Thermal Care TSE Operation, Installation, And Maintenance Manual
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Thermal Care TSE Operation, Installation, And Maintenance Manual

Central 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 ........................................3 Installation - Chiller ......................................3 Foundation .......................................... 3 Unit Location ........................................3 Rigging ..........................................3 Process Fluid Piping ......................................3 Condenser Water Piping ....................................
  • Page 4 Table 7 – System Overview Functions ..............................16 Starting and Stopping the Chiller ................................. 17 Starting the Chiller ......................................17 Figure 9 – Chiller Start ....................................17 Stopping the Chiller ...................................... 17 Figure 10 – Chiller Stop .................................... 17 Menu 1 - Overview ......................................17 Figure 11 –...
  • Page 5 Menu 1 – User Setup ......................................23 Figure 40 - User Setup - Menu 1 Screen ............................23 Figure 41 - User Setup - Menu 2 Screen ............................23 Figure 42 - User Setup - Menu 3 Screen ............................23 Figure 43 - User Setup - Menu 4 Screen ............................
  • Page 6 User Setup – Remote Setpoint ..................................29 Figure 60 - User Setup – Remote Setpoint Setup Screen ......................29 User Setup – Primary / Secondary ................................29 Figure 61 - User Setup – Primary / Secondary Setup Screen ....................29 User Setup –...
  • Page 7 Preventive Maintenance ....................................38 Once a Week ........................................38 Once a Month ........................................39 Once Every 6 Months ....................................39 Once a Year ........................................39 Cleaning the Operator Interface ................................... 40 General Troubleshooting ....................................41 Preventive Maintenance Checklist ................................42 Drawings..........................................

  • Page 8: 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 9: Pre-Installation

    Pre-Installation Only qualified personnel should install, start-up, and 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 10: Unit Storage

    A full refrigerant charge is included in chillers with an sudden jerking when lifting or lowering the chiller. integral water-cooled condenser. Chillers designed Use pads where abrasive surface contact may occur. for use with a remote air-cooled condenser and the Process Fluid Piping remote condensers themselves ship with a nitrogen holding charge.

  • Page 11: 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 System Temperature Sensor refrigeration pressures in the circuit.

  • Page 12: Installation - Remote Condenser

    Installation - Remote Condenser Table 1 - Condenser Clearance Requirements From From Ends Sides Chillers designed for use with a remote air-cooled Nominal Cooling Capacity (ton) (in) (in) condenser include a factory-selected remote condenser. The remote air-cooled condenser 10 to 80 single-circuit (flat coil) typically ships separately from a different location 100 single-circuit (V-coil) than the chiller.

  • Page 13: Lifting

    Figure 1 - Mounting Legs tube cutter or heat to remove the caps. When sweating copper joints it is important to evacuate all refrigerant present and flow dry nitrogen through the system. This prevents the formation of toxic gases, corrosive acids, and scale. CAUTION: Do not use soft solders.

  • Page 14: Determining Equivalent Line Length

    Figure 2 – Condenser Located at Chiller Level Follow these steps when calculating line size: 1. Start with an initial approximation of equivalent length by assuming that the equivalent length of pipe is 1.5 times the actual pipe length. 2. Determine approximate line sizes by referring to Table 3 for liquid lines, Table 4 and Table 5 for the discharge lines.
  • Page 15 Liquid lines do not typically require insulation. effect on sub-cooling. In these situations, insulate However, if exposing the lines to solar heat gain or the liquid lines. temperatures exceeding 110 °F, there is a negative Table 3 – Liquid Line Sizes for R410A 10 Ton Circuit (R410A) Liquid Line Size (Inch OD) 15 Ton Circuit (R410A) Liquid Line Size (Inch OD) Up Flow (Feet of Run)
  • Page 16 Table 3 – Liquid Line Sizes for R410A (continued) 30 Ton Circuit (R410A) Liquid Line Size (Inch OD) 40 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 17 Table 3 – Liquid Line Sizes for R410A (continued) 80 Ton Circuit (R410A) Liquid Line Size (Inch OD) 100 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 18: Discharge (Hot Gas) Line Sizing

    Discharge (Hot Gas) Line Sizing Figure 5 – Vertical Riser Traps The discharge line sizes depend on the velocity needed to obtain sufficient oil return. It is very important to minimize line length and restrictions to reduce pressure drop and maximize capacity. Upflow hot gas risers need to have a trap at the bottom and reverse trap at the top.

