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Thermal Care Accuchiller TCFW375 Operation, Installation, And Maintenance Manual

Central chiller
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Summary of Contents for Thermal Care Accuchiller TCFW375

  • Page 3: Table Of Contents

    Table of Contents Foreword ..........................................1   Safety Guidelines ........................................1   Pre-Installation ........................................2   Receiving Inspection ....................................... 2   Equipment Storage ......................................2   Installation - Chiller ......................................2   Foundation .......................................... 2   Rigging ..........................................3   Process Fluid Piping ......................................
  • Page 4 Menu 1 – Diagnostics ......................................10   Diagnostics Menu ......................................10   Figure 10 – Diagnostics Menu 1 ................................10   Figure 11 – Diagnostics Menu 2 ................................10   Figure 12 – Diagnostics Circuit Details .............................. 10   Figure 13 – Diagnostics Circuit Turbocor ............................10  ...
  • Page 5 Figure 40 - User Setup – Compressor Staging Setup ........................16   Table 6 – Compressor Staging Setup Parameters ......................... 16   User Setup – Stage Order ....................................17   Compressor Stage Order Screen ................................17   Figure 41 - User Setup – Stage Order Setup ........................... 17  ...
  • Page 6 User Setup – Miscellaneous Current Sensors ............................20   Figure 53 - User Setup – Miscellaneous Control Setup ......................20   Compressor Demand ......................................20   Figure 54 - User Setup – Compressor Demand Setup ........................ 20   Table 9 – Compressor Demand Parameters ............................ 20  ...

  • Page 7: Foreword

    Foreword Sharp Element Warning The central chiller consists of a refrigeration circuit to provide cooling of water or coolant. Hot Surface Warning This manual is to serve as a guide for installing, operating, and maintaining the equipment. Improper Flammable Material Warning installation, operation, and maintenance can lead to poor performance and/or equipment damage.

  • Page 8: Pre-Installation

    WARNING: This equipment contains refrigerant under damaged equipment are excellent documentation pressure. Accidental release of refrigerant under for your records. pressure can cause personal injury and or property damage. Start unpacking the equipment, inspect for concealed damage, and take photos of any damage WARNING: The exposed surfaces of motors, refrigerant piping, and other fluid circuit components can be very found.

  • Page 9: Rigging

    Chiller Location stream adversely affects performance. In order to reduce maintenance costs and chiller downtime, a To ensure proper airflow and clearance space for water treatment program is highly recommended for proper operation and maintenance allow a minimum the condenser cooling water. Contact our Customer of 36 inches of clearance between the sides of the Service Department for assistance in the proper equipment and any walls or obstructions.

  • Page 10: Chiller Flow Sensor

    The temperature sensor comes from the factory with % Imbalance = (Vavg – Vx) x 100 / Vavg a ½” NPT male fitting thermowell for direct mounting in the field piping. Mount the temperature Vavg = (V1 + V2 + V3) / 3 sensor in a minimum pipe size of 3”.

  • Page 11: Compressor Control Logic

    WARNING: The exposed surfaces of motors, refrigerant compressors to run at a capacity greater than their piping, and other fluid circuit components can be very minimum loading capability. hot and can cause burns if touched with unprotected hands. The PLC controls the designation of the lead and lag CAUTION: Disconnect and lock out incoming power before installing, servicing, or maintaining the compressors.

  • Page 12: Control Operation

    Control Operation The user-level password allows access to the most common functions; however, there are a few screens The chiller 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 13: Home - Chiller Home Screen

    Home – Chiller Home Screen Table 1 – 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 14: Starting And Stopping The Chiller

    Starting and Stopping the Chiller Menu 1 - Overview Starting the Chiller Menu 1 - Figure 5 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 15: Menu 1 - Alarms

