Bulletin 30-32-2011-01_ Chiller Installation Manual
Transcript of Bulletin 30-32-2011-01_ Chiller Installation Manual
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CustomerService
IfyouhavequestionsaboutInstallation,operationandMaintenanceoftheUnichillerorwouldliketoorder
replacementpartspleaseusethefollowingcontactinformation.
CustomerServiceandTechnicalSupport (7A.M.to5P.M.CentralTime)
Phone:80052708963144819000
Fax:3144579000
WebSite
Visitwww.unicosystem.comtofindinformationaboutUnicoProducts
2009Unico
Inc.
All
rights
reserved
Thisdocumentissubjecttochangewithoutnotice
7401AlabamaAve.,SaintLouis,MO631113144819000
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Contents
GeneralInstructions 1
PlacementoftheUnichiller 2
Location 2
Clearances 2
RoofRunoff 2
EquipmentPad 2
LawnIrrigation 2
InstallationsNearSaltWater 3
Electrical 3
Piping 3
ChillerPumpCharacteristics 3
EffectOfWaterTemperatureOnPressureDrop 5
UseofPropyleneorEthyleneGlycol 5
Installation 6
ConnectingChillertoWaterCircuit 6
ChillerPumpCharacteristics 6
Electrical 6
WaterSide
Only
Start
up
6
DigitalTemperatureController(DTC) 7
ProgrammingtheDTC 7
DTCTroubleShootingandErrorMessages 8
FullSystemStartup 9
ChillerMaintenance 10
TroubleshootingGuide 11
ChillerWiringDiagrams 12
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GeneralInstructions
TheUnichillerismanufacturedtomeetUSandEuropeanelectricalrequirements.
Installationandservicemustbeperformedbyqualifiedinstallerorserviceagency,andmustconformtoallnational,
state,andlocalcodesofthecountrywhereitistobeoperated.
UnichillershaveselfcontainedfactorychargedandtestedrefrigerationsystemscontainingeitherR22or
R407Crefrigerants.Thetypeofrefrigerantandquantityislistedonthefactoryinformationlabellocatedon
thebackpanel.Itisnotnecessarytoaccesstherefrigerationsystemforsysteminstallationandstartup.
AllUnichillersaretestedthroughafullcoolingandheatingcyclepriortoshipmentfromthefactory.
Beforeoperating,besuretheunitisproperlygroundedtopreventinjuryordeath
fromelectricalshock!
Disconnect electrical supplybeforewiring unit toprevent injuryordeath from
electricalshock!
Do not handle the top half of the scroll compressor as it operates at a
temperaturehighenoughtocauseseriousinjury.Operationofthechillerwithout
properfreezeprotectionshallvoidthewarranty.
Donotoperate this system for longperiodsof timewithwateralone.Aminimumof10%
propyleneorethyleneglycol isessentialtopreventfreezing.Higherconcentrationsofglyco
arerequiredtopreventheatexchangerfromrupturingincoldclimates.
Recommendedoperating temperaturesare115F forhotwaterand40F forchilledwater
Contact Customer Service if you wish to operate at water temperatures outside of the
recommendedrange.
Donotuseanyliquidsolutionotherthanthesolutionofwaterandpropyleneorethyleneglycolinthepiping
system.ThesolutionmustbemixedinaccordancewiththeguidelinesintheUnichillerDesignManual.
Pumpmustbeprimed(freeofairandsuctionpipefullof liquid)beforestarting. Ifpump isrundry,rotating
partswillseizeandmechanicalsealwillbedamaged.
All electrical wiring should be inaccordance with all local codes and regulations. A field provided electrica
disconnectshallbeinstalled.Theunitsaresafetycertifiedtosafetycodesofthecountrytheyaresoldin(refer
toUnichillerSpecificationsBulletinforfurtherdetails).
Allpipingmustbeinaccordancewithalllocalcodesandordinances.
Installationshouldbeinaccordancewithalllocalcodesandregulations.
TheseunitsaredesignedtooperatewithR22orR407Cinaselfcontained,precharged
refrigerantsystem.Donotaccesstheclosedrefrigerantsystemforanyreasonotherthan
aftersale,afterinstallationcomponentreplacement.Suchserviceistobeconductedby
qualifiedpersonnelonly.
