Water Cooled Ultimate Chiller Solution Model UCW/H 30, 50, 70, 85 Installation, Operation & Maintenance Manual
Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Pre-Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Pre-Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Pre-Startup Check List. . . . . . . . . . . . . . . . . .
Introduction General Description Safety ClimaCool’s dedication to energy and environmental leadership led to the Ultimate Chiller Solution design. Available in 30, 50, 70 and 85 tons, each module is compact, redundant, maneuverable, efficient, reliable and serviceable. Combined tonnages can obtain specific project turndown and capacity requirements from 30 to 1,000 tons per bank while having the ability to accommodate future growth and expansion needs.
Pre-Installation Inspection Upon receipt of equipment, carefully check the shipment against the bill of lading and inspect each chiller for any damage incurred during shipment. Thoroughly check for any visible damage of control panels and electrical and/or refrigeration components or broken copper lines. The carrier must make proper notation of any damages or shortages on all copies of the bill of lading and complete a common carrier inspection report prior to your final acceptance of the shipment.
Unit Installation Unit Placement ClimaCool modular chillers must be installed in a conditioned and dehumidified space. The minimum foundation requirement for the chiller is a level surface capable of bearing the combined operating weight of the modules (See Physical Data on page 5).
Model Key Rejection Means W = Water H = High Temperature ₁ ₂ W ₃ 030 ₄ ₅ ₆ A ₇ F ₈ A ₉ S ₁₀ A ₁₁ C ₁₂ M ₁₃ 0 ₁₄ S ₁₅ Ultimate Chiller Solution Model Key UC Refrigerant Options Model Configuration S = Standard X = Special Options 0 = (None) B = Hot Gas Bypass ‐ Both Circuits (Not available with Heat Pump application) P = Hot Gas Bypass with Pressure Relief Valves R = Pressure Relief Valves X = Special Options 0 = (None) B = Evap & Condsr Motorized Valves E = Evap.
Physical Data Model UCW/H Module and Compressor 30 50 70 85 Capacity (tons) ¹ 31.7 51.5 67.2 82.8 kW/Ton 2 Full-Load EER 0.738 0.746 0.744 0.740 16.3 16.1 16.1 16.
Dimensional Data and Drawings Chilled Water Inlet www.climacoolcorp.
Rigging and Lifting Procedures Rigging Each module should be lifted using lift straps threaded through the steel base cutouts and a spreader bar. Note: If no spreader bar is used, damage to the module may occur. Figure 1 Figure 1 Lifting Strap Figure 2 Figure 2 Spreader Bar Lifting Strap Spreader Bar Spreader Bar Lifting and Transporting Modules Pallet jacks or forklifts are required for lifting and transporting the module. Each module has base cutouts provided for ease of maneuverability.
Mounting Rail and Vibration Isolation ClimaCool recommends locking down the chiller to a concrete base or to three (3) 4” base mounting rails using the six 4” Rail Minimum (6) bolt holes provided in each base pan. Due to the low vibration of the modules, the application of spring isolators or Recommended (by others) pads is not required. Should isolators or padsSpring beVibration desired install in accordance with Figures 4 and 5.
Recommended Service Clearances Top View 30” 30” Rear Service Access Front Service Access 12” 36” 36” CoolLogic Control Panel (Wall Mounted) Notes: 1. Allow 36" clearance for electrical panels and 30" clearance for rear service access to modules. 2. Allow a minimum of 18" height clearance for 30, 50 and 70 ton modules. Allow a minimum of 24” height clearance for 85 ton modules. 3. Local building and/or electrical codes may require additional clearance. Consult applicable codes. 9 www.climacoolcorp.
Water Piping As with any water system, it is important that the system be clean. The pipe work installer must remove weld scale, rust and contamination during pipe work fabrication. The system water piping must be flushed thoroughly with recommended alkaline flush or other chemicals that are compatible with 316 stainless steel, prior to making connections to the ClimaCool chiller. There are certain necessary components that should always be installed in both the chilled water and condenser water systems.
Load Side System Bypass (Air Handlers, Fan Coils, etc.) ClimaCool offers two types of water header bypass kits, direct return (Figure 6) and reverse return (Figure 7) as shown on page 10. The bypass kits must be installed on each water source loop and controls are integrated with the CoolLogic software. Installation location can be found on page 12 – Water Piping Configuration.
