Chiller Installation Instructions

8/10/2019 Chiller Installation Instructions

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Marrone & Co., Inc.14020 Interdrive West, Houston, Texas 77032 Phone (800) 473-9178, (281) 227-8400

Fax (800) 473-9175, (281) 227-8404 www.waterchillers.com

INSTALLATION ANDOPERATING INSTRUCTIONS

AIR COOLED

WATER/GLYCOL CHILLERSEOR Model

Model#: ACWC-90-EOR

Serial#: _______________


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MNL_Sec1_ACWC-(2-10T-EOR)_0712.doc Pg 2

IMPORTANTThe United States Environmental Protection Agency (EPA) has issuedvarious regulations regarding the introduction and disposal of refrigerants in

this unit. Failure to follow these regulations may harm the environment andcan lead to the imposition of substantial fines. Because these regulationsmay vary due to the passage of new laws we suggest that, any work on thisunit be done by a licensed certified technician. Should you have anyquestions, please contact the local office of the EPA.

- IMPORTANT MESSAGE TO OWNER:These instructions should be carefully read and kept near the product, forfuture reference. While these instructions are addressed primarily to theinstaller, useful maintenance information is included. Have your installer

acquaint you with the operating characteristics of the product and periodicmaintenance requirements.

CODES AND REGULATIONSThis product is designed and manufactured to permit installation inaccordance with National Codes. It is the installers responsibility to install theproduct in accordance with National Codes and/or prevailing local codes andregulations. The manufacturer assumes no responsibility for equipmentinstalled in violation of any codes or regulations.

INSTALLATION/SERVICEContact your service provider, mechanical contractor, or other company forthe installation and/or service. Cold Shot Chillers provides 24/7 technicalsupport. Please provide complete model and serial number as shown on theunit nameplate when calling. All service is the responsibility of the customer.Labor Warranty (if included/purchased) details are on the Labor WarrantyCertificate.

REPLACEMENT PARTSFor information on replacement parts, contact Cold Shot Chillers. Whenordering parts, give complete model and serial number as shown on the unitnameplate. Most parts will be available through local distributors.


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INTRODUCTIONCongratulations on your new purchase. Each frozen yogurt, ice cream, softserve or frozen beverage machine is an individual piece of refrigerationequipment designed to freeze the product to the designed temperature and

consistency. Since a refrigerant is used to accomplish this task theequipment needs a source of cooling to condense the refrigerant so it can bereused over and over. The available cooling can be found either in theambient air surrounding the equipment (similar to a home air conditioner typesystem) or by an outside water source. The specific model or capacity of themachine will determine how much cooling will be required. If the units are aircooled they will absorb the cool air around the unit and blow hot air into theroom to which the machines are installed. If the machine is liquid cooled theheat given off by the unit is absorbed by the water and pumped off to either a

drain or a chiller

The water cooled units can be cooled by piping city water to the machinesand allowing the water to be discharged down the drain or choosing a moreecologically popular solution and installing a chiller to re-circulate the coolingwater keeping waste water to a minimum.

The purpose of this manual is to assist the owner and their chosencontractors in the selection, installation, operation, and maintenance of yourchiller system. Some specifications, design, or instructions may change, so

please contact Cold Shot Chillers if additional assistance is needed.


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REMOTE STATUS ON/OFF CONTROL BOXThis device is designed to allow storeoperations to monitor chiller operation andremotely turn the chiller ON and OFF.

SUPPLY AND RETURN MANIFOLD/HEADER(DISTRIBUTION MANIFOLD/CITY WATER SWITCHOVER)

The soft serve manifold isdesigned to ensure properflow and cooling for both thesoft serve machines and thechiller. On site fabrication ofthis manifold can inhibitequipment performance andreliability.

EQUIPMENT LOCATIONChiller Location:

The chiller should be located away from easyaccess from vandals but should be accessiblefor service. The unit MUST be installed toallow for adequate air circulation that is asdust free as possible. Allow three (3) feet of

clearance around the unit and at least 8unobstructed clearance above the unit toallow for proper air flow.

Most units are installed on a ground level pad outside the store or on the roof.Since glycol flow is critical to dependable operations, it is important to installthe chiller as close to the soft serve manifold as possible.


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Manifold Location:

The Soft Serve Distribution Manifold/City WaterSwitch Over is provided to allow for proper flow to

each machine and provide for sufficient flow back tothe chiller for dependable operation. This device willalso allow the owner to operate the processmachines on city water in the event of a mechanicalor electrical failure of the chiller.

The manifold consists of two sections:- Blue marked SUPPLY/PRESSURE MANIFOLD- Red marked RETURN MANIFOLDThese items should be installed on a flat wall as

close to the back end of the machines as possible.They should be fairly accessible with a foot stool orstep ladder. In the event of an issue with the chiller,they will need to be accessed to allow the timelyswitch over to city water as to not disrupt businessoperation. This will be discussed in greater detaillater in the manual under Start-up and Operation ofEquipment.

It is common protocol to install the Supply manifoldon top of the return header, but proper operationwill not depend on the placement of these itemsrelative to each other. It is important to mount themas close to the machines as possible.

Remote status ON/OFF Control Box Location:

This box is designed to be installed in plain view toapproved operators and employees.

Remote Box Includes:- Chiller ON/OFF switch.- GREEN operating light- RED alarm light


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INSTALLATION

CHILLER:

Please keep in mind that local codes andregulations may require a licensed technician toinstall the chiller to conform to local requirements.Once the proper location for the chiller has beenestablished, using a crane or other suitablematerial handling equipment, place the chiller onthe roof or on a ground level pad. It is importantto note that the chiller tank does come with adrain plug on the bottom of the unit. It may be

beneficial to set the unit to allow access to thedrain if in the event it becomes necessary to drainthe system for maintenance or repair. If this drainplug is covered the system can be drained usingthe chiller pump. If the unit is placed on the roof itshould be set as just above or as close to themanifold assemble as possible. Similarly, if it isset on a ground level pad, is should also beinstalled as close to the manifold as possible.

Connect piping, (insulated copper is most common) tothe unit. It is good protocol to install a pressure gaugeon the discharge side of the chiller and isolation ballvalves on both the inlet and outlet of the unit. Whilethis is a common practice it is not necessary for goodperformance. It is also good to note here that thechiller pipe marked OUT should be piped to theSUPPLY/PRESSURE header which will then berouted to the INLET on the soft serve machines. As

noted previously proper glycol flow is critical to reliableequipment performance. Be sure to use pipe with thesame or greater inside diameter (I.D.) than unitconnections. The total loop length of the system should be no longer than 60feet. If the piping loop required is greater than 60 feet please contact factoryto confirm the pump capacity on your chiller will provide at least 3 gpm/ton ofglycol flow.


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Complete piping to the pressure header from the chiller outlet and from thereturn header to the chiller inlet.

Pipe a full port city water supply line to the city water inlet to the pressureheader and a suitable drain line from the return header drain line to a freedrain. Be sure to comply with local codes and regulations as needed forbackflow prevention. Utility sinks are not recommended as a suitable drainfor the city water switchover.

Both headers of the soft serve manifold are equipped with NPT ballvalves. The quantity of these connections is dependent upon the quantity ofsoft serve machines the facility has decided to utilize.

The system is designed to connect suitablehose from the blue marked SUPPLYHEADER to the Inlet of the processmachines. The Outlet connection of the

soft serve machines are to be connectedby similar hose to the return headerthrough the NPT ball valve connections.It is common protocol to use Blue hosefor the cooling water coming from theSUPPLY HEADER to the soft servemachines and Red hose from the softserve machines to the Return Header.The actual color of the hose has no affecton the performance of the system. It is

important that the hose is at least 1/2 I.D.to allow for proper flow.