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PlacementoftheUnichiller
Location
Alwayslocatethechilleroutdoors.Neverinstallinsidearoom.
Installingthe
unit
in
apit
will
reduce
performance
Locatechillersothatgroundwaterwillnotentercabinet.
Inareaswithheavysnowfallitisrecommendedthattheunitbeelevated.
Donotattachductworktothechiller.IfairdeflectorsarenecessarycontactUnicoCustomerService
forinstructions.
Clearances
Thechillermust beplacedtoprovideclearancesonallsidesformaintenanceandinspection.
1. Atleast24mustbeavailableonthesideofthechillerthataccessesthecontrolbox,pumpand
compressor.SeeFigure1.
2. Allowatleast60onthefanside.
3. Theremainingtwosidesshouldhaveaminimumclearanceof12
RoofRunoff
TheUnichillershouldnotbelocatedwherelargeamountsofwatermayrunofffromaroofontoorintothe
unit.Best
practices
dictate
that
the
chiller
be
protected
from
large
amounts
of
run
off.
EquipmentPad
Placethechilleronaflatsolidsurfacesuchasaconcreteorfabricatedslab.Theslabshouldbeslightlytiltedso
thatcondensationfromthechillerwillrunofftheslabandnotpoolaroundthechiller.
LawnIrrigation
Makesurethatthereareabsolutelynosprinklerheadsnearenoughtothechillerthatwillspraywaterdirectly
onorintotheunit.Keepinmindthatprevailingwindsmaycarrymistfromsprinklersintothechillercausing
damagetoelectricalconnectionsandmechanicalparts.
Figure 1: Unichiller Clearances
12 inches(0.3 m)
6 inches (0.15 m) minimum or24 inches (0.6 m) for service
60 inches(1.5 m)
service accessside
air discharge
air inlet
air inlet
12 inches(0.3 m)
12 inches max(0.3 m)
shrubs or porous wall
Maximum height of wallis 4.5 ft (1.4 m)
Overhang
TOP VIEW
FRONT VIEW
24 inches(0.6 m)
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InstallationsNearSaltWater
Wheninstallingthechillerincoastalareasnearsaltwateritisbesttoinstallthechillersothatthebuildingis
betweentheshoreandtheunit.Toimprovethelifetimeitisbesttorequestatechnicoatcondensercoil.
Electrical
AllelectricalconnectionssuppliedtothechillermustmeetNationalandlocalcodes.
Checkforproperlinevoltageforthechillerandblowermodulesifused.Lowlinevoltagesmayrequirethe
useofasoftstartupgrade.CheckwithCustomerServicetodeterminewhetherornotasoftstartupgradewill
benecessary.
Piping
Makesureallpipesizingconformstoflowrequirements.
Recommendedchillerpipingconnectionsis1minimum.
Airinthepipingsystemcandamagethepumpseals.Makesurethatinthecaseofanonsealedwaterstorage
systemthatairseparatorsorairventsareplacedininletsideofthepipingsystem.
ChillerPumpCharacteristics
Thechillercanbeorderedwithorwithoutaninternalwaterpump.Wheninstallingthechillertotheexisting
watercircuititmaybenecessarytotroubleshootthewatercircuit.Figure2outlinesimportantdataregarding
chillercharacteristicswithandwithoutthepumptoaidinthetroubleshootingprocess.
0 5 10 15 20 25
0
5
10
15
20
25
30
35
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4
0
25
50
75
100
125
150
175
200
225
0
10
20
30
40
50
60
70
80 PumpCurve
ExternalStaticPressure(UniChillerwithpump)
InternalPressureDrop(UniChillerwithoutpump)
0601.UCH(R)06041,22.UCH(R)06043
3.UCH(R)06046,7,8
4.UCH(R)03641,2
5.UCH(R)03643
6.UCH(R)03646,7,8
R0843:Catalog4
6/3/2009
PressureDifference
Water Flow Rate
GPM
UniChiller models UCHR
PSI
16 2345
036
1/60/230V
1/60/264V
1/50/260V
L/s
GPM
kPa
ft.water
Figure2. Waterflowandpressuredifferentialsforvariouschillermodels.
