TECHNICAL, OPERATING & INSTALLATION MANUAL TC 15, 33, 52 AIR COOLED PACKAGED WATER CHILLERS

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1 TC SERIES OPTIONS TECHNICAL, OPERATING & INSTALLATION MANUAL TC 15,, 5 AIR COOLED PACKAGED WATER CHILLERS

2 CONTENTS EQUIPMENT AND COMPONENT DETAILS PERFORMANCE AND TECHNICAL DATA SCHEMATIC FLOW & SYSTEM DIAGRAM SWITCHBOARD LAYOUT SWITCH BOARD & WIRING DIAGRAM - TC 15 SWITCH BOARD & WIRING DIAGRAM - TC SWITCH BOARD & WIRING DIAGRAM - TC 5 DIMENSIONAL DATA TC & TC 5 INSTALLATION & PRE START UP CHECKS START UP & COMMISSIONING PROCEDURE RECOMMENDED SPARE PARTS PAGE

INTRODUCTION EQUIPMENT AND COMPONENT DETAILS The TC range of packaged air cooled chilled water generators are specifically designed for external mounting and matched to supply the TCAH range of

3 INTRODUCTION EQUIPMENT AND COMPONENT DETAILS The TC range of packaged air cooled chilled water generators are specifically designed for external mounting and matched to supply the TCAH range of packaged chilled water air handling units. The units are complete with all controls, safeties, chilled water pump and chilled storage tank. CONSTRUCTION COMPRESSOR The TC range of air cooled chillers utilise an aluminium cubic framework construction combined with 1.6mm thick aluminium panels. The aluminium panels and framework is epoxy powder coated to SABS standard. There are 3 models of TC units - TC15, TC & TC 5. The heavy duty hermetically sealed reciprocating compressor complete with crank case heater and service valves is also fitted with internal thermal and temperature protection. The compressor is mounted on neoprene anti vibration mounts. CONDENSER COIL The condenser coil is manufactured from refrigeration grade copper tube with mechanically bonded aluminium fins. The coil is housed in a galvanised steel casing. CONDENSER S All units utilise a direct drive airofoils shaped high efficiency plate mounted axial type condenser fans. The fan motor is of the direct drive and is of the external rotor type. The fan impeller and motor are statically and dynamically balanced. The fan impeller motor combination is mounted within a wire guard. The fan motor is fitted with an internal winding thermal cutout to protect the motor windings. CONTROLS Each TC unit is as standard fitted with the following controls :- Circuit breakers on all power components Anti-short cycle protection of the compressor Chilled water temperature control with offset chw temperature feature. Chilled water anti-freeze protection - manual reset. Chilled water flow safety switch. Chilled water tank level switch. Anti-flicker timer for chilled water flow switch & tank level switch. Condenser fan motor - internal thermal cutout. Condenser fan speed controlled Chilled water pump motor overload. HP / LP (manual reset) refrigeration pressure switch. Refrigeration liquid live solenoid valve. LED INDICATION The following LED s are fitted into each TC switch board unit :- Control power LED. Chilled water flow / level switch fault. Condenser fan failure. Chilled water anti-freeze LED. HP/LP & Compressor aux. Trip LED. CHILLED WATER TEMPERATURE RESET A "no volt" signal is available for resets the chilled water temperature should a second chilled water temperature setpoint be required - e.g. to dehumidify when the TCAH air handler calls for a lower temperature. OTHER REFRIGERATION EQUIPMENT Also fitted into the refrigeration circuit are a liquid line solenoid valve, a drier, liquid sight glass and a thermostatic expansion valve. STORAGE TANK Each chiller is fitted with a stainless steel storage tank insulated with 5mm closed cell insulation. PIPEWORK The TC range of air cooled water chillers are fitted and piped with seamless copper chilled water pipework. ELECTRICAL A complete electrical panel incorporating all the circuit breakers, motor overloads, relays controllers and terminals required for efficient and continuous operation is provided. All equipment is Din rail mounted and electronic component boards are enclosed suitably.

4 PERFORMANCE AND TECHNICAL DATA TC - 15 TC - TC - 5 STORAGE TANK CAP. LITRE MAX. OPERATING PRESS. kpa COND. COIL DETAIL 3 Rows /.11mm space 3 Rows /.11mm space 3 Rows /.11mm space NORMAL / EMERGENCY DUTY NORMAL / EMERGENCY DUTY WATER ON 0 C WATER OFF 0 C QUANTITY L/S AVAILABLE PRESS. KPa AMBIENT TEMP 0 C COOLING DUTY KW DEHUMIDIFICATION DUTY WATER ON 0 C WATER OFF 0 C QUANTITY L/S AVAILABLE PRESS. KPa AMBIENT TEMP (sea level) 0 C COOLING DUTY KW ELECTRICAL REQUIREMENTS 380V / 3PHASE / 50Hz 380V / 3PHASE / 50Hz 380V / 3PHASE / 50Hz COMPRESSOR AMPS 9.5 (max) (max) (max) COND. AMPS 1 X.9 AMPS(0V/1PH) X.9 AMPS(0V/1PH) 3 X.9 AMPS(0V/1PH) PUMP AMPS 1.0 AMPS 1.0 AMPS 1.3 AMPS AIR HANDLING UNIT AMPS 15 0 TOTAL POWER REQ AMPS SAFETY SET POINTS ANTI-FREEZE 0 C HIGH PRESSURE kpa LOW PRESS. CUT OUT kpa LOW PRESS. CUT IN kpa PUMP O/LOAD AMPS WATERLFOW TIMER SEC CHILLED WATER CONNECTIONS mm DRAIN & MAKE-UP CONNECTIONS mm

