Installation & Maintenance Guide

Transcription

1 Ice Bear 30 Unit Installation & Maintenance Guide for models: IB30A-521 IB30A-523 IB30A-543 serial numbers: #xxxx20150 and higher Phone: (877) Fax: (970) F003_E Ice Energy, Inc., All Rights Reserved. 21Jun10

2 Industry Recognition CALIFORNIA TITLE Optional Compliance Measure Energy Efficiency Standards, 2006 Consortium of US Federal Labs WORLD S BEST TECHNOLOGIES, Gold Award, 2004 TOP-10 GREEN BUILDING Product of 2005 BuildingGreen Magazine FLEX YOUR POWER AWARD for Permanent Peak Power Shifting, 2007 ENERGY VENTURE FAIR Most Promising Company Award, 2003, 2004, 2005 ASHRAE / ARI AHR Expo Product of the Year, 2004 Energy Management Green Building Innovation Award 2009 NORTHERN COLORADO BUSINESS REPORT Innovative Business Award, 2005 Copyright, Notices, and Trademarks Ice Energy, Inc., All Rights Reserved. No reproduction/distribution without permission. While this information is presented in good faith and believed to be accurate, Ice Energy disclaims the implied warranties of merchantability and fitness for a particular purpose and makes no express warranties except as may be stated in its written agreement with and for its customers. In no event is Ice Energy liable to anyone for any indirect, special or consequential damages. The information and specifications in this document are subject to change without notice. Visit to ensure that you have the latest version. Ice Energy, Ice Bear and CoolData are registered trademarks and Ice-Ready, Ice-Coil, Ice Pack, and Ice Tray are trademarks of Ice Energy, Inc. Other brand or product names are trademarks of their respective owners. ii Ice Bear 30 Unit Installation & Maintenance Guide

3 Table of Contents Introduction... 1 Definitions of Terms... 1 A Few of the Unique Installation & Startup Considerations... 2 Ice Bear 30 Unit Ratings by Ton-hour... 3 About this Guide... 3 Ice Bear 30 Unit Components... 4 Modes of Operation... 7 CoolData Controller... 9 Features... 9 Control Schematic Control Configuration Example Ice Pack Overview Applications Typical Applications Sample Ice Bear Unit Configurations Pre-installation General Precautions & Responsibilities Required Tools/Accessories Transporting the Ice Bear Unit Installation Minimum Clearances Ice Bear 30 Unit Lifting Instructions Mounting Ice Pack Line Set, Ice Tray, and Control Wiring Filling Ice Storage Tank Electrical Connections Network Communication Kit CoolData Controller Connections Controller Program and Configuration File Post Installation Installation Checklist Monitoring Service Switch System Startup & Verification Sequence of Operation Pre-startup Safety Warnings Pre-startup Startup CoolData Controller LEDs Software Verification Maintenance General Maintenance Periodic Maintenance Low Ambient Operation Water Pump Cycling Fan Cycling Appendix A Product Specifications Appendix B Power Interface Panel Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation Ice Bear 30 Unit Installation & Maintenance Guide iii

4 List of Figures Figure 1 - Ice Bear Unit Exterior Components... 4 Figure 2 Ice Bear Unit Internal Components (Left Side)... 5 Figure 3 Ice Bear Unit Internal Components (Right Side)... 6 Figure 4 Refrigerant Flow Schematic Ice Charging Mode... 7 Figure 5 Refrigerant Flow Schematic Ice Cooling Mode... 8 Figure 6 CoolData Controller... 9 Figure 7 Control Schematic Figure 8 Single Zone, Single-stage Thermostat with Economizer and Backup Condensing Unit Figure 9 Ice Pack Components Figure 10 Ice Bear ` Unit (Parallel) with Ice-Ready Rooftop Unit Figure 11 Redundant (Parallel) Split System Figure 12 Ice Bear 30 Unit Forklift Slot Dimensions Figure 13 Ice Bear 30 Unit Lifting Points Figure 14 Required Spreader Bar Configuration Figure 15 Sample Typical Roof Mount Installation (Steel Support Structure) Figure 16 Sample Typical Roof Mount Installation (Wooden Support Structure) Figure 17 Ice Bear 30 Unit on Structural Curb with Cap Figure 18 Minimum Recommended Concrete Pad Dimensions Figure 19 Sample Precast Concrete Pad Figure 20 Sample Ice Pack Line Set, Ice Tray, & Control Wiring System Installation Figure 21 Ice Bear Unit Water Fill Level and Water Treatment Installation Figure 22 Upper Link-Seal Figure 23 Link-Seal Tightening Sequence Figure 24 Routing Power and Service Disconnect Switch Figure 25 Network Communication Kit Location Figure 26 Primary Communication Unit for One Ice Bear Unit Figure 27 Primary Communication Unit for Multiple Ice Bear Units Figure 28 PCU and SCU Serving Multiple Ice Bear Units Figure 29 CoolData Controller Components Figure 30 Service Switch Location Figure 31 Removing Compressor Shipping Spacers Figure 32 Refrigerant Service Ports Figure 33 Ice Bear Unit Rear & Side Views Figure 34 Ice Bear Unit Top View Figure 35 Ice Bear 30 Unit Dry Center of Gravity (Left) Figure 36 Ice Bear 30 Unit Dry Center of Gravity (Top) Figure 37 Ice Bear 30 Unit Wet Center of Gravity (Left) Figure 38 Ice Bear 30 Unit Wet Center of Gravity (Top) Figure 39 Power Interface Panel Schematic Figure 40 Sample Ice Pack Line Set, Ice Tray, and Control Wiring System Installation Figure 41 Securing Tray to Tubing Bracket (Horizontal) Figure 42 Securing Tray to Tubing Bracket (Vertical) Figure 43 Removing Quick Connect Protector Figure 44 Expanded 90 Elbow Figure 45 Same Level Line Set Application Figure 46 Ground/Rooftop Line Set Application Figure 47 Installing Line Set at Ice-Ready Rooftop Unit (Horizontal Orientation) Figure 48 Installing Line Set at Ice-Ready Rooftop Unit (Vertical Orientation) Figure 49 Installing Line Set at Ice Bear Unit Figure 50 Control Wiring Figure 51 T568B Connector Figure 52 Euro Style Connector Figure 53 CoolData Wiring Figure 54 Valve Locations Figure 55 Installing Straight Tray Covers Figure 56 Securing Covers at Ice-Ready Rooftop Unit Figure 57 Installing Elbow Covers iv Ice Bear 30 Unit Installation & Maintenance Guide

5 Introduction Introduction The ICE BEAR 30 unit is an off-the-shelf distributed energy storage system for use with direct expansion air conditioning units. The Ice Bear unit is designed to store energy at night and then shift the on-peak electrical energy of a condensing unit common to packaged rooftop, split, and mini-split systems. A typical application will shift the electrical energy consumed by a 5-ton scroll compressor and its associated condensing unit fans operating under full load conditions for 6 hours continuously. Electrically, the Ice Bear unit shifts approximately 30 kw-hours of energy to the off-peak, thus reducing the on-peak demand by about 6 kw for six hours. The Ice Bear unit runs its integral condensing unit for about 10 hours continuously, during the coolest part of the night, to store energy in the form of ice (30 latent ton-hours). The control signal from the thermostat or building management system is received by the Ice Bear unit s CoolData controller. Based on the time-of-day, or upon a command to shed electrical demand initiated by the utility, the controller determines if the Ice Bear unit or the electrically operated condensing unit will operate. In the case of the Ice Bear unit, it pumps enough oil free R-410A refrigerant to an Ice-Coil evaporator to provide effective cooling for up to 5 tons of continuous load for six hours, using less than 300 watts of power. A unique and important design feature is the Ice Bear unit s cooling performance independent of outdoor ambient or rooftop temperature; in other words, it can be 75 F or 140 F and the Ice Bear unit and its associated Ice-Coil s cooling performance (5-ton rating) is unchanged. Definitions of Terms Base System: A refrigerant based, direct expansion (DX) air conditioning system, commonly referred to as a packaged rooftop unit, split system, or mini-split system. A typical base system includes a condensing unit, an evaporator, a blower, and controls. Circuit A: The circuit associated with Ice Charging mode; includes compressor, condenser, and Refrigerant Management System (RMS). Circuit B: The circuit associated with Ice Cooling mode; includes RMS, ice storage tank, refrigerant & water pumps, and Ice-Coil. CoolData Interface Module (CIM): A printed circuit board that provides control interface between an Ice-Ready rooftop unit and the Ice Bear unit. Ice-Coil Kit: An Ice-Coil and ancillary equipment needed to convert a packaged rooftop unit into an Ice-Ready Rooftop Unit. Ice-Coil : A flooded evaporator coil provided by Ice Energy, or modified to Ice Energy s specifications. The Ice-Coil is dedicated to the Ice Bear unit and is sometimes referred to as a liquid overfeed evaporator coil. Ice Cooling: The process whereby the Ice Bear unit s stored ice cools the refrigerant used to provide cooling to a building space during peak energy hours (typically noon to 6pm). Ice Charging: The nighttime process by which the Ice Bear unit converts its tank of water into a tank of ice to be used for cooling the next day during the peak energy hours (typically noon to 6pm); also known as Ice Make. Ice Pack : Term used to describe the components that support the Ice Bear unit, including the Network Communication Kit (NCK), CoolData Interface Module (CIM), Ice Tray gutter system, line set, control wiring, and the optional Power Interface Panel (PIP). Ice-Ready Rooftop Unit: A packaged rooftop unit modified to include an Ice-Coil. Ice Bear 30 Unit Installation & Maintenance Guide 1