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EffectofWaterTemperatureonPressureDropThetemperatureofthewatercanaffectthepressuredroponthechillersystemTable2liststhecoefficients
usedtocalculatepressuredropduetotemperature.
Table2.PressureDropCorrectionFactorBasedonTemperature(forwater)
TemperatureF 32 40 50 60 68 90 100 110 120 130
C (0) (4.4) (10) (15.6) (20) (32.2) (37.8) (43.3) (48.9) (54.4)
Factor
1.16
1.12
1.05 1.03 1.00 0.93 0.91 0.89
0.86
0.84
UseofPropyleneorEthyleneGlycolTheChillercanreachwatertemperatureswellbelowfreezing.Thereforeitisrecommendedthatthewater
systembechargedwithaminimum10%glycolsolution.Higherpercentagesofglycolwillbenecessarywhen
thechillerisoperatedinregionsofthecountrywhereoutdoortemperaturesfallbelowfreezing. Table3gives
therecommendedglycolpercentagesdependingontheexpectedlowtemperaturesfortheregion.
Table3. Percentageofpropyleneglycolsolutionnecessarytoprotectchillersystemincoldweather.
%PropyleneGlycol 10% 20% 30% 40% 50%
Minimum
Ambient
Temperature
F 26 18 8 7 29
C 3.3 7.8 12.8 21.7 33.9
Thepercentageofpropyleneglycolcanaffectthepressuredroponthesystem.Table4liststhecorrection
factorsrecommendtocalculatepressuredropbasedonthepercentageofglycolinthesystem.
Table4. PressureDropCorrectionFactorBasedonPercentageofGlycol
%Glycol
0
10
20
30
40
50
PropyleneGlycol 1.00 1.10 1.20 1.34 1.50 1.65
EthyleneGlycol 1.00 1.00 1.06 1.16 1.25 1.36
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ChillerInstallationConnectingthechillertoinstalledplumbingMakesureallpipesizingconformstoflowrequirements.
1. ChillerPipingconnections:
a. Supply1NPT
b. Return11/4NPT
2. Unitswithoutpumpsareprovidedwithaflowmeter.
3. Whenattaching
piping
to
chiller
double
wrench
to
prevent
damage
to
chiller.
4. Installstrainer(suppliedtochiller)intoreturnline.
5. Installfullportisolationvalvesinsupplyandreturnpiping.
6. Onmultiplechillerinstallations,installacheckvalveinsupplylinesofeachchiller.
7. Installallpipingvalvesflowregulators,pumpsandstoragetankspersystemdesign.
8. Locateallventsathighpointsofpipingsystemforeasyventing.
9. Makeaccommodationsforfillingsystemandaddingglycoltosystem10%glycolminimumrequired.
ElectricalInstallation
1. Installlinevoltagewiringincludingmanualdisconnectatunitperlocalcode.
2. Seewiringdiagramonunitorindocumentationpacketforspecificconnectioninformation.
3.
Install
low
voltage
control
wiring
per
code.
See
wiring
diagram
on
unit
or
in
documentation
packet
forspecificinformation.
Therearemanypossiblecontrolwiringvariations.Consultwiringdiagramsinbackofbulletinformost
commonhookups.AdditionalwiringinformationcanbeobtainedbycallingUnicocustomerserviceat
18005270896.
WaterSideOnlyStartUp
1. RemoveServiceaccesspanelfromchiller.Removechillertoppanel.
2. DisconnectorangeJumperfromterminalS1toS1ontheprintedcircuitcontrolboard.Thiswilldisable
thecompressorcontrolcircuit.
3. Fillsystemwithwateronly.Donotuseaglycolsolution.Youmayneedtodrainthesystemtorepair
leakswhichwouldmeanhavingtorecovertheglycol.
