CAP FRAC 03 and 05 AIR COOLED CHILLER 1 & 3 PHASE
Contents
1. 23 Thermostatic Expansion 02 23 High Condenser pressure 2 2 122 23 EE 24 Coaxial Heat Exchanger 24 Adding Refrigerant e 2 KRSRRGM PORK 25 Service and replacing 5 2 0 00 70 24 25 TROUBLESHOOTING 6 rra 26 List of the most common problems 8084 26 Inspection recommended for units with reciprocating compressors 28 START UP CHECK LIST iini i eth eet ed ee 29 MAINTENANCE ued stesaeciteecseasteceeaaeess 30 CHILLER FRAC 03 05 1 O Instructions 2014 Page2 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth 76106 Tel 817 624 0820 Farms COMMERCIAL CAP AIRE PRODUCTS INTRODUCTION You must read and be familiar with this operating manual prior to chiller startup Please closely follow the instructions We would like to stress the importance of training with respect to the correct operation of the chiller Please consult CAP on the options available for training It is important that this manual be stored in a permanent location i2. com 55 40 53 85 63 57 61 79 70 22 68 25 14 4 74 07 144 600 7199 144 144 75 70 73 58 8106 78 79 TONS 252 2 60 2 67 72 275 2 83 2 91 2 99 4 4 35 2 5 50 55 WT oF ET 86 90 84 46 93 08 9047 9751 94 78 RECIP CHILLER FRAC 03 05 1 O Instructions 2014 Page7 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 Am COMMERCIAL CCAP SIRE PRODUCTS Installation Before operating equipment please check the installation and operating instructions Warning Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations and who are experienced with this type of equipment Do not install the unit in places that could be considered dangerous for maintenance operations Transport It is necessary to stabilize the unit during transportation Therefore the unit is supplied with a transversal wooden beam placed on the unit base that must to be removed at final destination In case the unit has to be moved again a similar solution is necessary Handling and lifting Care should be taken to avoid rough handling or shock due to dropping Do not move the unit using anything other than the base When it is necessary to lift the unit suitable holes are provided in unit base to arrange spreader bars and cables to prevent damage to the condenser coils or cabinet 2
3. CHILLER FRAC 03 05 1 O Instructions 2014 Page8 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 AAG COMMERCIAL AIRE PRODUCTS Location The CAP FRAC units are designed for outside installation on roofs floors or below ground level on condition that the area is free from obstructions for the passage of condenser air The unit should be positioned on solid foundations and perfectly level in the case of installation on roofs or floors it may be advisable to arrange the use of suitable weight distribution beams When the units are installed on the ground a concrete base at least 12 wider and longer than the unit s footprint should be laid This base should withstand the unit weight mentioned in the technical data table When the units are positioned in areas which are easily accessible by persons or animals it is advisable to protect the condenser coils and when necessary also protect the evaporator area as applicable To obtain the best performance the location must follow precautions listed Avoid air flow recirculation Take care that obstacle do not obstruct air flow Free air flow is required to ensure the right air entry and discharge To reduce noise and vibration proper floor support is required To avoid dirty condenser coils dirty avoid dusty locations Chiller water must be clean and free of oil and rust If necessary a water filter and treatment should be insta
4. 1 5 screen shows 3 digits with decimal point between 99 9 y 99 9 Out of this value range the value will be shown without the decimal point but internally will operate considering the decimal point In normal operation the screen value will show the sensor B1 temperature Reading that correspond to the return water temperature Heat exchanger entering water 2 Screen symbols Figure 1 aShows the screen symbols the keyboard and the meanings Symbol Color LED on meaning LED off meaning 1 2 Amber Compressor 1 2 needs to start 1 3 Amber Compressor 3 on needs to start A Amber At least 1 compressor ON B Amber Water pump ON needs to start CAP CHILLER FRAC 03 05 1 O Instructions 2014 Page18 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 I L AB COMMERCIAL AIRE PRODUCTS Amber condenser fan ON Amber defrost cycle ON needs to start Amber Heater ON Red Active alarm Amber Heat pump cycle ON needs to start Amber Cooling Cycle ON needs to start Load preprogrammed values Push to start If some alarms are on Push once Direct Access to parameters Push for 5 seconds Go to the desire parameter and adjust it Push once Password protected parameters Push and hold Select an upper value Push and hold once Start up the controller Pressandholdfor5 sec Select a lower value Push once 3 Programming amp saving p
5. COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 m COMMERCIAL CAP AIRE PRODUCTS Changing the compressor time delay m Programming user password is 22 n Press and hold the amp 5 atthe same time until you see 00 and two in the screen o Push up arrow until reach 22 on the screen then push Sel twice p Push the Arrow up until reach c push SEL and c01 will appear on the screen q Press the down arrow until c03 appears on the screen r Pressthe Sel button This is the time delay in seconds between two starts of the same compressor Use the up or down arrows to change this setting s Pressthe Sel button when done c03 will arrear on the screen t Use the down arrow until c06 appears on the screen if you want to change the startup time delay or press the button to save and exit u The time delay at startup is at 06 To change the time in seconds you will press the sel button when the 06 is displayed on the screen v Pressthe button and the current delay time in seconds will appear Press the up or down arrows to change the setpoint uPrgu x Press the 5 button when done the press the e button to save and exit Note a modified parameters without confirmation using the will automatically go back to the previous value CHILLER FRAC 03 05 1 O Instr
