MOTIVAIR COOLING SOLUTIONS

85 Woodridge Dr. Amherst, NY 14228 – Phone# 716-691-9222 – Fax# 716-691-9229 www.motivaircorp.com

AIR COOLED CHILLERS

MODELS: MPCA0200 – MPCA9000

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*

INDEX – TABLE OF CONTENTS

PAGE

• LEGAL PROVISIONS & SAFETY INSTRUCTIONS 1

• TRANSPORTING & SITE HANDLING 2-3

• CHILLER INSTALLATION 4-15

• PIPING INSTALLATION 16-19

• MAIN ELECTRICAL INSTALLATION 20

• WATER/GLYCOL INSTRUCTIONS 21

• CHILLER SEQUENCE OF OPERATION 22

• MPCA0200 – MPCA9000 PROGRAMMING AND ALARM CODES 23-32

• BACNET – MODBUS – LON POINT LIST 33-36

• COMMISIONING AND STARTUP INSTRUCTIONS 37-38

• TROUBLESHOOTING 39-42

• PREVENTIVE MAINTENANCE 43-45

• CLEANING THE PLATE EXCHANGER (EVAPORATOR) 46

• MAINTENANCE AND REPAIR 47-48

• REFRIGERANT INFORMATION 49

• TERMS AND CONDITIONS OF SALE 50

PROVISIONS AND SAFETY

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.

WARNING 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.

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.

TRANSPORT AND HANDLING

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.

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.

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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.

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IInnssttaalllliinngg wwiitthh aa ffoorrkk lliifftt ttrruucckk 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.

CHILLER INSTALLATION

Foundation Site Installation Installation Structure-borne noise Vibrations Clearances

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 410F. 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 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. May be transmitted through the chilled water piping. This can be avoided by the use of flexible piping connections. 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.

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 MPC-A 0200-9000 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:

Compressors, filter-driers, and manual liquid line shutoff valves are accessible via the removable panels of the chiller. Each compressor(s) has its own contactors and overloads mounted in the control box located in the front of the chiller. 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.

On all MPC-A chillers, condenser fan assemblies can be removed from the top of the unit for service if necessary.

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CAUTION

Disconnect all power to the chiller while servicing condenser fan motors or compressors. Failure to do so can cause bodily injury or death.

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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

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. MPC-A 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 MPC-A 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.

SEE NOTES 2&4 PERTAINING TO WALL HEIGHT AT UNIT SIDES

AIR FLOW NO OBSTRUCTIONS ALLOWED ABOVE UNIT AT ANY HEIGHT

The Motivair MPC-A 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.

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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

Figure 4, Adjustment Factor

H D

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

Figure 6, Adjustment Factor

D

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

Figure 10, Wall Free Area Graph

D D

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

Figure 12, Adjustment Factor

D=10Ft

H D

Addendum: A

40”

40”

MIN. CLEARANCE FOR 1 FAN MPC-A

40” 4

0”

Control Panel

65”

40”

MIN. CLEARANCE FOR 2 FAN MPC-A

Control Panel

AIR FLOW

40” 4

0”

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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 45PSIG. 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 anti-freeze 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. This chiller is a CLOSED CIRCUIT system and is not open to atmosphere. This means that air will remain in all local high points 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. POSITIVE PRESSURIZATION OF THE SYSTEM There are (2) reasons for positive pressure in a closed loop, pump piping system:

1. Prevention of air being drawn into the system at vent locations close to the chiller, caused by the pump drawing a vacuum in the return line.

2. Optimizing pump performance by providing a net positive suction head (N.P.S.H.) to the pump. Positive system pressure can be imposed by carefully and slowly introducing city water pressure, via a hose connection anywhere in the system. After the system has been completely filled and vented, note the gauge pressure at the supply and return lines of the chiller. If there is no significant vertical piping connected directly to the chiller, the gauges should be at zero. If a pre-pressurized expansion tank is installed in the system, the initial system pressure should be approximately that of the expansion tank. Start the chiller and observe the operating pressure on both the return and discharge water pressure gauges. The return line to the chiller (while operating) should be approximately 5-10psig, confirmed by the return line pressure gauge. The discharge gauge on the chiller should be approximately 30-40psig, depending on the piping and system pressure losses of each installation. The return (or suction) pressure can be raised or lowered by carefully using city water pressure via a hose connection, or by adjusting the diaphragm pressure of the expansion tank, or combination of both. NOTE: The expansion tank should not normally be pressurized to more than 20psig, 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

PROVISIONS AND SAFETY

Operator's Responsibility

This chiller MUST be installed, maintained and operated by a person(s) qualified for this equipment. This chillercontains 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.

WARNING 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.

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.

MAIN ELECTRICAL INSTALLATION

The manufacturer of the supplied chiller accepts NO LIABILITY

for the work supplied by the customer or civil engineering contractor.

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.

MAIN VOLTAGE SUPPLY

MPCA0200-9000 460V/60Hz/3~ 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).

WIRING DIAGRAM INSPECTION Check that the wiring diagram supplied with the chiller is correct and complete:

WARNING – 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.

MODEL INFORMATION: REFER TO DATA ON SERIAL STICKER FOR

EACH MODEL

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.

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.

!!!WARNING!!! 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.

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).

MPC SEQUENCE OF OPERATION

MPCA0200 – MPCA1500

Mechanical Cooling – Inlet Control

On a call for cooling set point = 50*F + diff = 7*F entering temperature = 57*F glycol pump running flow switch closed 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

MPCA2200 – MPCA9000

Mechanical Cooling – Inlet Control

On a call for cooling set point = 50*F + diff = 7*F entering temperature = 57*F glycol pump running flow switch closed the first stage compressor(s) start. (NOTE: A STAGE COULD EQUAL 2 OR MORE COMPRESSORS BASED ON CHILLER SIZE) The control reads the Inlet temperature if the temperature is within SP + ½ diff (53.5*F) the compressor holds at the present stage. If the inlet temperature rises over 53.5*F (SP + ½ diff) and the delay staging timer has expired the next compressor(s) will stage on. If the inlet temp is < SP the compressors will stage off. As the loop temp falls, the first compressor on will turn off at intervals = ½ the differential setting to maintain set point. With the compressor rotation FOFO (first on first off) the next compressor to start will be the second stage.

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µC2 - +0�02207�1 - rel. 1.2 - 26.10.2007

1. INTRODUCTION

1.1 General descriptionThe µC2 is a new compact CAREL electronic controller, the same size as a normal thermostat, for the complete management of chillers and heat pumps: it can control air-air, air-water, water-water and condensing units.

1.1.1 Main functionscontrol of the water inlet and evaporator outlet temperature;defrost management by time and/or by temperature or pressure;fan speed control;complete alarm management;connection to serial line for supervision/telemaintenance;elimination of the expansion vessel.

- Driver functionManagement of electronic expansion valves.

1.1.2 Controlled devices compressor;condenser fans;reversing valve;water pumps for evaporator and/or condenser, and outlet fan (air-air);antifreeze heater;alarm signal device.

1.1.3 ProgrammingCAREL offers the possibility to configure all the unit parameters not only from the keypad on the front panel, but also using:

a hardware key;a serial line.

1.2 User interface

1.2.1 DisplayThe display features � digits, with the display of the decimal point between -99.9 and 99.9. Outside of this range of measurement, the value is automatically displayed without the decimal (even if internally the unit still operates considering the decimal part).In normal operation, the value displayed corresponds to the temperature read by probe B1, that is, the evaporator water inlet temperature (for water chillers) or the ambient air temperature for direct expansion units.Fig. 1.a show the symbols present on the display and on the keypad and their meanings.

1.2.2 Symbols on the displayDisplay with � green digits (plus sign and decimal point), ambersymbols and red alarm symbols.

symbol colour meaning reference refri-gerant circuitwith leD ON con leD lampeggiante

1; 2 amber compressor 1 and/or 2 ON start up request 11; � amber compressor � and/or � ON start up request 2A amber at least one compressor ON 1/2B amber pump/air outlet fan ON start up request 1/2C amber condenser fan ON 1/2D amber defrost active defrost request 1/2E amber heater ON 1/2F red alarm active 1/2G amber heat pump mode (P6=0) heat pump mode request

(P6=0)1/2

H amber chiller mode (P6=0) chiller mode request (P6=0) 1/2Table 1.a

••••••

•

••••••

••

fig. 1.a

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1.2.3 funzioni associate ai tastitasto stato della macchina modalità pressioneI Loading default values press at power ON

Go up a sub-group inside the programming area, until exiting (saving changes to EEPROM) press onceIn the event of alarms, mute the buzzer (if present) and deactivate the alarm relay press once

L Access the direct parameters press for 5 sSelect item inside the programming area and display value of direct parameters/confirm the changes to the parameters press once

I + L Program parameters afters entering password press for 5 sJ Select top item inside the programming area press once or press and hold

Increase value press once or press and holdSwitch from standby to chiller mode (P6=) and vice versa press for 5 s

K Select bottom item inside the programming area press once or press and holdDecrease value press once or press and holdSwitch from standby to heat pump mode (P6=0) and vice versa press for 5 s

J + K Manual alarm reset press for 5 sImmediately reset the hour counter (inside the programming area) press for 5 s

L + J Force manual defrost on both circuits press for 5 sTable 1.b

1.2.4 Programming and saving the parameters

press “ “ and “ ” for 5 seconds;the heating and cooling symbol and the figure “00” are displayed;use “ ” and “ ” to set the password (page 28) and confirm by pressing “ ”;use “ ” and “ ” to select the parameter menu (S-P) or levels (L-P) and then press “ ”;use “ ” and “ ” to select the parameter group and then press “ ”;use “ ” and “ “ to select the parameter and then press “ ”;after making the changes to the parameter, press “ ” to confirm or “ ” to cancel the changes;press “ ” to return to the previous menu;to save the modifications, press “ ” repeatedly until reaching the main menu.

Note:the parameters that have been modified without being confirmed using the “ ” button return to the previous value;if no operations are performed on the keypad for 60 seconds, the controller exits the parameter modification menu by timeout and the changes are cancelled.

1.2.5. KeypadThe keypad is used to set the unit operating values (see Parameters/alarms - Keypad combinations)

1.2.�.4.5.6.7.8.9.

a.

b.

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For 5”

And For 5”Sa ve in the EEPROM

OrOr

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4.1 General parametersThe parameters are divided into 4 different types, according to their level of access by the user (pas-sword) and their function.For each level, only the access to the parameters of the same or lower level can be set.This means that through “factory” password, acessing the menù “levels” (L-P), it is possible to set the desired level for each parameter.

factory parameters: Accessible with the 66 “Factory” password, allow the configuration of all the unit parameters.

Super User parameters: Accessible with the 11 “Super User” password, allow the configuration of the Super User, User and Direct parameters.

User parameters: Accessible with password 22, allow the configuration of the parameters that typically can be set by the user (User parameters) and the Direct parameters, consequently relating to the options.

