AIR COOLED CHILLERS MODELS: MPCA0005 MPCA0150 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

MOTIVAIR COOLING SOLUTIONS AIR COOLED CHILLERS MODELS: MPCA0005 MPCA0150 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL This chiller has been factory run tested to the specified water pressure *****DO NOT OVER PRESSURIZE CHILLER WHEN LEAK CHECKING PIPING OR FILLING HYDRAULIC SYSTEM***** *Isolate chiller from piping if higher test pressure is required for leak checking* *Chiller damaged caused by over pressurization is NOT covered by warranty* 85 Woodridge Dr. Amherst, NY 14228 Phone# 716-691-9222 Fax# 716-691-9229 www.motivaircorp.com

INDEX TABLE OF CONTENTS PAGE LEGAL PROVISIONS & SAFETY INSTRUCTIONS 1 TRANSPORTING & SITE HANDLING 2-3 CHILLER INSTALLATION 4-13 PIPING INSTALLATION 14-18 MAIN ELECTRICAL INSTALLATION 19 WATER/GLYCOL INSTRUCTIONS 20 CHILLER SEQUENCE OF OPERATION 21 MPCA0005 MPCA0150 PROGRAMMING AND ALARM CODES 22-25 MPCA0005 MPCA0150 STANDARD CONTROLLER LAYOUT 26 COMMISIONING AND STARTUP INSTRUCTIONS 27-28 TROUBLESHOOTING 29-32 PREVENTIVE MAINTENANCE 33-35 CHILLER REPAIR INFORMATION 36-37 CLEANING THE PLATE EXCHANGER (EVAPORATOR) 38 REFRIGERANT INFORMATION 39 TERMS AND CONDITIONS OF SALE 40

PROVISIONS AND SAFETY Operation of these systems involves potentially Iethal dangers (high voltage and high pressures). Therefore, all safety precautions and warnings described in this manual must be precisely observed. Otherwise, severe or fatal injury may be caused. Operator's Responsibility This chiller MUST be installed, maintained and operated by a person(s) qualified for this equipment. This chiller contains refrigeration, water circulation and electrical components. The person(s) most suited for this equipment is a qualified licenced refrigeration technician. Intervention by unauthorized or unqualified parties may void the warranty. SAFETY INSTRUCTIONS The installation, start-up and maintenance of the chillers are dangerous, Due to: High pressures is generated in the equipment Electrical parts are energized The equipment contains hot pipes (Refrigeration system) Rotating parts (fans and or pumps) can cause injury the chillers themselves may be installed in a dangerous position (roof, high built frame etc.) For these reasons, the chiller must be installed and connected to the electricity/water installations by qualified companies only. Startup and maintenance must be conducted by a qualified refrigeration company only. Simple maintenance operations on the equipment without opening them may be performed by the operator. All other work must be performed by specially qualified personnel.

LIFTING - UNLOADING POSITIONING Notices (symbols) on device packing must be observed. Check the center of gravity of the chiller. Use appropriate unloading equipment. Remove protective film from chiller and cardboard. behind condenser before use. TRANSPORT AND HANDLING MANUFACTURER'S NOTE The machine may be damaged by: Dropping or tipping it on the ground. Pulling the chiller by cords, straps, etc. Lifting the chiller by its piping system. Excessive shaking by cranes. Damage of this type is not covered by warranty. ECA ECA MAX 45 ECA ECA

LIFTING - UNLOADING POSITIONING Notices (symbols) on device packing must be observed. Check the center of gravity of the chiller. Use appropriate unloading equipment. Remove protective film from metal panels before use. MANUFACTURER'S NOTE The machine may be damaged by: Dropping it or tipping it on the ground. Pulling the chiller by cords, straps etc. Lifting the chiller by its piping system. Excessive shaking by crane. Damage of this type is not covered by warranty. Installing with a fork lift truck Use the forks to lift with: they must be as long as the chiller. Use of fork extensions if required, OR SERIOUS DAMAGE MAY RESULT. LIFTING WITH A CRANE Use the holes in the bottom framework for lifting. To distribute the weight evenly place a strong L-shaped section between the belts and structure work. INSERT SPREADER BARS TO PREVENT CRUSHING HOOKING TO THE STRUCTURE Hook only to the points indicated by the lifting labels. Make sure there is no possibility that the hooks can slip out due to swinging or movements from the crane

CHILLER INSTALLATION Foundation Site Installation All chillers must be mounted on a solid, horizontal surface, suitable for the weight of the chiller.* Note the chiller weight is incresed by filling with glycol/water mixture. Observe all local regulations. Must be dry and protected against freezing. The room temperature must not be colder than 41 0 F. The system must be installed horizontally. The components are not suitable for exterior installation, without factory modification and approval. Consult Motivair if chiller will be installed outdoors Installation Structure-borne noise Compliance with the following basic rules for the erection of devices with radial fans wiil ensure problem-free operation and the rated refrigeration capacity. Basic rules: 1. The condenser air is blown out vertically or horizontally. 2. Do not install the device close to heat sources. Heated air intake must be avoided. 3. The condenser fans are rated for ZERO external static pressure. The fan do not have the capacity to push air through ducting, which means that NO DUCTS OR MUFFLERS may be used on the inlet ot outlet of the chillers. 4. No air short-circuit is permitted, i.e. the heated discharge air from the condenser fans must never be drawn back into the condenser inlet. This will occur if the chiller is too close to a wall, or a low ceiling or other obstructions. 5. In the case of shaft or trench mounting, contact the manufacturer for advice on the installation site. It is possible that noise or vibration may be transmitted through the ground, or building structure. If this occurs, it may be necessary to install a vibration elimination device. The construction specifications of the customer/engineering contractor regarding structure transmitted noise or vibration must be observed. Vibrations May be transmitted through the chilled water piping. This can be avoided by the use of flexible piping connections. Clearances Must be maintained for servicing and ventilation purposes. All removable side panels must be available service. A minimum of 3 feet on all sides is required. Consult Motivair for irregular space requirements.

