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Check Before Operation for The Electrical Side

1. 24994949 q O S Se Se m DOS OS CS D pag 7 SES amp RWC 5 RWC Manual N A Connection 43 Electrical Connection Power Power wiring must be provided through molded case circuit breaker M CCB or fused disconnecting switch with the recommended rating refer to electrical data tables and according to the local code requirements Each unit is provided with an electrical cable inlet to supply the unit with the specified power rating By referring to the nameplate you can check the maximum operating current voltage supply and operating frequency The unit should be grounded in accordance with the local codes Control pp Each chiller is provided with terminal strip for easy connection of external devices to the control panel Some external devices should be connected in the field such as water flow switch auxiliary contact from the chilled water pump starter general alarm signal etc T hese signals should be interlocked with the control panel as illustrated in the electrical control diagram Refer to the wiring diagram attached with
2. enwc M anual One Stage Cooling Onl Units E 4 11 9 GERY POWER SUPFLY L 0420 IPH Er LISTS amp TABLES MESSAGES CONTROL CIRCUIT BREAKER 1 PUMP INTERLOCK CRANKCASE HEATER PER mast RELAY oeur CONDENSER worm SW sw Ex COMP ar annemede PROTECTION ACCESS TO SET POINT BY PUSHING THE SEL BUTTON FOR 5 Sec YOU WILL SEE THE DISPLAY PUSH THE SEL SUTTON AGAIN TO DeSPLAY THE SET VALUE EM THIS MODE TOU CAN CHANGE THE SET POINT BY PUSHING THE SILENCE THE BUZZER AFTER ALARM SITUATION AMD DOWN ARROWS PRESS THEH PUSH THE SEL BUTTON AGAIN TO EXIT AMD PRG FOR RESET THE CONTROLLER AFTER SITUATION STORING THIS VALUE AND TO RETURN TO THE WAIN MENU PRESS Clear BUTTON FOR 558 CASE OF KEYPAD OFF CHECK PIRS FOLLOW THE SAME PROCEDURE TO VIEW WATER OUT AMBIENT TOMP BB 2 One Stage Optional Heat Pump Units K 2 enc M anual One Stage Optional Heat Pump Units CFMZ S y L LE L Ha 2828 niri TH SUPPLY POWER Ll DONE POWER 5 1 2 BEATEN rro sri
3. gt E llatio um g General 01 Dear Customer qq 11 1 Safety Consideration 0 Introduction Eu It ee Me 104 Nomenclature Components Description 05 Outstanding Features 111111 11 1 1 TT 116 Specification qm modu Imc es ez Standard Features ee 120 Optional Features 23 Microprocessor Controller 11 126 Nameplate Description 11111 11 133 Installation 111 1 1 32 Loose Part Check 132 Storage Unloading AE LEST 33 Operating Space Site Requirements 11111 1 1 TT L 35 Installation 36 Petra Pumping Unit PPU 136 Connection 11111111 11111 1 137 Mechanical Connection 1111111111 TT TT 137 RWC amp PPU Connection 1111111 1 tT l 142 Electrical Connection BER We 1 43 Operation Before Starting the Unit First Operation Checklist Unit Check Before Start 11111111 Check Before Operation for The Electrical Side 47 Sequence of Operation Operation Limitation Maintenance Trouble shooting Sound
4. EJ UR enwc M anual APage 72 2 LOAD DISTRIBUTION RWC25N4 RWCSONA RWCAON 4 ODEL aruo Retko nota UNIT CRONE am Due me me 260 4 zer 310 4 sos 257 2 7 320 MODEL e RWC390N4 RWCA7O0NA Monet ec RWGA3ON4 ses mwcssons aue CAMES All weights above are in LB 748974087 Gf GGG N RW C Manual Q 2 PPU REFRIGERATION SCHEMATIC DIAGRAM PUMPING UNIT 0 SYSTEM FROM SYSTEM T T ok 5 Eh OUT lt 1 Din STD 10 Makeup SD 8 Manual Air STD i 74897088977 RW C Manual 74 2 REFRIGERANT SCHEMATIC DIAGRAM Cooling Onl Units RWC Models RWCc 25 55 Hot Gas Controller OPTION H Solenoid Valve OPTION STD ECTS TD CONTROLLER STATUS Charging Nipple 5 Low Pressure Gouge OPTION Suction Accumalator Low Pressure Switch STD Hi Pressure Switch ag m BB io Cooler Expansion Valve Solenoid Valve eight Glass shut Off Valve Fusible Plug OPTION Heat Exchanger OPTION Hi Pressure Gauge OPTION Hermatic Compressor FJ SJ w
5. enwc M anual APage 05 COMPONENTS DESCRIPTION Paik vnus 35 72 TERTII On Off Switc T his device is used to connect and disconnect the power to the wholeunit Control Circuit Breaker CCB T his device is incorporated in the unit as part of the control circuit to provide protection to the control circuit from a short circuit T he crankcase heater of each com pressor can be energized when T this control circuit breaker is switched ON It is highly CJ recommended to energize the crankcase heaters of the compressors 24 hours before operating the unit for the first time Power circuit breaker PCB T he function of the power circuit breaker is to provide protection from short circuit for the whole unit or for each motor as well Control Transformer Transform the voltage from primary voltage 220 240 volt into secondary voltage 24 volt ON OFF Convertor Converts a 10V dc signal into an ON OFF signal via relay and it is used to connect and disconnect the fan Contactor T he contactors are mainly used for controlling 3 phase motors A T he unit should contain all the required contactors to NOTE start all motors such as com pressors condenser fan motors AA E A enwc M anual APage 06 TN A enwc M anual Motor Saver The function of this device is to protect the uni
6. Water out high low temperature Water in high low tem perature Devices controlled p gt gt Compressors Condenser fans Reverse cycle valves for optional heat pump models Water pumps Anti freeze heaters Alarm signaling device Liquid line solenoid valves optional for Automatic Pump D own External communications optional Building M anagement System using different protocols BacN et M OD BUS Johnson Controls M etasys and LON T alk Building M anagement System using digital inputs and outputs H ard wire GSM Protocol allows sending and receiving SM S messages which could be used for signaling active alarms and resetting them where possible usinga GSM mobile phone RS485 serial board for Supervisor and T ele M ainten ance RS232 M odem interface card Yee Ye fl ff 2 e Rw c Manual Page 31 PETRA mr ENGINEERING INDUSTRIES CO P O BOX 141351 Amman 11814 JORDAN SERIAL No NOMINAL POWER SUPPLY VOLT Hz Ph QTY VOLT Max Amp COMP MOTOR QTY VOLT Max Amp cove VOLT J L J 1 IL 1 1 JN ELECTRIC HEATER d J J COIL TEST PRESSURE Psig REFRIGERENT LOOP VOLUME GAL WATER FLOW RATE GPM Made in Jordan Manufacturing Year RWC Nameplate with difference
7. FREEZE 0 WATER OUT 893 DMT COMMECTEB OF DOESNT DPERATE Units EJ CZ enwc M anual PFR INDICATOR LIGHT DIAGNDSTICS
8. GEAIAHP 17 j 1 5 0 0 1 Pie 40 CR47KQ 7 1 j EBM 02 N e 47 CRPQ 450 9 1 02 N 55 CRNO500 0 053 1 6 20 16 1 1027 053 2 105 280 22 j 1 EBMO2 053 2 128 ZR16 5 0 053 3 210 22 j 18 02 053 4 200 7816 25 2 SOMER22 55 2 310 2819 1 22 24 SOMER 55 2 30 2816 72827 25 18 SOMER22 55 2 5 5 5 3 3 5 7 9 1 1 11 11 11 5 5 30 ZR16 5 CC 3 j soME22 55 2 430 ar 8 1411 SOMER22 55 2 470 ZR19 32 3 SOMER22 55 2 115 50 ZRIG6 235 4 SOMER22 55 117 580 7 _ 60 ZR jJ 32 160 27 9 3 1 02 053 3 2 115 ES 1 1 1 N N 25 lt lt lt UTJUT 25 25 2 2 2 R w c Manual Page 64 e e 2 Gf N RW C Manual Page 65 2 PRESSURE DROP CURVES 50 Hz 1 Rwe 25 50 we 40 47 B RWE 55 4 we 74 PRESSURE DROP Jr El 5 Rwe 105 iJ fe RWE 128 160 111111 1000 COOLER FLOW EATE EH 210 EEEH fra 350 390
9. LT al hut Tunt RTL EL ih 1 il al TNNT ech DM Vides ite E aiquet eee aiat Estate x fs az i p am ua ME Pata host RWC 390 TJ K enwc M anual RWC 470 All Dimensions are in Inch 1 Electric inlet 2 Water in 3 Water out sy ry i s x 4 RWC 430 All Dimensions are in Inch 1 Electric inlet 2 Water in 3 Water out i LE J TJ K enwc M anual RWC 530 146 67 9 1146 679 All Dimensions are in Inch 1 Electric inlet 2 Water in Water out mr NE E DUM Sal x 1 Hi hii ahh o Proh aaa AA ipe d ptit hh B e o n ma t a ett Pa X X PL UA ES k XS E a E m ee Li LEM OC IM x d DN DN D e OK MN M UM DIN ON I ON XO ONE Oc RE cont E OE x od x FRE
10. or ro ra jes oe _ o oe os o1 fe E gt oa o e os oo gt s2 eese oo e e os oo fe SE o o ee es oo n f e s2 ee es _ gt fo fe fe fo fe 74 Sound Data as 150 BS 3744 standard For Standard U nits 4 Noise Data Accuracy 2 dBA Model 25 J s J 4 Jar Js j ve Jj ws us Power Supply Volt Phase Hz Volt 1PH 50Ez KE aaaea Finishing Baked Electro Static Powder mmm emae Reciprocating Hermeticlly Sealed Scroll 124 106 106 195 195 24 y 313 313 40 1 2 S S C GT 3 ss 3s 70 1 84 1 3 1 95 T Air Flow Rate CFM Operation Weight Approximately dei 50 o 44 ao 4 ee 85 ws 97 Finishing a 134 o 31 313 405 313 313 313 405 313 313 405 SF EEE SEE Face Area ell 240 2 9 T 3 9 T 50 aro 3 50 81 ssr Data Above Are Based On Water IN OUT 55 45 F For Power Supply Voltage Refer Electrical Data ables For Copeland compressor only for other compressors supply please refer to Petra Factory 2 Gf R w c Manual Page 62 Mod RWC Casing Fi
11. LAS 2 enc M anual Two Stage Optional Heat Pump Units FOYER DIAGRAM CIRCUIT SUPPL 7 H 18 SUPPL 4 28 50 11 d 1 UR POATE BREAKER 99 28 Il j LEE 1 1 a5 T M E MESSAGES i Ja Lie Hi SWITCHI HIGH PRESSURE CIRCUIT 1 1 CFM THERMAL MOTOR PROTECTIOH TMPT TMP Cz HIH PRESSURE Cer WATER IN PROBE FMRT t2 WATER QUT PROBE FAULT AMBIENT 1 TEMPERATURE PROBE COOLING COND TEMPERATURE PROBE HEATING ES 2 TEMPERATURE PROBE COOLING ES COND 2 TEMPERATURE PROSE HEATING Ai ANTIFREEZE PROTECTION Gm ERROR IN COMMUNICATION WITH KEYFAD dj CIRCUIT IN DEFROST d2 2 IN DEFROST a CIRCUIT 1 DEFROSTING ERROR CIRCUIT 2 DEPROSTING ERROR E TO SILENCE THE BUZZER AFTER ALARM SITUATION PRESS Mule BUTTOM RESET THE CONTROLLER AFTER ALARM SITUATION PRESS Clear BUTTON FOR 558 MCASE OF KEYPAD OFF CHECK PLAS L E LER 2 P 2 CFR ACCESS TO SET POINT BY PUSHING THE SEL BUTTON FOR 5 WILL SEE ON THE DISPLAY PARAM rl PUSH THE SEL BUTTON AGAIN TO DISPLAY THE SET VALUE W THIS MODE YOU CAM CHANGE THE SET PONT BY PUSHING THE UP AND DOWN ARROWS THEM PUSH TH
12. Operation Conditions 1 Operation hode z Running Time Atter Stabdization 3 Pressure Drop Al Cooler PS Evaporator Flow Rate Condenser Flow Raba CFM Ambient Tamparatune LFF Compreasor Running DOpergti n B Frequency 0 Hz 3 Enlenng Vest Bulb Terme CF 0 Leaving Wet Bulb Temp 11 Humidity 5 Ss mm Partial 60 Hz 5 10 Coole aN Condenser SN Refrigeration Test Readings r Condenser Orr MT Water ing Instruments 1 Low Pressure Gauge serial 2 High Pressure Gauge Tanal 3 Damp Meter Serial Mo 4 Air 9 Serial Ha Approvals PTS Engineer SAID AL GHOUL 1 1 Dade Ref Dept MUHANAD AWARTAN I signature 1 Date i Elec AL DASOUD Signature Apr 18 la CER PETIERE SERE TOM eT S ART DN ATEN eA ELO LE ym LIP OR ERE ec T tt PESE Ar PEER e PER DRE ME A Quality Engineer Haa cagnalune 4 Date Rew 5 Authorized Osama Abu Baha Date ZE OB 2003 Page 1 of 2 EJ CZ enwc M anual Petra Engineering Industries Co PETR 4 MECHANICAL amp ELECTRICAL FACTORY SETTING CHECK LIST Dear Client This check list has been specifically designed to ensure that all the necessary sett
13. i 1 E ab n 4 5 Hr XE Pace ere e WD 2 1 ed 5552 MODELS LAYOUT 50 amp 60 Hz Z enwc M anual MODEL L w H RWC2I0 898 551 636 All Dimensions are in Inch mM 1 Electric inlet 2 Water in Water out pihiriy Wee en tip ped DELE Pe d Heg abs Dr po ICM jo a ER oe S D S bee a OT Kt DE OK EK Tee ee R pride de de get aetati tear c atate 255 anqusaspa eati qe ene 20 alere etait E etate qae eia etl Wetten ee ea A dom d gt ae i o Eda Dad fr a EE ee e MODEL RWC 260 RWC3O 898 551 70 5 All Dimensions are in Inch 1 Electric inlet Water m 5 Water out A IRI 1 1 1 T m sp I
