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8/10/2019 Chiller Installation Instructions
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Marrone & Co., Inc.14020 Interdrive West, Houston, Texas 77032 Phone (800) 473-9178, (281) 227-8400
Fax (800) 473-9175, (281) 227-8404 www.waterchillers.com
INSTALLATION ANDOPERATING INSTRUCTIONS
AIR COOLED
WATER/GLYCOL CHILLERSEOR Model
Model#: ACWC-90-EOR
Serial#: _______________
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IMPORTANTThe United States Environmental Protection Agency (EPA) has issuedvarious regulations regarding the introduction and disposal of refrigerants in
this unit. Failure to follow these regulations may harm the environment andcan lead to the imposition of substantial fines. Because these regulationsmay vary due to the passage of new laws we suggest that, any work on thisunit be done by a licensed certified technician. Should you have anyquestions, please contact the local office of the EPA.
- IMPORTANT MESSAGE TO OWNER:These instructions should be carefully read and kept near the product, forfuture reference. While these instructions are addressed primarily to theinstaller, useful maintenance information is included. Have your installer
acquaint you with the operating characteristics of the product and periodicmaintenance requirements.
CODES AND REGULATIONSThis product is designed and manufactured to permit installation inaccordance with National Codes. It is the installers responsibility to install theproduct in accordance with National Codes and/or prevailing local codes andregulations. The manufacturer assumes no responsibility for equipmentinstalled in violation of any codes or regulations.
INSTALLATION/SERVICEContact your service provider, mechanical contractor, or other company forthe installation and/or service. Cold Shot Chillers provides 24/7 technicalsupport. Please provide complete model and serial number as shown on theunit nameplate when calling. All service is the responsibility of the customer.Labor Warranty (if included/purchased) details are on the Labor WarrantyCertificate.
REPLACEMENT PARTSFor information on replacement parts, contact Cold Shot Chillers. Whenordering parts, give complete model and serial number as shown on the unitnameplate. Most parts will be available through local distributors.
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INTRODUCTIONCongratulations on your new purchase. Each frozen yogurt, ice cream, softserve or frozen beverage machine is an individual piece of refrigerationequipment designed to freeze the product to the designed temperature and
consistency. Since a refrigerant is used to accomplish this task theequipment needs a source of cooling to condense the refrigerant so it can bereused over and over. The available cooling can be found either in theambient air surrounding the equipment (similar to a home air conditioner typesystem) or by an outside water source. The specific model or capacity of themachine will determine how much cooling will be required. If the units are aircooled they will absorb the cool air around the unit and blow hot air into theroom to which the machines are installed. If the machine is liquid cooled theheat given off by the unit is absorbed by the water and pumped off to either a
drain or a chiller
The water cooled units can be cooled by piping city water to the machinesand allowing the water to be discharged down the drain or choosing a moreecologically popular solution and installing a chiller to re-circulate the coolingwater keeping waste water to a minimum.
The purpose of this manual is to assist the owner and their chosencontractors in the selection, installation, operation, and maintenance of yourchiller system. Some specifications, design, or instructions may change, so
please contact Cold Shot Chillers if additional assistance is needed.
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REMOTE STATUS ON/OFF CONTROL BOXThis device is designed to allow storeoperations to monitor chiller operation andremotely turn the chiller ON and OFF.
SUPPLY AND RETURN MANIFOLD/HEADER(DISTRIBUTION MANIFOLD/CITY WATER SWITCHOVER)
The soft serve manifold isdesigned to ensure properflow and cooling for both thesoft serve machines and thechiller. On site fabrication ofthis manifold can inhibitequipment performance andreliability.
EQUIPMENT LOCATIONChiller Location:
The chiller should be located away from easyaccess from vandals but should be accessiblefor service. The unit MUST be installed toallow for adequate air circulation that is asdust free as possible. Allow three (3) feet of
clearance around the unit and at least 8unobstructed clearance above the unit toallow for proper air flow.
Most units are installed on a ground level pad outside the store or on the roof.Since glycol flow is critical to dependable operations, it is important to installthe chiller as close to the soft serve manifold as possible.
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Manifold Location:
The Soft Serve Distribution Manifold/City WaterSwitch Over is provided to allow for proper flow to
each machine and provide for sufficient flow back tothe chiller for dependable operation. This device willalso allow the owner to operate the processmachines on city water in the event of a mechanicalor electrical failure of the chiller.
The manifold consists of two sections:- Blue marked SUPPLY/PRESSURE MANIFOLD- Red marked RETURN MANIFOLDThese items should be installed on a flat wall as
close to the back end of the machines as possible.They should be fairly accessible with a foot stool orstep ladder. In the event of an issue with the chiller,they will need to be accessed to allow the timelyswitch over to city water as to not disrupt businessoperation. This will be discussed in greater detaillater in the manual under Start-up and Operation ofEquipment.
It is common protocol to install the Supply manifoldon top of the return header, but proper operationwill not depend on the placement of these itemsrelative to each other. It is important to mount themas close to the machines as possible.
Remote status ON/OFF Control Box Location:
This box is designed to be installed in plain view toapproved operators and employees.
Remote Box Includes:- Chiller ON/OFF switch.- GREEN operating light- RED alarm light
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INSTALLATION
CHILLER:
Please keep in mind that local codes andregulations may require a licensed technician toinstall the chiller to conform to local requirements.Once the proper location for the chiller has beenestablished, using a crane or other suitablematerial handling equipment, place the chiller onthe roof or on a ground level pad. It is importantto note that the chiller tank does come with adrain plug on the bottom of the unit. It may be
beneficial to set the unit to allow access to thedrain if in the event it becomes necessary to drainthe system for maintenance or repair. If this drainplug is covered the system can be drained usingthe chiller pump. If the unit is placed on the roof itshould be set as just above or as close to themanifold assemble as possible. Similarly, if it isset on a ground level pad, is should also beinstalled as close to the manifold as possible.