6 A Few of the Unique Installation & Startup Considerations Ice Tray : The gutter system used to enclose the line set and control wiring between an Ice Bear unit and an Ice-Ready rooftop unit. Multi-Stage System: A packaged rooftop unit, typically greater than 5 tons, that includes multiple independent refrigeration circuits, for example a 10-ton unit with two 5-ton circuits. Network Communication Kit (NCK): A kit, containing components such as a wireless router, antenna, and multi-port switch(es), designed to provide direct and exclusive communications from the field to Ice Energy servers. Peak Shifting: Shifting electric load from the utility defined on-peak period to the off-peak period. On- Peak hours are typically noon through 6 pm. Power Interface Panel (PIP): An electrical box that intercepts primary power from the dedicated circuit running to a packaged rooftop unit (RTU). The intent is to share a portion of the power that would typically run to the compressor(s). The PIP will lock out the target compressor to allow the Ice Bear unit to make ice during Ice Charging mode. Redundant Coil: The addition of an Ice-Coil to a packaged rooftop unit or split system. Summer Mode: The CoolData controller s programming is optimized to insure that stored cooling is available during peak energy hours. Standard Circuit: A common DX refrigeration circuit that includes an evaporator coil, expansion device, and condensing unit. Target Compressor: The compressor of a given base system (DX unit) that is locked out during onpeak cooling. Ton-hours: Capacity in tons times the number of hours (e.g., 5 tons for 6 hours = 30 ton-hours); an important design consideration for fixed capacity storage units such as the Ice Bear unit. Winter Mode: The CoolData controller is programmed to extend the Ice Cooling hours to more fully utilize the stored cooling capacity of the unit. A Few of the Unique Installation & Startup Considerations In addition to the Base System, an Ice-Coil must be used, which is typically a Redundant Coil. o A flooded evaporator coil is provided by Ice Energy, or modified to Ice Energy s specifications, or included as part of an Ice-Ready rooftop unit, whose sole purpose is to connect to the Ice Bear unit. Uniquely, an Ice-Coil does not use any type of expansion device (orifice, TXV, or EEV); hence the term liquid overfeed or flooded coil. A mixed phase of liquid and vaporized refrigerant may return to the Ice Bear unit. Length, Sizing, and Insulation of the refrigerant supply and return line sets. o The Ice Bear unit may be located on the ground or on the roof in close proximity to the Ice-Coil; there are distance and elevation limitations to consider. A unique feature of the Ice-Coil circuit is that it is charged with oil free R-410A refrigerant. o The liquid supply line from the Ice Bear unit to the Ice-Coil and the vapor return line from the Ice-Coil to the Ice Bear unit are uniquely sized to Ice Energy s design specifications. Both the liquid supply and the vapor return line sets must be insulated. When to fill with water and its associated weight o One of the last steps in the startup sequence is to fill the Ice Bear unit with about 450 gallons of tap water. When to fill the Ice Bear unit is important; filling too soon could cause significant and costly damage to the unit. 2 Ice Bear 30 Unit Installation & Maintenance Guide

7 Ice Bear 30 Unit Ratings by Ton-hour o The filled weight of the Ice Bear unit is an important consideration for both ground mount and roof mount applications. Remote Monitoring and Control o The Ice Bear unit is centrally monitored and may be controlled remotely. To enable this feature, the unit must be connected to the Ice Energy Network Operations Center by a Network Communication Kit (NCK). See the Network Communication Kit section for details. Heat Pumps o When applying an Ice Bear 30 unit to a heat pump, the Ice Bear unit must have a dedicated (redundant) Ice-Coil. o Additional control strategies vary based on RTU manufacturer. Ice Bear 30 Unit Ratings by Ton-hour Importantly, the Ice Bear unit has a limited amount of cooling capacity and therefore proper consideration of the building s cooling load profile is a critical step and must not be overlooked. The Ice Bear unit should not be used as the only source of cooling for typical office building, restaurant, and retail designs. Storage capacity: 30 ton-hours at a peak load of 5 tons o 5 tons for 6 hours, or 4 tons for 7.5 hours, or 3 tons for 10 hours Instantaneous output capacity is unaffected by ambient temperature About this Guide This installation guide is intended to provide basic product information, specifications, and general guidelines to assist in the installation and startup of the Ice Bear unit by persons with factory training certification. This guide is not intended to provide comprehensive instructions nor replace factory training. Consult your Ice Energy representative for additional information. Phone: (877) or (970) , Fax: (970) , productservices@ice-energy.com NOTE: Read and understand this entire manual before beginning installation. WARNING Before installing, modifying, or servicing the unit, the main electrical disconnect switch must be in the OFF position. Ice Bear 30 Unit Installation & Maintenance Guide 3

8 Ice Bear 30 Unit Components Ice Bear 30 Unit Components Ice Storage Tank Fan 2 Refrigerant Management System (RMS) Fan 1 Ice-Make Condensing Coil CoolData Controller Network Communication Kit (NCK) Low Voltage Control Wiring & Refrigerant Service Hose Control Wiring 7/8 Ice-Coil Return 1/2 Ice-Coil Supply Figure 1 - Ice Bear Unit Exterior Components 4 Ice Bear 30 Unit Installation & Maintenance Guide

9 Ice Bear 30 Unit Components Fan 2 CoolData Controller Electronic Expansion Valve (EEV) Ambient Temperature Sensor Service Switch Filter-Drier Refrigerant Pump (enclosed) 7/8 Ice-Coil Return 1/2 Ice-Coil Supply Control Wiring CoolData Controller Wiring Conduit Entrances Refrigerant Service Hose Entrances Figure 2 Ice Bear Unit Internal Components (Left Side) Ice Bear 30 Unit Installation & Maintenance Guide 5

10 Ice Bear 30 Unit Components Fan 1 Control Box (Main) Service Disconnect Switch Control Box External Fuse Location High Pressure (Safety) Manual Reset Compressor Compressor Liquid (High Side) Schrader Future Field Control Conduit Entrances Refrigerant Service Hose Entrances Figure 3 Ice Bear Unit Internal Components (Right Side) Compressor Suction (Low Side) Schrader Water Pump Tank Drain Valve Tank Overflow Drain Unit Power Conduit Entrance 6 Ice Bear 30 Unit Installation & Maintenance Guide

11 Modes of Operation Modes of Operation The Ice Bear unit is capable of operating in the following modes: Ice Charging mode o Night (off-peak) operation o Storing energy, charging, making ice Ice Cooling mode o Peak period operation (call for cooling) o Discharging the stored energy, melting the ice Ice Charging Mode (Circuit A) During Ice Charging (also known as Ice Make) mode, the integral and factory pre-charged Ice Bear condensing unit (R-410A refrigerant and miscible oil) provides low temperature refrigerant to the Ice Bear unit s Refrigeration Management System (RMS). On the secondary side of the RMS, a separate, oil-free R-410A charge automatically circulates through a heat exchanger until the tap water freezes into a solid block of ice. Ice Charging is typically 10 hours for a full 30 ton-hour charge and is made during the coolest time of night or when electrical utility rates are at their lowest, or off-peak times. Why Make Ice? It takes 1 BTU of energy to lower the temperature of one pound of water 1 F. For example, it takes 1 BTU of energy to lower the temperature of one pound of water from 38 F to 37 F. However, it takes 144 BTU s of energy to change the state of one pound of water from a liquid to a solid (ice). Therefore, it takes 144 BTU s of energy to change the state of one pound of 32 F water from a liquid into ice. The Ice Bear unit s block of ice is sized to store 30 ton-hours of energy. There are 12,000 BTU s per ton, so the 30 ton-hours of stored energy are equivalent to 360,000 BTU s. A 60,000 BTU/hour cooling load or exactly the cooling load of one 5-ton Ice Coil (12,000 BTU s / ton 5 tons) running for six hours would consume the entire Ice Charge or 360,000 BTU s of stored energy. Figure 4 Refrigerant Flow Schematic Ice Charging Mode Ice Bear 30 Unit Installation & Maintenance Guide 7

12 Modes of Operation Ice Cooling Mode (Circuit B) During Ice Cooling mode, the integral Ice Bear condensing unit is switched off and typically one 5-ton condensing coil on the Base System is locked out. The Ice Cooling circuit, which includes an ice-on-coil heat exchanger, a refrigerant pump, and Ice-Coil are physically isolated from the Ice-Make circuit and its refrigerant charge by a unique receiver/separator. When there is a request for cooling, a refrigerant pump circulates the oil-free liquid R-410-A refrigerant through the liquid supply line to an Ice-Coil located in the air stream. Typically this is a Redundant Ice-Coil installed into a packaged rooftop unit or a slab coil mounted in the air supply duct. The vapor return line returns vaporized or mixed phase refrigerant to the Ice Bear unit s ice-on-coil heat exchanger where it melts ice and is condensed back into its liquid state. Figure 5 Refrigerant Flow Schematic Ice Cooling Mode 8 Ice Bear 30 Unit Installation & Maintenance Guide

13 CoolData Controller CoolData Controller Features The CoolData controller is an advanced control system that provides both controlling and monitoring functions for the Ice Bear unit. Also, the CoolData controller has bidirectional control and communication capabilities for Smart Grid integration, including: configuration management real-time control advanced and optimal control real-time status, submetering, and monitoring performance analysis and automated diagnostics equipment health management event capture and analysis push and polling communications physical & cyber security data integrity readied for transactions with enterprise-level communication LED Indicators Figure 6 CoolData Controller Ice Bear 30 Unit Installation & Maintenance Guide 9

14 CoolData Controller Control Schematic Control Configuration Example Figure 7 Control Schematic Figure 8 Single Zone, Single-stage Thermostat with Economizer and Backup Condensing Unit 10 Ice Bear 30 Unit Installation & Maintenance Guide

15 Ice Pack Overview Ice Pack Overview The Ice Bear 30 system includes a number of additional components, collectively referred to as the Ice Pack, which provide installation and/or communications support. Ice Pack components, each delivered in the form of a kit (with accompanying installation instructions), include the following: Ice Tray includes trays, adapters, elbows, connectors, covers, and support blocks Line Set insulated, precharged 1/2 and 7/8 lines with quick connect fittings; prefabricated line sets in various lengths (e.g., 15, 25, and 50 feet) as well as custom lengths (up to 75 feet) Control Wiring necessary control wiring for communication between the Ice Bear unit and the Ice-Ready rooftop unit. CoolData Interface Module (CIM) a printed circuit board installed (per accompanying instructions) in the Ice-Ready rooftop unit that provides interface capabilities between the Ice- Ready rooftop unit and the Ice Bear unit Network Communication Kit (NCK) includes items such as antenna, router, and switches, which, together, provide bidirectional communication for one or more Ice Bear units Power Interface Panel (PIP) (optional) an electrical box that intercepts primary power from the dedicated circuit running to a packaged rooftop unit (RTU); see Appendix B Power Interface Panel for more details and application requirements Optional Power Interface Panel (PIP) CoolData Interface Module (CIM) Network Communication Kit (NCK) Ice Tray, Line Set, Control Wiring Figure 9 Ice Pack Components Ice Bear 30 Unit Installation & Maintenance Guide 11

