Thermal Care NQ Series User manual

Installation & Operation Manual

NQ Series Portable and Remote Condenser Chillers

Page Intentionally Blank

Table of Contents

Foreword ...........................................................................................................................................................................1

Safety Guidelines .............................................................................................................................................................2

General Data .....................................................................................................................................................................3

Table 1 –Air Cooled Chiller General Data (60 Hz) ......................................................................................................................... 3

Table 2 –Water Cooled Chiller General Data (60 Hz)................................................................................................................... 3

Table 3 –Remote Air Cooled Condenser Chiller General Data (60 Hz) .................................................................................4

Table 4 –Remote Air-Cooled Condenser General Data (60 Hz)............................................................................................... 4

Pre-Installation.................................................................................................................................................................5

Receiving Inspection ....................................................................................................................................................................................... 5

Unit Storage........................................................................................................................................................................................................ 5

Installation –Chiller Mechanical ...................................................................................................................................6

Foundation..........................................................................................................................................................................................................6

Unit Location......................................................................................................................................................................................................6

Rigging ................................................................................................................................................................................................................. 6

Chilled Water Piping ....................................................................................................................................................................................... 6

Figure 1 –Recommended Overhead Piping.....................................................................................................................................7

Figure 2 –4 Ton Chiller Net Pump Performances (60 Hz) ..........................................................................................................7

Figure 3 –4 Ton High Flow Chiller Net Pump Performances (60 Hz).....................................................................................8

Figure 4 - 5 Ton Chiller Net Pump Performances (60 Hz) ........................................................................................................... 8

Figure 5 –5 Ton High Flow Chiller Net Pump Performances (60 Hz).....................................................................................9

Figure 6 –7½ Ton Chiller Net Pump Performances (60 Hz) ...................................................................................................... 9

Figure 7 –7½ Ton High Flow Chiller Net Pump Performances (60 Hz) ..............................................................................10

Figure 8 - 10 Ton Chiller Net Pump Performances (60 Hz) ......................................................................................................10

Figure 9 –10 Ton High Flow Chiller Net Pump Performances (60 Hz) ................................................................................11

Figure 10 - 13 Ton Chiller Net Pump Performances (60 Hz)....................................................................................................11

Figure 11 –13 Ton High Flow Chiller Net Pump Performances (60 Hz)..............................................................................12

Figure 12 - 15 Ton Chiller Net Pump Performances (60 Hz)....................................................................................................12

Figure 13 –15 Ton High Flow Chiller Net Pump Performances (60 Hz)..............................................................................13

Figure 14 - 20 Ton Chiller Net Pump Performances (60 Hz)....................................................................................................13

Figure 15 –20 Ton High Flow Chiller Net Pump Performances (60 Hz)..............................................................................14

Figure 16 - 25 Ton Chiller Net Pump Performances (60 Hz)....................................................................................................14

Figure 17 –25 Ton High Flow Chiller Net Pump Performances (60 Hz)..............................................................................15

Figure 18 - 30 Ton Chiller Net Pump Performances (60 Hz)....................................................................................................15

Figure 19 –30 Ton High Flow Chiller Net Pump Performances (60 Hz)..............................................................................16

Figure 20 - 35 Ton Chiller Net Pump Performances (60 Hz)....................................................................................................16

Figure 21 –35 Ton High Flow Chiller Net Pump Performances (60 Hz)..............................................................................17

Figure 22 - 40 Ton Chiller Net Pump Performances (60 Hz)....................................................................................................17

Figure 23 –40 Ton High Flow Chiller Net Pump Performances (60 Hz)..............................................................................18

Figure 24 –Chiller Coolant Circuit Pressure Drop (4-Ton and 5-Ton) .................................................................................18

Figure 25 –Chiller Coolant Circuit Pressure Drop (7½-Ton and 10-Ton)...........................................................................19

Figure 26 –Chiller Coolant Circuit Pressure Drop (13-Ton and 15-Ton) ............................................................................19

Figure 27 –Chiller Coolant Circuit Pressure Drop (20-Ton and 25-Ton) ............................................................................20

