SCHREIBER ENGINEERING START UP SERVICE THE FOLLOWING ITEMS MUST BE COMPLETED PRIOR TO START UP SERVICE BE SURE YOU UNDERSTAND THOROUGH THE CONTENT CONTAIN IN THIS MANUAL; SHOULD YOU HAVE ANY QUESTION REGARD THIS MANUAL FOR INSTALLATION PLEASE CONTACT SCHREIBER ENGINEERING. 9 Appropriate piping has been completed between the chiller and the medical equipment. 9 Correct electrical power has been connected to the chiller. 9 Reservoir and all lines must be full of the proper water / glycol mix.
¥ Make sure you understand thorough the content contained in this manual before installation and operation of the chiller. ¥ Please follow installation instructions recommended in this manual. Failure to follow recommendation will result in void the warranty. ¥ Should you have any question about installation, or any contents in this manual, feel free to contact Schreiber Engineering for consultation. ¥ DO NOT install the chiller in a PIT, inside parking structure, enclosure area.
PREVENTIVE MAINTENANCE • Customer or end-user is advisable to contract with local HVAC contractor for Preventive and Maintenance on the equipment on a weekly basis. This is to ensure the equipment is performed optimumally and avoid down time in your process. • There are no lubrication points on the chiller. All motors have permanent lubrication in the bearings. All motors have internal overloaded protection otherwise; external overload is installed for non-overloaded motor.
OVERVIEW The Schreiber Medical Chillers are designed to supply constant chilled water to an Intera MRI system or other scanning system that requires chilled water. These chillers are also designed for Outdoor or Indoor installation. However, if indoor installation is desired, adequate ventilation is required. If necessary, consult with Schreiber Engineering for more information.
PRODUCT FEATURES CONSTRUCTION The chiller is built on a tubular steel base frame; with a 16 gauge powder coated steel cabinet. Components are internally mounted on a 16 gauge galvanized steel base. All of the access panels can be removed without tools. The electrical components are enclosed in a 2 compartment weather proof enclosure. REFRIGERATION SYSTEM Each chiller contains two 5 ton compressor/evaporator modules.
CONTROLS The chiller enclosure is a single enclosure with two compartments. The upper section houses the controller and pilot lamps. The lower section contains the main disconnect (non-fused) and all of the high voltage components. The upper section can be opened for an operator to check the control panel. The lower door is interlocked to disconnect. The main controller has a built in 4 x20 LCD display. The remote terminal can be wall mounted indoor.
PLANNING DATA Chiller Installation The chiller and condenser should be installed on a level surface or sub base. Vibration isolation is not provided by Schreiber Engineering and should be installed per requirements of local codes. The bolt pattern diagram contains the corner weights for chiller and condenser mounted together (AC configuration).
NETWORK REQURIMENT: Some chillers may be shipped with optional modem or TCP/IP connection. A phone line and number is required for the modem, and a permanent network connection is required for TCP/IP. Your network’s router will have to be configured so that the IP address for the chiller is exposed outside of the facility’s LAN. Piping Installation: Two chilled water loops are required for each chiller, one for the Cryo-compressor and one for the water-cooled heat exchangers. CHILLER CON.
REMOTE CONDENSER PIPING (NOT APPLICALBE FOR WC) There are two circuits in this chiller; therefore four pipes are required to connect the chiller and condenser. Refrigeration Piping Guidelines (Based on 150ft equivalent length) Hot Gas Line (comp-to-condenser) 1-1/8” Liquid Line (condenser-to-receiver) 7/8” These values are based on 150’ of total piping length, plus equivalent length of fittings.
REV. DESCRIPTIONS DATE BY 74.000 58.250 34.188 Minimum Clearances: Rear: 36 IN Front : 24 IN (Control Box) Right: 24 IN Left: 24IN COND. WATER: 45GPM @85F Condenser Water Connection at rear Refrigration piping connections for remote condensers are from the front panel of the chiller. UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCE ARE: FRACTION DECIMALS ANGLES + .XX +.03 +.5 .XXX + .015 MATERIAL 16 GA (.