Connect piping, (insulated copper is most common) tothe unit. It is good protocol to install a pressure gaugeon the discharge side of the chiller and isolation ballvalves on both the inlet and outlet of the unit. Whilethis is a common practice it is not necessary for goodperformance. It is also good to note here that thechiller pipe marked OUT should be piped to theSUPPLY/PRESSURE header which will then berouted to the INLET on the soft serve machines. As
noted previously proper glycol flow is critical to reliableequipment performance. Be sure to use pipe with thesame or greater inside diameter (I.D.) than unitconnections. The total loop length of the system should be no longer than 60feet. If the piping loop required is greater than 60 feet please contact factoryto confirm the pump capacity on your chiller will provide at least 3 gpm/ton ofglycol flow.
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Complete piping to the pressure header from the chiller outlet and from thereturn header to the chiller inlet.
Pipe a full port city water supply line to the city water inlet to the pressureheader and a suitable drain line from the return header drain line to a freedrain. Be sure to comply with local codes and regulations as needed forbackflow prevention. Utility sinks are not recommended as a suitable drainfor the city water switchover.
Both headers of the soft serve manifold are equipped with NPT ballvalves. The quantity of these connections is dependent upon the quantity ofsoft serve machines the facility has decided to utilize.
The system is designed to connect suitablehose from the blue marked SUPPLYHEADER to the Inlet of the processmachines. The Outlet connection of the
soft serve machines are to be connectedby similar hose to the return headerthrough the NPT ball valve connections.It is common protocol to use Blue hosefor the cooling water coming from theSUPPLY HEADER to the soft servemachines and Red hose from the softserve machines to the Return Header.The actual color of the hose has no affecton the performance of the system. It is
important that the hose is at least 1/2 I.D.to allow for proper flow.
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ELECTRICAL: Connect electrical at terminals tagged in
main control box. Usually at L1-L2-L3 onthe compressor contactor.
On 208/230V/3 systems with high orstinger leg, connect this leg to L2 ormiddle terminal. Failure to do so willcause early control componentmalfunction.
If 208V, verify that the control circuit voltage out of the transformer isthe proper voltage (24V or 120V as noted on the electrical print). If not,check the transformer for additional tap wires for changing to 208V.
Verify that the selector switch is in Off position before applying power.
If compressor has crankcase heaters, allow the power to be applied tothe heaters for at least 24 hours before starting the compressor.
REMOTE BOX: As noted your new chiller is equipped with a remote
operating control box. Connect numbered terminals on TB 1 in the chiller to
like numbered terminals on TB 2 in the control box.
On distances up to 50ft from the chiller, 18AWG control wire is appropriate. If greaterthan 50ft, size the control wire forapproximately 2.0 amps at 24VAC. ContactCold Shot Chillers if assistance.
Your Remote Box will allow you to turn thechiller On/Off and monitor operations. TheChiller is operating Normal when theGREEN light is illuminated. In the event thechiller incurs a problem the RED light willilluminate.
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START-UP
Refer to and complete the Start-Up Check List atthe end of the manual.
Once installation is complete, it would be appropriateto check the system for fluid leaks. If ambienttemperatures are not in the freezing temperatures, werecommend filling the system with water to test forleaks, flush and to verify flow through the system. Fillthe tank while observing the sight tube on the tank.Be sure all Soft Serve Manifold valves are open and the machines are allconnected. If the machines are not available, connect a jumper hose of sometype to allow flow from SUPPLY MANIFOLD valves to the RETURN
MANIFOLD valves.DO NOT OPERATE THE CHILLER IN COOLING CYCLE WITH PURE WATER INTANK!!!
All chillers designed for, and are intended for outdoor use. All safeties are set to allow forlow outside ambient conditions. Operating the chiller in cooling cycle with water only, may
freeze the chiller and void all warranties.
DO NOT ATTEMPT TO OPERATE THE PUMP WITHOUT FLUID IN THE TANK!!This will damage the mechanical seal in the pump and void the pump warranty.
Once the tank is full, locate the Power Selector Switch on the chiller. Thisswitch has three positions, Pump Only, OFF, and Cooling Cycle. Turnthis switch to Pump Only, and Off again to check pump rotation.The motor should be turning clockwise from the motor end. All three phasemotors within the chiller are wired in phase at the factory. If the pump isrotating properly all other motors will also be correct. If the pump turnscounterclockwise, turn all power off and rotate any two legs of power, makingsure that on incoming power with a high voltage leg this leg is on the L2 orcenter lug.Once proper rotation is confirmed, begin to circulate fluid
and bleed all entrapped air in the system, and check forleaks. Once all leaks are repaired, operate in Pump Onlyfor at least 15 minutes. Shut unit down and clean strainerto remove any debris that may have been in the system.Depending on the system this step may be conductedseveral times to help ensure all debris is removed from thesystem.
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Loosen the bolts for the compressor feet to allow it tofloat.Compressor rotation can also be confirmed with the useof refrigerant pressure gauges properly installed onservice ports located above the pump.
When the system has been cleaned and flushed, drain the water and refill thesystem with the appropriate concentration ofwater/glycol mix to within 2 of the top of the tank.(A 40% -50% glycol mixture is recommended-seeglycol chart in appendix for the appropriateconcentration for your geographic area if wintertemperatures are expected to be below 0F).