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ELECTRICAL: Connect electrical at terminals tagged in

main control box. Usually at L1-L2-L3 onthe compressor contactor.

On 208/230V/3 systems with high orstinger leg, connect this leg to L2 ormiddle terminal. Failure to do so willcause early control componentmalfunction.

If 208V, verify that the control circuit voltage out of the transformer isthe proper voltage (24V or 120V as noted on the electrical print). If not,check the transformer for additional tap wires for changing to 208V.

Verify that the selector switch is in Off position before applying power.

If compressor has crankcase heaters, allow the power to be applied tothe heaters for at least 24 hours before starting the compressor.

REMOTE BOX: As noted your new chiller is equipped with a remote

operating control box. Connect numbered terminals on TB 1 in the chiller to

like numbered terminals on TB 2 in the control box.

On distances up to 50ft from the chiller, 18AWG control wire is appropriate. If greaterthan 50ft, size the control wire forapproximately 2.0 amps at 24VAC. ContactCold Shot Chillers if assistance.

Your Remote Box will allow you to turn thechiller On/Off and monitor operations. TheChiller is operating Normal when theGREEN light is illuminated. In the event thechiller incurs a problem the RED light willilluminate.


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START-UP

Refer to and complete the Start-Up Check List atthe end of the manual.

Once installation is complete, it would be appropriateto check the system for fluid leaks. If ambienttemperatures are not in the freezing temperatures, werecommend filling the system with water to test forleaks, flush and to verify flow through the system. Fillthe tank while observing the sight tube on the tank.Be sure all Soft Serve Manifold valves are open and the machines are allconnected. If the machines are not available, connect a jumper hose of sometype to allow flow from SUPPLY MANIFOLD valves to the RETURN

MANIFOLD valves.DO NOT OPERATE THE CHILLER IN COOLING CYCLE WITH PURE WATER INTANK!!!

All chillers designed for, and are intended for outdoor use. All safeties are set to allow forlow outside ambient conditions. Operating the chiller in cooling cycle with water only, may

freeze the chiller and void all warranties.

DO NOT ATTEMPT TO OPERATE THE PUMP WITHOUT FLUID IN THE TANK!!This will damage the mechanical seal in the pump and void the pump warranty.

Once the tank is full, locate the Power Selector Switch on the chiller. Thisswitch has three positions, Pump Only, OFF, and Cooling Cycle. Turnthis switch to Pump Only, and Off again to check pump rotation.The motor should be turning clockwise from the motor end. All three phasemotors within the chiller are wired in phase at the factory. If the pump isrotating properly all other motors will also be correct. If the pump turnscounterclockwise, turn all power off and rotate any two legs of power, makingsure that on incoming power with a high voltage leg this leg is on the L2 orcenter lug.Once proper rotation is confirmed, begin to circulate fluid

and bleed all entrapped air in the system, and check forleaks. Once all leaks are repaired, operate in Pump Onlyfor at least 15 minutes. Shut unit down and clean strainerto remove any debris that may have been in the system.Depending on the system this step may be conductedseveral times to help ensure all debris is removed from thesystem.


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Loosen the bolts for the compressor feet to allow it tofloat.Compressor rotation can also be confirmed with the useof refrigerant pressure gauges properly installed onservice ports located above the pump.

When the system has been cleaned and flushed, drain the water and refill thesystem with the appropriate concentration ofwater/glycol mix to within 2 of the top of the tank.(A 40% -50% glycol mixture is recommended-seeglycol chart in appendix for the appropriateconcentration for your geographic area if wintertemperatures are expected to be below 0F).

Recirculate the system and check system for leaks and top off chiller tank asrequired. Be sure to maintain proper glycol concentration to preventpremature chiller failure. Once all the air is purged from the circuit, thesystem is free from debris, check fluid level in reservoir and fill as required.

Dependable chiller and process machine operation is heavily dependentupon proper glycol flow. All chiller pumps are sized to provide proper flowwhen loop lengths do not exceed 60. If a pressure gauge was installed atthe chiller discharge, compare the pressure on the gauge with the pumpcurve published for your specific chiller. Be sure that 3 gpm per ton isavailable as described in the chart below. The chiller by-pass may requireadjustment to allow for proper flow.CHILLER MODEL NUMBER REQUIRED FLOW RATE

ACWC-18-EOR 4.5 GPMACWC-24-EOR 6.0 GPM

ACWC-36-EOR 9.0 GPMACWC-60-EOR 15 GPMACWC-90-EOR 23 GPMACWC-120-EOR 30 GPM


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OPERATION

To operate using the remote control box turnselector switch to Cooling Cycle. Leave the

switch in this position on the chiller to utilizethe ON or OFF switch on the remote box.

Proper cooling for most frozen yogurt, soft serve, ice cream, or frozenbeverage machines is 60F.

Do not adjust the set point below the temperature listed on the unitnameplate.

Temperature Controller (Chromalox):a. Set the controller to the desired Set point Value (lowerLED readout): Push and hold the up or down scrollbutton for two seconds until the value starts changing.

Adjust the value to the desired temperature then stoppressing any buttons. After two seconds, the newvalue will become operative. (Do not adjust the set point below thetemperature listed on the unit nameplate).

b. The controller will also display Present Value (upper LED readout)which is an indication of the current temperature of the fluid in thechiller tank, or Leaving Fluid Temperature depending on the specificchiller design.

Unit is now ready to turn on for cooling. Move the selector switch to CoolingCycle setting and the unit will begin cooling.

a. During the cooling cycle, condenser fans may turn on and off, due tochanges in refrigerant pressure. This should be expected duringnormal operation and occurs due to ambient temperature and theamount of heat being returned in the water chiller.

b. All chillers designed for this application come are equipped with a LowAmbient fan speed controller to allow for dependable operation duringthe winter months. This will alter the fan speed at ambienttemperatures below 35.

Monitor the temperature at the process location and adjust the Set Value onthe temperature controller to achieve the desired value.


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VERIFY REFRIGERANT CHARGE:While cooling at low load conditions, bubbles may become visible in therefrigerant sight glass. The charging procedure requires the unit to be underfull load with 75F or above water temperature with clear sight glass for

optimum performance. Returning fluid temperature should not exceed 100Fon standard units or the chiller will cycle off on head pressure switch and notrun. Should this occur, allow water to cool down by running pump only andrestarting chiller once water is 100F or colder.Refrigerant charge may need to be adjusted to achieve the proper operationof the chiller during final installation as described above.

For any other questions regarding chiller installations, startup, or operation,please contact your service company or Cold Shot Chillers.


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System Components: (See your chillers specification for details.)LOW FLOW SAFETY CONTROLS1. FLOW SWITCH SAFETY (FSS):

a. A mechanical flow switch which monitors the fluidentering the evaporator. This switch is

automatically reset when the fluid flow returns to theproper flow rate. Adjustment should not beperformed unless necessary. If adjustments aremade, ensure that the flow entering the evaporatoris greater than 3 gallons per minute per ton ofrefrigeration rating of the chiller. For example, a 2Ton chiller will need a minimum of 6gpm.

2. This condition can occur when the fluid in theevaporator nears freezing.

3. Generally the cause will be low or insufficient water flow caused by a clogged Ystrainer or restricted flow in the process. Resetting any controls and not determining

the cause for tripping can cause the evaporator to freeze and rupture.4. This safety will automatically trip and stop the cooling circuit when no flow is detected.REFRIGERANT PRESSURE SAFETY CONTROLS1. LOW PRESSURE SAFETY (LPS)

a. Monitors the pressure of the refrigerant and will automatically open when thepressure drops below the sensor set point and will automatically reset whenpressure is above the reset setting.