30.000 REV. DESCRIPTIONS DATE BY 10.000 10.000 72.300 79.010 CONDENSER WATER CONNECTION 1" NPT FILL PORT 1" NPT 13.058 8.058 6.123 OVERFLOW 1" NPT PUMP 1 RETURN (1" FPT) PUMP 1 DISCHARGE PRESSURE GAUGE 10.000 58.214 PUMP 1 RETURN PRESSURE GAUGE PUMP 1 DISCHARGE (1" FPT) GCHE/GAHE PUMP PUMP 2 DISCHARGE PRESSURE GAUGE 7.471 33.500 21.093 CLEAN OUT 3/8" NPT PUMP 2 DISCHARGE (1/2" FPT) Cryo-Comp Pump 5.375 3.500 34.186 33.
REV. DESCRIPTIONS DATE BY 73.00 685 LBS O .625 584 LBS 30.00 575 LBS 685 LBS Air Intake UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCE ARE: FRACTION DECIMALS ANGLES + .XX +.03 +.5 .XXX + .015 MATERIAL 16 GA (.060 IN) C-ROLLED FINISH DO NOT SCALE DRAWING Schreiber 12111 EAST PARK STREET Engineering CERRITOS, CA 90703 A DOVER INDUSTRIES COMPANY TITLE Bolt Pattern For Base Frame SIZE SHT1 SHT2 DRAWING NO. B B B DRAWN BY: STEVEN Q.
Reservoir Drain 4 3 REV TITLE DESCRIPTION 2 REVISIONS DATE REVISED 1 APPROVED A B C D 1⁄2" Shutoff valve provided inside chiller 8 7 NOTES: Pressurized water line with shutoff valve must be provided at the chiller site. The chilled water reservoir is filled directly through the fill port, and not through the supply or return lines. A pressurized water supply with a shutoff valve and hose are all that is required. 6 Tank Fill 5 4 3 PHILIPS INTERCONNECT 2 PHILIPS PIPING INTERCONNECT.
A B C D E F G H 8 8 DRAIN 1⁄2" FPT SIGHT GLASS FILL PORT 1" MPT OVERFLOW 1" MPT 7 7 6 Chilled Water Reservoir 65 gallon capacity 6 Shutoff Shutoff 5 Cryo-Compressor Pump GCHE/GAHE PUMP Evaporator 2 and Isolation Valve Evaporator 1 and Isolation Valve 5 4 Pressure Relief Bypass Bypass Valve Backflow Solenoid Valve (NC) Check Valve Strainer 4 REV Strainer Clean Out 1⁄2" FPT 3 DESCRIPTION 2 REVISIONS 2 1055_REFRIGERATION_SK ID.
A B C D E F G H 8 8 DRAIN 1⁄2" FPT SIGHT GLASS FILL PORT 1" MPT OVERFLOW 1" MPT 7 7 6 Chilled Water Reservoir 65 gallon capacity 6 Shutoff Shutoff 5 Cryo-Compressor Pump GCHE/GAHE PUMP Evaporator 2 and Isolation Valve Evaporator 1 and Isolation Valve 5 4 Pressure Relief Bypass Bypass Valve Backflow Solenoid Valve (NC) Check Valve Strainer 4 REV Strainer Clean Out 1⁄2" FPT 3 DESCRIPTION 2 REVISIONS 2 1055_REFRIGERATION_SK ID.
24V L3 L2 HP1 L1 1W 1W J14 C8 NC8 J13 C7 NO8 C7 J12 NO7 C4 NO4 NO5 NO6 C4 J11 J9 C1 N01 NO2 N03 C1 Rx-/Tx- T3 J5 T2 Rx+/Tx+ GND T1 J15 J10 ID1 ID2 ID3 LP1 ID4 HP2 ID5 ID6 ID7 ID8 LP2 FS 1 IDC1 T1 FS2 T2 T3 LL-NO C1 N01 J12 T1 T3 1RS EXT-OVL 2W ` 24 VAC Black FS1 FS2 LL J13 N05 N06 C4 14/22 13no BF2 NO ON CONTACTOR 2C VFD 1FM 2RS TO 12V ON VFD T1 V T2 L3 W T3 FR ` U L2 NO5 J13 COM RED FM EXT-OVL 2 2FM T1 T3 N05 J15 FAN RELAY SPDT CRANKCASE H
START UP PROCEDURES INSTALLATION INSPECTION Visually inspect the chilled water piping system. There should be two pipe loops; 1” and 1⁄2”. The piping should be copper or PVC. Verify that all connections are made and that all required valves are open. Verify that the main breaker or disconnect is on (disconnect for branch circuit to the chiller, not the chiller disconnect), and check the fuse or breaker size. Compare with the installation requirements.