Recirculate the system and check system for leaks and top off chiller tank asrequired. Be sure to maintain proper glycol concentration to preventpremature chiller failure. Once all the air is purged from the circuit, thesystem is free from debris, check fluid level in reservoir and fill as required.
Dependable chiller and process machine operation is heavily dependentupon proper glycol flow. All chiller pumps are sized to provide proper flowwhen loop lengths do not exceed 60. If a pressure gauge was installed atthe chiller discharge, compare the pressure on the gauge with the pumpcurve published for your specific chiller. Be sure that 3 gpm per ton isavailable as described in the chart below. The chiller by-pass may requireadjustment to allow for proper flow.CHILLER MODEL NUMBER REQUIRED FLOW RATE
ACWC-18-EOR 4.5 GPMACWC-24-EOR 6.0 GPM
ACWC-36-EOR 9.0 GPMACWC-60-EOR 15 GPMACWC-90-EOR 23 GPMACWC-120-EOR 30 GPM
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OPERATION
To operate using the remote control box turnselector switch to Cooling Cycle. Leave the
switch in this position on the chiller to utilizethe ON or OFF switch on the remote box.
Proper cooling for most frozen yogurt, soft serve, ice cream, or frozenbeverage machines is 60F.
Do not adjust the set point below the temperature listed on the unitnameplate.
Temperature Controller (Chromalox):a. Set the controller to the desired Set point Value (lowerLED readout): Push and hold the up or down scrollbutton for two seconds until the value starts changing.
Adjust the value to the desired temperature then stoppressing any buttons. After two seconds, the newvalue will become operative. (Do not adjust the set point below thetemperature listed on the unit nameplate).
b. The controller will also display Present Value (upper LED readout)which is an indication of the current temperature of the fluid in thechiller tank, or Leaving Fluid Temperature depending on the specificchiller design.
Unit is now ready to turn on for cooling. Move the selector switch to CoolingCycle setting and the unit will begin cooling.
a. During the cooling cycle, condenser fans may turn on and off, due tochanges in refrigerant pressure. This should be expected duringnormal operation and occurs due to ambient temperature and theamount of heat being returned in the water chiller.
b. All chillers designed for this application come are equipped with a LowAmbient fan speed controller to allow for dependable operation duringthe winter months. This will alter the fan speed at ambienttemperatures below 35.
Monitor the temperature at the process location and adjust the Set Value onthe temperature controller to achieve the desired value.
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VERIFY REFRIGERANT CHARGE:While cooling at low load conditions, bubbles may become visible in therefrigerant sight glass. The charging procedure requires the unit to be underfull load with 75F or above water temperature with clear sight glass for
optimum performance. Returning fluid temperature should not exceed 100Fon standard units or the chiller will cycle off on head pressure switch and notrun. Should this occur, allow water to cool down by running pump only andrestarting chiller once water is 100F or colder.Refrigerant charge may need to be adjusted to achieve the proper operationof the chiller during final installation as described above.
For any other questions regarding chiller installations, startup, or operation,please contact your service company or Cold Shot Chillers.
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System Components: (See your chillers specification for details.)LOW FLOW SAFETY CONTROLS1. FLOW SWITCH SAFETY (FSS):
a. A mechanical flow switch which monitors the fluidentering the evaporator. This switch is
automatically reset when the fluid flow returns to theproper flow rate. Adjustment should not beperformed unless necessary. If adjustments aremade, ensure that the flow entering the evaporatoris greater than 3 gallons per minute per ton ofrefrigeration rating of the chiller. For example, a 2Ton chiller will need a minimum of 6gpm.
2. This condition can occur when the fluid in theevaporator nears freezing.
3. Generally the cause will be low or insufficient water flow caused by a clogged Ystrainer or restricted flow in the process. Resetting any controls and not determining
the cause for tripping can cause the evaporator to freeze and rupture.4. This safety will automatically trip and stop the cooling circuit when no flow is detected.REFRIGERANT PRESSURE SAFETY CONTROLS1. LOW PRESSURE SAFETY (LPS)
a. Monitors the pressure of the refrigerant and will automatically open when thepressure drops below the sensor set point and will automatically reset whenpressure is above the reset setting.
2. HIGH PRESSURE SAFETY (HPS)a. Monitors the pressure of the refrigerant and will automatically open when the
pressure rises above the sensor set point and will automatically reset whenpressure is below the reset setting. Some units may have a manual reset switch.
LOW AMBIENT CONDITION CONTROLS1. NOTE: They are equipped with a pressure controlled fan control system which is
controlled by the Low Ambient Thermostat which is set at approximately 35F.2. Low Ambient Conditions to 0F Kit (0)
a. Temperature of the chillers ambient condition is monitored and will change theoperation of the chiller to reduce the possibility of freezing condenser fan cycling.
3. Low Ambient Conditions to -20F Kit(M20) (Option)a. For potential ambient conditions below 0F but above -20F, the chiller will have a
similar condenser fan operation with additional possible accommodations for higherwind conditions such as internal or external condenser coil baffles. External bafflesnormally must be installed as needed in the field by the customer when
temperatures approach 0F.b. Hot Gas Bypass (HGB)
1) A bypass valve in the refrigerant system that permits that cooling outputcapacity of the chiller to vary based on the load of the system or for low ambientconditions on startup.
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REMOTE STATUS ON/OFF CONTROL BOXOnce the chiller is operational and with all process machines are running andmaking product, the chiller operation can be monitored using the indoorRemote Status ON/OFF Control Box.