Water Piping Configurations www.climacoolcorp.com Figure 9 - Field Piping Direct Return Figure 10 - Field Piping Reverse Return Notes: 1. Figures 9 and 10 are required piping for proper water regulation and distribution through ClimaCool modular chillers. 2. Module order and incoming/outgoing water flow as shown in both Figure 9 and 10 can be set up as either a left-to-right or right-to-left configuration. 3. Condenser hydronic circuit shown.
The ClimaCool Modular Chiller - Hydronic Configuration Hydronic Refrigeration Figure 1 - Condenser Hydronic Circuit Figure 11- Condenser Hydronic Circuit Isolation Ball Valve (2, 2-1/2 or 3”) Pete’s Port Service Port (3/4”) Refrigerant Circuit #1 To Cooling Tower Header Refrigerant Circuit #2 From Cooling Tower Header Pete’s Port Isolation Ball Valve (2, 2-1/2 or 3”) Service Port (3/4”) Heat Exchanger Figure 2 - Chilled Water Circuit Figure 12 - Chilled Water Circuit Refrigerant Circuit #1 Isola
Filling the Water System It is imperative that the water systems are free from debris prior to initial operation. See Water Treatment for a comprehensive list of precautions on page 15. Filling, Purging and Leak Testing the System After the water systems have been properly installed, visually inspect all joints for tightness. If the chiller is to be installed in an existing system, the cleanliness of the existing system can be judged from the operating conditions of the present machines.
Water Treatment Water quality is of the utmost importance for the proper care and maintenance of the modular chiller system. Proper water treatment is a specialized industry and it is recommended to consult an expert in this field to analyze the water for compliance with the water quality parameters listed in Table 1. The materials exposed to the water are type 316 stainless steel, pure copper and carbon steel. Other materials may exist external to the ClimaCool chiller.
Water Temperature Requirements Condenser Water Temperature Chilled Water Temperature The condensers are designed to operate most efficiently at lower entering water temperatures for lower power consumption. The expansion valve, however, relies on the pressure difference across the valve to drive the liquid refrigerant through.
Condenser and Evaporator Water Pressure Drop Charts - 030, 050, 070, 085 Condenser Water Pressure Drop 30, 50, 70 & 85-Ton, UCW/UCH Series Model# UCW/UCH050 Model# UCW/UCH070 Model# UCW/UCH085 100 43 3 43.3 80 34.7 60 50 45 40 35 30 25 26.0 21.7 19.5 17.3 15.5 13 20 18 16 14 12 10 8.7 7.8 7.0 6.1 5.2 8 3.5 6 2.6 4 1.7 2 0.87 Pressure Drop (PSI) Pressure Drop (Ftt. of Water) Model# UCW/UCH030 10.8 4.3 1 10 30 40 60 80 100 120 140 160 200 240 280 350 180 220 260 300 400 0.
Glycol Performance Adjustment Factors Charts Note: Correction factors shown above are to be applied to Std. Product Data @ ARI 550/590 44°F. Leaving Chilled Water / 85°F Entering / 95°F Leaving Conditioned Water. Note: Correction factors shown above are to be applied to Std. Product Data chiller pressure drop curves for straight water. Note: Correction factors shown above are to be applied to Std. Product Data @ ARI 550/590 44°F. Leaving Chilled Water / 85°F Entering / 95°F Leaving Conditioned Water.
Glycol Performance Adjustment Factors Charts Glycol Solution Freezing Point 19 www.climacoolcorp.
Electrical Connection The power for all modules is taken from a suitable circuit breaker/fused disconnect power supply within the main panel. The electrical service enters the individual modules through the top into the module’s control panel enclosure. Proper grounding of the module is mandatory. Before carrying out any electrical work, confirm that the main supply is isolated. A typical power wiring is located on page 47 – Power Distribution Drawing.
Voltage/Phase Monitor Wiring 21 www.climacoolcorp.
Pre-Startup All startups must be performed by ClimaCool factory trained personnel. Prior to chiller startup, there are certain essential checks which must be completed. Failure to carry out these checks could result in damage to the chiller voiding the modules warranty. 2. Electrical Water System It is imperative to turn off the main electrical power supply and follow proper lock-out/tag-out procedures prior to servicing any of the chiller’s electrical components.