2. HIGH PRESSURE SAFETY (HPS)a. Monitors the pressure of the refrigerant and will automatically open when the

pressure rises above the sensor set point and will automatically reset whenpressure is below the reset setting. Some units may have a manual reset switch.

LOW AMBIENT CONDITION CONTROLS1. NOTE: They are equipped with a pressure controlled fan control system which is

controlled by the Low Ambient Thermostat which is set at approximately 35F.2. Low Ambient Conditions to 0F Kit (0)

a. Temperature of the chillers ambient condition is monitored and will change theoperation of the chiller to reduce the possibility of freezing condenser fan cycling.

3. Low Ambient Conditions to -20F Kit(M20) (Option)a. For potential ambient conditions below 0F but above -20F, the chiller will have a

similar condenser fan operation with additional possible accommodations for higherwind conditions such as internal or external condenser coil baffles. External bafflesnormally must be installed as needed in the field by the customer when

temperatures approach 0F.b. Hot Gas Bypass (HGB)

1) A bypass valve in the refrigerant system that permits that cooling outputcapacity of the chiller to vary based on the load of the system or for low ambientconditions on startup.


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REMOTE STATUS ON/OFF CONTROL BOXOnce the chiller is operational and with all process machines are running andmaking product, the chiller operation can be monitored using the indoorRemote Status ON/OFF Control Box.

**In the event that the RED light becomes illuminated:To convert f rom CHILL Water to CITY Water Operation:

1. Turn Chiller switch to the OFF position.2. CLOSE both CHILL WATER VALVES (Supply and Return)3. OPEN both CITY WATER VALVES (Supply and Drain)

4. Call a licensed A/C Repair Company, as needed, to evaluatethe condition of the chiller.

To convert f rom CITY Water to CHILL Water Operation: 1. Turn Chiller switch to the ON position.2. Verify Chiller is operational.

a. The RED Safety light should be out.b. The GREEN Operating light should be lit.

3. CLOSE both CITY WATER VALVES (Drain and Supply).4. OPEN both CHILL WATER VALVES (Return and Supply).

**Failure to follow the sequence of operations above will dilute the glycol levelto below the required mixture and void factory warranty.


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MAINTENANCE

1. Periodically check condenser coils for dirt or airborne particle build-up. Check deepinto the coils with a flashlight and, if dirty, flush coils with a water hose- being careful todisconnect the power first and cover pump to prevent water from entering the ventports.

2. If EZ Clean filters are included on the condenser housing, then remove the filters byunsnapping from the unit and rinsing with water on a regular basis. Reattach whencompletely clean.

3. Set up a schedule to remove the screen from the return water line strainer and cleanout. Some particles may pass through the screen and collect as sediment in bottom ofthe tank. Again, disconnect the power then remove the tank drain plug and flush outbottom with water hose.

4. Check the pumps for leakage. Visual indication of leakage from the pump end at thepump connection to the motor is usually an indication of a seal failure. Only action is toreplace the seal with a new seal. Seals are a consumable item.

5. Remove all service valve service port caps to be sure Schrader valves aretight. Vibration from standard operation can over time loosen fittings andconnections. System should be periodically checked to be sure no minorrefrigerant leaks have caused low refrigerant charge.

6. Turn off power to the unit and check the condition of the contactor points for thecompressor and pump. Replace them if the edges become jagged or splattered toavoid premature compressor and/or pump failure. Contactor points are consumableand their life is dependent on the amount of use and power characteristics at the unit.

*NOTE: Not performing the above will cause early uni t failure and

considered abuse which is not covered by warranty.

WARRANTYAll new chillers purchased from Cold Shot Chillers include a one year partsanda five year compressor warranty. If a labor warranty was purchased, seethe labor warranty repair allowances in the for reimbursement conditions.

See the appropriate Warranty Certificates for details.


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Chromalox 1603E Temperature ControllerCold Shot Chillers Part# TCCH-000-160-3-0 (1603E-11150)

Cold Shot Chillers Part# TCCH-000-160-3-0

MNL-Chromalox1603E-ManualInsert_0312.docx Pg1

1. OPERATOR MODE

The display and modification of the operatorparameters can be protected by a secret code.

1.1 PRELIMINARY COMMENTS

It is assumed, at this point, that the instrument hasbeen correctly configured by thesupplier/manufacturer.The upper display indicates the value measured.The lower display indicates the operating set point(below this condition is defined as Normal display).

DO NOT MODIFY ANY PARAMETERSETTINGS WITHOUT FIRST CONTACTING COLDSHOT CHILLERS. Changes to the settings withoutfirst contacting Cold Shot Chillers will void allwarranties.

1.2 INDICATORS

OUT1 Lit up when output 1 is ON. (Call for cooling)OUT2 Serves two functions, when used as alarmindication: (see electrical diagram for details)1) Lit if only Alarm1 is in alarm condition.

2) Flashing at slow rate of about one blink every 2seconds (0.5 Hz ) if only Alarm 2 is in alarmcondition. (Typically for second stage purposesor when used for Hot Gas Bypass)

3) Flashing at fast rate of about two blinks everysecond (2 Hz) if both alarms are in alarmcondition.

C Lit up if the temperature is displayed in C.F Lit up if the temperature is displayed in F.SMT Flashes when the first part of the SMARTalgorithm is active. Lit when the second part of theSMART algorithm is active.

In addition:a) The decimal point on the right hand of the

LSD of the upper display, flashes when theinstrument is working with SP2.

b) The decimal point on the left hand of theLSD of the lower display, flashes when the displayshows the time count down.

1.3 FUNCTION OF THE PUSHBUTTONS

FUNC Saves the new value of the selectedparameter and goes to the next parameter(increasing order).

SMT Enables or disables the SMART functionand scrolls back all the parameters without savingthem. Increases the value of the selectedparameter. Decreases the value of the selectedparameter.+ FUNC Enables/disables the "LAMP TEST".NOTE: The operator parameters must be modifiedwithin 10 seconds. If, during operator parametermodification, no pushbutton is pressed during thistime, the instrument automatically reverts to thenormal display mode. Saving only the parametermodifications which were followed by pressing theFUNC pushbutton.

1.4 DIRECT MODIFICATION OF THE SET POINT

The set point value can be modified without usingthe FUNCpushbutton. When direct access to setpoint modification is required, proceed as follows:1) Press pushbutton or for more than 2

seconds; the set point value will be displayedand it will start to change.

2) Using the and pushbuttons, set thedesired value.

3) When the desired value is reached, DO NOTpress any pushbutton, the new set point willbecome operative 2 seconds after thepushbuttons were last pressed and theinstrument will return to the normal display. Ifduring this procedure the modification is not tobe saved, press the FUNCpushbuttonimmediately (within 2 seconds); the instrumentautomatically returns to the normal displaywithout saving the new set point.

1.5 LAMP TEST

To check the display efficiency,Press pushbuttons + FUNC. The instrument willturn ON, with a 50% duty cycle, all the LEDs of thedisplay (this state is called LAMP TEST). No timeout is applied to the LAMP TEST.To return to the normal display mode, presspushbuttons + FUNC again. No other keyboardfunctions are available during the LAMP TEST.


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Chromalox 1603E Temperature ControllerCold Shot Chillers Part# TCCH-000-160-3-0 (1603E-11150)

Cold Shot Chillers Part# TCCH-000-160-3-0

MNL-Chromalox1603E-ManualInsert_0312.docx Pg2

2. ERROR MESSAGES

2.1 MEASUREMENT ANOMALY SIGNAL

The instrument display shows the OVERRANGEand UNDERRANGE conditions with the following

indications:

The sensor break can be signaled as:- for TC/mV input: OVERRANGE or

UNDERRANGE selected by a solder jumperN O T E : When:- The instrument is set for one control out only andan OVERRANGE is detected, the OUT 1 turns OFF(if reverse action) or ON (if direct action).- The instrument is set to use two control outs and

an OVERRANGE is detected, OUT 1 turns OFF andOUT 2 turns ON.- The instrument is set for one control out only andan UNDERRANGE is detected, the OUT 1 turns ON(if reverse action) or OFF (if direct action).- The instrument is set to use two control outs andan UNDERRANGE is detected, OUT 1 turns ON andOUT 2 turns OFF.