    Menu 1 - Alarms Warning Glycol If the Chiller Setpoint goes below 45°F, the Glycol Alarms Active Warning Screen will appear. The amount of When a critical system fault occurs, the controller antifreeze will vary depending on the actual desired logs the faults to the HMI alarm handler.
  • Page 16 Menu 1 – Diagnostics Figure 13 – Diagnostics Circuit Turbocor Diagnostics Menu The diagnostics screens provide detailed information about the various portions of the system. Figure 10 – Diagnostics Menu 1 Figure 14 – Diagnostics Circuit Interlock Figure 11 – Diagnostics Menu 2 Figure 15 –...
  • Page 17 Figure 17 – Diagnostics Import/Export Data Figure 19 – Security Menu Figure 20 - Security – Log In Figure 18 – Diagnostics Overview Menu 1 – Security Security Menu To add protection to sensitive areas of the control program and provide a level of supervisory control to some operating parameters, the control system includes security level protections.
  • Page 18 Figure 23 - Security – Delete User Figure 22 - Security – Edit User Figure 24 - Security – Change Password Table 2 - Security – Users and Passwords Screen User Name Password Reference User 9999 None Supervisor 7720 None Admin Contact Thermal Care None...
  • Page 19 Menu 1 – Inputs / Outputs Figure 28 - Inputs/Outputs – Analog Inputs 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.
  • Page 20 Menu 1 – User Setup Figure 35 - User Setup - Menu 4 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 21 User Setup – Alarm Setup User Setup – Hot Gas Bypass Figure 37 - User Setup - Alarm Setup Figure 38 - User Setup – Hot Gas Bypass Setup Table 4 – Hot Gas Bypass Valve Setup Parameters Table 3 – Alarm Setup Parameters Menu Item Description Default Value...
  • Page 22 User Setup – EEV Control Table 6 – Compressor Staging Setup Parameters Menu Item Description Default Value The electronic expansion valve meters the amount of In Auto Mode, the control system AUTO refrigerant in the precise quantity in order to adjusts the number of staged maintain liquid level.
  • Page 23 User Setup – Stage Order User Setup – Discharge Control Setup Compressor Stage Order Screen Discharge Control Setup Screen Figure 41 - Compressor Stage Order Screen depicts An electric condenser water-regulating valve is the stage order of the local chiller. The stage order standard.
  • Page 24 Modbus RTU Settings: Baud-57600, Data Length-8, User Setup – Units Parity-Odd, Stop Bits-1. Figure 46 - User Setup – Display Units Setup Figure 43 - User Setup – Modbus RTU Setup User Setup – Remote Setpoint User Setup – Temperature Retransmit When the remote setpoint option is active, an Figure 44 - User Setup –...
  • Page 25 User Setup – Chiller Capacity User Setup – Evaporator Valve Chiller Capacity Screen Evaporator Valve Control Screen This screen is necessary to adjust the nominal pipe This feature provides the ability to close off size that the flow sensor is inserted into. evaporator fluid flow when a circuit is not in operation.

  • Page 26: User Setup - Miscellaneous Current Sensors

    User Setup – Miscellaneous Process Compressor Demand Control Figure 54 - User Setup – Compressor Demand Setup The chiller setpoint can be controlled via process supply or process return. Default control method is configured for process supply. In some applications, it is advantageous to control via process return.

  • Page 27: Menu 1 - Trending

    Menu 1 – Trending Menu 2 – Full Screen A graphical representation of the core operating This screen provides a simple, large-font display of parameters of the system are in the trending the process supply temperature for users who are screens.

  • Page 28: Modbus

    Modbus Table 10 – Modbus Type Index Size Variable Name Data Type Coil HMI_START Bool Coil HMI_STOP Bool Coil SYSTEM_RUNNING Bool Coil SYSTEM_STOPPING Bool Coil UNITS_TEMPERATURE Bool Coil UNITS_PRESSURE Bool Coil CKT1_COMPRESSORS_RUNNING Bool Coil CKT1_EVAP_FLOW_SWITCH_OK Bool Coil AL_ALARMS_PRESENT Bool Coil AL_GENERAL_ALARMS Bool Coil...

  • Page 29: Start-Up

    Start-Up switch two line leads on the main power terminal blocks (or the unit mounted disconnect). All Every chiller is factory set to deliver chilled water in electrical components are in-phase at the factory. Do accordance with the standard operating not interchange any load leads that are from the unit specifications for that particular chiller.

  • Page 30: Step 3 - Condenser Water Temperature And Flow

    WARNING: Ethylene Glycol is flammable at higher Step 6 – Turn On Control Power temperatures in a vapor state. Carefully handle this Turn on the control power by turning the control material and keep away from open flames or other power switch to "On.”...

  • Page 31: Preventive Maintenance

    Operate the system for approximately 30 minutes. to the Troubleshooting Chart or contact our Check the liquid line sight glass. The refrigerant flow Customer Service Department. past the sight glass should be clear. Bubbles in the refrigerant indicate either low refrigerant charge or 2.

  • Page 32: Once A Year

    11. Check for signs of hot spot/discoloration on Once Every 5 years power cables. Repeat items 1 through 20 and continue with the 12. Check the DC bus voltage. following. 13. Check all communication cables are secure and 21. Replace compressor capacitor set. tight.

  • Page 33: Troubleshooting

    Troubleshooting Symptom Possible Cause Action Required Low fluid flow Check fluid flow is within design Chilled fluid temperature too low Check set point Faulty pressure sensor Check sensor Low suction Low refrigerant charge Check sub-cooling and discharge temperatures pressure Restriction in refrigerant piping Check electronic liquid level valve and filter drier Inlet guide vane (IGV) stuck open Check position and operation...

  • Page 34: Drawings

    Troubleshooting (continued) Symptom Possible Cause Action Required No motor cooling Check motor cooling solenoid valve Drive temperature Insufficient sub-cooling Check refrigerant charge too high Faulty temperature sensor Check sensor Winding temperature Faulty power bolt Check power bolt continuity too high No cooling demand signal Check temperature set points Faulty chilled water temperature sensors...
  • Page 36 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 TCFW375 IOM 01...

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