MOTIVAIR MLC-SC-FC 0200 Installation, Operation And Maintenance Manual

Air cooled chillers

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MODELS: MLC-SC-FC 0200 – MLC-SC-FC 1100

INSTALLATION, OPERATION, AND MAINTENANCE

This chiller has been factory run tested to the specified

*****DO NOT OVER PRESSURIZE CHILLER WHEN LEAK

CHECKING PIPING OR FILLING HYDRAULIC SYSTEM*****

*Isolate chiller from piping if higher test pressure is

*Chiller damaged caused by over pressurization is NOT

85 Woodridge Dr. Amherst, NY 14228 – Phone# 716-691-9222 – Fax# 716-691-9229

www.motivaircorp.com

MOTIVAIR COOLING SOLUTIONS

AIR COOLED CHILLERS

MANUAL

water pressure

required for leak checking*

covered by warranty*

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Summary of Contents for MOTIVAIR MLC-SC-FC 0200

Page 1 MOTIVAIR COOLING SOLUTIONS AIR COOLED CHILLERS MODELS: MLC-SC-FC 0200 – MLC-SC-FC 1100 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL This chiller has been factory run tested to the specified water pressure *****DO NOT OVER PRESSURIZE CHILLER WHEN LEAK CHECKING PIPING OR FILLING HYDRAULIC SYSTEM*****...
Page 2: Safety Instructions
LEGAL PROVISIONS & SAFETY INSTRUCTIONS WARNING Operation of these systems involves potentially Iethal dangers (high voltage and high pressures). Therefore, all safety precautions and warnings described in this manual must be precisely observed. Otherwise, severe or fatal injury may be caused. Operator's Responsibility This chiller MUST be installed, maintained and operated by a person(s) qualified for this equipment.
Page 3: Transport And Handling
TRANSPORT AND HANDLING LIFTING - UNLOADING – POSITIONING MANUFACTURER'S NOTE Notices (symbols) –on device packing must be The machine may be damaged by: observed. Dropping or tipping it on the ground. Check the center of gravity of the chiller. Pulling the chiller by cords, straps, etc. Use appropriate unloading equipment.
Page 4 LIFTING - UNLOADING – POSITIONING MANUFACTURER'S NOTE Notices (symbols) –on device packing must be The machine may be damaged by: observed. Dropping it or tipping it on the ground. Check the center of gravity of the chiller. Pulling the chiller by cords, straps etc…. Use appropriate unloading equipment.
Page 5: Chiller Installation
May be transmitted through the chilled water piping. This can be avoided by Vibrations the use of flexible piping connections. Must be maintained for servicing and ventilation purposes. All removable Clearances side panels must be available service. *See CLEARANCE REQUIREMENTS section under MOTIVAIR INSTALLATION ENGINEERING BULLETIN...
Page 6: Service Access
Motivair Installation Engineering Bulletin Service Access: Compressors, filter-driers, and manual liquid line shutoff valves are accessible on the front end and both sides of the chiller. Each compressor (two) has its own contactors and overloads mounted in the control box located in the front of the chiller. The main control box contains the chiller PLC (Programmable Logic Controller).
Page 7: Clearance Requirements
See the following pages if the airflow clearance cannot be met. Restricted Airflow General The clearances required for design operation of MLC/MLC-FC air-cooled condensers are described in the previous section. Occasionally, these clearances cannot be maintained due to Motivair Installation Guide Page 2...
Page 8 The Motivair MLC/MLC-FC chillers have several features that can mitigate the problems attributable to restricted airflow.  The “W” shape of the condenser section allows inlet air for these coils to come in from both sides and the bottom.
Page 9: Case 1, Building Or Wall On One Side Of One Unit
It is also desirable to have prevailing winds blowing parallel to the unit’s long axis. The worst scenario is having wind blowing hot discharge air into the wall. Figure 3 Figure 4, Adjustment Factor Motivair Installation Guide Page 4...
Page 10: Case 2, Two Units Side By Side
See “Clearance” section of this guide for requirements for specific units. Pit or solid wall surrounds should not be used where the ambient air temperature exceeds 105°F. Figure 5, Two Chillers Side by Side Figure 6, Adjustment Factor Motivair Installation Guide Page 5...