NOTE: When an overrange or an underrange isdetected, the alarms operate as if the instrumenthad detected the maximum or the minimummeasurable value respectively.

To eliminate the out of span condition, proceed asfollows:1) Check the input signal source and the

connecting line.2) Make sure that the input signal is in

accordance with the instrument configuration.Otherwise, modify the input configuration (seesection 4).

3) If no error is detected, send the instrument toyour supplier to be checked.

2.2 ERROR MESSAGES

Diagnostics are made on switching on and during

normal operation.If the instrument detects an error condition thedisplay will show:

ERR in the lower display and the code whichidentifies the type of error in the upper display.The complete list of all the possible errors follows innumerical order.Some errors automatically reset the instrument: ifthe error persists, contact the supplier and providecode.

2.3 LIST OF POSSIBLE ERRORS

100 EEPROM writing error. Consult yoursupplier.150 Generic CPU error. Consult your supplier.2xx Error in the configuration parameters. Thetwo less significant figures indicate the number ofthe incorrect parameter (e.g. 209 ERR indicateserror of parameter P9). Press SMT and FUNC, thenset the parameter correctly. See section 4.301 RTD input calibration error. Contact yoursupplier.305 TC input calibration error. Contact yoursupplier.307 RJ input calibration error. Contact yoursupplier.400 Error in the operator parameters. To dealwith the problem, enter the predefined parameters(Default Parameters, see section B), pressingpushbuttons and at the same time. Then set

the operator parameters. This will not reset theconfiguration parameters.500 Auto-zero error. Contact your supplier.502 RJ error. Contact your supplier.510 Error during calibration. Contact your supplier.

3. MAINTENANCE

WARNING - Electric shock Hazard

Disconnect all power before servicing controller.Failure to do so could result in personal injury orproperty damage.1) SWITCH THE EQUIPMENT OFF (power supply,relay out, etc.).

2) Take the instrument out of it case.3) Using a vacuum cleaner or a compressed air jet(max. 3 kg/cm2) remove all deposits of dust and dirtwhich may be present on the louvers and on theinternal circuits being careful not to damage theelectronic components.4) To clean external plastic or rubber parts use onlya cloth moistened with:- Ethyl Alcohol (pure or denatured) [C2H5OH] or- Isopropyl Alcohol (pure or denatured)[(CH3)2CHOH] or - Water (H2O).5) Make sure that there are no loose terminals.6) Before putting the instrument back in its case,

make sure that it is perfectly dry.7) Put the instrument back and turn it ON.


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TECHNICAL SPECIFICATION



TechSpec_ACWC-90-EOR-_-_-0-_(0313).doc

Model: ACWC-90-EOR-_-_-0-_

Description:7 -Ton, air-cooled portable water chiller system. System will provide approximately 90,000 Btu/hr of cooling capacity

with a leaving fluid temperature of 50F with an ambient air temperature of 95F. The chill water system typically

includes a valve manifold for up to 8 soft serve machines. Manifold also includes city water switchover valves. Full

powder coated steel cabinet. Outdoor service with a low ambient kit good to 0F. Remote On/Off and status panel for

indoor monitoring.

CAPACITY

5% AT 50LCWT WITH 95F AMBIENT

7 TON

90,000 BTU /HR

COMPRESSOR COPELAND HERMETIC SCROLL

REFRIGERANT R410A

CONDENSER FANS / CFM 1 / 4,700

CONDENSER COILS COPPER TUBE / ALUMINUM FIN

EVAPORATOR STAINLESS STEEL / COPPER BRAZED

FLUID CONNECTION (IN/OUT) 1-1/4 NPT MALE 1-1/4 NPT MALE

VOLTAGE / PHASE / FREQUENCY 208/230V / 3 / 60HZ 460V / 3 / 60HZ

MINIMUM CIRCUIT AMPS 38A 19A

DIMENSIONS 44L X 32W X 61H

WEIGHT (APPROX.) 650 LBS

PUMP HP 1-1/2 HP

PUMP OUTPUT 55 GPM @ 30 PSI

TANK SIZE 41 GALLON

TANK CONSTRUCTION INSULATED 304 STAINLESS STEEL

Note: All specifications subject to change without notice.

Controls:Electronic temperature controller with constant (set point & process) temperature LED readout.

Refrigeration Components:Efficient scroll compressor, sight glass, moisture indicators, balance port expansion valves, filter drier, service

valves, stainless steel brazed plate evaporator, head pressure control. System includes fan controller for low

ambient conditions down to 0F.

Process Fluid Components:Stainless steel centrifugal pump, bronze Y strainer with 20 mesh 304 stainless steel screen, and insulated

stainless steel reservoir with tank level sight glass and fill port.

Safety Controls:High/low pressure safeties, internal overloads for compressor and fan motors, safety fuses for pump, low water

safety switch safety.

Construction:

Welded steel powder coated frame and cabinet.Warranty:

One year parts / five year compressor.


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TECHNICAL SPECIFICATION



TechSpec_ACWC-90-EOR-_-_-M20-_(0612).doc

Model: ACWC-90-EOR-_-_-M20-_

Description:7 -Ton, air-cooled portable water chiller system. System will provide approximately 90,000 Btu/hr of cooling capacity

with a leaving fluid temperature of 50F with an ambient air temperature of 95F. The chill water system typicallyincludes a valve manifold for up to 8 soft serve machines. Manifold also includes city water switchover valves. Full

powder coated steel cabinet. Outdoor service with a low ambient kit good to -20F. Remote On/Off and status panel for

indoor monitoring.

CAPACITY

5% AT 50LCWT WITH 95F AMBIENT

7 TON90,000 BTU /HR

COMPRESSOR COPELAND HERMETIC SCROLL

EVAPORATOR STAINLESS STEEL / COPPER BRAZED

FLUID CONNECTION (IN/OUT) 1-1/4 NPT MALE 1-1/4 NPT MALE

CONDENSER FANS / CFM 1 / 4,700

CONDENSER COILS COPPER TUBE / ALUMINUM FIN

VOLTAGE / PHASE / FREQUENCY 208/230V / 3 / 60HZ 460V / 3 / 60HZ

MINIMUM CIRCUIT 38 19

DIMENSIONS 44L X 32W X 61H

WEIGHT (APPROX.) 650 LBS

PUMP HP 1-1/2

PUMP OUTPUT 55 GPM @ 30 PSI

TANK SIZE 41 GALLON

TANK CONSTRUCTION 304 SS

REFRIGERANT R410A

Note: All specifications subject to change without notice.

Controls:Electronic temperature controller with constant (set point & process) temperature LED readout.

Refrigeration Components:Efficient scroll compressor, sight glass, moisture indicators, balance port expansion valves, filter drier, service

valves, stainless steel brazed plate evaporator, head pressure control. System includes fan speed controller and

hot gas bypass for low ambient conditions down to -20F.

Process Fluid Components:

Stainless steel centrifugal pump with open drip-proof motor, bronze Y strainer with 20 mesh 304 stainless steelscreen, and insulated stainless steel reservoir with level sight glass and fill port.

Safety Controls:High/low pressure safeties, internal overloads for compressor and fan motors, safety fuses for pump, low watersafety switch safety.

Construction:

Welded steel powder coated frame and cabinet. Internal wind baffle.Warranty:

One year parts / five year compressor.


