1025, BOUL. MARCEL-LAURIN INSTRUCTION MANUAL FOR WATER COOLED ENVIROCHILL CHILLER. Prepared par Claude Gadoury, P. Eng MTL TECHNOLOGIES INC.

Transcription

1 WYETH-AYERST CANADA INC. 1025, BOUL. MARCEL-LAURIN S T - L A U R E N T, Q U É B E C INSTRUCTION MANUAL FOR WATER COOLED ENVIROCHILL CHILLER MODEL P448800LT--55WC--22C66S Prepared par Claude Gadoury, P. Eng MTL TECHNOLOGIES INC.

2 TABLE OF CONTENTS CHILLER S CHARACTERISTICS 1 INSTALLATION 3 START-UP PROCEDURE 4 MAINTENANCE 4 CHILLER S OPERATION 4 ELECTRICAL DATA 5 CONTROL PANEL Buttons/Push-buttons 6 Light Indicators/Operation 7 Alarms 8 Remote Communication 9 Special Adjustment Mode 10 Supply 10 Relays 10 ANNEXE A ANNEXE B ANNEXE C ANNEXE D ELECTRONIC BOARDS COMPRESSORS PERFORMANCE GLYCOL S PROPERTIES SHOP DRAWINGS DRAWINGS : GENERAL M ELECTRICAL CONNECTION M REFRIGERATION DIAGRAM M PLUMBING SCHEMATIC M ELECTRICAL SCHEMATIC # 1 M ELECTRICAL SCHEMATIC # 1 M CONTROL PANEL ANNEXE E ANNEXE F PREVENTIVE MAINTENANCE SCHEDULE ADDITIONAL TECHNICAL INFORMATION ii

3 CHILLER S MAIN CHARACTERISTICS Model: Fluid: Refrigerant: Frame: System Net Capacity: Evaporator: Fluid Flow: Refrigeration Circuits: Compressors: P480LT-5WC-2C6S. 50% Propylene-Glycol. R-404A. Open type design assembled with bolted heavy gauge galvanised steel channels and a total of eight (8) legs for complete support and easy access to components 40.0 tons (480 kbtu/hr) for 6.0 F (-14.4 C) LGT, -4.0 F (-20.0 C) EGT, and a flow of usgpm. Condensing temperature is 85.0 F (29.4 C) with 45.0 F (7.2 C) EWT, 61.2 F (16.2 C) LWT and a flow of 45.7 usgpm. Shell and tube design with two(2) refrigeration circuits designed for 250 PSIG service pressure on the refrigerant side and 150 PSIG service pressure on the water side. The evaporator is factory insulated with 1½ armaflex. It includes seamless construction with carbon steel shell and deflectors, seamless copper tubes, drain connection and thermometer wells for temperature sensors. Chiller pump (BY OTHERS) designed to supply usgpm of a 50% propylene-glycol solution with head pressure to overcome the evaporator s pressure drop (14.0 PSI) and restriction due to piping. The chiller includes two(2) independent refrigeration circuits each c/w: one (1) screw compressor and required accessories, thermostatic expansion valve, solenoid valve, liquid line sight glass, liquid line filter drier with replaceable cores, and high/low pressure switch. Each compressor is a Bitzer model HSN semi-hermetic screw design with nominal capacity of 40.0 HP, mounted on vibrating insulators and c/w the following accessories; - solenoids coils for unloading (two-stages), suction and discharge service valves, ECO adapter, oil flow switch, transducer valve, oil filter c/w cartridges, rotation switch, oil solenoid valve and coil, ESC electronic screw controller, transformer for ESC 200, oil separator c/w two(2) heater wells, one(1) 100W heater, a heater thermostat and an oil separator sensor, subcooler c/w expansion valve, solenoid and coil 1

4 Water Cooled Condensers: Electric Panel Controls: Overall Dimensions: Approx. Weights: Standards: Included option(s): Warranty: Note: Two(2) horizontal, cleanable shell and tube condenser designed for 350 PSIG working pressure on the refrigerant side and 150 PSIG working pressure on the water side. It includes removable, epoxy coated water plates to facilitate cleaning. All electrical components are mounted in a NEMA 1 Enclosure c/w door, main input breaker with instantaneous magnetic trip, provision for padlocking up to three padlocks, control transformers, ground lug, ON-OFF selector switch, pump-down switch for each circuit, fuse protection and contactors (part winding configuration) for each compressor, anti-short cycling timer for each compressor, terminal blocks for remote controls, display and control boards. The chiller s operation, status and alarm modes are managed by two(2) microprocessor based electronic boards. It also allows the adjustment of temperature setpoint and differential, the reading of entering and leaving fluid temperatures and the displaying of any alarms. Please refer to Control Panel Instruction section for more information. 144,0" long, 60,0" deep, and 78,0" high lbs CSA ASME CRN (Quebec) for evaporator, condenser and reservoir Discharge, suction, and oil pressure gauges with service valves Pump down switches for each circuit Factory supplied field mounted flow switch for propylene glycol circuit Factory supplied field mounted flow switch for condenser water circuit Water Pressure Regulating Valves for each condensing water circuit 10% additional terminals for future. Commissioning and start-up assistance One(1) year parts only standard warranty A minimum space of 3 feet is required on at least three(3) sides of the unit to allow for proper servicing 2