Direct parameters: Accessible without password, this are used to read the probe measurements and any data, by any user, without compromising the operation of the unit.

N.b.: The modifications to the parameters regarding the configuration of the unit (type, number of compressors,…) must be performed with the controller in Standby.

4.2 Menu structure

•

•

•

•

4. paRameTeRs

main menù

setting password

parameter values

parameter level

parameters A*parameters F-r*

parameters r*parameters b*

regulationprobes

antifreezesoftware

parameters P*

alarm

parameters H*

unit setting parameters F*

fan

parameters D*

defrost

parameters c*

compressor

parameters /*

probe settings

parameter values F1 parameters F1 level value F1

parameters Fn

fig. 4.a

level level name password_d_ direct no password_U_ user 22_S_ super user 11_F_ factory 66

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4.3 Parameter tables The following tables show of the parameters divided by type/family (e. g. compressor, probes, fans etc.).

• Key to the parameter tablesLevel (default)S= super userF= factoryD= direct

Visibility: The visibility of some groups depends on the type of controller and the value of the parameters.

D= defrost (if D01=1)F= fan (if F01=1)N= NTC probe (if /04-/08=2)P= pressure (if /04-/08=3)V= driver (if H08 =1-3)X= expansion (if H08=2-3)- = always present

Supervisor variables:R/W = supervisor read/write parameterR= supervisor read-only parameter

4.3.1 Probe setting parameters: (/*)display indicat.

parameter and description default level

min. max. U.O.M. variat. default visibility supervis. variable

Modbus variabile type

/01 Probe type B1 0= not present 1= present

F 0 1 Flag 1 1 - 1 (R/W) 1 Digital

/02 Probe type B2 0= not present 1= present

F 0 1 Flag 1 0 - 2 (R/W) 2 Digital

/03 Probe type B3 0= not present 1= NTC Cond. Probe 2= NTC Out. Probe

F 0 2 fl ag 1 0 - 14 (R/W) 142 Integer

/04 Probe type B4 0= not present 1= ON/OFF (D.I) 2= NTC Out. Probe 3= ratiometric cond. Probe, 5 Vdc

F 0 3 fl ag 1 0 - 15 (R/W) 143 Integer

/05 Probe type B5 0= not present 1= present

F 0 1 Flag 1 0 X 3 (R/W) 3 Digital

/06 Probe type B6 0= not present 1= present

F 0 1 Flag 1 0 X 4 (R/W) 4 Digital

/07 Probe type B7 0= not present 1= NTC Cond. Probe 2= NTC Out. Probe

F 0 2 fl ag 1 0 X 16 (R/W) 144 Integer

/08 Probe type B8 (expansion)

0= not present 1= ON/OFF 2= NTC Out. Probe 3= ratiometric cond. Probe, 5 Vdc

F 0 4 int 1 0 X 17 (R/W) 145 Integer

/09 Min. value voltage input F 0 /10 0.01 Vdc 1 50 P 18 (R/W) 146 Integer/10 Max. value voltage input F /09 500 0.01 Vdc 1 450 P 19 (R/W) 147 Integer/11 Pressure min. value F 0 /12 bar 1 0 P 1 (R/W) 1 Analog/12 Pressure max. value F /11 99.9 bar 1 34.5 P 2 (R/W) 2 Analog/13 Probe B1 calibration F -12.0 12.0 °C/°F 0.1 0.0 - 3 (R/W) 3 Analog/14 Probe B2 calibration F -12.0 12.0 °C/°F 0.1 0.0 - 4 (R/W) 4 Analog/15 Probe B3 calibration F -12.0 12.0 °C/°F 0.1 0.0 - 5 (R/W) 5 Analog/16 Probe B4 calibration F -12.0 12.0 °C/bar/°F 0.1 0.0 - 6 (R/W) 6 Analog/17 Probe B5 calibration F -12.0 12.0 °C/°F 0.1 0.0 X 7 (R/W) 7 Analog/18 Probe B6 calibration F -12.0 12.0 °C/°F 0.1 0.0 X 8 (R/W) 8 Analog/19 Probe B7 calibration F -12.0 12.0 °C/°F 0.1 0.0 X 9 (R/W) 9 Analog/20 Probe B8 calibration F -12.0 12.0 °C/bar/°F 0.1 0.0 X 10 (R/W) 10 Analog/21 Digital fi lter U 1 15 - 1 4 - 20 (R/W) 148 Integer/22 Input limitation U 1 15 - 1 8 - 21 (R/W) 149 Integer/23 Unit of measure 0= °C

1= °FU 0 1 Flag 1 0 - 5 (R/W) 5 Digital

Table 4.a

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4.3.2 Antifreeze/auxiliary heater setting parameters (A*)display indicat.

parameter and description default level

min. max. U.O.M. variat. default visibility supervis. variable

Modbus variabile type

A01 Antifreeze/low ambient temp. (air/air) alarm set point U A07 A04 °C/°F 0.1 3.0 - 11 (R/W) 11 AnalogA02 Differential for antifreeze/low ambient temperature alarm U 0.3 122.0 °C °F 0.1 5.0 - 12 (R/W) 12 AnalogA03 Bypass time for antifreeze alarm/low ambient temp. when turning on the unit

in heating modeU 0 150 S 1 0 - 22 (R/W) 150 Integer

A04 Set point for the activation of antifreeze heater/auxiliary heater U A01 r16 °C/°F 0.1 5.0 - 13 (R/W) 13 AnalogA05 Diff. for antifreeze heater/auxiliary heater U 0.3 50.0 °C/°F 0.1 1.0 - 14 (R/W) 14 AnalogA06 Auxiliary heater probe

0= Control probe see (Table 5.a)1= Antifreeze probe see (Table 5.a)

F 0 1 Flag 1 0 - 6 (R/W) 6 Digital

A07 Antifreeze alarm set point limit F -40.0 176.0 °C °F 0.1 -40.0 - 15 (R/W) 15 AnalogA08 Auxiliary heater set point in heating mode U A01 r16 °C °F 0.1 25.0 - 16 (R/W) 16 AnalogA09 Auxiliary heater differential in heating mode U 0.3 50.0 °C/°F 0.1 3.0 - 17 (R/W) 17 AnalogA10 Antifreeze automatic start up

0= disabled function1= Heaters and pump on at the same time on A4/A82= Heaters and pump on indipendently on A4/A83= Heaters ON on A4/A8

U 0 3 Flag 1 0 - 23 (R/W) 151 Integer

Table 4.b

4.3.3 Probe reading parameters (B*)

display indicat.

parameter and description default level

min. max. U.O.M. variat. default visibility supervis. variable

Modbus variabile type

b00 Confi g. of probe to be shown on the display0= probe B11= probe B22= probe B33= probe B44= probe B55= probe B66= probe B77= probe B88= set point without compensation9= dynamic set point with possible compensation10= remote ON/OFF digital input status

U 0 10 Flag 1 0 - 24 (R/W) 152 integer

b01 Value read by probe B1 D - - °C /°F - - - 70 (R) 70 Analogb02 Value read by probe B2 D - - °C /°F - - - 71 (R) 71 Analogb03 Value read by probe B3 D - - °C /°F - - - 72 (R) 72 Analogb04 Value read by probe B4 D - - °C /°F/bar - - - 73 (R) 73 Analogb05 Value read by probe B5 D - - °C /°F - - X 74 (R) 74 Analogb06 Value read by probe B6 D - - °C /°F - - X 75 (R) 75 Analogb07 Value read by probe B7 D - - °C /°F - - X 76 (R) 76 Analogb08 Value read by probe B8 D - - °C /°F bar - - X 77 (R) 77 Analogb09 Driver 1 evaporator temperature D - - °C /°F - - V 78 (R) 78 Analogb10 Driver 1 evaporator pressure D - - bar - - V 79 (R) 79 Analogb11 Driver 1 superheating D - - °C /°F - - V 80 (R) 80 Analogb12 Driver 1 saturation temperature D - - °C /°F - - V 81 (R) 81 Analogb13 Driver 1 valve position D 0 100.0 % - - V 82 (R) 82 Analogb14 Driver 2 evaporator temperature D - - °C /°F - - XV 83 (R) 83 Analogb15 Driver 2 evaporator pressure D - - bar - - XV 84 (R) 84 Analogb16 Driver 2 superheating D - - °C /°F - - XV 85 (R) 85 Analogb17 Driver 2 saturation temperature D - - °C /°F - - XV 86 (R) 86 Analogb18 Driver 2 valve position D 0 100.0 % - - XV 87 (R) 87 Analogb19 Temp. probe at the outlet of the external coil c1 D - - °C /°F - - V 88 (R) 88 Analogb20 Temp. probe at the outlet of the external coil c12 D - - °C /°F - - XV 89 (R) 89 Analog

Table 4.c

4.3.4 Compressor setting parameters (c*)display indicat.

parameter and description default level

min. max. U.O.M. variat. def. visibi-lity

supervis. variable

Modbus variabile type

c01 Min. compressor ON time U 0 999 s 1 60 - 25 (R/W) 153 Integerc02 Min. OFF time compressor U 0 999 s 1 60 - 26 (R/W) 154 Integerc03 Delay between 2 starts of the same compressor U 0 999 s 1 360 - 27 (R/W) 155 Integerc04 Delay between starts of the 2 compressors U 0 999 s 1 10 - 28 (R/W) 156 Integerc05 Delay between 2 shut-downs of the 2 compressors U 0 999 s 1 0 - 29 (R/W) 157 Integerc06 Delay at start-up U 0 999 s 1 0 - 30 (R/W) 158 Integerc07 Delay in switching on the compressor after switching on the pump/inlet

fan (air/air)U 0 150 s 1 20 - 31 (R/W) 159 Integer

c08 Delay in switching OFF the compressor after switching OFF the pump/inlet fan (air/air)

U 0 150 min 1 1 - 32 (R/W) 160 Integer

c09 Maximum compressor operating time in tandem U 0 60 min 1 0 - 33 (R/W) 161 Integerc10 Compressor 1 timer D 0 800.0 100 hours 0.1 0 - 90 (R) 90 Analogc11 Compressor 2 timer D 0 800.0 100 hours 0.1 0 - 91 (R) 91 Analogc12 Compressor 3 timer D 0 800.0 100 hours 0.1 0 - 92 (R) 92 Analogc13 Compressor 4 timer D 0 800.0 100 hours 0.1 0 - 93 (R) 93 Analogc14 Operation timer threshold U 0 100 100 hours 1 0 - 34 (R/W) 162 Integerc15 Hour counter evaporator pump/fan 1 D 0 800.0 100 hours 0.1 0 - 94 (R) 94 Analogc16 Hour counter condenser backup pump/fan 2 D 0 800.0 100 hours 0.1 0 - 95 (R) 95 Analogc17 Minimum time between 2 pump starts U 1 150 min 1 30 - 35 (R/W) 163 Integerc18 Minimum pump ON time U 1 15 min 1 3 - 36 (R/W) 164 Integer