16 Applications Applications Typical Applications Single zone Single Ice Bear unit or multiple Ice Bear units Partial storage system in a multi-stage configuration (displacing one stage of a multi-stage system) NOTE: When applying an Ice Bear 30 unit to a heat pump, the Ice Bear unit must have a dedicated (redundant) Ice-Coil. Sample Ice Bear Unit Configurations Ice Bear unit (parallel) with Ice-Ready rooftop unit Redundant (parallel) split system Ice Bear Unit (Parallel) with an Ice-Ready Rooftop Unit The Ice Bear unit can be integrated with a modified packaged rooftop unit called an Ice-Ready rooftop unit. The Ice-Ready rooftop unit, illustrated in the figure below, is a standard rooftop unit that has been modified to include an additional liquid overfeed evaporator coil (Ice-Coil ) that is dedicated to the Ice Bear unit. Figure 10 Ice Bear ` Unit (Parallel) with Ice-Ready Rooftop Unit 12 Ice Bear 30 Unit Installation & Maintenance Guide

17 Applications Redundant (Parallel) Split System In a redundant split system, the Ice Bear unit is part of a separate and parallel redundant refrigerant loop. It is only designed to take on a load for a designated period of time. The liquid overfeed coil (connected to the Ice Bear unit) is placed downstream of the existing or regular standard DX coil. The Ice Bear unit handles the designated load during peak load conditions, while the rest of the system handles the cooling load during the remainder of the day. Figure 11 Redundant (Parallel) Split System Ice Bear 30 Unit Installation & Maintenance Guide 13

18 Pre-installation Pre-installation General Precautions & Responsibilities Installation by anyone other than an Ice Energy-certified installer voids warranty. Consult with structural engineer where applicable. Comply with existing governmental electrical codes. In the absence of local codes, the installation must conform to the National Electrical Code (NEC), ANSI/NFPA 70, as amended. Comply with EPA proper refrigerant handling & transportation practices. Adhere to the minimum and maximum air flow limits for condensing units and evaporator coils. Ensure that: o Existing mechanical equipment has been evaluated for performance and level of maintenance. Document your findings. o The cooling system design has been reviewed and approved by the appropriate heating, venting and air conditioning system designer. o The building s existing electrical system will accommodate the additional equipment. o All permits required for installation have been obtained from the appropriate authority having jurisdiction. Refer to the Network Communication Kit section in this manual when considering the placement of Ice Bear units with regard to network communications. Required Tools/Accessories digital micron vacuum gauge vacuum pump (6.5 CFM minimum) electronic refrigerant leak detector potable water supply brazing equipment 14 Ice Bear 30 Unit Installation & Maintenance Guide

19 Pre-installation Transporting the Ice Bear Unit Forklift slots are located on the bottom of the ICE BEAR UNIT. See Figure 12 for dimensions. Figure 12 Ice Bear 30 Unit Forklift Slot Dimensions Forks must be a minimum of 4 ft. long to properly accommodate the Ice Bear unit. Ensure that all lids and covers are bolted securely before transporting. When moving the Ice Bear unit using a crane or boom truck, refer to Ice Bear 30 Unit Lifting Instructions later in this manual. See Appendix A Product Specifications for weights, overall dimensions, and center of gravity dimensions. Ice Bear 30 Unit Installation & Maintenance Guide 15

20 Installation Installation Minimum Clearances In addition to the minimum clearances depicted in the figures below, ensure that a 60 vertical clearance exists to provide for proper CONDENSER FAN operation. NOTE: Local codes/regulations may prevail. 16 Ice Bear 30 Unit Installation & Maintenance Guide

21 Installation Ice Bear 30 Unit Lifting Instructions The lifting instructions below provide a safe, level lift that also protects the integrity of the equipment. CAUTION: Any lifting method other than the technique described below may cause damage to the exterior components of the unit. Ice Energy is not responsible for any damage caused by alternative lifting techniques (i.e., damage is not covered by the product warranty). NOTE: Use 2 or 3 wide nylon straps only. Steel choker cables will damage unit sides. This method involves using a 10 spreader bar and two cross bars in an H configuration (see Figure 14). 1. Attach (4) SHACKLES and LIFT STRAPS (10 long) using lifting points called out in Figure Attach other ends of LIFTING STRAPS to SHACKLES located on the crane s spreader bar. Ice Energy recommends a 10 spreader bar in an H configuration with two 6-8 bars running perpendicular (see Figure 14). 3. Adjust spreader bar so that LIFTING STRAPS do not touch the ICE BEAR UNIT. 4. Lift the ICE BEAR UNIT approximately 6 high to check leveling from side to side and back to back. 5. Lift the ICE BEAR UNIT, as appropriate. Lifting Points Figure 13 Ice Bear 30 Unit Lifting Points Ice Bear 30 Unit Installation & Maintenance Guide 17

22 Installation Figure 14 Required Spreader Bar Configuration 18 Ice Bear 30 Unit Installation & Maintenance Guide

23 Installation Mounting Preparation Follow structural drawings for proper location of the ICE BEAR UNIT. Consult a Structural Engineer. Provide leveling in compliance with local codes for clearance, easements, and soil compaction restrictions. The ICE BEAR UNIT must be level to within 1/8" in all directions. See Minimum Clearances section of this manual for minimum access clearances. See Appendix A Product Specifications for wet (water-filled) center of gravity dimensions. Consult local codes for any required seismic restraints. Rooftop Mounting 1. Lift the assembly up to the building s rooftop following the Ice Bear 30 Unit Lifting Instructions in this manual. 2. Position ICE BEAR UNIT over structural curb with cap (see Figure 17). 3. Remove SHACKLES and LIFTING STRAPS from the UNIT. 4. Secure ICE BEAR UNIT per local code. See Figure 15 for an illustration of a typical rooftop installation (steel support structure). NOTE: This is only an example. Local codes/regulations may prevail. Consult a structural engineer. Ice Bear 30 Unit Installation & Maintenance Guide 19

24 Installation Figure 15 Sample Typical Roof Mount Installation (Steel Support Structure) 20 Ice Bear 30 Unit Installation & Maintenance Guide

25 Installation See Figure 16 for an illustration of a typical rooftop installation (wooden support structure). NOTE: This is only an example. Local codes/regulations may prevail. Consult a structural engineer. Figure 16 Sample Typical Roof Mount Installation (Wooden Support Structure) Ice Bear 30 Unit Installation & Maintenance Guide 21

26 Installation Figure 17 illustrates an ICE BEAR UNIT mounted on a structural curb with cap. Contact Ice Energy for details. NOTE: This is only an example. Local codes/regulations may prevail. Consult a structural engineer. Figure 17 Ice Bear 30 Unit on Structural Curb with Cap Ground Mounting A concrete pad or other approved surface may be used, as designed and reviewed by a licensed structural engineer. See Appendix A Product Specifications for ICE BEAR UNIT weights and dimensions. See Figure 18 for minimum recommended pad dimensions. Figure 19 provides a sample drawing of a precast concrete pad. NOTE: Local codes/regulations may prevail. Consult a structural engineer. 22 Ice Bear 30 Unit Installation & Maintenance Guide

27 Installation Concrete Pad Ice Bear Unit Base Figure 18 Minimum Recommended Concrete Pad Dimensions CAUTION If a concrete pad is installed directly against building s foundation, an approved expansion joint must be installed to prevent possible noise transfer. Ensure that roof drainage system does not undermine the ICE BEAR UNIT s foundation and that ALL gutters and downspouts are properly placed and secured. Ice Bear 30 Unit Installation & Maintenance Guide 23

28 Installation Figure 19 Sample Precast Concrete Pad NOTE: Local codes/regulations may prevail. Consult a structural engineer. 24 Ice Bear 30 Unit Installation & Maintenance Guide

29 Installation Ice Pack Line Set, Ice Tray, and Control Wiring The Ice Pack line set, Ice Tray and control wiring system has been developed to support the overall Ice Bear system by offering weather protection for line sets and wiring and providing a neater installation appearance. Figure 20 depicts a sample Ice Pack line set, Ice Tray, and control wiring system. Note that your layout may differ from that shown in Figure 20. Figure 20 Sample Ice Pack Line Set, Ice Tray, & Control Wiring System Installation Please refer to Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation for instructions on installing the Ice Pack line set, Ice Tray, & control wiring system. See Appendix B Power Interface Panel for installation instructions for the optional Power Interface Panel. Ice Bear 30 Unit Installation & Maintenance Guide 25

30 Installation Filling Ice Storage Tank 1. Remove internal packaging, such as foam SHIPPING BLOCKS and CARDBOARD INSERTS from ICE STORAGE TANK. 2. Fill the ICE STORAGE TANK with potable water to the bottom of the top PIPE on the HEAT EXCHANGER (see Figure 21). Be sure drainage is in compliance with state/local codes and regulations. NOTE: Do not fill the ICE STORAGE TANK with water when the system is under a vacuum. Figure 21 Ice Bear Unit Water Fill Level and Water Treatment Installation 3. Add provided biocide to the ICE STORAGE TANK while it is filling. 4. Add provided WATER TREATMENT COMPOUND by hanging pouch (looping cord and passing pouch through loop) on the WATER DISTRIBUTION BRACKET as indicated in Figure Ice Bear 30 Unit Installation & Maintenance Guide