Pre Startup Check List (Water-Cooled) E-mail customerservice@climacoolcorp.com Fax 405-815-3052 Project Name: _________________________________________________Date:___________________ Address: _____________________________________________________________________________ YES ___ NO ___ 2. Is there a minimum of 60 mesh strainer on condenser and evaporator inlet water? (Fill water to chiller being sure to pass through a minimum of 60 mesh strainer.) ___ ___ 3.
Startup All startups must be performed by ClimaCool factory trained personnel. Nominal differential pressure ranges are from 3 to 10 psid. 1. Review all items are complete from the Pre-Startup Check List. 2. Cross reference model number with submittal sheet to verify that the units are the correct model type and voltage requirements. 3. Verify the location and wiring connections of all main header temperature sensors (should be a minimum of 36” from the bank).
the FN 7, or the service menu). Bump the compressor only for 1-2 seconds to ensure the correct rotation of the scroll compressors (indicated by a rising highside pressure and a falling suction pressure). 18. Verify proper communications from each module back to the master controller using the “STATUS” menu, then indexing down to the desired compressor data screen.
Subcooling & Superheat Flow Chart Run Compressor for 5 Minutes Is Superheat in Range? No Yes Is Superheat Low or High? Low Turn TXV Adjustment Stem Clockwise Is Subcooling in Range? High No Is Subcooling Low or High? Is Subcooling Low or High? Low Low High Yes Recheck Superheat and Complete Start-up and Warranty Form High Add Refrigerant Remove Refrigerant Turn TXV Adjustment Stem Counter Clockwise Add Refrigerant Caution: Do not charge to achieve subcooling temperature when the expansi
Startup and Warranty Registration Form (Water-Cooled) Sign, date and E-mail to: customerservice@climacoolcorp.com or Fax Ambient to: (405) 815-3052 Attn: Customer Service Temp: Project Name: Contractor Name: Address: Address: City/State Start-up Date: City/State Phone No.: Module: Page 1 of 3 Compressor: Model No.: Model No.: Serial No.: Chiller No.: Serial No. 1: Serial No. 2: Bank No.
Project Name: General System Settings Software Version: FN 2 COOLING PID Chiller Control Type Control Source Enable from Keypad Chiller Model Type HEAT & COOL SETPOINT MENUS Cool Setpoint Cool setpoint offset PID Interval Use Pre-calc PID values Below? Stage One Cool PID P-Gain Stage One Cool PID I-Gain Clg PID Rise Clg PID Fall Heat Setpoint Heat setpoint offset INPUTS 6 & 10 REM SETPT SETUP Input Chn #10 Type Min Heat Wat Out Setpt Max Heat Wat Out Setpt Or Manually Select PID Values Below Stage One
Mod Water & Air Temp Limits FN6 Channel 8 & 11 Setup Mod Evap Water Out Low Limit Use Channel #8 as diff pressure sensors? Mod Evap Water Out High Limit Use High Range Differential Pressure Sensors? Mod Cond Water Out High Limit High Range = 0-43 psid Low Range = 0-14.
Chiller Operation and Maintenance Pressure and Temperature Log A log of temperatures and pressures should be taken regularly. Periodically conduct a visual inspection of the chiller to identify problems before they reach the point of failure. As with any mechanical system, it is necessary to conduct a series of checks to confirm correct operation of the chiller. Date Chiller No. Technician Date Chiller No.
Heat Exchangers Draining When performing standard maintenance procedures such as flushing a heat exchanger, it will be necessary to close off a section of a module. This can easily be done if factory mounted water isolation valves are provided. Access to a floor drain is helpful when performing standard maintenance procedures. “soak” for a time and then pumped again. Upon successful cleaning of a module, proceed to isolate a second module separately from the bank to repeat the cleaning process.
Cleaning Arrangement Figure 1 - City Water Cleaning Arrangement Figure 14 - City Water Cleaning Arrangement Service Port (3/4") Connect to City Water To Cooling Tower Header Isolation Ball Valves (2, 2 ½ or 3") Refrigerant Circuit Pete's Ports Header Refrigerant Circuit From Cooling Tower Connect to Drain Service Port (3/4") Heat Exchanger Figure 15 - In Place Cleaning Arrangement Figure 2 - In Place Cleaning Arrangement Cleaning Pump Service Port (3/4") To Cooling Tower Header Isolation Ball Va
Operational Limitations Voltage Limitations The following voltage limitations are absolute and operation beyond these limitations may cause serious damage to the compressor.