Table 4.d

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4.3.5 Defrost setting parameters (d*)

display indicat.

parameter and description default level

min. max. U.O.M. variat. def. visibility supervis. variable

Modbus variabile type

d01 Defrosting cycle/Condenser antifreeze0= no; 1= sì, con sbrinamento unifi cato yes, with shared defrosting

U 0 1 Flag 1 0 - 7 (R/W) 7 Digital

d02 Time or temp.- press. based defrosting0= time1= temp. - press2= pressure start, temperature end

U 0 2 Flag 1 0 D 90 (R/W) 218 Integer

d03

Start defrosting temperature Condenser antifreeze alarm set point

U -40.0 d04 °C/°F 0.1 -5.0 DN 19 (R/W) 19 Analog

Start defrosting pressure /11 d04 bar 0.1 3.5 DP 18 (R/W) 18 Analogd04

End defrosting temperature U d03 176 °C 0.1 20.0 DN 21 (R/W) 21 Analog End defrosting pressure d03 /12 bar 0.1 14.0 DP 20 (R/W) 20 Analog

d05 Min. time to start a defrosting cycle U 10 150 s 1 10 D 37 (R/W) 165 Integerd06 Min. duration of a defrosting cycle U 0 150 s 1 0 D 38 (R/W) 166 Integerd07 Max. duration of a defrosting cycle U 1 150 min 1 5 D 39 (R/W) 167 Integerd08 Delay between 2 defrosting cycle requests within the same circuit U 10 150 min 1 30 D 40 (R/W) 168 Integerd09 Defrosting delay between the 2 circuits U 0 150 min 1 10 D 41 (R/W) 169 Integerd10 Defrost by external contact

0= disables function1= external contact start2= external contact end3= external contact start and end

F 0 3 Flag 1 0 D 42 (R/W) 170 Integer

d11 Antifreeze heaters activated while defrosting0= Non presenti/Not present; 1= Presenti/Present

U 0 1 Flag 1 0 D 9 (R/W) 9 Digital

d12 Waiting time before defrosting F 0 3 min 1 0 D 43 (R/W) 171 Integerd13 Waiting time after defrosting F 0 3 min 1 0 D 44 (R/W) 172 Integerd14 End defrosting with 2 refrigerating circuits

0= Indipendent1= If both at end defrost2= If at least one at end defrost

F 0 2 Flag 1 0 D 45 (R/W) 173 Integer

d15 Start defrost with 2 circuits0= Indipendent1= If both at start defrost2= If at least one at start defrost

F 0 2 Flag 1 0 D 46 (R/W) 174 Integer

d16 Forced ventilation time at the end of the defrosting F 0 360 s 1 0 D 47 (R/W) 175 Integerd17 Defrost with compressors OFF F 0 80.0 °C/°F 0.1 0 D 22 (R/W) 22 Analog

Table 4.e

4.3.6 Fan setting parameters (F*)

display indicat.

parameter and description default level

min. max. U.O.M. variat. def. visibility supervis. variable

Modbus variabile type

F01 Fan output 0= absent1= present

F 0 1 Flag 1 0 - 10 (R/W) 10 Diigital

F02 Fan operating mode0= always ON1= depending ON the compressor (in parallel operation mode)2= depending ON the compressors in ON/OFF control3= depending ON the compressors in speed control mode

U 0 3 Flag 1 0 F 48 (R/W) 176 Integer

F03 Min. voltage threshold for Triac F 0 F04 step 1 35 F 49 (R/W) 177 IntegerF04 Max. voltage threshold for Triac F F03 100 step 1 75 F 50 (R/W) 178 IntegerF05

Temp. value for min. speed Cooling U -40.0 °C 0.1 35.0 FN 24 (R/W) 24 Analog Pressure value for min. speed Cooling /11 /12 bar 0.1 13.0 FP 23 (R/W) 23 Analog

F06

Differential value for max. speed Cooling U 0 50.0 °C/°F 0.1 10.0 FN 26 (R/W) 26 Analog Pressure value for max. speed Cooling 0 50 bar 0.1 3.0 FP 25 (R/W) 25 Analog

F07

Fan shut-down differential in Cooling mode U 0 50.0 °C/°F 0.1 15.0 FN 28 (R/W) 28 Analog Fan shut-down pressure in Cooling mode 0 F5 bar 0.1 5.0 FP 27 (R/W) 27 Analog

F08

Temperature value for max speed in Heating mode U -40.0 °C 0.1 35.0 FN 30 (R/W) 30 Analog Pressure value for max speed in Heating /11 /12 bar 0.1 13.0 FP 29 (R/W) 29 Analog

F09

Temperature value for max. speed in Heating mode U 0 50.0 °C/°F 0.1 5.0 FN 32 (R/W) 32 Analog Pressure value for max speed in Heating 0 F08 bar 0.1 4.0 FP 31 (R/W) 31 Analog

F10

Temp. to turn OFF the fan in Heating 0.1 U 0 F08 °C/°F 0.1 5.0 FN 34 (R/W) 34 Analog Pressure to turn OFF the fan in Heating 0 30.0 bar 0.1 3.0 FP 33 (R/W) 33 Analog

F11 Fan starting time U 0 120 s 1 0 F 51 (R/W) 179 IntegerF12 Triac impulse duration (fan start) F 0 10 s 1 2 F 52 (R/W) 180 IntegerF13 Fan management in defrost mode

0= Disabled fans1= Fan in chiller mode2= Max. speed after defrost

F 0 2 Flag 1 0 F 53 (R/W) 181 Integer

F14 Fan on time when starting in high condensing temperature U 0 999 S 1 0 FN 91 (R/W) 219 IntegerTable 4.f

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4.3.7 Unit setting parameters (H*)

display indicat.

parameter and description default level

min. max. U.O.M. variat. def. visibility supervis. variable

Modbus variabile type

H01 Unit model 0= air_air unit1= air_air heat pump2= air_water chiller3= air_water heat pump4= water_water chiller5= water_water heat pump with reversal on gas circuit6= water_water heat pump with reversal on water circuit 7= condensing unit8= reverse-cycle condensing unit9= water-cooled condensing unit10= reverse-cycle water-cooled condensing unit

F 0 10 Flag 1 2 - 54 (R/W) 182 Integer

H02 Number of condensers 0=1 circuit; 1=2 circuits F 0 1 Flag 1 0 F 12 (R/W) 12 DigitalH03 Number of evaporators

0=1 evaporator1=2 evaporators

F 0 1 Flag 1 0 - 13 (R/W) 13 Digital

H04 Number of compressors per circuit0=1 comp. ON 1 circuit (single circuit)1=2 comp. in tandem ON 1 circuit (single circuit)2=1 comp. per circuit, 2 circuits (two circuits)3=2 comp. in Tandem, 2 circuits (two circuits)4=1 compressor and 1 Capacity step in one circuit5=1 compressor and 1 capacity Step per circuit

F 0 5 Flag 1 0 - 55 (R/W) 183 Integer

H05 Pump/outlet fan (Air/Air) mode (output N2)0= absent1= always ON2= ON upon request of the controller3= ON upon request of the controller and for set time

F 0 5 Flag 1 1 - 56 (R/W) 184 Integer

H06 Cooling/Heating digital input0= absent1= present

U 0 1 Flag 1 0 - 14 (R/W) 14 Digital

H07 ON/OFF digital input 0= absent1= present

U 0 1 Flag 1 0 - 15 (R/W) 15 Digital

H08 µC2 network confi guration0= µC2 only1= µC2 + valve2= µC2 + exp.3= µC2 +exp.+valve

F 0 3 Flag 1 0 - 57 (R/W) 185 Integer

H09 Lock keypad 0= disabled 1= enabled

U 0 1 Flag 1 1 - 16 (R/W) 16 Digital

H10 Serial address U 1 200 - 1 1 - 58 (R/W) 186 IntegerH11 Output modes (see Table 5.3 and following pag. 56) F 0 12 Flag 1 0 - 59 (R/W) 187 IntegerH12 Capacity- control logic valve and inversion valve

0= Both normally closed 1= Both normally open2= Inversion valve normally open and capacity-control valve normally closed3= Inversion valve normally closed and capacity-control valve normally open

F 0 3 Flag 1 1 - 60 (R/W) 188 Integer

H21 Second pump function0= Disabled1= Backup and weekly rotation2= Backup and daily rotation3= Condensing control on corresponding set point4= Condensing control always on

F 0 4 int 1 0 - 62 (R/W) 269 Integer

H22 Disable load default values0= Function disabled1= Function enabled

F 0 1 Flag 1 0 - 18 (R) 18 Digital

H23 Enable Modbus protocol F 0 1 Flag 1 0 - 11 11 DigitalTable 4.g

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4.3.8 Alarm setting parameters (P*)

display indicat.

parameter and description default level

min. max. U.O.M. variat. def. visibility supervis. variable

Modbus variabile type

P01 Flow switch alarm delay when starting the pump U 0 150 s 1 20 - 63 (R/W) 191 IntegerP02 Flow switch alarm delay during steady operation U 0 120 s 1 5 - 64 (R/W) 192 IntegerP03 Low pressure alarm delay at start-up U 0 200 s 1 40 - 65 (R/W) 193 IntegerP04 Enable part load in high pressure U 0 3 int 1 0 P 66 (R/W) 194 IntegerP05 Alarm reset

0= HP1-2/LP1-2/A1-2/Lt manual1= HP1-2/LP1-2/A1-2/Lt automatic2= HP1-2/A1-2/Lt manual LP1-2 automatic3= HP1-2 manual LP1-2/A1-2/Lt automatic4= HP1-2/LP1-2 manual A1-2/Lt automatic5= HP1-2/LP1-2 (thrice per hour) manual A1-2/Lt automatic6= HP1-2/LP1-2 (thrice per hour) manual; A1-2/Lt manual

F 0 6 Int 1 0 - 67 (R/W) 195 Integer

P06 Cooling/heating logic 0=: Chiller, : Heat pump 1=: Heat pump, : Chiller

F 0 1 Flag 1 0 - 19 (R/W) 19 Digital

P07 Low pressure alarm from transducer 0= Disabled 1= Enabled

F 0 1 Flag 1 0 P 68 (R/W) 196 Integer

P08 Digital input 1 selection 0= N 1=FL man. 2=FL auto. 3=TP man. 4=TP auto 5= TC1 man. 6= TC1 auto. 7= TC2 man. 8= TC2 auto. 9= Cool/Heat. 10= Cool/Heat. Delayed 11= LA man. 12= LA auto. 13= 2° Set 14= 2° Set timer 15= stop defrost c. 1 16= stop defrost c. 2 17= start defrost c. 1 18= start defrost c. 2 19= step 1 20 = step 2 21= step 3 22= step 4