31 Installation Link-Seal Adjustments During transit of the ICE BEAR UNIT, it is possible for LINK-SEALS surrounding the upper and lower COLLECTION HEADERS to loosen, causing leakage. If you notice any water leaking from the LINK- SEALS, follow the procedure below to ensure proper sealing. 1. Within the Refrigeration Management System (RMS) area, compress (or remove, if necessary) INSULATION blocking access to upper and lower COLLECTION HEADERS (see Figure 22 for an illustration of the LINK-SEAL surrounding the upper COLLECTION HEADER). Figure 22 Upper Link-Seal 2. Use a 3/8 drive inch-pound torque wrench (with a 6 long 5/32 ball-point hex-bit socket) to tighten in even increments all LINK-SEAL SCREWS in the sequence shown in Figure 23. Starting point is not critical. Final torque should be 20 in-lb. DO NOT tighten more than four turns at a time. NOTE: Be careful not to over torque the LINK-SEAL SCREWS. Figure 23 Link-Seal Tightening Sequence 3. Reinstall INSULATION when done. Ice Bear 30 Unit Installation & Maintenance Guide 27

32 Installation Electrical Connections Power Service Requirements Model System Type Minimum Circuit Ampacity Maximum Fuse IB30A /230V, 1φ 41.7 A 50 A IB30A /230V, 3φ 27.2 A 30 A IB30A V, 3φ 13.3 A 20 A Refer to the electrical schematic located inside the unit s electrical control box, or see the resources page at Note that electrical schematics are subject to change and do not reflect customizations performed by field technicians. Line Power Connections All electrical wiring, conduit, ancillary components and workmanship must comply with state and local electrical code requirements, as well as the NEC ANSI/NFPA 70, as amended. Use only copper conductors. NOTE: Depending on the installation site, a POWER INTERFACE PANEL may be used as an alternate solution to costly electrical service upgrades. The POWER INTERFACE PANEL is available as an orderable kit. See Appendix B Power Interface Panel, for more information. Grounding WARNING The ICE BEAR UNIT must have an uninterrupted electrical ground to minimize the possibility of personal injury if an electrical fault should occur, in accordance with NEC National Electrical Code (NEC), ANSI/NFPA 70 (as amended), or equivalent, and local electrical codes. Failure to adhere to this warning could result in personal injury or death. Figure 24 Routing Power and Service Disconnect Switch 28 Ice Bear 30 Unit Installation & Maintenance Guide

33 Installation Network Communication Kit The Network Communication Kit (NCK) provides bidirectional communication for one or many Ice Bear units at a given installation site. NCKs enable communication for the following purposes: commissioning diagnostics monitoring control The figure below indicates the location of a NCK within an Ice Bear unit. Network Communication Kit There are two types of NCKs (discussed below): Primary Communication Unit (PCU) Secondary Communication Unit (SCU) Figure 25 Network Communication Kit Location Primary Communication Unit (PCU) As indicated by its name, the PCU provides the primary or central communication networking between the Ice Bear unit in which it is installed and all the other (if any) Ice Bear units within its network at an installation site. Each PCU must be activated by Ice Energy Product Services at least two days prior to system startup. Ice Bear 30 Unit Installation & Maintenance Guide 29

34 Installation A PCU includes the following components: power supply antenna router box mounting brackets (internal and external) between (0) and (2) switches Each installation site (building) requires a minimum of one PCU. The number of required switches within the PCU depends on the number of Ice Bear units installed at a given site. If there is only one Ice Bear unit installed at the site, then no switch is necessary. Beyond that, one or two switches may be required based on the number of Ice Bear units. The figure below illustrates the PCU configuration for a single Ice Bear unit installation. Figure 26 Primary Communication Unit for One Ice Bear Unit Note that one PCU can support up to seven Ice Bear units (each depicted by a COOLDATA CONTROLLER in the following figure) without the use of a Secondary Communication Unit (SCU). Do not exceed 300 ft for any one CAT5e cable. Including SCUs, a maximum of 15 ICE BEAR UNITS are supported per PCU. 30 Ice Bear 30 Unit Installation & Maintenance Guide

35 Installation Figure 27 Primary Communication Unit for Multiple Ice Bear Units As indicated in Figure 27, wiring can be extensive and limited when wiring directly from each Ice Bear unit to the PCU. Using SCUs, you can achieve greater flexibility with less wiring. Ice Bear 30 Unit Installation & Maintenance Guide 31

36 Installation Secondary Communication Unit (SCU) An SCU differs from a PCU in that the SCU does not include a router or an antenna. An SCU contains the following components: power supply box mounting brackets (internal and external) between (1) and (3) switches The SCU enables a PCU to serve more Ice Bear units by daisy chaining units through the use of its switch(es). Rather than an installation site being limited to seven Ice Bear units by hardwiring each unit to the PCU, the SCU provides much more flexibility. See the figure below for an illustration of how SCUs can be used with a PCU to serve many Ice Bear units at an installation site. Figure 28 PCU and SCU Serving Multiple Ice Bear Units NOTE: Do not exceed 300 ft for any one CAT5e cable. Including SCUs, a maximum of 15 ICE BEAR UNITS are supported per PCU. 32 Ice Bear 30 Unit Installation & Maintenance Guide

37 Installation Model numbers for NETWORK COMMUNICATION KITS as follows: PCU PNs: o o PCU-3FP: PCU with 3 free ports PCU-6FP: PCU with 6 free ports SCU PNs: o o o SCU-3FP: SCU with 3 free ports SCU-6FP: SCU with 6 free ports SCU-9FP: SCU with 9 free ports Installation instructions are included with each NCK. Ice Bear 30 Unit Installation & Maintenance Guide 33

38 Installation CoolData Controller Connections LED Indicators LAN Connection Point Field Wiring Connection Points Figure 29 CoolData Controller Components NOTE: Refer to Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation for details on control wiring. Minimum Requirements for Connection of CoolData Controller Wiring The below items are the minimum requirements for basic common installations. Depending on the scope of a given installation, additional wiring may be required. Consult plans and engineering drawings to determine actual requirements. Contact Ice Energy Product Services (call or productservices@ice-energy.com) if you have questions. Conform to engineering layout drawings showing locations of wiring and thermostat. Document deviations in the Ice Bear 30 System Commissioning Report (F155-F160). 34 Ice Bear 30 Unit Installation & Maintenance Guide

39 Post Installation Use one #18AWG insulated 8 conductor cable and one unshielded (UTP) CAT5e cable between each monitored base system and the ICE BEAR UNIT. If an alternate data service connection is required, use one CAT5e cable between the ICE BEAR UNIT and the alternate data service (Internet) location. Refer to the CoolData electrical schematic located inside the CoolData CONTROLLER BOX, or see the resources page at Controller Program and Configuration File The ICE BEAR 30 UNIT includes multiple software-related components, including: Controller program controls the overall system operation and communication. If an Internet connection is available, the ICE BEAR UNIT will automatically connect to the Ice Energy server and check for program updates. Configuration files define the specific configuration for a given unit, including parameters for date/time as well as charging/cooling time periods used to optimize the product with regard to utility rates. The configuration file also includes sensor setup information. Configuration Web pages provide a way to facilitate entry and modification of settings. Currently, you must contact Ice Energy Product Services (call or productservices@ice-energy.com) to ensure that your system has the appropriate software components based on your specific installation. Post Installation Installation Checklist The following is a typical project checklist for reference purposes only. It is not intended to be all inclusive. Item Description 1. Secure required permits for project. 2. All components, tools, & equipment received and ready. 3. Site preparations completed. 4. ICE BEAR UNIT placed and unpacked. 5. New line sets installed, leak tested, & insulated. Are ICE-COIL supply and return lines insulated? 6. Finish roofing, as applicable (prior to filling TANK). 7. Fill TANK with water, add biocide, check LINK-SEALs. 8. Electrical power connections made. 9. Thermostat wiring connections made. 10. Secure lids & doors. 11. Site clean-up & removal of materials. 12. Complete Ice Bear 30 System Commissioning Report (F155-F160). 13. Ensure that SERVICE SWITCH is in the AUTO position. 14. Outstanding field issues: Ice Bear 30 Unit Installation & Maintenance Guide 35

40 Service Switch Monitoring If applicable, the following monitoring related tasks should be performed. Item Description 1. Activate Primary Communication Unit (PCU). 2. All SENSORS mounted and installed. 3. CoolData CONTROLLER configured to include additional sensors. 4. Verified all sensor readings. 5. Verified CoolData connectivity with Ice Energy Product Services. 6. Completed Ice Bear 30 System Commissioning Report (F155-F160). 7. Posted completed Monitoring Information form on Ice-Gate. NOTE: All installation details and system modifications must be accurately and completely documented in the project Ice Bear 30 System Commissioning Report (forms F155-F160). Include data gathered from the testing of Ice Charging and Ice Cooling modes. Service Switch The SERVICE SWITCH allows a technician to switch modes for the purpose of servicing the unit (see Figure 30 for location). The SERVICE SWITCH provides three service modes: BYPASS MODE allows the cooling signal to go directly to the existing/base equipment (thereby bypassing the ICE BEAR UNIT). AUTO MODE allows the cooling signal to go directly to the ICE BEAR UNIT s CoolData CONTROLLER. The CoolData CONTROLLER then decides the appropriate course of action (based on time, ice availability, and on-board programming). AUTO MODE is the normal operation mode for the system. OFF WARNING This mode does NOT disable line voltage. This mode only disables cooling control signals going through the CoolData CONTROLLER. All other functions will continue to operate. Follow approved servicing and maintenance procedures for all equipment; i.e., lockout/tagout procedures. SERVICE SWITCH Figure 30 Service Switch Location 36 Ice Bear 30 Unit Installation & Maintenance Guide