**In the event that the RED light becomes illuminated:To convert f rom CHILL Water to CITY Water Operation:
1. Turn Chiller switch to the OFF position.2. CLOSE both CHILL WATER VALVES (Supply and Return)3. OPEN both CITY WATER VALVES (Supply and Drain)
4. Call a licensed A/C Repair Company, as needed, to evaluatethe condition of the chiller.
To convert f rom CITY Water to CHILL Water Operation: 1. Turn Chiller switch to the ON position.2. Verify Chiller is operational.
a. The RED Safety light should be out.b. The GREEN Operating light should be lit.
3. CLOSE both CITY WATER VALVES (Drain and Supply).4. OPEN both CHILL WATER VALVES (Return and Supply).
**Failure to follow the sequence of operations above will dilute the glycol levelto below the required mixture and void factory warranty.
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MAINTENANCE
1. Periodically check condenser coils for dirt or airborne particle build-up. Check deepinto the coils with a flashlight and, if dirty, flush coils with a water hose- being careful todisconnect the power first and cover pump to prevent water from entering the ventports.
2. If EZ Clean filters are included on the condenser housing, then remove the filters byunsnapping from the unit and rinsing with water on a regular basis. Reattach whencompletely clean.
3. Set up a schedule to remove the screen from the return water line strainer and cleanout. Some particles may pass through the screen and collect as sediment in bottom ofthe tank. Again, disconnect the power then remove the tank drain plug and flush outbottom with water hose.
4. Check the pumps for leakage. Visual indication of leakage from the pump end at thepump connection to the motor is usually an indication of a seal failure. Only action is toreplace the seal with a new seal. Seals are a consumable item.
5. Remove all service valve service port caps to be sure Schrader valves aretight. Vibration from standard operation can over time loosen fittings andconnections. System should be periodically checked to be sure no minorrefrigerant leaks have caused low refrigerant charge.
6. Turn off power to the unit and check the condition of the contactor points for thecompressor and pump. Replace them if the edges become jagged or splattered toavoid premature compressor and/or pump failure. Contactor points are consumableand their life is dependent on the amount of use and power characteristics at the unit.
*NOTE: Not performing the above will cause early uni t failure and
considered abuse which is not covered by warranty.
WARRANTYAll new chillers purchased from Cold Shot Chillers include a one year partsanda five year compressor warranty. If a labor warranty was purchased, seethe labor warranty repair allowances in the for reimbursement conditions.
See the appropriate Warranty Certificates for details.
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Chromalox 1603E Temperature ControllerCold Shot Chillers Part# TCCH-000-160-3-0 (1603E-11150)
Cold Shot Chillers Part# TCCH-000-160-3-0
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1. OPERATOR MODE
The display and modification of the operatorparameters can be protected by a secret code.
1.1 PRELIMINARY COMMENTS
It is assumed, at this point, that the instrument hasbeen correctly configured by thesupplier/manufacturer.The upper display indicates the value measured.The lower display indicates the operating set point(below this condition is defined as Normal display).
DO NOT MODIFY ANY PARAMETERSETTINGS WITHOUT FIRST CONTACTING COLDSHOT CHILLERS. Changes to the settings withoutfirst contacting Cold Shot Chillers will void allwarranties.
1.2 INDICATORS
OUT1 Lit up when output 1 is ON. (Call for cooling)OUT2 Serves two functions, when used as alarmindication: (see electrical diagram for details)1) Lit if only Alarm1 is in alarm condition.
2) Flashing at slow rate of about one blink every 2seconds (0.5 Hz ) if only Alarm 2 is in alarmcondition. (Typically for second stage purposesor when used for Hot Gas Bypass)
3) Flashing at fast rate of about two blinks everysecond (2 Hz) if both alarms are in alarmcondition.
C Lit up if the temperature is displayed in C.F Lit up if the temperature is displayed in F.SMT Flashes when the first part of the SMARTalgorithm is active. Lit when the second part of theSMART algorithm is active.
In addition:a) The decimal point on the right hand of the
LSD of the upper display, flashes when theinstrument is working with SP2.
b) The decimal point on the left hand of theLSD of the lower display, flashes when the displayshows the time count down.
1.3 FUNCTION OF THE PUSHBUTTONS
FUNC Saves the new value of the selectedparameter and goes to the next parameter(increasing order).
SMT Enables or disables the SMART functionand scrolls back all the parameters without savingthem. Increases the value of the selectedparameter. Decreases the value of the selectedparameter.+ FUNC Enables/disables the "LAMP TEST".NOTE: The operator parameters must be modifiedwithin 10 seconds. If, during operator parametermodification, no pushbutton is pressed during thistime, the instrument automatically reverts to thenormal display mode. Saving only the parametermodifications which were followed by pressing theFUNC pushbutton.
1.4 DIRECT MODIFICATION OF THE SET POINT
The set point value can be modified without usingthe FUNCpushbutton. When direct access to setpoint modification is required, proceed as follows:1) Press pushbutton or for more than 2
seconds; the set point value will be displayedand it will start to change.
2) Using the and pushbuttons, set thedesired value.
3) When the desired value is reached, DO NOTpress any pushbutton, the new set point willbecome operative 2 seconds after thepushbuttons were last pressed and theinstrument will return to the normal display. Ifduring this procedure the modification is not tobe saved, press the FUNCpushbuttonimmediately (within 2 seconds); the instrumentautomatically returns to the normal displaywithout saving the new set point.