F 0 22 Flag 1 0 - 69 (R/W) 197 Integer

P09 Digital input 2 selection F 0 22 Flag 1 0 - 70 (R/W) 198 IntegerP10 Digital input 6 selection F 0 22 Flag 1 0 X 71 (R/W) 199 IntegerP11 Digital input 7 selection F 0 22 Flag 1 0 X 72 (R/W) 200 IntegerP12 Digital input 10 selection F 0 22 Flag 1 0 X 73 (R/W) 201 IntegerP13 Confi guration of B4 as P8 if /4=1 (digital input) F 0 22 Flag 1 0 - 74 (R/W) 202 IntegerP14 Confi guration of B8 as /8=1 (digital input) F 0 22 Flag 1 0 X 75 (R/W) 203 IntegerP15 low pressure alarm confi guration L

0= not active with compressor OFF1= active with compressor OFF

F 0 1 Flag 1 0 - 76 (R/W) 204 Integer

P16 High temperature alarm set U -40.0 °C 0.1 80.0 - 38 (R/W) 38 AnalogP17 High temperature alarm delay at start-up U 0 250 min 1 30 - 77 (R/W) 205 IntegerP18 High pressure alarm set from transducer F 0 99.9 bar 0.1 20.0 P 39 (R/W) 39 AnalogP19 System low temperature alarm set point U -40.0 °C 0.1 10.0 - 40 (R/W) 40 AnalogP20 Enable system start-up protection

0= Disabled 1= EnabledU 0 1 Flag 1 0 - 20 (R/W) 20 Digital

P21 Alarm relay management 0= normally de-activated1= normally activated

F 0 1 Flag 1 0 - 8 (R/W) 8 Digital

Table 4.h

4.3.9 Control setting parameters (r*)

display indicat.

parameter and description default level

min. max. U.O.M. variat. def. visibility supervis. variable

Modbus variabile type

r01 Cooling set point D r13 r14 °C/°F 0.1 12.0 - 41 (R/W) 41 Analogr02 Cooling differential D 0.3 50.0 °C/°F 0.1 3.0 - 42 (R/W) 42 Analogr03 Heating set point D r15 r16 °C/°F 0.1 40.0 - 43 (R/W) 43 Analogr04 Heating differential D 0.3 50.0 °C/°F 0.1 3.0 - 44 (R/W) 44 Analogr05 Compressor rotation

0= disabled; 1= FIFO type 2= con controllo ore/hour control3= direct relation between (D.I. and compressors D.O.)

F 0 3 fl ag 1 0 - 78 (R/W) 206 Integer

r06 Type of compressor control0= proportional on inlet 1= proportional on inlet + dead zone2= proportional on outlet3= proportional on outlet + dead zone4= time on outlet with dead zone

F 0 4 fl ag 1 0 - 79 (R/W) 207 Integer

r07 Dead zone differential F 0.1 50.0 °C/°F 0.1 2.0 - 45 (R/W) 45 Analogr08 Activation delay at lower limit of r07 F 0 999 s 1 120 - 80 (R/W) 208 Integerr09 Activation delay at upper limit of r07 F 0 999 s 1 100 - 81 (R/W) 209 Integerr10 Deactivation delay at lower limit of r12 F 0 999 s 1 120 - 82 (R/W) 210 Integerr11 Deactivation delay at upper limit of r12 F 0 999 s 1 100 - 83 (R/W) 211 Integerr12 Compressor deactivation differential F 0 50.0 °C/°F 0.1 2.0 - 46 (R/W) 46 Analogr13 Min. Cooling set point U -40.0 r14 °C/°F 0.1 -40.0 - 47 (R/W) 47 Analogr14 Max. Cooling set point U r13 °C 0.1 80.0 - 48 (R/W) 48 Analogr15 Min. Heating set point U -40.0 r16 °C/°F 0.1 -40.0 - 49 (R/W) 49 Analogr16 Max. Heating set point U r15 176.0 °C 0.1 80.0 - 50 (R/W) 50 Analog

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µC2 - +030220731 - rel. 1.0 - 27.07.2006

r17 Cooling compensation constant U -5.0 +5.0 - 0.1 0.0 - 51 (R/W) 51 Analogr18 Maximum distance from the set point U 0.3 20.0 °C/°F 0.1 0.3 - 52 (R/W) 52 Analogr19 Start compensation temperature in cooling mode U -40 176.0 °C/°F 0.1 30.0 - 53 (R/W) 53 Analogr20 Start compensation temperature in heating mode U -40 176.0 °C/°F 0.1 0 - 54 (R/W) 54 Analogr21 Second cooling set point from external contact D r13 r14 °C/°F 0.1 12.0 - 55 (R/W) 55 Analogr22 Second heating set point from external contact D r15 r16 °C/°F 0.1 40.0 - 56 (R/W) 56 Analogr27 Enable accumulation vessel suppression

0= Disabled1= Enabled in cool2= Enabled in Heat3= Always enabled

F 0 3 fl ag 1 0 - 88 (R/W) 216 Integer

r28 Minimum time to determine low load conditions F 0 999 s 1 60 - 89 (R/W) 217 Integerr29 Low load differential in chiller mode F 0.3 50.0 °C/°F 0.1 3.0 - 58 (R/W) 58 Analogr30 Low load differential in heat pump mode F 0.3 50.0 °C/°F 0.1 3.0 - 59 (R/W) 59 Analogr31 Heating compensation constant U -5.0 +5.0 - 0.1 0.0 - 60 (R/W) 60 Analog

Table 4.i

4.3.10 Firmware parameters (F-r*)

display indicat.

parameter and description default level

min. max. U.O.M. variat. def. visibility supervis. variable

Modbus variabile type

H96 Software version Driver 2 D 0 999 fl ag XV 4 (R) 132 IntegerH97 Software version Driver 1 D 0 999 fl ag V 3 (R) 131 IntegerH98 Expansion software version D 0 999 fl ag X 2 (R) 130 IntegerH99 Software version (to be displayed after instrument

start-up)D 0 999 fl ag - 1 (R) 129 Integer

Table 4.j

4.3.11 Supervisor only variables

display indicat.

parameter and description default level

min. max. U.O.M. variat. def. visibility supervis. variable Modbus variabile type

- Digital input 1 - 0 1 Flag 1 - - 43 (R) 43 Digital- Digital input 2 - 0 1 Flag 1 - - 44 (R) 44 Digital- Digital input 3 - 0 1 Flag 1 - - 45 (R) 45 Digital- Digital input 4 - 0 1 Flag 1 - - 46 (R) 46 Digital- Digital input 5 - 0 1 Flag 1 - - 47 (R) 47 Digital- probe B4 digital input - 0 1 Flag 1 - - 48 (R) 48 Digital- Digital output 1 - 0 1 Flag 1 - - 49 (R/W) 49 Digital- Digital output 2 - 0 1 Flag 1 - - 50 (R/W) 50 Digital- Digital output 3 - 0 1 Flag 1 - - 51 (R/W) 51 Digital- Digital output 4 - 0 1 Flag 1 - - 52 (R/W) 52 Digital- Digital output 5 - 0 1 Flag 1 - - 53 (R/W) 53 Digital- Unit status, 1= ON or 0= standby - 0 1 Flag 1 0 - 54 (R/W) 54 Digital- 1= Cooling or 0= Heating - 0 1 Flag 1 1 - 55 (R/W) 55 Digital- Digital input 6, 2nd circuit - 0 1 Flag 1 - - 56 (R) 56 Digital- Digital input 7, 2nd circuit - 0 1 Flag 1 - - 57 (R) 57 Digital- Digital input 8, 2nd circuit - 0 1 Flag 1 - - 58 (R) 58 Digital- Digital input 9, 2nd circuit - 0 1 Flag 1 - - 59 (R) 59 Digital- Digital input 10, 2nd circuit - 0 1 Flag 1 - - 60 (R) 60 Digital- Probe B8 digital inputs, 2nd circuit - 0 1 Flag 1 - - 61 (R) 61 Digital- Digital output 6 - 0 1 Flag 1 - - 62 (R/W) 62 Digital- Digital output 7 - 0 1 Flag 1 - - 63 (R/W) 63 Digital- Digital output 8 - 0 1 Flag 1 - - 64 (R/W) 64 Digital- Digital output 9 - 0 1 Flag 1 - - 65 (R/W) 65 Digital- Digital output 10 - 0 1 Flag 1 - - 66 (R/W) 66 Digital- Enable digital output from Supervisor - 0 8000 Flag 1 - - 13 (R) Integer Defrost status

0= no Defrost 1= Def. circuit 1 2= Def. circuit 2 3= Def. circuit 1 and 2 5= Fan Def. circuit 110= Fan Def. circuit 215= Fan Def. circuit 1 and 2

- - - - - - 104 (R) stato defrost Integer

Table 4.l

49

EN

GL

ISH

µC2 - +0�02207�1 - rel. 1.2 - 26.10.2007

6. Table Of alaRmsKey to the table of alarms:*: if the probe is set for the compensation function, in the event of probe faults, the unit continues to operate.ON*: if the expansion card is not present.EVD 1= EVD400 connected to µC2 (1st circ.)EVD 2= EVD400 connected to the expansion (2nd circ.)

alarm display

alarm type resetting Compres-sor

pump fan heater Valve alarm warning superv. variable

superv. variab. description

variab. type

HP1 High pressure Depends on P05 OFF C1-2 - ON(60”) - - ON - �1 (R) Circuit 1 alarm DigitalHP2 High pressure Depends on P05 OFF C�-4 - ON(60”) - - ON - �2 (R) Circuit 2 alarm DigitalLP1 Low pressure Depends on P05 OFF C1-2 - OFF 1 - - ON - �1 (R) Circuit 1 alarm DigitalLP2 Low pressure Depends on P05 OFF C�-4 - OFF 2 - - ON - �2 (R) Circuit 2 alarm DigitalTP General overload Depends on P08 OFF OFF OFF - - ON - �5 (R) General warning DigitaltC1 Circuit 1 overload Depends on P08 OFF C1-2 - OFF 1 - - ON - �1 (R) Circuit 1 alarm DigitaltC2 Circuit 2 overload Depends on P08 OFF C�-4 - OFF 2 - - ON - �2 (R) Circuit 2 alarm DigitalLA advice Depends on P08 - - - - - ON* ON 40 (R) General advice DigitalFL Flow controller alarm Depends on P08 OFF OFF OFF - - ON - �5 (R) General alarm DigitalFLb Backup pump warning Automatic - - - - - - ON 40 (R) General advice DigitalE1 Probe B1 alarm Automatic OFF OFF OFF OFF - ON - �6 (R) Probe alarm DigitalE2 Probe B2 alarm Automatic OFF OFF OFF OFF - ON - �6 (R) Probe alarm DigitalE�* Probe B� alarm Automatic OFF OFF OFF OFF - ON - �6 (R) Probe alarm DigitalE4* Probe B4 alarm Automatic OFF OFF OFF OFF - ON - �6 (R) Probe alarm DigitalE5 Probe B5 alarm Automatic OFF OFF OFF OFF - ON - �6 (R) Probe alarm DigitalE6 Probe B6 alarm Automatic OFF OFF OFF OFF - ON - �6 (R) Probe alarm DigitalE7* Probe B7 alarm Automatic OFF OFF OFF OFF - ON - �6 (R) Probe alarm DigitalE8* Probe B8 alarm Automatic OFF OFF OFF OFF - ON - �6 (R) Probe alarm DigitalHc1-4 Hour warning C1-4 Automatic - - - - - - ON �7 (R) Compressor advice DigitalEPr EEPROM error during

