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Process Fluid Chiller

1. 36 Cabinet Dimensions and 37 Electrical Connections 38 Emergency Switchover Electrical 39 Water Level Control Module 40 Water Level Control and Chiller System 40 General Piping Arrangement at WLC 43 Cabinet Dimensions and 44 Electrical Connections at WLC Module 45 Electrical and Piping Connections at the Process 46 Level Control and Alarm Option Module Electrical Schematic 47 Tables Model Number 1 Typical Propylene Glycol 7 Glycol Volume RIDERE UI Ree beue b E tute ds ce Bde elon iu 7 Typical Ethylene Glycol Data 7 Dimensional Data 8 Dimensional data 8 and 10 ton air cooled 9B Dimensional Data 8 10 ton air cooled models wit
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3. 18E Flow Control onerare a passa ee ap dic 18E TROUBLESHOOTING SEMIANNUAL MAINTENANCE INSPECTION CHECKLIST PARTS duo e OC athe aN oa 24 APPENDIX EMERGENCY WATER SOURCE MODULE Model Numbers u sise es er E NC AX rd 34 Typical Application sae sation evi CIS ea PERPE RUP UR 34 Sequence of 34 System Components o von n uu EE 34 Installation eu ER as Y In Nee Cera RE unt kd terree ep 35 Maintenance cca dv ban yew Pad SE P P wies 35 APPENDIX B THE WATER LEVEL CONTROL MODULE Model Number Rb ea sr vedete a eic oe PR ee 40 Typical Applications y ha Fer 40 Sequence of 40 System Components cei es utes enge yd AES dg 41 Installation haw Ge S s ae 41 Maintenance icu Wo ee Dg eee DEL e de nant Re Y 42 Figure 1 Figure 2 Figure 2A Figure 2B Figure 2C Figure 2D Figure 3 Figure 3A Figure 3B Figure 3C Figure 3D Figure 3E Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Table 1 Table 2 Table 3 Table 4
4. 39 Emergency Water Source Module Appendix A 9 0 APPENDIX THE WATER LEVEL CONTROL MODULE This module automatically adds water to the chiller system if the fluid level drops in the fluid res ervoir located within the chiller The module is a pre piped and wired assembly which consists of an almond colored powder coated and baked enclosure RCM4 monitor adjustable time delay relays double check valve back flow preventer and flow regulating solenoid valve Included for field installation and wiring is a multi point level switch junction box and automatic air vent The module has a local display for high fluid level low fluid level fluid fill problem and fluid fill lockout It also has a non powered common alarm contact It requires a 120 volt single phase power input This module is for use on systems that circulate water as the cooling medium it is not for use with glycol systems Figure 10 Water Level Control Module 9 1 9 2 Model Number WLCOOW K00 for application with 1 5 and 5 ton Typical Application Figure 11 Water Level Control and Chiller System 9 3 CITY WATER WLC MODULE 0 LOAD CHILLER FE Sequence of Operation In normal operation mode the Water Level Control Module is in a standby mode while sensing an acceptable level of water in the reservoir within the chiller When the multi point float switch installed in the water r
5. Outside the United States 614 888 0246 Locations United States 1050 Dearborn Drive Box 29186 Columbus OH 43229 Italy Via Leonardo Da Vinci 8 Zona Industriale Tognana 35028 Piove Di Sacco PD 39 049 9719 111 Fax 39 049 5841 257 Asia 23F Allied Kajima Bldg 138 Gloucester Road Wanchai Hong Kong 852 2 572 2201 Fax 852 2 831 0114 amp 5
6. The control voltage circuit is protected by a manual reset 3 2 Amp circuit breaker Circuit breaker is mounted to a bracket on the transformer Reset Button If the reset button is in the extended position eliminate all possible shorts in that circuit then depress the reset button Low Pressure Switch Adjustment The low pressure switch is located under the chiller control box The cut out is the point at which the switch will close The cut in is the point at which the switch will open See below for settings required for fluid at your installation The factory settings are for water Fluid Cut Out Cut In Water 53 PSI 65 PSI 4096 Glycol 40 PSI 50 PSI 5096 Glycol 30 PSI 40 PSI Temperature Adjustment The temperature control thermostat is located under the chiller control box The setpoint is the point at which the switch will close The differential is the temperature drop required to open the switch Factory Setpoint 52 F Allowable Range 40 to 70 F Differential 3 F High Pressure Switch models are equipped with a non adjustable high pressure switch This manual reset switch sets the maximum discharge pressure of the compressor If the pressure rises to the setpoint of 360 PSI the switch will shut off the compressor Operation 11 3 8 3 9 Positive Start Kit units have a non adjustable time delay relay that bypasses the low pressure switch for three minutes This ensures positive startin
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8. LLiebert Keeping Business In Business HEAT REMOVAL ENVIRONMENTAL CONTROL Process Fluid Chiller USER MANUAL 1 5 10 Tons 50 amp 60 Hz n amp EMERSON Table of Contents PRODUCT MODEL 1 1 0 INTRODUCTION 1 1 1 2 1 3 2 0 2 1 2 2 2 3 2 4 2 5 2 6 3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 Product D amp seription A weiss arte GP ER dm E 3 Optional 3 1 2 1 Refrigerant Gauges and Reservoir 3 Accessory Equipment Ship with 3 1 3 1 Emergency Water Source 3 1 9 2 Water Level Control and Alarm 3 1 9 9 Fluid Pr ssure Gauge ou tepore uen Ve p oer dp 3 lat Check Valve cte orta td Ese ed ee dp USE 4 13 5 Dial Thermometer y yaya seek 4 1316 Relier Valve od uode cupressus Dese ee t ocu is 1M e Dente 4 Circuit Setter yeh use hos e odios e t cre s eL Sa eco ust cha bo ca dg 4 1 9 9 Ball Valve teda Saec indices be nie tens n oer ed teh os E ath tels Ne ete 4 1 3 9
9. MAINTENANCE Refrigeration System 13 E Re ee aceto S ay S raise e RA a qp UR nea aac Os re a Mo doe 13 4 1 2 Discharge Pressure Vs Stc deor ae Bho ete o a oe WAS sia Pia aus p pae Gigs 13 4168 Superlieat oet gate ne b ted at ted uolet a eene eL t oA e ide th 13 4 1 4 Thermostatic Expansion Valve Operation 14 4 1 5 Hot Gas Bypass Valve Operation 14 41 6 zA1r Cooled Condenser sas de Le chat dte Heer eerta e 15 4 1 7 Compressor 15 Chilled Fluid Pump hot ees 17 Pump Differential 17 Pump Suction Pressure eh o e e RARE Xe teste 17 Refrigerant Gauges 17 Reservoir Heater a de CH Au VE dae ate peated slide 18 Reservoir Tank soss Pu A ES 18 8 AND 10 TON PROCESS CHILLER USER MANUAL SUPPLEMENT Product Heer ptn eet Oe qq Ee qa Id 18A 4A 1 1 Additional 18A Temperature Control for 8 and 10 Ton Process Chiller 18C Temperature Setpoint for Chiller
10. To obtain an accurate setpoint connect a voltmeter millivolt to TP1 and TP2 The readout will display tem perature in degrees Fahrenheit Turn the potentiometer to the desired setpoint well sensor is factory piped and wired to accurately measure the temperature of the water leaving the chiller This sensor provides input to the Electronic Hot Gas Bypass Controller The sensor changes electrical resistance in response to temperature changes To check or troubleshoot the sensor disconnect it from the controller and measure the resistance Figure 3E shows the relationship between temperature and resistance Figure 3E Temperature sensor resistance OHMS 4A 4 50 000 40 000 30 000 20 000 TEMPERATURE Degrees Fahrenheit Flow Control circuit setter is factory installed in the supply line and a ball valve is factory installed in a bypass loop The desired system flow to the load should be set by adjusting the circuit setter to the required flow rate If a flow rate of less than 5 gpm is required the ball valve should be adjusted to keep the overall system flow rate up If low suction pressures are present the circuit setter should be set to a higher flow with the bypass valve used to control flow to the load Maintenance 18E 5 0 TROUBLESHOOTING Use this section to assist in troubleshooting your unit Tables are grouped by product function for convenience WARNING ONLY QUALIFIED PERSONNEL SH
11. and add refrigerant Worn piston rings valves Replace compressor Noisy operation Slugging due to floodback of refrigerant See Symptom Flooding Refrigeration System Broken connecting rods valves or other running gear Replace compressor Low suction pressure Insufficient refrigerant in system Check for leaks repair and add refrigerant Plugged filter drier Replace filter Compressor motor protectors tripping or cycling High suction temperature Reduce suction temperature by TEV adjustment or provide desuperheating Compressor motor defective Check for motor winding short or ground Loose electrical connections Tighten connections 20 Troubleshooting Table 8 Compressor Troubleshooting Symptom Compressor cycles intermittently Possible Cause Low pressure switch erratic in Check or Remedy Check tubing to switch to see if operation clogged or crimped Check setting of Switch Insufficient refrigerant in system Check for leaks repair and add refrigerant Air in system Purge Compressor cycles on locked rotor Compressor motor defective Check for motor winding short or ground Low line voltage Check line voltage and determine location of voltage drop Single phasing Check voltage across all 3 legs at contactor Correct source of problem 3 phase units only Will not pump down B
12. kg PS018A 36 1 16 25 1 4 18 27 7132 2 1 3 8 2 14 827 32 1 15 16 314 914 1018 641 457 691 51 35 57 225 49 142 5024 36 40 146 25 1 4 18 N A 27 7132 2 1 3 8 2 14 827 32 1 15 16 344 914 1018 641 457 691 51 35 57 225 49 156 PSO36A 36 1 8 48 346 32 1 2 18 N A 34 3 32 1 7 8 2 2 1 2 10 3 32 2 425 918 1224 825 457 866 48 51 64 256 51 193 PSO48A 36 18 53 3 16 38 1 2 18 24 19 32 39 3 32 2 1 2 2 2 1 2 10 3 32 2 532 918 1351 978 457 625 993 64 51 64 256 51 241 PSO60A 36 1 8 53 3 16 38 1 2 18 24 19 32 39 3 32 2 1 2 2 2 1 2 10 3 32 2 582 918 1351 978 457 625 993 64 51 64 256 51 287 8 Installation Figure2 Electrical Connections ge E I Wed E i 8 OH S d if 2 H H b lt H H H H H Low Press Switch Temp Switch Xx E d E a 5 _ x HE 8 dou mue ce Sz B 5 oS 4 8 58 HE 9 Installation led models Ir coo t 8 and 10 ton a Iping arrangemen Figure 2A General p jJejsouliou jeuondo N 7 X ping 7 eoueuejureui pue Z