INSTALLATION GUIDE Location: Locate the unit to provide proper airflow to the condenser (see Figure 1 page 2) Due to the placement of the condenser coils on the MPCA0005-0150 chillers, it is desirable to orient the unit so that prevailing winds blow parallel to the unit length, thus minimizing the wind effect on condensing pressure performance. If low ambient temperature operation is expected, it is recommended that optional fan VFD system be factory installed. Using less clearance than shown in Addendum A can cause discharge air recirculation to the condenser and could have a significant negative effect on unit performance. See Restricted Airflow beginning on page 3 for further information. For pad-mounted units, it is recommended that the unit be raised a few inches with suitable supports, located at least under the mounting locations, to allow water to drain from under the unit to facilitate cleaning under it. Service Access: The main control box contains either the microprocessor or PLC (Programmable Logic Controller) for optimum chiller control. The solid state compressor starter, fan control and other power equipment are located in the main control box. Condenser fan VFD s and overloads are either located in an independent box on the side of the chiller or in the main cabinet. The side clearance required for airflow provides sufficient service clearance. CAUTION Disconnect all power to the chiller while servicing condenser fan motors or compressors. Failure to do so can cause bodily injury or death. Do not obstruct access to the sides or ends of the chiller with piping or conduit. These areas must be open for service access. Do not obstruct any access to the control panel(s) with field mounted disconnect switches. Make sure that the power conduit to control panel(s) does not restrict access to removable panels.

Clearance Requirements: Figure 1 AIR FLOW NO OBSTRUCTIONS ALLOWED ABOVE UNIT AT ANY HEIGHT SEE NOTES 2&4 PERTAINING TO WALL HEIGHT AT UNIT SIDES Notes: 1. Minimum side clearance between units is 6 feet (1.8 meters) with no perimeter obstructions within 10 feet of the units. 2. Unit must not be installed in a pit or enclosure that is deeper or taller than the height of the unit unless extra clearance is provided per note 4. 3. Minimum clearance on each side is 8 feet (2.4 meters) when installed in a pit no deeper than the unit height. 4. Minimum side clearance to a side wall or building taller than the unit height is 7 (2.1 meters) feet provided no solid wall above 7 (2.1 meters) feet is closer than 12 (3.7 meters) feet to the opposite side of the unit. 5. Do not mount electrical conduits where they can block service access to compressor controls, refrigerant driers or valves. 6. There must be no obstruction of the fan discharge. 7. Field installed switches must not interfere with service access or airflow. 8. MPCA chillers use axial fans and are NOT suitable for ducted applications. 9. See the following pages if the airflow clearance cannot be met.

Restricted Airflow: General The clearances required for design operation of MPCA air-cooled condensers are described in the previous section. Occasionally, these clearances cannot be maintained due to site restrictions such as units being too close together or a fence or wall restricting airflow, or both. The Motivair MPCA chillers have several features that can mitigate the problems attributable to restricted airflow. The single side of the condenser formation allows inlet air for the coil(s) to come in from that side and allows for smaller distances between the opposite side and encroaching obstructions to allow for maximum air flow to the condenser side. Facing the chiller control cabinet, the right-side of the unit is generally where the condenser(s) are located. NOTE: This is not exclusive as Motivair reserves the right to change chiller design without notice. The VFD option allows for optimum air flow at multiple year round conditions. This is best utilized when units are placed parallel to prevailing winds. Figure 2 The following sections discuss the most common situations of condenser air restriction and give capacity adjustment factors for each. CAUTION The unit capacity adjustment charts in this engineering bulletin serve only as a guide, and DO NOT take into account prevailing site conditions. 7

Case 1, Building or Wall on One side of One Unit: The presence of a screening wall or the wall of a building, in close proximity to an air-cooled chiller is common in both rooftop and ground level applications. Hot air recirculation on the coils adjoining the wall increases compressor discharge pressure, decreasing capacity and increasing power consumption. When close to a wall, it is desirable to place chillers on the north or east side of them (to minimize solar effect). It is also desirable to have prevailing winds blowing parallel to the unit s long axis. The worst scenario is having wind blowing hot discharge air into the wall. Figure 3 D H Figure 4, Adjustment Factor

Case 2, Two Units Side By Side: Two or more chillers positioned side by side are common. If spaced closer than 6 feet it is necessary to adjust the performance of each unit; circuits adjoining each other are affected. If one of the two units also has a wall adjoining it, see Case 1. Add the two adjustment factors together (Figure 4 and Figure 6) and apply to the unit between the wall and the other unit. Mounting units end to end will not require adjusting performance. Depending on the actual arrangement, sufficient space must be left between the units for access to the control panel door opening. See Clearance section of this guide for requirements for specific units. Pit or solid wall surrounds should not be used where the ambient air temperature exceeds 95 F. Figure 5, Two Chillers Side by Side D Figure 6, Adjustment Factor

Case 3, Three or More Units Side By Side: When designs call for three or more units to be side by side; contact Motivair with the desired placements of the units for approval. Capacity reduction is dependent on multiple possible orientations of the units. Figure 7, three or more chillers D D D

Case 4, Open Screening Walls: Decorative screening walls are common to help conceal a chiller either on grade or on a rooftop. These walls should be designed such that the combination of their open area and distance from the chiller do not require performance adjustment. It is assumed that the wall height is equal to, or less than the chiller height when mounted on its base support. This is usually acceptable for concealment. If the wall height is greater than the unit height, see Case 5 (Pit Installation). The distance from the sides of the unit to the side walls should be sufficient for service and opening control panel doors. If each side wall is a different distance from the unit, the distances can be averaged, providing either wall is not less than 8 feet from the unit. For example, do not average 4 feet and 20 feet to equal 12 feet. Figure 9, Open Screening Walls D D Figure 10, Wall Free Area Graph

