Home

product manual

1. Is the R 22 charge Find leak then repair and properly correct no charge system yes Are the liquid line filter 3 Replace driers clogged yes no Is the drive plate turning at correct Are the speed pots adjusted speed no correctly yes yes ANSA Remove drive y gt assembly and replace countercranks broken yes countercranks j no O in thesvaporat r Shut unit down Remove drive assembly and thaw out ice g up P gt Caution Unit will most likely freeze up again tubes i yes Cause for freeze up must be determined no Is the liquid level valve controlling Adjust repair or replace properly no yes Is the evaporator Check feed supply pressure solution flow rate gt in line strainer filter pump correct no operation yes Is the glycol solution concentration With no ice in the tank measure 0 9 percentage level and adjust to level above 7 LET yes 7 minimum MaximICE TES ORE 25 100 Owner s Manual 37 Part No 9840502 Effective September 1 1998 Revised December 1 2000 10 6 System will not make ice Is the solution temperature above 30 F 1 0 C Troubleshooting Chart 6 System Will Not Make Ice __ yes pra Allow unit to operate and decrease solution temperature Ice making should begin below 30 F 1 C Is the R 22 charge correct no yes Find leak repair and charge u
2. LINE LINE WET SUCTION OUT SUCTION HEAT EXCHANGER I ull Fw I i AS FILTER DRIER EXPANSION DEVICE LIQUID FEED RECIRCULATED DRY SUCTION RETURN OIL RETURN LINE FCV AN GLYCOL pd lt SOLUTION IN E ORE EVAPORATOR ASSEMBLY si MaximICE TES ORE 25 100 Owner s Manual 15 Effective September 1 1998 Part No 9840502 Revised December 1 2000 SECTION 4 0 PRE START UP INSTALLATION REQUIREMENTS 4 1 Evaporator Unit Drive The unit must be level within 1 5 3 mm over the entire length and width of the evaporator compartment shim and grout as necessary The unit must be uniformly supported along the base beams The unit must not have restricted access At least 4 1 2 m of clearance is required on all sides of the unit Service access must be provided for removal of whip rods approximately 4 or 1 2 m above evaporator compartment Do not suspend or support any piping or conduit from this unit This unit contains rotating equipment thus vibration and sound control may be required for this unit Where vibration may be transmitted to a structure all external piping to the unit should be vibration isolated 4 2 Water Loop Piping All piping must be complete and correctly installed Water piping shall be flushed and drained prior to final connection to the MaximICE The flushing procedure shall use an environmentally approved cleaning solution and consist of flushing the
3. Clean repair or replace yes y Readjust to maintain a slow yes steady liquid oil mixture flow ro Contact factory MaximICE TES ORE 25 100 Owner s Manual Part No 9840502 42 Effective September 1 1998 Revised December 1 2000 10 11 Does solution have correct phosphate levels 4 000 ppm no yes Is solution cloudy in appearance yes no Are the left countercranks worn more than the right or vice versa yes 155 Is the eccentric pin worn on one side only ro Is plastic housing bearing wallowed out ro Does drive plate have a number of oval shaped or enlarged holes no E Has the drive motor failed no HS yes yes no Is thrust face of sleeve bearing broken or worn out yes 2 yes plate clears it everywhere in orbit yes Unit ran while tubes full of ice and Are any countercranks cracked 3 countercrank frozen in position yes See Chart 1 yes __ yes yes Are whip rods worn at neck and bottom yes yes High solution level Check vent switch for proper operation See Chart 2 MaximICE TES ORE 25 100 Owner s Manual Part No 9840502 Troubleshooting Chart 11 Excessive Wear Add k HPO inhibitor Systems with stainless steel H tubes are especially sensitive to th
4. gt Add glycol and water no yes Does tank reach 50 ice fraction Reset high ice level temperature before shutting down yes switch no Are process building loads higher 3 than expected design basis yes Contact Factory MaximICE TES ORE 25 100 Owner s Manual 40 Effective September 1 1998 Part No 9840502 Revised December 1 2000 10 9 Troubleshooting Chart 9 Excessive Evaporator Shell Vibration Excessive Evaporator Shell Vibration F Remove drive assembly and install Are all countercranks installed left and right countercranks 2 GUS no correctly See Figures 3 5 yes Remove drive assembly and replace Are any countercranks damaged gt gt damaged countercranks Note Remove ice yes slurry pump and clean impeller vanes i no Is the drive plate damaged gt yes no Remove drive assembly and replace damaged Are any whip rods damaged gt whip rods Note Remove any whip rod material yes within ice slurry pump or ORE outlet shell no Is ice freezing up in the evaporator See Chart 1 Low Pressure tubes yes Evaporator Freeze Up no Adjust drive speed slightly higher Is system 50 hz gt or lower 10 to get away from yes resonance ro See Section 3 2 for foundation Is system supported properly _ details no i yes EEE Secure motor bolts with Loctite and yes split
5. STEEL RIVETS POSITIONED TOWARDS ALIGNMENT MARK P ALIGNMENT MARK 8200062 1 P1 MaximICE TES ORE 25 100 Owner s Manual 11 Effective September 1 1998 Part No 9840502 Revised December 1 2000 Figure 4 MaximICE ORE 50 Drive Assembly PLAT 0338 ING PE O nol O N O On fi EVAPORATOR ALIGNMENT MARK 40347 N 7 HOUSING T Ks pe CRANK 1 16 NZ 16 MM 0 8 No E BEARING SLEEVE DETAIL A Li PLATE GAP 7 MaximICE TES ORE 25 100 Owner s Manual Part No 9840502 HL ay A Sey 12 MOTOR 98 40319 ECHANCAL S 9840339 984268 AL EG CRANK BE ARIN VE G 9840320 9842349 DRIVE PLAT 9842626 RUBBER GASK 9840343 LET SHELL 9840301 9842676 9842677 WHIP ROD 8850044 POSITIO RIVETS ALIGNM STEEL TOWARDS Becca BE ARING ET a E ENT MARK 8200096 1 P1 Effective September 1 1998 Revised December 1 2000 Figure 5 MaximICE ORE 100 Drive Assembly DRIVE MOTOR EE 9840850 LEVEL ai ADJUSTMENT O MOUNTING PLAT ECCENTRIC CRANK 984088 9842681 O RING HOUSING_BEARING 9840347 9842349 DRIVE PLATE 5 COUNTERCRANK Meana RH 98426
6. 8 0 8 1 8 2 8 3 8 4 Maintenance ut Atri A Lua ANN ail 23 Daly Chek S errero S s ra Sat He hac ekkel ba at h kes ea AIR ir 23 Recommended Inspection Procedures ooo 23 Figure 8 Drive Plate Inspection Criteria 0 24 Figure 9 Drive Plate Inspection Criteria Le 25 Figure 10 Countercrank Inspection Criteria i 26 Figure 11 Whip Rod Inspection Criteria caor to EAA eee 27 Figure 12 Bearing Sleeve Inspection Criteria 1 ee eee 28 Figure 13 Tube Insert Inspection Criteria 0 eee 29 Figure 14 Eccentric Crank Inspection Criteria LL 29 Recommended Drive Component s Replacement Schedule 30 Recommended Monitoring Points Le 30 Section 9 0 Recommended Spare Parts 9 0 9 1 9 2 9 3 9 4 Recommended Spare Parts a da dd A AAA BER Ba del aed 31 ORE COMMON PA S AE AAA A a Ra Pe EE Oe A A A AD NIE EE ei ENA 31 ORE25 Past sect Airco ars ala A ag Ree Hee eau Me act Bel oa 31 ORESO Parts ricos eee RG Gy ee he Gude e OR RE hee A OE OE oh a Bey er AG E 31 ORES100 Bart A Ed a OE Patents ale Oa A de eee 32 SECTION 1 0 INTRODUCTION 1 0 Introduction The MaximICE evaporator assembly is a thermal energy storage system intended for producing a large amount of ice slurry The ice slurry is used to take advantage of off peak electrical power usage usually at night The ice slurry is then used during the on peak electrical usage periods for air conditioning or process cooling This in turn reduces the electrical d
7. Typical quaternary amines are C to Cig mixtures of n alkyl dimethyl benzyl ammonium chloride or n alkyl dimethyl ethyl benzyl ammonium chloride Manufacturers include Albemarle Chemical BQ 451 5 Lonza Barquat 50 65 and Stepan Company BTC 818 Dry ingredients such as dipotassium phosphate must be dissolved in water prior to addition to the ice slurry tank A small tank and mixer is convenient for this purpose Water Quality Water used to make up the glycol solution must meet certain standards of purity Distilled or de ionized water is recommended Levels of chlorides and sulfates should be less than 25 ppm each Total hardness should be less than 100 ppm expressed as ppm calcium carbonate If good quality water is unavailable pre diluted solutions are available from manufacturers Local conditions must always be taken into consideration particularly when it comes to biofouling and scaling fouling deposits A local water treatment authority should be consulted for guidance in this matter PMC recommends calling your county or city water department to find out the specification of your local water supply If the water contains less than 100 ppm of hardness it can be used to dilute your glycol based heat transfer fluid Another option would be to test the water yourself with a HACH test kit One word of caution about the common practice of using softeners when filling HVAC systems resins typically used in these softeners will replace
8. 15 0 WARRANTY WARRANTY Mueller MaximICE for Thermal Storage One Year Parts Warranty Paul Mueller Company hereinafter referred to as Company will repair or or at the Company s option replace any part or portion of a Mueller MaximICE Evaporator Assembly found to be defective in workmanship or material under normal use service and installation procedures for a period of one 1 year from date of installation by the original purchaser user or eighteen 18 months from the date of shipment from the Company factory whichever occurs first This Warranty covers replacement of parts or repair of the equipment only This warranty does not cover consumable products or parts such as refrigerant driers glass or rubber components See General Provisions Claim Procedure for One Year Parts Warranty All defective parts covered by the one year parts warranty must be returned to Paul Mueller Company with an attached Returned Goods Tag O 209 and with transportation cost prepaid Current instructions for return procedures provided by the Thermal Storage Products Service Department must be followed to receive warranty General Provisions This warranty does not cover items such as refrigerant transportation mileage freight product loss cost of substitutions or labor and parts charged by others Replacement and or repair of certain components not manufactured by the Company will be handled by authorized service stations designated b
9. 5mm OR MORE Az REPLACE IF ANY CRACKS ARE VISIBLE ORIGINAL DIMENSION 0 125 3 2mm REPLACE IF SHOULDER SURFACE IS WORN 040 1 0mm OR MORE ORIGINAL DIMENSION 0 313 8 0mm 1 438 ORIGINAL 36 5mm DIMENSION REPLACE IF DIAMETER IS WORN 040 1 0mm OR MORE MaximICE TES ORE 25 100 Owner s Manual 26 Effective September 1 1998 Part No 9840502 Revised December 1 2000 Figure 11 Whip Rod Inspection Criteria REPLACE IF ANY VISIBLE FLAT SPOTS ON WHIP ROD MEASURE BOW WITH FEELER GAUGE IF WHIP ROD WON T ROLL FREELY ON A FLAT SURFACE 1 16 1 5mm MAXIMUM BOW REPLACE IF A IS EQUAL OR LESS THAN 5 16 8mm AT ANY POINT ON THE ROD MaximICE TES ORE 25 100 Owner s Manual 27 Effective September 1 1998 Part No 9840502 Revised December 1 2000 Figure 12 Bearing Sleeve Inspection Criteria A Drive Plate Bearing Housing Make sure that there is not any apparent scoring inside the bearing sleeve Measure the ID of the bearing sleeve and refer to the tolerance chart to see if this part can be reinstalled or needs replacing The lip on the bearing sleeve should be fully seated into the bearing housing REPLACE IF A IS EQUAL OR GREATER THAN 1 015 25 78mm REPLACE IF LOOSE IN HOUSING BEARING REPLACE IF B IS EQUAL OR LESS THAN 040 1mm A Freeze Up Protection Switch Remove the 2 wires that are connected to the freeze up protection switch Shut the an
10. Horsepower 200 volts 380 volts 3 5 amps 2 1 75 amps 2 762 rpm 857 rpm 60 Hertz Drive Motor 3 Horsepower 60 Hertz Drive Motor 3 Horsepower 208 volts 230 volts 3 7 amps 2 3 05 amps 2 794 rpm 794 rpm 60 Hertz Drive Motor 3 Horsepower 60 Hertz Drive Motor 3 Horsepower 460 volts 380 volts 1 53 amps 2 1 75 amps 2 833 rpm 794 rpm 3 13 Electrical Specifications ORE 50 but not limited to PLC 24 Volts Inputs DC Outputs AC Power Supply 120 volts AC 50 Hertz Drive Motor 1 5 Horsepower 50 Hertz Drive Motor 1 5 Horsepower 200 volts 380 volts 6 0 amps 2 3 0 amps 2 850 rpm 850 rpm 60 Hertz Drive Motor 1 5 Horsepower 60 Hertz Drive Motor 1 5 Horsepower 208 volts 230 volts 5 2 amps 2 4 75 amps 2 850 rpm 850 rpm 60 Hertz Drive Motor 1 5 Horsepower 460 volts 2 35 amps 2 850 rpm MaximICE TES ORE 25 100 Owner s Manual 6 Effective September 1 1998 Revised December 1 2000 3 14 3 15 3 16 3 17 3 18 MaximICE TES ORE 25 100 Owner s Manual Part No 9840502 Electrical Specifications ORE 100 but not limited to PLC 24 Volts Inputs DC Outputs AC Power Supply 120 volts AC 50 Hertz Drive Motor 3 Horsepower 50 Hertz Drive Motor 3 Horsepower 200 volts 380 volts 13 8 amps 2 6 9 amps 2 850 rpm 850 rpm 60 Hertz Drive Motor 3 Horsepower 60 Hertz Drive Motor 3 Horsepower 230 volts 460 volts 12 6 amps 2 6 3 amps 2 850 rpm 850 rpm Ice Sto