6. Material may not be returned except by permission from the CAP parts department A Return Goods tag will be included with the returned material This tag will contain all information required to expedite handling at our factory Return of the parts does not constitute an order for replacement A purchase order must be entered through our nearest Sales Representative The order should include part name part number model number and serial number of the unit involved Following our personal inspection of the returned part if it is determined that the failure is due to faulty material or workmanship credit will be issued on the customer s purchase order All parts shall be returned to CAP factory transportation charges prepaid Service amp replacement parts Always quote the model number confirmation number and the machine s serial number stamped on the plaque attached to the machine itself whenever ordering maintenance service or replacement parts If replacement parts are being ordered state the date the machine was installed and the date the breakdown occurred For an exact definition of the replacement part requested make reference to the relevant code number or failing that attach a description of the part being requested CHILLER FRAC 03 05 1 O Instructions 2014 Page25 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 COMMERCIAL AIRE PRODUCTS Troubleshooting
7. Temperature probe exceeding maximum temperature Temperature probe exceeding mimimum temperature Low Supply Voltage Alarm Supply voltage exceeds the maximum allowed High Supply Voltage Alarm tLAN Communication Error tLAN Communication Error EEPROM Control Error Lt EHS CHILLER FRAC 03 05 1 O Instructions 2014 Page21 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Supply voltage is below the mimimum allowed tLAN Communication Error Driver 1 tLAN Communication Error Driver 2 Expansion Tel 817 624 0820 AB COMMERCIAL CAP AIRE PRODUCTS System Maintenance General To ensure proper operation at peak capacity and to avoid damage to package components a program of periodic inspections should be set up and followed The following items are intended as a guide and are to be used during inspection and must be combined with actual refrigeration and electrical practices to assure trouble free performance The liquid line sight glass indicator on all circuits must be checked to be sure the glass is full and clear If the indicator shows that a wet condition exists or if bubbles show in the glass even with a full refrigerant charge the filter drier element must be changed Fouled condenser will be indicated by an abnormally high condensing pressure and may result in unnecessary trip outs To clean the condenser a chemical de scaling solution should be us
8. 1 Strainer 40 Meshl Blow Down Valve 8 Flow Switch 2 Expansion Tank 9 Balance Valve Drain Plug 3 Pump 10 Pressure Helief 4 CheckValve 11 Isolation Valves 5 Air Vent Connection Port 12 Flex Connections 6 Pressure Temperature Access Port 13 Pressure Valve 7 Heat Exchanger 14 Air Separator and Vent 15 Optional Storage Tank This layout is not intended to be a design and is placed just to give an idea of the typical piping in a single chiller installation system CAP assumes no responsibility for any omission or errors in the drawing CHILLER FRAC 03 05 1 Instructions 2014 Page12 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 FP mm COMMERCIAL CAP AIRE PRODUCTS Minimum water content The minimum volume of the chilled water circuit must be calculated with the following formula If necessary install a storage tank Proper operation of regulating and safety devices can only be ensured if the volume of water is sufficient WATER RANGE Vt Minimum water volume of the installation in Gals Q Chiller cooling capacity TR N Number of capacity control steps available in the unit Dt maximum acceptable temperature rise Dt 10 F for an air conditioning application Vt 167xQ NxDt 18xN This formula is only applicable for air conditioning installation and is only a rule of thumb and m
9. 03 05 1 O Instructions 2014 Page24 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 ADN COMMERCIAL CAP AIRE PRODUCTS If burnt oil or sludge are found in the refrigerant circuit caused by the compressor motor burn out before the vacuum operation it will be necessary to carefully clean the system using the filter dryer clean out method which involves the use of special filter dryers incorporating a suitable desiccant in both the liquid and suction lines Adding refrigerant Bubbles in the liquid line sight glass during full load compressor operation indicate refrigerant shortage check carefully for leaks repair them and add refrigerant When the refrigerant circuit is empty or after the system has been opened for extensive repair check and repair any possible leak and evacuate the system before charging operation the compressor and liquid valves must be opened and chilled water should be circulated in the evaporator Caution Do not cut out any safety device while loading the refrigerator with refrigerant Note Do not discharge the refrigerant into the atmosphere To recover it use empty clean and dry bottles The liquid refrigerant recovery can be made through the valve provided on the condenser coil sub cooler outlet To facilitate the recovery of refrigerant put the bottle inside a container full of ice avoid excessive filling of the bottle 70 80 In warranty return material procedure