5 INSTALLATION Reception of material: Upon receipt of equipment, check the chiller for any damages and note on proper delivery documentation. Handle equipment with care during installation. When fork-lifts are used, ensure that the chiller weights is well balanced on both forks, that the forklift is stable and, and make sure that the position of the forks will not break any components. Chiller: The chiller must be installed inside the building on a surface capable of supporting its weights. Space must be made around the chiller to allow its servicing. General: Electrical installation: Refrigeration installation: Plumbing installation: Electrical installation should be conform with both Local and National Electric Codes. Check equipment nameplate information and compare to available power source. Select the proper wire size for a minimum allowable voltage drops to assure dependable operation during periods of peak power usage when Brownouts may occur. A safety ground should be connected to each equipment. Control wires must be installed in accordance to approved shop drawings. Install the factory supplied flow switch (shipped with the chiller) and connect it to terminals TBF of the control panel. Terminals TBD are available for automatic or manual remote start/stop of the chiller. Finally, terminals TBP could be use to signal chiller alarm condition to an external device. All refrigeration equipment should be installed according to both local and national codes. The installation should conform to good refrigeration engineering practice. All piping equipment should be installed according to both local and national codes. The installation should conform to good plumbing engineering practice. The flow switch supplied with the chiller must be installed at a minimum distance equivalent to five times the pipe s diameter from any devices capable of creating a disturbance such as elbows, valves, tees, etc... START-UP PROCEDURES Connect the evaporator (fluid in and fluid out) to the chiller pump. Note: For testing purposes, a short loop can be piped between the supply and the return lines. Close disconnect. Refer to the electrical diagram of Appendice D and to Table 1 and check different voltages. When applicable, also check rotation of each motor (water pump(s) and compressor(s)) to make sure the phases are hooked up in the proper sequence. 3

6 Fill chiller circuit with fluid. Allow the air to escape. Anti-corrosion additives can be added if there are some steel parts along the fluid circuit. With the fluid circuit open, run the pump to allow the fluid to fill all the system. With the pump running, add fluid as necessary. Using water mixed with crushed ice in a container, verify temperature sensors calibration. Temperature display should read 32 F (0 C). If not, use the potentiometer located on the electronic board to adjust the sensors. (For adjustment refer to Annexe A Electronic Boards ) Put chiller ON-OFF selector switch in the ON position and start process equipment to provide load to the chiller. If connected to output terminals of the chiller board, the pump will start immediately. The compressor(s) will be activated on demand according to the user programmed set point and differential. Each compressor(s) is protected by an adjustable anti-cycling timer relay. Please refer to Start-up Procedure Form provided with the chiller. This form must be properly filled and returned to the manufacturer. Failure to do so will avoid the standard one(1) year warranty on parts. MAINTENANCE The Envirochill chiller is a mechanical device including high quality components. It is thoroughly tested at factory according to industry standards. We strongly recommended that preventive maintenance visits are performed on a regular basis to ensure that the components stay in working order. Use qualified personal only. Please do not hesitate to consult factory at (450) in case of a chiller problem. CHILLER S OPERATION The Envirochill chillers controls the temperature of your process by comparing the entering fluid temperature (E.F.T.) to the SETPOINT value entered by the user. The controls will activate each cooling step as following; (Please note that there is 1 difference between each cooling step) - 1 st Cooling Step: E.F.T. = SETPOINT + ½ x DIFFERENTIAL - 2 nd Cooling Step: E.F.T. = SETPOINT + ½ x DIFFERENTIAL rd Cooling Step: E.F.T. = SETPOINT + ½ x DIFFERENTIAL th Cooling Step: E.F.T. = SETPOINT + ½ x DIFFERENTIAL th Cooling Step: E.F.T. = SETPOINT + ½ x DIFFERENTIAL th Cooling Step: E.F.T. = SETPOINT + ½ x DIFFERENTIAL + 5 Each cooling step will be de-activated by the chiller controls when the entering fluid temperature (E.F.T.) will be equal to its temperature of activation (as shown above) minus the differential programmed by the user. The Envirochill chillers controls includes other functions such as; manual or automatic lead-lag switch-over of the refrigeration circuits (see SPECIAL SETTING MODE), delay on low pressure alarm on cooling demand to allow pressure build-up, delay (10 seconds) on loss of flow alarm, autoreset (max 3 attempts) for each alarm. 4