41 System Startup & Verification System Startup & Verification Sequence of Operation The ICE BEAR UNIT is thermostatically controlled in the same manner as a conventional DX system. The controller for the ICE BEAR UNIT regulates the refrigerant and the UNIT s internal components similarly to a conventional DX air conditioning system. When a packaged unit is equipped with an economizer, the economizer and the HVAC system will operate normally in collaboration with the ICE BEAR UNIT. The ICE BEAR UNIT s programmable controller responds to a single- or two-stage thermostat input. Either configuration allows the ICE BEAR UNIT to control the base system (allowing DX cooling during Ice Charging, for example). With a two-stage input, the ICE BEAR UNIT and the additional system may be set up to provide cooling simultaneously; whereas, with a single-stage input, only one system will provide cooling at any given time. A single stage DX system connected to an ICE BEAR UNIT is referred to as the backup system. In a two-stage DX system with matching thermostat, the second DX system is referred to as a parallel system. The programming for the ICE BEAR UNIT s internal controller is based on the desired Ice Charging and Ice Cooling operations. The ICE BEAR UNIT can be configured to provide Ice Cooling for any period of time consistent with the maximum cooling capacity, tank charge capacity, and tank recharge requirements. The desired operating schedules are set prior to shipment or by a certified installer in the field and can, if required, be reprogrammed remotely for optimization purposes. The ICE BEAR UNIT integrates with facility control systems and simple thermostats through traditional 24VAC signals, both for control and status feedback. No other communications to a facility management system are required. The ICE BEAR UNIT is unique as an energy storage device in that it is a fully packaged, self-contained system. As such, it optimizes its performance independently of a facility management system. Integration for Supervisory Control and Data Access (SCADA), additional monitoring, and other advanced features are viable, but are not part of the standard offering. For California Title 24 compliance applications, the programming is unalterable and operates within the parameters of the specified product model. Control parameters are given at the factory. Charging (Ice Charging Mode) Startup Sequence 1. FAN #1 starts and the ELECTRONIC EXPANSION VALVE (EEV) is reset. (Charging LED blinks once.) 2. There is a 4 second delay. 3. FAN #2 starts. 4. Initial EEV position is set. 5. There is a 26 second delay. 6. Superheat set point is derived from the Condenser liquid temperature. 7. COMPRESSOR starts. (Charging LED blinks 3 times). 8. There is a 10 second delay. 9. EEV will start to control the system. (Charging LED is on solid.) Ice Bear 30 Unit Installation & Maintenance Guide 37

42 System Startup & Verification Full Charge Cutoff Sequence 1. Upon reaching charge cutoff pressure (typically 98.5 psia), the charging operation shuts down after 5 minutes. 2. The EEV is set to the closed position. Cooling (Ice Cooling Mode) Startup Sequence (call for cooling) 1. REFRIGERANT PUMP and SOLENOID VALVE are energized and WATER PUMP starts. 2. REFRIGERANT PUMP is initially set to minimum speed. (Cooling LED repeatedly blinks twice.) 3. There is a 10 second delay. 4. REFRIGERANT PUMP is set to its final speed. (Cooling LED on solid until call for cooling ends, ice is exhausted, or system transitions out of the configured ice cooling time window, as determined by unit s specific configuration.) Shutdown Sequence (no call for cooling) 1. WATER and REFRIGERANT PUMPS shut down. 2. There is a 15 second delay. 3. Individual zone relay is closed. Full Discharge Cutoff Sequence 1. Discharge cutoff condition is achieved; i.e., cutoff pressure is reached (typically 165 psia) or the TANK water reaches a temperature of 48 F (typical). 2. There is a 5 minute delay. 3. REFRIGERANT and WATER PUMPs are shut down. 4. There is a 15 second delay. 5. Individual zone relays are closed, if defined. 38 Ice Bear 30 Unit Installation & Maintenance Guide

43 System Startup & Verification Pre-startup Safety Warnings Failure to observe the following warnings could result in serious personal injury. WARNING 1. Follow recognized safety practices and wear protective eyewear when checking or servicing refrigerant system. 2. Do not operate the COMPRESSOR or provide any electrical power to the unit unless the COMPRESSOR TERMINAL COVER is in place and secured. 3. Do not remove the COMPRESSOR TERMINAL COVER until all electrical sources are disconnected. 4. Relieve all pressure from the system before touching or disturbing anything inside the COMPRESSOR TERMINAL BOX if a refrigerant leak is suspected near the COMPRESSOR TERMINALS. 5. Never attempt to repair a soldered connection while the refrigerant system is under pressure. 6. Do not use a torch to remove any component. The system contains oil and refrigerant under pressure. To remove a component, wear protective eyewear and proceed as follows: a. Shut off electrical power to the unit. Install lockout tag. b. Relieve all pressure from the system using both high-pressure and low-pressure ports. c. Cut the component connection tubing with a tubing cutter, and remove the component from the unit. d. Carefully unsweat the remaining tubing stubs when necessary. Oil can ignite when exposed to torch flame. Pre-startup Proceed as follows to inspect and prepare the unit for initial startup. 1. Remove all access DOORS. 2. Verify that the voltage supplied is the same as the unit s nameplate rating. 3. Read and follow instructions on all WARNING, CAUTION, and informational labels attached to, or shipped with, the ICE BEAR UNIT. 4. Remove (4) COMPRESSOR SHIPPING SPACERS from under COMPRESSOR (loosen BOLTS, remove C WASHERS, remove SPACERS from under COMPRESSOR, and retighten BOLTS). See Figure 31. Ice Bear 30 Unit Installation & Maintenance Guide 39

44 System Startup & Verification COMPRESSOR REMOVE C WASHERS (4X) REMOVE COMPRESSOR SHIPPING SPACERS (4X) RETIGHTEN BOLTS (4X) Figure 31 Removing Compressor Shipping Spacers 5. Make the following inspections: a. Inspect for shipping and handling damage such as broken lines, loose parts, or disconnected wires, etc. b. Inspect for oil at all refrigerant TUBING connections and on ICE BEAR UNIT BASE. Detecting oil generally indicates a refrigerant leak. Leak test all refrigerant TUBING connections using an electronic leak detector or liquid soap solution. c. Inspect all field wiring and factory wiring connections. Ensure that connections are completed and tight. d. Inspect COIL FINS. If damaged during shipping and handling, carefully straighten the FINS with a fin comb. 6. Verify that all tools and loose parts have been removed. Startup Unit Preparation Ensure that unit has been installed in accordance with these installation instructions and applicable codes. Be sure to complete the pre-startup checklist in the Ice Bear 30 System Commissioning Report (F155- F160). 40 Ice Bear 30 Unit Installation & Maintenance Guide

45 System Startup & Verification Refrigerant Service Ports To access refrigerant SERVICE PORTS, remove COMPRESSOR ACCESS DOOR (see Figure 3). The system has (2) Schrader-type SERVICE GAUGE PORTS: (1) on the SUCTION LINE and (1) on the LIQUID LINE. After servicing, ensure that CAPS on the PORTS are tight. Fan 1 Control Box (Main) Service Disconnect Switch Control Box External Fuse Location High Pressure (Safety) Manual Reset Compressor Compressor Liquid (High Side) Schrader Future Field Control Conduit Entrances Figure 32 Refrigerant Service Ports Refrigerant Service Hose Entrances Compressor Suction (Low Side) Schrader Water Pump Tank Drain Valve Tank Overflow Drain Unit Power Conduit Entrance NOTE: COMPRESSOR side and TANK side are factory charged. Compressor Rotation On three-phase ICE BEAR UNITs with scroll COMPRESSORS, it is important to be certain that COMPRESSOR is rotating in the proper direction. To determine whether or not COMPRESSOR is rotating in the proper direction: 1. Connect service gauges to suction and discharge pressure fittings. 2. Before powering up the unit, ensure that the SERVICE SWITCH is in Bypass Mode. Ice Bear 30 Unit Installation & Maintenance Guide 41

46 System Startup & Verification 3. Energize the COMPRESSOR by attaching a JUMPER from pin 7 to pin 1, 2, 3, or 4 on the digital input connector. After verification, remove JUMPER. NOTE: CONDENSER FANS will run 30 seconds before COMPRESSOR engages. 4. The suction pressure should drop and the discharge pressure should rise, as is normal on any startup. If the suction pressure does not drop and the discharge pressure does not rise to normal levels: 1. Turn off power to unit and install lockout tag. 2. Reverse any two of the unit POWER LEADS. 3. Reapply power to unit. Reenergize COMPRESSOR. The suction and discharge pressure levels should now move to their normal startup levels. NOTE: When the COMPRESSOR is rotating in the wrong direction, the unit will make an elevated level of noise and the REFRIGERATION MANAGEMENT SYSTEM will fail to operate. 42 Ice Bear 30 Unit Installation & Maintenance Guide

47 System Startup & Verification Final Startup Steps 1. Install additional monitoring SENSORS (e.g., supply & return air temperature, air handler work, building power, cooled area temperature). 2. Update configuration file to include monitoring SENSORS (contact Ice Energy Product Services for assistance). 3. Load configuration file (contact Ice Energy Product Services for assistance). 4. Set SERVICE SWITCH to Auto Mode. See CoolData Controller LED Codes section below. CoolData Controller LEDs Reference the following information for CoolData CONTROLLER LED descriptions: LED POWER STATUS CHARGING COOLING ERROR LAN CONNECT LAN ACTIVITY Description Lit when power is supplied to the CoolData CONTROLLER. Blinks when indicating the current system status. This LED will not indicate error status (see following section, CoolData Controller LED Codes). Blinks if the system is in the process of making ice. This may include delays where no activity is apparent. Blinks if the system is in the process of providing cooling by melting ice. This may include delays where no activity is apparent.. Blinks to indicate the current error code (see following section, CoolData Controller LED Codes). Lit if the ICE BEAR UNIT is connected to a Local Area Network (LAN). Blinks if network activity is present. Ice Bear 30 Unit Installation & Maintenance Guide 43