10. Checked YES ___ NO Nameplate Amps Actual Running Amps CHILLER FRAC 03 05 1 O Instructions 2014 Page29 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 COMMERCIAL ip Maintenance Log This log must be kept with the unit It is the responsibility of the owner and or maintenance service contractor to document any service repair or adjustments CAP Warranty Department is available to advise and provide phone help for proper operation and replacement parts The responsibility for proper start up maintenance and servicing of the equipment falls to the owner and qualified licensed technician MAINTENANCE LOG ACTION TAKEN NAME TELEPHONE CHILLER FRAC 03 05 1 O Instructions 2014 Page30 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820
11. clogged filter drier or a restriction elsewhere in the liquid line If sub cooling is low add charge to clear the sight glass If sub cooling is normal and flashing is visible in the sight glass check the pressure drop across the filter drier An element inside the sight glass indicates the moisture condition corresponding to a given element color If the sight glass does not indicate a dry condition after about 3 hours of operation the unit should be pumped down and the filter driers changed Thermostatic expansion valve The expansion valve allows the proper amount of refrigerant to enter the evaporator regardless of cooling load It does this by maintaining a constant superheat All are factory set for between 7 F and 12 F superheat If it is necessary to increase the superheat setting of the valve remove the cap at the bottom of the valve to expose the adjustment screw Turn the screw clockwise when viewed from the CHILLER FRAC 03 05 1 O Instructions 2014 Page23 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 AB COMMERCIAL CAP AIRE PRODUCTS adjustment screw end to increase the superheat and counter clockwise to reduce superheat Allow time for system rebalance after each superheat adjustment The expansion valve like the solenoid should not normally require replacement but if it does the unit must be pumped down by following the steps involved when charging a filter drier
12. damage shall not apply to injuries to persons in the case of consumer goods Some states do not allow the exclusion or limitation of liability for consequential or incidental damages or for strict liability in tort so the above exclusions and limitations may not apply CAP does not assume or authorize any person to assume for CAP any other liability for the sale of CAP products This warranty gives you specific legal rights You may also have other rights which vary from state to state The above warranty applies with respect to parts only and not labor Accordingly subject to the conditions and limitations set forth herein the above warrant entitles the Customer only to receive a repaired or replacement part and the installation labor is not covered However under certain circumstances CAP will provide labor services to repair a Product or install repaired or replacement parts at its designated repair facilities or at its option compensate its authorized dealers and authorized contractors at CAP s standard fixed rates then in effect irrespective of charges actually imposed and time actually expended to provide such services CHILLER FRAC 03 05 1 O Instructions 2014 Page11 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 AD COMMERCIAL CAP AIRE PRODUCTS Typical Piping for a Single Chiller Single Pipe Installation 3 ite did 3 10 LEGEND
13. expansion valve Replace High discharge pressure Non condensable in the system Fan not running System overcharged with refrigerant Dirty condenser coil Evacuate and Charge Check fan fuses and electrical circuits Check for excessive sub cooling Remove the excess charge Clean the condenser coil CHILLER FRAC 03 05 1 O Instructions 2014 Page26 Tel 817 624 0820 m Air recirculation from outlet into unit coils Air restriction into unit Low suction pressure Inadequate refrigerant charge quantity Evaporator dirty Clogged liquid line filter drier Expansion valve malfunctioning Insufficient water flow to evaporator Water temperature leaving evaporator is too low High suction pressure Excessive load high water temperature Superheat is too low COMMERCIAL AIRE PRODUCTS Remove the cause of recirculation Remove obstructions near unit Check liquid line sight glass Check unit for leaks Replace Replace Check expansion valve superheat and valve opening position Check water pressure drop across the evaporator and Adjust GPM Adjust water temperature to higher value Reduce load or add additional equipment Check suction line sensor installation and sensor CHILLER FRAC 03 05 1 O Instructions 2014 Page27 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 COMMER
14. finned copper tubes bonded in a staggered pattern into slit aluminum fins No maintenance is required except the occasional removal of dirt and debris from the outside surface of the fins CAP recommends the use of foaming coil cleaners available at air conditioning supply outlets Use caution when applying such cleaners as they may contain potentially harmful chemicals Care should be taken not to damage the fins during cleaning Refrigerant CAP air cooled chillers are shipped factory charged with a full operating charge of refrigerant but there may be times that a unit must be recharged at the jobsite In case moisture is noticed in the system through the moisture indicator the system must be evacuated to eliminate cause of trouble After the evacuation the system must be dried reducing it to an almost perfect vacuum For this purpose a displacement vacuum pump should be used When the system has been opened for extensive repairs as for an overhaul it is advisable to use the method of the evacuation as follows 1 Operate the vacuum pump down to a vacuum of 500 microns 2 Break the vacuum with refrigerant until the atmospheric pressure is reached 3 Repeat operation 1 and 2 4 Operate the pump until a final vacuum of 200 microns is reached Any moisture and air left in the system will be absorbed by the dry refrigerant used to break the vacuum and will be almost completely removed by the three evacuations CAP CHILLER FRAC