  • Page 19: Calculating Refrigerant And Oil Charge

    Table 5 - Upflow Discharge Line Sizes for R410A (inches OD) Total Equivalent Length (Ft) Circuit Tons A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A – 3/8 A –...

  • Page 20: Oil Charge Determination

    Installation - Electrical Table 6 – Chiller and Condenser Refrigerant Charge Total Combined Chiller and Condenser Circuit All wiring must comply with local codes and the Summertime Refrigerant Charge (Lbs. of R410A) Capacity National Electric Code. Minimum circuit amps (MCA) Single-Circuit Chiller Dual-Circuit Chiller (tons)
  • Page 21 WARNING: This equipment contains hazardous voltages that can cause severe injury or death. WARNING: This equipment contains refrigerant under pressure. Accidental release of refrigerant under pressure can cause personal injury and or property damage. WARNING: This equipment may contain fan blades or other sharp edges.

  • Page 22: Control Operation

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

  • Page 23: Home - Chiller Home Screen

    Home – Chiller Home Screen Table 7 – System Overview Functions Screen Function Description System Overview Reference This screen provides an overall synopsis of the chiller Informs the operator of the compressors in operation in each None system, quick links to other views, as well as other Demand circuit additional information.
  • Page 24 Starting and Stopping the Chiller Menu 1 - Overview Starting the Chiller Figure 11 - Menu 1 Screen contains buttons to allow navigation to various sections of the control system. This screen provides the ability to start chiller Some parameters are password protected. The main operation.
  • Page 25 Menu 1 - Alarms Warning Glycol If the Chiller Setpoint goes below 45°F, the Glycol Alarms Active Warning Screen will appear as in Figure 15. The When a critical system fault occurs, the controller amount of antifreeze will vary depending on the logs the faults to the HMI alarm handler.
  • Page 26 Menu 1 – Diagnostics Figure 19 – Diagnostics Pumps Screen Diagnostics Menu The diagnostics screens provide detailed information about the various portions of the system. Figure 16 – Diagnostics Menu Screen Figure 20 – Chiller Tank Screen Figure 17 – Diagnostics Circuit Details Screen Figure 21 –...
  • Page 27 Figure 23 – Diagnostics Import/Export Data Screen Figure 26 - Security Menu Figure 24 – Diagnostics Overview Screen Figure 27 - Security – Log In Screen Figure 25 – Diagnostics Import/Export Data Screen Figure 28 - Security – Add User Screen Menu 1 –...
  • Page 28 Figure 29 - Security – Edit User Screen Figure 31 - Security – Change Password Screen Figure 30 - Security – Delete User Screen Table 9 - Security – Users and Passwords Screen User Name Password Reference User 9999 None Supervisor 7720 None...
  • Page 29 Figure 33 - Inputs/Outputs – Temperature Inputs Figure 37 - Inputs/Outputs – Analog Outputs Screen Screen Figure 38 - Inputs/Outputs – Digital Outputs Screen Figure 34 - Inputs/Outputs – Pressure Inputs Figure 39 - Inputs/Outputs – Digital Outputs Screen Figure 35 - Inputs/Outputs – Analog Inputs Screen Note: This is an example of a chiller with an air-cooled condenser;...

  • Page 30: Menu 1 - User Setup

    Menu 1 – User Setup Figure 43 - User Setup - Menu 4 Screen 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.

