bulletin 30-32-2011-01_ chiller installation manual

8/3/2019 Bulletin 30-32-2011-01_ Chiller Installation Manual

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CustomerService

IfyouhavequestionsaboutInstallation,operationandMaintenanceoftheUnichillerorwouldliketoorder

replacementpartspleaseusethefollowingcontactinformation.

CustomerServiceandTechnicalSupport (7A.M.to5P.M.CentralTime)

Phone:80052708963144819000

Fax:3144579000

WebSite

Visitwww.unicosystem.comtofindinformationaboutUnicoProducts

2009Unico

Inc.

All

rights

reserved

Thisdocumentissubjecttochangewithoutnotice

7401AlabamaAve.,SaintLouis,MO631113144819000


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Contents

GeneralInstructions 1

PlacementoftheUnichiller 2

Location 2

Clearances 2

RoofRunoff 2

EquipmentPad 2

LawnIrrigation 2

InstallationsNearSaltWater 3

Electrical 3

Piping 3

ChillerPumpCharacteristics 3

EffectOfWaterTemperatureOnPressureDrop 5

UseofPropyleneorEthyleneGlycol 5

Installation 6

ConnectingChillertoWaterCircuit 6

ChillerPumpCharacteristics 6

Electrical 6

WaterSide

Only

Start

up

6

DigitalTemperatureController(DTC) 7

ProgrammingtheDTC 7

DTCTroubleShootingandErrorMessages 8

FullSystemStartup 9

ChillerMaintenance 10

TroubleshootingGuide 11

ChillerWiringDiagrams 12


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1

GeneralInstructions

TheUnichillerismanufacturedtomeetUSandEuropeanelectricalrequirements.

Installationandservicemustbeperformedbyqualifiedinstallerorserviceagency,andmustconformtoallnational,

state,andlocalcodesofthecountrywhereitistobeoperated.

UnichillershaveselfcontainedfactorychargedandtestedrefrigerationsystemscontainingeitherR22or

R407Crefrigerants.Thetypeofrefrigerantandquantityislistedonthefactoryinformationlabellocatedon

thebackpanel.Itisnotnecessarytoaccesstherefrigerationsystemforsysteminstallationandstartup.

AllUnichillersaretestedthroughafullcoolingandheatingcyclepriortoshipmentfromthefactory.

Beforeoperating,besuretheunitisproperlygroundedtopreventinjuryordeath

fromelectricalshock!

Disconnect electrical supplybeforewiring unit toprevent injuryordeath from

electricalshock!

Do not handle the top half of the scroll compressor as it operates at a

temperaturehighenoughtocauseseriousinjury.Operationofthechillerwithout

properfreezeprotectionshallvoidthewarranty.

Donotoperate this system for longperiodsof timewithwateralone.Aminimumof10%

propyleneorethyleneglycol isessentialtopreventfreezing.Higherconcentrationsofglyco

arerequiredtopreventheatexchangerfromrupturingincoldclimates.

Recommendedoperating temperaturesare115F forhotwaterand40F forchilledwater

Contact Customer Service if you wish to operate at water temperatures outside of the

recommendedrange.

Donotuseanyliquidsolutionotherthanthesolutionofwaterandpropyleneorethyleneglycolinthepiping

system.ThesolutionmustbemixedinaccordancewiththeguidelinesintheUnichillerDesignManual.

Pumpmustbeprimed(freeofairandsuctionpipefullof liquid)beforestarting. Ifpump isrundry,rotating

partswillseizeandmechanicalsealwillbedamaged.

All electrical wiring should be inaccordance with all local codes and regulations. A field provided electrica

disconnectshallbeinstalled.Theunitsaresafetycertifiedtosafetycodesofthecountrytheyaresoldin(refer

toUnichillerSpecificationsBulletinforfurtherdetails).

Allpipingmustbeinaccordancewithalllocalcodesandordinances.

Installationshouldbeinaccordancewithalllocalcodesandregulations.