11. ORE 25 50 and 100 MaximICE TES ORE 25 100 Owner s Manual 28 Effective September 1 1998 Part No 9840502 Revised December 1 2000 Figure 13 Tube Insert Inspection Criteria A REPLACE IF EITHER SURFACE SCORED OR HAS ROUGHNESS IS 250 u INCH Ra 6 25 u m OR MORE REPLACE IF ANY CRACKS VISIBLE Figure 14 Eccentric Crank Inspection Criteria REPLACE IF SURFACE ROUGHNESS IS 125 u INCH Ra 3 1 um OR MORE MaximICE TES ORE 25 100 Owner s Manual 29 Effective September 1 1998 Part No 9840502 Revised December 1 2000 8 3 8 4 Recommended Drive Component s Replacement Schedule A 1 000 hours a Disassemble drive assembly b Inspect wear surfaces c Apply a thin coating of Petroleum Gel to all surface wearing drive parts A 8 000 hours a Possible replacement of countercranks drive plate and flange bearing b Clean ORE inlet strainer NOTE The above schedule is based on good glycol solution quality and normal wear Systems with poor water quality and operational difficulties may require more frequent replacement Recommended Monitoring Points Temperatures F Ambient Solution Supply To Process Solution Supply To Evaporator Compressor Discharge Compressor Suction Condenser Liquid Outlet Pressures psig Compressor Discharge Condenser Liquid Outlet Drier Core AP Evaporator Suction Main Voltage AMPS Compressor Motor Evaporator Drive Motor Evaporator Solution Pump Motor di di
12. R 22 i i 9840556 Power Head amp Heater MVE VVE amp WVE R 22 i 9840564 Power Head amp Heater R 717 only i i 9842704 9 3 ORE 50 Parts T T Description Recommended Qty PMC Part Drive Plate i 1 i 9842626 Drive Plate Assembly plate housing bearing bearing sleeve 1 9842640 Drive Motor Shaft Seal l 1 i 9840339 Housing Bearing i 1 i 9842349 Liquid Level Valve Kit LMC MVE 42 1 i 9840560 Liquid Level Valve Kit LMC MVE 52 i 1 i 9840561 Liquid Level Valve Kit LMC MVE 70 1 9840562 Liquid Level Valve Kit LMC AAE 50 1 i 9842707 Power Head amp Heater LMC MVE VVE R 22 only i 1 9840564 Power Head amp Heater R 717 only 1 i 9842704 Crank Electric Assembly i 1 i 9842862 MaximICE TES ORE 25 100 Owner s Manual Part No 9840502 31 Effective September 1 1998 Revised December 1 2000 9 4 ORE 100 Parts Description Recommended Qty PMC Part Drive Plate i 1 i 9842620 Drive Plate Assembly plate housing bearing bearing sleeve 1 9842872 Drive Motor Shaft Seal i 1 i 9840666 Housing Bearing l 1 9842349 Bearing Sleeve i 1 i 9840320 Liquid Level Valve Kit LMC VVE 100 i 1 i 9840562 Liquid Level Valve Kit LMC AAE 100 1 9842705 Liquid Level Valve Kit LMC WVE 135 1 9840563 Power Head amp Heater R 22 only 1 9840564 Power Head amp Heater R 717 only 1 i 9842704 Crank Electric Assembly i 1 i 9842681 Max
13. TYPICAL WRING Unit Pumpdown Low Pressure Switch Provide normally closed dry contacis SCHEMATIC Contacts open when suction pressure drops to 5 psig condensing unit shuts down Condensing Unit Alarm 1 Provide normally closed dry contacts Contacts open upon condensing unit alarm condilion condensing unit shuts down Single compressor condensing unit wiring shown See unit wiring diagram for multiple condensing urits and optional items Condensing Unit Alarm 2 Jumper in control box OPTIONAL Remote temperature switch Wired to remote ice level inventory sensor Comacts close on full ice condition predetermined temperature setting OPTIONAL Condensing Unit Start 24VAC contacts close to siart condensing unit Compressor Unicading Step 1 24VAC contacts close to untoad compressor Compressor Untoading Step 2 24VAC contacts close to unload compressor Remote Alarm Dry contacts close upon alarm condition for remole alarm indication Remote Solution Pump Start Dry contacts close lo siart solution pump INPUT TO MaximiCE PLC O OUTPUT FROM MaximiCe PLC CUSTOMER SUPPLIED 3 PHASE WITH GROUND MUELLER eee 2 89 x m pra a gt 2586 er es Cane es Pete MODEL ORE 25 Flooded Refrigerant Feed Pumped Slush Discharge 820046 3 7 97 MaximICE TES ORE 25 100 Owner s Manual 49 Effective September 1 1998 Part No 9840502 Revised December 1 2000 13 3 Mod
14. adequate air circulation The most important consideration when determining the location of the air cooled equipment is ambient air supply and removal of heated air to prevent air recirculation A minimum distance of 3 0 9 m clearance should be provided for proper hot air removal and servicing The general rule of thumb for evaporative cooled units is to allow a minimum distance around the unit of 6 1 8 m for smaller units and 8 2 4 m or more with larger units Consult PMC for further details MaximICE TES ORE 25 100 Owner s Manual 5 Effective September 1 1998 Part No 9840502 Revised December 1 2000 Part No 9840502 3 11 Electrical The MaximICE wiring schematic identifies the minimum remote interconnecting field customer wiring required All power wiring and grounding must be installed in accordance with all local state and national codes Separate field supplied breaker disconnect is required and shall be supplied by others Article 440 of the NEC requires that the system have disconnecting means capable of disconnection of air conditioning and refrigeration equipment including motor compressor and controllers from the circuits feeder The circuit breaker and or fused disconnect switch should be selected and located within the NEC guidelines 3 12 Electrical Specifications ORE 25 but not limited to PLC 24 Volts Inputs DC Outputs AC Power Supply 120 volts AC 50 Hertz Drive Motor 3 Horsepower 50 Hertz Drive Motor 3
15. capacity Start up sequence complete 6 2 Shutdown Sequence A Shutdown initiated by either selecting OFF on the toggle switch removing the remote enable signal if in AUTO or high ice condition temperature set point reached in tank A Unload solenoids on 5 minute delay A End of 5 minute delay Condensing unit oil return solenoid unload solenoid and LLM heater turn off A After 15 minute delay drive shuts down MaximICE TES ORE 25 100 Owner s Manual 19 Effective September 1 1998 Part No 9840502 Revised December 1 2000 A End of 30 second delay Slush and feed pump shut down A Shutdown sequence complete NOTE When a unit shutdown is initiated for any reason the unit will complete the shutdown sequence before a restart is enabled If the unit is in the process of starting the start up sequence will be completed before the shutdown sequence begins If an immediate shutdown is required the E STOP switch must be pushed 6 3 Restart Sequence 60 minute typical delay for restart after full ice condition Unit will automatically start the solution pump s and check for absence of full ice condition If full ice exists the pumps shall shutdown and another 60 minute delay will take place and the restart process will repeat Pressing the E Stop push button or an alarm condition will initiate shutdown All operating components are de energized immediately Toggle switch must be moved t
16. continue until all requirements for correct and safe operation of the MaximICE are satisfied The installing trades should be available to resolve installation problems as required during the start up period Contractors personnel and the owner s representative who will be operating and maintaining the unit should be available for training during the entire start up period 4 6 Start Up Policy MaximICE units require two three or four days of start up assistance depending on the size of equipment Delays in the start up caused by failure to comply with any of the following procedures are not the responsibility of PMC Additionally start up time caused by delays not the responsibility of PMC must be authorized by customer in advance Failure to follow these procedures will result in delays and may result in the voiding of the equipment warranty Contact the Paul Mueller Company Thermal Energy Storage Department if you have any questions pertaining to the installation requirements of this equipment MaximICE TES ORE 25 100 Owner s Manual 17 Effective September 1 1998 Part No 9840502 Revised December 1 2000 SECTION 5 0 START UP REFRIGERANT CHARGING 5 0 Start Up Refrigerant Charging Apply main power at least 12 hours prior to starting unit This will allow the compressor crankcase ample time to boil off any possible liquid refrigerant within the compressor NOTE Refrigerant charges provided are conservative and will vary due
17. equivalent 100 30 m increase tubing size accordingly The liquid line should be sized to prevent excessive pressure drop to ensure a solid liquid column to the expansion valve Use only Trade K or L refrigerant grade tubing or Schedule 40 pipe When brazing refrigerant tubing an inert gas should be passed through the line at low pressure to prevent scaling and oxidation inside the tubing dry nitrogen is preferred Use suitable silver solder alloy on all refrigerant tubing Refrigerant lines should be supported and fastened properly 3 7 Refrigerant Piping Pressure Test After all lines are connected the entire system must be leak tested including the ORE and condensing unit The complete system should be pressurized to not more than 150 psig 1 000 kPa using dry nitrogen vapor The use of an electronic type leak detector is highly recommended due to its greater sensitivity of small leaks It is recommended that this pressure be held for a minimum of four hours and then rechecked 3 8 System Evacuation Prior to connecting hoses remove the core from the Schrader fitting A minimum evacuation to 500 microns and a five minute hold period is recommended Proper evacuation processes include vacuum pump oil changes and large diameter short hose connections to both high and low sides of the system 3 9 Refrigerant Charge See Section 5 0 for further details 3 10 Condensing Unit Provide a suitable solid base under protective shelter with
18. leak repair and properly charge system Is oil accumulating in evaporator Adjust repair or replace yes Increase oil return flow back to compressor Check inline strainer filter and pump operation and Check oil separator for missing filter elements Check pressure drop across flow control valve must be at least 12 psi 83 kPa Adjust replace Reduce compressor capacity Increase pre wash and post wash times 33 and Make sure compressor is unloaded gt 50 capacity during pump down and start up Effective September 1 1998 Revised December 1 2000 10 2 Troubleshooting Chart 2 Unit Fails on Vent Switch Unit fails on vent switch PLC Output O Y14 Continuous light l Is the ice slurry pump operating properly no Check power to pump fuses contactor and motor yes Is a valve closed on the ice slurry pump Discharge yes Open valve ie Is the vent line above the maximum glycol solution level i i yes Locate vent line above maximum glycol level pre Is the vent line float switch operating properly no Replace switch yes Is there excessive foaming in the inlet shell or vent line yes Add antifoam to solution MaximICE TES ORE 25 100 Owner s Manual Part No 98
19. on page 15 2 2 Ice Build Circuit The circuit consists of an insulated tank ice storage tank with necessary fittings for field plumbing It must include an internal water spray system for burning ice uniformly during the melt mode The ice slurry is pumped to the storage tank filling the tank as shown from the top down Once the ice inventory reaches the full ice a temperature sensing device will cycle the unit off MaximICE TES ORE 25 100 Owner s Manual 2 Effective September 1 1998 Part No 9840502 Revised December 1 2000 2 3 Building Cooling Circuit The circuit consists of a plate and frame heat exchanger coolant pumps and temperature regulating valve Low temperature glycol solution is pumped from the bottom of the ice storage tank into the plate and frame heat exchanger and returned over the ice pile via a spraying system The spraying system may consist of a specially designed spray ball s drilled with holes or a spraying nozzle s Warm building load water is then pumped into the heat exchanger and cooled Depending on the building temperatures may vary from 37 42 F 3 6 C NOTE The ORE glycol solution loop must incorporate a heat exchanger to separate the building process from the ORE solution loop This reduces the amount of piping which carries the glycol solution minimizing the cost and danger associated with piping leaks All system fluid piping should be properly insulated MaximICE TES ORE 25 100 Owner