7 Table 1- ELECTRICAL DATA MAIN POWER 575V / 3PH / 60 HZ + MALT DESCRIPTION POWER Rated Load Amp (RLA) Compressor HP 52.0 A Compressor HP 52.0 A Transformers Control Board 350 VA 50 VA 0.35 A 0.05 A TOTAL A Chiller Ampacity (125% of the large motor + sum of additional loads) A Maximum recommended protection A 5

8 CONTROL PANEL INSTRUCTIONS Buttons: ON-OFF Selector Switch: When the selector switch is put in the ON position, the cooling mode operates on demand WATER IN temperature above set point. Output contacts J12-13, J12-14 and J12-15 are activated. The ON-OFF selector switch is wired to the terminals J13-23 / J13-24 on the electronic board. Push Buttons: MODE: Press on MODE button to go through the five display modes. For each mode, the numerical value is shown on the two-digit display. After 10 seconds, it automatically goes back to the default mode, WATER IN. UP/DOWN Arrows: Press on UP/DOWN arrows to set the value of the parameter (MODE) displayed. Please note that WATER IN and WATER OUT are for legible purposes only, and that the displayed values cannot be modified. Freezestat value can be set in the special setting mode see section on SPECIAL ADJUSTMENTS. MANUAL RESET: Press on MANUAL RESET to allow restarting of the chiller after the problem related to the alarm code is cleared. If the problem persists, the alarm code will come back on after releasing the MANUAL RESET Button. 6

9 LIGHT INDICATORS Modes SET POINT: Indicates the desired chilled water temperature of a thermal storage tank or the maximum entering water temperature (EWT). DIFFERENTIAL: The leeway on the set point - an adjustable parameter. If the set point is 50 F and the differential is 4 F, a water temperature between 48 F and 52 F is acceptable. The differential should be set to the highest value accepted by the process. FREEZESTAT: The lowest acceptable value for the WATER OUT temperature. This parameter is adjustable in the special setting mode. We suggest you set the Freezestat a few degrees above the freezing point of your cooling fluid. WATER IN: Displays the actual temperature of the water entering the chiller s evaporator. This value is compared to the set point value to activate or not the cooling steps. When a thermal storage tank is used, it is the temperature of the water supplied to the process. WATER OUT: Displays the actual temperature of the water leaving the chiller s evaporator. This value is compared to the freezestat setting. Please note that the WATER IN and the WATER OUT are for legible purposes only, and that the displayed values cannot be modified. Operating modes LED: COOLING: REMOTE DISABLED ON when the unit is cooling the process water. At least one compressor is in operation. ON when the contact auxiliary contact is open (Terminals TBD and/or J13-9 and J13-10 on electronic boards). All the motors are OFF. 7

10 ALARM CODES PLEASE NOTE that continuous each alarm condition will stop respective defective circuit or the complete chiller (refer to following table). The chiller controls includes an auto-reset procedure that allows re-activation of the defective circuit (or the chiller) if alarm condition disappear within few minutes. This procedure could be repeated a maximum of three(3) times within a period of thirty(30) minutes, after what, the chiller or the defective circuit will have to be reset manually once the problem has been corrected. A1 Loss of flow: TBF terminals of Control Panel are open (J13-13 / J13-14 on board) It must be opened for at least 10 seconds before the alarm goes off. This is especially useful when air bubbles are present in the system. No water flows into the evaporator. Clogged strainer, empty water tank, pump malfunction, air trapped in the fluid circuit A3 High Pressure Circuit 1: Board terminals J13-15/16 are open. Refrigerant pressure is too high at compressor discharge. Water temperature into condenser too high, load capacity too high, condenser need to be cleaned A5 Low Pressure Circuit 1: Board terminals J13-17/18 are open. Refrigerant pressure is too low at compressor suction. (On each call for cooling there is a delay of approximately 3 minutes before the alarm is activated. This allows pressure build-up on low ambient conditions). A7 Customer Alarm(s) circuit 1: Insufficient water flow into the evaporator, dirty evaporator, low refrigerant charge, no load, clogged filter drier, Board terminals J13-19/20 are open. These terminals are reserved for the connections of customer optional alarm devices that will stop cooling circuit 1 only. Please refer to shop drawings. As per customer alarm devices function. If no devices are connected please verify that the jumper is well in place. A2 Not used Board terminals J13-1/2 are open. Sometimes used to automatically stop the chiller when the chiller pump is overloaded. If no pump overload is not connected, verify if the jumper is well in place. A4 High Pressure Circuit 2: Board terminals J13-3/4 are open. Refrigerant pressure is too high at compressor discharge. Water temperature into condenser too high, load capacity too high, condenser need to be cleaned A6 Low Pressure Circuit 2: Board terminals J13-5/6 are open. Refrigerant pressure is too low at compressor suction. (On each call for cooling there is a delay of approximately 3 minutes before the alarm is activated. This allows pressure build-up on low ambient conditions). 8