Case 5, Pit/Solid Wall Installation: Pit installations can cause operating problems and great care should be exercised if they are to be used on any installation. Recirculation and restriction are probable. A solid wall surrounding a unit is effectively the same as a pit and the data given in Case 5 should be used. Steel grating is sometimes used to cover a pit to prevent accidental falls or trips into the pit. The grating material and installation design must be strong enough to prevent such accidents, yet provide abundant open area or serious recirculation problems will occur. Have any pit installation reviewed by Motivair application engineers prior to installation to discuss whether it has sufficient airflow characteristics. The installation design engineer must approve the work and is responsible for design criteria. Figure 11, Pit Installation H D Figure 12, Adjustment Factor D=10Ft 12

Addendum: A 40 40 40 40 40 40 Control Panel 40 Control Panel 40 MIN. CLEARANCE FOR MPC-A 0005-0010 MIN. CLEARANCE FOR MPC-A 0150

NOTE: VENTS ARE REQUIRED AT ALL "LOCAL" HIGH POINTS IN SUPPLY AND RETURN

PIPING INSTALLATION This section is intended as a guide for the correct installation of the chilled water piping system, including this chiller. However, the chiller manufacturer accepts no responsibility what so ever for the installation of the chiller or the associated piping. All piping must be installed only by a licensed plumbing contractor, and in compliance with local codes. DO NOT USE GALVANIZED PIPING IF GLYCOL IS TO BE USED IN THE CHILLED WATER SYSTEM. Chemical reaction between the glycol and the galvanized piping can be detrimental to the cooling system, the glycol and chiller. Piping material may be copper, plastic, carbon or stainless steel depending on the requirements of each installation. It is the responsibility of the engineer and/or the piping contractor to insure that the piping is correctly sized in relation to the installation, and the available dynamic head of the pump installed inside the chiller. The chilled water pipe connections on the chiller are not necessarily the appropriate size for the system piping. As a general guide, the chiller pipe connections should be considered as the minimum pipe size required for the installation. Drastic reduction in pipe sizing (small hoses, etc.) will reduce the chilled water flow and may cause a low flow alarm, or freezing damage to the evaporator. Note: Installation with low water flow/high water temperature rise should always have a full-ported by-pass installed between the chiller inlet and outlet connections, with a manually adjustable gate valve in the by-pass line. Correctly adjusted, this blended return water will maintain an adequate flow through the chiller, at an acceptable return temperature. ALWAYS install a filter/strainer on the inlet off the chiller, in order to prevent particulates (rust, dirt and installation debris) from blocking the evaporator. Blockage will severely impair chiller performance and is not covered by warranty. Always install a pressure gauge in the return piping close to the chiller. This is essential for monitoring system pressure and pump performance. It is good piping practice, especially on systems with short piping runs and/or low system pressure loss, to install a gate valve in the DISCHARGE line from the chiller for throttling purposes. This allows the operator to maintain optimum pump performance by adding resistance to the system. NEVER throttle the water flow on the return line to the chiller. This will cause cavitations and over-heating of the pump. AUTOMATIC WATER MAKE-UP If the chilled water cooling system is expected to lose water during normal operation an automatic water make-up system should be installed, or can be supplied as a factory option. The auto make-up system must include a water pressure regulator and pressure gauge. CAUTION: The tank inside the chiller has a maximum pressure rating of 15 PSIG. Do not discharge city water (which can be 60-80psig) directly into the chiller. Instantaneous pressurization can cause the tank to rupture before the pressure relief valve opens. NOTE: Do not use an automatic water make-up system if glycol is installed for antifreeze protection. The glycol will become diluted and the freeze protection point will be higher (less protection from freezing). Some critical applications require the installation of emergency city water and drain solenoid valves, in the event of a chiller failure. In this case, the chiller MUST be isolated from the city water pressure to avoid damage. After operation of the emergency city water system, the glycol concentration must be carefully checked using a spectrometer. Add glycol to maintain the correct antifreeze concentration if required. NOTE: Vertical piping immediately connected to and from the chiller will impose a static (or standing) head pressure, which can be read on the pump discharge gauge of the chiller, and the gauge installed on the return line to the chiller, when the system is not operating. For example, if the supply and/or return piping from the chiller rises 15 feet before running above a ceiling, etc. this will show a gauge static

pressure of approximately 6-7psig on the gauges (feet x.424 = psig). This is simply the weight of water in the vertical piping at that location, and does not indicate an overall system pressure. SYSTEM VENTING The single most common problem in chiller piping installations is lack of chilled water flow caused by poor piping practices and/or inadequate venting of the system. The symptom is a repeated flow alarm, when the flow switch installed in the return line inside the chiller contacts open which in turns triggers the flow alarm on the control panel. The 0005-0150 size chillers are CLOSED CIRCUIT system and is open to atmosphere. This means that air will remain in all local high points above chiller of the system when it is initially filled with water. NOTE: A local high point is any point in the piping, which can be described as an inverted U section. More clearly defined, if the piping rises vertically ANYWHERE, AND AT ANY ELEVATION IN THE SYSTEM, travels horizontally, then drops again vertically, this inverted U section of piping IS A PERMANENT AIR LOCK AND MUST BE VENTED. Venting is required AT ALL LOCAL HIGH POINTS, and is required on both the supply and return pipes. Vents can be either manual, or automatic. Automatic vents should always be installed with an isolation valve for future service access, repair or replacement. Automatic vents are particularly susceptible to drawing air into the return chilled water piping if this line is allowed to fall into a vacuum. NOTE: The expansion tank should not normally be pressurized to more than 15 psig, measured when the system is not operating. The final discharge pump pressure should NEVER be allowed to exceed the maximum pump rating pressure (normally around 35-50psig). CAUTION: Supercharging the pump with city water pressure higher than nominal rating of the pump, can damage the mechanical pump seal(s), or cause damage to the chiller, piping system or customer equipment. This damage is not covered by the chiller warranty.