20. over the length and width All remote piping must be cleaned gt gt gt All pumps must be secured vertical shaft pumps should be properly protected and aligned A Control wiring connected between the ORE and the condensing unit A All shipping material removed from the inlet shell and the bottom of the evaporator 11 3 Refrigerant Piping For Remote Condenser Systems A All remote refrigerant piping must be installed in accordance with the approved piping practice ANSI AMSE All piping must be properly supported Pressure test complete system for leak including PMC equipment Complete system evacuated gt gt gt gt Full refrigerant charge provided by others to be on site at start up MaximICE TES ORE 25 100 Owner s Manual 44 Effective September 1 1998 Part No 9840502 Revised December 1 2000 11 4 Water Piping If required strainer installed Check for water leaks All flow controls checked and calibrated A A A A Water cooled condenser install water regulating valve on the condenser outlet A Oil cooler water piping installed A Check water loop design control A Freeze protection installed on all applicable piping 11 5 Electrical Adequate power supply to unit A Three phase and control wiring completed to the unit and any remote equipment A All wiring and grounding conforms to national state and local electrical codes A High voltage systems megohmmeter test main wirin
21. power off to the unit c Remove the insulation from the inlet shell and set aside d Remove the inlet solution header this will consist of removing 8 flange bolts and 2 union fittings e On the top plate there will be 12 nuts Remove all 12 nuts and the lock washers NOTE Do not remove the motor If this preventive maintenance is performed on an ORE 100 200 300 or 400 and a hoist is not available the motor may have to be removed due to the weight and the awkwardness of the drive motor and top plate If you have to remove the motor the following steps must be followed There are three 3 4 bolts with a lock nut on the bolt Remove the 3 bolts from the motor mounting plate not the adjusting inserts This will allow the motor to be removed by lifting it along with the motor lifting lugs that are provided with the motor straight up f With the motor and the top plate removed the drive plate will be visible Carefully lift the drive plate up and out of the evaporator and set aside g With the drive plate removed the counter cranks and the tops of the whip rods will be exposed You will notice they are configured in a left and right format Refer to Figures 3 4 or 5 for counter crank arrangement Randomly pull 8 to 10 counter cranks along with the whip rods out of the evaporator for inspection Look at the counter cranks to see if there is any sign of scoring or frictional wear If so refer to the tolerance chart to see if
22. pump must be properly protected against freeze damage The Paul Mueller Company warranty specifically excludes any liability for damage resulting from low ambient temperature Failure to maintain proper operation of the condenser by allowing fouling will result in decreased MaximICE system performance and operation Water cooled units may be provided with a condenser water regulating valve which is shipped loose for field installation at the outlet side of the condenser Remote evaporatively cooled air cooled condenser or cooling towers when supplied by other than PMC require head pressure capacity control Consult factory for details and minimum requirements If applicable Water cooled oil cooler if installed shall be connected by the installing contractor to a water source with a maximum water temperature of 85 F 30 C with the required flow rate shown on the submittal Supply water piping must be properly protected against freeze damage by the installer MaximICE TES ORE 25 100 Owner s Manual 16 Effective September 1 1998 Part No 9840502 Revised December 1 2000 4 3 Electrical All power wiring and grounding must be installed in accordance with all local state and national codes All wiring to the MaximICE shall be copper do not use aluminum wire The following control interlocks must be installed prior to operating the unit Water flow Proof of condenser water flow is required Either a flow switch or a pressure diff
23. 14 0 Start Up Request Form I request that a factory authorized service representative be scheduled to perform start up on or about the week of Please note that this is a requested date and must be confirmed by the service department Start up is usually performed within five days travel included Upon arrival on site the start up technician will verify that the system is capable of being started and that the items identified in the prestart up check list have been satisfied If site construction installation cannot be completed within 24 hours the service technician will depart from the job site In this situation all costs associated with this trip will be charged to the purchaser on a time and material basis The technician will return to the installation site to perform start up upon the following conditions A Verification of the purchaser that all construction items issues are in compliance with and satisfy the concerns of the start up technician A Full payment has been received for the initial start up trip Please fax to 417 862 9008 attention Thermal Energy Storage Department You will be contacted within two weeks to confirm the start up of your unit s Contact our service department if you have any questions regarding this form or the installation of your equipment We will be happy to assist you MaximICE TES ORE 25 100 Owner s Manual 60 Effective September 1 1998 Part No 9840502 Revised December 1 2000 SECTION
24. 40502 34 Effective September 1 1998 Revised December 1 2000 10 3 Troubleshooting Chart 3 Unit Will Not Start Unit will not start Check 115V power Is power supplied to supply control control box 4 no transformer and fuse yes Is the on off switch in Turn switch to on the on position no position yes Is the PLC Check for main power contact run light on 48 factory yes Is the PLC CPU fault light on _ Contact factory yes i no Is the PLC toggle switch in the Toggle to run position run position no j yes he full ice light on k full ice Is the full ice lig t on and tank fu Allow process load to melt ice Replace of ice yes a Allow unit to restart no pro Is the full ice light on but no ice is Is the PLC input I XO light on Are the ice level AS operating in storage tank yes yes properly no Ae Contact factory pro Is an alarm light on I Identify failure and restart unit yes Is there voltage 24 VDC at PLC output O Y11 ie Contact factory Is the temperature sensor showing full ice condition but full ice light is gt Is the PLC input I XO light on Contact factory not on yes MaximICE TES ORE 25 100 Own
25. 76 ee LH 9842677 o co pl N7 A E i INLET SHELL RUBBER EG 9840854 o r a 1 32 ECCENTRIC CRANK GAP e HOUSING BEARINC DRIVE PLATE BEARING SLEEVE PRONTI Tt VIVO E NG OG 2 amp D STEEL RIVETS SOS POSITIONED 90 OF THE ALIGNMENT da MARK NOTE AI NOT OPPOSITE JE x ARRANGEMENT i Sale CRANK 8200137 P1 HOUSING BEARING Da ae GaP a BEARING SLEEVE ENN 2 x E MaximICE TES ORE 25 100 Owner s Manual Part No 9840502 Effective September 1 1998 13 Revised December 1 2000 Figure 6 ORE Countercrank Assembly WHIP ROD COUNTERCRANK LEFT COUNTERCRANK RIGHT DRIVE PLATE RIVET 9842676 9842677 REVISED COUNTERCRANK AS OF OCT 99 8200135 P1 MaximICE TES ORE 25 100 Owner s Manual 14 Effective September 1 1998 Part No 9840502 Revised December 1 2000 3 23 Packing Material s The whip rods are secured in place with cellophane wrap which must be removed from the bottom of each evaporator On units with an ice discharge pump option the outlet manifold ships loose and should be installed after the cellophane wrap Figure 7 MaximICE Refrigeration Schematic Diagram CONDENSING UNIT I CONDENSER DA HIGH PRESSURE RECEIVER COMPRESSOR I LOW PRESSURE RECEIVER SUCTION LIQUDY
26. 9823978 47 Section 13 0 Equipment Specifications 13 1 13 2 13 3 13 4 13 5 13 6 13 7 13 8 13 9 Model ORE 25 Flooded Refrigerant Feed Pumped Slush Discharge Drawing No 8200139 48 Model ORE 25 Flooded Refrigerant Feed Pumped Slush Discharge Schematic Drawing No 8200146 49 Model ORE 25 Flooded Refrigerant Feed Gravity Slush Discharge Drawing No 8200153 50 Model ORE 25 Flooded Refrigerant Feed Gravity Slush Discharge Schematic Drawing No 8200160 51 Model ORE 50 Flooded Refrigerant Feed Pumped Slush Discharge Drawing No 8200140 52 Model ORE 50 Flooded Refrigerant Feed Pumped Slush Discharge Schematic Drawing No 8200147 53 Model ORE 50 Flooded Refrigerant Feed Gravity Slush Discharge Drawing No 8200154 54 Model ORE 50 Flooded Refrigerant Feed Gravity Slush Discharge Schematic Drawing No 8200161 55 Model ORE 100 Flooded Refrigerant Feed Pumped Slush Discharge Drawing No 8200141 56 13 10 Model ORE 100 Flooded Refrigerant Feed Pumped Slush Discharge Schematic Drawing No 8200148 57 13 11 Model ORE 100 Flooded Refrigerant Feed Gravity Slush Discharge Drawing No 8200155 58 13 12 Model ORE 100 Flooded Refrigerant Feed Gravity Slush Discharge Schematic Drawing No 8200162 59 Section 14 0 Start Up Request Form 60 Section 15 0 Warranty urta EA 61 A kreditten 28 5 ANER DER OPS Bed rd Tag a a aiaa 62 TABLE OF CONTEN
27. FLANGE SOLUTION N 2 FNPT 46 LEFT SDE VEW REFRIGERANT sala ca rca ee NR er rene sne amp 3 2 sm fam NOTES All dimensions are in inches unless specified otherwise 3 PMC reserves the right to make product design changes which may alter the weights and or dimensions without prior notification 3 Three foot 3 minimum service clearance is required on all sides of assembly 4 Three feet 3 minimum clearance above ORE is required for removal gr A of whip rods Single point electrical connection through side of control panel 6 Insulated paneling adds 5 to length 5 to width 2 1 2 to height MODEL ORE 25 Flooded Refrigerant Feed Pumped Slush Discharge 820009 3 7 97 MaximICE TES ORE 25 100 Owner s Manual Effective September 1 1998 Part No 9840502 48 Revised December 1 2000 13 2 Model ORE 25 Flooded Refrigerant Feed Pumped Slush Discharge Schematic Drawing No 8200146 Remote Start Provide normally open dry contacts lo start unit from remote location With unit toggle switch turned to Auto unit wil start upon contaci closure Load Pump Operation Provide mormaliy open dry contacts for monitoring of pump operalion either ouxiiary contacts or from EMS Contacts close upon pump siari Solution Pump Operation Provide normally open dry contacts for moniloring of pump operation either auxiliary contacts or from EMS Contacts close upon pump stort SINGLE PHASE ORE 25
28. MaximlICcE LIQUID ICE TES SYSTEM ORE 25 50 amp 100 OWNER S MANUAL PART NO 9840502 EFFECTIVE SEPTEMBER 1 1998 REVISED DECEMBER 1 2000 UT N THERMAL STORAGE PRODUCTS MIUELLER Part No 9840502 MaximiICE LIQUID ICE TES SYSTEM ORE 25 50 amp 100 OWNER S MANUAL TABLE OF CONTENTS Section 1 0 Introduction 1 0 1 1 1 2 Introduction nt ida ay Da GENT EL GE h fi ed Grad GY I iaia DE DET IA atdet he 1 Delivery Inspection Mi E A E Lee RN ee OA 1 Safety Considerations x puede A Aa A AS AA AAA Lila 1 Section 2 0 Thermal Storage System System Overview 2 0 2 1 2 2 2 3 Thermal Storage System System Overview sasaaa aa 2 Refrigeration Circuit sas a EA 4 hark ees Pees A dei 2 Tee Build Circuit s ren A ene SS Bae AA eee ee SL FRPS EE 2 Building Cooline Circuit li tate tae ee pie Gee Raid ween Ewe Ue ee ee dd 3 Section 3 0 Installation 3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 10 3 11 3 12 3 13 3 14 3 15 3 16 3 17 3 18 3 19 3 20 3 21 3 22 Installation cd e ON GAME El ENT E Ad 4 Equipment Rigging a ow acts La lai E AAA A dle n 4 Foundation dire eske a Oe A A eee th A Rana AAA 4 ANCHOrns gt spie ra ada Ata ee S ty Oe Bie Ber Aa Weg ae dca AAA aah ee 4 Figure d Anchorage Details evo O S r Oa ae san es WEN oe i 4 S rviceability sarete A Ea eee ee RS GE ih STIENE 5 Shipping AA mee ee FAG Ge ee EEA ON BER EEO REY Poa oem ee LG 5 Remote Refrigeration Pipi