operationAutomatic - - - - - - ON 40 (R) General advice Digital

EPb EEPROM error at the start-up Automatic OFF OFF OFF OFF OFF OFF OFF �5 (R) General alarm DigitalESP Expansion Error Automatic OFF OFF OFF OFF OFF ON - �5 (R) General alarm DigitalEL1-2 Zero cross Automatic - - 100% - - ON* ON 42 (R) Fan advice DigitaldF1-2 Defrosting error Automatic - - - - - - ON 40 (R) General warning Digitald1-2 Defrost on circuit in

question- - - - - - - - - Signal on display -

A1 Frost alarm circ. 1 Depends on P05 OFF C1-2 - OFF 1 - - ON - �1 (R) Circuit 1 alarm DigitalA2 Frost alarm circ. 2 Depends on P05 OFF C�-4 - OFF 2 - - ON - �2 (R) Circuit 2 alarm DigitalHt High temperature Automatic - - - - - ON* ON 41 (R) Temperature advice DigitalLt Low ambient temp. Depends on P05 - - - - - ON* ON 41 (R) Temperature advice DigitalAHt High temperature at the

start-upAutomatic OFF - OFF OFF - - ON 40 (R) General warning Digital

ALt Low temperature at the start-up

Automatic OFF - OFF OFF - - ON 40 (R) General warning Digital

ELS Low supply voltage Automatic - - - - - - ON 40 (R) General warning DigitalEHS High supply voltage Automatic OFF OFF OFF OFF OFF OFF OFF �5 (R) General alarm DigitalEd1 EVD 1 tLAN error Automatic OFF C1-2 - OFF - - ON - �� (R) EVD 1 warning DigitalEd2 EVD 2 tLAN error Automatic OFF C�-4 - OFF - - ON - �4 (R) EVD 2 warning DigitalSH1 EVD 1 superheat alarm - OFF C1-2 - OFF- - - ON - �� (R) EVD 1 warning DigitalSH2 EVD 2 superheat alarm - OFF C�-4 - OFF- - - ON - �4 (R) EVD 2 warning DigitalnO1 MOP 1 warning Automatic - - - - - - ON �8 (R) EVD 1 advice DigitalnO2 MOP 2 warning Automatic - - - - - - ON �9 (R) EVD 2 advice DigitalLO1 LOP 1 warning Automatic - - - - - - ON �8 (R) EVD 1 advice DigitalLO2 LOP 1 warning Automatic - - - - - - ON �9 (R) EVD 2 advice DigitalHA1 High inlet temperature

warning circ.1Automatic - - - - - - ON �8 (R) EVD 1 advice Digital

HA2 High inlet temperature warning circ. 2

Automatic - - - - - - ON �9 (R) EVD 2 advice Digital

EP1 EVD 1 Eeprom error Automatic OFF C1-2 - OFF- - - ON - �� (R) EVD 1 warning DigitalEP2 EVD 2 Eeprom error Automatic OFF C�-4 - OFF- - - ON - �4 (R) EVD 2 warning DigitalES1 EVD 1 probe error Automatic OFF C1-2 - OFF- - - ON - �� (R) EVD 1 warning DigitalES2 EVD 2 probe error Automatic OFF C�-4 - OFF- - - ON - �4 (R) EVD 2 warning DigitalEU1 Open valve EVD 1 error at

the start-upAutomatic OFF C1-2 - OFF - - ON - �� (R) EVD 1 warning Digital

EU2 Open valve EVD 2 error at the start-up

Automatic OFF C�-4 - OFF - - ON - �4 (R) EVD 2 warning Digital

Eb1 EVD 1 battery alarm Automatic OFF C1-2 - OFF - - ON - �� (R) EVD 1 warning DigitalEb2 EVD 2 battery alarm Automatic OFF C�-4 - OFF - - ON - �4 (R) EVD 2 warning Digital L Low load warning Automatic - - - - - - - - Signal on display -Ed1 tLan EVD 1 communication

error Automatic OFF C1-2 - OFF - - ON - �� (R) EVD 1 warning Digital

Ed2 tLan EVD 2 communication error

Automatic OFF C�-4 - OFF - - ON - �4 (R) EVD 2 warning Digital

PH1 Low pressure circ. 1 warning - - - - - - - - - Signal on display -PH2 Low pressure circ. 2 warning - - - - - - - - - Signal on display

Table 6.a

Note: The warning relay differs from the alarm relay as it is only activated for warnings, that is, signals only, which have no direct effect on the operation of the unit, and the display does not show the alarm symbol (bell).

CompressorN.b. The alarm relating to the circuit with the fault must not interact with the operation of the other circuit, as long as the condenser is not shared in common.

Factory IP address 10.0.0.101 (default)

BacNet IP Platform Motivair Microchiller BacNet Points

Type Parameter Description R/W

AV-1 B01 Entering Water Temp B1 R

AV-2 B02 Supply Water Temp (antifreeze) B2 R

AV-3 B06 Temp (antifreeze) B6 exp R

AV-4 R01 Setpoint (cooling) r01 R

AV-5 R02 Differential (cooling) r02 R

AV-6 A04 Hot gas Setpoint (cooling) A04 R

AV-7 A05 Hot gas Differential (cooling) A05 R

AV-8 C10 Comp #1 Run Hours R

AV-9 C11 Comp #2 Run Hours R

AV-10 C12 Comp #3 Run Hours R

AV-11 C13 Comp #4 Run Hours R

AV-12 C15 Pump #1 Run Hours R

AV-13 C16 Pump #2 Run Hours R

AV-14 R01 Setpoint (write) r01 R/W

AV-15 R02 Differential (write) r02 R/W

AV-16 A04 Hot gas Setpoint (write) A04 R/W

AV-17 A05 Hot gas Differential (write) A05 R/W

BV-1 Digital input 1 Flow Switch Din1 R

BV-2 Digital input 2 Comp Circuit 1 overload Din2 R

BV-3 Digital input 3 High Pressure Switch Din3 R

BV-4 Digital input 4 Low Pressure Switch Din4 R

BV-5 Digital input 5 On/Off Remote Input Din5 R

BV-6 Digital input 6 Comp Circuit 2 overload Din7 R

BV-7 Digital input 7 High Pressure Cir 2 Din8 R

BV-8 Digital input 8 Low Pressure Cir 2 Din9 R

BV-9 Digital output 1 Compressor 1 Cir 1 R

BV-10 Digital output 2 Hot Gas Valve/heat Cir 1 R

BV-11 Digital output 3 Pump 1 R

BV-12 Digital output 4 Compressor 2 Cir 1 R

BV-13 Digital output 5 Alarm Relay R

BV-14 Digital output 6 Compressor 3 Cir 2 R

BV-15 Digital output 7 Hot Gas Valve/heat Cir2 R

BV-16 Digital output 8 Pump 2 Backup R

BV-17 Digital output 9 Compresor 4 Cir 2 R

BV-18 Digital output 10 Alarm Relay Cir 2 R

BV-19

BV-20

This list contains all 1 and 2 circuit chillers with 1 to 4 compressors some points are not

valid unless options are installed.

Factory addressed Instance #9222

Station/MAC = 1 MSTPMotivair Microchiller BacNet Points

Type Parameter Description R/W

AV-1 B01 Entering Water Temp B1 R

AV-2 B02 Supply Water Temp (antifreeze) B2 R

AV-3 B06 Temp (antifreeze) B6 exp R

AV-4 R01 Setpoint (cooling) r01 R/W

AV-5 R02 Differential (cooling) r02 R/W

AV-6 A04 Hot gas Setpoint (cooling) A04 R/W

AV-7 A05 Hot gas Differential (cooling) A05 R/W

AV-8 C10 Comp #1 Run Hours R

AV-9 C11 Comp #2 Run Hours R

AV-10 C12 Comp #3 Run Hours R

AV-11 C13 Comp #4 Run Hours R

AV-12 C15 Pump #1 Run Hours R

AV-13 C16 Pump #2 Run Hours R

AV-14

AV-15

BV-1 Digital input 1 Flow Switch Din1 R

BV-2 Digital input 2 Comp Circuit 1 overload Din2 R

BV-3 Digital input 3 High Pressure Switch Din3 R

BV-4 Digital input 4 Low Pressure Switch Din4 R

BV-5 Digital input 5 On/Off Remote Input Din5 R

BV-6 Digital input 6 Comp Circuit 2 overload Din7 R

BV-7 Digital input 7 High Pressure Cir 2 Din8 R

BV-8 Digital input 8 Low Pressure Cir 2 Din9 R

BV-9 Digital output 1 Compressor 1 Cir 1 R

BV-10 Digital output 2 Hot Gas Valve/heat Cir 1 R

BV-11 Digital output 3 Pump 1 R

BV-12 Digital output 4 Compressor 2 Cir 1 R

BV-13 Digital output 5 Alarm Relay R

BV-14 Digital output 6 Compressor 3 Cir 2 R

BV-15 Digital output 7 Hot Gas Valve/heat Cir2 R

BV-16 Digital output 8 Pump 2 Backup R

BV-17 Digital output 9 Compresor 4 Cir 2 R

BV-18 Digital output 10 Alarm Relay Cir 2 R

BV-19

BV-20

* There are many more points that can be read but most are not necessary.

See manual for the complete list of modbus points

This list contains all 1 and 2 circuit chillers with 1 to 4 compressors some points are not

valid unless options are installed.