1.5 LAMP TEST
To check the display efficiency,Press pushbuttons + FUNC. The instrument willturn ON, with a 50% duty cycle, all the LEDs of thedisplay (this state is called LAMP TEST). No timeout is applied to the LAMP TEST.To return to the normal display mode, presspushbuttons + FUNC again. No other keyboardfunctions are available during the LAMP TEST.
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Chromalox 1603E Temperature ControllerCold Shot Chillers Part# TCCH-000-160-3-0 (1603E-11150)
Cold Shot Chillers Part# TCCH-000-160-3-0
MNL-Chromalox1603E-ManualInsert_0312.docx Pg2
2. ERROR MESSAGES
2.1 MEASUREMENT ANOMALY SIGNAL
The instrument display shows the OVERRANGEand UNDERRANGE conditions with the following
indications:
The sensor break can be signaled as:- for TC/mV input: OVERRANGE or
UNDERRANGE selected by a solder jumperN O T E : When:- The instrument is set for one control out only andan OVERRANGE is detected, the OUT 1 turns OFF(if reverse action) or ON (if direct action).- The instrument is set to use two control outs and
an OVERRANGE is detected, OUT 1 turns OFF andOUT 2 turns ON.- The instrument is set for one control out only andan UNDERRANGE is detected, the OUT 1 turns ON(if reverse action) or OFF (if direct action).- The instrument is set to use two control outs andan UNDERRANGE is detected, OUT 1 turns ON andOUT 2 turns OFF.
NOTE: When an overrange or an underrange isdetected, the alarms operate as if the instrumenthad detected the maximum or the minimummeasurable value respectively.
To eliminate the out of span condition, proceed asfollows:1) Check the input signal source and the
connecting line.2) Make sure that the input signal is in
accordance with the instrument configuration.Otherwise, modify the input configuration (seesection 4).
3) If no error is detected, send the instrument toyour supplier to be checked.
2.2 ERROR MESSAGES
Diagnostics are made on switching on and during
normal operation.If the instrument detects an error condition thedisplay will show:
ERR in the lower display and the code whichidentifies the type of error in the upper display.The complete list of all the possible errors follows innumerical order.Some errors automatically reset the instrument: ifthe error persists, contact the supplier and providecode.
2.3 LIST OF POSSIBLE ERRORS
100 EEPROM writing error. Consult yoursupplier.150 Generic CPU error. Consult your supplier.2xx Error in the configuration parameters. Thetwo less significant figures indicate the number ofthe incorrect parameter (e.g. 209 ERR indicateserror of parameter P9). Press SMT and FUNC, thenset the parameter correctly. See section 4.301 RTD input calibration error. Contact yoursupplier.305 TC input calibration error. Contact yoursupplier.307 RJ input calibration error. Contact yoursupplier.400 Error in the operator parameters. To dealwith the problem, enter the predefined parameters(Default Parameters, see section B), pressingpushbuttons and at the same time. Then set
the operator parameters. This will not reset theconfiguration parameters.500 Auto-zero error. Contact your supplier.502 RJ error. Contact your supplier.510 Error during calibration. Contact your supplier.
3. MAINTENANCE
WARNING - Electric shock Hazard
Disconnect all power before servicing controller.Failure to do so could result in personal injury orproperty damage.1) SWITCH THE EQUIPMENT OFF (power supply,relay out, etc.).
2) Take the instrument out of it case.3) Using a vacuum cleaner or a compressed air jet(max. 3 kg/cm2) remove all deposits of dust and dirtwhich may be present on the louvers and on theinternal circuits being careful not to damage theelectronic components.4) To clean external plastic or rubber parts use onlya cloth moistened with:- Ethyl Alcohol (pure or denatured) [C2H5OH] or- Isopropyl Alcohol (pure or denatured)[(CH3)2CHOH] or - Water (H2O).5) Make sure that there are no loose terminals.6) Before putting the instrument back in its case,
make sure that it is perfectly dry.7) Put the instrument back and turn it ON.
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TECHNICAL SPECIFICATION
Marrone & Co., Inc.14020 Interdrive West, Houston, Texas 77032 Phone (800) 473-9178, (281) 227-8400
Fax (800) 473-9175, (281) 227-8404 www.waterchillers.com
TechSpec_ACWC-90-EOR-_-_-0-_(0313).doc
Model: ACWC-90-EOR-_-_-0-_
Description:7 -Ton, air-cooled portable water chiller system. System will provide approximately 90,000 Btu/hr of cooling capacity
with a leaving fluid temperature of 50F with an ambient air temperature of 95F. The chill water system typically
includes a valve manifold for up to 8 soft serve machines. Manifold also includes city water switchover valves. Full
powder coated steel cabinet. Outdoor service with a low ambient kit good to 0F. Remote On/Off and status panel for
indoor monitoring.
CAPACITY
5% AT 50LCWT WITH 95F AMBIENT
7 TON
90,000 BTU /HR
COMPRESSOR COPELAND HERMETIC SCROLL
REFRIGERANT R410A
CONDENSER FANS / CFM 1 / 4,700
CONDENSER COILS COPPER TUBE / ALUMINUM FIN
EVAPORATOR STAINLESS STEEL / COPPER BRAZED
FLUID CONNECTION (IN/OUT) 1-1/4 NPT MALE 1-1/4 NPT MALE
VOLTAGE / PHASE / FREQUENCY 208/230V / 3 / 60HZ 460V / 3 / 60HZ
MINIMUM CIRCUIT AMPS 38A 19A
DIMENSIONS 44L X 32W X 61H
WEIGHT (APPROX.) 650 LBS
PUMP HP 1-1/2 HP
PUMP OUTPUT 55 GPM @ 30 PSI
TANK SIZE 41 GALLON
TANK CONSTRUCTION INSULATED 304 STAINLESS STEEL
Note: All specifications subject to change without notice.