29. N 7 0 SAFETY 7 1 Label Danger Unit Starts Up Automatically The unit is intended to operate automatically and will start at any time Power must be disconnected and locked out when servicing the unit DANGER STARTS AUTOMATICALLY BRADY SIGRMARE DM CAT MO 65172 MEN 7 2 Label Electrical Symbol Part No 8820623 Indicates the high voltage electrical components of the system 7 3 Label Danger High Voltage This unit should be serviced by qualified electrical and refrigeration technicians DANGER HIGH VOLTAGE BESO SGM MAAK D CATALOG NO 54875 MaximICE TES ORE 25 100 Owner s Manual 91 Effective September 1 1998 Part No 9840502 Revised December 1 2000 7 4 Label Caution Do Not Run Unit Dry Part No 8850229 Major damage will occur if the drive parts are ran without the solution A CAUTION DO NOT RUN UNIT DRY EQUIPMENT DAMAGE WILL OCCUR 7 5 Label Caution If this Gap Measurement Part No 9842772 If the bearing gap is not set correctly it will cause the failure of the drive bearing and the drive plate A CAUTION IF THIS GAP MEASUREMENT IS NOT CORRECT IT WILL CAUSE SERIOUS DAMAGE TO THE UMIT 7 6 Equipment dB Readings The equipment s dB readings A weighting taken during ice making at 3 feet 1 M from evaporator are listed below ORE 25 ORE 50 ORE 100 75 75 78 A WARNING When operatin
30. ONAL Condensing Unit Start 1 Z4VAC contacts close to start condensing unit Compressor Unloading Step 1 24VAC contacts close to unioad compressor 7 Condensing Unit Start 2 24VAC contacts close to start condensing unit OPTIONAL I Remote Alarm Dry conlacis close upon alarm condition for remote alarm indication 7 Remote Solution Pump Start Dry contacts close to start solution pump I INPUT TO MaximiCE PLC O OUTPUT FROM MaxmiCE PLC CUSTOMER SUPPLIED 3 PHASE WITH GROUND MAJE LL LE MODEL ORE 50 Flooded Refrigerant Feed Gravity Slush Discharge 820061 3 1V97 MaximICE TES ORE 25 100 Owner s Manual 55 Effective September 1 1998 Part No 9840502 Revised December 1 2000 13 9 Model ORE 100 Flooded Refrigerant Feed Pumped Slush Discharge Drawing No 8200141 LOW PRESSURE RECEIVER ORBITAL ROD EVAPORATOR 94 SLUSH OUT 3 ANSI 1505 FLANGE SOLUTION IN 4 ANSI 15028 FLANGE 78 BACK VIEW LEFT SIDE VEW SHP DESIGN REFRIGERANT WEIGHT WEIGHT REFRIGERANT CHARGE FLOW T tbe Fla oae oeron uoo T ae Seon HP OSTE ESA p 3 3 aet 30FT am e COME NOTES 1 All dimensions are in inches unless specified otherwise 2 PMC reserves the right to make product design changes which may alter the weights and or dimensions without prior notification 3 Three foot 3 minimum service clearance is required on all A sides of assembly a 4 Th
31. TS CONTINUED Section 4 0 Pre Start Up Installation Requirements 4 1 4 2 4 3 4 4 4 5 4 6 Evaporator Unit D VE riker Seah BE AS AA UNOS Le a e 16 Water LOOp Piping gt ora pra i ele ae a die de ohare Pane ele a 16 El Mid E Se Raf oa ele res ee We es 17 Refrigerant Piping a pe ee age ee Pa ING Fra Bek DEAD Re nad 17 Start Up Coordination Inspection o 17 Start UpsPOlCy A RR Gare 17 Section 5 0 Start Up Refrigerant Charging 5 0 Start Up Refrigerant Charging ui ira ed ea he eee en ele i Bete a aio sand dt 18 Section 6 0 Sequence Of Control 6 0 Sequence of Control ci ane ct te pe we Ee PERS wees db wale ODE oe ee aa Fe oe rane 19 GI Start Up Sequence vista side FA Arre aL A Beet 19 6 2 gt Shutdown Sequence sa da at ska A Bey SEG OS ao yay ee ek ee Sen ae ath 19 635 Restarksequencee Su E A AA na 20 64 Alarm Condition Sequence anta aI ENS SEE SO Ay Be WEEDS A SE Bia Ble 20 6 5 Additional Control Elements vrsqrrntar rra terra a ta aa p 20 Section 7 0 Safety 7 1 Label Danger Unit Starts Up Automatically 2 0 eee 21 7 2 Label Electria Symbol Part No 8820623 201000 rocne A piace 21 7 3 Label Danger High Voltage a a A A erat Ga Rai 21 7 4 Label Caution Do Not Run Dry Part No 8850229 o o o oo ooo 22 7 5 Label Caution If The Bearing Gap Part No 9842772 rosas ee 22 6 Equipment dB Ratings ton yea seai adie ee ng A A a pa 22 Section 8 0 Maintenance
32. ation The following information should be provided to the owner A Manufacturer s name address and telephone numbers A Material safety data sheet A Instruction for system cleaning flushing and testing of system water prior to charging A Off season lay up of equipment Solution Additives Prior to filling and charging the storage tank the interior of the tank and all piping runs should be thoroughly cleaned to remove pipe scale dirt and other impurities The system should also be checked for leaks at this time 7 Effective September 1 1998 Revised December 1 2000 It is imperative that these guidelines be followed Since the concentration in the tank will be between 7 0 and 7 5 by weight the additives present in the HVAC grade inhibited glycol will not be sufficient to protect the system from corrosion and bacterial growth Dipotassium phosphate K HPO must be used as a corrosion inhibitor to protect steel and stainless steel components at a concentration no less than 4 000 ppm as PO 7 350 ppm as dry K HPO An azole type corrosion inhibitor must be added to protect copper and brass components The best choice is halogen resistant azole like BetzDearborn AZ8104 10 ppm Alternatively one may use tolyl triazole 30 ppm of typical formulation with approximately 20 active ingredient Anti foaming agents such as Dow Corning 1410 may also be added as needed To inhibit bacterial growth add 200 ppm of quaternary amine
33. aximICE TES ORE 25 100 Owner s Manual 51 Effective September 1 1998 Part No 9840502 Revised December 1 2000 13 5 Model ORE 50 Flooded Refrigerant Feed Pumped Slush Discharge Drawing No 8200140 A LIQUID LINE SUCTION LINE 36 NOTE 4 fio ANSI 150 FLANGE 58 BACK VEW LEFT SIDE VIEW vela ea REF RANT REFRIGERANT CONNECTIONS SOLUTION FEED N SLUSH PUMP OUT FLOW NET DISCHARGE HEAD BST EER perreo SERE aeron on RE adem DES SO F FT sono asco LBZ 600 eos 13805 pg 2 ert ar NOTES 1 All dimensions are in inches unless specified otherwise 2 PMC reserves the right to make product design changes which may alter the weighis and or dimensions without prior notification 3 Three foot 3 minimum service clearance is required on all gt sides of assembly gt 4 Three feet 3 minimum clearance above ORE is required for removal 5 Si i a trical tion through side of control MODEL ORE 50 ingle point electrical connection rougn side of control panel 3 6 Insulated paneling adds 5 to length 5 to width 2 1 2 to height pied Suse Deschares 820040 3 0 97 MaximICE TES ORE 25 100 Owner s Manual 52 Effective September 1 1998 Part No 9840502 Revised December 1 2000 13 6 Model ORE 50 Flooded Refrigerant Feed Pumped Slush Discharge Schematic Drawing No 8200147 Remote Start Provide normally open dry contacts lo start unit from remote location With unit toggle switch turned to Auto
34. di dididididi di di di di di di di di di a Evaporator Slurry Pump Motor MaximICE TES ORE 25 100 Owner s Manual 30 Effective September 1 1998 Part No 9840502 Revised December 1 2000 SECTION 9 0 RECOMMENDED SPARE PARTS 9 0 Recommended Spare Parts The following list consists of specialty type or hard to find parts while most all other parts can be purchased locally See Figure 4 9 1 ORE Common Parts Description Recommended Qty PMC Part Oil Return Solenoid Valve R 22 1 i 9840018 Oil Return Solenoid Valve R 717 E 1 i 9841307 Whip Rod i ORE 25 20 ORE 50 40 ORE 100 80 i 8850044 Counter Crank Right Hand i ORE 25 20 ORE 50 40 ORE 100 80 9842676 Counter Crank Left Hand ORE 25 20 ORE 50 40 ORE 100 80 9842677 Thrust Washer manufactured before 10 1 99 ORE 25 20 ORE 50 40 ORE 100 80 i 9840477 Full Ice Sensor temperature controller l 1 l 9840492 Full Ice Sensor RTD i 1 i 9840550 Liquid Level Valve Heater amp Cord i 1 i 9840551 9 2 ORE 25 Parts Description Recommended Qty i PMC Part Drive Plate i 9840975 Drive Motor Shaft Seal 9823991 Housing Bearing i 9840455 Liquid Level Valve Kit LMC MVE 20 l i 9840557 Liquid Level Valve Kit LMC MVE 26 i i 9840558 Liquid Level Valve Kit LMC MVE 34 i i 9840559 Liquid Level Valve LMC AAB 30 i i 9842708 Power Head amp Heater MVE
35. e Evaporator Freeze Up Protection Alarm LL 33 10 2 Unit Fails on VentSwitchs ss e234 24586444 ee hi be ee deal e e pta 34 10 Unit Will Not Start fot pr aaa Ce dat PORT Meee A AAN e Ge tae or 35 10 4 Compressor Operates with High Discharge Pressure 0 36 10 5 Compressor Operates with Low Suction Pressure 1 0 eee 37 10 6 Syst m Will NOt Mak 166s n 41 pu eon ii ke ente an Ye eS ke Gs 38 10 7 Compressor Fails on Motor Overload nuaa auaa 39 10 8 System Will Not Cool Building Process Load coco 40 10 9 Excessive Evaporator Shell Vibration ius sax 40 44 44 paran e aa e ee ee Rs ean aa 41 10 10 Compressor Fails on Low Oil Pressure 0 42 10 11 EXCESSIVE Wear ad a alte tee EE apt ae VEE A hl Path note i ales Baa eS 43 Section 11 0 Start Up Requirements 11 1 11 2 11 3 11 4 11 5 11 6 11 7 MaximICE Start Up Request Form 11 aa eee eee 44 Maxim CE Evaporator Unit es ae ek eke Se glance eh eh eee ae Pa ele 44 Refrigerant Piping for Remote Condenser Systems 44 Water Pipino intere a ca Ra Mom Pag ay E ai bo ue wm re A 45 Electrical wie b we eas waa eae cada ad he Wee dd aie ea eder goe oO ales Wa Pe he oa ee he ae 45 Installing Contractor Shall Furnish the Following LL 45 Compressor Packager aye Pe eae AA th el WE EA RE JE ee Rata BRAC Na dae Lai 45 Section 12 0 Wiring Diagram 12 1 12 2 Schematic Wiring Diagram 50 hz Part No 9841026 46 Schematic Wiring Diagram 60 hz Part No
36. e taken if individual component s are selected and supplied by others System performance and operation can be compromised if any part of the system is incorrectly sized The typical MaximICE system consists of three individual circuits refrigeration circuit ice building circuit and cooling circuit The working system includes an ice storage tank plate and frame heat exchanger coolant pump s temperature control valve and piping The following information describes each component of the system along with its operational function 2 1 Refrigeration Circuit The expansion device consists of a standard Sporlan expansion valve equipped with a Level Master LMC The bulb of a conventional thermostatic element has been modified to an insert type bulb which incorporates a low wattage electrical heater The bulb is installed within a canister which is attached to the Low Pressure Receiver LPR As the refrigerant level drops electrically added heat increases pressure within the thermostatic element and opens the valve As the liquid refrigerant level raises the electrical input is balanced by heat transfer from the bulb to the liquid refrigerant and the LMC either modulates or eventually shuts off Liquid flows from the condenser to a suction line heat exchanger tube in tube where the refrigerant temperature is cooled approximately 10 F 5 5 C The high pressure liquid then enters the expansion valve flashing to intermediate pressure ente
37. ed December 1 2000 The supplier of the glycol should be consulted to determine correct RI for the inhibited solution used at the temperature tested Adjustments to the solution may be necessary to achieve the correct concentration This should always be done prior to starting the MaximICE system as glycol concentration will change as the production of liquid ice begins An accurate measurement of the concentration of glycol can be accomplished using a hand held refractometer This instrument is portable requires only a few drops of fluid and needs no adjustment for fluid temperature PMC recommends that the glycol solution be tested every month see Maintenance and Service Manual It is also recommended that the owner test the alkalinity four times per year for the first year and annually after that Glycol Solution Concentration Adjustments lt is sometimes necessary to increase or decrease the concentration of the glycol solution in your system to replace fluid lost through leakage or moisture absorbed from the atmosphere Either adjustment can be carried out in batch or continuous operation Procedure for Adjusting Freezing Point of Glycol Fluids If the concentration of glycol must be increased use the formula below to determine the amount of solution to drain and the number of gallons of glycol to add to increase glycol concentration A V D P 100 P To decrease the glycol concentration the following formula should be used to deter