14. refrigerant can be added while the system is not operating G eneral suggestions will not always apply to specific operations but the following outline may be helpful Connect the refrigerant cylinder to the charging port U se as short a line as possible to minimize water contamination or use a drier if indicated by conditions T he cylinder should be upside down if it does not have a liquid vapor valve Install a pressure gauge so that the compressor discharge pressure can be observed W ith the connection to the charging port loose crack cylinder valve and purge charging line with refrigerant using the VAPOR hand wheel of a cylinder fitted with a liquid vapor valve T ighten connection open cylinder valve and check for leaks Close the valve at the receiver outlet or if there is no receiver close the valve in the liquid line upstream from the charging port T his is necessary to prevent the condensing pressure from forcing liquid into the cylinder W ith the compressor running slowly open the charging port valve and charge liquid using the LIQUID hand wheel at a rate fast enough to keep the compressor from cutting out on low pressure control if possible T he refrigerant flow can also be controlled by the cylinder valve to avoid ending up with a hose full of liquid refrigerant T he same result can be obtained by closing the cylinder valve first when charging is finished W atch the discharge pressure A rapid rise in pressure indicates t
15. ACCESS TO SET POINT RW VALVE HPS PRESSURE SWITCH I PJ PFR R CONTROL RELAY LAK wn TERMINAL NUMBER v OTHERS SILENCE THE BUZZER AFTER ALARM SITUATION PRESS Mute BUTTON TO RESET THE COMTROLLER AFTER ALARM SITUATION PRESS Clear BUTTON FOR Saa INCASE OF KEYPAD OFF CHECK FEES eg OUT PROSE FAULT E3 SOND TEMPERATURE PROBE HEATING AMBIENT TEMPERATURE PROBE COOLING ERROR IN COMMUNICATION WITH KEYPAD IM DEFROST CIRCUIT DEFROSTING BY PUSHIMG THE SEL BUTTON FOR 546 0 WILL SEE OM THE DISPLAY PARAMETER USE UP DOWN ARROWS TO SCROLL THROUGH THE PARAMETERS PRESSING SEL AGAM WILL DISPLAY THE WALLE rh WATER GUT PROBE TEMPERATURE r amp COND PROBE TEMPERATURE 4MEATING AMB PROBE TEMPERATURE CODUMD Page 82 t RWC anual 74897088977 m cC ES T 2 o E 1 gt N O Two Stage Cooling Onl Units 2 enc M anual p d b il hI wu POWER CIRCUIT BREMER i mmn SUPPLE T H E LOW PRESSURE
16. F Suction Accumulator Liquid Receiver External Pressure Relief Valve Pressure Gauges High Low Water flow switch Required as a safety interlock to prevent operating of unit without evaporator flow available for field installation only Moisture sight glass indicator Heat reclaim heat exchanger for hot water supply de super heat exchanger None standard water inlet and water outlet temperature range which are needed for industrial applications Brine application for low working tem perature range Other refrigerant application R407c amp R134a Electronic expansion valve Microprocessor controller with seven day time schedule and or serial output port High entering water tem perature protection Automatic or manual pump down and or pump out upon refrigeration circuit shutdown or start Low ambient head pressure control by varying the speed of the condenser fan motor using speed controller or frequency inverter External overload for each compressor 2 fe Yee of 2 4 RWC Manual Ex N OPTIONAL FEATURES 24 External overload for each condenser fan motor Earth leakage relay for each compressor Earth leakage relay for the whole chiller Ampere meter and or voltmeter installed on electric panel door Circuit breaker for each compressor Circuit breaker for each condenser fan motor or each pair of condenser fan
17. PRESSURE DROP 50 RWG 450 470 530 fa RWC 152 530 TA Ow COOLER FLOW RATE GFR GE YO Gf GG Gf m N PRESSURE DROP CURVES 60 Hz Tage o j I a I I HH 25 40 42 47 9 4 u B Re 55 5 RWG 103 128 RWE li Ico OO FLOW RATE gt i 1000 L RWC 210 5 RYG 260 100 8 i2 RWC 310 B 4 11 RWG 350 350 4 1 i RWG 430 470 RWC 530 580 620 COOLER FLOW RATE GPM CLAY i ESS enwc M anual 50 amp 60 Hz g Page 67 MODEL W H RWC25 4518 264 45 5 RWC30 4518 264 455 RWC40 4518 323 44 1 RWC47 45 18 323 441 RWC 55 51 00 323 441 All Dimensions are in Inch 1 Electric inlet 2 Water in 3 Water out RW Manual Z if IR UP Inch lions are in RWC 128 r out All Dimensions are in Inch 1 Electric inlet 3 Water out W ate Water in All Dimens 1 Electric inlet ELT UN C Sa m E in le n F z BRI 4 a Le L ES
18. SouER11 J 3 50 7814 20 4 5 580 __ 6 ZR 26 4 EE 3 22 35 10 12 12 19 15 20 20 30 45 11 11 12 15 91 105 120 N O UT O Olle BRIN w R22 R407C 200 230V 60H Z RWC MODEL QTY ben 2225 CR3XKQ 4 1 42 1 30 CR37KQ 8 1 J 42 40 4 1 02 052 47 CRPQ450 17 1 02 053 55 CRNQ 500 18 1 02 053 6 1 1 053 105 ZRI2 6 1 EBMO2 053 1288 2816 42 1 02 053 9 160 2819 53 1 EBM02 053 210 ZR12 j 6 J 0 053 260 286 42 Pa J SOMER22 95 310 2819 2 j SOMER22 95 350 30 7816 42 3 40 281 936 4 SOMER22 95 40 7819 53 3 SOMER22 95 50 2816 422 SOMER22 95 580 __ 60 4 SER 22 95 2 2 0 55 2 ed NO olululululu U1 Oj O o o o o o uvu 3 4 3 12 12 1 mo 46 68 114 114 2 2 2 3 3 2 2 2 5 0 0 0 0 5 5 0 0 R22 R407C 380 60H Z RWC MOP MODEL MODEL FLA1 AMP FLA2 AMP MOTOR KW FLA AMP 25 CR 0 30 CR37KQ 6 1
19. been introduced close cylinder valve and disconnect charging line W hen satisfied that the system is operating as it should back seat both suction and discharge service valve Bleed pressure from both gauge lines through the manifold charging port Replace cylinder valve cap and fit flare plugs in open ends of charging and gauge lines Replace plugs in gauge ports of compressor service valve gt gt P P P gt P P gt gt gt gt NOTE If possible refrigerant should always be charged by weight using a good scale N MAINIENANCE JE JE fe If ff Oo RW C Manual Page 55 If cylinder pressure drops too low for further charging before the job 15 finished place cylinder in a bucket of warm 77 115 F water or use a heat lamp to increase pressure NOTE D o not apply heat with a torch N ever heat cylinder above 122 F Charging the refrigerant in the liquid phase has always been customary for larger systems It is essential for charging blend refrigerants such as 407 c If a complete charge is to be added to an evacuated system the liquid is frequently charged through the compressor discharge service valve T he compressor is not operated while charging T he procedure for attaching the manifold and purging the lines is similar to that described for vapor charging On most systems a charging port is located on the liquid line downstream from the receiver In this case
20. effect onto the suction line Check before Operation for the Electrical Side T hese check need to be performed sequentially The main cable for the power supply of the unit is as the manufacturer recommendation refer to the electrical table page 9 for the selection of the main power supply cable Proper disconnect main power switch is installed beside the unit for emergency or for maintenance purposes chiller is supplied through main power circuit breaker or fused disconnect switch refer to the attached electrical table for the proper selection of the circuit breaker size All field connection wrings were connected properly to the control terminal such as gt Water flow switch signal gt Pump inter lock signal gt General alarm signal Remote switch signal Refer to page electrical field wiring for more information Also it is important to refer to the wiring diagram for the exact field wiring connection field connection is represented by dash dot lines on the wiring diagram M ake sure that no obstacles exists that may stop the condenser fan s please test by moving the fan s by hand also check direction of rotation nspect visually for any loose wires O peration of the chiller is best understood by referring to the relevant power and control diagrams that are supplied with theunit T he control panel layout part of the wiring diagram shows the location of each electrical component that is installed inside th
21. flexible connection Connection Pipe Flexible Joint hreaded male connection RW C Manual N A Connection 38 All piping works to and from the cooler must be designed taking into considerations the followings Piping should be kept free of all foreign matters Avoid elbows tees and valves which decrease the pump capacity All piping should be kept as straight as possible All piping must be supported independent of the chiller Thechilled water piping system should be laid out so that the circulating pum p discharges directly into the cooler T he suction for this pump should be taken from the piping system return line Flushing the chilled water piping from any foreign material before the system is placed into operation should be done without cooler connection to the system Don t flush any foreign material into or through the cooler it should be done without AU cooler connection to the system Size of Piping Water Connection RWC Models Inlet outlet o 470 Oo Connection 39 Minimum Flow Rate RWC Minimum Cooler Flow Rate RWC 25 RWC 30 RWC 40 RWC 47 RWC 55 RWC 76 RWC 105 RWC 160 RWC 210 RWC 260 RWC 310 RWC 350 RWC 470 RWC 530 RWC 580 RWC 630 RWCc 30 RWCc 40 RWCc 47 RWCc 105 RWCc 128 RWCc 160 RWCc 210 RWC
22. motor nit mounted fused or non fused disconnect service switch with external handle to isolate unit from power for servicing M ain power circuit breaker for whole unit with door isolator Building automation system interface PETR Can provide a full supervisory system for full monitoring of chiller operation NOTE his includes hard ware devices and software program Main Function of Supervisor System M odification of control parameters of each single connected instrument Local or remote supervisory system U ser friendly interface Reading for the temperature sensor incorporated in the unit Status of the unit ON OFF alarm stand by Alarm management of the unit includes D isplay message with detailed alarm description Print out in real time of detected alarm Fax messages with alarm description and sender identification gt ransmission of telephone messages GSM gt set points PETR Water Pumping Unit PPU wit Bu PETR Pumping Unit PPU includes the hydraulic components necessary for chilled water for use with RWC units The PPU are designed for easy connection and quick integration into chilled water system equipment there by minimizing site labour requirements T he PPU Provides the following standard features H eavy gauge galvanized steel casing with polyester epoxy powder electrostatic paint oven baked for outside use Water pump with dynamically bala
23. occurs and a tem perature difference between the liquid in out and the filter can be sensed In this case the filter has to be changed T he process 15 as follows System pump down procedure has to be carried out Loosen the flare connection or solder of filter drier T ake out the old filter Install the new filter drier Evacuate the low pressure side do not forget to open solenoid valve O pen all valves and the unit is ready to start Compressor All units are factory charged with oil The approved oils to be added upon need are M obil RL 32CF D v7 not re use drain oil and do not use any oil that has been exposed to the atmosphere ZA d AD N A MAINTENANCE Page 57 Coil Cleaninc Clean the condenser coils at least ON CE each year or more frequently if the unit is located in a dirty environment T his will maintain proper unit operating efficiencies T o clean the coils use a soft brush and a vacuum cleaner Cleaning the Evaporator T he chilled water system is a closed loop and therefore should not accumulate scale or sludge If the chiller becomes fouled first attempt to dislodge the material by back flushing the system Water Flow Limits Evaporator flow rates below the tabulated values will results in laminar flow causing freeze up problems scaling and poor control Evaporator water flow rates exceeding those li