Station address # 1 Microchiller Modbus Points

Type Parameter Description Modbus Point Reg Address R/W

AV-1 B01 Entering Water Temp B1 70 40071 R

AV-2 B02 Supply Water Temp (antifreeze) B2 71 40072 R

AV-3 B06 Temp (antifreeze) B6 exp 75 40076 R

AV-4 R01 Setpoint (cooling) r01 41 40042 R/W

AV-5 R02 Differential (cooling) r02 42 40043 R/W

AV-6 A04 Hot gas Setpoint (cooling) A04 13 40014 R/W

AV-7 A05 Hot gas Differential (cooling) A05 14 40015 R/W

AV-8 C10 Comp #1 Run Hours 90 40091 R

AV-9 C11 Comp #2 Run Hours 91 40092 R

AV-10 C12 Comp #3 Run Hours 92 40093 R

AV-11 C13 Comp #4 Run Hours 93 40094 R

AV-12 C15 Pump #1 Run Hours 94 40095 R

AV-13 C16 Pump #2 Run Hours 95 40096 R

AV-14

AV-15

BV-1 Digital input 1 Flow Switch Din1 43 10044 R

BV-2 Digital input 2 Comp Circuit 1 overload Din2 44 10045 R

BV-3 Digital input 3 High Pressure Switch Din3 45 10046 R

BV-4 Digital input 4 Low Pressure Switch Din4 46 10047 R

BV-5 Digital input 5 On/Off Remote Input Din5 47 10048 R

BV-6 Digital input 6 Comp Circuit 2 overload Din7 57 10058 R

BV-7 Digital input 7 High Pressure Cir 2 Din8 58 10059 R

BV-8 Digital input 8 Low Pressure Cir 2 Din9 59 10060 R

BV-9 Digital output 1 Compressor 1 Cir 1 49 10050 R

BV-10 Digital output 2 Hot Gas Valve/heat Cir 1 50 10051 R

BV-11 Digital output 3 Pump 1 51 10052 R

BV-12 Digital output 4 Compressor 2 Cir 1 52 10053 R

BV-13 Digital output 5 Alarm Relay 53 10054 R

BV-14 Digital output 6 Compressor 3 Cir 2 62 10063 R

BV-15 Digital output 7 Hot Gas Valve/heat Cir2 63 10064 R

BV-16 Digital output 8 Pump 2 Backup 64 10065 R

BV-17 Digital output 9 Compresor 4 Cir 2 65 10066 R

BV-18 Digital output 10 Alarm Relay Cir 2 66 10067 R

BV-19

BV-20

* There are many more modbus point that can be read but most are not necessary.

See manual for the complete list of modbus points

For point # and register address add +1 to the listed point # in the Parameter list + 30000

for analoge and integer points and 10000 for digital points.

Example: Cooling set point - 70 (70 +1 + 30000 = 30071)

This list contains all 1 and 2 circuit chillers with 1 to 4 compressors some points are not

valid unless options are installed.

Factory addressed: Uncommissioned

Subnet: 1 Node: 1 Domain: 0 Microchiller LON_SNVT Points See BB485 unit for Nuron ID tag

Index Type Parameter NV Name R/W

1 ANL B01 nvoEnteringWaterTemp Read

2 ANL B02 nvoSupplyWaterTemp Read

3 ANL B06 nvoAntifreezeTemp Read

4 ANL R01 nvoSetpoint(cooling) Read

5 ANL R02 nvoDifferential(cooling) Read

6 ANL A04 nvoHotGasSetpoint Read

7 ANL A05 nvoHotGasDifferential Read

8 INT C10 nvoComp1RunHours Read

9 INT C11 nvoComp2RunHours Read

10 INT C12 nvoComp3RunHours Read

11 INT C13 nvoComp4RunHours Read

12 INT C15 nvoPump1RunHours Read

13 INT C16 nvoPump2RunHours Read

14 DIG Digital input 1 nvoFlow Switch Read

15 DIG Digital input 2 nvoCompCrt1Overload Read

16 DIG Digital input 3 nvoHighPressSwitch Read

17 DIG Digital input 4 nvoLowPressSwitch Read

18 DIG Digital input 5 nvoOnOffRemoteInput Read

19 DIG Digital input 6 nvoCompCrt2Overload Read

20 DIG Digital input 7 nvoHighPressureCrt2 Read

21 DIG Digital input 8 nvoLowPressureCrt2 Read

22 DIG Digital output 1 nvoCompressor1Crt1 Read

23 DIG Digital output 2 nvoHotGasValveCrt1 Read

24 DIG Digital output 3 nvoPump1 Read

25 DIG Digital output 4 nvoCompressor2Crt1 Read

26 DIG Digital output 5 nvoAlarmRelay Read

27 DIG Digital output 6 nvoCompressor3Crt2 Read

28 DIG Digital output 7 nvoHotGasValveCrt2 Read

29 DIG Digital output 8 nvoPump2(Backup) Read

30 DIG Digital output 9 nvoCompressor4Crt2 Read

31

32

33

34 ANL R01 nviSetpoint(cooling) Write

35 ANL R02 nviDifferential(cooling) Write

36 ANL A04 nviHotGasSetpoint Write

37 ANL A05 nviHotGasDifferential Write

COMMISIONING AND STARTUP INSTRUCTIONS

1. Main switch to OFF - Open the electrical panel 2. Input terminal voltage? IF YES then open the main

fuse 3. Check the electrical connections. Although these

connections are well-tightened at the factory, they may be Ioosened during transport. Retighten if necessary.

4. Check the external connections against the wiring diagram. Fit jumpers if necessary.

5. Check the customer's wiring up to the main disconnect for cable cross-section and correct grounding.

6. Check the supply voltage: Close the main switch and apply voltage to input terminals. +1-5% voltage tolerance

7. Check the generated control voltages of 24 Vac - microprocessor supply voltage at the output terminals of the isolating transformer.

COMMISSIONING Check the water connections

1. Check the supply and retum connection 2. If glycol solution:

Take a water sample to check the freeze protection level.

VisuaI inspection

1. Remove the access panels and check the condition of the system, especially if chilled water pipes have been installed by the customer and or contractor.

2. Check the system visually for: Accessibility and servicing clearances Has the system been modifled, e.g. by fixing cable ducting or similar equipment? Check that there are no screws next to copper pipes or the air-cooled condenser.

Note: Record any deviations on the commissioning report. Inspect control panel and electrical work

Preparations at the switch cabinet 1. Open the electrical cabinet (main switch OFF) CHILLED WATER PUMPS Inspection of chilled water circuit Preparations with the electrical panel OPEN 1. Switch main switch 0FF via extension. 2. OPEN both compressor overloads

(interrupt power supply to compressors) 3. Switch main switch ON via extension Note: The chilled water pump must respond and start after a short delay. 4. Bleed the system again 5. Check the chilled water piping in the entire system. Inspection of the cold water pumps 1. Measure the running amps of the pump and compare

with the values in the wiring diagram. If the measured value is greater than the pump nameplate, the extemal pressure drop is incorrect.

ALWAYS OBEY SAFETY INSTRUCTIONS

WARNING! Use only suitable tools and measuring equipment when inspecting the electrical installation.

WARNING - HIGH VOLTAGE RISK OF FATAL INJURY

Open the main fuse before reconnecting

MANUFACTURER'S NOTE The settings of the overloads must not be adjusted. WARRANTY WILL BE VOIDED

Inspect the water system (check filters/strainers) and remedy any faults. INSPECTION OF COMPRESSOR(S) Check each chiller circuit as follows: 1. Main switch OFF 2. Controller OFF by monitor pushbutton 3. Close opened fuse of circuit 4. Main switch ON 5. Controller ON by monitor pushbutton 6. Clear alarm messages on monitor System status: Chilled water pump running (otherwise compressor does not start) Fan(s) running. Inspection of chiller circuit Note: Operate the compressor(s) at Ieast 15 minutes at full Ioad.

Correct handover by the qualified company to the operator or operator's personnel is a basic precondition for operation of the refrigeration system. Safety Instructions The operator has been familiarised with the specified safety instructions. Operating Instructions The operator has been: − trained in chiller operation − instructed in the function and operation of the

installed microprocessor. − instructed in simple maintenance and

inspection work. The following have been handed over System documentation, consisting of: (check where applicable) Handover Report including commissioning data ____________ Instailation, Operating and Maintenance Specifications ____________ Instructions for Use of the microprocessor ____________ Safety instructions ____________ Electrical wiring diagram ____________ Certificates conforming to the "Pressure Vessel Order" ____________ "C.E." Certificate for export conforming to EC standard ____________ Miscellaneous: ____________________ ____________ ____________________ ____________ ____________________ ____________ INSPECTION – MAINTENANCE The operator has been informed in precise detail by the qualified company of the necessity for regular inspection and maintenance. Inspection and maintenance must be performed to validate any warranty claim.

MAINTENANCE INTERVALS

The Iist beIow contains recommendations based on practical experience. These recommendations must be adapted to the actual operating time of the chiller system, e.g. for continuous operation Weekly Inspections by operator Every 3 months Maintenance by qualified company Once a year General service by qualified chiller maintenance company

If the system is shut down for a long period (winter months), a complete inspection and service must be performed before switching on and restarting. MACHINE DATA

System type _____________

Serial number _____________

Year of manufacture _____________

Refrigerant _____________

Qualified Company (Stamp) - Signature Operator (Stamp) – Signature Date: ______________________

TROUBLESHOOTING

WARNING OBEY SAFETY INSTRUCTIONS

The table that follows lists a large proportion of the fault causes that can occur in practice. These descriptions are intended for information only and must not be considered as a repair manual. Often, the cause of a failure is due to a variety of factors. However, these factors can only be evaluated by a qualified refrigeration company with precise knowledge of the functional interactions.

WARNING Only qualified service and maintenance technicians may carry out repairs to the system. During operation, potentially fatal pressures and voltages are generated in the system. All safety precautions and warnings contained in these documents must be strictly observed.

Possible malfunctions to the chiller may occur due to the following factors:

1. Changes in operating conditions

2. lnsufficient maintenance and inspection

3. External environmental factors

4. Internal machine factors

5. System factors

6. Operating errors

CAUSES OF MALFUNCTIONS These causes can be divided into three groups: 1. Faults due to the water circuit.

The operator can generally remedy this type of problem.

2. Electrical faults With the aid of a qualified electrician, the operator can partially remedy this type of fault.

3. Faults in the refrigerant circuit.

This type of problem can only be remedied by a qualified refrigeration company.

IMPORTANT A large proportion of the functions, faults and operating states of the system are signalled by the microprocessor. The microprocessor monitors all the function areas of the system. Therefore, this information is also essential in troubleshooting the faults.

CHANGES IN OPERATING CONDITIONS Significant changes in the operating conditions of

the chiller may cause faults, because individual components important to the operation of the system wiII not be tuned to the new operating

mode. Inform the MANUFACTURER of any intended

change and obtain prior consent. WARRANTY WILL BE VOIDED

A) FAULT: COMPRESSOR DOES NOT START

SYMPTOM CAUSE POSSIBLE SOLUTION

1. No voltage at power terminals of motor starter 2. No voltage at power terminals of motor starter 3. Voltage on but not applied down

stream of the fuse 4. Main voltage too low 5. Correct voltage is coming to the

compressor terminals

6. Damaged contacts or burnt coil

7. Compressor relay does not close

8. Compressor does not start

Power failure Overload tripped Fuse Blown Main power grid low Compressor failure Defective starter contactor Control circuit interupted Inlet water temperature does not exceed differential set point

Check the fuses and wiring Determine the cause. lf all checks good reset the overload. Change fuse – Identify the fault. Contact electric company Replace compressor Repair or replace. ldentify the open safety switch and determine cause Check set point and differential

B) FAULT: COMPRESSOR NOISE - TOO LOUD.

