LDS Operating Manual HY-SAVE
Contents
1. HY SAVE LPA Liquid Pressure Amplification Established 1986 LDS Operating Manual for roof top applications The information contained herein is based on tests and technical data which we believe to be reliable and is intended for use by Competent trained personnel having the technical knowledge to perform the work described in this Manual Free Cooling LPA e Liquid Delivery System LDS BEFORE INSTALLING LDS READ THESE INSTRUCTIONS Models LPA 875 1 Metric HT Pack Capacities 150 210 kW 9 C LPA 860 1 Metric LT Pack Capacities 45 80 kW 37 C 50Hz English HT Rack Capacities 45 60 Tons 15F English LT Rack Capacities 13 22 Tons 35F HY SAVE UK Tel 44 0 1761 416123 www hysave com CONTENTS DECLARATION OF CONFORMITY THEORY OF OPERATION 1 HEALTH AND SAFETY 2 HEALTH AND SAFETY 3 SYSTEM AND SAFETY 4 START UP PROCEDURES FOR NEW SYSTEMS 4 GENERAL SPECIFICATIONS amp LIMITATIONS OF USE 6 MODEL 860 IND PERFORMANCE DATA 7 MODEL 875 FGN PERFORMANCE DATD 8 ENVIRONMENTALSPECIFICATIONS OF USE 9 ELECTRICAL WIRING amp CONTROL 10 PUMP PRO III SYSTEM CONTROL 11 LDS DESCRIPTION OF OPERATION 12 LDS KEYPAD FUNCTIONS 13 LDS MODES OF OPERATION 14 LDS SET UP PARAMETERS 15 TROUBLE SHOOTING 16 CE DECLARATION OF CONFORMITY HY SAVE Declares under its sole responsibility that the liquid refrigerant pump models to which this declaration relates Spec 35U743T204G1 Spec 34U743T204G1 Cat 860 IND Cat2. 8 are joined and insulated Wiring 6 and 9 are joined and insulated Wiring 10 11 and 12 are not used Terminate and insulate separately A wiring diagram is also located on the motor body For further details contact HYSAVE UK on Tel 44 0 1761 416 123 Fax 44 0 1761 417 123 PUMP PRO Ill SYSTEM CONTROL 1 THEORY OF OPERATION The function of PP3 is to control manage and protect the LPA free cooling pump from loss of refrigerant during normal running of the LDS system 2 FEATURES OF PUMP PRO III LI Can be used for a maximum of three circuits LI Configuration is through the key board panel LJ Employs 16 bit processor for high accuracy and speed computing LI Optical isolation is provided in IO terminals LI Uses LCD display to display dynamic values of inlet outlet differential pressures LJ LED indications for all operations WU Alarm for fault condition 3 SPECIFICATION 3 1 HARDWARE SPECIFICATION LInput Voltage 24V AC DC 4 5V LINormal operating current 100 mA LIPeak current 400 mA QAnalog channel 2 12 bit Sigma Delta conversion LIDigital channel 3 Inputs amp 6 Outputs pot Free electrically isolated LIOperating temperature 20 Deg C to 70 Deg C UHM interface 2x16 Alphanumeric LCD with backlight amp soft touch membrane keypad LIConnecting Terminals Horizontal plug in detachable screw head terminal connectors LIMounting provision DIN RAIL mountable enclosure WEnclosu
3. SSS oes R 114 R 123 R 124 R 134A fi E R 401a R 401b R 401c R 402a T R 402b R 404a R 407a R 407b e E R 407c R 408a R 408b R 409a R 410a R 410b R 411a R 41 1b ENVIRONMENTAL amp SPECIFICATIONS OF USE Pump Environment Environment Environment as classified in EN 60721 corresponds to IEC 60721 Outdoor installation IP54 Ambient temperature range 29 C to 60 C class 4K3 Altitude 2000 m Presence of hard solids class 4S2 no significant dust present Presence of corrosive and polluting substances class 4C2 negligible Vibration and shock class 4M2 Electric Motor Environment Provide adequate motor ventilation Do not place the pump in unvented enclosures Protect the motor against water damage The 875 IND amp 860 IND models TEFC Totally Enclose Fan Cooled are wash down and wind driven rain proof however the motor cannot be immersedin water due to the small vent holes in the motor body Design Duration of Life Under normal use your LDS will prove to be extremely reliable if installed correctly Follow the installation instructions manual for proper pump installation procedures and your LDS will provide years of trouble free operation Motor 7 10 years non continuous service Impeller Bushing gt 50 000 h continuous service Vibration During Operation Vibration during operation is not significant Since vibration is minimal during operation
