Related Manuals for Conair EC Series
Summary of Contents for Conair EC Series
- Page 1 USER GUIDE www.conairgroup.com UGH060-0620 EC Series Central Chillers Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861...
- Page 2 Thank you for purchasing Conair equipment. This manual is addressed to operators and qualified technicians to ensure correct use of this Conair equipment. IMPORTANT: THIS MANUAL MUST BE READ BEFORE INSTALLATION. KEEP THIS MANUAL IN A PLACE ACCESSIBLE FOR ALL OPERATORS.
-
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 Home - Full Screen ......................................11 Figure 6 – Full Screen Display Mode ..............................11 Menu 1 - Overview ......................................12 Figure 7 – Menu 1 Screen ..................................12 Table 7 – Menu 1 Functions ................................... 12 Menu 1 - Alarms........................................13 Alarms Active ........................................
- Page 5 Discharge Control Setup Screen ................................17 Figure 24 – Discharge Control Screen ..............................17 Figure 25 – Discharge Control Screen (TCR only) .......................... 17 Table 10 – Discharge Setup Parameters ............................17 Menu 1 – Modbus Compressor(s) ................................18 Compressor Modbus Screen ..................................18 Figure 26 –...
- Page 6 Step 5 – Check Low Temperature Alarm ............................... 24 Step 6 – Turn On Control Power ................................24 Step 7 – Establish Coolant Flow ................................24 Step 8 – Initial Unit Operation ................................... 24 Preventive Maintenance ....................................25 Once a Week ........................................25 Once a Month ........................................
-
Page 7: 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 8: 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 9: Unit Storage
Chillers with an integral water-cooled ship with a full sudden jerking when lifting or lowering the chiller. refrigerant charge. Chillers designed for use with a Use pads where abrasive surface contact may occur. remote air-cooled condenser and the remote Process Fluid Piping condensers themselves ship with a nitrogen holding charge. -
Page 10: Water Pressure Gauges
Installation - Remote Condenser Each condenser has a two-way condenser water- regulating valve. The condenser water-regulating Chillers designed for use with a remote air-cooled valve controls the amount of water allowed to pass condenser include a factory-selected remote through the condenser in order to maintain proper condenser. -
Page 11: Lifting
protection to the coil from possible damage caused reliability. All piping should conform to the by impact loading over rough roads and transit applicable local and state codes. conditions. CAUTION: Use refrigerant grade copper tubing ASTM B280 only and isolate the refrigeration lines from Lifting building structures to prevent transfer of vibration. -
Page 12: Determining Equivalent Line Length
angles connecting to the remainder of the liquid 2. Determine approximate line sizes by referring to connection piping. Table 2 for liquid lines and Table 3 for discharge 5. Position the condenser at the same elevation or lines. above the chiller. 3. -
Page 13: Discharge (Hot Gas) Line Sizing
Table 2 – Liquid Line Size/Circuit (inches OD) ambient operating charge is more (compared to the summer charge). In the worst case of -20°F, the Total Equivalent charge may nearly double. The best way to assure Length (Ft) proper charging is, on the coldest day of the year 1 3/8 1 5/8 1 5/8... -
Page 14: Installation - Electrical
Installation - Electrical WARNING: This equipment contains hazardous voltages that can cause severe injury or death. All wiring must comply with local codes and the National Electric Code. Minimum circuit amps (MCA) and other unit electrical data are on the unit WARNING: This equipment contains refrigerant under nameplate. -
Page 15: Compressor Control Logic
Compressor Control Logic running compressors. If the process heat load increases, the lag compressor will resume operation Single Circuit only once there is enough load to require both compressors to run at a capacity greater than their A single circuit chiller contains only one compressor. minimum loading capability. -
Page 16: General Control Operation
General Control Operation Home - System Overview System Initialization System Overview Upon power-up, the first screen to appear is the The System Overview Screen provides an overall Start-up Splash Screen. This screen will display while synopsis of the chiller system. It also provides quick the Programmable Logic Controller (PLC) and links to other views as well as additional useful Human-Machine Interface (HMI) establish... -
Page 17: Home - Full Screen
Home - Full Screen Table 6 – System Overview Functions Screen Function Description Reference The Full Screen (Figure 6) provides a simplified view Provides information about any of the EC Chiller. The SETPOINT and PROCESS Alarm warnings or alarms which may temperatures display in a large font easily seen from Messaging have occurred. -
Page 18: Menu 1 - Overview
Menu 1 - Overview Table 7 – Menu 1 Functions Screen Function Description Reference The Menu 1 Screen (Figure 7) provides a common A listing of all active, history, and Figure 8 location for most setting adjustments. Some Alarms frequency of system alarms. Figure 9 parameters are password protected. -
Page 19: Menu 1 - Alarms