Page 11: Case 3, Three Or More Units Side By Side
Case 2. All inside units (only chiller 2 in this case) are influenced on both sides and must be adjusted by the factors shown below. Figure 7, Three or more Chillers Chiller 1 Chiller 2 Chiller 3 Figure 8, Adjustment Factor Motivair Installation Guide Page 6...
Page 12: Case 4, Open Screening Walls
If each side wall is a different distance from the unit, the distances can be averaged, providing either wall is not less than 8 feet from the unit. For example, do not average 4 feet and 20 feet to equal 12 feet. Figure 9, Open Screening Walls Figure 10 Motivair Installation Guide Page 7...
Page 13: Case 5, Pit/Solid Wall Installation
Have any pit installation reviewed by Motivair application engineers prior to installation to discuss whether it has sufficient airflow characteristics. The installation design engineer must approve the work and is responsible for design criteria.
Page 14 System Volume Requirements: Customer is responsible for insuring there is an adequate amount of system volume. Motivair requires 3 to 5 times the amount of flow through the chiller at a minimum. (Example: 5 min X 292 GPM At design conditions = 1,460 Gallons.)
Page 15 PIPING INSTALLATION/RECOMMENDATIONS This section is intended as a guide for the correct installation of the chilled water piping system, including this chiller. However, the chiller manufacturer accepts no responsibility what so ever for the installation of the chiller or the associated piping. All piping must be installed only by a licensed plumbing contractor, and in compliance with local codes.
Page 16: Expansion Tank
AUTOMATIC WATER MAKE-UP If the chilled water cooling system is expected to lose water during normal operation an automatic water make-up system should be installed, or can be supplied as a factory option. The auto make-up system must include a water pressure regulator and pressure gauge. CAUTION: The tank inside the chiller has a maximum pressure rating of 45PSIG.
Page 17 POSITIVE PRESSURIZATION OF THE SYSTEM There are (2) reasons for positive pressure in a closed loop, pump piping system: 1. Prevention of air being drawn into the system at vent locations close to the chiller, caused by the pump drawing a vacuum in the return line. 2.
Page 18 WATER/GLYCOL FILLING If glycol is required for antifreeze protection, ALWAYS use an industrial inhibited ethylene glycol, or propylene (food grade) glycol. DO NOT use automobile antifreeze. Suitable glycols are manufactured by the Dow Chemical Company for this purpose, and available nationwide. There are other glycol suppliers available, but always exercise great caution in the selection of a glycol supplier, and always confirm the freeze protection after installation, using a spectrometer.
Page 20 WATER/GLYCOL INSTRUCTIONS MANUFACTURER'S SPECIFICATIONS COLD WATER PIPING CONT. The chiller circuit must be 100% filled with water/glycol for operation. If the cooling process Ensure that the water circuit is maintained at the causes a loss of water/glycol in the circuit a correct pressure by installing an appropriate sized automatic water make-up vavle must be installed.
Page 21 MAIN ELECTRICAL INSTALLATION WIRING DIAGRAM INSPECTION The manufacturer of the supplied chiller accepts NO LIABILITY Check that the wiring diagram supplied with the for the work supplied by the customer or civil chiller is correct and complete: engineering contractor. MODEL INFORMATION: MAIN ELECTRICAL CONNECTION REFER TO DATA ON SERIAL STICKER FOR EACH MODEL...
Page 22 Description of Free-Cooling Free-cooling control exploits the temperature of the outside air to provide free-cooling of the chiller water. This function uses a heat exchanger, through which a special valve diverts the return chilled water from the system. The favorable outside air temperature cools the water prior to its return, and the operation of the compressor is therefore delayed.
Page 23 Set-point plan for Compressors 50.0°F Compressor ON 100% Compressors OFF water in. Temp. PROP. BAND = 7.2°F SUMMER SET POINT SET+PROP.BAND =46.4°F 53.6°F Proportional band is divided in 8 equal parts to activate 8 step when inlet water temperature increases (so, when the required power increases). Set-point plan for Free-Cooling When there are free cooling conditions, the regulation of free cooling occurs at water outlet.