TheseunitsaredesignedtooperatewithR22orR407Cinaselfcontained,precharged

refrigerantsystem.Donotaccesstheclosedrefrigerantsystemforanyreasonotherthan

aftersale,afterinstallationcomponentreplacement.Suchserviceistobeconductedby

qualifiedpersonnelonly.


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2

PlacementoftheUnichiller

Location

Alwayslocatethechilleroutdoors.Neverinstallinsidearoom.

Installingthe

unit

in

apit

will

reduce

performance

Locatechillersothatgroundwaterwillnotentercabinet.

Inareaswithheavysnowfallitisrecommendedthattheunitbeelevated.

Donotattachductworktothechiller.IfairdeflectorsarenecessarycontactUnicoCustomerService

forinstructions.

Clearances

Thechillermust beplacedtoprovideclearancesonallsidesformaintenanceandinspection.

1. Atleast24mustbeavailableonthesideofthechillerthataccessesthecontrolbox,pumpand

compressor.SeeFigure1.

2. Allowatleast60onthefanside.

3. Theremainingtwosidesshouldhaveaminimumclearanceof12

RoofRunoff

TheUnichillershouldnotbelocatedwherelargeamountsofwatermayrunofffromaroofontoorintothe

unit.Best

practices

dictate

that

the

chiller

be

protected

from

large

amounts

of

run

off.

EquipmentPad

Placethechilleronaflatsolidsurfacesuchasaconcreteorfabricatedslab.Theslabshouldbeslightlytiltedso

thatcondensationfromthechillerwillrunofftheslabandnotpoolaroundthechiller.

LawnIrrigation

Makesurethatthereareabsolutelynosprinklerheadsnearenoughtothechillerthatwillspraywaterdirectly

onorintotheunit.Keepinmindthatprevailingwindsmaycarrymistfromsprinklersintothechillercausing

damagetoelectricalconnectionsandmechanicalparts.

Figure 1: Unichiller Clearances

12 inches(0.3 m)

6 inches (0.15 m) minimum or24 inches (0.6 m) for service

60 inches(1.5 m)

service accessside

air discharge

air inlet

air inlet

12 inches(0.3 m)

12 inches max(0.3 m)

shrubs or porous wall

Maximum height of wallis 4.5 ft (1.4 m)

Overhang

TOP VIEW

FRONT VIEW

24 inches(0.6 m)


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3

InstallationsNearSaltWater

Wheninstallingthechillerincoastalareasnearsaltwateritisbesttoinstallthechillersothatthebuildingis

betweentheshoreandtheunit.Toimprovethelifetimeitisbesttorequestatechnicoatcondensercoil.

Electrical

AllelectricalconnectionssuppliedtothechillermustmeetNationalandlocalcodes.

Checkforproperlinevoltageforthechillerandblowermodulesifused.Lowlinevoltagesmayrequirethe

useofasoftstartupgrade.CheckwithCustomerServicetodeterminewhetherornotasoftstartupgradewill

benecessary.

Piping

Makesureallpipesizingconformstoflowrequirements.

Recommendedchillerpipingconnectionsis1minimum.

Airinthepipingsystemcandamagethepumpseals.Makesurethatinthecaseofanonsealedwaterstorage

systemthatairseparatorsorairventsareplacedininletsideofthepipingsystem.

ChillerPumpCharacteristics

Thechillercanbeorderedwithorwithoutaninternalwaterpump.Wheninstallingthechillertotheexisting

watercircuititmaybenecessarytotroubleshootthewatercircuit.Figure2outlinesimportantdataregarding

chillercharacteristicswithandwithoutthepumptoaidinthetroubleshootingprocess.

0 5 10 15 20 25

0

5

10

15

20

25

30

35

0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4

0

25

50

75

100

125

150

175

200

225

0

10

20

30

40

50

60

70

80 PumpCurve

ExternalStaticPressure(UniChillerwithpump)

InternalPressureDrop(UniChillerwithoutpump)

0601.UCH(R)06041,22.UCH(R)06043

3.UCH(R)06046,7,8

4.UCH(R)03641,2

5.UCH(R)03643

6.UCH(R)03646,7,8

R0843:Catalog4

6/3/2009

PressureDifference

Water Flow Rate

GPM

UniChiller models UCHR

PSI

16 2345

036

1/60/230V

1/60/264V

1/50/260V

L/s

GPM

kPa

ft.water

Figure2. Waterflowandpressuredifferentialsforvariouschillermodels.