WATER/GLYCOL FILLING If glycol is required for antifreeze protection, ALWAYS use an industrial inhibited ethylene glycol, or propylene (food grade) glycol. DO NOT use automobile antifreeze. Suitable glycols are manufactured by the Dow Chemical Company for this purpose, and available nationwide. There are other glycol suppliers available, but always exercise great caution in the selection of a glycol supplier, and always confirm the freeze protection after installation, using a spectrometer. Damage caused by freezing is not covered under warranty. Glycol can be pre-mixed with water to the correct concentration, then pumped into the system, or pumped in separately from the water, provided the system capacity is calculated accurately. The most common method for filling the system is to pump the water glycol into the fill or drain connection of the chiller, with all system vents open. There is a manual vent located at the back of the chiller for initial filling/venting purposes, in addition to the high point piping vents. NOTE: The system should be filled slowly and carefully, allowing all the air to escape. The system can only be filled as fast as the air can escape. Be patient, and do not over-pressurize the system. After initial operation, check all air is vented from the system. GLYCOL CHART Ethylene Glycol Propylene Glycol % of Glycol Freeze Point % of Glycol Freeze Point 0% 32F 0% 32F 10% 26F 10% 26F 20% 16F 20% 19F 30% 4F 30% 8F 40% -12F 40% -7F 50% -34F 50% -28F 60% -60F 60% -60F

The manufacturer of the supplied chiller accepts NO LIABILITY for the work supplied by the customer or civil engineering contractor. MAIN ELECTRICAL INSTALLATION WIRING DIAGRAM INSPECTION Check that the wiring diagram supplied with the chiller is correct and complete: MAIN ELECTRICAL CONNECTION The connection of the device to the main electrical power supply must only be carried out by an licensed electrician, and in strict accordance with local electrical codes and safety standards. ELECTRICAL COMPONENTS FuIIy wired electrical panel The electrical panel is mounted in the chiller and contains all necessary controls for the chiller. Additional wiring in the electrical panel Additional wiring is permitted but must not modify the original condition of the factory-installed wiring. All changes must be recorded in the original wiring diagram and must be available to the manufacturer. MODEL INFORMATION: REFER TO DATA ON SERIAL STICKER FOR EACH MODEL MANUFACTURER S NOTICE The main disconnect switch on the chiller must be switched off before carrying out any wiring work. Do not switch on the microprocessor until startup and commissioning has been successfully completed. MAIN VOLTAGE SUPPLY MPCA0005-0010 MPCA0150 230V/60Hz/1~ 230V/60Hz/1~ The permissible voltage tolerance is ±5%. These values are BINDING and COMPULSORY. INFORMATION ON EXTERNAL WIRING Main power feed Note: If for local code or other reasons the cable size of the power supply line is larger than the terminal size on the main disconnect or power block: 1. A junction box must be fitted to the chiller in compliance with local codes in order to reduce the cable size Or 2. The main disconnect switch or power block of the chiller must be replaced (prior approval of the manufacturer is required).

WATER/GLYCOL INSTRUCTIONS MANUFACTURER'S SPECIFICATIONS The chiller circuit must be 100% filled with water/glycol for operation. If the cooling process causes a loss of water/glycol in the circuit a automatic water make-up vavle must be installed. Insufficient fluid in the water/glycol circuit wiil lead to failure of chiller 1. Safety devices 2. Controls,due to compressor fluctuations/ hunting (frequent switching). And compressor starts. 3. Cooling Capacity These can be avoided by adding a reservoir on the inlet side of the chiller. OnIy operate the chiller with a flow switch (supplied) that switches off the chiller in the event of insufficient water or a faulty pump. If this condition is not satisfied: ALL WARRANTY CLAIMS SHALL BE VOIDED Flow meter and a automatic water make-up system can be purchased from the factory. COLD WATER PIPING Water piping and connection to the chiller must conform with all generally accepted piping practices and local codes. All piping should be performed by a qaulified person(s) or company. The following specifications are intended to prevent damage to the chiller. 1. Avoid unnecessary pressure drop by ensuring correct pipe sizes and routing. 2. Connect the chiller with vibration eliminators to avoid transmission of noise and vibrations. 3. Shut-off valves should be installed at the inlet and outlet of the chiller so that maintenance and repair work can be performed without draining the piping system. 4. Y-Strainer (40 mesh) should be installed on the inlet piping to the chiller to ensure no foreign particles enter the evaporator and or pump.*without a Y-Strainer installed blockage of the evaporator will occur 5. Automatic vents should be installed at all local high points of the piping system to eliminate air locks. See chilled water system diagram for location(s). COLD WATER PIPING CONT. 6. Ensure that the water circuit is maintained at the correct pressure by installing an appropriate sized diaphragm expansion tank close to the inlet of the chiller. The return side of the chiller must be 5-10psig when the pump is running. 7. Install temperature and pressure gauges at the inlet and outlet of the chiller and the heat load to ensure easy inspection and maintenance. 8. All chilled water lines should be insulated. Only insulate pipes AFTER the circuit was tested for leaks. GLYCOL IN CIRCUIT Glycol mixture The following basic rules must be followed: 1. The freezing point of the mixture must be lower than the minimum evaporation temperature. Or the lowest outside piping temperature, whichever is the lower of the two. 2. See correction factors for glycol concentration on back page of the MPCA chiller brochure. 3. Use only an industrial grade inhibited ethylene glycol or food grade propylene glycol solution. DO NOT use automotive antifreeze. 4. Check the ph-value of the solution. lt should be about 9 and must never be less than 7.5. 5. Check the ph-value regularly (maintenance). 6. DO NOT use galvanized piping or fittings Operating the devices with a glycol mixture Check the extemal cold water network and pumps: sufficient pressure for increased water volume pumps suitable for glycol operation bleed valves (rapid bleeder unsuitable) IMPORTANT: NEVER change the antifreeze alarm parameter on chiller without written authorization from factory. If parameter is changed withour factory consent WARRANTY WILL BE VOIDED.!!!!!! The glycol/water mixture must not be discharged into the normal water drainage system. lt must be collected in suitable containers and disposed of in accordance with legal regulations.