*STOP THE COMPRESSOR* 1. Compressor “knocking” 2. Suction line exceptionally cold

Internal parts of compressor boken Expansion valve not closing

Compressor must be replaced Check the expansion valve Repair or replace

C) FAULT: COMPRESSOR LOSING OIL

*STOP THE COMPRESSOR*

1. Lack of oil in compressor 2. Oil level falling 3. Compressor turning on/off too often

4. Reduced compressor capacity

Oil level too low Clogged filter dryer Compressor hunting Possible bad compressor windings

Oil must be topped up Change the dryer Readjust superheat. Check TXV sensor position. Replace compressor

D) FAULT: COMPRESSOR “HUNTING”

SYMPTOM CAUSE POSSIBLE SOLUTION

1. Low pressure switch keeps tripping and

bubbles in sight glass during normal operation

2. Compressor turning on/off to

frequently 3. Suction pressure low, ice on top of

compressor 4. Noisy liquid line solenoid

Chiller low on refrigerant Loose contact in electrical panel Filter dryer plugged Liquid line solenoid leaking by

Repair possible leak in the circuit Top off with refrigerant. Repair or replace the defective switch Replace dryer Repair or replace

E) FAULT: INSUFFICIENT COOLING CAPACITY

1. TXV very noisy during operation

2. Temperature difference up/down

stream of filter dryer or LL solenoid valve

3. Frequent chiller cycling 4. High water temperature 5. Reduced water flow 6. Chiller wont make set point 7. Chiller wont make set point

Low on refrigerant or faulty TXV Dryer or LL solenoid valve clogged TXV seized or clogged Low flow across evaporator. Excessive pressure drop in evaporator Flow in water piping restricted or blocked Superheat is out of adjustment Overloading the chillers sized capacity

Top off refrigerant and or replace TXV Replace dryer/LL solenoid Clean or replace Ensure proper water flow. Check expansion valve superheat Check pump rotation, Remedy obstruction Adjust TXV superheat Correct the overloading condition

F) FAULT: SUCTION PRESSURE TOO LOW

1. Bubbles in sight glass 2. Compressor hunting 3. Temperature difference up/down

stream of filter dryer or LL solenoid 4. No refrigerant flow through TXV 5. Water flow low

Low on refrigerant Compressor hunting Dryer or LL solenoid valve clogged TXV clogged or powerhed defective Loss of water/glycol and or restriction

Possible leaks or insufficient refrigerant See D) above: Compressor hunting Replace the dryer Clean/ replace TXV or powerhead Meassure GPM and or find and repair restriction

G) FAULT: CONDENSING PRESSURE TOO HIGH

SYMPTOM CAUSE POSSIBLE SOLUTION

1. Normal operation high pressure switch

trips

2. High water temperature

Too much refrigerant in system Insufficant cooling air (ambient) Fan(s) do not delivery enough air Heat load exceeded chillers capacity

Check subcooling Remove refrigerant Clean the condenser Ambient is high than 95F Check phase rotation Defective fan motor External air resistance too high. Send proper load to chiller. Call factory to see what the chiller was sized for

H) FAULT: CONDENSING PRESSURE TOO LOW

1. Suction and discharge pressure

equalize after pumpdown 2. Bubbles in sight glass

High pressure valves in compressor are causing pressure to bleed by. Low on refrigerant

Replace the compressor Insufficient rerigerant due to refrigerant leak.

I) FAULT: CONDENSER FANS

1. Fan or fram vibration 2. No air flow or some fans not running

Fan out of balance Fan fuse blown

Inspect the bearings and visually check for damage. Is chiller level? Check the voltage. Check the VFD (if fitted) and measure the values. Check the fan motor(s)

L) FAULT: CHILLED WATER PUMP

1. Large delta T between inlet and

outlet temperatures 2. Water leaking from pump 3. Pump does not run although cooling

is required

Not enough flow through chiller Mechanical seal defective Mechanically seal defective or overload tripped

Pressure drop in process cooling circuit is too high. Check the GPM Replace mechanical seal Check amp draw of pump. External pressure loss may be too high causing the amp draw to be higher than normal

PREVENTATIVE MAINTENANCE

MAINTENANCE Before carrying out any maintenance work, the service technician must be made thoroughly familiar with the

following safety precautions and provisions.

WARNING Do not undo any refrigerant or hydraulic connections until the system is depressurised.

GENERAL SAFETY PRECAUTIONS

WARNING

High voltage - Risk of fatal injury Disconnect the unit from the power supply before opening the doors or removing the chiller panels.

WARNING Protective goggles and rubber gloves must be worn when handling refrigerant.

WARNING Avoid any skin contact with gas or refrigerating oiIs. Severe bums may be caused. Always wear rubber gloves when handling dirty parts.

MANUFACTURER’S SPECIFICATION

WARNING High voltage - Risk of fatal injury

After opening the electrical panel, voltage is applied at input terminals L1, L2, L3

WARNING Before carrying out any work in the electrical cabinet, make sure that the main switch is set to the “0FF” position.

WARNING Use only the appropriate tools and measuring equipment to check the electrical system.

WARNING Risk of burns

Exposed copper pipes may be hot.

WARNING Danger of suffocation when working with refrigerants, make sure of good ventilation. Do not smoke.

WARNING Refrigerant must never be discharged into the environment. It must be coIlected in a collecting container for reuse or for return to the manufacturer.

WARNING Risk of injury

If it is necessary to carry out work inside the system with the fans running, make sure that no parts of the body or clothing are caught in the fan blades or other moving parts.

The safety devices installed in the system such as flow meters, pressure switches etc. must not be bypassed.

WARRANTY WILL BE VOIDED

Microprocessor Changes to the programming domain protected by password may only be made after checking with the manufacturer.

WARRANTY WILL BE VOIDED

Modifications in the control panel The panel wiring may only be changed with the consent of the manufacturer.

Additional wiring is possible Any changes to the wiring must be marked in the wiring diagrams and made available to the operator.

Servicing tasks required every 6 months 1. Repeat the 3-month service 2. Preventive maintenance – additional − Check superheat and subcooling − Check the glycol/water mixture for good freeze

protection 3. Commissioning operations, as follows: − Check the glycol water pumps − Check the flow meters for proper GPM − Check all safety devices − Check the antifreeze protection (setting) Enter all repairs/changes in a maintenance log Note: The recommendations and specifications given here are based on experience. The type and scope of maintenance depends on the actual application of the system. More frequent and more comprehensive inspections may be necessary in the event of more adverse conditions, e. g.: − Higher or lower ambient temperatures − Power fluctuations − Dusty/Dirty installation conditions Checking the glycol solution lf the system is operated with a water/glycol mixture, the mixed percentage must be regularly checked. Recommendation: every 6 months

− Only a correct mixture can guarantee correct operation. Check the percentage with a portable spectrometer.

− Excess glycol concentration: reduces the cooling capacity

− Insufficient glycol concentration: risk of freezing. − The water sample should also be checked for

signs of corrosion. Note: Improper use of water treatment agents can cause major problems. Obtain information from the manufacturer on suitable inhibitors.

PREVENTIVE MAINTENANCE Maintenance Intervals Note: The maintenance intervals specified here are based on experience. Depending on individual conditions at any job site, required maintenance intervals may need to be performed more or less frequently than recommended within this manual.

WARNING

STRICTLY OBEY THE SAFETY INSTRUCTIONS

WARNING Maintenance must be carried out by qualified service and maintenance technician. During operation, potentially lethal high voltages and high pressures are generated in the chiller system. All safety precautions and wamings given in these documents must be precisely observed. Otherwise, severe or fatal injuries may be caused.

MANUFACTURER’S NOTE

When gather running data on chiller readings must be taken at full load and under the normal system operating conditions. Weekly tasks required 1. A general inspection of the chiller operation. 2. Carry out weekly inspections.

Servicing tasks required every 3 months: 3. Check the settings of all safety devices against the

Commissioning Report. 4. Preventive maintenance, as follows: − Check the fan(s) are running − Check the refrigerant pipes for any signs of leaks − Check the water/glycol pipes for any signs of leaks − Check the glycol water pump(s) − Check the condenser for dirt build up − Check the electrical cabinet − Check the compressor(s) amp draw 5. Carry out any maintenance issues once they are

found Enter all repairs/changes in a maintenance log

WARNING The glycol/water mixture must not be discharged into the normal water drains. It must be collected in suitable containers and disposed of in accordance with the local law specifications.

WARNING - RISK OF INJURY Risk of cuts due to the condenser fins. Wear gloves if

working on the condenser.

Preventive Maintenance

IMPORTANT NOTE The maintenance operations are described below. All operations must be performed step by step and must be completely finished.

WARNING High voltage - Risk of fatal injury

Disconnect the unit from the power supply before opening the doors or removing the chiller panels.

Risk of burns Exposed copper pipes may be hot.

Checking the refrigerant pipes 1. Check the refrigerant piping as far as possible for

cracks, damage and oil leaks. 2. Check the piping for chafing points, especially

where the pipes are routed very close to the frame work or along internal components of the chiller.

3. Check the pipe insulation and repair/replace if necessary.

4. Check the pipes for vibrations. Check the pipe mounting clips and re-tighten the screws if necessary.

Checking the water/ glycol Iines

1. Check all pipes for vibrations. 2. Check the mounting clips and tighten if necessary. 3. Check for leaks at screwed joints and weldings and

repair if necessary. 4. Squeeze the insulation to determine whether it

has filled with water. lf so: Locate the leak and repair

5. Check the insulations and repair/replace any damaged points.

Note: Condensation may form due to inadequately insulated chilled water pipes.

WARNING High voltage - risk of fatal injury

Disconnect the unit from the power supply

Checking the chilled water pumps - when mounted in the chiller -

1. Check for leaks around the pump. If leaking, tighten any flange fittings that might be leakingo or the mechanical pump seal might need to be changed.

2. Check on the motor electrical box for loose electrical connections. lf necessary, retighten the electrical connections. Reclose the terminal box.

3. Check the externally mounted Y-strainer and clean if necessary.

RISK OF INJURY If it is necessary to carry out work inside the system with the fans running, make sure that no parts of the body or clothing are caught in the fan blades or other moving parts.

Checking the air-cooled condenser 1. Check the condenser coil and clean CAREFULLY.

Low PSI compressed air can be used. DO NOT USE A BRUSH OR SCRAPER OR CODENSER COIL WILL BE PERMANENTLY DAMAGED.

2. Straighten bent fins with a fin comb set for the correct fin pitch.

WARNING After changing any components such as fan baldes, etc., insure balance is correct.