Initial Power Up NOTE: For the checkout procedure, it may be more convenient to use the remote terminal. It can be removed from the wall bracket and unplugged, and plugged into the chiller with another short length of telephone cable. All procedures are described using the terminal shortcut keys, but can be accessed through the menu on the built in display of the controller. See the controller operation section for more detail.
Fans (NOT APPLICABLE FOR WATER-COOLED VERSION) The fans should be spinning CLOCKWISE if looking down on the fan. Air should be drawn for the bottom of the chiller and be discharged out of the top. SYSTEM STARTUP ¾ Pump 2 (Cryo compressor pump) Startup and bypass adjustment ¾ Go to the ON/OFF screen. ¾ Turn on PUMP 1. Since the piping system is not full of water, and the flow switch is on the return line inside the chiller, the flow switch may trip before the pump has time to fill the pipe.
permanent settings are made, because they only change the display of sensor values, not setpoint values. For example, if the reservoir is at 68 F, and the setpoint is 50 F, changing the units to C will change the reservoir temperature display to 20 C, but the setpoint will be 50 C, not 10 C. Check the setpoints by pressing the SET button. They should match the default settings listed in the MAINTENANCE section. At the end of the setpoints screen is the compressor rotation screen. Rotation should be enabled.
OPERATION OVERVIEW OF OPERATING SEQUENCE: During normal operation, both pumps will run continuously. The Cryo-cooler pump continuously draws water from the reservoir, pumps it to the Cryo compressor, and back to the chilled water reservoir. The GCHE pump does the same, except that the water runs through the two refrigeration system evaporators before returning to the reservoir.
CHILLER SYSTEMS: CHILLED WATER CIRCUIT Cryo Compressor Pump The pump Cryo compressor pump is a positive displacement pump capable of delivering 4 GPM. This flow rate is constant under all conditions. The discharge pressure will vary according to the length of pipe and the number of fittings in the pipe system. A T-handle pressure relief valve allows adjustment of the discharge pressure. It should be set to no more than 50 psi The Cryo compressor pump motor is EXTERNALLY overload protected.
Chilled Water Reservoir The insulated chilled water reservoir inside the chiller is designed to eliminate wide swings in temperature during changing loads. It also provides a convenient location from adding water and glycol to the system. A float in the reservoir tells the controller that the water level is too low. The low lever alarm still allows the chiller to run, but water must be added immediately. Since the reservoir is open to the atmosphere, a small amount of water may be lost due to evaporation.
COMPRESSOR/EVAPORATOR SYSTEM Refer to the illustration on the next page for detail below: Each refrigeration system is mounted on a galvanized steel skid, and is completely self contained. It contains the following: High Pressure Switch The high pressure switch is a manually resetting, totally encapsulated switch that is mounted on a Schrader valve connection. If the switch requires replacement it can be unscrewed from the piping system without loss of refrigerant.
The sight glass moisture indicator is provided for charging purposes and to detect the presence of water in the refrigeration system. Thermostatic Expansion Valve (TEV) The TEV meters liquid refrigerant into the evaporator. It has a factory set superheat of 10 F and should not require adjustment. It is an externally equalized valve. In no circumstances should the equalizer tube me remove or plugged.
Controller Quick Reference Guide: (GENERAL) This section describes some of the common functions performed in the controller. Basic Navigation MAIN MENU Use the UP and DOWN arrow keys to scroll through the available menus. The currently selected menu will appear in all capital letters with an arrow next to it. Press the ENTER key to go into that menu. INSIDE A MENU LOOP Use the UP and DOWN arrow keys to scroll through the screens in a menu. When at a screen, the cursor is in the upper left hand corner.