4. or use it is not necessary to mount the pump on vibration eliminators instead it can be fixed directly to ground or any other solid surface providing that this surface is contained within the flexible structure Corrosion Your LPA 875 860 1 model pump conforms to EA 006 of which the protection level for this class is IP43B according to reference document IEC 60529 ELECTRICAL WIRING amp CONTROL WARNING lsolate and lock off electrical Supply before servicing this pump Release all pressure on system before working on any component Safety First Recover Refrigerant BEFORE servicing this product All HY SAVE LDS packs are extremely reliable and do not usually require routine maintenance although care should be taken to wipe clean any dust if operated ina dirty area lf service is required for any reason then follow the working instruction manual HYS W 860 875 for disassembly and assembly of the LPA pump Wire as per local or national electrical codes Use properly sized wire suitable conduit CE listed materials and properly ground the motor Grounding is essential to prevent any shock hazard as it will cause fuses to blow should a fault to ground occurin the motor Grounding can also aid in troubleshooting an electrical problem ALL HY SAVE LDS Motors are 3 Phase 415 460 Volts W ire according to the diagram on the left Wiring No 1 2 and 3 is supply Wiring 4 and 7 are joined and insulated Wiring 5 and
5. 875 IND FGN Are in conformity with the following standard s or other normative document s provided that these are used in accordance with our instructions Conforms to the following Product Specifications PED 97 23 EC References of Technical Standards and Specifications used eInternal Ref HYS 2005 I PTM ASTM B62 02 ANSI B16 22 ANSI B31 5 ASME Sec VIII ANSI ASRAE 15 ASTM B280 AWSAS5 8 Conformity Assessment Procedure Followed Module A Supplemental Information This product herewith complies with the requirements of the Low Voltage Directive 73 23 EEC and EMC Directive 89 336 EEC eIn accordance with Directive 97 23 EC eThis pressure assembly is manufactured tested and inspected for compliance and thus carries the CE marking Following the provisions Directives as amended Electromagnetic Compatibility 89 336 EEC Machinery Safety 98 37 EC Low Voltage 73 23 EEC PED 97 23 EC THEORY OF OPERATION The function of the Liquid Delivery System LDS is to deliver 100 liquid to the expansion valves without the penalty loss of capacity and other problems inherent with low refrigerant flow rates and poor oil return Thermostatic or Electronic expansion valves will maintain Capacity and meter properly with as little as 30 psi 2 bar pressure drop across the valve if vapor free liquid is present at the valve inlet Condensing temperatures can be lowered to float with ambient temperature and operating suction temperature
6. During normal running mode PumpPro3 displays the following parameters every 2 seconds a Inlet or Condensing Pressure in bar amp psig b LDS Outlet Pressure in bar amp psi c D P in bar amp psi Allthe above 3 parameters willbe displayed one after other in 2 seconds intervals At any point of time if the ENTER key is pressed The Pumppro3 enters in to setup mode In setup mode The Pumppro3 will not sample the pressure or other normal activities When the screen is brought to default the Pumppro3 operates as per the specification All the parameters can be changed using the navigation keys On EXIT key the parameters are saved in non volatile memory 4 LPAL PUMP PRO Ill KEY PAD FUNCTIONS KEY AND FUNCTIONS 1 Configures pump pro llIl when pressed in run mode 2 Confirms the current operation when pressed in setup mode To exit from the setup mode Scroll through menu and increment values while in setup mode Scroll through menu and decrement values while in setup mode 3 mntroller co 3 syste sq DetiveryY jquid INDICATIONS Power On indication Green color LED glows when the system is up and running Indicates ON OFF status of pump 1 pump 2 and pump 3 respectively Indicates the enable signals from compressor 1 compressor 2 and compressor 3 respectively Indicates the presence of corresponding fault signals from Pump 1 Pump 2 and Pump 3 respectivel 6 LD
7. S MODES OF OPERATION On power up Pump Pro Ill operates in three modes a Run b Setup c Shutdown 6 1 Run Mode This is the default mode of Pump Pro Ill system after power on The display would light up with the following message Line 1 Line 2 During run mode the second line of the display toggles one by one among INLET OUTLET amp DIFFERENTIAL PRESSEURES along with its BAR and PSI values for every two seconds Kindly refer the specification section of Pump Pro II for a detailed operational procedure of Pump Pro lll Run mode is terminated when l ENTER key is pressed leaves the Run Mode enters into Setup Mode 6 2 Setup This mode is selected whenever the ENTER key is pressed 6 3 To View Parameters After entering the setup mode the display shows SETUP on the first line and the parameter along with its value on the second line The display toggles among 1 St Delay 30 s Default value is 30 s and the range is 0 120 s 2 Sample Run 08 s Default value is 08 s and the range is 5 30 s 3 DP Set Pt 0 2 b Default value is 0 2 bar and the range is 0 1 0 5 bar 4 Off Delay 10 s Default value is 10 s and the range is 3 10 s 5 Repeat Cycle 50 Default value is 50 and the range is 10 50 6 3 To View Parameters Continued The default screen after entering the setup mode is Line 1 Line 2 Use or key to scroll through the aforesaid mentioned parameters 6 3 1 To Set Reset Pa