15. options save expensive field labor and material resulting in lower first and operating costs Water Pump The chiller water pump is carefully selected to fit most residential and small commercial applications is fully installed piped and wired to the control box and piped to chilled water system to save expensive field installation costs Condenser Air Fan Unit is also designed to start and operate in higher ambient conditions up to 115 degrees F The large surface low speed propeller fan for horizontal air flow fan is statically and dynamically balanced and operates at low tip speeds for low vibration and low sound levels Fan Guard Fan guard is chrome plated to meet OSHA requirements Refrigerant Circuit Each unit has one refrigerant circuit with one Reciprocant compressor The refrigerant circuit includes compressor filter dryer liquid line sight glass charging port and one expansion valve Power Connection Unit is provided with single point electrical power connection Field wiring connection point will be at the starter panel Voltage Options A 208 230 1 60 B 208 230 3 60 C 460 3 60 CHILLER FRAC 03 05 1 O Instructions 2014 Page4 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 Am COMMERCIAL AIRE PRODUCTS Bristol Compressors Bristol Compressors are the machine of choice in a wide range of applications that demand efficiency and reliabilit
16. 2014 Page28 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 Am COMMERCIAL AIRE PRODUCTS Job Name Date Address Model Serial Tag Contractor INITIAL CHECKLIST INSTALLING CONTRACTOR MUST VERIFY THE FOLLOWING ITEMS 1 Did you check the unit for any visible shipping damage YES NO 2 Is the unit level YES NO 3 Are the clearances adequate for operation and service YES NO 4 Can you open the access doors and removable panels YES NO 5 Have all the shipping braces and protections been removed YES ___ NO 6 Did you check the incoming voltage against the name plate YES NO 7 Have all electrical connections been tested YES NO 8 Has over current protection been installed matching the requirements YES ___ 9 Do the fan rotate freely YES NO 10 Is copper tubing isolated from any metal parts YES NO 11 Is the unit installed with proper ventilation YES NO 12 Connection cleaning rinsing and purging of the hydraulic System YES NO 13 Do you have strainers at the heat exchanger inlet YES ___ NO 14 Cooling load available at least 50 YES NO 15 Compressor crankcase heater ON 24 hours before start up YES NO 16 Ambient Dry Bulb Temperature Ambient Wet Bulb Temperature 17 Condenser Fan Aligned Checked YES NO Rotation Checked YES NO Motor RPM Nameplate Amps Actual Amps 18 Compressor Rotation
17. 5 i 19 361 4 46 133 38 316 x Y WATER EXIT B 4 470 WATER INLET a 48 719 UNIT DIMESIONS FRAC 03 and 05 FRAC 03 and 05 Capacity CAPACITY Compressor Number of Number of Fans FL EFF IPLV Tons Aguar FRAC Tons Kw Compressors Fans FSACS Kw Size Kw Kw EER EER 03 34 45 4 5 1 1 0 34 9 92 1245 EE 05 5 6 6 2 6 2 1 1 0 34 9 75 12 35 This unit is rated in accordance with AHRI 550 590 standard rating conditions options not included in these ratings EER Energy Efficiency Ratio COP Coefficient of Performance IPLV Integrated Part Load Value FRAC 03 and 05 Dimensions amp Weights Weight Length Height Shipping Shipping Dry Weight Volume CHILLER FRAC 03 05 1 O Instructions 2014 Page6 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 FSAC 03 05 ELECTRICAL DATA COMPRESSOR UNIT BREAKER SIZE DATA VOLTAGE FLA 208 230 1 60 RPM FLA 20 25 208 230 1 60 208 230 3 60 460 3 60 FRAC 03 COOLING PERFORMANCE DATA ENTERING AIR TEMPERATURE 1002F 1102F MBTU MBTU MBTU 30 27 29 42 28 60 31 14 30 27 29 42 32 04 31 14 30 27 32 96 7 2 32 04 7 2 31 14 33 91 32 96 32 04 34 89 33 91 32 96 35 90 34 89 33 91 3 08 36 93 35 90 34 89 3 17 37 99 36 93 35 90 ser m
18. Aaa COMMERCIAL CAP AIRE PRODUCTS CAP FRAC 03 and 05 AIR COOLED CHILLER 1 amp 3 PHASE EM MADE IN USA CAP CHILLER FRAC 03 05 1 O Instructions 2014 Page1 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 ADN COMMERCIAL CAP AIRE PRODUCTS TABLE OF CONTENTS INTRODUCTION e PC 3 3 DIMENSIONS e 6 INSTALLATION c 8 TRANS me 8 Mim 9 Lay out and installation 9 LOCA MOM ERE 9 Space 10 ACOUSTIC Protecti n suscrita 10 WARRAN TVs a 11 TYIPICAL PIPING LAYOUT FOR A SINGLE 12 Typical piping for two chillers in parallel 13 CONTROL PANEL oi 15 Nomenclature 2 14 Wiring Diagram 16 Ig Hlc a id 26 SYSTEM MAINTENANDGPE 3 ecc re Eee nnn rir sio cuoi e Donee Praia 17 GON CL 18 oo adds 21 Compressor Maintenance sss nere 22 Fiker Dry E 22 Refrigerant sight 01 55
19. CIAL CAP AIRE PRODUCTS Description of inspection duties Liquid chiller with Recip compressor s START UP Check unit installation Check water flow and water circuit ancillaries Check safety devices Check leak tightness Configuration of the microprocessor based management system if used Verification of operating parameters and unit performance Transmission of the machine service log 500 H 1000 H VISITS Post wear in inspection Oil acidity test leak test Replacement of the filter drier cartridges depending on the results of the test above Monitor unit performance and any eventual variations linked to use of the installation INSPECTION VISIT Leak test Operating test with record of measurements taken and functional analysis MAJOR TECHNICAL INSPECTION Inspection visit Acid test Oil change if necessary Replacement of filter drier cartridges Check up on the microprocessor based management system if used Adjustment of safety devices Verification of unit interlocks Lubrication of bearings dampers if necessary HEAT EXCHANGER VERIFICATION Inspection of water cooled evaporator by checking the pressure drop across the heat exchanger to be sure it is not clogged or obstructed to prevent potentially serious problems Frequency Every 5 years up to 10 years depending on the quality of water then every 3 years CHILLER FRAC 03 05 1 O Instructions