4. Checkforleaks.
5. TurnchillerpumponusingtheON/AUTOswitchonthecontrolboard.
6. Bleedairoutofthesystemandadjustflowrates.Usethechartsbelowtosetflowratebymeasuring
pumpcurrentdraw.Designflowratefor3Tonchillersis7.2gpmand
5Tonchillersare12.0gpm.Ifthereisnoflowmeterinthehydronicsystemflowratecanbe
determinedbythecurrentdrawonthepump.Refertotablexforampdrawonvariouschillemodels
attherecommendedflowrates.
7. Checksecondarypumpoperationandflowratesifapplicable.
8. Checkforleaks.
9. Itis
recommended
that
system
be
leak
tight
prior
to
starting
full
operation.
10.Oncewatersystemisfreeofleaksthesystemshouldbedrainedandthewaterreplacedwitha
minimum10%glycolmixture.Table3liststhepercentageofpropyleneglycolsolutionrecommended
basedonminimumambienttemperaturesexpectedintheareatheunitisinstalled.Unico
recommendsthoroughlymixingthepropyleneglycolwithwaterbeforeaddingtothesystem.
11.Insulatepipingtolimitheatlossandsweating
12.Restartsystemandventair.
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DigitalTemperatureController(DTC)
Programming the DTC
1. PressSet keytoenterprogrammode.
2. AnnunciatorwilldisplayeitheranFforFahrenheitoraCforCelsius. Usetheupordownarrow
keystotogglebetweenthetwoselections.PressSetwhenthedesiredtemperaturescale hasbeen
selected.PressSetkeyto inputthescaleandmovetothenextsetting.
3. Annunciatorwill
now
display
S1
heating
set
point.
Use
the
up
or
down
arrow
keys
to
change
the
set
point.Reccomendedheatingsetpointforstartuppurposesis115F.Presssetkeytoinputdesired
temperaturevalueandmovetonextsetting.
4. AnnunciatorwillnowdisplayablinkingDIF1theheatingdifferential temperaturesetting.
Recommendedsettingis10.Usetheupanddownarrowkeystosetto10.Presssetkeytoinput
desiredtemperaturevalueandmovetonextsetting.
5. AnnunciatorwillnowdisplayC1/H1CoolingorHeatingmode.Useupordownarrowkeytotoggle
betweenC1andH1.ChooseH1.PressSetkey.
6. AnnunciatorwillnowdisplayablinkingS2Coolingsetpoint.Useupanddownarrowkeystoselect
thedesired
temperature.
Recommended
cooling
temperature
at
start
up
is
44
F.
Press
set
key
to
inputdesiredtemperaturevalueandmovetonextsetting.
7. AnnunciatorwillnowdisplayablinkingDIF2CoolingDifferentialTemperature.Recommended
settingis10.Usetheupanddownarrowkeystosetto10.Presssetkeytoinputdesired
temperaturevalueandmovetonextsetting.
8. AnnunciatorwillnowdisplayC2/H2CoolingorHeatingmode.Useupordownarrowkeytoselect
C2.Presssetkeytoinputdesiredtemperaturevalue.andmovetonextsetting.
9. DTCwillnowbeinoperatingmodeandwilldisplaycurrentwatertemperature.
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DTCTroubleShootingandErrorMessages
Whennotworkingproperly,theDTCwilldisplayerrorcodesontheannunciator.Adescriptionoftheerror
codes,whatconditionmaycausethecodetocomeupandhowtocleartheerrorarelistedintable5.
Table5. DTCTroubleshootingErrorMessages
Display
Message
Description ToCorrect
E1Appearswheneithertheup ordown
keyispressedwhennotintheprogramming
mode.
IftheE1messageappearseven
whennokeysarebeingpressed,
replacethecontrol.
E2Appearsifthecontrolsettingsarenot
properlystoredinmemory.
Checkallsettingsandcorrectif
necessary.
EPAppearswhentheprobeisopen,shortedor
sensingatemperature
that
is
out
of
range.
Checktoseeifthesensed
temperatureisoutofrange.If
not,checkforprobedamageby
comparingittoaknownambient
temperaturebetween30Fand220F.Replacetheprobeif
necessary.
EEAppearsiftheEEPROMdatahasbeen
corrupted.