24. plates are stacked together and from flow cham bers for two fluids BPH E cooler is used for one stage application with allowable working pressure maximum 435 Psi T he cooler is insulated with 3 4 closed cell foam insulation BPH E cooler Shell and Tube Cooler T he cooler is shell and tube type with inner grooved copper tubes for two circuits and more It is tested and stam ped for refrigerant side working pressure of 360 Psi and a design waterside working pressure of 150 Psi The cooler is installed with closed cell foam insulation Coolers are ASM E stamped Shell and T ube cooler N STANDARD FEATURES Page 20 EJ CZ enwc M anual A gt P gt gt gt gt gt Construction Easily accessible system components Galvanized formed sheet metal chiller base Air cooled condenser allows less installation space requirements Easily accessible system components Plastic mesh guard around chiller perimeter W eather proof with ample space for easy access power and control panels H ermetic suction gas cooled compressor motor U nit Frame M odular design with multiple compressor execution provides flexibility for varying load conditions and avoids total shut down of chiller during service of any of the refrigeration circuits H eavy structure unit weatherproof electro static polyester powder paint oven baked for sheet metal a
25. scroll Built in non return valve in discharge spud C om pact Smaller unit Foot print of 8 66 8 66 inch one of the narrowest in the industry Serviceable Friendly user unit Pressure taps Oil sight glass Oil adjustment valve schrader type Du PT FE Journal Bearings gt gt RE gt Yl fl 2 2 2 2 EN OUTSTANDING FEATURES prege 16 Superior Efficienc RWC series exceed ASH RAE 90 1 new efficiency levels at both full load and part load efficiency Low Noise Chillers RW C series offer a low sound power level chillers measured in accordance of BS 150 3744 standard by adopting low noise scroll reciprocating compressors and condenser fans and special design refrigerant piping Compact Physical Footprint RWC offers a compact footprint to serve the areas and applications that have a space constrains and it is offer a close spacing installation Outstanding Finishino All exposed piping including coil headers are epoxy coated for extra protection and long life All coils U Bends are protected with a galvanized steel painted cover plate mounted at U Bend coil side the plate covers the whole U Bends coil side All suction lines are covered with rubber insulation wrapped in cheese clothes and epoxy painted for extra protection T o ensure the best performance each unit is 100 factory run tested RWC series is produced in ISO
26. sound compressors with low discharge pulse levels which insures quiet operation Hi efficiency with high energy efficiency ratings Low foaming mineral base lubricant Full maximum load rundown capability nternal inherent line break motor protection with start winding protection on single phase models Crank case heater on all 3 phase models Suction gas motor cooling External baked enamel finish provides rust protection Aluminum piston cast iron ring assemblies that provide reduced reciprocating mass and positive pressure seal Applications and specifications All compressors used has the approval to operate as a heat pump compressor The motor protector used inside the compressors is mounted internally and its proven design is the result of extensive laboratory research and field testing It protects the motor from gt aximum operating overload gt High voltage gt Low voltage 4 It is both current and heat sensing It is wired at the connection point of the motor s three legs T herefore the protector protects all three legs If a problem occurs with one or more of them the protector will break all three phases the single phase protector protects both the run and start windings Rated load amps 15 the value used for contactor and other electrical component selection E l Il GG 2 COMPONENTS DESCRIPTION Page 14 Compressors Scroll T yoe Compre
27. the unit for interlocking signals with the control panel External devices that should be field installed indicated by dash dot lines in the wiring diagram gt gt R S Terminal T hese two terminals can be used for remote control enabling disabling of the unit and can also be connected with the B M System T hese terminals must be jumpered if they are not intended to be used as indicated on wiring diagram mA Y 4 CAUTION hese two terminals should be connected to volt free contacts gt General alarm terminals T hese two terminals can be used for the remote fault indication which can also be used with the B M System to indicate the faulty of the unit T hese terminals are potential free terminals gt W F S Water Flow Switch hese two terminals are available in chiller units and must be connected without any voltage potential free terminal T hese terminals exist to protect the unit from starting without the correct water flow gt P I Terminal pump interlock hese two terminals are available in chiller units and must be connected with the auxiliary contact at the pump controller T hese two terminals exist to ensure that the chiller starts only after the pump has started 2 fe Yee E vc A M anual N OPERATION Page 44 Before Starting the Unit Check the electrical connection for tightness Switch on the main power supply U se the following formula to determine the pr
28. unit s exterior panels for secureness and damage After each major electrical strom check the unit for blown fuses or tripped overloads Check the unit s insulation periodically to make sure that it 15 secure Perform all maintenance procedures and inspections at the recommended intervals T his will prolong the life of the equipment and minimize the possibility of costly failures Wee Maintenance After the unit has been operating for approximately 30 minutes and the system has stabilized check the operating conditions amp complete the procedures below C heck the evaporator refrigerant pressure amp the condenser refrigerant pressure C heck the liquid line sight glasses T he refrigerant flow past the sight glasses should be clear Bubbles in the refrigerant indicate either low refrigerant charge or excessive pressure drop in the liquid line f operating pressure and sight glass conditions seem to indicate refrigerant shortage measure the system superheat and system sub cooling f operating conditions indicate a refrigerant overcharge remove refrigerant at the liquid line service valve Allow refrigerant to escape slowly to minimize oil loss Do not discharge refrigerant into the atmosphere M easure the power supply voltage compressors and fans running amperes nspect the entire system for unusual conditions and inspect the condenser coils Annua Maintenance for dirt amp debris If the coils are di
29. 9001 2000 listed manufacturing facility RWC series are rated in accordance with ARI standard 550 590 RWC units construction comply with ASHRAE 15 safety requirements Eas Installation Complete factory wiring easy listing provisions factory installed options and start up facilitate quick and easy installation A complete factory run test is performed on each unit Design Flexibil it U nit Capacities in this series have a wide range depending on design requirements A wide choice of chillers capacities and options are available to meet the precise design requirements T he advanced microprocessor control enable the consumer to the advanced microprocessor control enable the consumer to select specific operating param eters according to particular needs 74970897 2 Gf GG ff A M anual Page 17 N SPECIFICATIONS Compressor T he compressor used is a hermetic Piston and Scroll type refrigerant gas cooled with thermal overload protection in each phase Theterminal box is rain tight direct on line starting With high performance and efficiency low sound so as to match all other Petra products reliability and efficiency and with crank case heater for models RW C 40 and above e Piston T ype C om pressor Air Cooled Condensers Scroll T ype C ompressor P E T R 55 air cooled condensers are designed to deli
30. CIRCUIT 1 HIGH PRESSURE 1 WATER PROBE FAULT Tei WATER OUT PROBE FAULT AMBIENT PROBE FAULT LAK AMBIENT PROBE 2 FAULT CLAK 02 r u 2 3 ia 70 SEEMLE THE BUZZER AFTER SITUATKIKH PRESS Muls BUTTOWN ID RESET THE CONTROLLER AFTER ALARM SITUATION PRESS BUTTON FOR 5586 CASE DF OFF CHECK ESFI LETS k TABLES B _ CONDENSER FAN MOTOR TR Win IMP THERMAL MOTOR PROTECTOR TERMINAL NUMBER Ex ACCESS TO SET POINT HY PUSHING THE SEL BUTTON FOR 5 Zec YOU WILL SEE ON THE DISPLAY PARAM ri PUSH THE SEL BUTTON AGAIN TO DISPLAY THE SET WALUE THES MODE YOU CAM CHANGE THE SET FONT PUSHING THE UP AND DOWN ARROWS THEM PUSH THE SEL BUTTON AGAIN TO EXIT AND PRG FOR STORING THIS VALUE AMD TO TO THE MAIN MENU FOLLOW THE SAME PROCEDURE TO VIEW WATER OUT TEMP r AMBIENT TEMP RB R3 LEGEND CONTROL CHRCUIT BREAKER LIQUID SOLENOID VALVE CRANKCASE HEATER LOW AMBIENT KIT WATER FLOW SWITCH PHASE FAILURE RELAY LH PRESSOR SV TRANSFORMER 2 20 24 FELD CONNECTION OTHERS 2 WIRING DIAGRAM Heat Pump Units Optional Two Stage umi LF 8 158 838 N32 FY FE PE PEN ETTE PP ETE EP PG EM
31. D CTMTEIRIER VILL Druga Ea TH CUMEITIUM APPEMED THE BT TU THE BITTEN TEN C TD HRT 3 AFTER FDTM TH ALTO EAT THE AEH ALES da Bi CASE OF TREET M EE DF ME MATEM HEEE Ge GET CORRECTED GET ZPERATE Four Stage Cooling Units pCO built in terminal small 220 Four Stage Cooling Onl Units ae THB E POWER DIAGRAM LISTS amp TABLES LEGEND CCB CONTROL CIRCUIT BREAKER LSV 65440 SOLEMONO VALVE CCH CRANKCASE HETEN Pl Pe PER PHASE FALURE RELAY NFS WATER now seni TMP POTEET COMP COMPRESSOR Wr WIRING NUWEER TERMINAL NUMBER Sw SWITCH FELD CONNECTION EY OTHERS LAK LOW AMEMENT ERROR CONDITION 2 enwc M anual AMY COMDITION COULD HAPPENED THE COHTROLLER WILL AUTOMATICALLY SWITCH OFF THE CONCERNED DECUIT OR THE WHOLE CHILLE OM ALARM THEN IT WILL 2 F THE 280 08 HAPPEMED PUSH THE BUTTON FO DISPLAY THE ALARM MESSAGE 5 AFTER FONG THE ALAFMTO RESET THE ALARM PUSH ALARM BUTTON AGAN FFR INDICATOR LIGHT DIAGNOSTICS RESTART DELAY GREEN RED REVERSE PHASE Page 92 RV C
32. E SEL BUTTON AGAIN TO EXIT AND PRG FOR STORING THIS VALUE AND TO RETURN TO THE MAIN MENU BY PUSHING THE SEL BUTTON FOR 5 Sec YOU WILL SEE OH THE DISPLAY PARAH ri PUSH THE DOWN ARROW TO SEE PARAM FX FUSH THE SEL BUTTON AGAIN TO DISPLAY THE SET VALUE 84 THIS MODE YOU CAM CHANGE THE SET POINT BY PUSHING THE UF AND ARROES THEN PUSH THE SEL BUTTON AGAIN TO EXIT AND PRG FOR STORING THIS VALUE AND TO RETURM TO THE MAIN MENU PROBES BY PUSHING THE SEL BUTTON FOR 5 Sec YOU WILL SEE OM THE DISPLAY PARAM ri NOW USE UP DOWN ARROWS SCROLL THROUGH THE 5 PRESSING SEL AGAIN WILL DISPLAY THE VALUE 48 AMBIENT 1 PROBE TEMPERATURE COOUNG Ca PROBE TEMPERATURE COOUNG 18 606 2 PROBE TEMPERATURE WEATING Page 86 RW C Manual AT WIRING DIAGRAM Units Three Stage Three Stage MAMME UEH POE CIRCUIT emn t fer Lt j dr F T Se he 4 n TA n ki 1 I HES i i n Coolino LISTS amp TABLES LEGEND ERROR LE EH FELE 815 Units COA OPTION Wel Gl fl fl fl 5 R W C M anual Page 87 AMY X3HORM AL CONDITION COULD HAPPENED THE CONTROLLER WILL AUTOMATICALLY SWITCH 4 ALARM THEW WiL
33. L CONCERHED in WHOLE CHILLER ALASH MESSAGI 1g IF THIS HILI HAPPENED PUSH THE ALARM BUTTON ENERGIZE TH RAL ALARM RELAY 4E MESSA T2 3 AFTER THE RESET THE PUSH 1 BUTTDA d HN STANT DLLAT REX LEIA LANE I He vil TAGE HT DIAGHOSTES FHASE 7 FET RET Page 88 RWC Manual AT AD A UA WIRING DIAGRAM Heat Pump Units Optional Three Stage aW TE JUDA EN ER 0 58 RECEN mar EY ir am k TOHLNO 2 enwc M anual Three Stage Optional Heat Pump Units I EN TT n 8 8 1 MONET bs 11 om a k ka irm d rd 1 43 4 Ei T H COMP COMPRESSOR PFR mase PELAY Ry REVERSE wave Sw HEAT COOL Rom k K AL GSE HAPPONS THE CORLL VILL ATE 24 8 TH KEFEN TENT THE WHOLE JEPEMDUMZ UM TT VILL REIS HIHI AME SAT AR
34. Manual Oe SER P 5 a E L GCHVOH HOSSHOO0HdOHOIN 1100000 O 0 1 0 Staqe lt lt Q 2 cc Four Four Stage Optional Heat Pump POWER DIAGRAM rote uem H BGA FO FH Si Va TL UT FT XM hii POWEH Toe ET FELD SUPPLY roa 1 3 8 THE LETS amp TABLES LPS Low PRESSURE 5 CONTACTOR TMP THERMAL MOTOR PROTECTION COMP C CH SW FM CONTROL CIRCUIT BREAKER RS REMOTE ON OFF SWITCH COMPRESSOR FFR PHASE FAILURE RELAY REVERSE VALVE CHES PRESSURE On TERMINAL NUMBER AELD CONNECTION BY OTHERS PROGRAM Gro CHA ERROR CONDITION ABMORMAL HTM COULD HAPPENS THE CONTROLLER WEL AUTOMATICALLY SWITCH OF THE CONCERNED CIRCUIT THE WHOLE CHILLER DEPEMDING ON ALARM THEN WILL GIVE 5350 AMD ALARM MESSAGE AMD THE CONTROLLER WILL EMERGI E THE GEHERAL ALARM RELAY THIS OHMI HAPPENED PUSH THE ALARM SUTTON TD SILENCE THE UTER THK O GT DISPLAY THE MESSAGE THE ALARM 8 AFTER THE ALARM TU RESET THE ALARM PUGH BUTTON AGAIN 4 CF FREEZE IT MEARE DINE DF THE