13. 00 5 20 3 00 SCH 30 08 12 00 RIGHT VIEW REAR VIEW LEFT VIEW 7 P SHADED AREAS RECOMMENDED CLEARANCE FOR COMPONENT REMOVAL AND ACCESS RIGHT FRONT ISO Figure 8 Electrical Connections 8 POWER CORD COMMON ALARM CONNECTION NON POWERED FIELD SUPPLIED NEC CLASS 2 24V WIRING FROM CUSTOMER SUPPLIED ALARM DEVICE HAVING 6 RATING OF 5 VA 24VAC MAX CONNECT TO TERMINAL STRIP LOCATIONS 11 12 AND 13 FOR COMMON ALARM INDICATION OF ALL MALFUNCTIONS REMOTE UNIT SHUTDOWN 7 COMMON ALARM 24 OPTIONAL FIELD SUPPLIED 24V NEC CLASS 2 CONTROL WIRING DRY CONTACTS Table 18 Emergency Water Source Electrical Data Input Voltage 115 V Input Amps 55 A Minimum supply circuit ampacity 69 A Maximum fuse or circuit breaker 15 A Transformer 1 secondary FLA 55 Transformer 2 secondary FLA 33 38 Appendix Emergency Water Source Module Figure 9 Emergency Switchover Electrical Schematic Y INO W3LSAS HIT Sde 31000N YIAOHILIMS A9N398U3 3 Se mere mt E opt mmh 1299911 Fo iu NOIL93NNO2 901 NOIL23NNOO 9181 VNIMH3L 110 031719915 01313 ONISIM 110 03119915 4301393 JOVLIOA JN 03179915 01313 ONIMM JOVLIOA INIT 03114905 4301393 S6 21 S BELA iii 1030317 40 1435MQ DOG 509410 VOS
14. 047 060 059 1 1 Fan Blade 1C21119P1 1 1D21122P1 1 1 1C21120P1 1 1 127914P1 1 1 1 1 1 2 Motor 208 230V 1D21121P1 Motor 200 208 230V 1D21122P1 1 1 1 Motor 380 420 460V 1D21122P2 1 1 1 Motor 200 208 230V 127902P1 1 1 1 1 1 1 Motor 380 420 460V 127902P2 1 1 1 1 Table 12 Compressor and Refrigerant Valves Model Numbers Capacity 1 5 Ton 2Ton 3Ton 4Ton 5 Ton Hz 60 50 60 50 60 50 60 50 60 50 FN Description Part No 018 021 024 028 036 038 048 047 060 059 Compressor 1 3 208 230V 1 Phase 146300P1 1 208 230V 1 Phase 146303P1 1 200 208 230V 1 Phase 1D21116P1 1 1 208 230V 3 Phase 1D21116P2 1 380 420 460V 3 Phase 129102P2 1 1 208 230V 3 Phase 138980P2 1 460V 3 Phase 138980P1 1 200 208 230V 3 Phase 127650P1 1 1 200 230 1 Phase 1C19511P1 1 200 230V 1 Phase 130913P2 1 208 230V 3 Phase 129102P1 1 208 230V 3 Phase 132082P1 1 380 420V 3 Phase 132082P2 1 380 420 460V 3 Phase 127650P2 1 1 Crankcase Heater All Voltages 1 21138 2 1 1 1 1C21138P1 1 1 1 1 1 24 Parts Table 12 Compressor and Refrigerant Valves Model Numbers Capacity 1 5 Ton 2Ton 3Ton 4Ton 5 Ton Hz 60 50 60 50 60 50 60 50 60 50 FN Description Part No 018 021 024 028 036 038 048 047 060 059 380 420V 1C21138P2 1 1 200 230V 1C211
15. 1 inch NPT female depending on model The supply line to the computer and return line from the computer are labeled on the unit Install all accessories supplied with your unit These may include switchover modules flow switch valves gauges and monitors Flush the coolant loop to remove foreign materials before filling Use a mixture of water and ethylene glycol or propylene glycol if the chiller will be outdoors and subjected to freezing temperatures Refer to 2 5 Preparation of Glycol Solution Fill system with enough coolant for chiller unit lines and equipment to be cooled Filling and air bleeding can be done at the schrader fittings on the chiller Make sure to bleed all air out of the system from the highest point in the loop NOTE Q Do not bleed air from the coolant reservoir tank Fill the system to put the fluid level in the tank at the height of the sightless The air volume in the top of the tank is required to allow for coolant expansion and for the proper functioning of the optional WLC accessory CAUTION To prevent leaks the coolant loop should not exceed the designed maximum working pressure of 50 PSI 344 kPa For installations using an alternate water source above this rating isolation valves or a pressure reducing valve customer supplied is required Installation 5 2 4 2 5 Electrical Connections Connect unit to the required AC power source as indicated on the unit nameplate throug
16. Control for 8 and 10 Ton Process Chiller Liebert 8 and 10 ton process chillers include a Sporlan Electronic Hot Gas Bypass Valve and con troller This control provides a precise method of capacity control by bypassing hot gas to the evaporator inlet Figure 3B shows a schematic representation of this piping system Figure 3B Piping bypass to evaporator inlet External Equalizer Solenoid Valve Condenser Compressor Receiver The system is factory piped and wired Figure 3C shows the connections to the control board Figure 3C Electronic hot gas bypass valve SDR 4 5 8 21 m J Fitting size available 3 8 or 1 1 8 ODF k 8 08 Maintenance 18C Figure 3D Electronic hot gas bypass control board connections The sensor 24 VAC power and the electronic valve are factory wired to the control board Jump ers are factory set to the following pins P7 Temperature sensor enable selector P9 Close on rise logic selector P12 Valve selector In addition a jumper can be field installed on the following pins to troubleshoot operation of the valve P5 Force valve open valve opens and remains open as long as jumper is installed P6 Force valve closed valve closes and remains closed as long as jumper is installed 18D Maintenance 4A 3 Temperature Setpoint for Chiller The temperature setpoint for the chiller should be set by turning the potentiometer
17. For installations using a water source above this rating a pressure reducing valve supplied by others is required Connect city water to the appropriate connection on the WLC module as shown on Figure 12 The line should be sized to carry 0 5 gpm Connect a similar line from the WLC module to an appropriate location in the chilled water system 1 4 NPT connection is located on the return water line in the chiller for this purpose if suitable see Figure 15 Connect optional control wiring for remote shutdown and common alarm as required Plug mod ule power cord into receptacle with appropriate rating see Figure 14 NOTE Q Once connected and operational the WLC module may be used to initially fill the system with water However manual reset using the reset switch on the WLC module and alarm silence on the RCM4 will be required every 8 minutes during this initial system fill Allow WLC to fill system or fill manually referring to chiller installation instructions in 2 3 Piping Connections The expansion air volume must be maintained in the top of the reservoir tank for the WLC float switch to operate properly Refer to 4 5 Reservoir Tank for mainte nance recommendations 9 6 Maintenance Periodic maintenance should include a monthly observation to verify that the electrical system is energized and that the water supply line 1s open 42 Appendix B The Water Level Control Module Figure 12 General Piping Arrangement at
18. High Temperature 4 1 9 10 Low Flow sue bises eer 4 Jo PP ROMS Monitor ir rss Ae ere eret o eere a qute teu bas 4 INSTALLATION EquipmentInspection 5 Location 4 5 Piping Connections oie dose edo eiut b doe w Rb 5 Electrical Connections 6 Preparation of Glycol 0 6 eS RIP TURN E s 7 OPERATION Pre Startup Checklist u u dis wa uer HAS otre bu poe fe 10 Startup Proc dure A Se DEE 10 Overview of Op rations ss fa sent qaa aya AER 11 Pranstormer s yau ta A e nt b Nets a as 11 Low Pressure Switch Adjustment 11 Temperature Adjustment 11 High Pressure Switch ve PERI ue E D UR 11 Positive Star Kat Bon aiio ed PEE DES Ss ew Se os SS 12 Short Cycle Prevent 12 4 0 4 1 4 2 4 2 1 4 2 2 4 8 4 4 4 5 4A 4A 1 4 2 4A 3 4 4 5 0 6 0 7 0 7 1 8 0 8 1 8 2 8 3 8 4 8 5 8 6 9 0 9 1 9 2 9 3 9 4 9 5 9 6
19. Table 5 Table 5A Table 5B Table 6 Table Table 8 Table 9 Table 10 Table 11 Table 12 Table 13 Table 14 Table 15 Table 16 Table 17 Table 18 Table 19 Table 20 Figures Dimensional Data and Piping Connections 8 Electrical Connections etd backs PES RUN e t e em IL E CES 9 General piping arrangement 8 and 10 ton air cooled models 9A Cabinet and floor planning dimensional data 8 and 10 ton air cooled models 9B Electrical field connections 8 and 10 ton air cooled models 9C Cabinet and floor planning dimensional data 8 and 10 ton air cooled with thermal storage tank cabinet RITU E weds de ed M 9D Hot Gas Bypa88 rts ttes EUR Meda EE 15 Process chiller pump performance 60 2 18B Piping bypass to evaporator inlet 18C Electronic hot gas bypass 18C Hot gas bypass control board 18D Temperature sensor 18E The Emergency Water Source Module 33 Emergency Waters stes Gos WIDE RE D ee LN deems A wie A aua NE 34 General Piping
20. WLC Module TO CHILLER FROM CITY WATER SUPPLY FILL VALVE BACKFLOW PREVENTER Table 19 WLC Module Connection Sizes Supply Pressure 100 psig Max Connection FPT Supply from city water source 1 4 To chiller water system 1 4 Appendix B The Water Level Control Module 43 44 Appendix B The Water Level Control Module Figure 14 Electrical Connections at WLC Module BR FIELD CONNECTED WIRES Rar EDU FROM MULTILEVEL FLOAT YL FIELD INSTALLED IN CHILLER REMOTE UNIT SHUTDOWN 1 amp 2 SUPPLIED 24V CLASS 2 WIRING COMMON AL ARM CONNECTION INON POWERED FIEND SUPPLIED NEC CLASS 2 24V WIRING 24VAC MAX CONNECT TO TERMINAL Re LOCATIONS 13 14 amp 15 FOR COMMON ALARM INDICATION OF ALL MALFUNCTIONS 8 POWER CORD REMOTE UNIT SHUTDOWN CUNIT 24VAC OPTIONAL FIELD SUPPLIEO 24V NEC CLASS 2 COMMON ALARM CONTROL WIRING DRY CONTACTS REQUIRED FIELD SUPPLIED 24V NEC CLASS 2 CONTROL WIRING FLOAT SWITCH CONNECTIONS UNIT 24VAC Table 20 WLC Module Electrical Data Input Voltage 115 V Input Amps 0 46 A Minimum Supply Circuit Ampacity 0 58A Maximum Fuse or Circuit Breaker 15A Appendix B The Water Level Control Module 45 Figure 15 Electrical and Piping Connections at the Process Chiller ZO tut SSE gt Jac ZO Leg Su tu lt Ze ul zo