Figure 28 –Chiller Coolant Circuit Pressure Drop (30-Ton and 35-Ton) ............................................................................20

Figure 29 –Chiller Coolant Circuit Pressure Drop (40-Ton) .....................................................................................................21

Condenser Water Piping..............................................................................................................................................................................21

Figure 30 –Water Cooled Condenser Pressure Drop Curve (5-Ton to 15-Ton) ..............................................................22

Figure 31 –Water Cooled Condenser Pressure Drop Curve (20-Ton to 40-Ton)............................................................22

Installation –Remote Air-Cooled Condenser ............................................................................................................23

Location..............................................................................................................................................................................................................23

Mounted Legs and Lifting (5 - 10 ton Units).......................................................................................................................................23

Mounted Legs and Lifting (15 –40 ton Units)....................................................................................................................................24

Interconnecting Refrigerant Piping.........................................................................................................................................................24

Refrigeration Piping Design .......................................................................................................................................................................24

Figure 32 –Condenser Located with No Elevation Difference................................................................................................25

Figure 33 –Condenser Located above Chiller Unit .....................................................................................................................25

Figure 34 - Condenser Located Below Chiller Unit ......................................................................................................................26

Determining Equivalent Line Length ......................................................................................................................................................26

Table 5 –Equivalent Lengths of Fittings ..........................................................................................................................................27

Liquid Line Sizing............................................................................................................................................................................................27

Table 6 –Liquid Line Sizes for R410A................................................................................................................................................28

Discharge (Hot Gas) Line Sizing................................................................................................................................................................30

Figure 35 –Vertical Riser Traps............................................................................................................................................................30

Figure 36 - Double Discharge Riser ...................................................................................................................................................31

Table 7 - Horizontal or Downflow Discharge Line Sizes for R410A (inches OD)..............................................................31

Table 8 - Upflow Discharge Line Sizes for R410A (inches OD)................................................................................................31

Calculating System Refrigerant and Oil Charge.................................................................................................................................32

Table 9 –Combined Chiller and Remote Condenser Summer Refrigerant Charge........................................................32

Table 10 - Field Piping R-410A Refrigerant Charge per 100 Feet of Run (Lbs.) ...............................................................32

Oil Charge Determination...........................................................................................................................................................................32

Setting Condenser Fan Controls...............................................................................................................................................................32

Table 11 - Condenser Fan Pressure Settings (psig) .....................................................................................................................32

Installation - Electrical ..................................................................................................................................................33

Table 12 –Air Cooled Chiller Electrical Data (60 Hz)...................................................................................................................34

Table 13 –Water Cooled & Remote Air Cooled Condenser Chiller Electrical Data (60 Hz) ........................................38

Table 14 –Remote Air Cooled Condenser Electrical Data (60 Hz) ........................................................................................42

Standard Controller Operation....................................................................................................................................43

Start Button.......................................................................................................................................................................................................43

Stop Button.......................................................................................................................................................................................................43

Alarm Silence / Alarm Reset Button........................................................................................................................................................43

Compressor Running Hours Button........................................................................................................................................................43

Pump Running Hours Button ....................................................................................................................................................................44

Pump Test Button...........................................................................................................................................................................................44

Display/Program Button ..............................................................................................................................................................................44

Up Button ..........................................................................................................................................................................................................44

Down Button ....................................................................................................................................................................................................44

Control Power On LED..................................................................................................................................................................................44

Autostart Signal LED......................................................................................................................................................................................44

Pump LED ..........................................................................................................................................................................................................45

Hot Gas Bypass LED.......................................................................................................................................................................................45

Compressor #1 LED .......................................................................................................................................................................................45

Compressor #2 LED .......................................................................................................................................................................................45

Temperature Limit LED.................................................................................................................................................................................45

Electrical Phase Error LED............................................................................................................................................................................45

Low Flow LED ...................................................................................................................................................................................................45

Freezestat LED .................................................................................................................................................................................................46

Low Reservoir Level LED ..............................................................................................................................................................................46

Compressor Recycle LED .............................................................................................................................................................................46