  • Page 31: User Setup - Hot Gas Bypass

    User Setup – Hot Gas Bypass Table 10 – Alarm Setup Parameters Menu Item Description Default Value Figure 46 - User Setup – Hot Gas Bypass Setup High Fluid Temperature Screen This deviation determines the Supply 10.0°F Deviation warning trigger above chiller Return 50.0°F setpoint Displays the calculated setpoint...

  • Page 32: User Setup - Pump Control

    User Setup – Pump Control User Setup – EEV Control Pump Control Screen The electronic expansion valve meters the amount of refrigerant into the evaporator in the precise This screen displays pertinent pump status quantity in order to maintain superheat. The information for a system with the optional integral difference between the saturated suction pump controls and provides the ability to change...

  • Page 33: User Setup - Compressor Staging

    User Setup – Compressor Staging User Setup – Stage Order Compressor Stage Order Screen Figure 51 - User Setup – Compressor Staging Setup Screen The Compressor Stage Order Screen – Figure 52 depicts the stage order of the local chiller. The stage order calculation uses the hours entered in the auto- stage threshold parameter.

  • Page 34: User Setup - Discharge Control Setup

    User Setup – Discharge Control Setup Figure 54 - User Setup – Discharge Control Setup Screen (Remote Air Cooled) Discharge Control Setup Screen An electric condenser water-regulating valve is standard on chillers with a water-cooled condenser. The valve is a butterfly type valve with a modulating actuator and is located in the condenser water piping at the outlet of the condenser.

  • Page 35: User Setup - Dynamic Lift Setup

    User Setup – Dynamic Lift Setup User Setup – Temperature Retransmit Dynamic Lift Setup Screen Figure 57 - User Setup – Temperature Retransmit Setup Screen The Dynamic Lift control logic adjusts the chiller head pressure to improve energy efficiency. Figure 55 - User Setup – Dynamic Lift Setup Screen User Setup –...

  • Page 36: User Setup - Remote Setpoint

    User Setup – Remote Setpoint User Setup – Chiller Capacity Chiller Capacity Screen When the remote setpoint option is active, an incoming 4-20mA or 0-10VDC signal controls the This screen is necessary to adjust the nominal pipe setpoint of the master chiller. The signal will span size where the flow sensor is inserted.

  • Page 37: User Setup - Pump Down

    User Setup – Pump Down User Setup – Miscellaneous Local Mode Pump Down Screen This screen allows for adjustments to the pump The Local/Remote Mode toggle indicates if the down sequence. The default mode depends on chiller is set to use a remote contact closure for chiller configuration remote start/stop.

  • Page 38: User Setup - Chiller Tank And Water Makeup

    User Setup – Chiller Tank and Water Figure 69 - System Trending 2 Screen Makeup On integral tank systems a pressure transducer is included in order to indicate tank level. A water makeup option existed and can be configure with the following screen.

  • Page 39: Menu 2 - Full Screen

    Menu 2 – Full Screen This screen provide a simple, large-font display of the process supply temperature for users who are primarily concerned only with this data point of the system operation. Figure 72 - Menu 2 – Full Screen...

  • Page 40: Modbus

    Modbus Table 18 – Modbus Table Type Index Size Variable Name Data Type Coil HMI_START Bool Coil HMI_STOP Bool Coil SYSTEM_RUNNING Bool Coil SYSTEM_STOPPING Bool Coil PULSE_2SEC Bool Coil UNITS_TEMPERATURE Bool Coil UNITS_PRESSURE Bool Coil CKT1_COMPRESSORS_RUNNING Bool Coil CKT2_COMPRESSORS_RUNNING Bool Coil CKT1_EVAP_FLOW_SWITCH_OK Bool...
  • Page 41 Table 18 – Modbus Parameters (continued) Type Index Size Variable Name Data Type InputRegister CKT1_SUCTION_PRESSURE_HMI Real InputRegister CKT2_SUCTION_PRESSURE_HMI Real InputRegister CKT1_SUCTION_SATURATED_TEMP_HMI Real InputRegister CKT2_SUCTION_SATURATED_TEMP_HMI Real InputRegister CKT1_SUPERHEAT_HMI Real InputRegister CKT2_SUPERHEAT_HMI Real InputRegister CKT1_RFRG_DISCHARGE_TEMP_HMI Real InputRegister CKT2_RFRG_DISCHARGE_TEMP_HMI Real InputRegister CKT1_DISCHARGE_PRESSURE_HMI Real InputRegister CKT2_DISCHARGE_PRESSURE_HMI Real...