Page 24 Valve and Fan Modulation “Min. inverter speed threshold for free cooling” = 25% of free cooling band (=41.18+1.26°F) = 42.44°F water out Temp. FANS: MAX. SPEED VALVE: 100% Free Cooling FANS: MIN SPEED VALVE: 0% Free Cooling Free cooling band = 5.04°F “Max.
Page 25 Other NOTES on Free-Cooling with Carel Controller: With electronic control there are 4 temperature probes: 3 ways valve inlet; evaporator inlet (outlet free cooling coil) evaporator outlet (anti freeze) external air (suction side of free cooling coil) 3 way valves can be choosen or modulating kind (0-100% of opening) or ON-OFF (all open or all closed in free cooling).
Page 26 SEQUENCE OF OPERATION: Free-Cooling Chillers Mechanical cooling – inlet control On a call for cooling set point = 50*F + diff = 7*F entering temperature = 57*F glycol pump running flow switch closed the first stage compressor(s) start. (NOTE: A STAGE COULD = 2 COMPRESSORS BASED ON CHILLER SIZE) The control reads the Inlet temperature if the temperature is within SP + ½...
Page 27: Main Functions
PLC CONTROL SYSTEM A PLC controls all unit functions and allows any adjustments to be made. By means of the microprocessor the set-point values and functioning parameters can be entered directly. This type of PLC can control up to four compressors. It is equipped with an acoustic and visual alarm, push buttons for the various functions, continuous control of the system and a data saving system in the case of a power cut.
Page 28: General Features
VERSIONS WITH TANKS AND PUMPS GENERAL FEATURES MLC-FC, MLC-SC-FC, and MPC-FC Version with tank The version has an integrated tank. Completely insulated, with the relevant connections for water inlet and outlet. The tank is fitted with a drain for water and there is also the possibility of installing a heating element (4000 BTU/h) as accessory.
Page 29 Motivair MLC-SC-FC BMS points list 3.7v BMS ModBus ModBus Type Direction Description Address Register TCP/IP Condenser Inlet Temperature (Water-cooled units Only) 40001 40001 Condenser Outlet Temperature Water-cooled units Only) 40002 40002 Outside Temperature (F.C. Only) 40003 40003 Water Inlet Temperature 40004 40004 Water Outlet Temperature 40005 40005 Freecooling Temperature 40006 40006 High Pressure Circuit 1 40007 40007 High Pressure Circuit 2 40008 40008 Freecooling Valve 40009 40009 Cooling Set Point...
Page 30 Unit ON‐OFF 10002 10002 Compressor 1 Status 10011 10011 Compressor 2 Status 10012 10012 Liquid Solenoid Valve Circuit 1 10013 10013 Compressor 3 Status 10014 10014 Compressor 4 Status 10015 10015 Liquid Solenoid Valve Circuit 2 10016 10016 Main Pump Status 10017 10017 General Alarm 10018 10018 Condenser Fan Status 10019 10019 Freecooling Valve Status 10020 10020 Antifreeze Heater Status 10021 10021 ON ‐ OFF From Supervisor 10043 10043 Reset the alarms 10058 10058 Unit 1 Online...
Page 31 MLC-SC-FC pCo Point List ANALOGUE VARIABLES DIGITAL VARIABLES OBJECT DESCRIPTION OBJECT DESCRIPTION A001 Condenser Inlet Temperature (MPCW Only) D001 Unit ON-OFF A002 Condenser Outlet Temperature (MPCW Only) D010 Compressor 1 Status A003 Outside Temperature (F.C. Only) D011 Compressor 2 Status A004 Water Inlet Temperature D012...
Page 32 Standard modular Chiller HP 1 / 8 compressors with CAREL driver Chiller unit with freecooling, configuration “1” AIR/WATER units with maximum 8 tandem hermetic compressors. DIGITAL INPUTS MEDIUM MEDIUM MEDIUM Master (address 1) Slave (address 2) Master (address 1) Slave (address 2) Master (address 1) Slave (address 2) ID 1...
Page 33 pCO Controller Instructions: MLC-SC-FC Chiller Rev.0...
Page 34 1. START-UP Before starting this type of unit, ensure that all personnel involved have read and understood the “SAFETY” chapter in this manual 1.Check that the unit shut-off valves are open. 2.With a “closed” type hydraulic circuit ensure that a suitably sized expansion vessel has been installed. 3.Check that the ambient temperature is within the range indicated on the unit's data plate.
Page 35: Regulation And Control