High Refrigerant Pressure LED..................................................................................................................................................................46

Low Refrigerant Pressure LED....................................................................................................................................................................46

Program Mode LED .......................................................................................................................................................................................46

Set Point Temperature Display .................................................................................................................................................................46

Process Temperature Display ....................................................................................................................................................................46

Program Menu.................................................................................................................................................................................................46

Table 15 - Controller Program Menu ................................................................................................................................................48

Table 16 –Controller Control Fault Logic........................................................................................................................................49

SPI Communications (Optional) ...............................................................................................................................................................50

Table 17 - SPI Parameters ......................................................................................................................................................................50

Modbus RTU (Optional)...............................................................................................................................................................................51

Table 18 –ModBus RTU Option Parameters (Integer Values).................................................................................................51

Table 19 –ModBus RTU Option Parameters (Floating Point Values) ...................................................................................52

Optional Controller Operation.....................................................................................................................................54

Start-Up Screen & Thermal Care Contact Information ...................................................................................................................54

Main Screen......................................................................................................................................................................................................54

Local/ Remote Button (Press to Toggle) ..........................................................................................................................................54

Set Point Temperature Display & Entry............................................................................................................................................54

Actual Supply Water Temperature Display .....................................................................................................................................54

Alarms Button .............................................................................................................................................................................................54

Setup Button ...............................................................................................................................................................................................54

Process Diagnostic Button.....................................................................................................................................................................54

Refrigereration Diagnostic Button......................................................................................................................................................54

Active Alarms Screen.....................................................................................................................................................................................55

Alarm Reset Button...................................................................................................................................................................................55

Alarm History Button ...............................................................................................................................................................................55

Main Button.................................................................................................................................................................................................55

Alarm History Screen ....................................................................................................................................................................................55

Up and Down Buttons .............................................................................................................................................................................55

Acknowledge Button................................................................................................................................................................................55

Process Diagnostic Button.....................................................................................................................................................................55

Compressor Setup Screen...........................................................................................................................................................................56

Process Setup Button...............................................................................................................................................................................56

PID Setup ......................................................................................................................................................................................................56

FreezeStat Setup Button .........................................................................................................................................................................56

Process Setup Screen....................................................................................................................................................................................56

HGBP PID Button .......................................................................................................................................................................................56

Compressor Setup Button......................................................................................................................................................................56

Main................................................................................................................................................................................................................56

Hot Gas Bypass Screen PID Tuning Screen ..........................................................................................................................................57

Refrigeration Diagnostic Button..........................................................................................................................................................57

Compressor Setup Button......................................................................................................................................................................57

Freezestat Setup Screen...............................................................................................................................................................................57

Compressor Setup Button......................................................................................................................................................................57

Process Diagnostic Screen..........................................................................................................................................................................58

I/O Status Button.......................................................................................................................................................................................58

I/O Status Screen............................................................................................................................................................................................58

Output Designation Button...................................................................................................................................................................58

Input Status Button...................................................................................................................................................................................58

Refrigeration Diagnostic Screen...............................................................................................................................................................59

Process Diagnostic Button.....................................................................................................................................................................59

Start-Up...........................................................................................................................................................................59

Step 1 - Connect Main Power ...................................................................................................................................................................60

Step 2 - Fill Coolant Circuit.........................................................................................................................................................................60

System Fill Water Chemistry Requirements....................................................................................................................................60

Table 20 –Fill Water Chemistry Requirements..............................................................................................................................61

Table 21 - Recommended Glycol Solutions....................................................................................................................................61

Step 3 - Check Condenser ..........................................................................................................................................................................61

Intergral Air-Cooled Condenser Check.............................................................................................................................................61

Water-Cooled Condenser Check.........................................................................................................................................................61

Remote Air-Cooled Condenser Check ..............................................................................................................................................61

Step 4 –Check Refrigerant Valves...........................................................................................................................................................62

Step 5 –Verify Freezestat Setting ............................................................................................................................................................62

Step 6 –Turn On Control Power ..............................................................................................................................................................62