  • Page 42: Start-Up

    Start-Up Step 1 – Connect Main Power Connect main power properly ensuring it matches Every unit is factory set to deliver chilled water in the voltage shown on the nameplate of the unit. accordance with the standard operating specifications for Check the electrical phase sequence prior to start- that particular chiller.
  • Page 43 Unwanted Side Effects of Improper Water Quality Table 19 – Fill Water Chemistry Requirements Corrosion • Water Characteristic Quality Limitation Scale • Alkalinity (HCO 70-300 ppm Fouling • Aluminum (Al) Less than 0.2 ppm Biological Contamination • Ammonium (NH Less than 2 ppm Chlorides (Cl Less than 300 ppm Cooling Water Chemistry Properties...

  • Page 44: Step 3 - Check Condenser

    Step 4 – Check Refrigerant Valves Table 20 - Recommended Glycol Solutions During shipment or installation it is possibe valves Chilled Water Percent Glycol Temperature By Volume were closed. Verify that all refrigerant valves are 50°F (10°C) Not required open. 45°F (7.2°C) Step 5 –...

  • Page 45: Step 8 - Initial Unit Operation

    Step 7 – Establish Coolant Flow CAUTION: A clear sight glass alone does not mean that the system is properly charged. Also check system Establish flow through the chiller. superheat, subcooling, and unit operating pressures. If both suction and discharge pressures are low but Note: The compressor will not start as long as the flow switch is subcooling is normal, a problem other than refrigerant open.

  • Page 46: Once A Month

    2. Check and optional integral chiller and/or 11. Check the system superheat and sub-cooling. process pump discharge pressures. Investigate Normal superheat is approximately 10°F; further if the pressure starts to stray away from however, it may be high but not more than 15°F. Normal sub-cooling ranges from 10°F to 20°F.

  • Page 47: Cleaning The Operator Interface

    Cleaning the Operator Interface 20. (TSEW Models) Check the condition of the condenser water for algae, scale, and particulate Use of abrasive cleaners or solvents may damage the fouling. Rod out the tubes and back flush the window. Do not scrub or use brushes. To clean the condensers.

  • Page 48: General Troubleshooting

    General Troubleshooting Problem Possible Cause Remedy Three-phase power monitor tripped Check correct phasing of incoming power Compressor overload Check supply voltage, amperage of each leg, contactor and wiring, overload set point Compressor will not start Compressor contactor Replace if faulty PLC output card Replace if faulty Compressor failure...

  • Page 49: Preventive Maintenance Checklist

    Preventive Maintenance Checklist The following is a sample of a typical dual-circuit chiller checklist. Week Number Maintenance Activity Date Temperature Control Pump Discharge Pressure Refrigerant Suction Pressure #1 Refrigerant Suction Pressure #2 Refrigerant Discharge Pressure #1 Refrigerant Discharge Pressure #2 Refrigerant Sight Glass #1 Refrigerant Sight Glass #2 Check and clean evaporator Y-strainer...
  • Page 52 New Equipment Sales Customer Service Parts Department 5680 W. Jarvis Ave. Niles, IL 60714 • 847-966-2260 info@thermalcare.com 847-966-2260 847-966-2636 847-966-8560 847-966-9358(fax) • • www.thermalcare.com sales@thermalcare.com service@thermalcare.com tcparts@thermalcare.com April 2022 TSE IOM 11...

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