Thisconditioncannotbefield
repaired.Replacethecontrol.
CL Appearsifcalibrationmodehasbeenentered.
Removepowertothecontrolfor
atleastfiveseconds.Reapply
power.IftheCLmessagestill
repairs,replacethecontrol.
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FullSystemStartUp
1. Shutdownmainpowertochiller,
2. ReconnectorangewiretoterminalsS1andS1oncontrolboard.
3. Turnonmainpowertochillers,AirHandlers,PumpsandControls.
4. UseRun/Autoswitchonchillercontrolboardtooperatechiller.
5. Using Table6determinethecorrectswitchpositionsforthedesiredchilleroperation.
Table6. Chilleroperationasdeterminedbycontrolboardswitchpositions.
Run/AutoSwitch
Position
Heat/CoolSwitch
PositionResultingChillerOperation
Run Heat Heatingmodeonly.WatertemperaturecontrolledbyDTC.
Run Cool CoolingModeonly.WatertemperaturecontrolledbyDTC.
Auto Heat Externallycontrolledheatingonly.
Auto Cool Externallycontrolledheatingandcooling.
6. Checkflowratesthroughsystemandadjustasnecessary.
7. Duringnormaloperationthereshouldbea810Ftemperaturedifferencebetweenwatergoinginto
thechillerandwatercomingout.Temperaturedifferencesgreaterorlessthan810mayindicatea
waterflowproblem.
8. After24hoursruntimeremovestrainerandcleanfilterscreenofdirtanddebris.Thescreencanbe
removesbutshouldberetainedincaseitisnecessarytodoanymajorrepairsorupgradesonthewater
system.
9. Accessingrefrigerantsystemisnotnecessaryundernormalcircumstances.
10.Fillout
bulletin
30
101
unichiller
service
report.
Leave
acopy
with
the
customer
and
retain
one
for
yourfiles.
11.Ifchillerdoesnotoperateproperly,refertothetroubleshootingguideinthismanualorcontactUnico
Customerserviceat8005270896.
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UnichillerMaintenance
ThefollowingaretheperiodicmaintenancerequirementsofUnichillers
1. Cleanthecoilsurfacesatleasttwiceayearorwhenvisiblydirtybyhosingthecoilwithwater.Usinga
coilcleanerisoptional.
Donotusehighpressuresprayertocleanthecoilasthismaydamageor
flattenthefins.
2. Ifthereistheproperleveloffreezeprotectioninthelines,thereisnoneedtodrainthesystemifitwil
notberunoverthewintermonths.Unicorecommendsusingpropyleneglycolforfreezeprotection.
RefertoTable3forrequiredpercentagesofpropyleneglycol.
Tomeasurethefreezeprotectionlevelinthesystemtakeasampleofthefluidthroughthedrainor
storagetankanduseanantifreezetesteroranantifreezerefractometerthatissuitablefortheglycol
(ethyleneorpropylene)thatisused inthesystem.
3. Ifthechilleristobedrainedoverthewintermonthsitisimportantthatallwaterisremovedfromthe
heatexchanger.DrainsystemfromtheInletconnection.Useawet/dryvacuumtoremoveresidual
water.Orblowtheexcesswateroutfromtheoutputwaterconnection.
4. TheUnichillersareprechargedwithR22orR407Crefrigerants.Onlyexperiencedlicensedrefrigerant
servicepersonnelshouldcheckthechargeandrepairleaksshouldtheyoccur.
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TroubleshootingGuide
Theprintedcircuitboardhastestpointswhichcanbeusedfortroubleshooting.Whentroubleshootinginsert
thecommonprobeofthevoltmeterintotheCOMterminalonthecircuitboardandprobethetestpointsfor
voltagereadings.Table7listscommontroubleshootingtestpointsandwhatitmeanswhentheyread24V+/
2volts.
Socket For Common Probe
From Volt Meter
Figure4. CloseupoflowerleftHandcornerofprintedcircuitboardshowingsometestpinscommonprobe
socket.