Basic Tasks Enabling/Disabling pumps and compressors: At the chiller: 1. 2. 3. 4. Press the PRG key Scroll down to the CURRENT STATUS Screen and press enter. The screen will change to the RUNNING STATUS screen. Press the UP arrow key once to go to the SYSTEM ON/OFF screen. 5. Press the ENTER key to move the cursor to the different devices. Use the UP or DOWN arrow keys to turn each device off or on. At the terminal 1. Press the ON/OFF key. 2.
Checking Alarm History At the chiller 1. 2. 3. 4. Press the PRG key. Scroll down to the ALARM HISTORY menu and press ENTER. Use the UP arrow to review past alarms. To clear the alarm history, press the UP and DOWN arrow keys simultaneously for 5 seconds.
Controller Operation The chiller can be controlled from 2 locations; the built-in display on the controller (located inside the main chiller enclosure) or from the remote mounted terminal. All control functions can be performed at both locations; however, there are more buttons on the remote terminal that allows faster access to various menu functions.
MENU TREE The diagram below shows the hierarchy of the controller menus. Menus shown in gray are password protected.
Chiller menu descriptions Key name in parentheses denotes the shortcut key for accessing that screen directly. MAIN MENU (MENU or PROG) CURRENT STATUS (BLUE key) RUNNING STATUS Shows the current on or off status of the system pumps and compressors. LOOP STATUS Displays the current discharge temperature and return temperature for each pump loop. COMPRESSOR STATUS Displays the head pressure and suction pressure for each refrigeration circuit. Suction pressure display is optional.
Sets and displays the main temperature setpoints. DISCHARGE SETPOINT DISCHARGE: The setpoint for the chilled water reservoir. This temperature will be delivered through both pump loops. HIST: This is the differential around the setpoint of which the system will cycle. HIST = Histeresis. A 50 F setpoint with a 1.0F differential means the system will turn on at 51 F and shut off at 49 F.
automatically choose the correct rotation sequence, either forward or reverse. RUN HOURS (MAINTENCE key) Displays the run hours for each compressor, pump and fan. FACTORY SETTINGS- Password Protected These parameters are discussed in the special maintenance section of the manual. ALARM HISTORY Displays the last 25 alarms. Use the UP key to scroll through each alarm. Every alarm is time and date stamped. Pressing the UP and DOWN arrows simultaneously will reset the alarm history.
DELAY: A filter on the input to prevent nuisance trips. MANUAL CONTROL (INPUT/OUTPUT key, password protected) Allows the inputs and outputs to be bypassed around the control system and manually set to specific values. This is used for service and test purposes only. The special maintenance section describes the functions of manual control.
Maintenance This section describes routine maintenance functions that need to be performed periodically. Chilled Water System Glycol Solution Concentration and Level • A warning alarm will be generated when the reservoir level becomes too low. Filling with water will clear the alarm. By reviewing the alarm history, the rate of water loss can be determined by checking the time between subsequent water level alarms. The water level should be inspected by a time in between those alarms.
SERVICE NOTE: This section is for qualified service personnel only. Procedures outlined in this section of the manual can cause personal injury or permanent damage to the chiller and the equipment it is cooling. If you have any questions about the procedures outlined in this section please contact Schreiber Engineering directly. Refrigeration System The Chiller is made up of two separate refrigeration system, the only shared components is the condenser and it’s fans.
3. Stop the compressor when the suction pressure is just above vacuum. 4. Disable the compressor. Compressor Removal 1. 2. 3. 4. 5. 6. Pump down system to be replaced. Close suction and discharge valves. Evacuate remaining refrigerant out of the compressor. Shut down compressor system. Turn off main disconnect. Remove crankcase heater leads, and compressor power leads from the contactor. Record color sequence of leads. 7. Turn on disconnect. 8. Remove leads from the compressor motor adapter. 9.
fan speed. The band is the value around the setpoint of which controls the speed signal. If the head pressure is below the setpoint by the value of the band or more, the controller sends the minimum output of 0 volts DC. If the head pressure is greater than the setpoint by the value of the band or more, the controller sends the max output; 10 VDC. If the head pressure falls between the setpoint value plus or minus the band, the speed is adjusted accordingly.