21. capillaries and all electrical connections 5 Remove failed compressor Lal CAUTION In three phase models with scroll compressors record compressor motor connections when removing failed compressor A scroll compressor must rotate in the proper direction Wire the replacement compressor motor the same way to maintain proper rotation direction Install replacement compressor and make all connections Pressurize and leak test the system at approximately 150 PSI 1034 kPa pressure Follow manufacturer s instructions for clean out kits Connect a vacuum pump to both sides of the system through properly sized connections Evacuate the system twice to 1500 microns and the third time to 500 microns Break the vacuum each time with dry nitrogen to 2 PSI 13 8 kPa 10 Charge the system with refrigerant R 22 based on requirements of the evaporator condensing unit and lines Refer to the unit nameplate 11 Apply power and operate the system Check for proper operation Chilled Fluid Pump Pump Differential Pressure Refer to chart below Pump differential pressure must be above minimum PSI to prevent over loading and subsequent motor protector tripping Measure the pump suction and discharge pres sures at the 1 4 flare fittings on the pump piping The differential is the difference between these two pressures If the differential pressure is too low then check pump suction pressure and check system is filled with fluid
22. local display for high fluid level low fluid level fluid fill and fluid fill lockout as well as separate non powered contacts for high fluid level low fluid level and fluid fill It also has a non powered common alarm contact It requires a 120 60 1 power input It automatically adds water to the reservoir in the chiller when the water level drops below a set level and continues until the water rises to a preset level An alarm circuit activates if the tank has not filled after a preset time period and a lock out cir cuit deenergizes the solenoid valve if the tank has not filled after an additional time period The level switch contains additional high and low level alarm points Fluid Pressure Gauge An analog gauge with 2 1 2 inch 63 mm dial for panel mounting and bourdon tube for monitor ing supply or return pressure Scale is 0 to 100 PSI 0 to 690 kPa Introduction 3 1 3 4 1 3 5 1 3 6 1 3 7 1 3 8 1 3 9 1 3 10 1 3 11 Check Valve Brass body swing check valve for installation in the fluid piping to prevent back flow Dial Thermometer A 2 1 2 inch 63 mm dial thermometer for panel mounting for supply or return fluid tempera ture measurement Dual scale 1s 20 F to 130 F and 10 C to 55 C Relief Valve A brass body 3 4 inch FPT valve set at 50 PSI for installation in the fluid piping The Process Fluid Chiller is supplied with a relief valve as standard equipment An additional optional
23. metals of construction than water itself Aqueous solutions of these glycols however assume the corrosivity of the water from which they are prepared and may become increasingly corrosive with use if not properly inhibited There are two basic types of corrosion inhibition they are classified as corrosion inhibitors or environmental stabilizers The corrosion inhibitors function by forming a surface barrier which protects the metals from attack Environmental stabilizers while not corrosion inhibitors in the strict sense of the word decrease corrosion by stabilizing or favorably altering the overall environ ment An alkaline buffer such as borax is a simple example since its prime purpose is to main tain an alkaline condition pH above 7 The quality of the water used for dilution must be considered because water may contain corro sive elements which reduce the effectiveness of the inhibited formulation Preferably surface 6 Installation 2 6 water that is classified as soft low in chloride and sulfate ion content less than 100 parts per million each should be used Before an inhibited glycol solution is charged into a new or old sys tem residual contaminants such as sludge rust brine deposits oil etc should be flushed out as completely as possible Avoid the use of strong acid cleaners However if they are required inhib ited acids should be considered In any event assure that the cleaning agent is complete
24. relief valve is required only for special applications Note If a special pump is selected a special relief valve may be required Circuit Setter A bronze body calibrated balancing valve for flow balance metering and shut off Ball Valve Brass body 1 4 turn for isolation of fluid piping components as a service aid High Temperature Thermostat A remote bulb adjustable thermostat Provides alarm contact when the fluid temperature rises above design limit Adjustable range is 40 F to 90 F 4 4 to 32 C Low Flow Switch Brass body flow switch Provides alarm contact when fluid flow falls below design limit RCM8 Monitor The RCMS is an eight point dry contact monitoring system that can be used as a stand alone panel dial an alarm to a remote location or connected to a Liebert SiteScan system The RCM8 is equipped with two RS 232 ports for a local VDT and modem connection eight LED s common alarm contact and an audible alarm for local annunciation The RCM8 requires 120 or 220 VAC 50 or 60 Hz and has an internal battery rated for one hour of operation 4 Introduction 2 0 INSTALLATION 2 1 2 2 2 3 Equipment Inspection Upon arrival of the unit inspect all items for either visible or concealed damage Damage should be immediately reported to the carrier and a damage claim filed Location Considerations The air cooled chiller should be located for maximum security and maintenance ac
25. rubbing on fan housing 22 Troubleshooting 6 0 SEMI ANNUAL MAINTENANCE INSPECTION CHECKLIST Liebert Process Fluid Chiller Date Prepared by Model Serial Air Cooled Condenser 1 Condenser coil clean ___2 Motor mounts tight 3 Bearings in good condition Chilled Water Pump 1 Check for leaks ___2 Check pump operation Compressor __1 Check for leaks Electrical Panel 1l Check electrical connections ___2 Check operation sequence and cycling Refrigeration Cycle Section 1 Check refrigerant lines 2 Check for moisture sight glass 3 Check suction pressure 4 Check head pressure 5 Check discharge pressure 6 Check hot gas bypass valve 7 Check thermostatic exp valve 8 Check superheat Signature Make photocopies of this form for your records Semi Annual Maintenance Inspection Checklist 23 7 0 PARTS NOTE Q The numbers in the FN column in the following tables refer to the figures at the end of this section For example FN 1 3 indicates Figure 1 part number 3 7 1 Parts List Table11 Fans Motors Model Numbers Capacity 1 5 Ton 2 4 5 2 60 50 60 50 60 50 60 50 60 50 Description Part No 018 021 024 028 036 038 048
26. sure to bleed all air out of the water system Note that the pressure limit of the Emergency Water Source Module is 100 psig CAUTION To prevent leaks within the Emergency Water Source Module the water pressure should not exceed100 psig For installations using an emergency water source above this rating a pressure reducing valve supplied by others is required Connect optional control wiring for remote shutdown and common alarm as required Plug mod ule power cord into receptacle with appropriate rating See Figure 8 Maintenance Periodic maintenance should include a monthly manual switch over to insure that the system operates properly Appendix A Emergency Water Source Module 35 Figure General Piping Arrangement FLOW SWITCH SUPPL Y SOLENOID BACKFLOW PREVENTER EMERGENCY SUPPLY FROM WATER SOURCE CHILLER SOLENOID FROM EMERGENCY WATER SOURCE amp a TO DRAIN OR RECIRCULATOR RETURN TO CHILLER 9 THERMOSTAT RETURN ISOLATION VALVE FROM LOAD ISOLATION VALVE DRAIN SOLENOID VALVE RETURN SOLENOID VALVE Table 17 Emergency Water Source Piping Connection Sizes Connection MPT l Supply from chiller r From emergency water source 3 4 To drain or recirculator 3 4 Return to chiller 1 Supply to load 1 Return from load 1 36 Appendix A Emergency Water Source Module 12 00 6 08 Y 4 50 D 5 H 4 4 58 2 00 16
27. without 100 gallon storage tank 12 4 gallons 8 ton model PS096A 12 6 gallons 10 ton model PS120A Multistage Circulating Pump The model number indication for the multistage pump is an or in the ninth character of the model number For example PSO96A AM40 The chiller includes a factory installed and wired multistage circulating pump It is important that the pump be properly primed before operating Fully unscrew the pin located the drain plug Close the discharge valve Remove the vent plug and fully unscrew the drain plug pin Open the suction valve until liquid flows out of the vent plug connection Install and torque the vent plugs to 15 Ibs ft Close the drain plug pin and open the discharge valve ge WN a For additional information refer to the pump user manual that is shipped with the chiller and attached to the pump with a cable tie Figure shows the flow and pressure characteristics Maintenance 18A Figure Process chiller pump performance 60 Hz 300 x 2 hp multistage 250 x 200 iL O L 3 9 150 3 hp single stage 100 1 hp single stage 90 3 4 hp single stage 0 10 20 30 40 50 60 Flow Rate GPM 18B Maintenance 4A 2 Temperature
28. 1 1 127130P5 1 1 1 1 Pressure Switch 127972P1 1 1 1 1 1 1 1 1 1 1 Check Valve W 0092 1 1 1 1 1 1 W 0091 1 1 1 1 Relief Valve 127140P1 1 1 1 1 1 1 1 1 1 1 Table 13 Quick Disconnect Couplings Hot Gas Suction Line Liquid Line FN Models Female Male Female Male Female Male 018 021 1C19509P1 1C19509P5 1C19508P6 1C19509P4 1C19508P1 1C19509P6 024 028 1C19509P1 1C19509P5 1C19508P2 1C19509P1 1C19508P1 1C19509P5 036 038 1C19508P6 1C19509P4 1C19508P2 1C19509P2 1C19508P1 1C19509P5 048 047 1C19508P2 1C19509P1 1C19508P7 1C19509P8 1C19508P6 1C19509P4 060 059 1C19508P2 1C19509P1 1C19508P7 1C19509P8 1C19508P6 1C19509P4 Table 14 Fluid Controls Model Numbers Capacity 1 5 Ton 2Ton 3 Ton 4 Ton 5 Ton Hz 60 50 60 50 60 50 60 50 60 50 FN Description Part No 018 021 024 028 036 038 048 047 060 059 Evaporator and Reservoir 2 1 Evaporator 140212P1 1 1 140212P2 1 1 140212P3 1 1 140212P4 1 1 140212P5 1 1 2 2 Reservoir 140203P1 1 1 1 1 140203P2 1 1 1 1 1 1 Optional Reservoir 140215P1 1 1 1 1 1 1 1 1 1 1 Heater Relief Valve P 4730 1 1 1 1 1 1 1 1 1 1 26 Parts Table 14 Fluid Controls Model Numbers Capacity 1 5 Ton 2 Ton 3 Ton 4 Ton 5 Ton Hz 60 50 60 50 60 50 60 50 60 50 FN Description Part No 018 021 024 028 036 038 048 047 060 059 Circulating Pump and Valves 1 3 P