5 TC SERIES SCHEMATIC FLOW & SYSTEM DESIGN CONDENSER S CONDENSER SPEED CONTROLLER HOT GAS LINE CONDENSER COIL LIQUID LINE FILTER DRIER HP / LP SWITCH COMPRESSOR SOLENOID PLATE HEAT EXCHANGER HOT GAS LINE SUCTION LINE DISCHARGE SUCTION SIGHT GLASS LIQUID LINE EXPANSION RELIEF & PURGE MAKE-UP LEVEL SWITCH FLOW SWITCH PUMP TEMP. SENSOR CHILLED WATER RESERVOIR DRAIN CHILLED WATER SUPPLY CHILLED WATER RETURN

6 TC SERIES - SWITCH BOARD LAYOUT MAINS ISOLATOR CONTROL HEATER COMPR. AUX. SW COMPR. PUMP AHU COND 1 COND COND 3 TRANSFORMER CONTROL FUSE T T1 O/L E N N N N N B1 B FR1 FR FR3 TR CHILLED WATER TEMPERATURE CONTROLLER R1 HOUR METER CONDENSER SPEED CONTROLLER POWER LEVEL & FLOW COND FREEZE CONDENSER HP/LP & COMPR AUX SPEED CONTROLLER

7 TC15 SWITCHBOARD COMPONENT POWER WIRING DIAGRAM 40 A MAIN ISOLATOR CONTR. 5 Amp H 5 Amp COMPR 9.5 A FLA 4 A LRA AUX PUMP 5 AMP AHU 1 AMP COND. 1 3 Amp OVERLOAD 1.3 AMPS COND. A1 SPEED A A3 CONTROL TRANSDUCER N N 1 TRANS- FORMER 0V / 4V CONDENSER -N/O 9 KLIXON 6 BIN+ B1 3 40v N0 7 COM- COM C B 0 SEN SOL. 1 1 SENSOR 9 1 FR1 N 0 V 4 V WATER FLOW 4 T1-N/O N/O N/O FREEZE 37 LP AUTO HP MANUAL TANK LEVEL 4 38 FR1-N/C FUSE COMPR. 9 CONTROL AUX 3 O/L T1-N/C T-N/O R1-N/C R1-N/O SEC 3 3 TO 5 MIN. GREEN PUMP HM TIMER S TIMER COMPR. R1 TR T1 T

8 TC SWITCHBOARD COMPONENT POWER WIRING DIAGRAM MAIN ISOLATOR CONTR. 5 Amp H 5 Amp COMPR A FLA 115 A LRA AUX PUMP 5 AMP AHU AMP COND. COND. 1 5 Amp 5 Amp OVERLOAD 1.3 AMPS COND. A1 SPEED A A3 CONTROL TRANSDUCER g b r N N 1 -N/O 9 6 BIN+ 3 40v N0 7 COM- COM C 0 SEN SOL. B1 B SENSOR CONDENSER KLIXONS FR1 FR N T1-N/O 0 V 37 WATER N/O LP TRANS- FLOW AUTO FORMER 3 0V / 4V 3 4 HP FREEZE MANUAL 4 V N/O b TANK r FR1-N/C FUSE COMPR. 9 CONTROL 5 AUX 3 T1-N/C PUMP FR-N/C T-N/O R1-N/C LEVEL g R1-N/O SEC 3 3 TO 5 MIN. GREEN 1 6 O/L 18 HM TIMER S TIMER COMPR. R1 TR T1 T

9 TC5 SWITCHBOARD COMPONENT POWER WIRING DIAGRAM MAIN ISOLATOR CONTR. 5 Amp H 5 Amp COMPR A FLA 115 A LRA AUX PUMP 5 AMP AHU AMP COND. COND. COND Amp 5 Amp 5 Amp OVERLOAD 1.3 AMPS COND. A1 SPEED A A3 CONTROL TRA NSDUCER g b r COND. A1 SPEED A A3 CONTROL TRA NSDUCER g b r N N N 1 T1-N/O 0 V 37 WATER N/O LP TRANS- FLOW AUTO FORMER 3 0V / 4V 3 4 HP N/O FREEZE MANUAL 4 V b TANK LEVEL g 40 r FR1-N/C FUSE COMPR. 9 CONTROL 5 AUX 3 T1-N/C PUMP FR-N/C T-N/O R1-N/C FR3-N/C R1-N/O SEC 3 3 TO 5 MIN. GREEN 1 6 O/L 18 HM TIMER S TIMER COMPR. R1 TR T1 T CONDENSER KLIXONS -N/O 9 6 BIN+ B1 3 40v N0 7 COM- COM C B 0 SEN SOL. SENSOR 1 FR FR FR3 3 N