38. el ORE 25 Flooded Refrigerant Feed Gravity Slush Discharge Drawing No 8200153 LIQUID LINE 36 NOTE 4 LOW RECEIVER SOLUTION IN 2 FNPT SOLUTION IN 2 FNPT LEFT SIDE VIEW SIDE VIEW NOTES All dimensions are in inches unless specified otherwise gt PMC reserves the right to make product design changes which may alter the weights and or dimensions without prior notification Three foot 3 minimum service clearance is required on all sides of assembly Three feet 3 minimum clearance above ORE is required for removal of whip rods Single point electrical connection through side of control panel Insulated paneling adds 5 to length 5 to width 2 1 2 to height On u 18 DIA ICE OPENING MODEL ORE 25 Flooded Refrigerant Feed Gravity Slush Discharge 8200183 3 7 97 OCA A E 230 oem reefurom MaximICE TES ORE 25 100 Owner s Manual 50 Effective September 1 1998 Part No 9840502 Revised December 1 2000 13 4 Model ORE 25 Flooded Refrigerant Feed Gravity Slush Discharge Schematic Drawing No 8200160 Remote Start Provide normally open dry contacts to start unit from remote location With unt toggle switch turned lo Auto unit wil start upon contact closure Load Pump Operation Provide normally open dry contacts for monitoring of pump operation either auxiliory contacts or from EMS Contacts close upon pump start Solution Pum
39. emand usage and energy costs Compared to traditional cooling systems the MaximICE system utilizes smaller equipment thus reducing capital cost The MaximICE should only be operated by trained personnel and serviced by qualified electrical and refrigeration technicians Any use of the equipment not covered by the instructions is prohibited This manual has been prepared to present to the owner and service technician the installation operation and maintenance procedures recommended by Paul Mueller Company for the MaximICE thermal storage system The installation plans piping layouts etc must be detailed in accordance with local codes If you are uncertain about any installation or operating procedure outlined in this manual please contact the Mueller Thermal Storage Department for guidance at 1 800 683 5537 or 417 831 3000 1 1 Delivery Inspection Each MaximICE evaporator is tested operational or electrical test at the factory prior to shipment however damage can occur during shipment The unit should be thoroughly inspected upon arrival at the installation site Any damage noted should be reported immediately to the transportation company so that an authorized transportation representative can examine the unit determine the extent of the damage and take the necessary steps to rectify the claim At the same time a Paul Mueller Company representative should be notified of any claim made 1 2 Safety Considerations Installation star
40. er s Manual 35 Effective September 1 1998 Part No 9840502 Revised December 1 2000 Effective September 1 1998 10 4 Troubleshooting Chart 4 Compressor Operates with High Discharge Pressure Compressor operates with high discharge pressure Air Cooled Verify that the fan contactor Condenser Is the condenser fan on is pulled in Check for failed fan motor Clean coil with condenser coil soap Is the condenser coil clean gt i no solution j yes Any Type of al Condenser AA Adjust repair or replace controlling properly do yes Is the liquid line Mer y Replace drier clogged yes Water Check the temperature rise Cooled Is the cooling water flow sufficient L through the condenser and adjust Condenser no cooling water flow as necessary yes Is the cooling water inlet temperature too high above Check cooling tower for problems design yes no Is the condenser fouled or scaled Cleanithe tube to rem v fo ling or yes scale MaximICE TES ORE 25 100 Owners Manual 36 Part No 9840502 Revised December 1 2000 10 5 Compressor operates with low suction pressure Troubleshooting Chart 5 Compressor Operates with Low Suction Pressure Is the motor operating properly Check voltage and amp draw
41. erential switch can be employed For a remote evaporatively cooled condenser Proof of condenser water pump and fan operation is required For a remote air cooled condenser Proof of operation or signal upon a unit failure is required 4 4 Refrigerant Piping The installing contractor shall provide and install all interconnection piping and service valves All refrigerant R 22 piping shall be Type L or K hard copper or Schedule 40 steel piping All piping shall be purged with an inert gas during welding or brazing Ammonia R 717 must be piped per ASHRAE 15 latest revision A pressure leak test of the complete refrigeration system is required once field piping is complete The system shall be proven tight at 25 psig 175 kPa below the lowest setting pressure relief valve The entire system must be evacuated to at least 500 microns with a five minute hold period The contractor shall provide a charging line from the charging connection on the MaximICE unit to the charging drum s 4 5 Start Up Coordination Inspection Upon arrival of PMC authorized start up personnel at the job site a start up coordination meeting will be held and a walk through inspection of the job site conditions will be conducted All trades involved in the installation should be represented This includes but is not limited to the general contractor mechanical contractor plumbing contractor tank contractor and owner s representative The start up will not
42. ffective September 1 1998 Part No 9840502 Revised December 1 2000 13 8 Model ORE 50 Flooded Refrigerant Feed Gravity Slush Discharge Schematic Drawing No 8200161 Remote Start Provide normally open dry contacts to start unit from remote location With unit toggle switch turned lo Auto unit will start upon contact closure Load Pump Operation Provide normally open dry contacts for monitoring of pump operation either auxiiary contacts or from EMS Contacts close upon pump stort Solution Pump Operation Provide normaliy open dry contacts for monitoring of pump operation either auxiliary contacts or from EMS Contacts close upon pump start SINGLE PHASE ORE 50 TYPICAL WRING gt Condensing Unit Pumpdown Low Pressure Switch Provide normally closed dry contacts SCHEMATIC Contacts open when suction pressure drops to 5 psig condensing unit shuts down Dual compressor condensing unt wring shown See unit wiring diagram for single condensing unit and optional ilems Condensing Unit Alarm 1 Provide normally closed dry contacts Contacts open upon condensing unit alarm condition condensing unit shuts down Candensing Unit Alarm 2 Provide normally closed dry contacts Contacts open upon condensing unit alarm condition condensing unit shuts down OPTIONAL Remote temperature switch Wired to remote ice level inventory sensor Conacts close on full ice condition predetermined temperature setting OPTI
43. for approximately 1 1 6 mm clearance between the eccentric crank and drive plate bearing no pressure on drive plate Figure 2 ORE Drive Assembly Detail HOUSING BEARING ECCENTRIC CRANK 1 16 IN 1 32 16 MM 08 CAP iS TOIT ML 4 N EZ LLL 22 dt SS SS BEARING SLEEVE DETAIL A 3 22 Gravity Feed System A gravity feed ice discharge system with a telescopic type housing mounted to the evaporator bottom that extends into the ice opening is incorporated for systems where the evaporator is installed on top of the ice storage tank A watertight seal must be applied once the unit is set in place and the housing is lowered into the opening The gap about 12 mm can be filled with insulation rope and sealed with a layer of silicone MaximICE TES ORE 25 100 Owner s Manual 10 Effective September 1 1998 Part No 9840502 Revised December 1 2000 Figure 3 MaximICE ORE 25 Drive Assembly MOTOR Oy DRIVE SHAFT TOP PLATE 9823989 OAS DRIVE PLATE MOUNTING 9840975 i oa __ at fal STEEL PIN 5 KA WT 7 Al RUBBER GASKET_ L 9823996 SA A La 9825000 TOA satin COUNTERCRANK INSERT l RH 9842676 9840476 i LH 9842677 WHIP ROD 8850044 n ERE di a Ai cd 1 16 IN HOUSING n 16 na f i prat i i da i DRIVE PLATE se BEARING SLEEVE Gr K DETAIL A J WHIP ROD
44. g circuit complete to compressor motor A All wire is copper no aluminum wiring 11 6 Installing Contractor Shall Furnish The Following A All materials and labor necessary to assist in the installation start up Arefrigeration service mechanic to assist PMC start up personnel during start up for necessary training in the operation of the unit This training is essential in performing in warranty labor incumbent upon contractor and or end user 11 7 Compressor Package A Check compressor motor alignment and align as necessary to within 004 0 1 mm angular parallel A Check oil pump motor alignment and align as necessary to within 004 0 1 mm angular parallel MaximICE TES ORE 25 100 Owner s Manual 45 Effective September 1 1998 Part No 9840502 Revised December 1 2000 SECTION 12 0 WIRING DIAGRAMS 12 1 Schematic Wiring Diagram 50 hz Part No 9841026 MaximICE TES ORE 25 100 Owner s Manual 46 Effective September 1 1998 Part No 9840502 Revised December 1 2000 12 2 Schematic Wiring Diagram 60 hz Part No 9823978 MaximICE TES ORE 25 100 Owner s Manual 47 Effective September 1 1998 Part No 9840502 Revised December 1 2000 SECTION 13 0 MUELLER MaximiCE LIQUID ICE EVAPORATOR EQUIPMENT SPECIFICATIONS 13 1 Model ORE 25 Flooded Refrigerant Feed Pumped Slush Discharge Drawing No 8200139 LIQUID LINE SUCTION LINE 36 NOTE 4 PRESSURE ORBITAL ROD EVAPORATOR 87 5 z ANS 1502
45. g or servicing the equipment adequate hearing protection must be used MaximICE TES ORE 25 100 Owner s Manual 22 Effective September 1 1998 Revised December 1 2000 Part No 9840502 SECTION 8 0 MAINTENANCE 8 0 Maintenance The MaximICE system is designed to be a low maintenance piece of equipment Preventive maintenance is the key to a properly operating unit It is recommended to maintain an inspection log book for tracking the history of operation 8 1 Daily Checks A Inspect the ORE unit for solution leaks and excessive vibrations Check for proper compressor suction pressure and temperature Inspect around ice storage tank for solution leaks piping fittings and tank surface Check for oil spots around condensing unit Listen to compressor for any noises different than normal Sound level s should be constant gt gt gt gt Listen to the ORE The whip rods should make a sibilant noise sh Rattling noises may indicate one or more frozen tubes 8 2 Recommended Inspection Procedures The following points should be inspected when performing preventive maintenance on the MaximICE thermal energy storage system A Drive Component Inspection a Turn the on auto off control switch inside the ORE control panel to the off position At this time the liquid line solenoid and the oil return solenoid will close and the unit will pump down b After the pumps and the drive assembly stop turn the main
46. gle valve off at the evaporator and remove the hose that is connected to the freeze up protection switch NOTE Loosen the hose fitting very slowly because of the possibility of the presence of liquid in the line Using a VOM meter set the meter to the OHM position Attach the leads to the NC set of contacts on the freeze up protection switch Attach the suction hose from your gauge set blue hose to the freeze up protection switch Attach your charging hose yellow hose to a bottle of pressurized gas preferably nitrogen When pressure is applied to the switch it will show you the exact pressure of your suction gauge The freeze up protection switch should be set to open at 35 psig 240 kPa If the switch opens before the 35 psig 240 kPa adjust the switch accordingly A Water Regulating Valve You will see 2 valve stems on the inlet and on the outlet side of the solution regulating valve Using a 0 50 0 350 kPa psig gauge with the proper valve stem connection take a pressure reading on the inlet side of the solution regulating valve This pressure must be at least 5 psig 35 kPa and no more than 32 psig 220 kPa If the pressure on the inlet of the regulator is not within these parameters the machine is either not getting enough solution and has the possibility of freeze up or if it exceeds the pressure the unit will not be running at the designed capacity The design flow rates are 65 130 and 245 gpm 245 490 and 930 1 min for the