The range around the setpoint in which the fans run at partial speed. Above the band the fans are full speed, below the band the fans are off. Condenser Fans Service Procedures Transducer Replacement 1. 2. 3. 4. 5. Disable Variable Speed operation Unplug the signal cable from the faulty sensor, Unscrew the sensor. Replace with new sensor and reconnect cable. Enable Variable Speed operation VFD Bypassing.
8 7 6 5 4 3 2 1 24VAC Red 24VAC Black Fan Relay J9 J11 J12 NC8 C7 J14 C8 NO8 C7 J13 NO7 NO6 C4 C4 NO5 NO4 C1 N03 C1 N01 NO2 Rx+/Tx+ GND Rx-/Tx- Controller H H J15 J10 14 c 11 7 G FUSE 5X20 J3 J4 J5 ID1 ID2 ID3 ID4 ID5 ID6 ID7 ID8 IDC1 G FR1 J2 VG VG0 Y1 Y2 Y3 Y4 J1 B4 BC4 B5 BC5 1 B1 B2 B3 GND +VDC G G0 2 Circular Connectors F F Aux Wire Pass Through CC1 CC2 Backflow Kit Terminal Block E c E BFTB Transformer D D Disconnect Wire Duct A1 C
Non Fused GCHE Pump C1 Compressor 1 P2 4 4 C2 Compressor 2 Crankcase Heater 3 3 REV TITLE VFD REVISIONS Fan Motors 5A DESCRIPTION 2 DATE REVISED 1 4/8/2003 APPROVED D E F G H A 7 6 5 Cryo Cooler Pump 2 1055_TERMINAL_WIRING.
Controller NO1 11 F1 14 CC1-11 A1 2 P1 CC1-14 4 3 REV TITLE DESCRIPTION 2 REVISIONS DATE REVISED 1 APPROVED A B C D E F 8 C4 C2 C1 VFD-12V NO8 NO5 NO4 NO3 NO2 7 6 CC2-7 A1 A1 A1 A2 A2 A2 5 VFD-FWD F1 7 LL2 C2 BF2 P2 LL1 C1 BF1 A2 CC2-14 4 VFD Start Signal ALARM Lamp Fan Relay Liquid Line Solenoid Compressor 2 Pilot Lamp Backflow Kit Valve Cryo Compressor Pump Pilot Lamp Liquid Line Solenoid Compressor 1 Pilot Lamp Backflow Kit Valve GCHE Pu
A B C D E F G H 8 8 7 24VAC Red c CC2-7 CC2-2 CC1-7 CC1-2 24VAC Black 6 6 REMOTE ON/OFF (OPTIONAL) FIELD INSTALLED Float FS2 FS1 LP2 HP2 LP1 HP1 G0 G 5 CC2-3 CC2-1 CC1-3 CC1-1 5 4 4 ID3 7 3 REV 3 IDC1 ID8 ID7 ID6 ID5 ID4 ID2 ID1 TITLE REVISIONS 2 DATE REVISED 1 JEFF JOHNSON DRAWN BY 1 DATE APPROVED 4/8/2003 4/4/2003 DIGITAL INPUT WIRING 1055_TERMINAL_WIRING 1055_TERMINAL_WIRING.
Factory default setting For PCO2 Controller: (1055AC/WC and 15MED) Under Main Menu CURRENT STATUS CURRENT ALARMS USER SETTINGS RUN HOURS FACTORY SETTINGS ALARM HISTORY DATE AND TIME SENSOR CALIBRATION DIG-IN CALIBRATION MANUAL CONTROL CURRENT STATUS – THESE ARE ONLY INFORMATION SCREENS – NOTHING CAN BE CHANGE Running Status Pumps: 1 2 yes Comps: 2 no TCON TCOFF System Status Discharge: Discharge temperature reading Return #1: Return #1 temperature reading Return #2: Return #2 temperature reading Circuit #1
Setpoints – The customer can change this setting based on their requirement. Temp Rise: 10.0 0F Hist: 01.0 0F High Temp Alarm – The customer can change this setting based on their requirement. Set: 85.0 0F Hist: 05.