21/36

DRAWN ENGINEERING

SSUED

SIZE DIMENSION NOTES DW

AUnits are in inches.

+/-

Front-Rig

ACWC-90-E

3 April 2012 SCALE 1 : 16 DWG-INST_ACWC-90-EOR_(0412).vsd

GENERAL NOTES

Specifications subject to change without notice.

Shown with Full Metal Cabinet included.

RIGHT

VIEW

FRONT

VIEW

32.0in. 44.0in.

60.0in.

"Y" Strainer

(inside)

Chiller Pump

(inside)

Insulated Tank with Lid

(inside)

Access Panel

Temperature Controller

Control Switch

(PumpOnly/Off/Cooling)

Outlet (NPT-Male)

Inlet (NPT-Male)


22/36

DRAWN ENGINEERING

SSUED

SIZE DIMENSION NOTES DW

AUnits are in inches.

+/-

Top-Botto

ACWC-90-E

3 April 2012 SCALE 1 : 16 DWG-INST_ACWC-90-EOR_(0412).vsd

GENERAL NOTES

Specifications subject to change without notice.

Shown with Full Metal Cabinet included.

BOTTOTOP VIEW

Control Switch &

Temperature Controller

Front

2.8in.

Electrical Panel


23/36

FUSES 8 AMP

WIRING SCHEMATIC

ACWC-090-EOR-_-_

FILE: ACWC-090-EOR_-_-0-5 (02

DESCRIPTION

1. REPLACEMENT WIRE AND FUSES MUST BE THE SAME

SIZE AS ORIGINAL.

2. UNIT MUST BE PERMANENTLY GROUNDED AND

CONFORM TO N.E.C. & LOCAL CODES.

3. MINIMUM WIRE SIZE BASED ON 75 DEGREES C

INSULATION COPPER WIRE.

4. OPTIONAL HOT GAS BYPASS FOR CAPACITY CONTROL.5. SEE MANUAL IF ADJUSTMENT IS NECESSARY ABOVE

FACTORY SET MINIMUM.

NOTES:

COMPONENT CODE

CC

M

COMPRESSOR

BLK

BLK

BLK

T1

T2

T3

CCH

(opt)

C

S

R

GND

BLK

BLK

BLK

L1

L2

L3

TO

POWER

SUPPLY

GROUNDING LUG

TC

TEMPERATURE CONTROLLER

1603 E

RED

WHITE

2

3

4

5

7

8

9

16

10

12

13

14

11

15

RED/WHT

BRN

HPS LPS

OPEN 10

CLOSE 25 PSI

OPEN 630

CLOSE 480 PSI

BLUBLUYELYEL

BRN

(see note #4)

WHT

2TB1

3

RED

BLU

GRN

GRN

Pump Only

Cooling Cycle

GRN

FS

YEL YEL

(see note #5)

BLKTB1

HGB

FB-2 PC

M

CHILLER PUMP

BLK

BLK

BLK

BLK

BLK

BLK

FU2

FU1

FU3

1

208/230V460V

CT

CONNECT FOR

APPROPRIATE

VOLTAGE

NOTE

24V

secondaryYEL

(COM)

CB

LAT

SET 0 DEG.

GRA

FCC

OPEN 260 PSI

CLOSE 450BLKBLK

Connect TB1 1,2,3,4,5, to TB2 in

remote box 1,2,3,4,5,respectively.

NOTE Field Installed Wiring

GRN/YELGND

BLKBLK

SW

DISCONNECT

FIELD

SUPPLIED

RC

M1 P

L2/NBLK

BLK/WHT

ORN

ORN

L1

WHT

BLK

BRN M

FMUsed with low ambient

Used withlow ambient

kit only

BRN

GRA BRN

P266 CA

BRNGRA

Used with low ambient kit only

24V Control

VIO

BRN

4

TB1

YEL BRN

5

TB1

VIO

CIRCUIT BREAKER

COMPRESSOR CONTACTOR

H CRANKCASE HEATER

M COMMONCONTROL TRANSFORMER

FUSE BLOCK

C FAN CYCLE CONTROL

FAN MOTOR

FLOW SWITCH

FUSE

D GROUND

B HOT GAS BYPASS

S HIGH PRESSURE SAFETY

LINE

R LOW AMBIENT RELAY

T LOW AMBIENT T-STATS LOW PRESSURE SAFETY

MOTOR

T OPTIONAL

PUMP CONTACTOR

6 FAN SPEED CONTROL

PUMP RELAYRUN CAPACITOR

SAFETY RELAY

CHILLER ON/OFF SWITCHTERMINAL BLOCK

THERMOCOUPLE-TYPE J

BLU

BRN

GRN/YEL

GND

L2

L3

L1

T2

T3

T1

BLURED/WHT FU3

5 AMP

SR

BLK

BLK

FU1

FU2

FB-1

(2)-1 AMPFuse may be used in

place of circuit breaker

BRN

BLU

GRN

BRN

SRC1 C2

PCC1 C2

LARC1 C2

CCC1 C2

REDWHT

BLK

VPC

P1

P266 Electronic

Pressure Transducer

If a second P266 transducer is

used, wire the P2 terminal the

same as P1 terminal

Pressure Transducer Class 2

Wiring forALL P266 Models

Used with low ambient kit only

LAR

2

3

1

LAR

12

1TB1

RED

CM450

4

6

COM

RUN


24/36

PUMP MOTOR FUSE SIZES

HP

2 9 AMP 4.5-6.5 AMP

15 AMP 7.5-11 AMP

30 AMP 13-19 AMP

3

5

30 AMP 18-25 AMP7.5

FUSE OVERLOAD

UNIT VOLTAGE

208/230-3-60, 197/220-3-50

WIRING SCHEMAT

ACWC-090-EORM-_-_

FILE: ACWC-090-EOR_-_-0-5 (021

DESCRIPTION

1. REPLACEMENT WIRE AND FUSES MUST BE THE SAME

SIZE AS ORIGINAL.

2. UNIT MUST BE PERMANENTLY GROUNDED AND

CONFORM TO N.E.C. & LOCAL CODES.

3. MINIMUM WIRE SIZE BASED ON 75 DEGREES C

INSULATION COPPER WIRE.

4. HOT GAS BYPASS FOR TEMPERATURE CONTROL.5. SEE MANUAL IF ADJUSTMENT IS NECESSARY ABOVE

FACTORY SET MINIMUM.

NOTES:

COMPONENT CODE

CC

M

COMPRESSOR

BLK

BLK

BLK

T1

T2

T3

BLKBLK

CCH

(opt)

C

S

R

GND

BLK

BLK

BLK

L1

L2

L3

TO

POWER

SUPPLY

GROUNDING LUG

TC

TEMPERATURE CONTROLLER

1603 E

RED

WHITE

2

3

4

5

7

8

9

16

10

12

13

14

11

15

RED/WHT

BRN

HPS LPS

OPEN 10

CLOSE 25 PSIOPEN 630

CLOSE 480 PSI

BLUBLUYEL

YEL

2TB1

3

RED

BLU

GRN

GRN

Pump Only

Cooling Cycle

GRN

FS

YEL YEL

(see note #5)

BLKTB1

208/230V460V

CT

CONNECT FOR

APPROPRIATE

VOLTAGE

NOTE

24VYEL

(COM)CB

BLU

LAT

SET 0 DEG.

GRA

RC

FCC

OPEN 260 PSI

CLOSE 450

M1 P

L2/NBLK

BLK/WHT

ORN

BLKBLK

L1

WHT

BLK

BRN M

FM

Connect TB1 1,2,3,4,5, to TB2 in

remote box 1,2,3,4,5,respectively.