47. he program is causing a failure The on auto off switch located in the control enclosure facilitates unit operation within the panel A manual switch reset is required after a system failure shutdown The MaximICE unit is programmed with a unique system start up and shutdown sequence unlike common refrigeration equipment The following information describes a typical system operation sequence NOTE The PLC is equipped with dual low voltage 24V input side is 24VDC and output side is 24VAC 6 1 Start Up Sequence A Select either MANUAL or AUTO on local 3 position toggle switch MANUAL System starts immediately AUTO System starts when remote Enable signal is received A Slush pump and feed pump on Enable temperature sensor while system fluid circulates for 5 minutes A End of 5 minute circulation Check to see if high ice condition exists No full ice condition Drive motor pump down solenoid and LLM heater are energized Continue start up Full ice condition exists System shutdown on full ice Periodically the system shall restart the glycol solution to verify a full ice condition If full ice exists after a 5 minute check the system should remain off A 10 seconds delay after drive is on Condensing unit oil return solenoid and unload solenoid s are energized system operates unload for 2 minutes At the end of 2 minutes the unload solenoid s are de energized allowing for full load compressor
48. igh Verify expansion device operation MaximICE TES ORE 25 100 Owner s Manual Part No 9840502 39 Effective September 1 1998 Revised December 1 2000 10 8 Troubleshooting Chart 8 System Will Not Cool Building Process Load System will not cool building process load Allow system to operate and begin Is there ice in Kop the storage tank gt making ice If possible turn ge tank no pi building process cooling pump off yes Check pump motor voltage amp draw pump discharge pressure and impeller Most likely the motor is faulty Repair replace Is the building process cooling pump operating properly no yes Is the pressure drop across the Is the process flow rate correct plate heat exchanger above no normal yes yes Disassemble and clean heat exchanger plates Is the heat exchanger Disassemble valve Clean spray ball or spray nozzle in temperature water regulating valve Clean repair or install no ice storage tank controlling properly no repair kit yes Is refrigerant level too low Add charge Fix leaks yes no Are some of the tubes frozen See Chart Section 9 1 yes no Is solution bypassing ice in tank Check spa Ad performanc LWT will be higher than design yes gt pray P no Is solution level in tank correct
49. imICE TES ORE 25 100 Owner s Manual 32 Part No 9840502 Effective September 1 1998 Revised December 1 2000 SECTION 10 0 TROUBLESHOOTING FAILURES 10 1 Low pressure evaporator freeze up protection PLC Output O Y12 Continuous light y Is the glycol solution concentration level above 7 no yes Is the drive plate rotating at the correct speed no yes Are any of gt EEE roken yes ro Is the R 22 charge correct See Section 5 0 for discussion of gt gt correct charge no yes Is the liquid level valve operating 3 properly no 0 yes Is evaporator solution flow rate correct no yes no Is the full ice sensor faulty and the tank over filling with ice allowing ice slurry gt gt to be pumped into the evaporator yes no Is compressor capacity too large for ORE gt yes mo Does ice build up on tubes during either start up or gt pump down yes no MaximICE TES ORE 25 100 Owner s Manual Part No 9840502 With no ice in the tank measure percentage level and adjust to 7 minimum Are the drive motor speed pots adjusted correctly 50 hz units only Troubleshooting Chart 1 Low Pressure Evaporator Freeze Up Protection Alarm 3 gt yes Is the motor operating properly Check voltage and amp draw Remove drive assembly and replace countercranks no Find
50. is issue and may experience rapid wear of eccentric tube inserts countercrank pins whip rod heads and necks Add 1 micron sidestream filter to remove suspended solids Run until solution is clear Systems with agitated ice slurry tanks are especially sensitive to this issue and may experience rapid wear of eccentric tube inserts whip rod neck and countercranks This is normal for Acetal countercranks especially in chilling service Replace with PEEK countercranks yes Drive running too fast Adjust speed to lt 850 rpm This is normal Only one side is loaded load force rotates with eccentric To extend life switch drive motor leads so opposite side of pin becomes loaded Replace with stainless steel H housing bearing and new sleeve bearing Check for proper clearance between drive plate and eccentric Replace sleeve bearing Sleeve bearing is worn out or loose in housing See above yes Unit ran while tube full of ice and countercranks frozen in position See Chart 1 Low Pressure Evaporator Freeze Up Drive plate not centered inside inlet shell Adjust inner shell so drive Pin on countercrank has rough surface Replace drive plate and countercrank Driveplate lifted off countercranks Contact PMC to discuss problem Motor overloaded because tubes frozen solid See Troublesho
51. lycol solution NOTE Refer to Figures 3 through 6 with the following drive installation steps A Using a flashlight inspect each tube for any foreign debris A Apply a thin coat of petroleum jelly on each countercrank prior to installing lower end top edges MaximICE TES ORE 25 100 Owner s Manual 9 Effective September 1 1998 Part No 9840502 Revised December 1 2000 A Working clockwise at the alignment mark place each countercrank in a left hand right hand arrangement Countercrank type is determined by positioning the drive pin at six o clock and checking the slot point direction NOTE The ORE 50 and 100 have several countercranks that may appear out of sequence See the appropriate layout drawing for specific alignment A A A A Install each whip rod Position all drive pins towards the evaporator top tube sheet alignment mark Install lower rubber gasket Install drive plate by matching the top tube sheet alignment mark with the drive plate NOTE The evaporator top sheet and drive plate are labeled with an alignment mark s to ensure proper assembly gt gt gt gt Install clear PVC top water chamber Install upper rubber gasket Install top head Install drive motor Adjustments can be made to the eccentric crank during assembly by rotating the motor fan blades with small screwdriver Tighten top plate mounting bolt using a star pattern while tightening bolts Adjust motor
52. mine the volume to drain and replace with high quality water A V P D P Where A The quantity in gallons or m3 of glycol to be added to the system to lower the freeze point or the quantity in gallons or m3 of glycol solution that must be drained from the system to decrease glycol concentration V The total solution capacity of the system in gallons or m3 D The volume percent of glycol desired in the system P The volume percent of glycol presently in the system 3 19 Freeze Protection Units located outside shall require freeze up protection heat tape on all solution lines A glycol solution is required for the MaximICE system however during low ambient conditions outside temperatures below 27 F or 3 C the solution may freeze and cause piping damage 3 20 Insulation All glycol solution piping should be insulated with 2 50 mm polyfoam Armaflex to prevent external heat gain The ice storage tank s supplied by PMC polyethylene type must be placed on top of at least 3 75 mm of styrofoam with a loading strength of 25 psi 175 kPa Heat gain and proper insulation practices should be considered for concrete tanks constructed on site 3 21 ORE Drive Assembly The drive system is designed with very close tolerances to ensure proper clearance water sealing and operation of all drive components extreme caution should be taken during installation A CAUTION Do not operate drive system without circulating g
53. n with appropriately sized hold down anchor bolts not furnished with equipment and are to be securely anchored to the concrete pad by the customer Refer to Figure 1 below for anchorage details Polyethylene tank s will require tie down straps All applicable seismic zone regulations and proper construction practices should be considered in areas designed by the state Figure 1 Anchorage Details TANK OPTIONAL WELD 1 RED HEAD WELD 25 mm TANK BASE RING PLATE BASE RING SHIM PLATE BEAM CONCRETE PAD CONCRETE PAD ALTERNATE ANCHORAGE 1 ALTERNATE ANCHORAGE 2 MaximICE TES ORE 25 100 Owner s Manual 4 Effective September 1 1998 Part No 9840502 Revised December 1 2000 3 4 Serviceability Accessibility is required for servicing the equipment A 3 0 9 m clearance around the evaporator compartment and a 4 1 2 m clearance above the top are required Review the appropriate submittal drawing for exact required top clearance 3 5 Shipping Charge All units are shipped with a dry nitrogen charge approximately 5 psig 35 kPa that is required to be bled off prior to installation Extreme care must be taken while removing flanges or caps when the system is under pressure 3 6 Remote Refrigeration Piping The refrigerant connections suction liquid on the evaporator skid are sized based on the condensing unit located within 10 3 m of equivalent length tubing of the ORE skid For systems with more than the
54. ng LL 5 Refrigerant Piping Pressure Testi ii a Re AI 5 System EVAGUAHONi tiran delas a Ee aaa bbb eee we vague tele 00 5 Refrigerant Charge os fice aa Oe bee bean et dep ode aa e edad 5 Condensing Unite tl RIS etna REG iS oa 5 Electrical E AR A ee EEE ROR ani Rae aes II 6 Electrical Specifications ORE 25 musas pa e ee ee a EEE GE HOE EM ee 6 Electrical Specifications ORE 50 ais ei a Gee Re gah Mas ea 6 Electrical Specifications ORE 100 lt a terser ad sogar Rb a ee ee n 7 Ice Storage Tank Full Ice Sensor Option LL 7 Ice Storage Tank Vent Line Leo he BAe io See TEST EN eee ed hee AP SoeEe ni 7 Ice Storage Tank Spraying System ess ianen cadre A A Ge dea e ben a 7 Glycol Solution Specification ri aA ooo 7 Freeze PTOLECLON 1 4 tack ioe ue e RE ie Fr uk S eee E Gare ale STEG RE Re ie 9 Insulation se A AA ate be a La ee ehh E A A 9 ORE Drive Assembly iy ets Sag A ee eh La RESALES and ee AA 9 Figure 2 ORE Drive Assembly Detail 2 44522 64 4444eGee09R Eso e bee put end 10 Gravity Feed System A ia 10 Figure 3 MaximICE ORE 25 Drive Assembly 11 Figure 4 MaximICE ORE 50 Drive Assembly ooo o o oocooooo eee 12 Figure 5 MaximICE ORE 100 Drive Assembly 13 Figure 6 ORE Countercrank Assembly 14 Packins Material s xy os i RAEE ILL RA rap AAA REIS id SEG 15 Figure 7 MaximICE Refrigeration Schematic Diagram LL 15 TABLE OF CONTENTS CONTINUED Section 10 0 Troubleshooting Failures 10 1 Low Pressur
55. nit Is the liquid level valve controlling properly gt no j yes Adjust repair or replace Is the compressor operating properly no yes Check suction versus discharge pressure Normally discharge pressure exceeds suction by approximately 150 psig Is the unit shutting off on temperature sensor prior to making ice Operating as a chiller only yes V yes Check set point on high ice sensor It should be 24 26 F 4 4 to 3 3 C MaximICE TES ORE 25 100 Owner s Manual Part No 9840502 Glycol concentration solution may be too high With no ice in the tank measure glycol concentration and adjust to 7 8 38 Effective September 1 1998 Revised December 1 2000 10 7 Compressor continues to fail on internal motor overload Troubleshooting Chart 7 Compressor Fails on Motor Overload Is the voltage correct at the motor yes no Check motor nameplate data and apply correct voltage Do all three legs draw some amps 0 yes Is the compressor discharge pressure above 300 psig Check motor wiring to find cause of single phasing ie Verify condenser operation Is the compressor discharge temperature above 180 F 82 C gt yes ro Verify oil cooling condenser operation Is the suction superheat extremely h
56. nit Condensing Unit Alarm 2 Provide normally closed dry contacts Contacts open upon condensing unit alarm condition condensing unit shuts down OPTIONAL Remote temperature swilch Wired to remole ice level nventory sensor Conacts close on ful ice condition predetermined temperature setting OPTIONAL Condensing Unit Start 1 24VAC contacts close to start condensing unil Compressor Unloading Step 1 24VAC contacts close to unload compressor Condensing Unit Start Z 24VAC contacts close to start condensing unit OPTIONAL Remote Alarm Dry contacis close upon alarm condition for remole alarm indication Remote Solution Pump Start Dry contacts close to start solution pump INPUT TO MaximiCE PLC O OUTPUT FROM MaxmiCE PLC CUSTOMER SUPPLIED 3 PHASE WITH GROUND MUELLER MODEL ORE 100 Flooded Refrigerant Feed Pumped Slush Discharge 3200148 3 97 LOT TE 1 387 MaximICE TES ORE 25 100 Owner s Manual 57 Effective September 1 1998 Part No 9840502 Revised December 1 2000 13 11 Model ORE 100 Flooded Refrigerant Feed Gravity Slush Discharge Drawing No 8200155 EE ae 11 2 I I 36 LIQUID LINE NOTE 4 ai LOW PRESSURE RECEIVER ORBITAL ROD I EVAPORATOR Sr MEET Er PN SOLUTION N 4 ANSI 1501 FLANGE TETT en 78 ACK VIEW LEFT SIDE VIEW NOTES 1 All dimensions are in inches unless specified otherwise 2 PMC reserves the right to moke p