Table7. LowVoltageTestPinsat24VAC
TestPin
NumberAreadingof24Vfromthetestpinlistedtocommonindicatesthefollowing:
19 Chillerhaspower;Transformerconnectedandgood
6
Externalcall
for
chiller;
enable
pump
18 Flowswitchortimerisclosed
14 Externalcallforcompressor
13 HighPressureSwitchisclosed
12 LowPressureSwitchisclosed(ordefrostrelayisenergizedifindefrost)
17 DigitalTemperatureControllerCallingforHeatingorCooling
8 TimerIsNotInTimeDelayMode;ContactorIsEnergized
7 NotinDefrostOrDefrostPressureSwitch(DPS)IsClosedDueToHighPressure
9PressuresNormal,LowAmbientPressureSwitch(ifcooling)MildWeatherPressure
Switch(ifheating)areclosed;Fanrelayisenergized
10
FanRelay
Is
Energized
4 InDefrostMode;Defrostrelayisenergized
1 ExternalCallForHeatMode
Table8. HighVoltageTestPins
22and24 UnitiscorrectlyPowered
22and23 FanRelayIsClosed(FanShouldBeOn)
22and21 PumpRelayisClosed(PumpRelayShouldbeOn)
22and26 HeaterRelayIsClosed(ShouldBeInDefrostMode)
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The following table is to be used for troubleshooting problems that may occur with the chiller. This table
shouldbeusedonlyiftherearenomodificationstothecontrols.
Table9a:UnichillerTroubleshootingChart Main
Problem ProbableCause CorrectiveAction
Uponstartupnothinghappens
Powernotgettingtothechillerorthe
controlboard.
Checkpowercomingintotheunit.
ConfirmAuto/RunSwitchissettoRun.
Testfor230VbetweenTP22andTP24.
277Vfor3p/460Vchillersunitis
correctlypowered.
Checkcircuitboardterminalblockfor24
voltsbetweenRandCBoardpowered
up.
BypassTimerBad
Pumpdoes
not
come
on.
Waterflowrestricted,defectiveflow
switch,pumprelaynotclosed Seepumptroubleshooting.
Pumpdoesnotstayon
Nowaterinthesystem. Putwaterinthesystem.
Watertemperaturesetpointistoo
high/low.
Adjustthetemperaturecontrollerset
point(nolowerthan38Fforcooling,no
higherthan125Fforheating).
Faultytemperaturecontroller.Checktheoperationofthetemperature
controller. Iffaulty,replace.
NoLowvoltageCheckfor24Vontransformer.Fuseon
controlboard
Unichillershutsdowncompletely
(includingthepump).
Openflowswitch(Liquidsolutionis
interruptedorairinthesystem).Checkforairordebrisinthesystem.
Table9b:UnichillerTroubleshootingChart Compressor
Problem ProbableCause CorrectiveAction
Compressorandfanmotorsshutdown
beforethesetwatertemperatureis
reached.
Openlowpressureswitch.
Checkforarefrigerantleak,inoperative
thermalexpansionvalve,lowliquid
solutioncontrolsetting,lowambient
operation,orlowliquidsolutionflow.
OpenCompressortimedelay
BadDefrostBoard
BadDTC
Openhigh
pressure
switch.
Checkforadirtycondenser,inoperable
fanmotor(s),
or
the
re
circulation
of
condenserair.
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Table9c:UnichillerTroubleshootingChart Pump
Problem ProbableCause CorrectiveAction
Pumpshutsoffshortlyafterthepoweris
appliedfrom
the
circuit
breaker
with
switchturnedtocoolorheatposition.
Airinthesystemorlackofwaterinthe
system.
Purgetheairinthesystembyopeningthe
ventplugonthepump. Installautoair
vent.Checkwyestrainer.
Lowwater
flow.
Check
pipe
sizing
and
operation
of
the
pump.Flowswitchwillopenatflowrates
lessthan3gpm.
Faultyflowswitch.Checkcontinuityoftheflowswitch. If
faulty,replace.
Table9d:UnichillerTroubleshootingChart Other
Problem ProbableCause CorrectiveAction
Airinthesystemorlackofwaterinthe
system.Waterleak.
Checkforcrackedpipeorloosefittings.
Repair,ifnecessary.
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