48 System Startup & Verification CoolData Controller LED Codes LED Activity Description STATUS CHARGING (ICE MAKE) COOLING (ICE COOLING) ERROR 1 blink Idle 2 blinks ICE BEAR UNIT active, backup system inactive (Ice Charging / Ice Cooling state determined by other LEDs) 3 blinks ICE BEAR UNIT may be active, backup system is active (Ice Charging / Ice Cooling state determined by other LEDs) Off Idle 1 blink COMPRESSOR short cycle delay (5 min) or Charging delay (based on estimated charging time). Temperature is determined during final 30 seconds of delay. 3 blinks Startup control delay of 10 seconds On Off Actively Charging Idle 1 blink SOLENOID VALVE open delay 2 blinks REFRIGERANT PUMP running at minimum output for 10 seconds On Actively providing Ice Cooling. REFRIGERANT PUMP runs at configured output. 1 blink Ice Charging not allowed 2 blinks Ice Cooling not allowed 3 blinks Ice Charging and Ice Cooling not allowed 4 blinks Bypass active 5 blinks System disabled Software Verification Confirm that the CoolData CONTROLLER software program version matches the software configuration associated with the unit s model number (TDV units only). The proper operating program should already be loaded into the ICE BEAR UNIT s programmable CoolData CONTROLLER (TDV units only). Contact Ice Energy Product Services to verify the latest revision of the CoolData CONTROLLER software. CAUTION Keep in mind that time delays may exist in the CoolData CONTROLLER program and the COMPRESSOR control circuit. CAUTION During the verification process, the installer must closely observe the charging manifold gauges for signs of abnormal operating conditions. WARNING In the case of inclement weather or high winds, to prevent damage and/or injury, secure the TANK LID, FAN LID ASSEMBLY, and UNIT DOORS. 44 Ice Bear 30 Unit Installation & Maintenance Guide

49 Maintenance Maintenance General Maintenance Ice-Coil Follow industry standards for service and maintenance of evaporator coils. Condensate Drain Check and clean each year at the start of cooling season. In winter, keep drain dry or protect against freeze-up. Condenser Coil Keep CONDENSER COIL fins clean and inside of CONDENSER free of debris, following standard practices. Maintaining Adequate Water Level Inspect water level annually. If necessary, fill ICE BEAR UNIT STORAGE TANK with tap water to the bottom of the top PIPE shown in Figure 21. Periodic Maintenance When performing a service call on an ICE BEAR UNIT, use each of the following lists as reminders on what to check. Interval During each service/maintenance call, or at a minimum, annually Annually As needed Maintenance Required Verify CoolData CONTROLLER program, including time/date (daylight savings, if applicable). Cycle all applicable modes of operation (Ice Charging, Ice Cooling). Verify operating pressures (during Ice Charging). Check electrical connections. Check and record Amp draws of ICE BEAR 30 UNIT and corresponding DX unit. Visually inspect FAN BLADES. Visually inspect overall system (look for leaks, inspect FAN BLADES, inspect INSULATION & PIPING, etc.). Check operation of REFRIGERANT PUMP and WATER PUMP. Check water level in TANK; top off water level if necessary to the bottom of top PIPE, shown in Figure 21. Add water treatment. Suggested biocides: MB-10 (Quip Laboratories Inc.) two (2) 6 gram tablets #90 Algaecide (Nu-Calgon) two (2) tablets for clean water; five (5) tablets for fouled water Oil CONDENSER FAN MOTOR BEARINGS, if applicable. Clean CONDENSER COIL. Ice Bear 30 Unit Installation & Maintenance Guide 45

50 Low Ambient Operation Low Ambient Operation The ICE BEAR UNIT s ICE STORAGE TANK is insulated to prevent excessive system freezing. The ICE BEAR UNIT also includes an automatic control feature that periodically circulates water to help prevent freezing in water distribution components. Water Pump Cycling Based on CABINET temperature (CBt), the ICE BEAR UNIT s WATER PUMP will cycle (for a 20 minute period) for freeze protection as follows: Runs 5% duty cycle at 33/35 F ambient Runs 20% duty cycle at 30/33 F ambient Runs 50% duty cycle at 27/30 F ambient Runs 75% duty cycle at 24/27 F ambient Runs 100% duty cycle at 21/24 F ambient The cycle will repeat, as necessary, based on measured CABINET temperature. If the above parameters are incompatible with your region, or your unit requires an extended shutdown period, contact productservices@ice-energy.com. Fan Cycling During low ambient temperatures, the ICE BEAR UNIT s two FANS will cycle as follows based on CONDENSER liquid temperature (CLt): FAN #1 (on left when facing CONDENSER) o Off if CLt < 45 F o On if CLt > 67 F and FAN2 has been on for 3 min FAN #2 (on right when facing CONDENSER) o Off if CLt < 45 F and FAN1 has been off for 5 min o On if CLt > 63 F 46 Ice Bear 30 Unit Installation & Maintenance Guide

51 Appendix A Product Specifications Appendix A Product Specifications Ice Bear Unit Physical Properties Dimensions (W x D x H) 100-1/2 x 60-1/2 x 48-1/4 Weight (without water) 1,400 lb Weight (filled) 5,400 lb Load distribution (filled) 152 lb per ft 2 Water Volume 480 gallons Refrigerant Charge, TANK (Ice Cooling) 35 lb R-410A (factory) Refrigerant Charge, COMPRESSOR (Ice Charging) 11 lb 8 oz R-410A (factory) Figure 33 Ice Bear Unit Rear & Side Views Figure 34 Ice Bear Unit Top View Ice Bear 30 Unit Installation & Maintenance Guide 47

52 Appendix A Product Specifications See the below figures for dry center of gravity. Figure 35 Ice Bear 30 Unit Dry Center of Gravity (Left) Figure 36 Ice Bear 30 Unit Dry Center of Gravity (Top) 48 Ice Bear 30 Unit Installation & Maintenance Guide

53 Appendix A Product Specifications See the below figures for wet (water-filled) center of gravity. Figure 37 Ice Bear 30 Unit Wet Center of Gravity (Left) Figure 38 Ice Bear 30 Unit Wet Center of Gravity (Top) Ice Bear 30 Unit Installation & Maintenance Guide 49

54 Appendix B Power Interface Panel Appendix B Power Interface Panel The optional Power Interface Panel (PIP) intercepts power from the building s electrical panel and splits the power between the Ice Bear unit and the rooftop unit. The Ice Bear unit s CoolData Controller ensures that the RTU s target compressor 1 and the Ice Bear unit s charging compressor cannot operate at the same time, thereby ensuring that total available power limits are not exceeded. The PIP provides the following benefits: Alternate solution to costly building electrical service upgrade Reduced electrical installation costs of Ice Bear unit Supports the following voltages: o 208/230/3/60 up to 100 maximum load amps o 480/3/60 up to 50 maximum load amps Figure 39 Power Interface Panel Schematic **Application Requirements (2) or (3) 5 ton compressor stages (between 10 and 17.5 ton RTUs) Target compressor stage is not required to run during Ice Charging (off-peak) hours. All wiring, conduit, components and workmanship shall comply with latest NEC and Local Codes. **PIP option is only available for combination gas heat/electric cooling or electric cooling only RTUs. 1 The target compressor is the compressor being displaced by the Ice Bear unit typically stage Ice Bear 30 Unit Installation & Maintenance Guide

55 Appendix B Power Interface Panel Installation Referencing Figure 39, follow the steps below to install the POWER INTERFACE PANEL. 1. Mount POWER INTERFACE PANEL on supporting structure or Unistrut support rack. 2. Intercept existing branch circuit from building s main power. 3. Run new wiring and conduit from POWER INTERFACE PANEL to RTU SERVICE DISCONNECT. 4. Run new wiring and conduit from POWER INTERFACE PANEL to ICE BEAR UNIT SERVICE DISCONNECT. Sequence of Operation POWER INTERFACE PANEL supplies power to both RTU and ICE BEAR UNIT. RTU TARGET COMPRESSOR and ICE BEAR UNIT ICE CHARGING COMPRESSOR are control sequenced so that only one COMPRESSOR load is allowed to be energized, thereby ensuring that available power limits are not exceeded. The ICE BEAR UNIT S COOLDATA CONTROLLER and the RTU-mounted COOLDATA INTERFACE MODULE perform control sequence functions. On Peak Cooling: RTU 1 st stage TARGET COMPRESSOR locked out ICE BEAR UNIT CHARGING COMPRESSOR locked out Ice Cooling enabled Off Peak Cooling: RTU TARGET COMPRESSOR enabled ICE BEAR UNIT CHARGING COMPRESSOR locked out Ice Cooling locked out Off Peak Ice Charging Mode: RTU Target COMPRESSOR locked out Ice Bear Charging COMPRESSOR enabled Ice Cooling locked out Ice Bear 30 Unit Installation & Maintenance Guide 51

56 Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation The Ice Pack line set, Ice Tray and control wiring system has been developed to support the overall Ice Bear system by offering weather protection for line sets and wiring and providing a neater installation appearance. Depending on the installation site, an Ice Pack system may include insulated line sets, Ice Tray (gutters, adapters, elbows, connectors, covers, support blocks), and control wiring. Note that Ice Pack includes other components in addition to those mentioned; (e.g., Network Communication Kit (NCK), Power Interface Panel (PIP), and CoolData Interface Module (CIM)). See Appendix B Power Interface Panel for information on the optional Power Interface Panel. For installation instructions for NCK and CIM kits, refer to the installation documentation accompanying each respective kit. Figure 40 depicts a sample Ice Pack line set, Ice Tray, and control wiring system. Note that your layout may differ from that shown in Figure 40. Figure 40 Sample Ice Pack Line Set, Ice Tray, and Control Wiring System Installation NOTE: Ensure that no sharp SCREWS come in contact with line set TUBING. Provide appropriate support for GUTTERS. Ensure not to block any access doors or hamper any airflow to ROOFTOP UNIT. ICE TRAYS must be routed a minimum of 6 away from any airflow regions of a ROOFTOP UNIT. The minimum bend radius on tubing is 9 (recommended tool: Yellow Jacket Ratchet Tube Bender # 60331). Be sure not to kink any control wiring. Ice Tray, Line Set, & Control Wiring Installation (Field Connections) Note that figures in this section include illustrations for both angled and straight quick-connect fittings. This section includes the following steps: 1. Ice Tray Installation 2. Line Set Installation (includes measurement, equipment selection, and installation) 3. Control Wiring Installation 4. Releasing Unit Refrigerant Charge 5. Leak Testing 6. Ice Tray Cover Installation 52 Ice Bear 30 Unit Installation & Maintenance Guide