29. 38P1 1 1 Pressure Switches High Pressure Switch Voltages 1C21139P1 1 1 1 1 208 230V 1C21139P1 1 200 230V 1 Phase 1C21139P1 1 Voltages 127938P2 1 1 1 1 200 230V 3 Phase 127938P2 1 460V 127938P2 1 380 420V 127938P2 1 Low Pressure Switch P 3070 1 1 1 1 1 1 1 1 1 1 Refrigerant Valves HGBP Valve P 0180 1 1 1 1 1 1 HGBP Solenoid P 0070 1 1 1 1 HGBP Solenoid P 0080 1 1 HGBP Valve P 018A 1 1 1 1 HGBP Solenoid P 287A 1 1 1 1 Thermal Expansion 140201P1 1 1 1 1 Valve 140201P3 1 1 140201 4 1 1 1 1 Liquid Line Solenoid 126630P1 1 1 1 1 valve 127935P5 1 1 127935P1 1 1 1 1 Sight Glass 1A21133P1 1 1 P 3870 1 1 1 1 P 0050 1 1 1 1 Filter Dryer 1C21132P1 1 1 P03 0030 1 1 1 1 128177 1 1 1 1 1 Condenser Coils 1 5 Condenser Coil 1021107P1 1 1 1D21106P1 1 1 1D21108P1 1 1 127900P1 1 1 1 1 Parts 25 Table 12 Compressor and Refrigerant Valves Model Numbers Capacity 1 5 Ton 2Ton 3Ton 4Ton 5 Ton Hz 60 50 60 50 60 50 60 50 60 50 FN Description Part No 018 021 024 028 036 038 048 047 060 059 Lee Temp Parts Head Pressure Control 1C21207P1 1 1 1 1 1 1 VANS 127956P1 1 1 4 Receiver 127130P1 1 1 127130P2 1 1 127130P3
30. Check pump is not air locked Pump Suction Pressure Pump suction pressure must be at least 0 psig 14 7 psia Measure If too low check system is filled and check that pump suction line valve is open Table 6 Pump Suction Pressure Minimum Pressure Model Pump Differential PS048 60 1 0 HP 43 PSI 296 kPa PS018 24 36 75 HP 35 PSI 241 kPa Refrigerant Gauges The optional gauges display suction and discharge pressures They are located the unit exterior panels next to the field wiring connections Refer to Figure 2 Maintenance 17 4 4 4 5 replace the gauges follow proper maintenance procedures There is a schrader valve on the 1 4 in flare connection on the piping at the capillary tube connection Remove the capillary tube at the pipe end to minimize release of refrigerant Use the capillary tube with the new gauge Reservoir Heater The optional reservoir heater maintains the reservoir coolant fluid temperature during the unit off cycle to improve low ambient temperature start ups The heater is located low in the reservoir and is accessed through the louvered panel If the heater needs to be replaced drain the system first Then have a container to catch the remaining fluid that will come out through the heater fitting Reservoir Tank The coolant reservoir tank provides a volume of coolant to reduce temperature fluctuations and a volume of air to allow for expansion of the c
31. D SC Se RIGHT HEIGHT AIR INTAKE J n D LL P Fan Rotation c as a cw T ue Gage SHADED AREA B e INDICATES RECOMMENDED Temm TT CLEARANCE OF 36 914mm TLL FOR PROPER AIR FLOW SHADED AREA INDICATES A RECOMMENDED CLEARANCE OF 36 914mm BE PROVIDED FOR COMPONENT ACCESS AND REMOVAL SHADED AREA INDICATES A RECOMMENDED CLEARANCE OF 36 914mm INBICATES A RECOUMENDED BE PROVIDED FOR COMPONENT CLEARANCE OF 36 914mm ROCESS AND REMOVAL BE PROVIDED FOR PROPER AIR FLOW 60 MC 1524mm 3 72 6 ee 76mm 1844mm 3 1 2 Bolt Down Holes gt 76mm 4 places FOOTPRINT DIMENSIONS Table 5A Dimensional data 8 and 10 ton air cooled Dimensional Data Module Weight Net Model Numbers in mm Ibs kg 60 HZ 50 HZ A B D PF096A PS095A 77 39 1 4 38 1 2 5 1 2 750 PS120A PS119A 1956 997 978 140 340 Installation 9B Figure 2C Electrical field connections 8 and 10 ton air cooled models See Detail Below High pressure switch reset buttons Pressure and temperation gauges Field supplied unit disconnect switch recommended within sight of uniit gt Single or three phase electrical service SS not by Li
32. OULD PERFORM SERVICE ON THESE UNITS LETHAL VOLTAGE IS PRESENT IN SOME CIRCUITS USE CAUTION WHEN TROUBLESHOOTING WITH POWER ON DISCONNECT AND LOCK OUT POWER BEFORE REPLACING COMPONENTS USE CAUTION AND STANDARD PROCEDURES WHEN WORKING WITH PRESSURIZED PIPES AND TUBES AN CAUTION When using jumpers for troubleshooting always remove jumpers when maintenance is complete Jumpers left connected could override controls and cause equipment damage Table 7 Chilled Fluid Pump Troubleshooting Symptom Will not start Possible Cause No main power Check or Remedy Check L1 L2 and L3 for rated voltage Overloads tripped Push reset button on pump overload Check amp draw No output voltage from transformer Check for 24 VAC between 3 and 37 If no voltage check primary voltage Transformer circuit breaker tripped Check for 24 VAC between 3 and 37 If no voltage check for short and reset breaker Noisy operation Worn motor bearings Replace pump Low discharge head Throttle discharge improve suction conditions Cavitating pumps Adjust system pressures Debris lodged in impeller Remove cover and clean out Trips overload relay Loose electrical connections Tighten connections Incorrect overload relay or must trip amp setting too low Replace with correct overload relay Pump motor defective Check for motor winding short or ground Low line v
33. Operation if required 9 Test for proper operation of all functions including temperature and pressures of chilled fluid and refrigerant 10 Inspect all piping connections for leaks during initial operation 10 Operation 3 3 3 4 3 5 3 6 3 7 Overview of Operation If there is an increase in leaving fluid temperature beyond the setpoint the thermostat will ener gize the liquid line solenoid valve and the discharge bypass solenoid valve Refrigerant will flow through the evaporator to the compressor The compressor is activated when the low pressure switch senses sufficient pressure see 3 5 Low Pressure Switch Adjustment When chilled fluid temperature drops below the thermostat differential setting typically 3 F 1 7 C the liquid line solenoid valve is deenergized and the compressor pumps down Condenser fan motor operation is regulated by the compressor operation They operate simulta neously The air cooled condensing section uses a propeller fan It also includes a Lee Temp flood back head pressure control which includes a receiver and a head pressure control valve This control system floods the condenser coil with refrigerant that is warmed in the receiver to maintain head pressure during low ambient temperature operation Transformer Transformer is line voltage primary with 24 volt 75 VA secondary This transformer is used to operate various relays and contacts in the control circuit Circuit Breaker
34. WHO4SNvHI SE s H3118S 330 40 Q31H91 IS vl YOLINOW 12V1NO02 vW2H 95 25 FC OI D SHOLSIS3u e Td S2 Wavy 0 13 Ou ge 19073 01073 4 tt 1 917 01013 11 A9138 01073 H9IH HH __ 19073 01074 HOIH 3H EZ 8 er AV I3H 71713 Olfri3 u3 AVT3Y 7713 E Or 19073 7114 043 33 NMOQ 310N 335 Tu 99 25 1095 310933 1 5801139493 199 3 d 1995 t 10073 71713 NI938 38 S33IA30 1VNOILdO S30IA30 QHVONVIS mQ I 901 200 Lv 19N3AON 2m 4 dii T 110 C H b i ei Wey Ty Si dNI NOWWDI L FMI JU e ON 103815 j O3LVTIVISNI 0733 e SIHOLIMS 19013 sIQAH3S3H H3lliH 7 0349201 31 3H 43 38 53HD1MMS 19013 E S31 NIN 08 H313V 31VAILOV OL 13S SI 8801 SALNNIN Or 33139 OL 135 S 1 ANO SHOLINGNOD E Gei Je 338302 JSN 5300 gt 1w301 u3d 38 Ol 0133 11 UI 2v 102 er 1 310N 47 Appendix B The Water Level Control Module 3 I Liebert Keeping Business In Business HEAT REMOVAL ENVIRONMENTAL CONTROL Process Fluid Chiller USER MANUAL The Company Behind the Products Technical Support Service With over a million installations around the globe Liebert is the world leader in computer protection sy
35. ater both must be kept from freezing Allow adequate clearance for convenient maintenance see Appendix B The Water Level Control Module 41 Figure 13 Set unit on the floor or bolt securely to the wall using the key hole slots in the WLC module and appropriate anchors supplied by others N WARNING FAILURE TO FASTEN UNIT SECURELY TO WALL STUDS OR STRUCTURAL MEMBERS WITH APPROPRIATE ANCHORS SUPPLIED BY OTHERS MAY RESULT IN PRODUCT FAILURE AND HUMAN INJURY At the chiller remove the top panel over the chiller section Make sure there is not water pressure in the system Install the multi point level switch into the top of the chiller fluid reservoir refer to Figure 15 Use an appropriate pipe sealant Attach the 2 x 4 junction box to the top of the multi point level switch Attach and route wiring from the level switch to the WLC module see Figure 14 A knockout is provided in the piping connection panel on the left side of the chiller through which to route this wiring Install the automatic air vent in the return line to the chiller water reservoir A 1 4 NPT pipe thread is provided in this line Use an appropriate pipe sealant The air vent must be installed vertically for proper operation NOTE Automatic air vents should be installed at all high points in the system or where ever air might be trapped Failure to vent unwanted air can cause poor system performance CAUTION Water pressure should not exceed 100 psig