GRA

GRN/YELGND

SW

DISCONNECT

FIELD

SUPPLIED

secondary

M

CHILLER PUM

FU2

FU1

FU3

FB-2

SEE CHART

BLK

BLK

BLK

BLK

BLK

BLKPC OL

L2

L3

L1

T2

T3

T1

95 96

OL

VIO

X AUXILIARY CONTACTSCIRCUIT BREAKER

COMPRESSOR CONTACTOR

H CRANKCASE HEATER

M COMMON

CONTROL TRANSFORMER

FUSE BLOCKC FAN CYCLE CONTROL

FAN MOTOR

FLOW SWITCH

FUSE

D GROUND

B HOT GAS BYPASS

R HOT GAS RELAY

HIGH PRESSURE SAFETY

LINE

R LOW AMBIENT RELAY

LOW AMBIENT T-STAT

LOW PRESSURE SAFETY

MOTOR

OVERLOAD

T OPTIONAL

PUMP CONTACTOR

6 FAN SPEED CONTROL

RUN CAPACITOR

SAFETY RELAY

CHILLER ON/OFF SWITCH

TERMINAL BLOCKTHERMOCOUPLE-TYPE J

TIME DELAY ON MAKE

BLU

AUX

13 14

PC

YEL

NOTE Field Installed Wiring

FB-1

GRNGRN BRN

VIO

BRN

4

TB1

YEL BRN

5

TB1

BRN

P266A

BRNGRA

C

BRN

GRN/YEL

GND

24V Control

BRN

BRN

SRC1 C2

PCC1 C2

CCC1 C2

LARC1 C2RED

WHTBLK

VPC

P1

P266 Electronic

Pressure Transducer

If a second P266 transducer isused, wire the P2 terminal the

same as P1 terminal

Pressure Transducer Class 2

Wiring forALL P266 Models

Used with low ambient kit onlyUsed with low ambient kit only

BLURED/WHT FU3

5 AMP

SR

BLK

BLK

FU1

FU2

(2)-1 AMPFuse may be used in

place of circuit breaker

Used with low ambient

LAR

2

3

1

LAR

12

ORN

Used withlow ambient

kit only

1TB1

RED

CM450

4

6

COM

RUN


25/36

DRAWN ENGINEERING

ISSUED

SIZE FSCM NO DWG NO

TONCOLD SHOT CHILL

Model: REMOTE STATU

12/10 SCALE 1 : 8 SHE

6.504.25

6.50

7/8" Low Voltage

SW

SAFETY

LIGHT

OPERATING

LIGHT

OFF/ON

COLD SHOT CHILLERS


26/36

CIRCUIT BREAKERCOMPRESSOR CONTACTOR

H CRANKCASE HEATERCONTROL TRANSFORMERFUSE BLOCK

C FAN CYCLE CONTROLD GROUNDB HOT GAS BYPASS

FAN MOTORFLOW SWITCHFUSE

S HIGH PRESSURE SAFETYR LOW AMBIENT RELAYT LOW AMBIENT THERMOSTATS LOW PRESSURE SAFETYT OPTIONAL66 FAN SPEED CONTROL

PUMP CONTACTORRUN CAPACITORSWITCH 2 POSITION SELECTORTERMINAL BLOCKTHERMOCOUPLE-TYPE J

COMPONENT CODE

NOTES:

COLD SHOT

CHILLERS

DESCRIPTION

FILE: ACWC-090-EOR_-_-0-5 (0213).vsd

1. REPLACEMENT WIRE AND FUSES MUST BE THE SAME SIZE AS ORIGINAL2. UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N.E.C. & LOCAL CODES3. MINIMUM WIRE SIZE BASED ON 75 DEGREES C INSULATION

COPPER WIRE

Connect TB2 1,2,3,4,5, to TB1 in chiller 1,2,3,4,5,respectively.

NOTE FIELD INSTALLED WIRING

#6 Not used

REMOTE BOX

ACWC-036-EOR-_-_-

ACWC-060-EOR-_-_-

ACWC-090-EOR-_-_-

1TB-2 2 3 4 5 6

REMOTE BOX FIELD INSTALLED

RED

RED/WHT

BRN

YEL

BLK

BRN

OFF/ONSWITCH

OPERATING

X1 X2

SAFETY

X1 X2BRN


27/36

Delay On Break

% Phase Unbalance

Reset Mode

Control Mode

Average phase to phase line voltage 190-630

3 minutes**

Amount of time before the load de-energizes due to a non-critical fault*

Amount of time between the load de-energizing and re- energizing

Maximum phase to phase average voltage

Amount of allowable voltage unbalance

460V

8 seconds**

2%

OFF

Based

on wiring

0-10 minutes

0-15 secondsDelay on Fault

% Over Voltage 2-25%

2-20%

AUTO,

0-10

ON or OFF

3

Parameter Description Range Factory Setting

Line Voltage 230V

3 minutes**

8 seconds**

13%

2%

3

OFF

Based

on wiring

10%

Incoming 3-phase

voltage from line side of

compressor contactor

The incoming 3-phase

voltage is used to

power up the ICM450

as well (190-600)

Incoming 3-phase voltage

from load side of

compressor contactor

THREE PHASE VOLTAGE MONITOR

190-630 VAC 50-60 Hz

6 5 4 3 1

CONTROL

VOLTAGE

19-240-

VAC

RED

COMALARMRUN

LOAD

ENERGIZED

RED

CONNECT FOR

OPTIONAL ALARM

FUSE BLOCK

FU1

FUSES 1 AMP

FU3

FU2

SETUP FAULTREAD

SHORT PINS WHEN USING 24

VAC CONTROL VOLTAGE

LOAD1A

LOAD2B

CLOAD3

LINE1

A

LINE2

LINE3

B

C

CONTROLS

P/N ICM450

ICM

TO CHILLER

OFF/ON SWITCH

24V FROM

TRANSFORMER

AUTO or number of times the load can be re-engerized after a load side

fault before a manual reset is necessary. Note: when monitoring line side

only, the reset mode will always be AUTO

With control mode set to OFF, the load will energize if no 3- phase fault

conditions exist; with control mode ON, the load will energize if no fault

conditions exist and control voltage is present at 1 and 3 of the ICM450

*Non-critical fault are faults such as High/Low Voltage and Phase Unbalance. Critical faults, such as Phase Loss and Phase Reversal have a fault

interrogation of under 2 seconds and it is not user adjustable.

ICM 450C; Parameter Settings and Wiring Diagram For 230-460 Volt Units, 24Volt Control

Parameters

Minimum phase to phase average voltage% Under Voltage 2-25% 13% 10%

NOTES:

FAULT- PRESS TO READ FAULTS.HOLD FOR 5 SECONDS TO

CLEAR AND RESET MEMORY.

READ- HOLD FOR VOLTAGE DISPLAY

SETUP-PRESS TO ENTER SETUP MODE AND SELECT USER

PARAMETERS.

PRESS ARROWS TO SCROLL THROUGH AND SELECT USERPARAMETER SETTINGS IN SET UP MODE. HOLD DOWN FOR

FAST EDIT.FILE:

ICM450C 3ph voltage monitor0413.vsd


28/36



MNL_ICM450-Insert_(0313).docx - 1 -

ICM450Three Phase Voltage MonitorsProgrammable, 25-Fault Memory, Protects motors from premature failure and burnouts

MODE OF OPERATIONAt power up, the ICM450 evaluates the incoming power for proper phase sequence, amplitude, and symmetry (voltage

unbalance). If the three phase input at the line side connections is within user-set parameters, the load energize LED is turned on

and the internal relay is energized. Continuity will be across terminals 4 and 6. If connections are made to the load side terminals,

the ICM450 will transfer monitoring over to the load side only.

When a critical fault condition (phase loss or phase reversal) is present, the relay will immediately de-energize, the load

energized LED will turn off, the fault LED will flash, and the fault is written to memory. Continuity will be across terminals 4 and 5.