Minimum Off: 010 s Fan Control – Head Pressure Control Setp: 190 Band: 030 Vspeed: ENABLE / DISABLE Min Freq: 030 Max: 060 Condenser Fan Config VFD minimum: 000 Hz VFD Maximum: 065 Hz Factory Settings Temperature Unit: 0F Pressure Units: PSI Changing this parameter will not display correct reading in BAR Password Maintenance Factory Pass: 0177 Supervisor setup Ident: 001 Baud: 1200 Protocol: n/a Unit Configuration Evap Sensors: No Voltage Monitor: Yes Misc Settings Tiem Betw Comps: 010 s Screen Saver Delay:
Current: Discharge temperature current reading Offset: 00.0 Offset value Return Temp #1 Current: Discharge temperature current reading Offset: 00.0 Offset value Return Temp #2 Current: Discharge temperature current reading Offset: 00.
Float switch Enabled: Yes Current: Closed Delay Alarm if: Open 01 s Remote ON/OFF Enabled: Yes Current Closed Delay Alarm if: Open 01s MANUAL CONTROL PASSWORD PROTECTED 0177 Digital input #1 Control State: AUTO / MANUAL Input State: Closed / OPEN HP switch #1 Digital input #2 Control State: AUTO / MANUAL Input State: Closed / OPEN LP switch #1 Digital input #3 Control State: AUTO / MANUAL Input State: Closed / OPEN HP switch #2 Digital input #4 Control State: AUTO / MANUAL Input State: Closed / OPEN LP swit
Digital Output #2 Control State: AUTO /MANUAL Input State: Closed / OPEN Compressor #1 Status Digital Output #3 Control State: AUTO / MANUAL Input State: Closed / OPEN Pump #2 Status Digital output #4 Control State: AUTO / MANUAL Input State: Closed / OPEN Compressor #2 Status Digital Output #5 Control State: AUTO / MANUAL Input State: Closed / OPEN Condenser Fan Status Digital output #6 Control State: AUTO / MANUAL Input State: Open / CLOSED AUX_OUT Digital output #7 Control State: AUTO / MANUAL Input Stat
Input State: :0000 – manually input values Return Temperature 2 Analog Output #1 Control State : AUTO / MANUAL Input State: :0000 – manually input values Condenser Fan Speed Analog Output #2 Control State : AUTO / MANUAL Input State: :0000 – manually input values Damper opening This controller has two-stage compressor settings, the discharge temperature for stage 1 and temp rise for stage 2. These setting are located in USER SETTINGS screen. Stages cycle ON/OFF is based on these settings.
Setting point: In this example, we ignore HIST. setting Discharge: 47 0F Temp rise: 10 0F Water temperature reading: Discharge: Return #1: 60 0F 63 0F Again, stage 1 is activated since discharge temperature reading is above discharge temperature setting. This time stage 2 is also activated. The discharge temperature reading is 60 0F, which is above the sum of the discharge setting and temp rise setting (47+10 = 57).
TROUBLE SHOOTING ALARM CONDITIONS Low Pressure Circ. #1 or #2 High Pressure Circ. #1 or #2 POSSIBLE CAUSES CHECKS & REPAIR Low in Gas due to leak *Check for leak & Repair Liquid line sol. Valve not energizing. *Verify valve is good by applying 24 vac directly. Inadequate return water. *Check and clean strainer. Ambient Temperature *If ambient temp below 20°F additional gas is needed. Bad Fan Motors *Manually turn on fan and check current. Restricted flow through condenser.
Lose of Water Circ. #1 or #2 Bad pump *Measure amp draw U physically check pump condition. Bad Flow Switch *Measure terminal ID5/ID6 and IDC1 if voltage below is 20 vac it is bad. Restricted Water Return *Water not allowed to return to chiller.