Compressor Information Model UCW/H uses scroll compressors which are highly efficient and extremely reliable. The information contained in this manual will be useful for their care. Compressor Rotation connection on the suction line or injected into the oil process port at the bottom of the compressor housing. Only enough oil should be added to raise the level above the ⅓ sight glass point. All scroll-type machines are unidirectional and will only compress in one direction.
Refrigeration Circuit Diagram Heat Recovery CHILLER WATER PIPING CHILLER OUTLET WATER MAIN (6"or 8") CONDENSER WATER PIPING CONDENSER OUTLET WATER MAIN (6" or 8") CHILLER INLET WATER MAIN (6"or 8") CHILLER WATER OUTLET VALVE (W HEN USED) CONDENSER INLET WATER MAIN (6" or 8") CONDENSER WATER OUTLET VALVE (W HEN USED) CHILLER WATER INLET VALVE (W HEN USED) (W HEN USED) S5 FILL SHUT-OFF VALVE 5 FLUSH SHUT-OFF VALVE FILL SHUT-OFF VALVE (W HEN USED) CONDENSER WATER INLET VALVE 8 (W HEN USED) 7
Refrigeration Circuit Diagram Heat Pump CHILLER WATER PIPING CHILLER OUTLET WATER MAIN (6"or 8") CONDENSER WATER PIPING CONDENSER OUTLET WATER MAIN (6"or 8") CHILLER INLET WATER MAIN (6"or 8") CHILLER WATER OUTLET VALVE (WHEN USED) CONDENSER INLET WATER MAIN (6"or 8") CONDENSER WATER OUTLET VALVE (WHEN USED) CHILLER WATER INLET VALVE (WHEN USED) (WHEN USED) FLUSH SHUT-OFF VALVE S5 FILL SHUT-OFF VALVE (WHEN USED) CONDENSER WATER INLET VALVE FILL SHUT-OFF VALVE 5 8 (WHEN USED) 6 7 S4 S3
Refrigeration System Re-Processing and Charging Conforming to local and national codes is the responsibility of the service technician or installing contractor. The service technician should be familiar with the following codes: • ASHRAE Standard Safety Code for Mechanical Refrigeration, ANSI/ASHRAE 15-1978 • American National Standard Code for Pressure Piping, ANSI B31.5-1974 reaches zero psig or slightly higher. Then, repeat the entire evacuation process described above.
Options and Accessories Motorized or Manual Water Isolation Valves and Flush Ports Factory installed water isolation valves and flush ports shall provide isolation to the module for maintenance and cleaning of evaporator and condenser heat exchangers while adjacent modules continue normal operation. Both motorized and manual valves include standard ¾” fill and flush valves. Note: All Heat Pump configurations require motorized valves.
Stainless Steel Strainer Option Figure 16 Strainer Installation Recommendations We recommend following the guidelines below when installing the strainer: 1. 2. 3. Safety Considerations Prior to installation, this manual must be read carefully and all instruction understood. Personal injury or product damage can occur if the following safety precautions are overlooked or ignored.
Table Table 21 Strainer 3CS 4CS 6CS 8CS 10CS Bolt Size Recommended Torque (ft. lbs) 5/16 3/8 1/2 1/2 5/8 - 60 15 45 45 80 (inches) 18 16 13 13 11 Strainer Operation Periodically, it will be necessary to flush out the debris that is collected and settles to the bottom of the strainer reservoir. CS-3 strainers must have a valve installed on the drainage port. The larger CS strainers (4CS, 6CS, 8CS and 10CS) are equipped with a flush port (or drainage port) extending inside the strainer.
What is Water Hammer? Figure 18 Water hammer is a phenomenon that can occur in fluid systems with long pipes. Water hammer is a rapid change of pressure caused by a rapid change in velocity. If the flow has been abruptly shut off downstream, the pressure in the entire system is raised very quickly. What Causes Water Hammer? Any action that can cause a rapid change in the velocity of the flow can set off a water hammer, such as closing a downstream valve, pump stoppage, etc.