36. cessibility Avoid ground level sites with public access or areas which contribute to heavy snow or ice accumu lations To assure adequate air supply locate chiller in a clean air area away from loose dirt and foreign matter that may clog the coil In addition chillers should not be located in the vicinity of steam hot air or fume exhausts Also chillers should be located no closer than three feet 1 meter from a wall obstruction or adjacent unit Install chillers in a level position to assure proper refrigerant flow and oil return For ground installation a concrete pad will provide adequate support Chiller support rails have mounting holes for securing the chiller to the concrete pad For roof installation mount chillers on steel sup ports in accordance with local codes To minimize sound and vibration transmission mount steel supports across load bearing walls Prepare the location s for the unit The unit includes both chiller and condensing sections mounted together with connecting wiring and piping Bolt the unit to the floor or slab Piping Connections CAUTION Galvanized pipe must not be used in Glycol Systems Connect the chiller unit to the coolant loop of the processing equipment to be cooled by chilled water Install a shut off valve in each line so that equipment can be isolated for maintenance Insulate the coolant lines to prevent the condensation of water from the air on the pipes The connections are 3 4 inch or
37. d baked enclosure RCM4 monitor adjustable time delay relays now switch high tem perature thermostat solenoid valves ball valves on the entering and leaving lines connected to the chiller a fluid pressure gage and valve and a digital display of supply fluid temperature It also includes a ball valve and double check backflow preventer on the entering city water line The module has a local display for high fluid temperature loss of fluid flow and emergency water on It also has a non powered common alarm contact It requires a 120 volt single phase power input This module is for use on systems that circulate water as the cooling medium it is not for use with glycol systems It automatically switches to emergency water on a high fluid alarm or a loss of fluid now alarm Figure4 The Emergency Water Source Module Appendix A Emergency Water Source Module 33 8 1 8 2 Model Numbers EWSO05W K00 for application with 1 5 and 2 ton Process Chillers EWS10W K00 for application with 3 4 and 5 ton Process Chillers Typical Application Figure5 Emergency Water Bypass 8 3 8 4 Chiller Sequence of Operation In normal operation mode cold water flow from the chiller passes across the flow switch through the energized supply solenoid valve across the supply temperature sensor and out to the load Water from the load passes back through the energized return solenoid valve and out to the chiller If the flow switch se
38. e hot gas bypass valve 1 Install suction and discharge pressure gauges on the compressor to monitor refrigeration 2 Setthe control thermostat at 3 F 1 7 C below required leaving fluid temperature Measure the leaving fluid temperature by strapping a thermometer to the leaving fluid piping NOTE Compressor should not cycle off and on to match a constant load 3 While adjusting the hot gas bypass valve for proper leaving fluid temperature maintain nominal load on chiller 14 Maintenance a Remove the TOP adjusting nut from the valve b Insert an Allen wrench in the brass hole at the top of the valve in the adjusting port and turn CLOCKWISE if a HIGHER leaving fluid temperature is required or COUNTERCLOCKWISE if a LOWER leaving fluid temperature is required c After obtaining the leaving fluid temperature required reinstall the adjusting nut tightly on the valve making sure that there are no leaks d Let the system operate at nominal load for approximately 10 to 15 minutes longer if thermal storage tank 1s used to make sure that the suction pressure 1s within the range desired NOTE There is a fluctuation of 3 to 6 PSI of the suction pressure due to the differential on the hot gas bypass 4 Final Adjustment a For applications with constant load re adjust the control thermostat to the required leaving fluid temperature b Forapplications with varying load operate the system at both minimum and maximum load
39. e reduces the ability of the refrigerant to cool compressor components and can result in compressor damage Minimum pressure switch cut out setting and maximum design operating suction pressures are shown below Minimum Suction Pressure 53 PSI for water systems factory setting 40 PSI for 4095 Glycol 30 PSI for 5096 Glycol Maximum Suction Pressure 92 PSI Discharge Pressure Discharge Pressure can be increased or decreased by load conditions or condenser efficiency The high pressure switch will shut the compressor down at its cut out setting Maximum Discharge Pressure 360 PSI Superheat Superheat can be adjusted by the Thermostatic Expansion Valve TEV To determine superheat Measure the temperature of the suction line at the point the TEV bulb is clamped Measure the gauge pressure of the compressor suction line Add the estimated pressure drop between bulb location and suction valve Convert the sum of the two pressures to the equivalent temperature Subtract this temperature from the actual suction line temperature The difference is superheat m Maintenance 13 4 1 4 4 1 5 Thermostatic Expansion Valve Operation The thermostatic expansion valve TEV keeps the evaporator supplied with enough refrigerant to satisfy load conditions It does not turn the compressor on or off but correct valve adjustment 1s necessary for proper system operation Determine TEV operation by measuring superheat see 4 1 3 Supe
40. ebert SCH D se SS Right US UE sess 3 6m WS Rear L ET E 3 3 84mm UNS Se e 2 9 64mm Optional field supplied 24 Class 2 control wiring m Piping connections 1 1 4 NPT Female Supply Factory wired to components on electrical panels High voltage electric power supply entrance Line voltage connection block Remote Unit Shutdown 37 amp 38 n di Replace existing jumper between terminals 37 amp 38 with normally closed non powerde switch having a minimum 75 VA rating Use field supplied 24 V Class 2 wiring lor om Low voltage control wiring entrance Earth ground connection Left access door removed NOTE Refer to spefication sheet for full load amp and wire size amp ratings 9C Installation Figure 2D Cabinet and floor planning dimensional data 8 and 10 ton air cooled with thermal storage tank cabinet PIPING AND WARING CONNECTIONS THIS END SHADED AREA INDICATES A RECOMMENDED CLEARANCE OF 38 814mm BE PROVIDED FOR PROPER AIR FLOW SHADED AREA INDICATES A RECOMMENDED OM ESS AND REMOVAL SHADED AREA SHADED AREA INDICATES A RECOMMENDED INDICATES RECOMMENDED GLEARANCE OF 36 814mm CLEARANCE OF 36 944mm BE PROVIDEO FOR COMPONENT BE PROVIDED FOR PROPER ACCESS AND REMOVAL AIR FLOW 252 63 5 75 Dia Typ 4 places Mounting Holes Tab
41. escription Part No 018 021 024 028 036 038 048 047 060 059 Condenser Exterior Panels 6 1 Front Access 121694P1 1 1 1 1 6 2 Cover Top 121695P1 1 1 1 1 6 3 Exterior Left 140127P1 1 1 1 1 6 4 Exterior Right 121691P1 1 1 1 1 6 5 Exterior Rear 121699P1 1 1 1 1 6 6 Outlet Air Grill 1C21128P1 1 1 1 1 6 1 Front Access 121701P1 1 1 6 2 Cover Top 121702P1 1 1 6 3 Exterior Left 140128P1 1 1 6 4 Exterior Right 121705P1 1 1 6 5 Exterior Rear 121706P1 1 1 6 6 Outlet Air Grill 1C21129P1 1 1 6 1 Front Access 127913P1 1 1 1 1 6 2 Cover Top 127910P1 1 1 1 1 6 3 Exterior Left 140129P1 1 1 1 1 6 4 Exterior Right 127912P1 1 1 1 1 6 5 Exterior Rear 127907P1 1 1 1 1 6 6 Outlet Air Grill 127915P1 1 1 1 1 Parts 29 Figure 1 Condenser Assembly Figure 2 Chiller Assembly Figure 3 Chiller Electric Panel tolojo si 1515 6 Figure 4 Condenser Electric Panel 31 Parts Figure 5 Chiller Exterior Panels Figure 6 Condenser Exterior Panels Parts 32 8 0 APPENDIX EMERGENCY WATER SOURCE MODULE This module is a pre piped and wired assembly which consists of an almond colored powder coated an
42. eservoir drops to the BEGIN FILL level the flow limiting solenoid valve is activated within the Water Level Control Module O VLC and 40 Appendix B The Water Level Control Module 9 4 9 5 city water flows to fill the chiller system This solenoid is deactivated when the float switch rises to the END FILL level that should occur in less than 4 minutes If after 4 minutes of filling the END FILL level has not been reached an alarm is sounded on the RCMA indicating a possible problem with the till system requiring attention The WLC module continues to attempt to fill the system for 4 more minutes 8 total minutes from first BEGIN FILL after this first alarm at which time a second alarm is sounded on the RCMA the fill system is locked out and attempts to fill the system cease until the lock out is MANUALLY RESET Time Delay Settings seconds Condition Factory Minimum Maximum Fill System Problem TDRA 240 1 600 Fill System Lockout TDRB 480 1 600 The WLC module also alarms through the RCMA on conditions of LOW FLUID and HIGH FLUID in the reservoir These alarms respectively indicate water levels below the BEGIN FILL level and above the END FILL level The LOW FLUID and HIGH FLUID alarms must be MANUALLY RESET at the WLC module alarms enunciated by the RCMA also active the common alarm contacts on this device NOTE The remote shutdown function see Figure 14 prevents operation of all WLC module functions and alarm
43. g during periods of low outdoor temperature Short Cycle Prevent Relay All units have a non adjustable time delay relay that prevents a compressor start within three 3 minutes of a compressor shut off 12 Operation 4 0 4 1 4 1 1 4 1 2 4 1 3 Refrigeration System CAUTION Only qualified personnel should perform refrigeration system maintenance Periodic Inspections Each month the components of the refrigeration system should be inspected for proper function and signs of wear Since in most cases evidence of malfunction is present prior to component fail ure periodic inspections can be a major factor in the prevention of most system failures Liquid Line Sight Glass The liquid line has a sight glass that indicates liquid refrigerant flow and the presence of mois ture Excessive bubbles in the sight glass may indicate a shortage of refrigerant or a restriction in the liquid line The moisture indicator changes from green to yellow when moisture is present in the system Refrigerant Charge The unit is supplied from the factory fully charged If refrigerant must be replaced weigh in the charge specified on the serial tag rather than using the sight glass to determine a full charge Suction Pressure Suction pressure will vary with load conditions The low pressure switch will shut the compressor down if suction pressure falls below the cut out setting High suction pressur