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5

EffectofWaterTemperatureonPressureDropThetemperatureofthewatercanaffectthepressuredroponthechillersystemTable2liststhecoefficients

usedtocalculatepressuredropduetotemperature.

Table2.PressureDropCorrectionFactorBasedonTemperature(forwater)

TemperatureF 32 40 50 60 68 90 100 110 120 130

C (0) (4.4) (10) (15.6) (20) (32.2) (37.8) (43.3) (48.9) (54.4)

Factor

1.16

1.12

1.05 1.03 1.00 0.93 0.91 0.89

0.86

0.84

UseofPropyleneorEthyleneGlycolTheChillercanreachwatertemperatureswellbelowfreezing.Thereforeitisrecommendedthatthewater

systembechargedwithaminimum10%glycolsolution.Higherpercentagesofglycolwillbenecessarywhen

thechillerisoperatedinregionsofthecountrywhereoutdoortemperaturesfallbelowfreezing. Table3gives

therecommendedglycolpercentagesdependingontheexpectedlowtemperaturesfortheregion.

Table3. Percentageofpropyleneglycolsolutionnecessarytoprotectchillersystemincoldweather.

%PropyleneGlycol 10% 20% 30% 40% 50%

Minimum

Ambient

Temperature

F 26 18 8 7 29

C 3.3 7.8 12.8 21.7 33.9

Thepercentageofpropyleneglycolcanaffectthepressuredroponthesystem.Table4liststhecorrection

factorsrecommendtocalculatepressuredropbasedonthepercentageofglycolinthesystem.

Table4. PressureDropCorrectionFactorBasedonPercentageofGlycol

%Glycol

0

10

20

30

40

50

PropyleneGlycol 1.00 1.10 1.20 1.34 1.50 1.65

EthyleneGlycol 1.00 1.00 1.06 1.16 1.25 1.36


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6

ChillerInstallationConnectingthechillertoinstalledplumbingMakesureallpipesizingconformstoflowrequirements.

1. ChillerPipingconnections:

a. Supply1NPT

b. Return11/4NPT

2. Unitswithoutpumpsareprovidedwithaflowmeter.

3. Whenattaching

piping

to

chiller

double

wrench

to

prevent

damage

to

chiller.

4. Installstrainer(suppliedtochiller)intoreturnline.

5. Installfullportisolationvalvesinsupplyandreturnpiping.

6. Onmultiplechillerinstallations,installacheckvalveinsupplylinesofeachchiller.

7. Installallpipingvalvesflowregulators,pumpsandstoragetankspersystemdesign.

8. Locateallventsathighpointsofpipingsystemforeasyventing.

9. Makeaccommodationsforfillingsystemandaddingglycoltosystem10%glycolminimumrequired.

ElectricalInstallation

1. Installlinevoltagewiringincludingmanualdisconnectatunitperlocalcode.

2. Seewiringdiagramonunitorindocumentationpacketforspecificconnectioninformation.

3.

Install

low

voltage

control

wiring

per

code.

See

wiring

diagram

on

unit

or

in

documentation

packet

forspecificinformation.

Therearemanypossiblecontrolwiringvariations.Consultwiringdiagramsinbackofbulletinformost

commonhookups.AdditionalwiringinformationcanbeobtainedbycallingUnicocustomerserviceat

18005270896.

WaterSideOnlyStartUp

1. RemoveServiceaccesspanelfromchiller.Removechillertoppanel.

2. DisconnectorangeJumperfromterminalS1toS1ontheprintedcircuitcontrolboard.Thiswilldisable

thecompressorcontrolcircuit.

3. Fillsystemwithwateronly.Donotuseaglycolsolution.Youmayneedtodrainthesystemtorepair

leakswhichwouldmeanhavingtorecovertheglycol.