Step 7 –Establish Coolant Flow................................................................................................................................................................62

Step 8 –Intial Unit Operation....................................................................................................................................................................62

Preventive Maintenance ...............................................................................................................................................63

Once a Week ....................................................................................................................................................................................................63

Once a Month..................................................................................................................................................................................................63

Every Three Months.......................................................................................................................................................................................63

Preventive Maintenance Checklist ..............................................................................................................................64

General Troubleshooting..............................................................................................................................................65

Drawings .........................................................................................................................................................................66

Warranty .........................................................................................................................................................................67

Extended 5 Year Compressor Warranty –(Optional)...............................................................................................68

Foreword

The portable chiller is a packaged unit typically

consisting of a refrigeration circuit and a coolant

reservoir and pumping system in a compact

packaged cabinet for easy location in industrial

applications where chilled water is required.

The intent of this manual is to serve as a guide for

placing your portable chiller in service and operating

and maintaining it properly. Improper installation

can lead to poor equipment performance or severe

equipment damage. Failure to follow the installation

instructions may result in damage not covered by

your warranty. It is extremely important that a

qualified refrigeration installation contractor perform

all installation line sizing and piping. Please supply

these instructions to your authorized refrigeration

contractor.

This manual is for our standard product line with

supplements as required to accommodate any

special items provided for a specific application. The

written information contained in this manual, as well

as various drawings, are intended to be general in

nature. Unit specific drawings are included with the

equipment for troubleshooting and servicing of the

unit. Additional copies of drawings are available

upon request. We strive to maintain an accurate

record of all equipment during the course of its

useful life.

Due to the ever-changing nature of applicable

codes, ordinances, and other local laws pertaining to

the use and operation of this equipment we do not

reference them in this manual. There is no substitute

for common sense and good operating practices

when placing any mechanical equipment into

operation. We encourage all personnel to familiarize

themselves with this manual's contents. Failure to do

so may unnecessarily prolong equipment down time.

The chilling equipment uses chemical refrigerants for

heat transfer purposes. This chemical is sealed and

tested in a pressurized system containing ASME

coded vessels; however, a system failure will release

it. Refrigerant gas can cause toxic fumes if exposed

to fire. Place these units in a well-ventilated area,

especially if open flames are present.

Failure to follow these instructions could result in a

hazardous condition. The standard refrigerant used

in these units is a hydro fluorocarbon (HFC) trade

named R-410A. We strongly recommend a

refrigerant management program be implemented

which includes a survey of all equipment to

document the type and quantity of refrigerant in

each machine. In addition, we recommend only

licensed and EPA certified service technicians work

on our refrigeration circuits. Follow good piping

practices and the information in this manual to

ensure successful installation and operation of this

equipment. We are not responsible for liabilities

created by substandard piping methods and

installation practices external to the chiller.

We trust your equipment will have a long and useful

life. If you should have any questions, please contact

our Customer Service Department specifying the

serial number and model number of the unit as

indicated on the nameplate.

Safety Guidelines

Observe all safety precautions during installation,

start-up, and service of this equipment. The

following is a list of symbols used in this manual and

their meaning.

General Warning

Electricity Warning

Sharp Element Warning

Hot Surface Warning

Flammable Material Warning

Explosive Material Warning

General Mandatory Action

Wear Eye Protection

Wear Protective Gloves

Wear Ear Protection

Disconnect Before Carrying Out Maintenance or

Repair

Connect an Earth Terminal to Ground

Only qualified personnel should install, start-up, and

service this equipment. When working on this

equipment, observe precautions in literature, and on

tags, stickers, and labels located on the equipment.

WARNING: Any use or misused of this equipment

outside of the design intent may cause injury or

harm.

WARNING: Vent all refrigerant relief valves in

accordance to ANSI/ASHRAE Standard 15, Safety

Code for Mechanical Refrigeration. This

equipment should be located within a well-

ventilated area. Inhalation of refrigerant can be

hazardous to your health and the accumulation

of refrigerant within an enclosed space can

displace oxygen and cause suffocation.