If a non-critical fault condition (unbalance, high or low voltage) is present, the ICM450 will ignore it during the interrogation

delay time. If it is still present following the interrogation delay time, the relay will de-energize, the load-energized LED will turn off,

the fault LED will flash, and the fault is written to memory. Continuity will be across terminals 4 and 5.

The ICM450 will store the last 25 faults in memory. The relay will not energize if any fault conditions exist. The integral

adjustable delay on break timer will prevent short cycling.

SETTING THE PARAMETERS

1.Press the green SETUP button to enter Setup mode. Setup LED will light.

2.Use the and arrows to change user parameters.

3.

Scroll through setup by pressing and releasing the SETUP button.

4.When the last parameter has been set, the phase average will be displayed and the Setup LED will automatically turn OFF.

BUTTON FUNCTIONS

Press arrows to scroll through and select user

parameter settings in Setup mode.

HOLD down for fast edit.

Press to enter Setup mode

and select user parameters.

Hold for voltage display

a->b, b->c, a->c

(simultaneously).

Press to read faults.

Hold for 5 seconds to clear

faults and reset memory.

Parameters (See Wiring Diagram for Factory Settings)

Parameter Description Range

Line Voltage Average phase to phase line voltage 190-630

Delay On Break Amount of time between the load de-energizing and re-energizing 0-10 mins

Fault Interrogation Amount of time before the load de-energizes due to a non-critical fault* 0-15 secs

% Over/Under Voltage Maximum/minimum phase to phase average voltage, respectively 2-25%

% Phase Unbalance Amount of allowable voltage unbalance 2-20%

Reset Mode AUTO or number of times the load can be re-energized after a load side fault before a

manual reset is necessary. Note: When monitoring line side only, the reset mode will

always be AUTO

AUTO,

0-10

Control Mode With control mode set to OFF, the load will energize if no 3- phase fault conditions

exist; with control mode ON, the load will energize if no fault conditions exist and

control voltage is present at terminals 1 and 3 of the ICM450

ON or OFF

*Non-critical faults are faults such as High/Low Voltage and Phase Unbalance. Critical faults, such as Phase Loss and Phase Reversal,

have a fault interrogation of under 2 seconds and it is not user adjustable.

** For best recommendations, consult manufacturer of equipment.

FAULTREAD

SETUP


29/36

MNL_ICM450-Insert_(0313).docx

- 2 -

Fault Conditions

Press and release fault button to scroll through all saved faults.

Note: For initial setup, press and hold FAULTfor 5 seconds to remove any previously stored faults.

Fault Problem Corrective Action

Back Phase

Loss

Not all three of the phases

on the load side are

present

1. Re-energize the contactor.

2. If the fault reappears after the load energizes:

a. Turn all power OFF

b. Check all load side connections

c. Check the contacts of the contactor for debris or excess carbon.Back Phase

Rev

Loads 1, 2, or 3 are not in

sequence

(not 120 phase shifted)

1. Turn OFF all power.

2. Swap any 2 phases on the load side of the unit only (example: swap load 1 and load 2) *

3. Re-apply power.

Back Phase

Unbal

A voltage unbalance

between the three load

phases exceeds the

unbalance setpoint

1. Press the READ button to observe the present load voltages. Check system for

unbalance cause.

2. Increase the fault interrogation time if necessary.

3. Increase the percent unbalance setting if necessary.

Front Over

Volt

Average phase-phase

voltage exceeds the

maximum percentage

1. Check system for over-voltage cause.

2. Increase the percent over-voltage setting if necessary.


Front Phase

Loss

Not all three of the phases

on the line side are present

1. Press and hold the READ button on the phase monitor or use an AC voltmeter to

carefully measure all three phase-phase line voltages

(example: Line 1 Line 2, Line 2 Line 3, Line 3 Line 1).2. Repair the missing phase.

Front Phase

Rev

Lines 1, 2, or 3 are not in

sequence (not 120 phase

shifted)

1. Turn OFF all power.

2. Swap any 2 phases on the line side of the unit. For example: swap load 1 and load 2*.

3. Re-apply power.

Front Phase

Unbal

A voltage unbalance

between the three line

phases exceeds the

unbalance setpoint

1. Press the READ button to observe the present load voltages. Check system for

unbalance cause.


3. Increase the percent unbalance setting if necessary.

Front Under

Volt

Average phase-phase

voltage is below the

minimum percentage

1. Check system for under-voltage cause.

2. Increase the percent under-voltage setting if necessary.


* Onlyswap phases during initial setup, notafter unit has been in operation without errors.

Troubleshooting

Problem LCD Readout LED Status Corrective Action

Load will not energize Phase

Avg.

All LEDs Off Confirm that the control input is properly connected and

configured

Load will not energize Phase

Avg.

Load LED Off,

Fault LED Blinking

Press FAULT to observe the current fault; correct the

condition of the first fault that appears (see Fault Conditions,

Page 6 for a list of corrective actions)

Fault LED blinks repeatedly

while load is energized

Phase

Avg.

Fault LED Blinking,

Load LED On

Indicates there are faults saved in the memory, press FAULT

rapidly to scroll through saved faults; to clear the faults,

press and hold FAULT for more than 5 seconds

Load will not de-energize

when control voltage is OFF

Phase

Avg.

Load LED On,

Control LED Off

The control mode setting is OFF; press SETUP to get to the

control mode. Press to set the control mode ON

Setup LED is on while load is

being energized

Anything Other

Than PhaseAvg.

Setup LED On,

Load LED On

To exit the setup mode, press either READ or FAULT

Load will not energize Reset Fault LED Blinking Unit in lockout; maximum number of retries in manual reset

mode has been reached; to reset unit, press FAULT and hold

for more than 5 seconds

Load turns ON and OFF

repeatedly

Readout is

Irrelevant

Fault LED Blinking Fix load side fault; press FAULT to observe condition; the

delay on break period may be too short; press SETUP to

enter the delay on break mode; press to lengthen the delay


30/36

COLD SHOT CHILLERS

DRAWN ENGINEERING

ISSUED

SIZE FSCM NO DWG NO

ACHILL WATER CIRC

E - Portable with

04/2011 SCALE NA DWG-CHW_AllFlowDesigns_0411d.vsd

CHILLER

PUMP

MANUAL

BYPASS

STRAINER

FS

FLOW SWITCH

DRAIN

STAINLESS STEEL/COPPER BRAZED

PLATE EVAPORATOR

STAINLESS STEEL

TANK WITH SHOE BOX

LID

TEMPERATURE

SENSOR

(Temperature

Controller)


31/36

COLD SHOT CHILLERS

DRAWN ENGINEERING

ISSUED

SIZE FSCM NO CHILL WATER

Chiller M

ACWC-90

(TYPICA

0210 SCALE 8 CONNECTIONS

NOTES

ALL PIPING IS TO BE INSULATED

CHILL

WATER IN

WATER

OUT TO

CHILLER

65.5

CITYWATER IN

TO

DRAIN

TO MACHINES

FROM MACHINES

60.0

1 BALL

VALVE

1 BALL

VALVE

3/4 BALL

VALVE

3/4 CHECK

VALVE

1 CHECK

VALVE

3/4 BALL

VALVE


32/36


Fax (800) 473- 9175, (281) 227-8404 www.waterchillers.com

Pump/Motor Assembly ASP-SSPC

Exploded View and Cross Section of Pump and Motor Assembly

CSC_ASP-TechnicalInfo_0511.doc

Item

No. Part Description

Standard

Materials

100 Casing 304 SS

200 Impeller (Enclosed) 304 SS

300

Mechanical Seal - Type 6 (std.)