11 A8 A9 Customer Alarm(s) circuit 2: Low Temperature: (Freezestat) Insufficient water flow into the evaporator, dirty evaporator, low refrigerant charge, no load, clogged filter drier, Board terminals J13-7/8 are open. These terminals are reserved for the connections of customer optional alarm devices that will stop cooling circuit 2 only. Please refer to shop drawings. Verify if the jumper is well in place. WATER OUT temperature is lower than Freezestat set value. Set point too low, insufficient water flow into the evaporator, dirty evaporator, defective pump A0 General Alarm: Board terminals J13-21/22 are open. These terminals are reserved for the connections of customer optional alarm devices that will stop the chiller. Please refer to electrical schematic included in Appendices C. Often used to report fan overload on chiller with built-in air cooled condenser. As per customer general alarm devices function. If no devices are connected please verify that the jumper is well in place. - - High Water Temperature WATER IN temperature is above 99 F or C. The chiller has been stopped for a long period or load was started before chiller. Note: If any of the above alarm conditions happen continuously, it is recommended to have the unit verified by a qualified technician. Contact MTL Technologies Inc. at (888) MTL-9959 as soon as possible. REMOTE COMMUNICATION Auxiliary Contact: TBD terminals are open (Board connections J13-9 / 10). When these terminals are open, the chiller stops and the disabled LED of control panel illuminates. It is therefore possible for the operator to easily control the start and stop of the chiller from a remote location Common Alarm Signal: TBP1 & TBP2 for NC contact. TBP3 & TBP2 for NO contact. Board connections J12-16/17/18. This relay is activated when one of the alarms goes off. The user could install a horn, a remote pilot light, a programmable controller or other, to remotely inform his personal that the chiller is in the alarm mode. 9

12 SPECIAL SETTING MODE This is a special setting mode used to set other parameters such as low temperature alarm (Freezestat) and manual or auto lead-lag sequence. Pushing and maintaining the MODE button on the membrane switch sticker for 5 seconds allows the technician to enter the special setting. Like the Mode button, this function allows the technician to go through the five modes. The flashing of the mode light indicates that the special setting mode is active. For each mode, a numerical value is shown on the two-digit display. These values are adjustable with two arrow keys. SPECIAL SETTING MODE PARAMETERS SET POINT: DIFFERENTIAL: FREEZESTAT: Unused variable. Lead-Lag Sequence of the circuits (compressors). Enter 1 = Compressor 1 «Lead» and Compressor 2 «Lag» Enter 2 = Compressor 2 «Lead» and Compressor 1 «Lag» Enter 3 to 99 to programmed the number of days of circuit operation between automatic switch-over of Lead-Lag sequence. Sets the freezestat value. WATER IN: Modulated Hot Gas step parameter usually set at 2 WATER OUT: Modulated Hot gas time parameter usually set at 2 SUPPLY Three wires are used to power the electronic board. Connection J11-3 receives +12V, connection J11-12 is grounded, and connection J11-1 receives 12V. RELAYS Six double throw relays (N.O and N.C.) control the operation of the chiller components such as the compressor(s) and the solenoid(s). They are connected as follows: Connections J12-7, J12-8 and J12-9 Cooling (Step 1) LED 1 Connections J12-4, J12-5 and J12-6 Cooling (Step 2) LED 2 Connections J12-1, J12-2 and J12-3 Cooling (Step 3) LED 3 Connections J12-10, J12-11 and J12-12 Cooling (Step 4) LED 6 Connections J12-13, J12-14 and J12-15 Cooling (Step 5) LED 5 Connections J12-16, J12-17 and J12-18 Cooling (Step 6) LED 4 Contacts should read as follows: N.O. (normally open), Common, N.C. (normally closed) 10

13 3800 ISABELLE, LOCAL D BROSSARD (QUÉBEC) J4Y 2R3 TÉLÉPHONE: (450) TÉLÉCOPIEUR: (450) MTL-9959