44. ge 60 Hz Heater 1 phase 380 415 Stainless 50 Hz Steel 3 phase Pump N 200 230 Gauge 50 Hz Heater SS 3 phase Pump W 200 230 50 Hz 1 phase Y 208 230 60 Hz 3 phase 1 0 INTRODUCTION 1 1 1 2 1 2 1 1 3 1 3 1 1 3 2 1 3 3 Product Description The Process Fluid Chiller is a self contained air cooled chiller containing a hermetic compressor four ton model has a scroll compressor copper tube aluminum fin condenser coil direct drive propeller condenser fan and motor Lee Temp low ambient head pressure control high pressure and low pressure switches filter drier sight glass expansion valve hot gas bypass valve solenoid valves and crankcase heater The insulated fluid circuit contains a 304 stainless steel close cou pled centrifugal pump stainless steel reservoir and expansion tank two isolating ball valves and unions at the pump inlet and discharge Optional Equipment Refrigerant Gauges and Reservoir Heater This option is factory installed and includes a 250 watt immersion heater with thermostat for the fluid reservoir The adjustable heater thermostat is set to turn on at 35 F 1 7 C and turn off at 42 F 5 6 C to maintain minimum reservoir temperatures during low ambient periods The suc tion and discharge refrigerant gauges are 2 1 2 inch 63 mm diameter with stainless steel hous ings Accessory Equipment Ship with Kits The following accessories are
45. h a remote on off switch field supplied Electrical service shall conform to national and local electri cal codes Refer to unit nameplate for wire size amps WSA full load amps FLA and overcur rent protection device OPD required Refer to electrical schematic when making connections AN WARNING USE VOLTMETER TO MAKE SURE POWER IS TURNED OFF BEFORE MAKING ANY ELECTRICAL CONNECTIONS CAUTION Liquid tight conduit fittings are required where wires are brought into the electrical enclosure CAUTION In three phase models pump and compressor motors are phase synchronized at the factory At initial installation change phase leads outside of the chiller to obtain proper rotation for the pump and compressor Connect all control and monitoring options required for your installation including remote shut down Preparation of Glycol Solution Typical ethylene glycol manufacturers and suppliers are Union Carbide Ucartherm or Dow Chemical Company Dowtherm SR 1 Propylene glycol such as Dow Chemical Company Dow frost HD may also be used in the chiller Glycols are supplied with an inhibitor and do not con tain an anti leak formula NOTE For glycol solution preparation and periodic testing follow manufacturer s recommendations Do not mix products of different manufacturers CAUTION Automotive anti freeze is unacceptable and must not be used Commercial glycol when pure is generally less corrosive to the common
46. h thermal storage tank cabinet 9D Pump SUCHON EE ees RN EVER ne ere 17 Chilled Fluid Pump Troubleshooting 19 Compressor 20 Refrigeration System 21 Condenser Fan Troubleshooting 22 Fans dnd Motors p LEER E ERN C 24 Compressor and Refrigerant 24 Quick Disconnect Couplings 26 Fluid Controles eec duca CRM n ER RI eec Sus yma av A a 26 eir toute uw kad D gta Sag ya ues 27 Exterior Panels le We wes Megs Ge We ee Bs 28 Emergency Water Source Piping Connection 36 Emergency Water Source Electrical 38 WLC Module Connection Sizes 43 WLC Module Electrical 45 PRODUCT MODEL INFORMATION Table 1 Model Number Designation PS036A PB2 PS 036 2 Process Nominal A Air A 460 No options 2 Revision Fluid Capacity Cooled 60 Hz Level Chiller in 3 phase UE P 208 230 Gau
47. lan System Cleaner and Alco Dri Kleener Follow the manufacturer s procedure N CAUTION Avoid touching or contacting the gas and oils with exposed skin Severe burns will result Use long rubber gloves in handling contaminated parts Compressor Replacement Procedure Replacement compressors are available from your Liebert supplier They will be shipped in a per manent crate to the job site as required by the service contractor Upon shipping a replacement compressor the service contractor will be billed in full for the com pressor until the replacement has been returned to the factory The compressor should be returned in the same container used for shipping to the job The possi ble damage causes or conditions that were found should be recorded by marking the compressor return tag 1 Disconnect power 2 Ifyour system does not include optional gauges attach suction and discharge gauges to access fittings 3 Recover refrigerant using standard recovery procedures and equipment Use a filter drier when charging the system with recovered refrigerant CAUTION Do not loosen any refrigeration or electrical connections before relieving pressure 16 Maintenance 4 2 4 2 1 4 2 2 4 3 NOTE Release of refrigerant to the atmosphere is harmful to the environment Refrigerant must be recycled or discarded in accordance with federal state and local regulations 4 Disconnect refrigerant lines pressure switch
48. le 5B Dimensional Data 8 10 ton air cooled models with thermal storage tank cabinet Model Dimensional Data Module Weight Numbers in mm Storage Tank empty Capacity 60 Hz A B D E Ibs kg gal L PS096A 77 39 1 4 38 1 2 5 1 2 69 1 4 1170 100 PS120A 1956 997 978 140 1759 531 380 Note Add weight of fluid for operating weight Installation 9D 3 0 OPERATION 3 1 Pre Startup Checklist 1 Proper clearances for service access have been maintained around the equipment 2 Equipment is level and mounting fasteners are tight 3 Piping completed to fluid loop 4 System filled with proper fluid level and air bled per installation instructions in 2 3 Piping Connections See also instructions for optional accessories located in Sections 8 and 9 as required 5 Relief valve drain line connected if required 5 8 inch OD copper 6 All piping connections are tight 7 Line voltage to power wiring matches equipment nameplate 8 Power wiring connections completed to customer supplied disconnect switch and process chiller unit including earth ground 9 Power line circuit breakers or fuses have proper ratings for equipment installed 10 Control wiring connections completed if required including wiring to optional controls 11 wiring connections are tight 12 Foreign materials have been removed from in and around all equipment installed shipping ma
49. lock 1 1 1 1 1 1 1 Phase Power Block S 1 1 1 1 1 1 Phase 3 3 T1 Transformer 208 1 1 1 1 1 230V T1 Transformer 200 1 1 1 1 1 230V T1 Transformer 1 1 1 1 1 460V T1 Transformer 315 1 1 1 1 1 415V 3 4 Overload Relay 1 1 1 1 1 1 1 1 1 1 Overload Cover 1 1 1 1 1 1 1 1 1 1 3 5 PSK Relay 1 1 1 1 1 1 1 1 1 1 3 6 AR Relay 1 1 1 1 1 1 1 1 1 1 Table 16 Exterior Panels Model Numbers Capacity 1 5 Ton 2 Ton 3 Ton 4 Ton 5 Ton Hz 60 50 60 50 60 50 60 50 60 50 FN Description Part No 018 021 024 028 036 038 048 047 060 059 Chiller Exterior Panels 5 1 Exterior Left 140101P1 1 1 1 1 5 2 Exterior Right 140104P1 1 1 1 1 5 3 Front Access 121694P1 1 1 1 1 5 4 Cover Top 140135P1 1 1 1 1 5 5 Exterior Rear 140107P1 1 1 1 1 5 6 Lowered 140118G1 1 1 1 1 5 1 Exterior Left 140102P1 1 1 5 2 Exterior Right 140105P1 1 1 13 Front Access 121701P1 1 1 5 4 Cover Top 140136P1 1 1 5 5 Exterior Rear 140108P1 1 1 5 6 Louvered 140119G1 1 1 5 1 Exterior Left 140103P1 1 1 1 1 5 2 Exterior 140106P1 1 1 1 1 5 3 Front Access 121913P1 1 1 1 1 5 4 Cover Top 140137P1 1 1 1 1 5 5 Exterior Rear 140109P1 1 1 1 1 5 6 Louvered 140120G1 1 1 1 1 5 7 Gauge Hole Cover 140138P1 1 1 1 1 1 1 1 1 1 1 28 Parts Table 16 Exterior Panels Model Numbers Capacity 1 5 Ton 2 Ton 3 Ton 4 Ton 5 Ton Hz 60 50 60 50 60 50 60 50 60 50 FN D
50. ly removed before charging with glycol Contact your Liebert representative for additional recom mendations Start up Refer to 3 0 Operation for start up check list and procedure Table 2 Glycol Volume Chiller Tank Evaporator and Internal Piping Model Tons Glycol Volume gal liters 1 5 7 1 26 9 2 0 7 2 27 3 2 0 9 8 37 1 4 0 9 9 37 5 5 0 10 0 37 9 Table 3 Typical Ethylene Glycol Data Glycol by 0 10 20 30 40 50 VOLUME Freezing Point 32 0 25 3 9 16 8 9 5 15 0 10 23 3 32 35 5 F C Apparent 1 000 1 014 1 028 1 042 1 057 1 071 Specific Gravity 50 F Table 4 Typical Propylene Glycol Data Glycol by 0 10 20 30 40 50 VOLUME Freezing Point 32 0 25 3 9 20 6 7 10 12 2 5 20 6 30 34 4 C Apparent 0 999 1 008 1 018 1 028 1 039 1 048 Specific Gravity 50 F Installation 7 Figure1 Dimensional Data and Piping Connections OPTIONAL REFRIGERANT PRESSURE GAUGES SHADEDAREAS UNIT DIMENSIONAL DATA 1 FEMALETYPICAL FEMALE ON MODELS G ON MODELS N PS036A PSO48A 8 2 SPS018A PS024A Z P RAILS REST HERE CENTER RAIL ON MODELS PS048A amp ONLY FOOTPRINT DIMENSIONS Table 5 Dimensional Data in mm DIMENSIONAL DATA IN mm Weight Model A B D E F G H J K Ib