20. If the problem can be traced to the power element only it can be unscrewed from the valve body without removing the valve but only after pumping the unit down Warning Adjustment of expansion valve should only be performed by a qualified refrigeration service technician High condenser pressure control Units are supplied with high pressure sensors on each refrigerant circuit Although the main purpose of the high pressure sensor is to maintain proper head pressure control another is to convey a signal to the control to unload the compressor in the event of an excessive rise in discharge pressure The control is set to not allow additional circuit loading approximately 29 PSI below the high pressure switch trip setting The high pressure alarm is in response to the signal sent by the pressure sensor The high pressure sensor can be checked by elevating discharge pressure and observing the pressure gauge and unit operation as the pressures pass the rising high pressure values noted Evaporator The evaporator is of the direct expansion COAXIAL heat exchanger type It is designed to provide extended surface as well as turbulent flow of refrigerant through them Normally no service work is required on the evaporator When the evaporator gets clogged you must replace it it is very important to be very careful with the water quality to avoid evaporator clogs and replace Air cooled condenser Condensing coil Condensers are air cooled Internally
21. ODUCTS Standard controls 1 INTRODUCTION Flow switch A flow switch is factory installed on the evaporator water inlet to enable detection of water flow through the heat exchanger before the unit is started up This will protect the compressors against any eventual liquid slugging during the starting phase and prevent accidental ice formation in the evaporator if the flow of water is interrupted If the Flow switch is by passed the warranty will be voided The normally closed contact can be used as lack of flow alarm circuit Warranty is void if a flow detection device is bypassed or disconnected from the CAP control panel Safety Precautions Precautions for Installation Never install the product in the environment beyond the one specified in the brochure and user manual such as high temperature humidity dust corrosive gas vibration impact condition resulting in the risk of inductive electricity fire and error operation Please comply with the installation instruction in the user manual to avoid damage or operation error Pay close attention to avoid cable or conductor parts falling into the digital controller to prevent fire or electrical fault Precautions for Wiring Connect Class 3 grounding in accordance with the local Electricity Engineering Regulations Apply the rated power supply and specified cables Incorrect power supply could result in damage to the unit The wiring shall be carried out by the certified electri
22. arameters The temperature settings are based on return temperature and are preprogrammed to start the first circuit at 569F and stop at 469F and the second circuit will start at 589F and stop at 489F If you want to modify these settings follow the instructions to change and save Programming user password is 22 uPrgu Press and hold the mw A Sel at the same time until you see 00 and two in the screen Push up arrow until reach 22 on the screen then push Se twice Push the Arrow up until reach c push Sel and 01 will appear on the screen Press the down arrow until c03 appears on the screen Press the 5 button This is the time delay in seconds between two starts of the same compressor Use the up or down arrows to change this setting Press the Sel button when done The c03 will arrear on the screen Use the down arrow until c06 appears on the screen if you want to change the uPrg startup time delay or press the button to save and exit The time delay at startup is at 06 To change the time in seconds you will press the se button when the 06 is displayed on the screen Sel Press the button and the current delay time in seconds will appear Press the up or down arrows to change the setpoint Press the 5 button when done the press the button to save and exit CHILLER FRAC 03 05 1 O Instructions 2014 Page19
23. centre it is advisable to study the wiring diagram so that you understand the operation of the water chiller Electrical components do not require particular maintenance other than a monthly tightening of cables Warning The warranty is void if the wiring is not in accordance with the specifications A blown fuse or tripped protector indicates a short or overload Before replacing the fuse or restarting the compressor the problem must be found and corrected It is important to have a qualified control panel electrician service this panel CHILLER FRAC 03 05 1 O Instructions 2014 Page22 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 COMMERCIAL CAP AIRE PRODUCTS Unqualified tampering with the controls can cause serious damage to equipment and void the warranty Filter driers A filter drier is installed in each refrigeration circuit and shall be replaced any time excessive pressure drop is read across the filter drier and or when bubbles occur in the sight glass with normal sub cooling A partially clogged filter can also cause trips on the no liquid run sensor The maximum recommended pressure drop across the filter drier at 7596 to 10096 circuit loading is 10 PSI The maximum recommended pressure drop across the filter drier at 2596 to 5096 circuit loading is 5 PSI The filter drier should also be changed if the moisture indicating liquid line sight glass indicates excess mo