(Other seal types available)

Car/Cer/Buna

N/316 SS

400 Seal Plate 304 SS

500 Casing O-Ring Buna N

510 Impeller O-Ring Buna N

600 Motor Adapter Plate 304 SS

7CS Casing Screw - 1/4-20 (3/16 Allen)

Nickel Plated

Steel

7DP Drain Plug - 1/8" NPT 304 SS

7MB Motor Bolt - 3/8-16 (7/32 Allen) 304 SS

7SC

Impeller Screw - 10-32LH (1/8

Allen) (Standard on 3-Ph motors

1-hp or larger) 304 SS

800

Pump Base (not supplied with

footed motors) 304 SS


33/36

PUOD-000-015-0-0.docx

Performance Curve Data Sheet - PUOD-000-015-0-0

(Pump with Motor, 1-1/2Hp, ODP, 208-230/460V/3ph/60Hz)

Performance Curve Data Sheet


34/36

CKL_StartupChecklist-2-20ton_0312.docx

START-UP CHECK LIST

2 thru 20-TON

EQUIPMENT MODEL#: SERIAL#:

OWNER NAMEADDRESS

CITY STATE ZIP

INSTALLING CONTRACTOR

ADDRESS PHONE#

START-UP PERFORMED BY

1. Manual referred to for details on installation and startup. Yes No

2. Add additional information and notes on back of form. Yes No

3. Is there any physical damage? Yes No

a.

Will this prevent start-up? Yes NoDescription:

4. Unit is installed level as per the installation instructions. Yes No

5. Power supply agrees with the unit nameplate. V Yes No

6. Control voltage is appropriate per electrical drawing. V Yes No

7. Electrical power wiring is installed properly. Yes No

8. Unit is grounded properly. Yes No

9. Electrical circuit protection has been sized & installed properly. Yes No

10.

All terminals are tight. Yes No11.All plug assemblies are tight. Yes No

12.Crankcase heaters energized for 24 hours before start-up. Yes No

13.All chilled water valves are open. Yes No

14.All piping is connected properly. Yes No

15.All air has been purged from the system. Yes No

16.Chilled water pump is operating with the correct rotation. Yes No

17.Water loop volume greater than 6gal/ton. Yes No18.Proper loop freeze protection provided to F

i. Freeze Protection Fluid Type /ii. Concentration / %

19.

Outdoor piping wrapped with electric heater tape. Yes No20.Check the pump seals for any signs of leaking.

Chiller pump(s) free of leaks? Yes No

Process pump(s) free of leaks? Yes No21.Measure the following under full load with clear refrigerant sight glass.

Discharge Pressure: PSI

Suction Pressure: PSI

Suction Line Temp: F

Entering Fluid Temp: F

Leaving Fluid Temp: F


35/36

"ECONOMICALLY

PRICED DEPENDABILITY"

1 YEAR

COMPLETE PARTS

PRODUCT WARRANTY

LIMITED

EFFECTIVE

WITH

PRODUCT MANUFACTURED

BEGINNING

JANUARY

1995

Dear Consumer:

Congratulations on your purchase of this new Water Chiller.

This certificate is our warranty

to

you. Please ensure

that

you

have completed the reverse side of this certificate and mail

a copy back

to

us

.

COMPLETE

UNIT

WARRANTY

THE WATER CHILLER DESCRIBED ON THE

REVERSE

SIDE

OF THIS

CERTIFICATE

IS

WARRANTED

AGAINST

DEFECTS

N MATERIAL OR WORKMANSHIP

UNDER

NORMAL USE AND

MAINTENANCE

FOR

A PERIOD

OF ONE

(1) YEAR FROM THE

PURCHASE DATE

WE

WILL PROVIDE A REPLACEMENT

PART

FOR ANY

PART FOUND

TO

BE

DEFECTIVE.

THIS

WARRANTY

DOES NOT INCLUDE SERVICE OR LABOR CHARGES

CONNECTED

WITH THE DETERMINATION OR REPLACEMENT

OF

DEFECTIVE

PARTS OR

FREIGHT CHARGES

TO SHIP THESE

PARTS.

EXTENDED

PARTS WARRANTY

n

addition

to

the

above Complete Unit Warranty, the

following extended warranties may apply

to

your unit:

FOUR YEAR ADDITIONAL EXTENDED WARRANTY of

compressors. LIFETIME

WARRANTY of

tanks against

leakage, base frames against rust through (20 tons and

under) and casters.

Upon the expiration of the "Complete Unit Warranty", the

above listed components are warranted for an additional

term as listed above against defects in material or

workmanship under normal use and maintenance. We

will provide a replacement part

for

any part found to be

defective. This warranty does not include service or labor

charges connected with the determination or replacement

of defective parts

or freight

charges

to

ship these parts.

EXCLUSIONS

The foregoing provisions state the exclusive remedy for any

breach of warranty

or

any other claim in respect

to

the product

described on the reverse side

of

this certificate. THE

EXPRESS

WARRANTIES CONTAINED HEREIN

ARE

N LIEU OF ALL

OTHER

WARRANTIES. IMPLIED WARRANTIES, INCLUDING

WARRANTIES

OF

MERCHANTABILITY ARE LIMITED TO

THE

DURATION OF

THE

COMPLETE UNIT

WARRANTY DESCRIBED

ABOVE.

CONSEQUENTIAL

OR

INCIDENTAL

DAMAGES

FOR

BREACH OF ANY WARRANTY EXPRESS OR IMPLIED

ARE

EXCLUDED.

Some states do

not

allow limitations on how long an implied

warranty lasts or the exclusions of consequential or incidental

.

damages,

so

the above limitations and exclusions may not

apply

to

you. This warranty gives you speCific legal rights

and you may also have other rights which vary from state

to

state.

. .

This warranty shall be void if:

1. The unit is not installed, operated or serviced in

accordance with the installation and operation

instructions furnished, and with

the

recommendations

of the Air Conditioning Contractors of America (ACCA).

f you do not have a copy of

the

installation and

operation instructions, please write directly to

our

office

to receive one.

2. Components or other accessories not compatible with

the unit have been used with or attached to the unit.

3. The user has otherwise abused or failed to maintain the unit.

4. The unit is installed outside the United States

of

America,

Canada or Mexico.

5.

The defect or damage

is

not caused

by

the manufacturer

(see reverse side).

RETAIN

THIS CERTIFICATE WITH YOUR VALUABLE DOCUMENTS

SHOULD YOU REQUIRE IN-WARRAN1Y PARTS

UNDER

THE

TERMS

STATED

ABOVE,

CONTACT

US FOR

REPLACEMENT PARTS .

Marrone Co.,

Inc.

14020 Interdrive West Houston, TX 77032


36/36

OWNER - PLEASE RETAIN A Opy OF THIS CERTIFICATE

WITH YOUR VALUABLE DOCUMENTS

EQUIPMENT DESCRIPTION & INSTALLATION DATA

MODEL NUMBER

INSTALLED BY (SERVICE AGENCY OR PERSON)

UNIT SERIAL

NO

.

ADDRESS STREET

PURCHASER

CITY STATE

ADDRESS STREET DATE INSTALLED

CITY STATE AIR CONDITIONING REFRIGERATION LICENSE

,

CLASS, STATE

IMPORTANT

The following are the responsibilities of the user. They are examples of defects or

damages that are not manufacturing defects, and are, therefore, not included in this

Limited Warranty.

1.

Damage to unit or unsatisfactory operation due to improper cleaning or use of unit in

corrosive atmosphere.

2.

Damage to unit from unsatisfactory operation due to blown fuses, inadequate or

interrupted electrical protective devices or operations of unit

on

power supply other

than covered by name plate rating of unit.

3. Damage due to transportation or handling prior to and during installation.

4. Damage due to accident or from alteration, improper installation, or tampering.

Documents

Chiller Installation Instructions