4. Checkforleaks.

5. TurnchillerpumponusingtheON/AUTOswitchonthecontrolboard.

6. Bleedairoutofthesystemandadjustflowrates.Usethechartsbelowtosetflowratebymeasuring

pumpcurrentdraw.Designflowratefor3Tonchillersis7.2gpmand

5Tonchillersare12.0gpm.Ifthereisnoflowmeterinthehydronicsystemflowratecanbe

determinedbythecurrentdrawonthepump.Refertotablexforampdrawonvariouschillemodels

attherecommendedflowrates.

7. Checksecondarypumpoperationandflowratesifapplicable.

8. Checkforleaks.

9. Itis

recommended

that

system

be

leak

tight

prior

to

starting

full

operation.

10.Oncewatersystemisfreeofleaksthesystemshouldbedrainedandthewaterreplacedwitha

minimum10%glycolmixture.Table3liststhepercentageofpropyleneglycolsolutionrecommended

basedonminimumambienttemperaturesexpectedintheareatheunitisinstalled.Unico

recommendsthoroughlymixingthepropyleneglycolwithwaterbeforeaddingtothesystem.

11.Insulatepipingtolimitheatlossandsweating

12.Restartsystemandventair.


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7

DigitalTemperatureController(DTC)

Programming the DTC

1. PressSet keytoenterprogrammode.

2. AnnunciatorwilldisplayeitheranFforFahrenheitoraCforCelsius. Usetheupordownarrow

keystotogglebetweenthetwoselections.PressSetwhenthedesiredtemperaturescale hasbeen

selected.PressSetkeyto inputthescaleandmovetothenextsetting.

3. Annunciatorwill

now

display

S1

heating

set

point.

Use

the

up

or

down

arrow

keys

to

change

the

set

point.Reccomendedheatingsetpointforstartuppurposesis115F.Presssetkeytoinputdesired

temperaturevalueandmovetonextsetting.

4. AnnunciatorwillnowdisplayablinkingDIF1theheatingdifferential temperaturesetting.

Recommendedsettingis10.Usetheupanddownarrowkeystosetto10.Presssetkeytoinput

desiredtemperaturevalueandmovetonextsetting.

5. AnnunciatorwillnowdisplayC1/H1CoolingorHeatingmode.Useupordownarrowkeytotoggle

betweenC1andH1.ChooseH1.PressSetkey.

6. AnnunciatorwillnowdisplayablinkingS2Coolingsetpoint.Useupanddownarrowkeystoselect

thedesired

temperature.

Recommended

cooling

temperature

at

start

up

is

44

F.

Press

set

key

to

inputdesiredtemperaturevalueandmovetonextsetting.

7. AnnunciatorwillnowdisplayablinkingDIF2CoolingDifferentialTemperature.Recommended

settingis10.Usetheupanddownarrowkeystosetto10.Presssetkeytoinputdesired

temperaturevalueandmovetonextsetting.

8. AnnunciatorwillnowdisplayC2/H2CoolingorHeatingmode.Useupordownarrowkeytoselect

C2.Presssetkeytoinputdesiredtemperaturevalue.andmovetonextsetting.

9. DTCwillnowbeinoperatingmodeandwilldisplaycurrentwatertemperature.


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8

DTCTroubleShootingandErrorMessages

Whennotworkingproperly,theDTCwilldisplayerrorcodesontheannunciator.Adescriptionoftheerror

codes,whatconditionmaycausethecodetocomeupandhowtocleartheerrorarelistedintable5.

Table5. DTCTroubleshootingErrorMessages

Display

Message

Description ToCorrect

E1Appearswheneithertheup ordown

keyispressedwhennotintheprogramming

mode.

IftheE1messageappearseven

whennokeysarebeingpressed,

replacethecontrol.

E2Appearsifthecontrolsettingsarenot

properlystoredinmemory.

Checkallsettingsandcorrectif

necessary.

EPAppearswhentheprobeisopen,shortedor

sensingatemperature

that

is

out

of

range.

Checktoseeifthesensed

temperatureisoutofrange.If

not,checkforprobedamageby

comparingittoaknownambient

temperaturebetween30Fand220F.Replacetheprobeif

necessary.