57 Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation Note that figures in this section include illustrations for both horizontal and vertical quick-connect fittings. 1. Ice Tray Installation NOTE: Always begin at the ICE-READY ROOFTOP UNIT when installing the ICE TRAY system. Some access areas may differ slightly in appearance. Adjust as necessary. 1. Slide TRAY around TUBING BRACKET and secure with #10 self-drilling SCREWS. See Figure 41. Note that vertical applications require the use of a VERTICAL TO HORIZONTAL ADAPTER (see following step, if applicable). Figure 41 Securing Tray to Tubing Bracket (Horizontal) 2. If using a vertical application, secure a VERTICAL TO HORIZONTAL ADAPTER to the TUBING BRACKET using (3) #10 self-drilling SCREWS. Then, secure the TRAY to the VERTICAL TO HORIZONTAL ADAPTER with (4) #10 self-drilling SCREWS. See Figure 42. Figure 42 Securing Tray to Tubing Bracket (Vertical) 3. Install TRAYS, CONNECTORS, ELBOWS (45, 90, and expanded 90 ), and SUPPORT BLOCKS, as appropriate to lay the TRAY toward the ICE BEAR UNIT. Note that TRAY material may be cut with tin snips or reciprocating saw, as needed. Use #10 x ½ self-drilling SCREWS to join members. Ice Bear 30 Unit Installation & Maintenance Guide 53

58 Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation Rules for Routing the Ice Tray If required, a HORIZONTAL or VERTICAL 90 ICE TRAY ELBOW must be installed up to 41 away from the ICE BEAR UNIT BASE or beyond 57 from the ICE BEAR UNIT BASE. TRAY is to be supported at first drop point, every 5 feet, and the center of all HORIZONTAL ELBOWS. Fasten TRAY to SUPPORT BLOCKS using (2) #8 x 1 long sheet metal SCREWS. Use straight TRAY to splice ELBOWS together. TRAY CONNECTORS are to have a 2 overlap on both sides of the joint. TRAY CONNECTORS and TRAYS are to be mounted on the inside of ELBOWS. Each straight TRAY and straight TRAY CONNECTOR is to be secured with (2) #10 x ½ long, bittipped SCREWS per ELBOW from the inside of the TRAY. 4. When you have laid the TRAY to within a maximum of 54 from the ICE BEAR UNIT BASE, remove the ICE BEAR UNIT S QUICK CONNECT PROTECTOR, as shown in Figure 43. Retain the SCREWS for later use. Figure 43 Removing Quick Connect Protector 5. Install an EXPANDED 90 ELBOW, as shown in Figure 44. The EXPANDED 90 ELBOW provides some wiggle room to allow you to make final adjustments to the TUBING length. 6. Install TRAY, CONNECTORS, and ELBOWS as necessary. See Figure Ice Bear 30 Unit Installation & Maintenance Guide

59 Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation 7. Install TRAY ADAPTER to ICE BEAR UNIT BASE using SCREWS removed earlier. See Figure 44. NOTE: The following section describes the procedure for installing a line set with quick connect FITTINGS. If you are installing a line set that requires brazed FITTINGS, then substitute standard brazing procedures in place of the quick connect procedures. Also, ensure that both line sets (ICE-COIL return and ICE-COIL supply) are insulated. Figure 44 Expanded 90 Elbow Ice Bear 30 Unit Installation & Maintenance Guide 55

60 Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation 2. Line Set Installation General Standard Ice Pack line sets consist of the following: Prefabricated Line Set 1/2 OD insulated, precharged line set o a female one-time quick-connect fitting on one end o a male one-time quick-connect fitting on the other end 7/8 OD prefabricated insulated, precharged line set o a female one-time quick-connect fitting on one end o a male one-time quick-connect fitting on the other end Custom Line Set (up to 75 ft long, including 48 of flex tubing) 1/2 OD insulated, precharged line set o a female one-time quick-connect fitting on one end o flex tubing with a female multi-use quick-connect fitting on the other end 7/8 OD insulated, precharged line set o a female one-time quick-connect fitting on one end o flex tubing with a female multi-use quick-connect fitting on the other end See Figure 45 and Figure 46 for sample line set layouts. Figure 45 Same Level Line Set Application 56 Ice Bear 30 Unit Installation & Maintenance Guide

61 Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation The unit is shipped with the following charges: Figure 46 Ground/Rooftop Line Set Application Component COMPRESSOR (Ice Charging) TANK (Ice Cooling) Factory Charge 11 lb 8 oz R-410A 35 lb R-410A NOTES: Both ICE-COIL refrigerant lines must be insulated. All piping must adhere to the specifications called out in the following table. Ice Bear Unit Line Set Specifications Item Specification Line Set Sizing ICE-COIL supply line = 1/2 ICE-COIL return line = 7/8 (Both lines must be insulated.) Maximum overall length (to ICE-COIL) 150 ft including vertical head (maximum 20 fittings) Maximum vertical head ICE-COIL supply 35 ft line Maximum vertical head ICE-COIL below 20 ft ICE BEAR UNIT Maximum fittings per line (supply & return) 20 Minimum insulation wall thickness 1/2 or minimum required by local code, whichever is greater. Ice Bear 30 Unit Installation & Maintenance Guide 57

62 Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation Installation Procedure The overall line set installation procedure consists of the following activities: a. Line Set Measurement b. Line Set Selection c. Line Set Installation a. Line Set Measurement One Section Line Set Applications: Same Level Note: For use on simple short line set installations (less than50 ft) 1. Measure from the end of the ICE-READY ROOFTOP UNIT quick connect FITTING through the centerline of the ICE TRAY FITTINGS and TRAY to the end of the ICE BEAR UNIT quick connect FITTING to establish length of custom line set to be installed. Record measurement for ICE BEAR UNIT line set construction.* Two Section Line Set Applications: Roof / Ground or Same Level NOTE: For use on average line set installations (greater than50 ft, less than 100 ft) 1. Measure from the end of the ICE-READY ROOFTOP UNIT quick connect FITTING through the centerline of the ICE TRAY FITTINGS and TRAY to establish installed length end point of premade ICE-READY ROOFTOP UNIT line set selected to be installed. Mark line set quick connect FITTING end point in ICE TRAY. NOTE: On Roof / Ground applications, to optimize ease of installation, it is recommended to end ICE-READY ROOFTOP UNIT line set section at 1 ft or more prior to vertical drop off the roof. 2. Measure from the end of the ICE BEAR UNIT quick connect FITTING through the centerline of the ICE TRAY FITTINGS and TRAY to the marked end point of the ICE-READY ROOFTOP UNIT line set quick connect FITTING. Record measurement for ICE BEAR UNIT line-set construction.* Three Section Line Set Applications: Roof / Ground or Same Level NOTE: For use on complex or long line set installations (greater than 100 ft) 1. Measure from the end of the ICE-READY ROOFTOP UNIT quick connect fitting through the centerline of the ICE TRAY FITTINGS and TRAY to establish installed length end point of premade ICE-READY ROOFTOP UNIT line set selected to be installed. Mark line set quick connect FITTING end point in ICE TRAY. On Roof / Ground applications, to optimize ease of installation, it is recommended to end ICE-READY ROOFTOP UNIT line set section at 1 ft or more prior to vertical drop off the roof. 2. Measure from ICE-READY ROOFTOP UNIT line-set end mark in ICE TRAY through the centerline of the ICE TRAY FITTINGS and TRAY to establish installed length end point of pre-made center line set selected to be installed. Mark center line-set quick connect FITTING end point in ICE TRAY. 3. Measure from the end of the ICE BEAR UNIT quick connect FITTING through the centerline of the ICE TRAY FITTINGS and TRAY to the marked end point of the center line set quick connect FITTING. Record measurement for ICE BEAR UNIT line set construction.* * Allowance for ICE BEAR UNIT line set quick connector FITTING engagement will be automatically added during line set construction. 58 Ice Bear 30 Unit Installation & Maintenance Guide

63 Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation b. Line Set Selection Use the following guide in determining the appropriate line set equipment for a given project. Refer back to Figure 45 and Figure 46. Line Set Selection Guide Ice-Coil to Ice Bear Unit Application Site length requirement, "L", where L is: Fixed lengths available from stock Custom lengths With Ice Bear unit flex-end¹ [non-flex, w/ (2) single-use quick connect fittings] [(1) multi-use and (1) singleuse quick connect fitting] Same level Up to 60 ft N/A Use a custom length, "L" Same Level Use (1) section of length "L" -or- >60ft to 110 ft Use (1) 50 ft section minus 50 ft Ground / Roof Same Level -or- Ground / Roof >110ft to 150 ft Use (2) 50 ft sections (Alternate: (1) 25ft + (1) 75ft section ²) NOTES: Custom flex-end line set must be used for connection to ICE BEAR UNIT. Use (1) section of length "L" minus 100 ft 75 ft line set sections are difficult to handle and recommended only on same level applications. c. Line Set Installation One Section Line Set Applications: Same Level 1. Starting at the ICE-READY ROOFTOP UNIT, connect the female 7/8 quick connect line set FITTING to the male 7/8 quick connect FITTING, per the Quick Connect Assembly Guidelines later in this document. 2. Form the 7/8 ICE-READY ROOFTOP UNIT line set to the ICE TRAY by gently rolling the copper into the ICE TRAY. It will be necessary at times to use a copper bending tool to complete this procedure. 7/8 Copper Bending Procedure 1. Locate center of ICE TRAY fitting on line-set TUBING insulation. 2. Cut INSULATION at the marked location and mark center of ICE TRAY FITTING on copper TUBING. 3. Slide the INSULATION away from the center mark on copper TUBING and install tubing bender oriented in desired direction of bend. Align the center mark on copper TUBING with the center mark of bender. Ratchet tubing bender until desired angle is achieved. 4. Remove tubing bender. Push line set insulation back together and recreate a vapor seal by using foam INSULATION TAPE. Recommended Tube Bender: Yellow Jacket UPC No Connect the Flex End female 7/8 ICE BEAR UNIT line set quick connect FITTING to the male 7/8 ICE BEAR UNIT quick connect FITTING, per the Quick Connect Assembly Guidelines later in this document. 4. For ½ line set, repeat steps above using ½ line set. (Note that bending of ½ copper TUBING will not require a bending tool.) Ice Bear 30 Unit Installation & Maintenance Guide 59