35. ONAL FEATURES 23 Construction Chiller Sound Enhancement ptions T here are 3 options to enhance the chiller sound pressure level Sound jacket kit for compressor gt U low fan speed 720 rpm 900 rpm 50 60H 2 and compressor with compartment Special design fan blades with external rotor motor and compressor with Sound jacket kit Coils Protection material T here are 3 options for coils material Polyurethane pre coat aluminum fins with copper tubes Copper fins with copper tubes Polyurethane post coat copper fins with copper tubes Galvanized wire mesh guard around the chiller perimeter Cooler cladding For shell and tube coolers Cooler cladding can be aluminum stainless steel or polyester painted 22 gauge galvanized steel Cooler insulation Cooler can be insulated with 1 5 or more thickness closed cell foam insulation Chiller Vibration Isolation T he following options are available for chiller vibration isolation gt Neoprene Rubber Pads 1 Spring isolator with restraints gt 2 Seismic Spring Isolators Refrigeration Heat pump chillers Cooler tape heater Factory installed heater to protect cooler from freeze up at low ambient down to 20 F ce storage option Special chillers are available for this option please consult the factory for more details Glycol option U sed for applications requiring water outlet temperature below 40
36. Power Data General Data Tables Electrical Data Tables Pressure Drop Curves Models Layout Load Distribution IIIIII 49 PPU Refrigerant Schematic Diagram EE 73 Refrigerant Schematic Diagram Wiring Diagram 74 N RAL 2 fe Ye JEG JE RWC Manual A GENE Page 01 T he following symbols will used in this operational manual to alert you to areas of potential hazard AMG NOTE is used to highlight additional data that may be helpful to you IMPORFANN An IMPORTANT is used to focus upon information which must be noted T A CATION is used to identify a hazard which could lead to personal or machine injury A WARNING A WARNING ts used to identify a hazard which could lead to personal death or machine destruction or break down T his manual covers the installation operation and maintenance of PE TR4 s RWC Series T his will ensure proper operation and ensures a long service life of the unit All procedure presented this manual like installation operation and maintenance OZ must be performed by trained and qualified person For more information please contact your local PE T R and service center or refer to NOTE PETRA Factory RWC Manual lt A DEAR CUSTOMER Page 02 Thank You for choosing PE TR Residential Water Chiller RW C u
37. RIPTION Page 09 Pressure Switches High Pressure Switch M anual Reset gt gt T he switch has fixed non adjustable settings and is mounted in the discharge side of the compressor T he switch is provided to protect the compressor and the refrigeration system from unsafe high pressure conditions If an unsafe high pressure condition should exist the switch opens and shuts OFF the com pressor The unit control module prevents the unit from restarting Don t operate the unit on high pressure more than 410 psig Low Pressure Switch Automatic Reset gt T his switch which is mounted on the compressor has fixed non adjustable settings It is of the automatic reset type Pressure Switches High Pressure psig om 275 TJ K enwc M anual APage 10 COMPONENTS DESCRIPTION Filter Drier Disposable Type oisture will enter system any time it is operated for field services A filter drier is a very effective method for removing small amounts of moisture and contamination It is installed in the refrigerant liquid line so that all the refrigerant in the circulation passes through the drier each time it circulates through the system BPHE cooler Brazed Plate Heat Excnanger cooler C ooler T he brazed plate heat exchanger is a complete heat exchanger which consists of st
38. adoption has an advantage of reliable changeover operation and is a unique device for short cycle prevention Designed for instantaneous reversing and operations under small minimum pressure differential between the high and low side Pressure drop across the valve and valve leakage are minimized Provided with drip proof resin encapsulated solenoid coil E l RT Z Z 2 COMPONENTS DESCRIPTION Page 12 Suction Accumulator For Heat Pump Option It s purpose is to protect the compressor from damage due to the sudden return of liquid through suction lines Compressors on many air conditioning units are often subjected to this sudden return resulting in broken valves pistons connecting rods crank shafts blown gaskets or bearing failure Thesuction accumulator will protect the compressor although several pounds of refrigerant may suddenly return through the suction line it does not flood into the compressor T he liquid refrigerant is temporarily held in the suction accumulator and metered back to the compressor at a controlled rate through the metering orifice YTB Thermostat This component used for ambient temperature from 15 30 Temperature Probe Sensor U sed to measure inlet outlet temperatures accurately 2 Gf gt COMPONENTS DESCRIPTION Page 13 Compressors Piston Compressor Pp gt gt gt Low
39. ainless steel plates permanently brazed together with pure copper The plates are stacked together and from flow cham bers for two fluids BPH E cooler is used for one stage application with allowable working pressure maximum 435 Psi T he cooler is insulated with 3 4 closed cell foam insulation 2 3 Page 11 N COMPONENTS DESCRIPTION Page 11_ Sight Glass Option T he sight glass allows the operator or service man to observe the flow of liquid refrigerant It provides a warning signal in the event that moisture has entered the system indicating that the filter should be changed or that some action needs to be taken to effectively dry the system Clear flow of liquid refrigerant indicates sufficient charge in the system moisture indicator can give an accurate reading With the unit running the indicating element must be in contact NOTE with the liquid refrigerant to give a true reading U nit must be in operation at least 12 hours before Solenoid Valve This ts normally closed with a de energized coil solenoid valve and is fitted on the liquid line solenoid valve is opened when the compressor is ON and closed when the compressor is OFF Four Way Reversing Valves Optional For Heat Pump Units Pilot operated 4 way reversing valves are suitable for heat pump application on unitary spilt system type air conditioners etc 4 way pilot valve
40. aken Shut off the liquid line solenoid valve LSV 1 T he compressor crankcase heaters will energize keeping the small amount of refrigerant in the heat exchanger from migrating to the compressor Chiller alarms If any abnormal condition occurred the controller will T ake the correct action stop the compressor or the complete unit Give alarm signal on the display to inform the user with the error condition Energize the general alarm relay for remote indication of the error condition 2 fe Ye le If ff nw anual Page 49 PETR Mark II Controller pb gt gt Refer to the error code displayed the keypad and com pare it to the error codes table attached with the wiring diagram you can find exactly the location of error that had stopped the unit Refer directly to text alarm message Some of the error signals are manually reset others are automatic reset For the manual reset alarms you might need to Reset the alarm from the external device such as high pressure or and gt From the reset button on the keypad of the controller For the automatic reset no need for user intervention the controller will take the proper action automatically Operation Limitation If the unit is to be used in area with high solar radiation unit should be mounted so that the control box is not exposed to direct solar rad
41. c 260 RWCc 310 RWCc 350 RWCc 390 RWCc 430 RWCc 470 RWCc 530 RWCc 580 RWCc 630 10 0 F Water Temp Diff Between inlet amp outlet Water Temp o 10 0 Water Temp Diff Between inlet amp outlet Water Temp 2 Gf R w c Manual Minimum Loop Volume Gallon Minimum Loop Volume Gallon Z enwc M anual PRESSUER GUAGE RWC with brazed plate cooler 2 Gf Manual Page 41 Typical Water Piping Diagram Refrigerant Qul Water n Water Out Nas mil Refrigerant In TR 2 Shell and Tube Cooler Dir a THERMOMETER ny U PRESSUER E a Y EI 7 4 lt H H SHUT OFF VALVE 2 H 15 s m A B Hi cn a L E STRAINBE SHUT OFF FLOW 8 VALVE PEA MTA FLEXIBELU SON FRESSITER GUMAGE RWC with shell and tube cooler Page 42 RW Manual w CPL E AES IG 72 FROM SYSTEM q O m o k 5 Un 3 25 OK ON o
42. c Manual H Page 75 N REFRIGERANI SCHEMATIC DIAGRAM Q Cooling Onl Units RWCc 76 63 0 74970897 2 Gf GG ff N REFRIGERANT SCHEMATIC DIAGRAM Page 76 Models RWCc 1 5 5 5 Optional Heat Pump Units RWC Al 16 17 18 gt 16 a EN T 1 1 x yo adm 1 q ox 1 NT rm LER Mun n a COOLING HEATING Low Pressure Switch Hi Pressure Switch Shut Off Valve CONTROLLER Chack Valve PTION sm 12 Cooler STD Expansion Valve Sight Glass Suction Accumalator Check Valve un Shut Off Valve Condenser Coil a a 8 Hi Pressure Gauge OPTION Charging Nipple SID Hermatic Compressor SID ITEM STATUS 2 Gf WRWC Manual N REFRIGERANT SCHEMATIC DIAGRAM 77 Optional Heat Pump Units RWCc 7 6 6 30 CUDL NEU HEATING 5 7 sight Gas ITEM B Low Pressure Suriieh STD Hi Pressure ST owner 3 e x 3 4 Mm 81 Ea EA Page 78 SG C Manual AT WIRING DIAGRAM Cooling Onl Units One Stage TONOJ CPL
43. compressor ENGINEERING INDUSTRIES CO 141351 Amman 11814 JORDAN NOMINAL POWER SUPPLY VOLT Hz Ph QTY vor Hz LRA EA EA compressormoToR L 8 W FLA EA conpFANMoToR wa COIL TEST PRESSURE REFRIGERANT REFERENCE No j RLACOPM P LOOP VOLUME GAL WATER FLOW RATE GPM Made in Jordan RWC Nameplate with similar compressor PETRA When the unit arrives compare all nameplate information with the data of submitted NOT order 2 w M anual N INSTALLATION 32 Loose Part Loose items appearing on the submitted order list should be inspected to verify receipt of the correct quantity of each T ypical items to check in RWC are listed below Expansion tank W ater switch optional If the RWC units are to be stored before installation it is important to take the following precautions Keep the unit in a safe area away from the construction site in order to maintain the integrity of the unit Keep the protective packing of the unit until it is finally installed If the packing is torn or lost protective covering should be provided to avoid subjecting the unit to site and weather conditions and manipulation t is recommended that the unit is periodically inspe
44. cted during storage CAUTION M oisture debris and minerals can cause permanent damage to the com ponents 2 am A w Manual Page 33 INSTALLATION Unloadinc T hese units are designed for overhead rigging So for proper unloading and handling a suitable crane IS needed U se wear flex slings All units are supplied with lifting lugs on base sides spreader bars Should be used to keep cables or slings clear from the unit sides to avoid damages for unit frame D D D o not use metal slings to lift the machine because it might damage the unit se wear CAUTION flex slings and do not use forklift trucks on the units 2 Gf EW C Manual N INSTALLATION Page 34 Operatina W hen installing the unit consider the followings Foundation should be made of flat leveled concrete or steel stand Free space beside the condenser coil Free space on both sides of the unit for service and maintenance if there is no barrier on adjacent wall Free space of not less than 3 meters above the condenser fans should be available Once the unit is in place Check again that the unit is leveled gt gt 39 4 lt 1 Flat Leveled Foundation 2 Electric Inlet HA Free Space For Service 4 Water in 5 Water out 6 Ele