24. chart PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS Compressor will not run Cause Main power switches open Unit system switches open Circuit switch in pump down position Circuit breakers open Fuse blown or circuit breakers tripped Unit phase voltage monitor not satisfied Compressor overload tripped Defective compressor contactor or contactor coil System shut down by safety devices 10 No cooling required 11 Motor electrical trouble 12 Loose wiring COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 solution Close switch Check unit status control box Change position Close circuit breakers Check electrical circuits and motor windings for shorts or grounds Check unit power wiring to unit for correct phasing Check voltage Overloads are manual reset Reset overload at button on overload Check wiring Repair or replace contactor Determine type and cause of shutdown and correct problem before attempting to restart Check control settings Wait until unit calls for cooling See 6 7 and 8 above Check circuits for voltage at required points Tighten all power wiring terminals Compressor will stop and restart repeatedly Differential range at low pressure controls too close Lack of refrigerant Erratic wire connections Low voltage Compressor noisy or vibrating Flooding of refrigerant into crankcase Worn compressor Check setting of
25. cian pursuant to the provisions set forth in the local Electricity Engineering Regulations Precautions for Operation When the power is on never contact the terminal to avoid short circuit It is recommended to add safety protection such as an emergency stop and external protection to prevent the controller from electrical damage Run the controller after safety confirmation Error operation will result in mechanical damage Please pay attention to the power linkage procedure Wrong process flow would lead to mechanical damage or other hazards CHILLER FRAC 03 05 1 O Instructions 2014 Page17 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 Aaa COMMERCIAL CAP AIRE PRODUCTS 1 General The Carel Chiller Control System is a micro processor based controller which provides all control protection and self diagnostic features for a chiller system with simplified wiring and an easy to use control panel The air conditioner can use either hermetic Scroll or recip or semi hermetic type compressor s The condenser side can be up to 2 refrigerating circuits with 2 compressors per circuit controller consists of Main control board 1temperature sensor water out with standard 6 feet length Low pressure switches High pressure switches The microprocessor controller is factory preprogrammed and all the factory settings are password protected 1 USERINTERFACE
26. ected that all work on equipment be carried out in accordance with all local standards and codes It is expected that all work will be carried out with good working practices General Description Units are leak and pressure tested at 500 psig high side 250 psig low sides then evacuated and charged All Air cooled Model FRAC chillers are factory tested to confirm operation prior to shipment Units ship with full operating charge of oil and refrigerant Unit panels structural elements and control boxes are constructed of galvanized steel and mounted on a structural steel base Unit panels and control boxes are finished with baked on powder paint and the structural base is galvanized All paint meets the requirement for outdoor equipment RECIP CHILLER FRAC 03 05 I O Instructions 2014 Page3 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 Am COMMERCIAL AIRE PRODUCTS Standard Features CAP s horizontal air discharge chiller model FRAC 03 amp 05 are cost efficient package Chillers environmentally friendly CFC Free with R 410A non ozone depleting using state of the art recip compressors high efficiency counter flow coaxial evaporator proven for durability efficiency and performance and copper tube aluminum fins condenser water pump and controls installed in the unit making this unit one of the most cost efficient for small commercial and residential applications Many factory mounted
27. ed according to the manufacturer s directions Flow switch A flow switch is factory installed on the evaporator water inlet to enable detection of water flow through the heat exchanger before the unit is started up This will protect the compressors against any eventual liquid slugging during the starting phase and prevent accidental ice formation in the evaporator if the flow of water is interrupted If the Flow switch is by passed the warranty will be voided The normally closed contact can be used as lack of flow alarm circuit Warranty is void if a flow detection device is bypassed or disconnected from the CAP control panel Strainer A strainer with a minimum of 40 meshes must be installed within 10 ft 3 m of the heat exchanger fluid inlet to prevent debris from clogging the heat exchanger This strainer is required and is available as an accessory The strainer has to be inspected and cleaned on a regular basis to prevent heat exchanger to clogging and damage Compressor maintenance Since the compressor is a Reciprocant compressor no yearly maintenance is normally required However vibration is an excellent check for proper mechanical operation Electrical control centre Warning Electric shock hazard Turn off all power before continuing with following service Caution It is necessary to de energize the complete panel including crankcase heater before doing any servicing inside Prior to attempting any service on the control