Controls:Electronic temperature controller with constant (set point & process) temperature LED readout.
Refrigeration Components:Efficient scroll compressor, sight glass, moisture indicators, balance port expansion valves, filter drier, service
valves, stainless steel brazed plate evaporator, head pressure control. System includes fan controller for low
ambient conditions down to 0F.
Process Fluid Components:Stainless steel centrifugal pump, bronze Y strainer with 20 mesh 304 stainless steel screen, and insulated
stainless steel reservoir with tank level sight glass and fill port.
Safety Controls:High/low pressure safeties, internal overloads for compressor and fan motors, safety fuses for pump, low water
safety switch safety.
Construction:
Welded steel powder coated frame and cabinet.Warranty:
One year parts / five year compressor.
8/10/2019 Chiller Installation Instructions
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TECHNICAL SPECIFICATION
Marrone & Co., Inc.14020 Interdrive West, Houston, Texas 77032 Phone (800) 473-9178, (281) 227-8400
Fax (800) 473-9175, (281) 227-8404 www.waterchillers.com
TechSpec_ACWC-90-EOR-_-_-M20-_(0612).doc
Model: ACWC-90-EOR-_-_-M20-_
Description:7 -Ton, air-cooled portable water chiller system. System will provide approximately 90,000 Btu/hr of cooling capacity
with a leaving fluid temperature of 50F with an ambient air temperature of 95F. The chill water system typicallyincludes a valve manifold for up to 8 soft serve machines. Manifold also includes city water switchover valves. Full
powder coated steel cabinet. Outdoor service with a low ambient kit good to -20F. Remote On/Off and status panel for
indoor monitoring.
CAPACITY
5% AT 50LCWT WITH 95F AMBIENT
7 TON90,000 BTU /HR
COMPRESSOR COPELAND HERMETIC SCROLL
EVAPORATOR STAINLESS STEEL / COPPER BRAZED
FLUID CONNECTION (IN/OUT) 1-1/4 NPT MALE 1-1/4 NPT MALE
CONDENSER FANS / CFM 1 / 4,700
CONDENSER COILS COPPER TUBE / ALUMINUM FIN
VOLTAGE / PHASE / FREQUENCY 208/230V / 3 / 60HZ 460V / 3 / 60HZ
MINIMUM CIRCUIT 38 19
DIMENSIONS 44L X 32W X 61H
WEIGHT (APPROX.) 650 LBS
PUMP HP 1-1/2
PUMP OUTPUT 55 GPM @ 30 PSI
TANK SIZE 41 GALLON
TANK CONSTRUCTION 304 SS
REFRIGERANT R410A
Note: All specifications subject to change without notice.
Controls:Electronic temperature controller with constant (set point & process) temperature LED readout.
Refrigeration Components:Efficient scroll compressor, sight glass, moisture indicators, balance port expansion valves, filter drier, service
valves, stainless steel brazed plate evaporator, head pressure control. System includes fan speed controller and
hot gas bypass for low ambient conditions down to -20F.
Process Fluid Components:
Stainless steel centrifugal pump with open drip-proof motor, bronze Y strainer with 20 mesh 304 stainless steelscreen, and insulated stainless steel reservoir with level sight glass and fill port.
Safety Controls:High/low pressure safeties, internal overloads for compressor and fan motors, safety fuses for pump, low watersafety switch safety.
Construction:
Welded steel powder coated frame and cabinet. Internal wind baffle.Warranty:
One year parts / five year compressor.
8/10/2019 Chiller Installation Instructions
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DRAWN ENGINEERING
SSUED
SIZE DIMENSION NOTES DW
AUnits are in inches.
+/-
Front-Rig
ACWC-90-E
3 April 2012 SCALE 1 : 16 DWG-INST_ACWC-90-EOR_(0412).vsd
GENERAL NOTES
Specifications subject to change without notice.
Shown with Full Metal Cabinet included.
RIGHT
VIEW
FRONT
VIEW
32.0in. 44.0in.
60.0in.
"Y" Strainer
(inside)
Chiller Pump
(inside)
Insulated Tank with Lid
(inside)
Access Panel
Temperature Controller
Control Switch
(PumpOnly/Off/Cooling)
Outlet (NPT-Male)
Inlet (NPT-Male)
8/10/2019 Chiller Installation Instructions
22/36
DRAWN ENGINEERING
SSUED
SIZE DIMENSION NOTES DW
AUnits are in inches.
+/-
Top-Botto
ACWC-90-E
3 April 2012 SCALE 1 : 16 DWG-INST_ACWC-90-EOR_(0412).vsd
GENERAL NOTES
Specifications subject to change without notice.
Shown with Full Metal Cabinet included.
BOTTOTOP VIEW
Control Switch &
Temperature Controller
Front
2.8in.
Electrical Panel
8/10/2019 Chiller Installation Instructions
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FUSES 8 AMP
WIRING SCHEMATIC
ACWC-090-EOR-_-_
FILE: ACWC-090-EOR_-_-0-5 (02
DESCRIPTION
1. REPLACEMENT WIRE AND FUSES MUST BE THE SAME
SIZE AS ORIGINAL.
2. UNIT MUST BE PERMANENTLY GROUNDED AND
CONFORM TO N.E.C. & LOCAL CODES.
3. MINIMUM WIRE SIZE BASED ON 75 DEGREES C
INSULATION COPPER WIRE.