WARNING: This equipment contains hazardous

voltages that can cause severe injury or death.

WARNING: This equipment contains refrigerant

under pressure. Accidental release of refrigerant

under pressure can cause personal injury and or

property damage.

WARNING: This equipment may contain fan

blades or other sharp edges. Make sure all fan

guards and other protective shields are securely

in place.

WARNING: The exposed surfaces of motors,

refrigerant piping, and other fluid circuit

components can be very hot and can cause burns

if touched with unprotected hands.

CAUTION: Disconnect and lock out incoming

power before installing, servicing, or

maintaining the equipment. Connecting power to

the main terminal block energizes the entire

electric circuitry of the unit. A power supply

provides 24 VDC control power. Electric power at

the main disconnect should be shut off before

opening access panels for repair or maintenance.

CAUTION: Wear eye protection when installing,

maintaining, or repairing the equipment to

protect against any sparks, debris, or fluid leaks.

CAUTION: The chiller will exceed 70 dBA sound

pressure at 1 meter distance and 1 meter

elevation when operating. Wear ear protection

as required for personnel comfort when

operating or working in close proximity to the

chiller.

CAUTION: Wear protective gloves when

installing, maintaining, or repairing the

equipment to protect against any sparks, debris,

or fluid leaks.

General Data

Table 1 –Air Cooled Chiller General Data (60 Hz)

Model

NQA04

NQA05

NQA08

NQA10

NQA13

NQA15

NQA20

NQA25

NQA30

Cooling Capacity (tons)1

4.4

5.1

7.8

11.0

12.5

14.9

20.9

25.6

30.6

Set Point Range (°F)

20 to 80

Refrigerant

R410A

Condenser Air Flow (cfm)

4,000

8,000

10,450

18,000

20,000

24,000

Sound Pressure @ 1 meter (dBA)2

73.8

74.0

75.8

76.2

82.2

84.4

85.9

Minimum Unloaded Capacity (tons)

1.0

1.2

1.8

2.7

3.1

3.6

4.8

6.0

7.2

Pump Motor Size (hp)

1.5

Pump Flow (gpm)

Net Available Pump Pressure (psi)3

Unit MCA @ 460/3/60 (amps)4

15.6

18.1

26.1

30.9

36.5

44.3

55.5

70.0

83.1

Length (inches)

105

Width (inches)

Height w/standard fans (inches)

Height w/high pressure fans (inches)

n/a

Reservoir Holding Capacity (gal)

Process Connections (inches)

1.5

Shipping Weight (lbs)

720

1,195

1,215

3,200

3,300

3,800

4,150

1Cooling tons based on 12,000 BTU/Hr/ton with 50°F leaving coolant and 95°F ambient air.

2Sound power shown is for standard high-efficiency constant-speed AC motor fans. A high-pressure variable-speed EC motor

fan option is available for NQA08 and larger units that changes the sound pressure at 1 meter (dBA) to 75 for NQA08-10, 82

for NQA15, 84 for NQA20, 85 for NQA25, and 82 for NQA30.

3Net available pressure at outlet of chiller is pump discharge pressure less the internal coolant-circuit pressure loss.

4MCA is Minimum Circuit Amps (for wire sizing), complies with NEC, Section 430-24.

Table 2 –Water Cooled Chiller General Data (60 Hz)

Model

NQW05

NQW08

NQW10

NQW15

NQW20

NQW25

NQW30

NQW35

NQW40

Cooling Capacity (tons)1

5.5

8.1

12.0

16.5

22.6

28.1

33.3

38.9

43.4

Set Point Range (°F)

20 to 80

Refrigerant

R410A

Condenser Water Flow (gpm)

111

124

Sound Pressure @ 1 meter (dBA)

69.8

70.3

71.3

73.3

73.7

74.7

76.6

78.1

Minimum Unloaded Capacity (tons)

1.3

1.9

2.9

3.9

5.2

6.6

7.8

8.9

9.9

Pump Motor Size (hp)

1.5

Pump Flow (gpm)

102

Net Available Pump Pressure (psi)2

Unit MCA @ 460/3/60 (amps)3

16.4

22.6

27.4

39.7

46.3

60.8

69.3

73.7

77.2

Length (inches)

105

Width (inches)

Height (inches)

Reservoir Holding Capacity (gal)

Process Connections (inches)

1.5

2.5

Condenser Connections (inches)

1.5

2.5

Shipping Weight (lbs)

720

1,195

1,315

1,900

2,100

2,250

3,400

3,900

1Cooling tons based on 12,000 BTU/Hr/ton with 50°F leaving coolant and 85°F condenser water.