45. ctric 354 35 4 gt V Manual e EN INSTALLATION 35 Site Requirements To achieve optimum performance and free maintenance it is essential to prepare an installation site meets with the location and space requirements for the model being installed T UL source that may attack any parts of the unit T he unit site should be selected for minimum sun exposure and far away from any is not responsible for equipment problems resulting from an improperly IMPORFANI designed or construction foundation RWC units may be locate as two type Ground Level Units Roof M ounted U nits RWC must be installed with adequate vibration isolation beneath the unit to prevent IMPORTANT any vibrations which is might be transmitted to the building 2 CAUTION Do not locate the RWC unit beside or closed to other building or large building because it might reflect the sound back this may attack the sound sensitive receiver On rooftop locations RWC should locate a place with adequate structural strength to tolerate its weight and to be more safe for the whole building Z 7 n Ly INSTALLATION Installation Establish position where unit is to be installed make four holes in the ground for double thread anchor bolts Place the unit properly and fix into the anch
46. e electrical panel such as contactors circuit breakers controllers etc T he power diagram shows the power connection for each motor D O L Direct on Line starting method will be used as standard connection for all motors Before starting the chiller M ake sure that Themain incoming power supply is as per nameplate specification and the main power supply cables are well tightened and in the right sequence Switch On the M ain Power Circuit Breaker M PC B supplied by others this will energize the PFR Phase Failure Relay Voltage M onitor if installed which will sense the main incoming power supply and will give Red Led signal if one of the following conditions was detected gt Lose in one of the phases at the main power terminal Phase reversal between two phases at the main power terminals Voltage drop in the main power supply that exceeds more 10 of the set value 3 Phase unbalance gt Over Voltage T he PFR Green LED signal indicates correct power supply Check the water flow rate G PM also check that system does not contain air bubbles and the system water pump is consuming normal current am ps w M anual aan N 4 OPERATION Chiller Starting b At thetimethe CCB is this will energize compressor crankcase heaters if available he compressor motor protections if available gt T he control transformer that supplies the p
47. eding the pumping capacity of the unit and filling of the condenser with liquid increased cooling of suction line as well as an increase in noise of the working valve in the compressor Liquid knocking also indicates unit overcharge or incorrect adjustment and or incorrect function of the control system G aseous refrigerant is only charged if small quantities are intended Refrigerant bottles with double or single valves stand upright and refrigerant is charged by means of the pressure gauge connection in the compressor suction shutoff valve When doing so check condenser pressures when charging liquid refrigerant and determine charging weight If cylinder pressure drops too low for further charging before the job is finished place cylinder in a bucket of warm 77 113 F water or use a heat lamp to increase pressure D o not apply heat with a torch N ever heat cylinder above 122 F Refrigerant Charging WARNING N ever heat bottles with the flame of the lamp such as a Bunsen or welding burner T he process used most often to determine the correct refrigerant quantity is by observing the refrigerant flow in the sight glass in the liquid line Since an uninterrupted supply of liquid is necessary for the proper functioning of expansion valves it may be assumed that the unit has been correctly filled when a clear flow of liquid refrigerant is visible Bubbles or foam usually indicate insufficient refrigerant H oweve
48. esent voltage imbalance Example Present Voltage Imbalance 100 x Max Voltage Deviation Supply Voltage 460 volt 3ph 60Hz AB 463 volt BC 462 volt AC 460 volt Average Voltage 463 456 458 3 459 volt Average Voltage Determine maximum deviation from average voltage GEN AB 463 459 4v BC 462 459 3v AC 460 459 lv M 20 M aximum deviation is 4v D etermine present voltage imbalance Voltage imbalance 100 x4 0 87 459 The amount of phase imbalance is satisfactory as it is below the maximum allowable phase imbalance value 2 ontact your local electric utility company immediately if supply voltage phase NOTE a imbalance is more than 2 Check that the voltage monitor Phase Failure Relay Lamp is and check that the setting is as specified on the nameplate Switch the control circuit breaker ON to energize compressor crankcase heater C rankcase heaters are wired in the control circuit so they are always operable when the control power supply disconnect is ON even if any safety device is open or the unit NOTE switch is in the OFF position IMPORTANN Start unit under supervision of qualified service technician 74897088977 A First Operation Checklist Running Check List Petra Engineering Industries Ca Project Name Project
49. excessive line drop Repair or rewire Check all connections and tighten 2 SOUND POWER DATA dBA 50 Hz 60 Sound Power dBA Band Frequency H z Slee ZS HRB ET sn o o 09 oe se r r sr rs o si iege oi e o Jos on oe so jet os 72 o HRB iege s r omo eee or r o jes E gt 07 ooo BRR _ or r jes gt fee fo r fe fe fro CS Be fre oo 22 jer Sound Data as ISO BS 3744 standard For Standard U nits Noise D ata Accuracy 2 dBA Ue IL RW Manual EN SOUND POWER DATA dBA 60 H Page 61 Z peu Sound Power dBA Band Frequency H z Band Frequency O U UOO OOO ee eee _ e so r mem ss ss oe os se 15 r2 EE e je n r5 ve v6 oa e 76 oa cc so e re 79 os BRB o o r
50. frigerant such as 134a are usually charged through the gauge port of the compressor suction service valve N ormal procedure is Back seat suction service valve as for normal operation Loosely connect line from service manifold to suction service valve gauge port Connect center line from manifold to the refrigerant cylinder Back seat discharge service valve Loosely connect remaining line from service manifold to discharge service valve gauge port Slightly open cylinder valve to purge vapor up to the compressor discharge service valve Tighten discharge service valve connection at gauge port Purge vapor from cylinder up to compressor suction service valve Tighten suction service valve connection gauge port Open both compressor service valve Place cylinder of refrigerant on weighing scale Pressurize system to full cylinder pressure and make final leak check Start compressor Run unit head pressure and suction pressure stabilize O pen the cylinder valve com pletely and control the flow of refrigerant from the manifold From time to time note suction pressure with the cylinder valve closed From time to time note discharge pressure to see that it does not rise above the level normally expected under operating conditions For air cooled system the discharge pressure should be approximately the pressure corresponding to ambient tem perature plus 52 F refrigeration to 63 F air conditioning When correct weight of refrigerant has
51. hat the condenser is filling with liquid If this is the case the system pum p down capacity still seems low on charge an auxiliary receiver m ay be needed f UL Never charge the liquid in the low pressure side of the system 55 D on t overcharge O vercharging results in higher pressure possible com pressor dam age TION and higher power consumption D uring charging or removal of refrigerant be sure water fluid is continually circuiting through the cooler to prevent freezing D am age caused by freezing is considered abuse and may void PET RA warranty 2 fe Yee of 2 nw c Manual Page 56 System Pump Down T his procedure is used to isolate the refrigerant in the condenser coil This process can be utilized for maintenance repairs and long periods of shutdown Pump down procedure Install pressure gauge in the unit if not installed Install a jumper across the terminals of the low pressure cutout Operate the unit Start closing the shut off valve while the unit is operating When low pressure gauge reaches about 5 Psig shut down the unit Immediately close the compressor suction valve Repeat the above once again Remove the jumper from the low pressure cutout A A A Charging Filter Drier The main function of the filter dryer is to eliminate any humidity or deposits inside the system When the filter is blocked a certain pressure drop across the filter
52. huqpaq HLL Qr Ero E ELA E gaa tg arf OQ d Eris LOB Tepes i eL B eae he 7 numer LEUR UR oho d E UN M 2 2 2 niu st od 1 ri i us dp ole s MODEL L _ RWC630 1146 67 9 w All Dimensions are in Inch 1 Electric inlet 2 Water in 3 Water out ee PST EMIMIEDS ee eee Roe be a ue ee kl i pe HTH HI t Mie He ee on i ua gn as i x ETT EE EH THT m E See LLL PEI PL ES bed bee iud uu m wm MIME i il 5 4 pg 4 EE PE TU a dA AM E E P tar CP LR A LEE XE X X BEE cae REO scare quic ENE FREE ogg da x sa EET atat mide eode GE tee brer
53. iation sun light Refer to the T emperature T able below LWT Leaving Water T emperature T emperature T able But upon a brine chiller application the minimum Maximum Ambient Temp D on t operate the chiller at water temperature below 38 F Applications in that range require chillers with factory modification for brine duty Contact your PETR CAUTION representative for more details Low Ambient Temperature optional If the chiller is intended to be used at low ambient condition lt 45 F Low ambient kit must be added to the chiller control panel T his is can be achieved through varying the speed of the condenser fan motor by using frequency inverter or voltage speed regulator T he speed of condenser fan motor can be regulated with reference to the ambient temperature to maintain constant condensing pressure in the condenser 2 fe Ye le If ff GB anual N MAINTENANCE Page 50 Each RWC unit is designed and constructed for minimum maintenance and dependable operation H owever certain maintenance procedures are required to ensure maximum operating efficiency Some Suggested procedures with the recommended intervals are listed below A sure to disconnect power before attem pting to check or service the unit to prevent WARNING accidental start up of the unit Special Maintenance After each severe windstorm check the
54. ings for your product have been made according to Petra s standards Stage Stage 3 Stage 4 Evaporator Fan Motor Overload Setting Evaporator Fan Motor Overload Setting Condenser Fan Motor Overload Setting Phase Failure relay Setting Valve Anti Freeze Temperature Set Point Fluid In Set Point Fluid Out Set Point Times Between Compressors On Off Frequency Invertor Speed Regulator Settings Amb Temp j Min Amb Temp Max Speed Min Speed the undersigned certify that this product has been successfully tested according to the specified requirements Notes PTG Engineer SAID AL GHOUL QA Engineer Rev 5 Authorized OSAMA ABU Date 28 08 2003 Page 2 of 2 2 Gf e R w c Manual Page 47 Unit Check before Start Ensure that all piping has been completed Check for refrigerant piping leak Open liquid line valve for each system Ensure water pumps are on Check and adjust water pump flow and pressure drop across the cooler Verify flow switch operation Check the control panel and compressor electrical box to assure it s free of foreign material Be certain all water temperature sensors are inserted completely in their respective wells and are coated with heat conductive compound Ensure that thermal expansion valve bulb are strapped and well insulated from other than suction tem perature