8. TALLATIONS 1 For new equipment care should be taken to flush away any foreign particles that may have been left behind after installation Close the LDS inlet ball valve and ensure LDS electrical isolator is in the off position Do not close LDS discharge or minimum flow by pass line ball valves Run the Pack as normal for at least 24 hours before commissioning or starting the LDS pack 2 Once the pack has been running for 24 hours and that the pack condensing pressures are Stable open the LDS inlet ball valve and turn on the LDS pump After an initial delay of 30 seconds the LDS will start Check rotation by turning the LDS isolator off then back on again 3 Once the LDS has started and has been running for 60 seconds check refrigerant levels in receiver to ensure adequate 1 3 level is maintained The LPA pump will cycle off if there is insufficient levels in the receiver to prevent proper operation Please refer to page 10 for LPA method of Control and Operation 4 After the LDS has started and has been running continuously for 1 hour and pack suction Superheats are stable condensing pressure can be reduced It is recommended that condensing pressure be reduced by 1 bar every 15 minutes to allow for the temperature of the liquid in the receiver to reach its new saturation temperature Do not raise and lower the condensing pressure which will cause unstable LPA operation and repeat cycling 5 For both HT and LT Packs set final condensing temperat
9. V 2 2 1 Connection Sizes Discharge 7 8 ODM Materials in contact with solution h ol 0 0 O J weer es HSS S S Bronze Kynar Ceramic Neoprene PEEK Copper Brazing Silver Solder eee ec een aera Packed Weight Kg kW Box Dimensions mm 660 x 400 x 270 Allowable Pressures bar o 44 2 bar Allowable Temperatures C Fluid S TS maxi TS mini Sa a Manufactured to DIR 97 23 EC CE CAT 1 Fluid Type GROUP 2 GAS _ _ _ R 11 R12 R22 R 114 R 123 R 124 R 134A R 401a R 401b R 401c R 402a R 402b R 404a R 407a R 407b R 407c R 408a R 408b R 409a R 410a R 410b R 411a R 411b T 5 N rn O1 JJ O1 N ix O1 N PAGE 8 MODEL 875 FGN PERFORMANCE DATA J A N Q aia O1 O D Ol O N T O1 O N O Mode LPA 875 1 Nominal Flow GPM 50Hz 60Hz 35 40 Head Nominal Flow Feet 50Hz 60Hz 24 34 5 Motor Power Watts 500 Power supply frequency variation 2 Hz 56CZ TEFC RPM 50Hz 60Hz 2850 3450 Motor Protection Thermal O L Voltage 3ph 220 460 Rated Amperage 208 230 460V 2 2 1 1 Po Comnection Sizes S O Suction 1 5 8 ODM 1 1 8 ODM Materials in contact with solution HSS S S Bronze Kynar Copper Brazing Silver Solder Packed Weight Kg 2614kg 660 x 400 x 270 Allowable Pressures bar o PS maxi 44 2 bar Manufactured to DIR 97 23 EC CE CAT 1 Fluid Type GROUP 2GAS _ _ _ R A11 R12 R22
10. ccur Io avoid use a recovery machine and reduce pressure gradually Refer to Service Manual HYS SM08 for further advice and guidance Observe regulations concerning proper system evacuation recovery and disposal of regulated refrigerants and lubricants SYSTEM SAFETY AND START UP PROCEDURES For New Equipment A BEFORE STARTING THE LDS CHECK THE FOLLOWING 1 Electrical Power Supply Wiring Field Wiring A 415 V 3ph Neutral and Earth supply is required to operate the LDS The minimum cable c s area permitted is 2 5mm Ensure cable glands at panel entry are secure and wiring to terminal blocks F1 F2 F3 Earth and Neutral in the LDS control panel is wired according to DW G EW LDS08 2 Compressor Start Control Signal Field Wiring Ensure volt free start control cable from each compressor n o contactors are wired across ALL compressors and terminated in the LDS control panel terminals 7 amp 8 according to DWG EW LDS0O8 3 LPA Pump Rotation All models rotate clockwise when looking at pump inlet Do not check rotation unless there is refrigerant in the system and the pack is in operation To change rotor direction reverse any phase 4 Condenser Drain Pipework from condenser outlet to LDS receiver inlet Natural condenser drainage and receiver venting essential for proper operation Check that there are no traps in this section and verify that bi directional flow and receiver venting is available A COMMISIONING THE LDS FOR NEW INS