Operation Instructions Water Resistance Flush valve line must be piped to atmospheric pressure such as an open floor drain. The flush line should not undergo any changes in elevation and should be sloped downward in the direction of drainage. Do not pipe the flush or drain line into a pressurized line. The valve and controller are water-resistant, but not water-proof. Do not install below ground level where the component can be submerged in water.
When the differential set point is reached both the audible and visual alarms will be triggered and will remain engaged until both the alarm condition is corrected and the alarm-reset button is pressed (if the alarm-reset button is pressed but the differential pressure is beyond the set point, the alarms will re-engage immediately). After the strainer is cleaned and put back in service, the differential pressure should return to 1 psi.
“Y” Strainer Basket Strainer Before installing the “Y” strainer, be sure its pressure rating is correct for the system. If the end connections are threaded or designed for soldering or brazing, be sure the piping is straight and not at an angle or offset. If the strainer has flanged ends, be sure the flanges of the connecting piping are square with the pipe soIOM-MS-YStrainers that no undue stress is put on the strainer or piping when tightening the flange bolts.
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Electrical Data UCH Model Type Model # Voltage Size MaxFuse Fuse Rec. Switch Discon. Load Rated Amps Min.Cir. Rotor Locked Size MaxFuse Fuse Rec. Internal Wiring - per Compressor Amps Min.Cir. Power Wiring - per Module Load Rated 40 90 50 35 Size4, 5 173 45 150 125 31.9 128 200 70 (MOP)3, 4 25.5 25.5 605 90 60 425 80 20.4 118.4 272 70 200 (LRA)7 70 70 94.7 53.5 238 250 90 70.5 80 60 300 42.8 42.8 599 125 70 (MCA)2 57 60 250 150 34.3 155.
Power Distribution Drawing Figure 22 Notes: 1. Breaker panel represents field power supply and is to be installed by others. Not provided as part of the ClimaCool modular chiller system. 2. Breaker panels can be supplied for skid mount pump/tank packages or new construction projects as options. Consult your local ClimaCool Representative. 3. Control wiring by others. 4. Field connections are simplified requiring only a two-conductor shielded cable daisy chain from the master controller to the modules.
Wiring Diagrams - 030, 050, 070 48 www.climacoolcorp.
Wiring Diagrams - 030, 050, 070 49 www.climacoolcorp.
Wiring Diagrams - 030, 050, 070 Heat Pump 50 www.climacoolcorp.
Wiring Diagrams - 030, 050, 070 Heat Pump 51 www.climacoolcorp.
Wiring Diagrams - 085 52 www.climacoolcorp.
Wiring Diagrams - 085 53 www.climacoolcorp.
Wiring Diagrams - 085 Heat Pump 54 www.climacoolcorp.
Wiring Diagrams - 085 Heat Pump 55 www.climacoolcorp.
Wiring Diagrams 56 www.climacoolcorp.
Wiring Diagrams 57 www.climacoolcorp.
Troubleshooting Guide WARNING! The troubleshooting guidelines recommended in this section could result in exposure to electrical safety hazards. Please refer to the safety warnings provided in this manual. Failure to follow all of the recommended safety warnings provided could result in death or serious injury. When possible, disconnect all electrical power including remote disconnects before servicing. Follow proper lockout/tagout procedures.
Troubleshooting Guide Compressor Cycle On High Pressure Control Possible Cause Remedy Main condenser water valve closed or restricted Open valve to full open position. Module condenser water isolation valves, if Open valves to full open position. provided, closed or restricted Water regulating valve incorrectly set or Reset or replace. defective Compressor discharge valve partially closed Open valve to full open position.
60 www.climacoolcorp.com forms\ccool\standard forms\word files\warranty compressor certificate 04-12 Please refer to the CC Installation, Operation and Maintenance Manual for operating and maintenance instructions. NOTE: Some states or Canadian provinces do not allow limitations on how long an implied warranty lasts, or the limitation or exclusion of consequential or incidental damages, so the foregoing exclusion and limitations may not apply to you.
15 S. Virginia Oklahoma City, OK 73106 Phone: 405-815-3000 Fax: 405-815-3052 www.climacoolcorp.com ClimaCool works continually to improve its products. As a result, the design and specifications of each product at the time for order may be changed without notice and may not be as described herein. Please contact ClimaCool’s Customer Service Department at 405-815-3000 for specific information on the current design and specifications.