55. lete drainage of the cooler Air vent or small valves should be installed on the cooler to facilitate servicing for water or fluid flow balancing Locate valves in the return and supply cooler water of fluid lines as closed to the cooler as possible A strainer must be installed in the cooler inlet line just ahead of the cooler T his is important to protect the cooler from entrance of large particles which could cause damage to the cooler Recommended 40 mesh strainer Thermometers and pressure gauges could be installed in the inlet and outlet water lines A chilled water flow switch could be installed in the leaving water piping of the cooler T here should be a straight horizontal run of at least 5 diameters on each side of the switch Choose the right size of the flow switch blade which complies with the pipein which its installed The switch to be wired to terminals located in the control panel as shown on the unit s wiring diagram PETR 4 S cooler could be supplied with two types of water or fluid connections threaded male connection for small size cooler flexible connection U pon receiving the chillers check the type of connections If it is of the threaded connection type use an adaptor of the same cooler inlet and outlet sizes and connect directly other connection is a flexible connection with clamps after installing the flexible joint apply a suitable weld to connect the water or fluid pipe to the
56. lications It could be activated to perform different functions for cooling and heat pump applications H owever in order to render the microprocessor control and peripherals easy to use by all skill levels of service teams only necessary function for safety sequence of operation and alarm function are activated as standard In standard execution while using the microprocessor for chiller control it communicates with the standard conventional control such as high pressure flow switches etc thus allowing the service technicians to inspect and maintain such devices in the conventional manner NOTE M icroprocessor controller is a standard feature on all units PETRA Mark II Controller Advantages For units including 1 or 2 Compressors Extremely compact dimensions Excellent reliability Icon ergonomic display Simple wiring M odular architecture Power ON indication light Connection to remote terminals Built in real time clock card Temperature reading C or F Flash memory to prevent data loss in case of power failure M odification of the fundamental operating parameters set points differentials alarm thresholds time settings password protected access levels Built in keypad LED display 2 Gf MICROPROCESSOR CONTROLLER 759927 Main Functions T emperature control on water inlet Fan control Co
57. mp down optional External setpoint reset optional due to external analogue signal for remote modification of setpoint 4 20 mA or 0 10 V ac Forcing device ON OFF refer to manual operation A uto restart after power failure Displayed Data A A A U nit Status Freon T ype U nit Cooling capacity T R Compressor and Fan status Compressor operating hours Compressor starts number Pump operating hours Compressor Ampere reading O ptional Compressor Suction D ischarge Pressure readings O ptional Chilled water temperature leaving and entering Ambient tem perature Value of analog output fan inverter O ptional Compressor Suction D ischarge T em perature readings O ptional Status of high and low pressure switches Status of water flow switch Status of all inputs and outputs Automatic Pump down optional 2 Gf RW C Manual Page 30 2 MICROPROCESSOR CONTROLLER Alarm Management p Alarm history Visible full text alarm message High low ambient temperature protection Anti freeze function High AT protection across cooler to prevent unit from working under low evaporator flow Trip indication light High low pressure alarm Compressor thermal alarm Flow switch or pump interlock alarm Anti frost alarm Probe error alarm Condenser fan motor alarm
58. mplete alarm management Compressor T ime M anagem ent Pump M anagement A utomatic lead Lag function A uto restart after power failure Connection to remote terminals Pump T ime M anagement T emperature reading C or F Anti Recycling timer to limit number of compressor starts per hour Smart defrost management for optional heat pump units only gt gt gt P P b P gt P P pb Displayed Data Compressor and Fan status Compressor operating hours Pump operating hours Chilled water tem perature leaving and entering Ambient temperature Head Pressure Control By ON OFF condenser Fan standard By providing analogue output signals for fan speed controller O ptional Alarm Management Trip indication light Visible alarm code Anti freeze function High low pressure alarm Compressor thermal alarm Flow switch or pump interlock alarm Anti frost alarm Probe error alarm Condenser fan motor alarm Devices Controlled Compressors Condenser fans Reverse cycle valves Water pumps Anti freeze heaters Alarm signaling device Z enwc M anual APage 28 Remote Control optional Extended wall mounted display for remote control up to 492 ft External communications optional RS 485 interface card t
59. n roof elevated structure etc T herefore only trained and qualified installation and service technicians should install start up or service this equipment We would like to remind you that failure to respect installation and maintenance instructions may void the unit warranty NOTE Follow all safety codes W hen working with the equipment observe precautions in the literature as well as the tags stickers and labels attached to the units Keep all doors and screws installed on unit while moving unit and installing ductwork NOTE T his will helpensure that the unit stays square allowing for easier removal of doors after the ductwork is attached Before operating be sure the unit Is properly grounded to prevent injury or death from electrical shock Be sure to disconnect power before servicing this equipment DO NOT VENT refrigerant relief valves within a building Relief valves outlet must be vented outdoors Wear safety glasses and work gloves U se care in handling rigging and setting bulky equipment Keep quenching cloth and extinguishers nearby when brazing Do not tip units on their side during transportation or installation or severe internal damage may occur Before driving screws into the cabinet check on the inside of the unit to be sure the screw will not hit electrical or water lines RWC Manual N INTRODUCTION Page 04 TR Residential Air C o
60. nced impeller mounted directly into the motor drive shaft with m echanical seal to prevent leaks Buffer tank insulated with 0 75 inch thick rubber foam insulation for protection against freeze up and reduce heat losses Buffer tank made of 0 12 inch galvanized steel to cover a wide range of applications fitted with manual air vent make up and drain The whole pipe work assembly is insulated galvanized steel material Expansion tank come in a closed vessel system pressurized valve protected by a cap ensures that constant pressure is maintained in the system Rubber mounted water pump T wo isolating valves Z enwc M anual APage 25 NAL FEATURES T he PPU can also provide the following optional features Pressure gauges in the water pump inlet and outlet Water strainer built into the return water pipe Globe valve to be installed on water pump discharge Mixingtank for industrial applications and process Contractor for each pump mounted and wired in RWC electrical panel External overload for each pump W ater Out 2 fe Yee of 2 nw c Manual Page 26 NOTE For more information about these controllers please refer to the PETRA M ark and PETRA Mark VII 2 controller user s manual PE TR 45 microprocessor controller is engineered to meet the most demanding requirements of all control and data monitoring app
61. nd multi epoxy coating for base frame H eavy duty mounting chassis for whole unit welded steel base with lifting lugs painted and epoxy coated Anti vibration mounts under compressor Rubber In Shear lifting lugs Rubber In Shear Vibration Isolator Under Compressor Refrigeration ndependent refrigeration circuit per each compressor Fully charged unit with R22 or R 407c refrigerant Liquid discharge and suction pipes are all of type L hard copper pipes which formed using CNC high accurate pipe bending machine to minimize pipes brazed joints to increase system reliability Epoxy paint for all exposed copper piping system of the refrigeration circuit Expansion tank one in system Loose item Charging points with charge nipples Each refrigeration circuit component 2 Gf R w c Manual Page 21 gt Thermostatic Expansion Valve Liquid line solenoid valve Liquid line shut off valve Disposable filter drier High Low safety pressure switches capsule type factory pre set Charging points with charge nipples Electrica Weatherproof Electrical Panel All power and control components including the microprocessor controller shall be assembled inside electro static polyester powder paint oven baked electrical panel with index protection of 5 M icroprocessor control for full management of the chiller opera
62. nishing Oven Baked Electro Static Powder Coating Reciprocating Hermetcaly Sealed Scroll ros To 195 15 242 s5 as PI TT gt 3 98 38 osa T us 1 gt 3 Juan lj 5 Oil Charge mel 3151 335 T 95 351 351 31 45 313 35 465 Refrigeration Circuits Copper Tubes Aluminum Fins 0 nser 240 280 j 310 420 40 410 420 581 581 607 2 Air Flow Rate CFM 2 Gf R w c Manual Page 63 Data Above Are Based On Water IN OUT 55 45 F F For Power Supply Voltage Refer T o Electrical D ata T ables For Copeland compressor only for other compressors supply please refer to Petra Factory ELECTRICAL DATA TABLES R22 R407C 380 420V 50H Z RWC MODEL QTY 25 1PH 30 220 16 1 14 30 CR3KQ 6 1 GtEIAHP 14 40 Rag 7 1 02 048 47 CRPQ450 9 1 02 048 55 CRNO50 9 1 02 048 6 7284 4 1 EBMO2 0 48 105 2415 17 1 02 048 128 7814 20 1 02 048 1600 289 26 1 EBMO2 08 2100 7815 17 2 02 048 260 7814 20 2 SOMER11 3 30 7819 6 D 2 50 11 13 350 30 7414 20 SOMER11 3 430 28 25 17 4 SOMER11 3 40 7R19 3 J
63. nit with hermetic reciprocating scroll compressor Please take the time to go through this manual as it contains valuable information on installation operation and maintenance of the unit T his will help you to use your unit for a long time U nit capacities in this series range are as follow RW C 2 50 nominal tons 50 Hz 2 55 nominal tons 60 Hz RWCc 1 9 45 5 nominal tons 50 Hz 2 1 56 8 nominal tons 60 Hz NOTE do not hesitate to contact us at your nearest sales office RecelviIno On arrival inspect the unit before signing the delivery note Specify any damage on the delivery note If you need any more information about PE TR 4 s RWC units or other units please and send letter of protest to the last carrier of the goods Inspection Check the shipment received against the shipping list to make sure that shipment is complete After inspecting the unit protect properly during storage or while moving it to the actual installation site maintain warranty protect unit against adverse weather theft or vandalism on jobsite T ake stock all the accessories and loose com ponents that comes with the unit and y NOTE com pare it with the submitted order list Damage to Units Be sure to Inspect the unit upon receipt for damage If the unit has been damaged in transit filea claim with the transportation company immediately and advise your insurance company immediately Be sure to inspec