2 REGULATION AND CONTROL 2.1The pCO terminal buttons Function Press once to poll the pCO for active alarms.Once the alarm cause has been removed, press the button again to reset the indication. Press once to enter the DIRECT menu loop. Used to return from the various menu loops to the main display mask.
Page 36 low evaporation pressure alarm;freeze alarm on water at evaporator outlet; compressor fault alarm, and pump (if present); alarm for insufficient water flow through the evaporator; water inlet and outlet high temperature alarm; operating hours count of chiller and individual compressors with signal when the programmed maintenance hours are exceeded; alarm device for minimum/maximum voltage, incorrect phase sequence and phase imbalance beyond the permissible limit.
Page 37 k-CLOCK MENU Press to scroll the clock Press to return in MENU LIST Info p-USER MENU Press to insert the user password Press to confirm the user password Press to set the user password p –Termoregolation Press to scroll the user x –freecooling (not used) Menu list q-defrost (not used)
Page 38 c-MANUFACTORY MENU Press to insert the manufactorer Press to confirm the user password manufactorer password Press to set the manufactorer password c –Configuration g -parameter f-EXV drivers (not used) t-timing Press to scroll the v-Default value manufactorer Menu list Press to enter in MENU Press to scroll the...
Page 39 2.5.1 How to change the set-point s-SETPOINT MENU Press to enter in setpoint changing mode Press to change the setpoint Press to increase or decrease setpoint Press to return in MENU LIST Press to confirm new setpoint...
Page 40 2.6. Types of controlled compressors Inlet temperature control The temperature control depends on the values measured by the temperature probe located at the evaporator inlet, and follows proportional logic. Depending on the total number of compressors configured and the number of load steps per compressor, the control band set will be divided into a number of steps of the same amplitude.
Page 41 2.8 Antifreeze control Each pCO unit can manage the antifreeze control function, as long as the evaporator water outlet temperature probe is connected and enabled. Antifreeze control is always active, even when the unit is off, in cooling and heating operation. The antifreeze alarm is a system alarm, and consequently in multi-board systems, when activated on any unit causes the total shutdown of the unit.
Page 42: Alarm Table
ALARM TABLE AL001 Serious Alarm from Digital Input AL002 Antifreeze Alarm AL003 Evaporator Pump Thermal Overload AL004 Condenser Pump Thermal Overload AL005 Evaporator Flow Switch AL006 Condenser Flow Switch AL007 Main Fan Thermal Overload AL008 Evaporator Pump 2 Thermal Overload AL010 Low Pressure Switch Circuit 1 AL011...
Page 43: Alarm Menu
2.10 Alarm signals 2.10.1 Alarms display During operation of the unit alarm conditions may occur which, depending on the hazard level, are managed by the pCO by means of a simple warning signal or with the partial or complete shut down of the unit.When an alarm is signalled, the message “OFF BY ALARM” appears on the pCO display and the red LED of button illuminates.
Page 44 2.10.2 Alarm masks Ref. Mask Reset Control action Input Notes AL00 No active alarm masks. Master It 'been pressed the emergency button AL01 Manual Unit complete stop or RVG alarm The water outlet temperature is equal to AL002 Manual Compressors stop Master or lower than the alarm threshold.
Page 45 Ref. Mask Reset Control action Input Notes Master AL017 Manual Compressor 2 stop Compressor overload. Master AL018 Manual Compressor 3 stop Compressor overload. Master AL019 Manual Compressor 4 stop Compressor overload. ID10 The pressure value is equal to or higher AL23 Manual Compressor stop...
Page 46 The probe measures an off range value: AL037 Manual warning Master may be damaged, disconnected or short- circuited.
Page 47: Preventative Maintenance
PREVENTATIVE MAINTENANCE MAINTENANCE Before carrying out any maintenance work, the service technician must be made thoroughly familiar with the following safety precautions and provisions. WARNING GENERAL Avoid any skin contact with gas or refrigerating oiIs. SAFETY PRECAUTIONS Severe bums may be caused. Always wear rubber WARNING gloves when handling dirty parts.