Menu 1 - Alarms Menu 1 – Circuit Details Alarms Active Circuit Details Screen When a critical system fault occurs, the controller To access the Circuit Details Screen (Figure 10 and activates the HMI alarm handler (Figure 8). The alarm Figure 11) use Menu 1 (Figure 7) or touch the option screen will display the current faults. -
Page 20: Circuit Details Screen - Turbocor
Circuit Details Screen – Turbocor Figure 14 – Critical Interlocks Touching the Compressor button on the bottom of the Circuit Details Screen displays the Turbocor information. Figure 12 – Turbocor Screen Menu 1 – Circuit Demand Circuit Demand Screen Figure 15 – Demand Circuit Circuit Details Screen –... -
Page 21: Menu 1 - Trending
Menu 1 – Trending Figure 19 – Digital Outputs Screen The trending screen (Figure 17) displays the setpoint temperature, process temperature, demand, expansion valve, and optional hot gas bypass valve (if present) resisters for easy analysis of the system operation. Trending is always enabled and always running. -
Page 22: Menu 1 - Hot Gas Bypass
Menu 1 – Hot Gas Bypass Menu 1 – Expansion Valve Setup Hot Gas Bypass Setup Screen EXV Control Setup Screen Figure 22 – Hot Gas Bypass Screen Figure 23 – EXV Control Screen Table 8 – HGBP Setup Parameters Table 9 –... -
Page 23: Menu 1 - Discharge Control Setup
Menu 1 – Discharge Control Setup Table 10 – Discharge Setup Parameters Menu Item Description Default Value Discharge Control Setup Screen In Auto Mode, the valve adjusts to maintain optimum An electric condenser water-regulating valve is Mode Automatic performance. In manual mode, it standard on chillers with a water-cooled condenser. -
Page 24: Menu 1 - Modbus Compressor(S)
Menu 1 – Modbus Compressor(s) Menu 1 – Flow / Capacity Compressor Modbus Screen Flow/Capacity Screen The controller communicates with the compressor The graph displays trend data for the process fluid via Modbus communications. This communication is flow measured at the outlet of the evaporator on critical for compressor operation. -
Page 25: Menu 1 - Pump Control
Menu 1 – Pump Control Menu 1 – Staging Pump Control Screen Compressor Staging Setup Screen This screen displays pertinent pump status information for a system with the optional integral Figure 29 – Compressor Staging Screen pump controls and provides the ability to change mode selection. -
Page 26: Menu 1 - Stage Order
Menu 1 – Stage Order Menu 2 – Overview Compressor Staging Setup Screen Figure 31 – Menu 2 Screen Figure 30 – Compressor Stage Order Screen Table 15 – Menu 2 Functions Screen Function Description Reference Table 14 – Compressor Staging Local Parameters Provides the ability to restore the Figure 32 Menu Item... -
Page 27: Menu 2 - Defaults
Menu 2 – Defaults Menu 2 – Remote Mode CAUTION: The Defaults screen provides the ability to The Remote Mode toggle indicates if the chiller is restore the control system back to factory defaults in set to use a remote contact closure for remote the case that an unknown setting modification start/stop. -
Page 28: 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 Check the electrical phase sequence prior to start- specifications for that particular chiller. - Page 29 To avoid the unwanted side effects associated with Table 16 – Fill Water Chemistry Requirements water cooling, proper chemical treatment and Water Characteristic Quality Limitation preventive maintenance is required for continuous Alkalinity (HCO3-) 70-300 ppm Aluminum (Al) Less than 0.2 ppm plant productivity.
-
Page 30: Step 3 - Check Condenser
Step 3 - Check Condenser Step 6 – Turn On Control Power There are two possible types of condensers present Turn on the control power by turning the control in the chiller: water-cooled and remote air-cooled. It power switch to "On.” The panel should be on. Due is important to verify the chiller will have adequate to extreme ambient temperatures during shipment condenser cooling for proper chiller operation. -
Page 31: Preventive Maintenance
cooling is not within this range, check the superheat problem, have the unit serviced as soon as and adjust if required. The superheat should be possible. approximately 10°F. If the operating pressures, sight glass, superheat, and subcooling readings indicate a 4. -
Page 32: Once A Year
Maintenance 13. Check for signs of hot spot/discoloration on Cleaning the Operator Interface power cables. Use of abrasive cleaners or solvents may damage the 14. Check the DC bus voltage. window. Do not scrub or use brushes. To clean the display window: 15. -
Page 33: Troubleshooting
Troubleshooting Symptom Possible Cause Action Required Low water flow Check fluid flow is within design, clean Y-strainer Chilled water 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 expansion valve and filter drier... -
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 35: We're Here To Help
We’re Here to Help Conair has made the largest investment in customer support in the plastics industry. Our service experts are available to help with any problem you might have installing and operating your equipment. Your Conair sales representative also can help analyze the nature of your problem, assuring that it did not result from misapplication or improper use. -
Page 36: Equipment Guarantee
Goods Authorization Number (RGA) will be issued by Conair’s Service Department. Returned equipment must be well crated and in proper operating condition, including all parts. Returns must be prepaid. Purchaser must notify Conair in writing of any claim and provide a customer receipt and other evidence that a claim is being made.
Need help?
Do you have a question about the EC Series and is the answer not in the manual?
Questions and answers