64. o connect the controller to a supervisory network Petra software to communicate with a remote control room through modems for monitoring and controlling the unit providing complete supervision for all functions setting and alarm condition Advanced PETRA Controller Advanced Petra C ontroller For units including more than 2 C ompressors N MICROPROCESSOR CONTROLLER Page 29 w Advantages pr Built in keypad ease of use with 4row 20column LCD display Built in real time clock M ulti language management 2 Gf R w c Manual M odification of the fundamental operating param eters set points differentials alarm thresholds time settings password protected access levels Daily weekly and holidays management Extended wall mounted display for remote control up to 492 ft with external keypad only optional Direct printer connection optional Demand limiting function optional External set point reset optional Main Functions T emperature control on water inlet outlet Smart defrost management for optional heat pump units only Fan control Complete alarm management Compressor Time M anagement Pump M anagement A utomatic lead Lag function nti Recycling timer to limit number of compressor starts per hour D aily weekly and holidays management Demand limiting function optional Automatic Pu
65. of refrigerant Open cylinder valves and loosen the center hose at gauge manifold Purge the hose for a few seconds then tighten the connection Close the refrigerant cylinder valves and admit refrigerant into the system until a pressure of about 5 Psig 35 Kpas is indicated on the gauges Disconnect the hose from the cylinder Open the gauge manifold hand valves and purge the pressure from the system Repeat steps 3 through 11 Repeat steps 3 through 9 only Open the gauge manifold hand valves and admit refrigerant into the system cylinder pressure as indicated on the gauges Close the high side gauge manifold hand valves Start the unit and add the proper charge of refrigerant ZA d AD N MAINTENANCE Page 53 Refrigerant Charging unit is charged with the refrigerant for which it is designed Efficient operation of an air conditioning unit depends on the correct charge of refrigerant by weight In case of an under charged unit the evaporator is starved of refrigerant which leads to low compressor suction pressure loss in output and perhaps overheating of the compressor motor in case of suction gas cooled compressors high superheat O vercharging the unit can lead to condenser overflow and thus too high condenser pressure to evaporator flooding and possibly to compressor damage due to liquid coming into the compressor Sudden pressure in the condenser indicates exce
66. oled Liquid Chillers RWC with hermetic scroll or reciprocating Compressors and R22 or RA07 c refrigerant offers a wide range of sizes to meet the custom er requirement for different applications within residential and commercial buildings PETRA RWC Chillers are designed to meet the customer requirement by offering state of the art Low sound reliable high energy efficient and small physical footprint chillers The wide range cooling capacities and flexible installation arrangement makes it easy to install and maintain T hese Packaged air cooled water chillers meet the same high engineering and performance standards that are characteristic of all PET RA Air Conditioning Systems his manual contains all the information required for correct installation of the unit together with operating and maintenance instructions This manual should be read NOTE thoroughly before attem pting to operate or service the unit For more technical details please refer to the nearest Sales Office or P E T R Factory Coil Corrosion Protection M aterial AC Aluminum Fin Copper Tube PC Pre Coat Aluminum Fin Copper Tube C C Copper Fin Copper T ube BC Coated Copper Fin Copper Tube Chiller S Hermetic Scroll ompressor s X Hermetic Reciprocating C ompressor s ame Compressors N ominal Sizes Different Compressors E COD 105 310 530 12304 128 350 580 160 390 630 210 430 AA
67. ors ake sure the unit is properly leveled Install and connect pipes between the RWC unit and your system as follows the RWC is ordered with system water circulating pump you just have to connect the supply and return pipes the RWC is ordered without system water circulating pump selection of pump is based on water flow rate gom and total pressure drop in system Petra Pumping Unit PPU PPU MODEL PPU 75 PPU 100 PPU 125 PPU 150 PPU 200 PPU 250 1 PPU 300 W ater W ater PPU PPU i i i MODEL Connection Size RWC unit Connection Size RWC unit in in PPU 75 0 50 RWC 25 PPU 200 1 25 RWC 160 PPU 100 0 50 RWC 30 PPU 200 2 00 RWC 210 RWC RWC PPU125 0 75 40 55 PPU 250 2 00 2605310 RWC 76 RWC PPU 150 1 00 PPU 300 2 50 350 470 RWC RWC PPU 150 1 25 1055128 9300 3 00 530 630 2 Gf R w c Manual Page 37 Mechanical Connection Chilled Water Piping Once the unit has been located in its final position the chiller water piping may be connected A A Stop valves should be installed tn all lines to facilitate servicing Flexible connections should be installed on the cooler inlet and outlet to prevent transmission of water pipe vibration Drain connections should be provided at drain connection of the cooler for comp
68. ower for the controller Y ou must keep this situation for around 24 hours If the chiller is going to be started for the first time or if the chiller has been idle for long period of time T he controller will start its self diagnostic check if all checks were satisfied and found correct Enables unit operation from local keypad digital input or Building Automation System T he controller will start its normal operation by givingthe START signal for the system water pump Switch on the switch related to each compressor on the control diagram The controller will read the water temperature and compare it to the set point Duringthe P B proportional band the controller will calculate the number of stage that must start to meet the cooling or heating load demand gt D ifferential C ontrolled measurement Proportional Band C ontrol for 2 C ompressors T he controller will operate the compressors according to the lead lag function that is the compressor with the minimum number of operating hours should start first This is to ensure equal operating hours for each compressor Chiller Shut down Controller will continue operating the unit until the water temperature is satisfied the controller will switch off the lag compressor unloading the unit if the load still decreasing the controller will switch off the next lag compressor When switching off a compressor the following action will be t
69. r care should be taken that no bubbles are seen in the sight glass even though the unit has been fully filled RWC Manual lt H MAINTENANCE Page 54 Additionally the tem perature in the condenser could also lead to sudden evaporation e g by switching the fan ON at the condenser T hus the sight glass is a valuable device in determining the correct filling quantity After all field connections electrical and mechanical have been completed and the system has been evacuated the system can be fully charged with refrigerant in two ways as shown below T he main job of a service engineer is to upkeep modern mechanical cooling system running It is essential to know the proper way to handle refrigerant to all types of systems All systems do not use the same refrigerant All systems do not use the same amount of charge even when capacities may be entirely com parable All manufacturers include a name plate that clearly lists the refrigerants for which the system was designed H ow much charge to use will vary widely from system to system T his makes it doubly important always to check the catalogues amp service bulletins D o not charge blends in vapor phase T his means that the refrigerant should be removed from the cylinder as a liquid either from the dip tube in a two valve cylinder or by inverting the cylinder The liquid is allowed to evaporate flush in the charging lines Small systems with a single component re
70. roper superheat Repair or replace if necessary 2 Gf R w c Manual Page 59 Source of Trouble Possible Causes Corrective Steps Compressor loses oil Internal thermal protection lockout opened Compressor short cycles Motor overload relays open Shortage of refrigerant Low suction pressure Expansion valve stuck open Restriction in refrigeration system High condensing temperature Low voltage during high load Loose power wiring Defective relay Defective or grounded wiring in motor or power circuits Power line fault causing single phase running or unbalanced voltage Thermostat differential set too close b Overcharge of refrigerant c Lack of refrigerant Defective relay assembly Low voltage during high load Defective or grounded wiring in motor Loose power wiring Repair leak and recharge system with refrigerant and oil See entry low suction pressure Repair or replace expansion valve Locate restriction and remove See corrective steps for high discharge pressure Check supply voltage and for excessive line drop Check all connections and tighten Replace Repair or rewire Check supply voltage Check evaporator temperature Reset differential ensuring that there is no freeze up b Remove excess Check for leaks Repair and add charge Repair or replace Check supply voltage and for
71. rty clean Refer to coil cleaning procedure Perform all weekly maintenance procedures H ave a qualified service technician to check the setting amp function of each control Inspect the condition of compressor amp control contactors and replace as required nspect all piping components for leakage and dam age Clean amp repaint any areas that show signs of corrosion nspect electrical wiring condition tighten any loose connections Clean the condenser coils Clean the condenser fans check the fan assemblies for proper clearance in the fan openings and for motor shaft misalignment abnormal and play vibration amp noise C heck the oil level if available RW C Manual N MAINTENANCE 51 Leak Test System All units should be under sufficient pressure to conduct a leak test after installation If there is no system pressure admit nitrogen into the system until some pressure is observed and then proceed to test for leaks After leaks are repaired the system must be dehydrated U se dry nitrogen and refrigerant to raise the system pressure up to 150 Psig 1050K pas T he procedure requires a separate relief valve with gauge set and a gas cylinder With the compressed gas cylinder in the upright position admit the dry nitrogen slowly until the desired pressure is obtained Carefully check the complete system for leaks by means of soap bubbles W here bubbles appear a leak exi
72. se Motor rotor is loose SRC Discharge shut off valve partially closed High ambient temperature System overcharged with refrigerant d Excessive loading e Non condensable in system Suction shut off valve partially closed Insufficient refrigerant in system Low suction pressure Excessive load Expansion valve over feeding Lack of refrigerant Evaporator dirty or iced up Clogged liquid line filter drier Expansion valve malfunctioning Close switch See point 9 Repair or replace Determine type and cause of shutdown and correct it before resetting safety switch Check evaporator temperature Lower thermostat setting if possible without freeze up Repair or replace g Check motor for opens short circuits or burn out Check all wire junctions Tighten all terminal screws Check isolator operation b Relocate add or remove hangers Check rating and setting of expansion valve Check key fit and tightness of rotor locking bolt Open valve Provide cooler air to condenser Remove excess d Reduce load Purge the non condensable Open valve Check for leaks Repair and add charge See point 6 Reduce load or add equipment Check remote bulb Regulate superheat Check valve rating against the application Check for leaks Repair and add charge Clean or defrost Replace cartridge s Check and reset for p