MPCA0005 MPCA0150 Mechanical cooling inlet control On a call for cooling set point = 50*F + diff = 7*F entering temperature = 57*F glycol pump running the compressor starts. The controller reads the Inlet temperature and the compressor operates to pull down to set point. As the loop temp falls 0.1*F below set point the compressor shuts off glycol pump remains running. Compressor will turn back on when set point + differential is exceeded.

dixel Installing and Operating Instructions 1592020030 Digital controller with off cycle defrost and AUX relay XR30CX 4. FRONT PANEL COMMANDS CONTENTS 1. GENERAL 1 2. GENERAL DESCRIPTION 1 3. CONTROLLING LOADS 1 4. FRONT PANEL COMMANDS 1 5. MAX & MIN TEMPERATURE MEMORIZATION 1 6. MAIN FUNCTIONS 1 7. PARAMETERS 2 8. DIGITAL INPUT (ENABLED WITH P3P = N) 3 9. TTL SERIAL LINE FOR MONITORING SYSTEMS 3 10. X-REP OUTPUT OPTIONAL 3 11. INSTALLATION AND MOUNTING 3 12. ELECTRICAL CONNECTIONS 3 13. HOW TO USE THE HOT KEY 3 14. ALARM SIGNALS 3 15. TECHNICAL DATA 4 16. CONNECTIONS 4 17. DEFAULT SETTING VALUES 4 1. GENERAL 1.1 PLEASE READ BEFORE USING THIS MANUAL This manual is part of the product and should be kept near the instrument for easy and quick reference. The instrument shall not be used for purposes different from those described hereunder. It cannot be used as a safety device. Check the application limits before proceeding. 1.2 SAFETY PRECAUTIONS Check the supply voltage is correct before connecting the instrument. Do not expose to water or moisture: use the controller only within the operating limits avoiding sudden temperature changes with high atmospheric humidity to prevent formation of condensation Warning: disconnect all electrical connections before any kind of maintenance. Fit the probe where it is not accessible by the End User. The instrument must not be opened. In case of failure or faulty operation send the instrument back to the distributor or to Dixell S.p.A. (see address) with a detailed description of the fault. Consider the maximum current which can be applied to each relay (see Technical Data). Ensure that the wires for probes, loads and the power supply are separated and far enough from each other, without crossing or intertwining. In case of applications in industrial environments, the use of mains filters (our mod. FT1) in parallel with inductive loads could be useful. 2. GENERAL DESCRIPTION Model XR30CX, format 32 x 74 mm, is a digital thermostat with off cycle defrost designed for refrigeration applications at normal temperature. It provides two relay outputs, one for the compressor, the other one can be used as light, for alarm signalling or as auxiliary output.. It is also provided with 2 NTC or PTC probe inputs, the first one for temperature control, the second one, optional, to connect to the HOT KEY terminals to signal the condenser temperature alarm or to display a temperature. The digital input can operate as third temperature probe. The HOT KEY output allows to connect the unit, by means of the external module XJ485-CX, to a network line ModBUS-RTU compatible such as the dixel monitoring units of X-WEB family. It allows to program the controller by means the HOT KEY programming keyboard. The instrument is fully configurable through special parameters that can be easily programmed through the keyboard. 3. CONTROLLING LOADS 3.1 COMPRESSOR The regulation is performed Temper. according to the temperature measured by the thermostat probe SET with a positive differential from the set point: if the temperature Time increases and reaches set point plus Compr. differential the compressor is started ON and then turned off when the temperature reaches the set point value again. In case of fault in the thermostat probe the start and stop of the compressor are timed through parameters COn and COF. 3.2 DEFROST Defrost is performed through a simple stop of the compressor. Parameter IdF controls the interval between defrost cycles, while its length is controlled by parameter MdF. : To display target set point; in programming mode it selects a parameter or confirm an operation. (DEF) To start a manual defrost (UP): To see the max. stored temperature; in programming mode it browses the parameter codes or increases the displayed value. (DOWN) To see the min stored temperature; in programming mode it browses the parameter codes or decreases the displayed value. To switch the instrument off, if onf = off. To switch the light, if oa1 = Lig KEY COMBINATIONS: + To lock & unlock the keyboard. + To enter in programming mode. + To return to the room temperature display. 4.1 USE OF LEDS Each LED function is described in the following table. LED MODE FUNCTION ON Compressor enabled Flashing Anti-short cycle delay enabled ON Defrost enabled ON An alarm is occurring ON Continuous cycle is running ON Energy saving enabled ON Light on ON C/ F ON C/ F Flashing Auxiliary relay on Measurement unit Programming phase 5. MAX & MIN TEMPERATURE MEMORIZATION 5.1 HOW TO SEE THE MIN TEMPERATURE 1. Press and release the n key. 2. The Lo message will be displayed followed by the minimum temperature recorded. 3. By pressing the n key again or by waiting 5s the normal display will be restored. 5.2 HOW TO SEE THE MAX TEMPERATURE 1. Press and release the o key. 2. The Hi message will be displayed followed by the maximum temperature recorded. 3. By pressing the o key again or by waiting 5s the normal display will be restored. 5.3 HOW TO RESET THE MAX AND MIN TEMPERATURE RECORDED 1. Hold press the SET key for more than 3s, while the max. or min temperature is displayed. (rst message will be displayed) 2. To confirm the operation the rst message starts blinking and the normal temperature will be displayed. 6. MAIN FUNCTIONS 6.1 HOW TO SEE THE SETPOINT 1. Push and immediately release the SET key: the display will show the Set point value; 2. Push and immediately release the SET key or wait for 5 seconds to display the probe value again. 6.2 HOW TO CHANGE THE SETPOINT 1. Push the SET key for more than 2 seconds to change the Set point value; 2. The value of the set point will be displayed and the C or F LED starts blinking; 3. To change the Set value push the o or n arrows within 10s. 4. To memorise the new set point value push the SET key again or wait 10s. 6.3 HOW TO START A MANUAL DEFROST Push the DEF key for more than 2 seconds and a manual defrost will start. 1592020030 XR30CX GB m&m r1.1 05.03.2007.doc XR30CX 1/4

