for further assistance. • Prior to resetting any safety devices, ensure that the issue is resolved or use care in operating the system until the cause is determined.
  • Page 16 SYMPTOM AND PROBABLE CAUSE PROBABLE REMEDY UNIT OPERATES TOO LONG OR CONTINUOUSLY 9. Low refrigerant charge. 9. Add refrigerant. 10. Control contacts fused. 10. Replace control. 11. Air in system. 11. Purge and evacuate system. SYSTEM IS NOISY 1. Piping vibration. 1.
  • Page 17 7. Motor defective. 7. Check motor winding for open or short. Replace motor/pump, if necessary. VOLTAGE IMBALANCE 1. Voltage Imbalance over 2% - Incoming Power 1. Main Incoming Voltage – - (Check Voltage at front and backside of each - A voltage imbalance may be an indication of loose contactor during operation.) wires/cable connections or faulty contactors.
  • Page 18 TEMPERATURE CONTROLLER - CHROMALOX 6040 Reset or Auto/Manual Key Lower or Down Menu Key Raise or Up Menu Key Function Key 1/16 DI Figure 37 Typical front panel and keys Keypad Each instrument has either three or four switches, which are used to navigate through the user menus and make adjustment to the parameter values.
  • Page 19 6 Messages and Error Indications The following displays are shown when an error occurs or a hardware change is detected. Table 4. Error/Faults conditions Lower Error/Faults Display Conditions Upper display (where fitted) Configuration & Setup is required. Seen at first turn on or if Goto Conf hardware configuration changed.
  • Page 20 TECHNICAL SPECIFICATION Model: ACWC-24-E-__ Description: Single stage air-cooled portable water chiller system. System will provide approximately 24,000 Btu/hr of cooling capacity with a leaving fluid temperature of 50°F and an ambient air temperature of 95°F. CAPACITY 24,000 BTU /HR ±5% AT 50° LCWT / 95°F AMBIENT COMPRESSOR / REFRIGERANT HERMETIC SCROLL / R-410A CONDENSER FANS / AIRFLOW...
  • Page 21 • Reference the chiller serial number when ordering parts for specific supplied pump. COLD SHOT CHILLERS / Marrone & Co., Inc. 2730 Maximilian Drive, Houston, Texas 77032 • Phone (800) 473-9178, (281) 227-8400 Fax (800) 473- 9175, (281) 227-8404 • www.waterchillers.com...
  • Page 22 FRONT RIGHT SIDE BACK VIEW VIEW VIEW Access Panel Temperature Controller Control Switch (PumpOnly/Off/Cooling) Insulated Tank with Lid (inside) 45.4in Inlet (NPT-Male) Tank Fill Port Outlet (NPT-Male) Tank Level Sightglass Ø 1.7in. (SS304 Pipe) Tank Drain 6.5in. 27.6in 40.5in GENERAL NOTES Specifications subject to change without notice.
  • Page 23 Tandem Compressor Models only Compressor Low Pressure Switch Suction Line Flow Safety Thermostat Service Valve/Port Air Cooled Condenser Compressor Sensing Bulb Tube Suction Condenser Coils Accumulator* Evaporator CHILLER (Fluid System) Hot Gas Bypass Additional Valve Fans* (Optional) Head Pressure High Pressure Sensing Bulb Tube Liquid Line Switch...
  • Page 24 COPPER BRAZED SWITCH PLATE EVAPORATOR WATER RETURN (IN) STRAINER Heat Bypass Exchanger WATER SUPPLY (OUT) DRAIN PUMP THERMOCOUPLE TO TEMPERATURE CONTROLLER SIZE FSCM NO DWG NO COLD SHOT CHILLERS Typical E-WATER CIRCUIT ENGINEERING DRAWN 05/03 1 : 16.67 ISSUED SCALE SHEET...
  • Page 25 GROUNDING LUG GRN/YEL COMPRESSOR POWER SUPPLY FIELD STRIPED SUPPLIED HERM DISCONNECT FAN MOTOR CHILLER PUMP Remove jumper for remote on/off FB-1 connect TB1 #1 and TB1 #2 to a WITH REMOTE “DRY” non-voltage terminals ON/OFF ONLY “NOTE” 208/230V CONNECT FOR 460V APPROPRIATE (2)-1 AMP...
  • Page 26 TYPICAL START-UP CHECK LIST EQUIPMENT MODEL# SERIAL# OWNER NAME PHONE# ADDRESS CITY STATE INSTALLING CONTRACTOR PHONE# ADDRESS CITY STATE START-UP PERFORMED BY PHONE# * Designates Pre-Startup items. To be performed before Startup of system. 1. *Manual referred to for details on installation and startup (IMPORTANT). 2.

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