1. Check the fan mounting and, if necessary, tighten the securing screws.

2. Check the electrical terminal box. 3. Check to make sure the rotation of fans are

correct After completing these operations, re-install any side or top panel that was removed. This is to ensure proper air flow is going through condenser Record any repairs/changes on the maintenance log.

CLEANING THE PLATE EXCHANGER (EVAPORATOR)

Clean exchangers subject to fouling (scale, sludge deposits, etc.) periodically, depending on specific conditions. A marked increase in pressure drop and/or reduction in performance usually indicate cleaning is necessary. Since the difficulty of cleaning increases rapidly as the scale thickens or deposits increase, the intervals between cleanings should not be excessive. Back flush with a high pressure stream of hot water to remove loose deposits. Circulating hot wash oil or light distillate will usually effectively remove sludge or similar soft deposits. In some applications the fouling tendency can be very high, e.g. when using extremely hard water at high temperatures. Use a tank with weak acid, 5% phosphoric acid or, if the exchanger is frequently cleaned, 5% oxalic acid. Pump the cleaning liquid through the exchanger. For optimum cleaning, the cleaning solution flow rate should be a minimum of 1.5 times the normal flow rate, preferably in a back-flush mode. After use, DO NOT to forget to rinse the heat exchanger carefully with clean water. A solution of 1-2% sodium hydroxide (NaOH) or sodium bicarbonate (NaHCO) before the last rinse ensures that all acid is neutralized. Clean at regular intervals. If the heat exchanger is excessively fouled and it cannot be cleaned by commercial cleaning methods, then replacement of the unit is suggested. It is recommended that the refrigerant circuit NOT be chemically cleaned.

MAINTENANCE/REPAIR

FAILURE OF A COMPRESSOR

Occasionally, a fault in the motor insulation can cause the motor to burn out. On a maintained system, this type of failure is very rare. However, if it does occur, it wiII generally be caused by mechanical or lubrication faults that result in burn-out. Compressor damage can be Iargely prevented if the problems Ieading to motor burn-out are remedied. Regular service inspections - That identify fault conditions play an active role in ensuring operating safety and reducing maintenance costs. Mechanical fault - The refrigerant gas from the service port does not smell burnt. The motor tries to start. Electrical fault - This type of fault is identified by a characteristic smell when the coolant is removed from the service port. After severe burn out, the oil is black and acidic. Check all electrical components before replacing a compressor assumed to be defective. 1. Check the main disconnect switch and fuse 2. Check all safety devices of the compressor. 3. Check whether the mechanical or electrical fault

has damaged the compressor. 4. Perform an acid test.

Compressor replacement after mechanical fault lf a mechanical fault is found, and the acid test is negative, replace the compressor as follows: 1. Check: the power supply to the circuit must be

disconnected.

WARNING - RISK OF BURNS Do not undo any refrigerant connections until the system is depressurised.

WARNING When working on the refrigerant circuit, open the compressor breaker in the electrical cabinet.

2. Connect refrigerant pressure gauges to the service ports.

3. Close the service valves by tuming them clockwise. Reclaim the refrigerant pressure from the compressor.

4. Remove all mechanical and electrical connections on the compressor, and then the remove the defective compressor.

5. Install the new compressor and connect up all connections correctly.

6. Evacuate the refrigerant circuit to 500microns. 7. Open the service valves on the compressor. 8. Start up the compressor. Check the refrigerant

level and ensure the circuit is perfectly sealed. 9. Dispose of the defective compressor in accordance

with local laws.

Compressor replacement after burn-out In the case of an electrical fault and compressor motor burn-out, proceed very carefully. lf the motor burns out, the stator windings break down, forming carbon, water and acid, which contaminate the refrigerant system. These impurities must be completely removed from the system in order to prevent repeated motor damage.

WARNING! lf the replacement compressor is damaged due to inadequate system cleaning, warranty will be voided

1. Carry out the acid test and send it with the compressor to the manufacturer for damage analysis.

2. Check: the power supply of the refrigerant circuit must be disconnected.

CARE High voltage - Risk of fatal injury

Disconnect the main current supply to the unit if the power supply has to be maintained (to operate the second circuit)

OBEY THE SAFETY INSTRUCTIONS

3. Check the electrical circuit in the electrical cabinet for blown fuses, charred contacts, overload contacts and relays. Check the input and output terminals of the compressor circuit.

MAINTENANCE/REPAIR CONTINUED Compressor replacement after burn-out 4. Check the connection line of the compressor for

charred or damaged connectors, insulation and short-circuited or grounded.

5. Meg the compressor. 6. Establish the cause of the electrical fault. Take all

necessary corrective action to ensure that the new compressor does not experience the same result.

Removing the compressor 1. Reclaim the refrigerant circuit 2. Close the compressor inlet and outlet service

valves. 3. Remove the burnt out compressor. Dispose of in

accordance to local laws Note: Check that the inlet and outlet valves are not fouled after the severe burn-out. Before connecting the new compressor, the valves must be carefully cleaned and/or replaced. Check the seals in the service valves . Cleaning the refrigerant circuit Clean the circuit with great care and in conformity with the manufacture.

WARNING Refrigerant must never be discharged into the environment. It must be collected in a collecting container for proper disposal

WARNING Avoid any skin contact with gas or refrigeration oils. Severe burns may be caused. Always wear rubber gloves when handling dirty parts.

WARNING! lf the replacement compressor is damaged due to inadequate system cleaning, warranty will be voided.

CHLORINE - FREE REFRIGERANTS The compressors designed for operation with chlorine-free refrigerants are factory-filled with ester oils approved by the compressor manufacturer and are marked accordingly. Compared to single-substance refrigerants and azeotropic and quasi-azeotropic mixtures, the zeotropic refrigerant mixtures are characterised by a wider temperature variation. Specific effects on system maintenance and repairs must therefore be taken into account. Due to the fact that zeotropic mixtures can have different compositions in the liquid and gas phases, it is especially important that these refrigerants are only ever poured into the system in the Iiquid state. Therefore: strictly follow the filling instructions of the refrigerant manufacturer. In the event of a Ieak, the change in mixture composition Ieads to reduced superheat at the thermostatic expansion valve and ultimately to liquid flood back in the compressor. Another aspect of the mixture change is sudden ‘hunting’ of the expansion valve. Tests by refrigerant manufacturers and the past experience of users have shown that this situation can be stabilized by filling the system with the original composition. Before replacing the entire refrigerant charge, a mixture concentration analysis is recommended.

The use of polyester oils ("POE"s) is necessary for operation with chlorine-free refrigerants. Compared to mineral oils, POEs have high hygroscopicity (moisture absorption). If POE is exposed for only a short time to the ambient air, it absorbs so much moisture that it is no longer acceptable for use in refrigeration circuits. Since a POE binds moisture more firmly than mineral oil, the moisture is more difficult to remove from the system by vacuum. Consequently, we recommend filling the system with a POE containing Iess than 50ppm moisture particles. With the use of appropriately sized filter dryers, the moisture content in the system can be kept below 50 ppm. lf the moisture level rises to unacceptable Ievels, corrosion and copper-plating can occur. By perfect evacuation, the residual moisture can be reduced to 10 ppm. The system is evacuated to 500 microns. In the event of any doubt regarding the moisture level in the system, an oil sample should be taken and analysed for water content. The installed indicator sight glasses can be used for the new refrigerants and oils, but they do not show the actual moisture content, which may be higher than shown in the sight glass due to the high hygroscopicity (moisture absorption). The display in the sight glass only gives the moisture content of the refrigerant. To determine the real moisture level, an oil sample must be taken from the system and analysed.

Terms & Conditions of Sale

1) All orders are subject to approval & acceptance by the Seller. 2) Prices are quoted FOB point of shipment, and are subject to change without notice. All prices are exclusive of any sales, use, State, Federal, or local taxes. The collection & payment of such taxes are the responsibility of the Buyer. 3) Upon transfer of the equipment from the Seller to a common carrier, title shall pass to the Buyer. The Buyer assumes all risks of loss or damage during transit. The buyer must file claims for such loss or damage with the carrier, with assistance from the Seller. 4) Seller shall not be liable for any damages or consequential losses of any kind, arising out of its inability to deliver due to labor, suppliers, fire, flood, delays of any kind, acts of God, or any other cause whatsoever. 5) Seller warrants all equipment to be free from defects in materials and workmanship for a period of fourteen (14) months from the date of shipment or 12 months from the date of startup, provided the equipment is applied, installed and maintained in accordance with Seller’s recommendations. Seller’s liability is limited solely to repair or replacement of the defective item, at Sellers option, excluding labor or freight. Under no circumstances shall Seller be liable for any losses, rental equipment charges, or consequential damages of any kind, howsoever caused. All warranty interpretations and limitations are defined in the Motivair Standard Product Warranty, a copy of which is available to Buyer on request. 6) Seller makes no warranty or representation of any kind, expressed or implied, as to the merchantability, fitness or suitability for any particular purpose, with respect to the equipment. 7) Buyer must obtain written permission from Seller, prior to returning any equipment for warranty, credit, or any other reason whatsoever. The terms of any warranty returns or associated credits are in strict accordance with the above referenced Motivair Standard Product Warranty. All goods returned for reasons other than warranty shall be subject to a re-stocking charge of no less than 15%, not to exceed the full invoiced value of the equipment, to be determined at the sole discretion of the Seller. Return freight charges, plus the risk of loss or damage, whether or not it occurs during shipment back to Seller, will be borne solely by the Buyer. 8) Order changes must be submitted in writing by the Buyer and acknowledged in writing by the Seller, before such changes shall be deemed valid. Cancellations shall be subject to a charge not to exceed the value of the original order, at the sole discretion of the Seller. Buyer shall also be responsible for all freight costs associated with any order changes or cancellations. 9) Terms of payment shall be net 30 days to all credit-approved Buyers, from the date of shipment or consignment to a common carrier, for all standard or inventoried items. Seller will allow a cash discount of 1% for prompt payment received within ten (10) days of Sellers invoice date. 10) Terms of payment for large or custom orders shall be specified at the time of order acknowledgement. No contractor or performance payment retention is allowed for any reason whatsoever, beyond these payment terms. 11) A finance charge of 1.5% per month will be applied to all overdue accounts. In the event Seller utilizes a collection agency or legal proceedings to recover money due and payable to Seller under this agreement, Buyer agrees to pay for all costs directly associated with this collection. 12) This contract shall be governed in strict accordance with the laws of New York State. If any of these terms are held to be invalid by a prevailing court of law, the remainder of these terms shall remain in effect, and shall not be affected by the invalid portion. 13) This contract shall constitute the entire agreement between Buyer and Seller. All terms and conditions contained herein shall be deemed acceptable by the Buyer and shall prevail over any and all terms stipulated within the Buyer’s purchase order, unless specifically amended by the Buyer, and agreed by the Seller in writing. Customer Signature of Acceptance: ______________________________ Date: ____________________________