dixel Installing and Operating Instructions 1592020030 6.4 HOW TO CHANGE A PARAMETER VALUE To change the parameter s value operate as follows: 1. Enter the Programming mode by pressing the Set + n keys for 3s (the C or F LED starts blinking). 2. Select the required parameter. Press the SET key to display its value 3. Use UP or DOWN to change its value. 4. Press SET to store the new value and move to the following parameter. To exit: Press SET + UP or wait 15s without pressing a key. NOTE: the set value is stored even when the procedure is exited by waiting the time-out to expire. 6.5 THE HIDDEN MENU The hidden menu Includes all the parameters of the instrument. 6.5.1 HOW TO ENTER THE HIDDEN MENU 1. Enter the Programming mode by pressing the Set + n keys for 3s (the C or F LED starts blinking). 2. Released the keys, then push again the Set+n keys for more than 7s. The Pr2 label will be displayed immediately followed from the HY parameter. NOW YOU ARE IN THE HIDDEN MENU. 3. Select the required parameter. 4. Press the SET key to display its value 5. Use o or n to change its value. 6. Press SET to store the new value and move to the following parameter. To exit: Press SET + o or wait 15s without pressing a key. NOTE1: if none parameter is present in Pr1, after 3s the nop message is displayed. Keep the keys pushed till the Pr2 message is displayed. NOTE2: the set value is stored even when the procedure is exited by waiting the time-out to expire. 6.5.2 HOW TO MOVE A PARAMETER FROM THE HIDDEN MENU TO THE FIRST LEVEL AND VICEVERSA. Each parameter present in the HIDDEN MENU can be removed or put into THE FIRST LEVEL (user level) by pressing SET + n. In HIDDEN MENU when a parameter is present in First Level the decimal point is on. 6.6 HOW TO LOCK THE KEYBOARD 1. Keep pressed for more than 3 s the UP + DOWN keys. 2. The POF message will be displayed and the keyboard will be locked. At this point it will be possible only to see the set point or the MAX o Min temperature stored 3. If a key is pressed more than 3s the POF message will be displayed. 6.7 TO UNLOCK THE KEYBOARD Keep pressed together for more than 3s the o and n keys, till the Pon message will be displayed. 6.8 THE CONTINUOUS CYCLE When defrost is not in progress, it can be activated by holding the o key pressed for about 3 seconds. The compressor operates to maintain the ccs set point for the time set through the CCt parameter. The cycle can be terminated before the end of the set time using the same activation key o for 3 seconds. 6.9 THE ON/OFF FUNCTION With onf = off, pushing the ON/OFF key, the instrument is switched off. The OFF message is displayed. In this configuration, the regulation is disabled. To switch the instrument on, push again the ON/OFF key. : Loads connected to the normally closed contacts of the relays are always supplied and under voltage, even if the instrument is in stand by mode. 7. PARAMETERS REGULATION Hy Differential: (0,1 25,5 C / 1 255 F) Intervention differential for set point. Compressor Cut IN is Set Point + differential (Hy). Compressor Cut OUT is when the temperature reaches the set point. LS Minimum set point: (- 50 C SET/-58 F SET): Sets the minimum value for the set point. US Maximum set point: (SET 110 C/ SET 230 F). Set the maximum value for set point. Ot Thermostat probe calibration: (-12.0 12.0 C; -120 120 F) allows to adjust possible offset of the thermostat probe. P3P Third probe presence (P3): n= not present:, the terminal operates as digital input.; y= present:, the terminal operates as third probe. O3 Third probe calibration (P3): (-12.0 12.0 C; -120 120 F). allows to adjust possible offset of the third probe. P4P Fourth probe presence: (n = Not present; y = present). o4 Fourth probe calibration: (-12.0 12.0 C) allows to adjust possible offset of the fourth probe. OdS Outputs activation delay at start up: (0 255min) This function is enabled at the initial start up of the instrument and inhibits any output activation for the period of time set in the parameter. AC Anti-short cycle delay: (0 50 min) minimum interval between the compressor stop and the following restart. CCt Compressor ON time during continuous cycle: (0.0 24.0h; res. 10min) Allows to set the length of the continuous cycle: compressor stays on without interruption for the CCt time. Can be used, for instance, when the room is filled with new products. CCS Set point for continuous cycle: (-50 150 C) it sets the set point used during the continuous cycle. COn Compressor ON time with faulty probe: (0 255 min) time during which the compressor is active in case of faulty thermostat probe. With COn=0 compressor is always OFF. COF Compressor OFF time with faulty probe: (0 255 min) time during which the compressor is OFF in case of faulty thermostat probe. With COF=0 compressor is always active. CH Type of action: CL = cooling; Ht = heating. DISPLAY CF Temperature measurement unit: C=Celsius; F=Fahrenheit. : When the measurement unit is changed the SET point and the values of the parameters Hy, LS, US, Ot, ALU and ALL have to be checked and modified if necessary). res Resolution (for C): (in = 1 C; de = 0.1 C) allows decimal point display. dly Display delay: (0 20.0m; risul. 