28. finitions as agreed upon in the order All parts have one year warranty from the date of shipment against manufacturing defects and it is expected that the design and installation of the unit utilizes good working practices The warranty will be legally void if Service and maintenance have not been executed in accordance with the CAP instructions repairs have not been carried out by CAP personnel or have been implemented without prior written permission by CAP Modifications have been made to the equipment without prior written permission by CAP Settings and protections have been modified without prior written permission by CAP Non original or other than the prescribed refrigerants or lubricants is used The equipment has not been installed and or connected in accordance with the installation instructions The equipment is being used improperly incorrectly negligently or not in accordance with its nature and or purpose Aflow switch protection device is not installed or disabled the factory installed one An appropriate strainer and water treatment is not installed close to the water inlet of the chiller Under these circumstances CAP is indemnified from any product liability claims from third parties In the event of a warranty claim the machine serial number and CAP order number must be quoted The above limitations shall inure to the benefit of CAP suppliers and sub contractors The above limitation on consequential
29. isture by the wet system color indicators During the first few months of operation the filter drier replacement may be necessary if the pressure drop across the filter drier exceeds the values listed in the paragraph above To change the filter drier pump the unit down Turn off all power to the unit and install jumpers across the low pressure control Close the manual liquid line shutoff valve Turn the power on and restart the unit by moving the ON OFF switch The unit will start pumping down past the low pressure setting Move switch to the off position when the evaporator pressure reaches 4 PSI and remove the jumper Close the suction line valve Remove and replace the filter drier Evacuate the lines through the liquid line manual shutoff valve to remove non condensable that may have entered during filter replacement Open the suction line valve A leak check is recommended before returning the unit to operation Refrigerant sight glass The refrigerant sight glasses should be observed periodically a weekly observation should be adequate A clear glass of liquid indicates that there is adequate refrigerant charge in the system to insure proper feed through the expansion valve Bubbling refrigerant in the sight glass during stable run conditions indicates that the system may be short of refrigerant charge Refrigerant gas flashing in the sight glass could also indicate an excessive pressure drop in the liquid line possibly due to a
30. lled Space requirements 12 MIN ad SIDE WALL OR OBSTRUCTION RECIP CHILLER FRAC 03 05 1 O Instructions 2014 Page9 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 AAD COMMERCIAL AIRE PRODUCTS It is recommended to have at least 4 feet between the two chillers and at least 3 feet between any exterior walls that can obstruct the air flow through the coils It is not acceptable to install any kind of roof over the chillers The FRAC units are air cooled hence it is important to observe the minimum distances which guarantee the best ventilation of the condenser coils Limitations of space reducing the air flow could cause significant reductions in cooling capacity and an increase in electricity consumption To determine unit placement careful consideration must be given to assure sufficient air flow across the condenser heat transfer surface To achieve the best performance the following must be avoided warm air recirculation and coil starvation Both of these conditions cause an increase in condensing pressures that cause reductions in unit efficiency and capacity Each side of the unit must be accessible after installation for periodic service The minimum clearance on each side of the unit should be enough to walk around the unit The compressor and evaporator side should have enough space to replace the compressor Horizontal condenser air discharge must be unobstruc
31. n the vicinity of the chiller Important general instruction Danger of Injury or damage to the chiller This manual contains important instructions regarding the startup of the chiller It also includes important instructions to prevent personal injury and damage to the machine during operation Furthermore in order to promote fault free operation of the chiller maintenance information has been included Please do not hesitate to contact one of our employees should you require further information on specific chiller subjects Order related documentation to be forwarded under separate cover This documentation consists of Installation and Operation manual for the chiller Operating manual for control system Wiring diagram Unit detail is given on unit nameplate The data published in this manual is based on the most recent information available It is supplied conditional to later modifications We reserve the right to modify the construction and or design of our chillers at any time without prior notification or obligation to adapt previously supplied equipment Any work on the Chiller should be carried out by trained and or licensed competent technicians The following risks are present on the unit Risk of electrical shock Risk of injury from rotating parts Risk of injury from sharp edges and heavy weight Risk of injury from high pressure gas Risk of injury from high and low temperatures components It is exp