11. rameters To set any one of the aforesaid parameters follow these steps after entering into the setup mode 1 Use or Og to select the parameter to be modified to select the current parameter being displayed on the display 3 The cursor blinks at the position of the value to be changed 4 Use or rey to increment or decrement the corresponding value Fa ty 5 Press ENTER G confirm the change or press EXIT to discard ks Mn ral 6 Once the new value is confirmed the same Is stored into the nonvolatile memory and pops up the message Updated on the first line of the display 7 Redo the steps 1 through 6 for all parameters ir N 8 Press EXIT to come out of the setup mode and enter into the run mode he nail Upon completion of the above steps Pump Pro lll revives its normal operation with respect to the new configurations 6 4 Shutdown Mode Pump Pro lll is forced to shutdown mode whenever it entertains a fault signal caused by either external internal aspect As a result the pump operation is locked out along with the fault indication The fault is indicated with the buzzer and fault lights The Pump Pro lll must be power cycled to revoke its normal operations 7 TROUBLESHOOTING 7 1 PROBLEM Display is unstable ll Unreadable characters are displayed Ill The character display is erroneous IV Single line display V Pump Pro lll is in shutdown mode SOLUTION Power cycle the Pump Pro Ill when one of
12. re IP 65 LApproval CE 3 3 DESCRIPTION OF OPERATION 3 3 3 LDS Sample Period After the initial start delay period expires the Pump Pros will switch the LDS ON fora sample period default 8 Seconds During the sample period the differential pressure generated by the LDS is sampled If this pressure exceeds the preset pressure default 0 2 bar Spsi the Pump Pro3 permits the LDS to enter running condition 3 3 4 LDS Retry Mode lf the pressure does not achieve the preset set point within the sample period the LDS which is enabled by the corresponding compressor is stopped and the retry timer is started default 10 Seconds After the retry timer expires the LDS sample period is then restarted This cycle willbe retried until either the LDS achieves the preset pressure or the number of pump retries default 50 is equaled If the number of retries is equaled then Pump Pro will enter into fault mode and the corresponding Fault output is switchedon and the LDS operation is locked out while the LDS enable signal remains This is usually due to low refrigerant levels 3 3 5 LDS Running Mode In this mode the LDS pressure is continually sampled ensuring the LDS is running ina healthy condition and the retry counter is reset to default value 50 Any Fault condition previously occurred is cleared In this mode if LDS pressure is reduced below the set point for longer than 6 seconds the LDS enters the retry mode 3 3 6 LCD Display
13. s and supplies DO NOT ISOLATE THE LPA PUMP OR SECTIONS OF TUBING that may contain liquid refrigerant as dangerous hydraulic pressure can develop which may cause the piping or other system devices to burst The LPA pump described in this manual has a safety pressure device set at 25 4 bars between the pump inlet and outlet isolation valves as a Safety precaution For service between these points close minimum flow bypass line and recover using suitable refrigerant recovery equipment LEAK TESTING All Liquid Delivery Systems have been factory tested at 24 5 bar 350 psi Testing of field welds must be done at or below 22 bar 320 psi Do not apply power to the LDS panel without first verifying that the LDS control panel is wired correctly for the applied voltage Refer to DWG EW LDS0O8 Electrical Panel wiring schematic provided in the LDS Control Panel HEALTHY AND SAFETY CONTINUED READ AND FOLLOW SAFETY INSTRUCTIONS For new installations do not run the LPA Pump for 24 hours after the pack has been in operation to ensure any foreign particles left over from the installation have been removed via the system s filter drier circuit During this period it is recommended that the LPA inlet ball valve be closed Do not run the LPA pump with the inlet or outlet ball valve closed Do not run the LPA pump with the Minimum Flow By pass closed Do not oump down the LPA pump housing or decompress suddenly as impeller damage may o