2Net available pressure at outlet of chiller is pump discharge pressure less the internal coolant-circuit pressure loss.

3MCA is Minimum Circuit Amps (for wire sizing), complies with NEC, Section 430-24.

Table 3 –Remote Air Cooled Condenser Chiller General Data (60 Hz)

Model

NQR05

NQR08

NQR10

NQR15

NQR20

NQR25

NQR30

NQR35

NQR40

Cooling Capacity (tons)1

5.3

7.6

11.0

15.3

20.8

25.8

30.7

35.5

39.9

Set Point Range (°F)

20 to 80

Refrigerant

R410A

Sound Pressure @ 1 meter (dBA)2

69.8

70.3

71.3

73.3

73.7

74.7

76.6

78.1

Minimum Unloaded Capacity (tons)

1.2

1.8

2.7

3.6

4.8

6.0

7.2

8.4

9.6

Pump Motor Size (hp)

1.5

Pump Flow (gpm)

Net Available Pump Pressure (psi)3

Unit MCA @ 460/3/60 (amps)4

16.4

22.6

27.4

39.7

46.3

60.8

69.3

73.7

77.2

Length (inches)

105

Width (inches)

Height (inches)

Reservoir Holding Capacity (gal)

Process Connections (inches)

1.5

2.5

Refrigerant Liquid Line (inches)

0.625

0.875

1.125

1.375

Refrigerant Suction Line (inches)

0.625

0.875

1.125

1.375

Shipping Weight (lbs)

720

1,195

1,315

1,900

2,100

2,250

3,400

3,900

1Cooling tons based on 12,000 BTU/Hr/ton with 50°F leaving coolant and 95°F ambient air.

2Sound pressure is for chiller unit only; see the Remote Air-Cooled Condenser table for condenser sound pressures.

3Net available pressure at outlet of chiller is pump discharge pressure less the internal coolant-circuit pressure loss.

4MCA is Minimum Circuit Amps (for wire sizing), complies with NEC, Section 430-24.

Table 4 –Remote Air-Cooled Condenser General Data (60 Hz)

Condenser

Model

Chiller

Used

With

Dimensions (in)

Weights (Lbs)

Total Air

Flow

(cfm)

Sound

Pressure

(dBA)1

MCA @

460/3/60

(amps)2

Refrigerant

Connections (in)

Ship

Oper

Inlet

Outlet

KCM009

NQR05

53.625

43.625

48.125

245

Operating

weight

varies

based on

system

charge

and

operating

conditions

6,870

1.4

0.875

1.125

KCM011

NQR08

53.625

43.625

48.125

265

6,620

1.4

0.875

1.125

KCM014

NQR10

93.625

43.625

48.125

415

14,400

2.6

1.375

1.125

KCL023

NQR15

125.750

45.625

54.000

670

24,000

7.0

2.125

1.375

KCL030

NQR20

125.750

45.625

54.000

720

22,600

7.0

2.125

1.625

KCL037

NQR25

125.750

45.625

54.000

800

20,600

7.0

2.125

1.625

KCL045

NQR30

180.750

45.625

54.000

1,075

33,900

10.1

2.625

1.625

KCL054

NQR35

180.750

45.625

54.000

1,175

32,000

10.1

2.625

2.125

KCL056

NQR40

180.750

45.625

54.000

1,200

30,900

10.1

2.625

2.125

1Sound pressure at 3 meters.

2MCA is minimum circuit amps (for wire sizing) as provided by the remote condenser manufacturer.

This manual suits for next models

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