4. OPTIONAL HOT GAS BYPASS FOR CAPACITY CONTROL.5. SEE MANUAL IF ADJUSTMENT IS NECESSARY ABOVE
FACTORY SET MINIMUM.
NOTES:
COMPONENT CODE
CC
M
COMPRESSOR
BLK
BLK
BLK
T1
T2
T3
CCH
(opt)
C
S
R
GND
BLK
BLK
BLK
L1
L2
L3
TO
POWER
SUPPLY
GROUNDING LUG
TC
TEMPERATURE CONTROLLER
1603 E
RED
WHITE
2
3
4
5
7
8
9
16
10
12
13
14
11
15
RED/WHT
BRN
HPS LPS
OPEN 10
CLOSE 25 PSI
OPEN 630
CLOSE 480 PSI
BLUBLUYELYEL
BRN
(see note #4)
WHT
2TB1
3
RED
BLU
GRN
GRN
Pump Only
Cooling Cycle
GRN
FS
YEL YEL
(see note #5)
BLKTB1
HGB
FB-2 PC
M
CHILLER PUMP
BLK
BLK
BLK
BLK
BLK
BLK
FU2
FU1
FU3
1
208/230V460V
CT
CONNECT FOR
APPROPRIATE
VOLTAGE
NOTE
24V
secondaryYEL
(COM)
CB
LAT
SET 0 DEG.
GRA
FCC
OPEN 260 PSI
CLOSE 450BLKBLK
Connect TB1 1,2,3,4,5, to TB2 in
remote box 1,2,3,4,5,respectively.
NOTE Field Installed Wiring
GRN/YELGND
BLKBLK
SW
DISCONNECT
FIELD
SUPPLIED
RC
M1 P
L2/NBLK
BLK/WHT
ORN
ORN
L1
WHT
BLK
BRN M
FMUsed with low ambient
Used withlow ambient
kit only
BRN
GRA BRN
P266 CA
BRNGRA
Used with low ambient kit only
24V Control
VIO
BRN
4
TB1
YEL BRN
5
TB1
VIO
CIRCUIT BREAKER
COMPRESSOR CONTACTOR
H CRANKCASE HEATER
M COMMONCONTROL TRANSFORMER
FUSE BLOCK
C FAN CYCLE CONTROL
FAN MOTOR
FLOW SWITCH
FUSE
D GROUND
B HOT GAS BYPASS
S HIGH PRESSURE SAFETY
LINE
R LOW AMBIENT RELAY
T LOW AMBIENT T-STATS LOW PRESSURE SAFETY
MOTOR
T OPTIONAL
PUMP CONTACTOR
6 FAN SPEED CONTROL
PUMP RELAYRUN CAPACITOR
SAFETY RELAY
CHILLER ON/OFF SWITCHTERMINAL BLOCK
THERMOCOUPLE-TYPE J
BLU
BRN
GRN/YEL
GND
L2
L3
L1
T2
T3
T1
BLURED/WHT FU3
5 AMP
SR
BLK
BLK
FU1
FU2
FB-1
(2)-1 AMPFuse may be used in
place of circuit breaker
BRN
BLU
GRN
BRN
SRC1 C2
PCC1 C2
LARC1 C2
CCC1 C2
REDWHT
BLK
VPC
P1
P266 Electronic
Pressure Transducer
If a second P266 transducer is
used, wire the P2 terminal the
same as P1 terminal
Pressure Transducer Class 2
Wiring forALL P266 Models
Used with low ambient kit only
LAR
2
3
1
LAR
12
1TB1
RED
CM450
4
6
COM
RUN
8/10/2019 Chiller Installation Instructions
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PUMP MOTOR FUSE SIZES
HP
2 9 AMP 4.5-6.5 AMP
15 AMP 7.5-11 AMP
30 AMP 13-19 AMP
3
5
30 AMP 18-25 AMP7.5
FUSE OVERLOAD
UNIT VOLTAGE
208/230-3-60, 197/220-3-50
WIRING SCHEMAT
ACWC-090-EORM-_-_
FILE: ACWC-090-EOR_-_-0-5 (021
DESCRIPTION
1. REPLACEMENT WIRE AND FUSES MUST BE THE SAME
SIZE AS ORIGINAL.
2. UNIT MUST BE PERMANENTLY GROUNDED AND
CONFORM TO N.E.C. & LOCAL CODES.
3. MINIMUM WIRE SIZE BASED ON 75 DEGREES C
INSULATION COPPER WIRE.
4. HOT GAS BYPASS FOR TEMPERATURE CONTROL.5. SEE MANUAL IF ADJUSTMENT IS NECESSARY ABOVE
FACTORY SET MINIMUM.
NOTES:
COMPONENT CODE
CC
M
COMPRESSOR
BLK
BLK
BLK
T1
T2
T3
BLKBLK
CCH
(opt)
C
S
R
GND
BLK
BLK
BLK
L1
L2
L3
TO
POWER
SUPPLY
GROUNDING LUG
TC
TEMPERATURE CONTROLLER
1603 E
RED
WHITE
2
3
4
5
7
8
9
16
10
12
13
14
11
15
RED/WHT
BRN
HPS LPS
OPEN 10
CLOSE 25 PSIOPEN 630
CLOSE 480 PSI
BLUBLUYEL
YEL
2TB1
3
RED
BLU
GRN
GRN
Pump Only
Cooling Cycle
GRN
FS
YEL YEL
(see note #5)
BLKTB1
208/230V460V
CT
CONNECT FOR
APPROPRIATE
VOLTAGE
NOTE
24VYEL
(COM)CB
BLU
LAT
SET 0 DEG.