10s) when the temperature increases, the display is updated of 1 C/1 F after this time. DEFROST IdF Interval between defrost cycles: (0 120h) Determines the time interval between the beginning of two defrost cycles. MdF (Maximum) length for defrost: (0 255min) When P2P = n, (not evaporator probe: timed defrost) it sets the defrost duration, when P2P = y (defrost end based on temperature) it sets the maximum length for defrost. dfd Temperature displayed during defrost: (rt = real temperature; it = temperature at defrost start; SEt = set point; def = def label) dad MAX display delay after defrost: (0 255min). Sets the maximum time between the end of defrost and the restarting of the real room temperature display. ALARMS ALC Temperature alarms configuration: (Ab; re) Ab= absolute temperature: alarm temperature is given by the ALL or ALU values. re = temperature alarms are referred to the set point. Temperature alarm is enabled when the temperature exceeds the SET+ALU or SET-ALL values. ALU MAXIMUM temperature alarm: (SET 110 C; SET 230 F) when this temperature is reached the alarm is enabled, after the ALd delay time. ALL Minimum temperature alarm: (-50.0 SET C; -58 230 F when this temperature is reached the alarm is enabled, after the ALd delay time. AFH Differential for temperature alarm recovery: (0,1 25,5 C; 1 45 F) Intervention differential for recovery of temperature alarm. ALd Temperature alarm delay: (0 255 min) time interval between the detection of an alarm condition and alarm signalling. dao Exclusion of temperature alarm at startup: (from 0.0 min to 23.5h) time interval between the detection of the temperature alarm condition after instrument power on and alarm signalling. CONDENSER TEMPERATURE ALARM (detected by the fourth probe) AP2 Probe selection for temperature alarm of condenser: np = no probe; P1 =thermostat probe; P2 = evaporator probe; P3 =configurable probe; P4 = Probe on Hot Key plug. AL2 Low temperature alarm of condenser: (-55 150 C) when this temperature is reached the LA2 alarm is signalled, possibly after the Ad2 delay. Au2 High temperature alarm of condenser: (-55 150 C) when this temperature is reached the HA2 alarm is signalled, possibly after the Ad2 delay. AH2 Differential for temperature condenser alarm recovery: (0,1 25,5 C; 1 45 F) Ad2 Condenser temperature alarm delay: (0 255 min) time interval between the detection of the condenser alarm condition and alarm signalling. da2 Condenser temperature alarm exclusion at start up: (from 0.0 min to 23.5h, res. 10min) bll Compressor off with low temperature alarm of condenser: n = no: compressor keeps on working; Y = yes, compressor is switched off till the alarm is present, in any case regulation restarts after AC time at minimum. AC2 Compressor off with high temperature alarm of condenser: n = no: compressor keeps on working; Y = yes, compressor is switched off till the alarm is present, in any case regulation restarts after AC time at minimum. SECOND RELAY tba Alarm relay silencing (with oa1=alr): (n= silencing disabled: alarm relay stays on till alarm condition lasts, y =silencing enabled: alarm relay is switched OFF by pressing a key during an alarm). oa1 Second relay configuration: ALr: alarm; Lig: light; AuS: Auxiliary relay; onf: always on with instrument on; db = do not select it; def: do not select it!.; FAn: do not select it!.; df2: do not select it. AoP Alarm relay polarity: it set if the alarm relay is open or closed when an alarm happens. CL= terminals 1-2 closed during an alarm; op = terminals 1-2 open during an alarm DIGITAL INPUT i1p Digital input polarity: op: the digital input is activated by opening the contact; CL: the digital input is activated by closing the contact. i1f Digital input configuration: EAL = external alarm: EA message is displayed; bal = serious alarm CA message is displayed. PAL = pressure switch alarm, CA message is displayed; dor = door switch function; def = activation of a defrost cycle; AUS =to switch on the second relay if oa1 = AUS; Htr = kind of action inversion (cooling heating); FAn = not set it; ES = Energy saving. did: (0 255 min) with i1f= EAL or i1f = bal digital input alarm delay: delay between the detection of the external alarm condition and its signalling. with i1f= dor: door open signalling delay with i1f = PAL: time for pressure switch function: time interval to calculate the number of the pressure switch activation. 1592020030 XR30CX GB m&m r1.1 05.03.2007.doc XR30CX 2/4