57. o OFF position to reset alarm condition after shutdown is complete gt gt gt Alarm status 6 4 Alarm Condition Sequence A Condensing unit alarm Compressor motor overload high discharge switch and low oil pressure switches are wired in series Motor overload Drive motor slush pump and solution pump in series Freeze Up Protection Evaporator low pressure switch set for 3 psi 20 kPa to 5 psi 35 kPA below normal operating pressure lowest A High level solution vent line switch Ice slurry discharge from ORE interruption A Glycol solution flow switch Glycol solution feed to ORE interruption A Emergency stop 6 5 Additional Control Elements A Vent switch intermediate trip alarm a Vent switch must be tripped for 10 seconds before intermediate trip condition b Condensing unit will shut down for 10 minutes while the rest of the system continues to function as usual c After 10 minutes 1 Vent switch clear Condensing unit restarts 2 Vent switch not clear System shutdown on vent alarm If intermediate trip condition occurs three times in 30 minutes system shuts down on vent alarm A High vent switch The entire unit shuts down after a 5 second delay Drive motor will not operate when the high temperature solution feed indicates glycol temperatures above 55 F 13 C MaximICE TES ORE 25 100 Owner s Manual 20 Effective September 1 1998 Part No 9840502 Revised December 1 2000 SECTIO
58. or remote alarm indication Remote Solution Pump Start Dry contacts close to start solution pump INPUT TO MaximiCE PLC O OUTPUT FROM MaxmiCE PLC THREE PHASE POWER CUSTOMER SUPPLIED 3 PHASE WITH GROUND MUELLER MODEL ORE 50 Flooded Refrigerant Feed Pumped Slush Discharge 820047 31497 MaximICE TES ORE 25 100 Owner s Manual 53 Effective September 1 1998 Part No 9840502 Revised December 1 2000 13 7 Model ORE 50 Flooded Refrigerant Feed Gravity Slush Discharge Drawing No 8200154 LIQUID LINE LIQUID LINE CONTROL LIFTI PANEL 36 NOTE 4 gt 70 FRAME 58 FRAME SOLUTION N 3 ANSI 1502 FLANGE dl contro Box NOTES lait 1 All dimensions are in inches uniess specified otherwise 2 PMC reserves the right to make product design changes which may alter the weights and or dimensions 3 Three foot 3 minimum service clearance is required on all sides of assembly 4 Three foot 3 minimum clearance above ORE is required for removal of whip rods 5 Single point electrical connection through side of control panel 6 Insulated paneling adds 5 to length 5 to width 24 DIA 2 1 2 to height ICE OPENING OP VEW bs tbs tbs acmon Loun RATE eeit eoo spa amo 00 19009 ye T sao ar o aro reo MODEL ORE 50 Flooded Refrigerant Feed Gravity Slush Discharge 8200154 3 1V97 MaximICE TES ORE 25 100 Owner s Manual 54 E
59. oting Chart 1 Whip rod cannot roll Replace bent whip rod Check head thickness Make sure only one thrust washer is used Acetal countercranks Mechanical seal failure Replace seal and bearings yes Condensation build up inside motor Add drainage holes at motor bottom flange Do not run cold yes solution in unit when drive off Unit ran while tubes full of ice See a Chart 1 Replace whip rods yes Notify PMC if problem continues May lead to tube failure if underlying problem is not fixed 43 Effective September 1 1998 Revised December 1 2000 SECTION 11 0 START UP REQUIREMENTS 11 1 MaximiCE Start Up Request Form Prior to requesting start up verify that all the following items are complete Only PMC qualified start up personnel shall be authorized for start up Unauthorized start up of equipment will result in immediate void of warranty Purchaser Address Contact Person Telephone No Facsimile No Unit Model Unit Serial No Installation Location Address 11 2 MaximiCE Evaporator Unit A Equipment must be inspected for any damage that may have occurred during shipping If damage is found a claim should be made against the trucking company Check the packing slip or bill of lading to ensure that all accessory parts called for in the sales order are included The unit must be level to within g G mm
60. p Operation Provide normally open dry contacts for monitoring of pump operation either auxiliary conlacts or from EMS Contacts close upon pump start SINGLE PHASE ORE 25 TYPICAL WIRING Condensing Unit Pumpdown Low Pressure Switch Provide normally closed dry contacts SCHEMATIC Contacts open when suction pressure drops to 5 psig condensing unit shuts down Condensing Unit Alarm 1 Provide normally closed dry contacts Contacts open Single compressor upon condensing unit alarm condition condensing unit shuts down condensing unit wring shown See unit wring dagram for multiple condensing units gt Condensing Unit Alarm 2 Jumper in conirol box OPTIONAL and optiond items Remote temperature switch Wired to remote ice level inventory sensor Conacts close on full ice condition predetermined temperature setting OPTIONAL I Condensing Unit Start ZAVAC contacts close to start condensing unit Compressor Unloading Step 1 24VAC contacts close to unload compressor Compressor Unloading Step 2 24VAC contacts close to unload compressor 7 Remote Alarm Dry contacis close upon alarm condition for remole alarm indication gt Remote solulion Pump Start Dry contacis close to start solution pump I INPUT TO MaximiCE PLC O OUTPUT FROM MaximiCE PLC CUSTOMER SUPPLIED 3 PHASE WITH GROUND MUELLER MODEL ORE 25 Flooded Refrigerant Feed Gravity Slush Discharge 220060 3 10 97 M
61. piping at not less than 10 ft sec 3 m sec velocity for six hours The water piping shall then be flushed with clean water to remove any residue All exposed exterior water piping shall be heat traced and insulated The Paul Mueller Company warranty specifically excludes any liability for freezing damage resulting from low ambient temperatures The ice storage tank must be cleaned with an approved cleaning solution and rinsed with clean water prior to adding water glycol solution The water piping system including the tank shall then be filled with clean water and 7 glycol to 60 of the height of the tank The water glycol solution should be analyzed by a water treatment authority and properly treated for oxygen corrosion scales algae and fungus growth The water should be periodically checked by a water treatment authority Water cooled condenser water piping shall be cleaned and flushed to remove all debris The condenser cooling tower water shall be properly treated A properly sized strainer should be used on the condenser water supply to the MaximICE The condenser condenser water piping condenser pump and cooling tower must be properly protected against freeze damage resulting from low ambient temperatures Evaporative condensers shall be flushed and properly treated A proper water treatment system usually consists of a continuous blow down and chemical feeder The condenser condenser water piping condenser water make up line and
62. rage Tank Full Ice Sensor Option To determine a full ice storage tank condition a temperature bulb is mounted in the evaporator solution inlet which sends a signal to a digital temperature controller located in the PMC control box As the amount of ice increases within the storage tank the glycol percentage increases and lowers the solution freeze point At approximately 24 to 26 F 4 4 to 3 3 C the PLC receives an input from the controller initiating a full ice shutdown Ice Storage Tank Vent Line To ensure proper solution flow a vent system is incorporated Attach the vent line to the top of the ice storage tank top The line must be mounted to ensure full draining with no loops or kinks Ice Storage Tank Spraying System To ensure that the stored liquid ice is burned efficiently and a low temperature supply solution can be maintained to the cooling loads spray devices s must be used to distribute the warm solution over the liquid ice For field fabricated storage tanks spray distribution system should be supplied in sufficient numbers and location based upon spray pattern to provide maximum coverage over the liquid ice Please consult PMC for field fabricated storage tank spray distribution systems Glycol Solution Specification The MaximICE TES system uses a very low concentration of propylene or ethylene glycol solution as the storage medium to promote the growth of the ice crystals Glycol Manufacturer Supplied Inform
63. ree feet 3 minimum clearance above ORE is required for removal of whip rods 5 Single point electrical connection through side of control panel MODEL ORE 100 6 Insulated paneling adds 5 to length 5 to width 2 1 2 to height Flooded Refrigerant Feed Pumped Slush Discharge 820041 31 97 MaximICE TES ORE 25 100 Owner s Manual 56 Effective September 1 1998 Part No 9840502 Revised December 1 2000 13 10 Model ORE 100 Flooded Refrigerant Feed Pumped Slush Discharge Schematic Drawing No 8200148 Remote Start Provide normally open dry contacts to start unit from remote location With unt toggle switch turned lo Auto unit will start upon contact closure Load Pump Operation Provide normally open dry contacts for monitoring of pump operation either auxiliary contacts or from EMS Conlacts close upon pump start Solution Pump Operation Provide normally open dry contacts for moniloring of pump operation either auxiliary contacts or from EMS Contacts close upon pump start SINGLE PHASE ORE 100 TYPICAL WIRING Condensing Unit Pumpdown Low Pressure Switch Provide normally closed dry contacts SCHEMATIC Contacts open when suction pressure drops lo 5 psig condensing unit shuts down Candensing Unit Alarm 1 Provide normally closed dry contacis Contacts open upon condensing unii alarm condition condensing unit shuts down Dual compressor condensing unit wring shown See unil wing dagram for single i i condensing u
64. roduct design changes which may alter ihe weights and or dimensions 3 Three foot 3 minimum service clearance is required on all sides of assembly 4 Three foot 3 minimum clearance above ORE is required for removal of whip rods 5 Single point electrical connection through side of control panel 6 Insulated paneling adds 5 to length 5 to width 2 1 2 to height 32 DIA ICE OPENING TOP VIEW Feen REFRIGERANT CONNECTIONS SOLUTION FEED IN MER CHARGE FLOW NET lbs b be SucTON uouo Raf rett neon n so vevos 1518005 25 550 am es EEE M bo Flooded Refrigerant Feed Gravity Slush Discharge 8200855 3 1497 MaximICE TES ORE 25 100 Owner s Manual 58 Effective September 1 1998 Part No 9840502 Revised December 1 2000 13 12 Model ORE 100 Flooded Refrigerant Feed Pumped Slush Discharge Schematic Drawing No 8200162 Remote Start Provide normally open dry contacis lo start uni from remote location With unit toggle switch turned to Auto unit will start upon contact closure Load Pump Operation Provide normally open dry contacts for monitoring of pump operation either auxiiary contacts or from EMS Contacts close upon pump start Solution Pump Operation Provide normally open dry contacts for monitoring of pump operation either auxiliary contacts or from EMS Contacts close upon pump start SINGLE PHASE ORE 100 TYPICAL WIRING Condensing Unit Pumpdown Low Pres
65. rs the evaporator bottom and surrounds the evaporator tubes The evaporator is also coupled to the LPR employing a gravity feed constant liquid refrigerant recirculation effect Gravity feed liquid flows from the LPR enters the evaporator bottom and mixes with refrigerant supplied from the expansion valve A two phase refrigerant flows from the evaporator into the accumulator where dry suction gas is then returned to the compressor Inside each evaporator tube is a free hanging 3 3 9 5 mm stainless steel rod running the entire tube length A plastic countercrank holds the whip rod in place while a small pin is attached to the drive plate The drive motor coupled to the drive plate rotates the attached whip rods continuously approximately 800 rpm during system operation The drive is equipped with a soft start system to reduce starting internal torque A seal gasket provides an air tight seal at the drive shaft penetration point located on the top plate Solution pouring into the evaporator tubes and gravity drains gives up heat to the refrigerant producing a boiling effect pushing liquid gas out the top As two phase refrigerant enters the LPR gas velocity is reduced and the separated dry vapor is drawn into the compressor The whip rod spinning action creates a high agitation rate increasing solution to tube surface contact The end result is a highly efficient slurry ice maker see Figure 7 MaximICE Refrigeration Schematic Diagram