EEAppearsiftheEEPROMdatahasbeen

corrupted.

Thisconditioncannotbefield

repaired.Replacethecontrol.

CL Appearsifcalibrationmodehasbeenentered.

Removepowertothecontrolfor

atleastfiveseconds.Reapply

power.IftheCLmessagestill

repairs,replacethecontrol.


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9

FullSystemStartUp

1. Shutdownmainpowertochiller,

2. ReconnectorangewiretoterminalsS1andS1oncontrolboard.

3. Turnonmainpowertochillers,AirHandlers,PumpsandControls.

4. UseRun/Autoswitchonchillercontrolboardtooperatechiller.

5. Using Table6determinethecorrectswitchpositionsforthedesiredchilleroperation.

Table6. Chilleroperationasdeterminedbycontrolboardswitchpositions.

Run/AutoSwitch

Position

Heat/CoolSwitch

PositionResultingChillerOperation

Run Heat Heatingmodeonly.WatertemperaturecontrolledbyDTC.

Run Cool CoolingModeonly.WatertemperaturecontrolledbyDTC.

Auto Heat Externallycontrolledheatingonly.

Auto Cool Externallycontrolledheatingandcooling.

6. Checkflowratesthroughsystemandadjustasnecessary.

7. Duringnormaloperationthereshouldbea810Ftemperaturedifferencebetweenwatergoinginto

thechillerandwatercomingout.Temperaturedifferencesgreaterorlessthan810mayindicatea

waterflowproblem.

8. After24hoursruntimeremovestrainerandcleanfilterscreenofdirtanddebris.Thescreencanbe

removesbutshouldberetainedincaseitisnecessarytodoanymajorrepairsorupgradesonthewater

system.

9. Accessingrefrigerantsystemisnotnecessaryundernormalcircumstances.

10.Fillout

bulletin

30

101

unichiller

service

report.

Leave

acopy

with

the

customer

and

retain

one

for

yourfiles.

11.Ifchillerdoesnotoperateproperly,refertothetroubleshootingguideinthismanualorcontactUnico

Customerserviceat8005270896.


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10

UnichillerMaintenance

ThefollowingaretheperiodicmaintenancerequirementsofUnichillers

1. Cleanthecoilsurfacesatleasttwiceayearorwhenvisiblydirtybyhosingthecoilwithwater.Usinga

coilcleanerisoptional.

Donotusehighpressuresprayertocleanthecoilasthismaydamageor

flattenthefins.

2. Ifthereistheproperleveloffreezeprotectioninthelines,thereisnoneedtodrainthesystemifitwil

notberunoverthewintermonths.Unicorecommendsusingpropyleneglycolforfreezeprotection.

RefertoTable3forrequiredpercentagesofpropyleneglycol.

Tomeasurethefreezeprotectionlevelinthesystemtakeasampleofthefluidthroughthedrainor

storagetankanduseanantifreezetesteroranantifreezerefractometerthatissuitablefortheglycol

(ethyleneorpropylene)thatisused inthesystem.

3. Ifthechilleristobedrainedoverthewintermonthsitisimportantthatallwaterisremovedfromthe

heatexchanger.DrainsystemfromtheInletconnection.Useawet/dryvacuumtoremoveresidual

water.Orblowtheexcesswateroutfromtheoutputwaterconnection.

4. TheUnichillersareprechargedwithR22orR407Crefrigerants.Onlyexperiencedlicensedrefrigerant

servicepersonnelshouldcheckthechargeandrepairleaksshouldtheyoccur.


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11

TroubleshootingGuide

Theprintedcircuitboardhastestpointswhichcanbeusedfortroubleshooting.Whentroubleshootinginsert

thecommonprobeofthevoltmeterintotheCOMterminalonthecircuitboardandprobethetestpointsfor

voltagereadings.Table7listscommontroubleshootingtestpointsandwhatitmeanswhentheyread24V+/

2volts.

Socket For Common Probe

From Volt Meter

Figure4. CloseupoflowerleftHandcornerofprintedcircuitboardshowingsometestpinscommonprobe

socket.