73. ses physical separation of suction and discharge gas High capacity at conditions where it is most needed high ambient tem perature in cooling mode and heat pum p conditions M ore comfort in cooling and heating modes Reasons mass flow at high compression ratios due to high volumetric efficiency 2 Gf R w c Manual Page 15 High durability Less failures Reasons 4 Robust design three T eflon impregnated bearings integral cast iron housing for better compressor alignment IP 54 enclosure class of terminal box Scroll inherent durability few moving parts low motor strains always starts unloaded low running torque required because compression and discharge is a continuous process Spiral surfaces wear in not out due to unique compliant design Solid state thermal motor protection M otro Protector is available High charge limit Low applied costs no accumulator no external check valve in discharge line Reasons 4 Large internal volume Protected under extreme conditions Reliable systems in rough applications Reasons Tolerant to returning liquid or debris double compliance Suction screen Centrifugal oil pump with filter Solid state motor protection module Protected against excessive pressure ratios floating seals Protected against excessive discharge tem perature internal temperature sensor located at discharge port of fixed
74. ssor Low sound level Quieter system lower applied costs no sound blanket no need for Special compressor compartment 4 Scroll is the quietest compressor in it s range with the sound level of 6dB less than the hermetic reciprocating compressor 4 Very regular sound spectrum with no peaks more sound comfort 4 Reasons Absence of dynamic suction and discharge valves Absence of reversing piston strokes gt ouble compliance the forces maintaining both scrolls in axial and radial leak free contacts depends on gas operating pressures this prevents excessive contact load and associated noise Absence of shut off noise M ore end user comfort Immediate internal pressure balancing high side low side at shut off Low vibration and discharge pulses M ore durable system lower applied costs no need for discharge muffler quieter system Smooth continuous compression process absence of rapid piston motion Each model supplied with rubber vibration absorbers High energy efficiency Lower energy costs C O P averages 3 3 this is 5 to 15 more than reciprocating compressors Reasons High volumetric efficiency no dead space no valve plate no spiral tip seals leak free compression due to double compliance gt inimized pressure losses no valve plate no internal suction and discharge piping uniform gas compression in the scroll pockets at low velocities heat transfer los
75. sted may result in excessive tube erosion T he use of improperly treated or untreated water in this equipment may result in scaling NOTE erosion corrosion algae or slime Final Check Before leaving the unit check all controls and protective devices function properly Yee Yl ff if fe Ff e R w c Manual Page 58 U se the tables in this section to assist and help you in identifying the cause or causes of any malfunctions in the unit s operation T he column headed RECOMMENDED ACTION will suggest repair procedures D isconnect electrical power inspection before servicing the unit and allow all rotating AUT ON equipment to stop com pletely Failure to do so may result in personal injury or death from electrical shock or any moving parts Source of Trouble Possible No Sourceof Trouble Possible Causes CorrectiveSteps Corrective No Sourceof Trouble Possible Causes CorrectiveSteps 1 Compressors fails to start Compressor noisy or vibrating High discharge pressure Low discharge pressure High suction pressure Low suction pressure Main switch open Thermal lockout relay opened Defective contactor System shut down by safety devices Thermostat set too high f Liquid line solenoid will not open Motor electrical trouble Loose wiring Improper isolation b Improper piping support Flooding of refrigerant into crankca
76. sts Check at all points that are expected to leak such as flare connections flanges quick coupling brazing joints etc Leave the system for a certain time and watch the gauge for any drop in reading When the test is complete system pressure should be reduced to 0 Psig OKpas the compressor is evacuated and charged with the proper kind of refrigerant Cylinder Pressure Pressure Regulator Cauge T System Pressure Guage To System Pressure Relief Valve Compressed Gas Cylinder RW C Manual EN MAINTENANCE Page 52 System Evacuation System evacuation is considered the most important process to prepare the unit for charging and to remove both air and moisture from the system and it could be done as follows Gauge Manifold CJ E Vacuum Pump vr Suc 1315 From Evaporator gt To Condenser Compressor Connect gauge manifold to the system Purge all pressure from the system by opening the system services valve s and the gauge manifold hand valves Connect the center hose on the gauge manifold to the vacuum pump Connect gauge manifold to the system Close off the gauge manifold hand valve Stop the vacuum pump but not before closing the gauge manifold hand valves Disconnect the center hose of the gauge from the vacuum pum p and connect it to a cylinder containing the proper type
77. t from the main Microprocessor Controller LLL Z Manual Page 08 N COMPONENIS DESCRIPTION Thermostatic Expansion Valve T his device controls the superheat of refrigerant vapor at the outlet of the evaporator it acts as a throttle device between the high pressure and low pressure sides of a refrigeration system and ensure that the rate of refrigerant flow into the evaporator exactly matches the rate of evaporation of liquid refrigerant in the evaporator T hus the evaporator is fully utilized and no liquid refrigerant may reach the compressor Service Valve T his is a manual valve located in the liquid line used for pum p down applications and for liquid line accessories repair or maintenance Crankcase Heater T he heater minimizes the absorption of the liquid refrigerant by the oil in the crankcase during brief or extended shutdown periods e T he heater is located in the bottom cover of the compressor T he heater fixture must be tight to prevent it from backing out of the heater well T he heater eventually burns out if exposed to air for an extended period N ever open any switch that de energizes the crankcase heater unless unit is being serviced is to be shut down for a prolonged period After a prolonged shutdown on TO NL service job energize the crankcase E l RT Z Z anual 2 COMPONENTS DESC
78. t in the following conditions Phase sequence not suitable Loss of one phase Lower voltage Variation between phases T he controller will give an alarm signal in case any of the above condition occur to indicate the fault condition The PFR has a small indication LED to indicate its status as follow Green light to indicate the correct power supply and normal operation Red light to indicate fault condition P If the unit was tripped on the PFR it should restart automatically after the cause of the CAUTION trip has been eliminated When turning on the power to the unit the LED will alternate red and green until a start delay period is elapsed Then the LED will turn solid green to indicate that the device energizes its output contacts and operates normally without any faults In case of fault the LED will turn solid red to indicate that the device has been tripped and its output contacts don t energize When cause s of trip is eliminated the LED will alternate red and green until an automatic restart delay period is elapsed and then turn solid green to indicate the normal operating of the device The under voltage tripping occurs at a deviation of 6 of the nominal voltage The automatic restart in this case is carried out when the deviation ratio becomes equal to 4 5 of the nominal voltage respecting the restart delay time _ The device is automatically reset but the unit must be manually rese
79. t the unit upon receipt for damage If damage is found file a claim IMPORTANT right away with the insurance company PETR warrants all equipment and materials against defects in workmanship and materials for one year from initial start up or eighteen months from delivery whichever occurs first unless extended warranty has been agreed as part of the contract All warranty claims must specify the unit model serial number and order number T hese details are printed on the unit identification plate For warranty purposes the following conditions must be satisfied he initial start of the unit must be carried out by trained personnel from an Authorized P E T R Service Center All the scheduled maintenance operations detailed in this manual must be perform ed at the specified times by suitably trained and qualified personnel Failure to satisfy any of these conditions will automatically void the warranty T he warranty is void if the equipment is repaired or modified due to misuse lack of IN maintenance or failure to comply with P E T R 4 s instructions or recommendations If the user does not conform to the above mentioned general notes it may result IMPORTANI in cancellation of the warranty 2 fe Ye le If ff Z a i A p N 4 SAFETY CONSIDERATION Page 03 Installation start up and service of air conditioning equipment can be hazardous due to system pressures electrical components and equipment locatio
80. tion and safety circuits Smart lead lag operation for compressors Short cycling protection for compressors time delay Freeze protection through water out probe Low ambient based on ambient control down to 45 F by cycling fan ON OFF for the units with 2 fans or more For units with one fan speed controller can be used as an optional feature Control voltage is 220 240V for all components Control transformer O n O ff switch for each compressor Starting contactors for compressors and condenser fan motors Direct On Line start Inherent motor protection for each compressor Inherent motor protection for each condenser fan motor Control circuit breaker for short circuit protection Key Lock and door handle for electric panel Control terminal strip for easy connection with electrical board and easy field installation Free terminal for remote O N OFF connection Free terminal for general alarm output Power supply monitor phase failure relay For unit models RWC 76 and above Single point power connection for electrical panel refer to electrical data tables Z enwc M anual APage 22 2 STANDARD FEATURES Key Lock and door handle Jm 8 ue al Electrical Panel Power amp Control Control Panel VDS ED 7 22 A R w c Manual N OPTI
81. ver their respective duties at optimum performance for all design conditions Coils are manufactured from seamless copper tubes mechanically expanded into aluminum fins All coils are tested at 450Psi air pressure under water to avoid leakage T hey also undergo dry chemical cleaning after coil manufacturing for optimum system cleanliness 2 enwc M anual APage 18 2 SPECIFICATIONS Direct Driven ondenser Prope er ans All condenser fans are of propeller axial type which are directly mounted on the motor shaft All fans run at approximately 900 1100 RPM 9 50 60 z for optimum fan efficiency and maximum sound power reduction Fan blades are made of corrosion resistance material and are statically and dynamically balanced before installation T his offers a low noise operation with high efficiency performance All condenser fans are equipped with wire guards Condenser Fan Motors All fan motors are of induction type totally enclosed air cooled squirrel cage type externally thermal over current protected and with class F insulation and IP 55 Fan M otor d Yo w Manual N SPECIFICATIONS Page 19 Brazed Plate Heat Excnanger cooler BPHE cooler C ooler T he brazed plate heat exchanger is a complete heat exchanger which consists of stainless steel plates permanently brazed together with pure copper T he

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