64 Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation Two Section Line Set Applications: Roof / Ground or Same Level 1. Starting at the ICE-READY ROOFTOP UNIT, connect the female 7/8 quick connect line set FITTING to the male 7/8 quick connect FITTING, per the Quick Connect Assembly Guidelines later in this document. 2. Form the 7/8 ICE-READY ROOFTOP UNIT line set to the ICE TRAY by gently rolling the copper into the ICE TRAY. It will be necessary at times to use a copper bending tool to complete this procedure. See 7/8 Copper Bending Procedure earlier in this document. 3. Connect the male 7/8 ICE BEAR UNIT line set quick connect FITTING to the female 7/8 middle line set quick connect FITTING, per the Quick Connect Assembly Guidelines later in this document. 4. Form the ICE BEAR UNIT line set section to the Ice Tray by gently rolling the copper into the TRAY. Use copper bending tool as necessary. 5. Connect the Flex End female 7/8 ICE BEAR UNIT line set quick connect FITTING to the male 7/8 ICE BEAR UNIT quick connect FITTING, per the Quick Connect Assembly Guidelines later in this document. 6. For ½ line set, repeat steps above using ½ line set. (Note that bending of ½ copper tubing will not require bending tool.) Three Section Line Set Applications: Roof / Ground or Same Level 1. Starting at the ICE-READY ROOFTOP UNIT, connect the female 7/8 quick connect line set FITTING to the male 7/8 quick connect FITTING, per the Quick Connect Assembly Guidelines later in this document. 2. Form the 7/8 ICE-READY ROOFTOP UNIT line set to the ICE TRAY by gently rolling the copper into the ICE TRAY. It will be necessary at times to use a copper bending tool to complete this procedure. See 7/8 Copper Bending Procedure earlier in this document. 3. Connect the female 7/8 middle line set quick connect FITTING to the male 7/8 ICE-READY ROOFTOP UNIT line set quick connect FITTING, per the Quick Connect Assembly Guidelines later in this document. Note that if you are using a VERTICAL TO HORIZONTAL ADAPTER, you will need to remove it temporarily to install the line set quick connect FITTINGS. 4. Form the 7/8 middle line set section to the ICE TRAY by gently rolling the copper into the ICE TRAY. Use copper bending tool as necessary. Continue this step until the entire middle line set is installed in the ICE TRAY. 5. Connect the male 7/8 ICE BEAR UNIT line set quick connect FITTING to the female 7/8 middle line set quick connect FITTING, per the Quick Connect Assembly Guidelines later in this document. 6. Form the ICE BEAR UNIT line set section to the ICE TRAY by gently rolling the copper into the TRAY. Use copper bending tool as necessary. 7. Connect the Flex End female 7/8 ICE BEAR UNIT line set quick connect FITTING to the male 7/8 ICE BEAR UNIT quick connect FITTING, per the Quick Connect Assembly Guidelines later in this document. 8. For ½ line set repeat steps above using ½ line set. (Note that bending of ½ copper TUBING will not require bending tool.) 60 Ice Bear 30 Unit Installation & Maintenance Guide

65 Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation Quick Connect Assembly Guidelines 1. Apply refrigerant oil to the entire surface of DIAPHRAGM, O-RING, and threaded area of MALE COUPLING ASSEMBLY. The amount of lubricant used must cover all designated surfaces sufficiently. Ideal application is a small applicator brush saturated with lubricant and applied liberally. An alternate lubricant for this application is a refrigerant compatible silicone grease product like Dow Corning DC200/60,000 cst. 2. Ensure that the COUPLING halves are held in proper alignment with each other prior to starting the threads of the female COUPLING NUT onto the male half. The COUPLING end faces should be parallel with each other and visually in line with each other; this allows the female COUPLING NUT to be easily threaded on by hand for the initial 2-3 rotations of the UNION NUT. These initial rotations will bring the DIAPHRAGM in contact and a sharp increase in torque will be felt when they come into contact. NOTE: If the NUT will not start by hand, adjust the position of the LINE SET to ensure proper COUPLING alignment and eliminate/minimize all side-load force on the COUPLING during assembly. 3. Using appropriate size wrenches, for the female COUPLING body and female UNION NUT, tighten the female UNION NUT while preventing rotation of the female body with respect to the male half. The NUT should be tightened until a definite increase in resistance, metal to metal contact occurs and is felt (at this point, the NUT will have covered most of the threads on the male body). It is important to ensure that the male and female COUPLING bodies DO NOT ROTATE during any portion of the wrench installation. 4. Using a permanent marker or scribe, mark a line lengthwise from the female COUPLING UNION NUT to either the bulkhead or female COUPLING body. Then tighten an additional (1) wrench flat (60 ); refer to the marking on the UNION NUT to confirm the rotation has occurred. This final rotation is necessary to ensure the formation of the leak-proof seal, between the male and female COUPLINGS. 5. Repeat step 1 through 4 for all connections. 6. Leak check all connections with an electronic leak detector. Leak detector must be suitable and calibrated to detect refrigerant R-410A at a leak rate of.25 oz. per year or smaller. Ice Bear 30 Unit Installation & Maintenance Guide 61

66 Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation Figure 47 Installing Line Set at Ice-Ready Rooftop Unit (Horizontal Orientation) Figure 48 Installing Line Set at Ice-Ready Rooftop Unit (Vertical Orientation) NOTE: If you have a vertical quick connect access application, reattach the VERTICAL TO HORIZONTAL ADAPTER, removed earlier during line set installation. 62 Ice Bear 30 Unit Installation & Maintenance Guide

67 Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation Figure 49 Installing Line Set at Ice Bear Unit Ice Bear 30 Unit Installation & Maintenance Guide 63

68 Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation 3. Control Wiring Installation 1. Determine the optimal routing for the interconnecting CABLES between the two units. In almost all cases, the CABLE will run in the ICE TRAY along with the line set and will enter the ICE BEAR UNIT at the connection point for the line set. On the ICE-READY ROOFTOP UNIT, the CABLES may enter the unit at the connection point for the line set and be routed through the body of the unit, or FLEXIBLE CONDUIT may be required to pass the CABLES to a convenient spot on the ICE- READY ROOFTOP UNIT for routing to the CIM BOARD. 2. Lay out one run of 8/24 AWG conductor thermostat WIRE and one run of CAT5 CABLE along the predetermined routing path between the two units. Ensure that enough CABLE length is available on either end to route the CABLE through the unit to the COOLDATA CONTROLLER in the ICE BEAR UNIT and to the CIM BOARD in the ICE-READY ROOFTOP UNIT. 3. Finalize CABLE lengths and secure them with CABLE TIES. The CABLES should be secured in the ICE TRAY to the line set (Figure 50) and in the units as appropriate. NOTE: Splicing is not allowed in either of these CABLES. Control Wiring Figure 50 Control Wiring 64 Ice Bear 30 Unit Installation & Maintenance Guide

69 Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation 4. Attach an 8P8C (RJ45) connector to the ICE-READY ROOFTOP UNIT end of the CAT5 cable using the T568B format (Figure 51). T568B format Pin Wire Color 1 White/Orange stripe 2 Orange Solid 3 White/Green stripe 4 Blue Solid 5 White/Blue stripe 6 Green Solid 7 White/Brown stripe 8 Brown Solid Figure 51 T568B Connector 5. Plug this CONNECTOR into J2 on the CIM BOARD. 6. Attach the Euro Style CONNECTOR that should be located in J1 on the CIM BOARD to the ICE- READY ROOFTOP UNIT side of the 8 conductor Thermostat WIRE using the following color to pin convention (Figure 52). Note that screw terminal placement on CONNECTORS may vary. NOTE: If the WIRE colors in the thermostat WIRE do not match those shown below, ensure that the alternate colors are used on both ends to provide the correct connections. Pin Wire Color 1 Black 2 Yellow 3 Green 4 White 5 Brown 6 Blue 7 Orange 8 Red Figure 52 Euro Style Connector 7. Plug this CONNECTOR into J1 on the CIM BOARD. 8. Route and secure WIRES with WIRE TIES. Ice Bear 30 Unit Installation & Maintenance Guide 65

70 Appendix C Ice Pack Line Set, Ice Tray, and Control Wiring Installation 9. In the Ice Bear unit, route the CAT5 cable into the left side of the CoolData Controller enclosure. Trim the wire to a length that is 5 past the bottom corner of the PRINTED CIRCUIT BOARD. Remove the overall insulation to expose 5 of individual wire pairs. Cut off the green and orange wire pairs at this point. Strip off 3/8 of insulation on the remaining four wires and connect the blue and brown pairs of wires as shown in Figure 53. Brown White with Brown Stripe Blue White with Blue Stripe Figure 53 CoolData Wiring 10. Route the thermostat WIRE into the right side of the COOLDATA CONTROLLER enclosure. 11. Strip off 6 of overall INSULATION. 12. Strip 3/8 of INSULATION off of the 8 individual WIRES. 13. If not already in place, install the WIRING ASSEMBLY, connecting each of the lower terminals of the following ports: I1, I2, I3, (I4 for ICE BEAR UNITS with a serial number below 150, and single phase units), S7, and S8. This WIRING ASSEMBLY will be connected to the blue WIRE #60 along with the black thermostat WIRE. If the WIRING ASSEMBLY is already in place, connect the black thermostat WIRE to the short blue WIRE stub that should be available and capped in the compartment. Use a CRIMP CAP to connect these WIRES together. 14. Connect the red thermostat WIRE to the short yellow WIRE stub that should available and capped in the compartment. Use a CRIMP CAP to connect these WIRES together. 15. Connect the orange thermostat WIRE into the open terminal of I Connect the brown thermostat WIRE into the open terminal of I Connect the white thermostat WIRE into the open terminal of I Connect the blue thermostat WIRE into the open terminal of I4, if available, or use a RELAY ASSEMBLY if the attached RTU requires it (multi-stage units). (Follow instructions included with RELAY ASSEMBLY.) Otherwise, cap this loose WIRE. 19. Connect the green thermostat WIRE into the open terminal of S Connect the yellow thermostat WIRE into the open terminal of S8. 66 Ice Bear 30 Unit Installation & Maintenance Guide