14. s be restored back to design condition both improving capacity and efficiency Expansion valve commissioning will be for a full bore of liquid at all fixtures regardless of fixture location Expansion valves are designed to meter the flow of liquid refrigerant to the evaporator and work properly only if the liquid metering device has a liquid seal to the valve inlet Since the expansion valve controls the flow of refrigerant pumping the liquid ahead of a properly sized and adjusted valve will not lead to overfeed the evaporator It may be necessary to reset superheat on the valve only if the valve has been misadjusted previously in attempt to deliver cooler case temperatures Because the LDS will always feed the liquid metering device with a solid column of liquid only a one time adjustment should be required to the misadjusted valve Seasonal changes will not affect the settings Restore back to factory default setting for each case Occasionally it may be necessary to add extra refrigerant due to increased density of the liquid at the lower operating condensing temperatures or if flash gas volume previously occupied the liquid line At part load conditions evaporators can operate with as muchas 70 more liquid than at full load condition While the LDS is in operation outlet pressure can vary between 0 5 to 1 2 bar depending on pack demand and loading The LDS pack and operating performance of the LDS controller has been set up to run under mo
15. st operating conditions Therefore it would not be necessary to make any adjustments or parameter changes to the LDS sequence of operation via the LCD display The LDS pack has been programmed to run in default mode which Is suitable under most running conditions HEALTHY AND SAFETY READ AND FOLLOW SAFETY INSTRUCTIONS AN This is a safety alert Warns about hazards symbol When you see that will or can cause serious this symbol on your pump or in this personal injury death or major manual look for one of the following property damage if ignored signal words and be alert to the potential for personal injury Warns about hazards Warns about hazards that that will cause serious personal injury can cause serious personal injury death or major property damage if death or major property damage if ignored ignored IMPORTANT INFORMATION The Label NOTICE indicates special instructions which are important but not related to hazards Carefully read and follow all safety instructions and method of operation in this manual Hazards associated with installation include death severe injury or equipment damage due to electric shock fluids under high pressure extremely cold fluids flammable fluids under pressure the use of a torch near combustibles and on piping systems containing flammable liquids or vapors asphyxiation exposure to toxic chemicals and toxic chemical by products hazardous moving parts and working with heavy part
16. the above mentioned conditions meets Should you have the same problem repeatedly contact the Help desk number at the bottom of this manual Help Desk No UK 44 0 1761 416 123 USA 813 395 2375
17. ure to 18 C For HT and LT suction pressures set at 9 C and 37 C respectively 6 Check expansion valve superheats and adjust as necessary for a full bore of liquid AN GENERAL SPECIFICATIONS amp LIMITATIONS OF USE For New Equipment I mportant The liquid Delivery System LDS and associated system duties below are designed for use at ROOF TOP LEVEL LOCATIONS ONLY For other system configuration duties or LOCATIONS please contact HY SAVE UK Ltd for detail 44 0 1761 416 123 HT SYSTEM LT SYSTEM efrigerant R404A R407A R404A System Compressor Duty KW 180 210 180 210 60 80 PA Pump M odel 875 1 875 1 860 1 ump Quantity ae ed 1 DSM odel Number LPA 875 1 LPA 875 1 LPA 860 1 efrigerant R404A R407A System Compressor Duty KW 150 179 150 179 PA Pump M odel 875 1 860 1 ump Quantity SSS aa l DS M odel Number LPA 860 1 LPA 860 1 LPA 860 1 eceiver Type Flow Through Flow Through Flow Through 1 1 eceiver Volume L 18 esign SST Temp C 4 3 1 5 180 sian SCT Temp 7 esign Ambient Temp C 32 otal Superheat K 17 seful Superheat K e 5 iquid sub cooling K E PAGE 7 MODEL 860 IND PERFORMANCE DATA LPA 860 1 21 25 24 34 5 Nominal Flow GPM 50Hz 60Hz Head Nominal Flow Feet 50Hz 60Hz Motor Power Watts 370 Power supply frequency variation 2 Hz Motor Frame 56CZ TEFC RPM 50Hz 60Hz 2850 3450 Motor Protection Thermal O L Voltage 3ph 220 46 Rated Amperage 208 230 460
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