51. ndix A Emergency Water Source Module 8 5 8 6 to open the switch is adjustable from 1 to 30 F The thermostat includes a digital display mounted on the right side of the module which indicates the supply water temperature and the setpoint Flow Switch Monitors supply water flow The flow switch setpoint is adjustable see below Flow Switch Setpoints gpm Model Minimum Maximum EWSO05W K00 0 3 1 1 EWS10W K00 3 7 13 3 Solenoid Valves 24VAC 2way pilot or direct operated with brass body Isolation Valves 1 4 turn brass body ball valves for isolation of piping components in the event of a service necessity Fluid Pressure Gage Displays pressure of either the supply or return water line selectable by a 3way ball valve adjacent to the gage Backflow Preventer Double check design located at the city water alternate water piping con nection point Installation Prepare the location s for the unit See Figure 7 Allow adequate clearance for convenient main tenance Set unit on the floor or bolt securely to the wall using appropriate anchors supplied by others Lal WARNING FAILURE TO FASTEN UNIT SECURELY TO WALL STUDS OR STRUCTURAL MEMBERS WITH APPROPRIATE ANCHORS SUPPLIED BY OTHERS MAY RESULT IN PRODUCT FAILURE AND HUMAN INJURY Connect the unit piping to the chiller load city alternate water and drain or recirculator as shown in Figure 6 Piping connections are also labeled on the unit Make
52. nses loss of flow or the thermostat senses high water temperature then a time delay is initiated This is to prevent nuisance switchovers After the time delay see below switchover occurs to the emergency water source Time Delay Settings seconds Condition Factory Minimum Maximum Loss of flow 10 0 90 High water temperature 180 O 480 On switchover the supply and return solenoid valves are de energized to close and the alternate and drain solenoid valves are energized to open The RCM4 displays the switchover condition and switches the common alarm contacts The switchover is locked in Pressing the reset button returns the module to normal operation NOTE During normal operation the auto manual switch is set to auto The switch can be set to manual to force switchover for troubleshooting or maintenance NOTE The remote shutdown function prevents emergency switchover operation regardless of other controls status System Components RCM4 Monitor Configured to activate an LED an audible alarm and switch the common alarm output contacts in response to a loss of flow or high supply water temperature switchover The silence reset button silences the alarm The button also resets the LED s and contacts if the unit has returned to normal mode Thermostat monitors supply water temperature The thermostat switchover setpoint is adjustable from 30 to 130 F The differential temperature drop required 34 Appe
53. oltage Check line voltage and determine location of voltage drop Single phasing Check voltage across all 3 legs at contactor Correct source of problem 3 phase units only Running hot Clogged bypass orifice See Symptom Trips overload relay Remove orifice unions check screen Troubleshooting 19 Table 8 Compressor Troubleshooting Symptom Will not start Possible Cause Contactor not pulling in Check or Remedy Also see Fan Compressor controlled by same contactor as Fan No main power Check L1 L2 and L3 for rated voltage No output voltage from transformer Check for 24 VAC between 3 and 37 If no voltage check primary voltage Transformer circuit breaker tripped Check for 24 VAC between 3 and 37 If no voltage check for short and reset breaker Solenoid valve not energizing Hold screwdriver over solenoid and check for magnetic field This indicates solenoid is energized Low pressure switch not making contact Check gas pressure manually energize low pressure switch High pressure switch open Reset switch Refer to other refrigeration troubleshooting suggestions Loose electrical connections Tighten connections Compressor motor burned out Check and replace compressor if defective Short cycle prevention control Low discharge pressure Insufficient refrigerant in system Check for leaks repair
54. oolant The systems engineer who designs the installa tion must confirm whether or not the coolant and air volumes are suitable for each application and may decide to add additional fluid storage tanks expansion tanks or air vents The fluid should typically be a t the level of the sightglass in the coolant reservoir tank Periodic maintenance should include checking the fluid level and checking for any leaks in the system If the system is opened to access or replace a piping component then the fluid level must be checked and may need to be adjusted 18 Maintenance 4A 0 8 AND 10 TON PROCESS CHILLER USER MANUAL SUPPLEMENT 4A 1 4A 1 1 Product Description The 8 and 10 ton process chiller is a self contained air cooled system containing two 2 scroll compressors and two 2 heat exchangers An optional 2 HP multistage stainless steel pump may be included see model number to overcome the high pressure drop found in some MRI and CT systems Additional Equipment The chiller includes a panel of gauges attached to the end of the cabinet Eight 8 gauges are included Suction Pressure Refrigerant Circuit 1 Suction Pressure Refrigerant Circuit 2 Discharge Pressure Refrigerant Circuit 1 Discharge Pressure Refrigerant Circuit 2 Water Inlet Pressure Water Outlet Pressure Water Inlet Temperature Water Outlet Temperature Refrigerant Charge 29 4 per circuit R 22 Internal Glycol Volume
55. rheat If too little refriger ant is being fed to the evaporator the superheat will be high if too much refrigerant is being sup plied the superheat will be low The correct superheat setting is between 10 and 15 F 5 5 and 8 3 C Adjustment adjust the superheat setting proceed as follows 1 Remove the valve cap at the bottom of the valve 2 Turn the adjusting stem to change the superheat CW to increase CCW to decrease NOTE Make no more than 1 4 turn of the stem at a time As long as thirty minutes may be required for the new balance to take place Hot Gas Bypass Valve Operation The hot gas bypass is inserted between the compressor discharge line and the outlet side of the expansion valve When the system is operating at full capacity the valve remains closed If the load decreases the evaporator will get colder When the evaporator is too cold the internal pressure 1n the evapora tor drops and allows the hot gas bypass valve to open Hot gas then mixes with the liquid coolant on the discharge side of the expansion valve raising the temperature and pressure in the evapora tor The net result is a reduction in the cooling capacity of the unit to match the load The leaving fluid temperature will determine the hot gas bypass valve setting as well as the com pressor suction gauge pressure Adjustment After determining the desired leaving fluid temperature the following procedure should be used to adjust th
56. rigerant charge Check refrigerant charge Hot gas bypass valve adjusted improperly Adjust properly Insufficient air flow across condenser coil Remove debris from coil and air inlets Low discharge Faulty head pressure control valve or Replace if defective pressure condenser fan speed control Worn piston rings valves Replace compressor Flooding Defective or improperly set expansion Increase superheat or replace valve valve Low condensing pressure Check head pressure control device Troubleshooting 21 Table 10 Condenser Fan Troubleshooting Symptom Will not start Possible Cause Contactor not pulling in Check or Remedy Also see Compressor Fan controlled by same contactor as Compressor No main power Check L1 L2 and L3 for rated voltage No output voltage from transformer Check for 24 VAC between 3 and 37 If no voltage check primary voltage Transformer circuit breaker tripped Check for 24 VAC between 3 and 37 If no voltage check for short and reset breaker Fan motor capacitor defective Check capacitor Trips internal motor protector Fan motor defective Check for motor winding short or ground Noisy operation Fan blade loose Check tighten set screws on fanblade hub Worn motor bearings Replace motor Fanblade not rotating freely Check for debris in fanblade path Check for
57. roken connecting rods or pistons Replace compressor Leaking liquid line solenoid valve or Replace valve if clean clean out dirt in valve valve if dirty Running hot Compression ratio too high Check setting of high and low pressure switches Check condenser is it plugged Check that condenser fan is operating properly worn rings or valves Excessive blow by into crankcase Replace compressor See Symptom Compressor cycles on locked rotor Table 9 Refrigeration System Troubleshooting Symptom Low suction pressure High superheat Possible Cause Insufficient refrigerant in system Check or Remedy Check for leaks repair and add refrigerant Plugged filter drier Replace filter Improper superheat adjustment Reset expansion valve for 10 to 15 F superheat Defective expansion valve sensing element Replace element Restricted external equalizer Liquid indicator High suction pressure Low superheat Plugged filter drier Replace filter Improper superheat adjustment Reset expansion valve for 10 to 15 F superheat Restricted external equalizer Liquid indicator TEV seat leak Check valve for leaks Low suction pressure Low superheat Evaporator oil logged Increase HGBP setpoint High discharge pressure Dirty condenser or drycooler fins Clean coil Condenser fan not operating Check fan operation High ref
58. rz TO 50 z gt DO S Ee leide ga O o CO qi 01292 JO LEZ DETAIL IN WLC MODULE FIELO SUPPLIED AND INSTALLED CONDUIT ROUTEO TO TERMINAL BLOCK Ou Tr gt gt i usss H H T 42 i oy p gt ac ood ul OL Lu Fax FAUNE a 2 z EO T SE CH Ll a ez O c D 5 gt gt L at 46 Appendix B The Water Level Control Module Figure 16 Level Control and Alarm Option Module Electrical Schematic L d p 66 1 71 ue 557 99 YAT HO Sd 3100 7 NOlLdO Wav iv SG D TOYLNOD 13431 es HR woo NOLL YT t xg A 0104 Dung d 39NYUO N33HD ND NAONG Ug 938 8 3002 50105 NOIL23NNOJ 901 9NIONnONS NOILDANNOD 4815 2 ONIHIM LIOA PZ 0311895 9193 st ite ONIMIM LIOA 03119915 AH012Y4 39V170 JINI 03119915 0733 Q lt lt ge 2NiBIM 39V1710A 7 03119905 AH012V J 1 03937 AQ138 Av130 Iu bb 3WIL 170 201 eg OION330S 3113 8901 49734 45730 GION370S d oil 7113 cayal U3