10 DIMENSIONS FOR THE TC SERIES DOOR DOOR ELECT. CONT. PANEL TC 15 SIDE VIEW (L.H.) FRONT VIEW DOOR DOOR ELECT. CONT. PANEL DOOR TC SIDE VIEW (L.H.) FRONT VIEW DOOR ELECT. CONT. DOOR PANEL DOOR TC 5 SIDE VIEW (L.H.) FRONT VIEW

11 INSTALLATION REQUIREMENTS AND PRE START UP CHECKS During installation the following items should be checked to ensure satisfactory operation of the equipment. 1 In final position, the unit must be level. ( Use adjustable feet to level if required). Chilled water pipes, drain and make-up water must be correctly installed. (supply & return) and that the make up water & drains are functional. 3 Chilled water storage tank should be filled leaving the vent valve open - NB 4 The required electrical power supply (380V/3PH/50Hz neutral & earth) should be connected into the main isolator switch. 5 A power cable (3 phases, neutral & earth) should be taken from the TC unit Air Handling Unit circuit breaker to the TCAH air handling unit. 6 A wire Dehumidification control cable should be connected between terminals B1 & B on the chiller and teminals 7 & 8 on the air handling unit. ( volt free contacts open for dehumidification - drops chilled water to a lower temp.) 7 Check the entire unit for loose electrical terminals and any other shipment damage. 8 Check the unit, once filled with water, for any sign of leaks.

12 START UP & COMMISSIONING PROCEDURE Once all the pre-startup checks have been completed the following procedure must be followed when starting the TC units for the first time :- 1 The TC unit would have been received with all the electrical circuit breakers in the OFF position. Once connected, check that the mains power supply is correct & adequate. 3 Switch on the main isolator and the crank case heater circuit breaker only. Leave all the other circuit breakers OFF. 4 Confirm that the compressor crank case heater gets warm. The crank case should be heated for at least 18 hours prior to operation of the compressor. 5 Leaving the control circuit breaker & the compressor circuit breaker in the off position, switch on all the other circuit breakers. 6 Open the chilled water valves on the pump. 7 After ensuring that the storage tank is full, switch the pump breaker on and check the rotation direction and running amps of the pump. 8 Run the pump and purge the chilled water system of all air by venting the storage tank. 9 At this stage, with the compressor off, the power on lamp is on together with the HP/LP/compr. Aux lamp. (if there is adequate water flow). If there is inadequate water flow, or the tank water level is not high enough, the water flow / water level lamp will be on. 10 Check that the chilled water flow switch in the TC unit is operating and fully functional. This operation is checked by slowly closing the chilled water discharge valve on the pump. Before the flow is stopped completely, the water flow switch pilot warning light should come on after the 5 second anti-flicker delay when there is inadequate flow. 11 Once the correct water flow is established, switch on the compressor circuit breaker. The compressor anti short cycle timer times out for 3 minutes before the compressor is started. The compressor would bring the chilled water temperature down to the required temperature set point set on the chilled water temperature controller. The temperature sensor for the chilled water is in the storage tank and is factory set at 8 degrees C for dehum. And an offset temperature of deg. C. For normal operation. The chilled water temperature differential is set at deg. C. 1 The Condenser fans, except the first one, are controlled by head pressure of the refrigeration system. At 00 kpa all condenser fans should be fully operational. 13 The condenser fans are fitted with internal thermal overload / current protection. The condenser fan Light should be on if all the fans are operational. Should any one of the condenser fans be faulty the Condenser fan light will go off. Note: under normal operational conditions, the condenser fans are not operational when the compressor is not running. 14 The Chilled water system is protected by an anti freeze thermostat. This thermostat is set at 4 deg.c. and has a manual reset. Should the anti freeze stat trip the Anti freeze light will come on. 15 The TC chiller is fully charged with refrigerant (R). The liquid line sight glass should only clear when the refrigeration circuit is running fully loaded and the temp. Less than 1 degrees and the head pressure is greater than 1500 kpa.

13 AIR OPTIONS (PTY) LTD P.O Box Blackheath Trafford Road Blackheath 7581 Phone +7 (0) Fax +7 (0) Literature Order Number: Air Handling Units Date: April 004 airoptions@safivegroup.co.za

Commercial High-Efficiency Condensing Units

FORM NO. A22-194 REV. 2 Supersedes Form No. A22-194 Rev. 1 Commercial High-Efficiency Condensing Units RAWL High Efficiency 6.5 & 7.5 TON MODEL [22.86 & 26.38 kw] TABLE OF CONTENTS Model Number Designation...2