Page 48 PREVENTATIVE MAINTENANCE [Continued...Pg. 2] Servicing tasks required every 6 months Maintenance Intervals 1. Repeat the 3-month service Note: The maintenance intervals specified here 2. Preventive maintenance – additional are based on experience. Depending on individual  conditions at any job site, required maintenance Check superheat and subcooling ...
Page 49: Important Note
PREVENTATIVE MAINTENANCE [Continued...Pg. 3] IMPORTANT NOTE WARNING - RISK OF INJURY The maintenance operations are described below. Risk of cuts due to the condenser fins. Wear gloves if All operations must be performed step by step and working on the condenser. must be completely finished.
Page 50 At shutdown the oil level can fall to the lower limit of the a system failure occurs due to improper maintenance during the warranty period, MOTIVAIR shall not be liable for costs incurred oil sight glass. to return the unit to satisfactory condition.
Page 51 Normally a ‘minor’ service should be carried out every three to six months and a ‘major’ service once a year. It is recommended that MOTIVAIR Service Center is contacted for recommendations for individual sites.
Page 52: Maintenance And Repair
MAINTENANCE AND REPAIR 2. Connect refrigerant pressure gauges to the service FAILURE OF A COMPRESSOR ports. 3. Close the service valves by tuming them clockwise. Occasionally, a fault in the motor insulation can cause Reclaim the refrigerant pressure from the the motor to burn out.
Page 53 MAINTENANCE AND REPAIR [Continued...Pg. 2] WARNING! Compressor replacement after burn-out lf the replacement compressor is damaged due to [Continued...] inadequate system cleaning, warranty will be voided. 4. Check the connection line of the compressor for charred or damaged connectors, insulation and short-circuited or grounded.
Page 54: Refrigerant Information
REFRIGERANT INFORMATION CHLORINE - FREE REFRIGERANTS The use of polyester oils ("POE"s) is necessary for The compressors designed for operation with chlorine- operation with chlorine-free refrigerants. free refrigerants are factory-filled with ester oils approved by the compressor manufacturer and are Compared to mineral oils POEs have high hygroscopicity marked accordingly.
Page 55: Troubleshooting
Trouble Shooting On the next pages you will find a list of the most common causes that may cause the chilling unit to fail or malfunction. These causes are broken down according to easily identifiable symptoms. Be especially careful during the operations suggested for the solution of the various problems: overconfidence can result in injuries, even serious ones, to inexpert individuals.
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Page 59 COMMISIONING AND STARTUP INSTRUCTIONS COMMISSIONING ALWAYS OBEY SAFETY INSTRUCTIONS WARNING - HIGH VOLTAGE Check the water connections RISK OF FATAL INJURY 1. Check the supply and retum connection Open the main fuse before reconnecting 2. If glycol solution: Preparations at the switch cabinet Take a water sample to check the freeze protection 1.
Page 60: Maintenance Intervals
Correct handover by the qualified company to the MAINTENANCE INTERVALS operator or operator's personnel is a basic The Iist beIow contains recommendations based on precondition for operation of the refrigeration practical experience. system. These recommendations must be adapted to the actual operating time of the chiller system, e.g.
Page 61 Cooling Solutions 85 Woodridge Drive, Amherst New York 14228 Phone: (716) 691‐9222 Fax: (716) 691‐9229 CHILLER PRE‐STARTUP CHECK LIST CUSTOMER: JOB NAME: ADDRESSS: LOCATION: PHONE: ORDER NO: ...
Page 62: Terms And Conditions Of Sale
7) Buyer must obtain written permission from Seller, prior to returning any equipment for warranty, credit, or any other reason whatsoever. The terms of any warranty returns or associated credits are in strict accordance with the above referenced Motivair Standard Product Warranty. All goods returned for reasons other than warranty shall be subject to a re-stocking charge of no less than 15%, not to exceed the full invoiced value of the equipment, to be determined at the sole discretion of the Seller.

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Mlc-sc-fc 1100