59. s costly to take the steps necessary to ensure proper system operation than it 1s to allow a com pressor to fail and require replacement Maintenance 15 When troubleshooting a compressor check all electrical components for proper operation Check all fuses Check Hi Lo Pressure switch f a compressor failure has occurred determine whether it is an electrical or mechanical fail ure Mechanical Failure A mechanical compressor failure will be indicated by no burned odor The motor will attempt to run If you have determined that a mechanical failure has occurred the compressor must be replaced If a burnout does occur correct the problem that caused the burnout and clean the system It is important to note that successive burnouts of the same system are usually caused by improper cleaning Electrical Failure An electrical failure will be indicated by a distinct pungent odor If a severe burnout has occurred the oil will be black and acidic In the event that there is an electrical failure and a complete burnout of the refrigeration com pressor motor the proper procedures must be performed in order to clean the system to remove any acids that would cause a future failure CAUTION ZN Damage to a replacement compressor caused by improper system cleaning constitutes abuse under the terms of the warranty and the WARRANTY WILL BE VOID There are two kits that can be used with a complete compressor burnout Spor
60. s regardless of status System Components RCM4 Monitor Configured to activate an LED an audible alarm and switch the common alarm output contacts in response to a Fill System Problem Fluid Fill Lockout High Fluid Level and Low Fluid Level The silence reset button silences the alarm The button also resets the LED s and contacts if the unit has returned to normal mode Solenoid Valve 24 VAC 2 way direct operated with brassbody Includes an integral serviceable strainer and limits the waterflow rate to 0 5 gpm Backflow Preventer Double check design located inside the city water piping connection point on the WLC module Multi point Level Switch consists of 4 revel switches mounted in a single assembly that includes a 1 inch NPT fitting for mounting This switch is shipped loose with the WLC module and must be field installed into the water reservoir of the process chiller 8 wiring connections are field made between this device and the WLC module Automatic Air Vent Shipped loose with the WLC module and must be field installed into the water piping of the chiller It automatically vents air from the system which will enter the system with each water fill NOTE Trapped air will rise to the highest point in the system It is recommended that additional automatic air vents be added to the system at appropriate locations Installation Prepare the location for the module Since this device and the chiller must contain only w
61. s to verify adequate control of leaving fluid temperature Figure3 Hot Gas Bypass External Equalizer Solenoid Valve External Side Connection Equalizer Distributor or ASC Hot Gas Discharge Solenoid Valve tn Bypass Valve Compressor 4 1 6 Air Cooled Condenser 4 1 7 Restricted airflow through the condenser coil will reduce the operating efficiency of the unit and can result in high compressor head pressure and loss of cooling Clean the condenser coil of all debris that will inhibit air flow This can be done with compressed air or commercial coil cleaner Check for bent or damaged coil fins and repair as necessary In win ter do not permit snow to accumulate around the sides or underneath the condenser Check all refrigerant lines and capillaries for vibration isolation Support as necessary Visually inspect all refrigerant lines for signs of oil leaks Compressor Replacement Infrequently a fault in the motor insulation may result in a motor burn but in a properly installed system burnouts rarely occur Of those that do most are the effects of mechanical or lubrication failures resulting in the burnout as a secondary consequence If problems that can cause compressor failures are detected and corrected early a large percent age can be prevented Periodic maintenance inspections by alert service personnel on the lookout for abnormal operation can be a major factor in reducing maintenance costs It is easier and far les
62. shipped separately This facilitates customization and permits installation at indoor locations more accessible to the operator Emergency Water Source Module This module is a prepiped and wired assembly which consists of an almond colored baked on poly urethane painted enclosure RCM4 monitor adjustable time delay relays flow switch high tem perature thermostat solenoid valves ball valves on the entering and leaving lines connected to the chiller a fluid pressure gauge and valve and a dial thermometer on the entering fluid line It also includes a ball valve and double check back flow preventer on the entering city water line The module has a local display for high fluid temperature loss of fluid flow and emergency water It also has a non powered common alarm contact It requires a 120 volt single phase power input This module is for use on systems that circulate water as the cooling medium it is not for use with glycol systems It automatically switches to emergency water normally city water on a high fluid temperature alarm or loss of fluid flow alarm Water Level Control and Alarm System This accessory consists of a multi point level switch flow regulating solenoid valve with integral strainer double check back flow preventer automatic air vent time delay relays and prewired RCMA monitor This accessory is to be used only when water is used as the cooling medium not glycol All items are field installed It has a
63. stems Since its founding in 1965 Liebert has developed a complete range of support and protection systems for sensitive electronics Environmental systems close control air conditioning from 1 to 60 tons Power conditioning and UPS with power ranges from 300 VA to more than 1000 kVA Integrated systems that provide both environmental and power protection in a single flexible package Monitoring and control from systems of size or location on site or remote Service and support through more than 100 service centers around the world and a 24 7 Customer Response Center While every precaution has been taken to ensure the accuracy and completeness of this literature Liebert Corporation assumes no responsibility and disclaims all liability for damages resulting from use of this information or for any errors or omissions 2002 Liebert Corporation All rights reserved throughout the world Specifications subject to change without notice Liebert and the Liebert logo are registered trademarks of Liebert Corporation All names referred to trademarks registered trademarks of their respective owners SL 16530 10 02 Web Site www liebert com Monitoring 800 222 5877 monitoring liebert com Outside the US 614 841 6755 Single Phase UPS 800 222 5877 upstech liebert com Outside the US 614 841 6755 Three Phase UPS 800 543 2378 powertech liebert com Environmental Systems 800 543 2778
64. terials construction materials tools etc 13 Fan and pump rotate freely without unusual noise 14 Make sure all optional accessories selected for this installation have been installed 3 2 Startup Procedure 1 Complete pre startup checklist 2 Close the customer supplied disconnect switch to energize the unit The same switch will also stop the unit Check for proper voltage For initial startup or if the unit has been idle for some time follow the procedure below CAUTION The compressor crankcase heater is energized as long as power is supplied to the unit If the main switch is disconnected for long periods do not attempt to start a condensing unit until 8 hours after applying power This allows enough time for all liquid refrigerant to be driven out of the compressor Note that this is especially important at low ambient temperatures and for units with Lee Temp receivers 3 Verify that the fluid pump is rotating correctly clockwise from motor end 4 Onunits with 3 phase scroll compressors verify rotation is in proper direction Refer to 2 4 Electrical Connections 5 Turn the Temperature Control adjustment knob counterclockwise until the liquid line solenoid valve and hot gas bypass solenoid valve are energized 6 Adjust low pressure switch if required per 3 5 Low Pressure Switch Adjustment 7 Adjust temperature control per 3 6 Temperature Adjustment 8 Adjust hot gas bypass per 4 1 5 Hot Gas Bypass Valve
65. ump 60 Hz Iron 140205P1 1 1 1 140205P1 1 1 Pump 60 Hz SS 140204P1 1 1 1 140204P2 1 1 Pump 50 Hz Iron 140255P1 1 1 1 140255P1 1 1 Pump 50 Hz SS 140254P1 1 1 1 140254P2 1 1 Ball Valve 1C14431P1 2 2 2 2 1C14431P2 2 2 2 2 2 2 Fluid Relief Valve P 4730 1 1 1 1 1 1 Table 15 Electrical Panels Model Numbers Capacity 1 5 Ton 2 Ton 3 Ton 4 Ton 5 Ton Hz 60 50 60 50 60 50 60 50 60 50 FN Description Part No 018 021 024 028 036 038 048 047 060 059 Condenser Electric Panel 4 1 Contactor 1 Phase E 011B 1 1 1 1 1 1 Contactor 3 Phase E 009F 1 1 1 1 1 1 4 2 Fan Capacitor B 1220 1 1 1 1 1 1 B03 0030 1 1 1 1 Comp Start Cap 1 127194P1 1 1 1 1 1 1 Phase Comp Run Cap 1 C03 005A 1 1 1 1 1 1 Phase 4 3 Transformer 380 127937P3 1 1 1 415V Transformer 460V 127937P1 1 1 1 4 4 Fuse 380 415 460V 127977P1 1 1 1 1 1 1 Fuse Holder 380 4A10033P1 1 1 1 1 1 1 415 460V Chiller Electric Panel 3 1 Contactor 1 Phase 1 1 1 1 1 1 Contactor 3 Phase 1 1 1 1 1 1 Parts 27 Table 15 Electrical Panels Model Numbers Capacity 1 5 Ton 2 Ton 3 Ton 4 Ton 5 Ton Hz 60 50 60 50 60 50 60 50 60 50 FN Description Part No 018 021 024 028 036 038 048 047 060 059 3 2 Power B

Process Fluid Chiller

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