32. system CAP assumes no responsibility for any omission or errors in the drawing CHILLER FRAC 03 05 1 O Instructions 2014 Page14 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 COMMERCIAL AIRE PRODUCTS CAP CHILLER DESCRIPTION MODEL NUMBER NOMENCLATURE Lei ee eee eee ee COMPR REFRIGERANT TYPE F R 410A M NU 22 B R 134A X SPECIAL COMPRESSOR TYPE 5 SCROLL R RECIP w SCREW CONDENSER TYPE A AIR COOLED UNIT TYPE c CHILLER UNIT CAPACITY TON 03 3 TON 36 000 BTUH NOMINAL 05 5TON 60 000 BTUH NOMINAL UNIT VOLTAGE A 208 230 1 60 B 208 230 3 60 460 3 60 D 380 3 50 E 575 3 60 unit capac CHILLER FRAC 03 05 1 O Instructions 2014 Page15 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 A COMMERCIAL AIRE PRODUCTS mm uc cw XY ES CGAP COMMERCIAL ARE PRODUCTS MADE IN USA WIRING DIAGRAM FOR MODEL F2AC 06 E DRAWING SY JOHN CHARLES PARTNUMBER SIFIACIES Wiring Diagram for FRAC 05 A 208 230 1 60 Wiring Diagram for FRAC 05 B 208 230 3 60 CHILLER FRAC 03 05 1 O Instructions 2014 Page16 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 COMMERCIAL CAP AIRE PR
33. ted or the unit will have its capacity and efficiency significantly reduced If the units are positioned in places surrounded by walls or obstacles of the same height as the units the units should be at least 36 from obstacles In the event the obstacles are higher than the units the units should be at least 48 from the obstacle Units installed closer than the minimum recommended distance to a wall or other vertical riser may experience a combination of coil starvation and warm air recirculation thus causing reduction in unit capacity and efficiency reductions Once again the controls will allow the chiller to stay on line producing the maximum available capacity even at less than recommended lateral clearances When two or more units are positioned side by side it is recommended that the condenser coils be at least 48 from one another For other installation recommendations consult CAP technicians Acoustic protection The low noise level of the FRAC unit meets the most restrictive regulations When the noise level must meet special requirements to the support base apply appropriate vibration insulator devices vibration insulator mounts on the water piping and electrical connections CAP CHILLER FRAC 03 05 1 O Instructions 2014 Page10 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 EAD COMMERCIAL CAP AIRE PRODUCTS WARRANTY The warranty of the chillers is subject to the warranty de
34. uctions 2014 Page20 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 TABLE FEN Display Alarm Descritpion Controller High Pressure Alarm COMMERCIAL AIRE PRODUCTS OF ALARMS uC2 Expansion Description and or Problem Exceerding pressure limit or disconnected 3 Exceerding pressure limit or disconnected High Pressure Alarm Eier tae Pes Aire E 2 Low Pressure Alarm Under pressure limit or disconnected F Controller Thermo Overload Circuit 2 re Advise Waring alarm Probe Bl Alarm E3 Probe B3 Alarm ES Probe BS Alarm Temperature probe exceeding limit or not connected E6 Probe B6 Alarm E7 Probe B7 Alarm Probe B8 Alarm 4 Compressor Hour Warning Temperature probe exceeding limit or not connected Problem occurred while saving paramerters to memory Problem occurred to memory during startup EEPROM Controller Error Power Supply Errors Problem occurred while saving paramerters to memory Variable speed fans run at maximum during this error Defrost time exceeded the max allowed a dF1 Defrost Cycle Time out Error 41 2 Defrost Error on circuit in question Al Antifreeze Alarm EEPROM Expansion Control Error Low Temperature Alarm Defrost error was detected on circuit in question Alerm activated when water temp drops below setpoint i Alerm activated when water temp drops below setpoint
35. ust not be used for process cooling where particular temperature stability is required If the calculated volume in the system adding the pipe volume with the chiller and AHU water volume is less than the minimum calculated the storage tank has to be sized to cover the difference TIPICAL STORAGE TANK CHILLER FRAC 03 05 1 O Instructions 2014 Page13 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 Fas COMMERCIAL CAP AIRE PRODUCTS TYPICAL PIPING FOR TWO CHILLERS IN PARALEL primary secondary circuits secundary tothe system secundary from the system gt zx pq Ds 8 w 9 ano ama Th CHILLER 2 COUNTER FLOW COAXIAL HEAT EXCHANGER CHILLER 81 COUNTER FLOW COAXIAL HEAT EXCHANGER 170 438 LEGEND 1 Strainer 40 Meshl Blow Down Valve 8 Flow Switch 10 2 Expansion Tank 9 Balance Valve Drain Plug Pump 0 Pressure Relief Check Valve 11 Isolation Valves 5 Air Vent Connection Port 12 Flex Connections 6 Pressure Temperature Access Port 13 Pressure Reducing Fill Valve 7 Heat Exchanger 14 Separator and Vent 15 Optional Storage Tank This layout is not intended to be a design and is placed just to give an idea of the typical piping in a parallel installation
36. y with low sound output This time proven technology has been enhanced with continuous improvements and innovation in materials machining assembly techniques and quality assurance Bristol Compressors are durable robust and are used world wide by leading manufacturers in applications across virtually every HVAC R market segment Chiller Evaporator Coaxial counter flow high efficiency evaporators are UL listed The evaporator has a uniquely built direct expansion distributor designed specifically for chillers Refrigerant Piping Refrigerant circuit includes e Liquid charging connection Sealed Filter drier e Suction service connection Sight glass e Expansion valve Control Center All power operating and safety controls are mounted in a NEMA 3R enclosure Single point electrical terminal block e Compressors Contactor e Fan Motor Relay e High pressure switch with manual reset Low pressure switch with auto reset e Chiller digital controller Factory Mounted Available Options e Variable Speed compressor Straight cooling or Heat pump e Sound enclosure Heat recovery with factory mounted hot water pump e Choice of flanges or grooved connections e Indicating lights e Low ambient kit CHILLER FRAC 03 05 1 O Instructions 2014 Page5 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 COMMERCIAL CAP AIRE PRODUCTS 28 000 30 000 dj 47 941 15 36
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