Table7. LowVoltageTestPinsat24VAC

TestPin

NumberAreadingof24Vfromthetestpinlistedtocommonindicatesthefollowing:

19 Chillerhaspower;Transformerconnectedandgood

6

Externalcall

for

chiller;

enable

pump

18 Flowswitchortimerisclosed

14 Externalcallforcompressor

13 HighPressureSwitchisclosed

12 LowPressureSwitchisclosed(ordefrostrelayisenergizedifindefrost)

17 DigitalTemperatureControllerCallingforHeatingorCooling

8 TimerIsNotInTimeDelayMode;ContactorIsEnergized

7 NotinDefrostOrDefrostPressureSwitch(DPS)IsClosedDueToHighPressure

9PressuresNormal,LowAmbientPressureSwitch(ifcooling)MildWeatherPressure

Switch(ifheating)areclosed;Fanrelayisenergized

10

FanRelay

Is

Energized

4 InDefrostMode;Defrostrelayisenergized

1 ExternalCallForHeatMode

Table8. HighVoltageTestPins

22and24 UnitiscorrectlyPowered

22and23 FanRelayIsClosed(FanShouldBeOn)

22and21 PumpRelayisClosed(PumpRelayShouldbeOn)

22and26 HeaterRelayIsClosed(ShouldBeInDefrostMode)


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12

The following table is to be used for troubleshooting problems that may occur with the chiller. This table

shouldbeusedonlyiftherearenomodificationstothecontrols.

Table9a:UnichillerTroubleshootingChart Main

Problem ProbableCause CorrectiveAction

Uponstartupnothinghappens

Powernotgettingtothechillerorthe

controlboard.

Checkpowercomingintotheunit.

ConfirmAuto/RunSwitchissettoRun.

Testfor230VbetweenTP22andTP24.

277Vfor3p/460Vchillersunitis

correctlypowered.

Checkcircuitboardterminalblockfor24

voltsbetweenRandCBoardpowered

up.

BypassTimerBad

Pumpdoes

not

come

on.

Waterflowrestricted,defectiveflow

switch,pumprelaynotclosed Seepumptroubleshooting.

Pumpdoesnotstayon

Nowaterinthesystem. Putwaterinthesystem.

Watertemperaturesetpointistoo

high/low.

Adjustthetemperaturecontrollerset

point(nolowerthan38Fforcooling,no

higherthan125Fforheating).

Faultytemperaturecontroller.Checktheoperationofthetemperature

controller. Iffaulty,replace.

NoLowvoltageCheckfor24Vontransformer.Fuseon

controlboard

Unichillershutsdowncompletely

(includingthepump).

Openflowswitch(Liquidsolutionis

interruptedorairinthesystem).Checkforairordebrisinthesystem.

Table9b:UnichillerTroubleshootingChart Compressor


Compressorandfanmotorsshutdown

beforethesetwatertemperatureis

reached.

Openlowpressureswitch.

Checkforarefrigerantleak,inoperative

thermalexpansionvalve,lowliquid

solutioncontrolsetting,lowambient

operation,orlowliquidsolutionflow.

OpenCompressortimedelay

BadDefrostBoard

BadDTC

Openhigh

pressure

switch.

Checkforadirtycondenser,inoperable

fanmotor(s),

or

the

re

circulation

of

condenserair.


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13

Table9c:UnichillerTroubleshootingChart Pump


Pumpshutsoffshortlyafterthepoweris

appliedfrom

the

circuit

breaker

with

switchturnedtocoolorheatposition.

Airinthesystemorlackofwaterinthe

system.

Purgetheairinthesystembyopeningthe

ventplugonthepump. Installautoair

vent.Checkwyestrainer.

Lowwater

flow.

Check

pipe

sizing

and

operation

of

the

pump.Flowswitchwillopenatflowrates

lessthan3gpm.

Faultyflowswitch.Checkcontinuityoftheflowswitch. If

faulty,replace.

Table9d:UnichillerTroubleshootingChart Other


Airinthesystemorlackofwaterinthe

system.Waterleak.

Checkforcrackedpipeorloosefittings.

Repair,ifnecessary.


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