66. s Manual 3 Effective September 1 1998 Part No 9840502 Revised December 1 2000 SECTION 3 0 INSTALLATION 3 0 Installation NOTE It is very important in installations where the customer supplies certain components ice storage tank heat exchanger valves and or fittings that the following information and details are addressed PMC shall not be held responsible for performance on systems constructed piped or designed differently than outlined in this manual 3 1 Equipment Rigging The MaximICE unit and ice storage tank must be lifted in accordance with industry practice Lifting lugs and sleeves are not intended to be used for extended periods of time The evaporator section is designed for four point top lifting only Please refer to equipment specifications section for weights CAUTION A spreader bar must be employed during the lifting process failure to do so will result in equipment damage 3 2 Foundation MaximICE units should be anchored to a concrete or structural steel base Due to the varying conditions across the globe it is recommended than an architectural engineer be consulted to determine the thickness of the concrete pad or structural steel in accordance with local codes The concrete pad or structural steel must be level within 3 mm to adequately support the refrigeration equipment 3 3 Anchoring According to local codes and practices the refrigeration equipment should be welded or bolted dow
67. sure Switch Provide normally closed dry contacts SCHEMATIC Contacts open when suction pressure drops to 5 psig condensing unit shuts down Condensing Unit Alarm 1 Provide normally closed dry contacts Contacts open upon condensing unii alarm condition condensing unit shuts down Dual compressor condensing unit wring shown See unil wiring diagram for single condensing unit and optional items Condensing Unit Alarm 2 Provide normally closed dry contacts Contacts open upon condensing uni alarm condition condensing unit shuts down OPTIONAL Remote temperature switch Wired to remote ice level inventory sensor Conacts close on full ice condition predetermined temperature setting OPTIONAL Condensing Unit Start 1 24VAC contacts close to start condensing unit 4 Compressor Unicading Step 1 24VAC contacts close to unload compressor Condensing Unit Start 2 24VAC contacts close to start condensing unit OPTIONAL Remote Alarm Dry contacts close upon alarm condition for remote alarm indication 7 Remote Solution Pump Start Dry contacts close to siart solution pump INPUT TO MaximiCE PLC O OUTPUT FROM MaximiCE PLC CUSTOMER SUPPLIED 3 PHASE WITH GROUND MODEL ORE 100 Flooded Refrigerant Feed Gravity Slush Discharge 820062 3 1V97 MaximICE TES ORE 25 100 Owner s Manual 59 Effective September 1 1998 Part No 9840502 Revised December 1 2000 SECTION 14 0 START UP REQUEST FORM
68. t up and service of this equipment pose hazards due to automatic equipment operation high system pressure and electrical power service It is extremely important to consider all aspects of safety when working on or around machinery and high voltage This equipment will be connected to a high voltage and or current power supply which can seriously injure or kill a worker There is moving equipment which can start automatically and cause serious injury It is imperative that only qualified service personnel install and service this equipment This equipment is designed for use with and contains R 22 hydrochlorofluorocarbon HCFC R 717 ammonia or other types of refrigerant This equipment shall be serviced and disposed of in accordance with the current Ozone Depleting Substance Regulation Clean Environment Act When working on this equipment observe precautions identified in the literature provided any tags stickers and labels attached to the equipment and any other safety precautions that apply A Follow all applicable safety codes A Wear safety glasses and work gloves A Use care in handling rigging and setting bulky equipment MaximICE TES ORE 25 100 Owner s Manual 1 Effective September 1 1998 Part No 9840502 Revised December 1 2000 SECTION 2 0 THERMAL STORAGE SYSTEM SYSTEM OVERVIEW 2 0 Thermal Storage System System Overview It is very important that each component be properly sized and selected Extreme care must b
69. the calcium and magnesium ions with sodium ions This in itself is fine However these resins do not sufficiently reduce high concentrations of chloride or sulfate ions To accomplish the latter another type of ion exchange resin must be used Resins that remove calcium and magnesium ions are typically regenerated with a strong brine solution and the excess sodium chloride is flushed out as waste water This must be followed by thoroughly flushing the regenerated resin bed with water Otherwise an excess of chloride ions will be flushed into the so called good quality water Glycol manufacturers recommend using de mineralized water that has been distilled de ionized or passed through a reverse osmosis RO process to remove certain minerals and salts Good water quality is typically defined by the following parameters Less than 50 ppm of calcium Less than 50 ppm of magnesium Less than 100 ppm or 6 grains of total hardness Less than 25 ppm of chloride Less than 25 ppm of sulfate gt gt gt gt gt After combining the proper amounts of water and inhibited glycol the system should be mixed for a minimum of four hours to achieve uniformity This can be accomplished with the MaximICE feed and solution pumps or with the cooling load pump Solution concentration should be verified using a refractometer to measure Refractive Index RD MaximICE TES ORE 25 100 Owner s Manual 8 Effective September 1 1998 Part No 9840502 Revis
70. these parts need to be replaced or if they are in specification Then they can be reinstalled in the evaporator and returned to service MaximICE TES ORE 25 100 Owner s Manual 23 Effective September 1 1998 Part No 9840502 Revised December 1 2000 A Drive Plate With the drive plate removed and placed on a flat surface check all the holes and make sure the holes in the drive plate are round and not elongated If there are any holes that are out of round please refer to the tolerance chart to see if the drive plate can be reinstalled or if it needs to be replaced Figure 8 Drive Plate Inspection Criteria 3 4 HOLE DRIVE PLATE REPLACE IF GROOVE DEPTH IS EQUAL OR GREATER THAN 080 2mm CHECK SCREW TIGHTNESS REPLACE IF HOLE DIAMETER OR MAJOR DIAMETER IF HOLE IS ELLIPTICALLY SHAPED IS EQUAL OR GREATER THAN 7 8 22mm MaximICE TES ORE 25 100 Owner s Manual 24 Effective September 1 1998 Part No 9840502 Revised December 1 2000 Figure 9 Drive Plate Inspection Criteria 5 8 HOLE DRIVE PLATE REPLACE IF GROOVE DEPTH IS EQUAL OR GREATER THAN 080 2mm CHECK SCREW TIGHTNESS REPLACE IF HOLE DIAMETER OR MAJOR DIAMETER IF HOLE IS ELLIPTICALLY SHAPED IS EQUAL OR GREATER THAN 3 4 19mm MaximICE TES ORE 25 100 Owner s Manual 25 Effective September 1 1998 Part No 9840502 Revised December 1 2000 Figure 10 Countercrank Inspection Criteria REPLACE IF THRUST SURFACE IS WORN 060 1
71. to condenser type and equipment layout Final charging will be necessary once the system is under a stable operating condition Approximate refrigerant charge s ORE 25 400 lbs 180 kg ORE 50 700 Ibs 320 kg ORE 100 1 000 lbs 450 kg Locate the 5 3 flare fitting on the ORE evaporator Only this fitting can be used to charge the system with liquid refrigerant Add refrigerant to bring the pressure up and equalize prior to starting Continue to add refrigerant until a 10 liquid level is reached in the high pressure receiver during normal operation The air evaporative condenser package is equipped with a fan cycling head pressure control system which maintains a minimum compressor discharge pressure during low ambient conditions 175 psig 1 200 kPa MaximICE TES ORE 25 100 Owner s Manual 18 Effective September 1 1998 Part No 9840502 Revised December 1 2000 SECTION 6 0 SEQUENCE OF CONTROL 6 0 Sequence of Control The operation of the MaximICE unit is controlled by a Programmable Logic Controller PLC a very reliable continuous duty automatic control device By observing LED input output lights the operational status can be determined serving as a useful tool during troubleshooting It is recommended to study the system wiring diagram while matching the proper input output LED lights with each function Exhaust all other possible failure causes before assuming a PLC control malfunction It is highly unlikely that t
72. unit wil start upon contact closure Load Pump Operation Provide normally open dry contacts for monitoring of pump operation either auxiliary contacts or from EMS Contacts close upon pump start Solution Pump Operation Provide normaliy open dry contacts for monitoring of pump operation either auxiliary contacts or from EMS Contacts close upon pump start SINGLE PHASE ORE 50 TYPICAL WIRING Condensing Unit Pumpdown Low Pressure Switch Provide normally closed dry contacts SCHEMATIC Contacts open when suction pressure drops to 3 psig condensing unit shuts down Condensing Unit Alarm 1 Provide normally closed dry contacis Contacts open upon condensing unit alarm condition condensing unit shuts down Dual compressor condensing unit wiring shown See unit wiring dagram for single compressor condensing unit and optional items Condensing Unit Alarm 2 Provide normally closed dry contacts Contacts open upon condensing uni alarm condition condensing unit shuts down OPTIONAL Remote temperature switch Wired to remote ice level inventory sensor Conacts close on full ice condition predetermined temperature setting OPTIONAL _ Condensing Unit Start 1 24VAC contacts close to start condensing uni 7 Compressor Unloading Step 1 Z4VAC contacts close to unload compressor 7 Condensing Unit Start 2 24VAC contacts close to start condensing unit OPTIONAL Remote Alarm Dry contacts close upon alarm condition f
73. washers i no Replace bearings and mechanical seal as necessary Make Are motor bearings worn out 3 gt sure motor drainage holes at motor bottom flange aren t plugged Do not run cold solution in unit when drive off no Is bearing sleeve worn out or loose yes Remove drive assembly and replace damaged drive plate For ORE 50 and 100 models manufactured before 11 1 99 an improved mounting plate is available Replace bearing sleeve Also replace I housing bearing if plastic on 100 amp 50 with stainless steel version MaximICE TES ORE 25 100 Owner s Manual Effective September 1 1998 Part No 9840502 41 Revised December 1 2000 10 10 Low Compressor Oil Pressure Is an oil level visible in the compressor crankcase sight glass yes Is compressor oil pressure low y ro Is the compressor rotation correct Troubleshooting Chart 10 Compressor Fails on Low Oil Pressure Add oil to compressor at suction gt service valve until level reaches no middle of sight glass a Replace oil pump yes Change compressor motor no rotation yes Is the oil return solenoid valve faulty or damaged yes Is the oil hand expansion valve adjusted incorrectly
74. y the manufacturer of the component Transportation and inspection cost incurred by the Company will be charged to the purchaser user if returned material is not found to be defective The above will constitute the Companys total responsibility The above warranties will not apply in the event of abuse negligence improper installation procedures alterations by unauthorized service damage by flood fire windstorm lightning or acts of God Oral statements made by employees or representatives of the Company will not constitute warranties The above warranties apply only to the original purchaser user and original installation location and are not transferable NOZIONI SIN J THERMAL STORAGE PRODUCTS Paul Mueller Company P O Box 828 Springfield Missouri 65801 0828 U S A Telephone 417 831 3000 e Facsimile 417 862 9008 MaximICE TES ORE 25 100 Owner s Manual 61 Effective September 1 1998 Part No 9840502 Revised December 1 2000 NOTES MaximICE TES ORE 25 100 Owner s Manual 62 Effective September 1 1998 Part No 9840502 Revised December 1 2000 MUELLER P O Box 828 e Springfield Missouri 65801 0828 U S A Phone 417 831 3000 1 800 MUELLER e Fax 417 862 9008 www muel com e E mail thermal muel com International Inquiries Fax 417 831 6906 E mail international muel com 12 00 Part No 9840502

product manual

Contents

Download Pdf Manuals

Related Search

Related Contents