dixel Installing and Operating Instructions 1592020030 nps Pressure switch number: (0 15) Number of activation of the pressure switch, during the did interval, before signalling the alarm event (I2F= PAL). If the nps activation in the did time is reached, switch off and on the instrument to restart normal regulation. odc Compressor status with door open: no, Fan = normal; CPr; F_C = Compressor OFF. rrd Outputs restart after doa alarm: no = outputs not affected by the doa alarm; yes = outputs restart with the doa alarm; HES Temperature increase during the Energy Saving cycle : (-30,0 C 30,0 C/-22 86 F) it sets the increasing value of the set point during the Energy Saving cycle. OTHER Adr Serial address (1 244): Identifies the instrument address when connected to a ModBUS compatible monitoring system. PbC Type of probe: it allows to set the kind of probe used by the instrument: PbC = PBC probe, ntc = NTC probe. onf on/off key enabling: nu = disabled; off = enabled; ES = not set it. dp1 Thermostat probe display dp3 Third probe display- optional. dp4 Fourth probe display. rse Real set point: (readable only), it shows the set point used during the energy saving cycle or during the continuous cycle. rel Software release for internal use. Ptb Parameter table code: readable only. 8. DIGITAL INPUT (ENABLED WITH P3P = N) The free voltage digital input is programmable in different configurations by the i1f parameter. 8.1 DOOR SWITCH INPUT (i1f = dor) It signals the door status and the corresponding relay output status through the odc parameter: no, Fan = normal (any change); CPr, F_C = Compressor OFF. Since the door is opened, after the delay time set through parameter did, the door alarm is enabled, the display shows the message da and the regulation restarts is rtr = yes. The alarm stops as soon as the external digital input is disabled again. With the door open, the high and low temperature alarms are disabled. 8.2 GENERIC ALARM (i1f = EAL) As soon as the digital input is activated the unit will wait for did time delay before signalling the EAL alarm message. The outputs status don t change. The alarm stops just after the digital input is de-activated. 8.3 SERIOUS ALARM MODE (i1f = bal) When the digital input is activated, the unit will wait for did delay before signalling the CA alarm message. The relay outputs are switched OFF. The alarm will stop as soon as the digital input is de-activated. 8.4 PRESSURE SWITCH (i1f = PAL) If during the interval time set by did parameter, the pressure switch has reached the number of activation of the nps parameter, the CA pressure alarm message will be displayed. The compressor and the regulation are stopped. When the digital input is ON the compressor is always OFF. If the nps activation in the did time is reached, switch off and on the instrument to restart normal regulation. 8.5 START DEFROST (i1f = dfr) It starts a defrost if there are the right conditions. After the defrost is finished, the normal regulation will restart only if the digital input is disabled otherwise the instrument will wait until the MdF safety time is expired. 8.6 INVERSION OF THE KIND OF ACTION: HEATING-COOLING (i1f = Htr) This function allows to invert the regulation of the controller: from cooling to heating and viceversa. 8.7 ENERGY SAVING (i1f = ES) The Energy Saving function allows to change the set point value as the result of the SET+ HES (parameter) sum. This function is enabled until the digital input is activated. 8.8 DIGITAL INPUTS POLARITY The digital input polarity depends on the i1p parameter. i1p=cl: the input is activated by closing the contact. i1p=op: the input is activated by opening the contact 9. TTL SERIAL LINE FOR MONITORING SYSTEMS The TTL serial line, available through the HOT KEY connector, allows by means of the external TTL/RS485 converter, XJ485-CX, to connect the instrument to a monitoring system ModBUS-RTU compatible such as the X-WEB500/3000/300. 10. X-REP OUTPUT OPTIONAL As optional, an X-REP can be connected to the instrument, trough the HOY KEY connector. The X-REP output EXCLUDES the serial connection. To connect the X-REP to the instrument the following connectors must be used CAB- 51F(1m), CAB-52F(2m), CAB- 55F(5m), 11. INSTALLATION AND MOUNTING Instrument XR30CX shall be mounted on vertical panel, in a 29x71 mm hole, and fixed using the special bracket supplied. The temperature range allowed for correct operation is 0 60 C. Avoid places subject to strong vibrations, corrosive gases, excessive dirt or humidity. The same recommendations apply to probes. Let air circulate by the cooling holes. 12. ELECTRICAL CONNECTIONS The instrument is provided with screw terminal block to connect cables with a cross section up to 2,5 mm 2. Before connecting cables make sure the power supply complies with the instrument s requirements. Separate the probe cables from the power supply cables, from the outputs and the power connections. Do not exceed the maximum current allowed on each relay, in case of heavier loads use a suitable external relay. 12.1 PROBE CONNECTION The probes shall be mounted with the bulb upwards to prevent damages due to casual liquid infiltration. It is recommended to place the thermostat probe away from air streams to correctly measure the average room temperature. Place the defrost termination probe among the evaporator fins in the coldest place, where most ice is formed, far from heaters or from the warmest place during defrost, to prevent premature defrost termination. 13. HOW TO USE THE HOT KEY 13.1 HOW TO PROGRAM A HOT KEY FROM THE INSTRUMENT (UPLOAD) 1. Program one controller with the front keypad. 2. When the controller is ON, insert the Hot key and push o key; the "upl" message appears followed a by flashing End 3. Push SET key and the End will stop flashing. 4. Turn OFF the instrument remove the Hot Key, then turn it ON again. NOTE: the Err message is displayed for failed programming. In this case push again o key if you want to restart the upload again or remove the Hot key to abort the operation. 13.2 HOW TO PROGRAM AN INSTRUMENT USING A HOT KEY (DOWNLOAD) 1. Turn OFF the instrument. 2. Insert a programmed Hot Key into the 5 PIN receptacle and then turn the Controller ON. 3. Automatically the parameter list of the Hot Key is downloaded into the Controller memory, the dol message is blinking followed a by flashing End. 4. After 10 seconds the instrument will restart working with the new parameters. 5. Remove the Hot Key.. NOTE the message Err is displayed for failed programming. In this case turn the unit off and then on if you want to restart the download again or remove the Hot key to abort the operation. 14. ALARM SIGNALS Message Cause Outputs P1 Room probe failure Compressor output acc. to par. Con and COF P3 Third probe failure Outputs unchanged P4 Fourth probe failure Outputs unchanged HA Maximum temperature alarm Outputs unchanged. LA Minimum temperature alarm Outputs unchanged. "HA2" Condenser high temperature It depends on the Ac2 parameter "LA2" Condenser low temperature It depends on the bll parameter da Door open Compressor according to rrd EA External alarm Output unchanged. CA Serious external alarm All outputs OFF. (i1f=bal) CA Pressure switch alarm All outputs OFF (i1f=pal) 14.1 ALARM RECOVERY Probe alarms P1, P3 and P4 start some seconds after the fault in the related probe; they automatically stop some seconds after the probe restarts normal operation. Check connections before replacing the probe. Temperature alarms HA, LA HA2 and LA2 automatically stop as soon as the temperature returns to normal values. Alarms EA and CA (with i1f=bal) recover as soon as the digital input is disabled. Alarm CA (with i1f=pal) recovers only by switching off and on the instrument. 14.2 OTHER MESSAGES Pon Keyboard unlocked. PoF Keyboard locked nop In programming mode: none parameter is present in Pr1 On the display or in dp2, dp3, dp4: the selected probe is nor enabled noa None alarm is recorded. 1592020030 XR30CX GB m&m r1.1 05.03.2007.doc XR30CX 3/4