GRA
RC
FCC
OPEN 260 PSI
CLOSE 450
M1 P
L2/NBLK
BLK/WHT
ORN
BLKBLK
L1
WHT
BLK
BRN M
FM
Connect TB1 1,2,3,4,5, to TB2 in
remote box 1,2,3,4,5,respectively.
GRA
GRN/YELGND
SW
DISCONNECT
FIELD
SUPPLIED
secondary
M
CHILLER PUM
FU2
FU1
FU3
FB-2
SEE CHART
BLK
BLK
BLK
BLK
BLK
BLKPC OL
L2
L3
L1
T2
T3
T1
95 96
OL
VIO
X AUXILIARY CONTACTSCIRCUIT BREAKER
COMPRESSOR CONTACTOR
H CRANKCASE HEATER
M COMMON
CONTROL TRANSFORMER
FUSE BLOCKC FAN CYCLE CONTROL
FAN MOTOR
FLOW SWITCH
FUSE
D GROUND
B HOT GAS BYPASS
R HOT GAS RELAY
HIGH PRESSURE SAFETY
LINE
R LOW AMBIENT RELAY
LOW AMBIENT T-STAT
LOW PRESSURE SAFETY
MOTOR
OVERLOAD
T OPTIONAL
PUMP CONTACTOR
6 FAN SPEED CONTROL
RUN CAPACITOR
SAFETY RELAY
CHILLER ON/OFF SWITCH
TERMINAL BLOCKTHERMOCOUPLE-TYPE J
TIME DELAY ON MAKE
BLU
AUX
13 14
PC
YEL
NOTE Field Installed Wiring
FB-1
GRNGRN BRN
VIO
BRN
4
TB1
YEL BRN
5
TB1
BRN
P266A
BRNGRA
C
BRN
GRN/YEL
GND
24V Control
BRN
BRN
SRC1 C2
PCC1 C2
CCC1 C2
LARC1 C2RED
WHTBLK
VPC
P1
P266 Electronic
Pressure Transducer
If a second P266 transducer isused, wire the P2 terminal the
same as P1 terminal
Pressure Transducer Class 2
Wiring forALL P266 Models
Used with low ambient kit onlyUsed with low ambient kit only
BLURED/WHT FU3
5 AMP
SR
BLK
BLK
FU1
FU2
(2)-1 AMPFuse may be used in
place of circuit breaker
Used with low ambient
LAR
2
3
1
LAR
12
ORN
Used withlow ambient
kit only
1TB1
RED
CM450
4
6
COM
RUN
8/10/2019 Chiller Installation Instructions
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DRAWN ENGINEERING
ISSUED
SIZE FSCM NO DWG NO
TONCOLD SHOT CHILL
Model: REMOTE STATU
12/10 SCALE 1 : 8 SHE
6.504.25
6.50
7/8" Low Voltage
SW
SAFETY
LIGHT
OPERATING
LIGHT
OFF/ON
COLD SHOT CHILLERS
8/10/2019 Chiller Installation Instructions
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CIRCUIT BREAKERCOMPRESSOR CONTACTOR
H CRANKCASE HEATERCONTROL TRANSFORMERFUSE BLOCK
C FAN CYCLE CONTROLD GROUNDB HOT GAS BYPASS
FAN MOTORFLOW SWITCHFUSE
S HIGH PRESSURE SAFETYR LOW AMBIENT RELAYT LOW AMBIENT THERMOSTATS LOW PRESSURE SAFETYT OPTIONAL66 FAN SPEED CONTROL
PUMP CONTACTORRUN CAPACITORSWITCH 2 POSITION SELECTORTERMINAL BLOCKTHERMOCOUPLE-TYPE J
COMPONENT CODE
NOTES:
COLD SHOT
CHILLERS
DESCRIPTION
FILE: ACWC-090-EOR_-_-0-5 (0213).vsd
1. REPLACEMENT WIRE AND FUSES MUST BE THE SAME SIZE AS ORIGINAL2. UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N.E.C. & LOCAL CODES3. MINIMUM WIRE SIZE BASED ON 75 DEGREES C INSULATION
COPPER WIRE
Connect TB2 1,2,3,4,5, to TB1 in chiller 1,2,3,4,5,respectively.
NOTE FIELD INSTALLED WIRING
#6 Not used
REMOTE BOX
ACWC-036-EOR-_-_-
ACWC-060-EOR-_-_-
ACWC-090-EOR-_-_-
1TB-2 2 3 4 5 6
REMOTE BOX FIELD INSTALLED
RED
RED/WHT
BRN
YEL
BLK
BRN
OFF/ONSWITCH
OPERATING
X1 X2
SAFETY
X1 X2BRN
8/10/2019 Chiller Installation Instructions
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Delay On Break
% Phase Unbalance
Reset Mode
Control Mode
Average phase to phase line voltage 190-630
3 minutes**
Amount of time before the load de-energizes due to a non-critical fault*
Amount of time between the load de-energizing and re- energizing
Maximum phase to phase average voltage
Amount of allowable voltage unbalance
460V
8 seconds**
2%
OFF
Based
on wiring
0-10 minutes
0-15 secondsDelay on Fault
% Over Voltage 2-25%
2-20%
AUTO,
0-10
ON or OFF
3
Parameter Description Range Factory Setting
Line Voltage 230V
3 minutes**
8 seconds**
13%
2%
3
OFF
Based
on wiring
10%
Incoming 3-phase
voltage from line side of
compressor contactor
The incoming 3-phase
voltage is used to
power up the ICM450
as well (190-600)
Incoming 3-phase voltage
from load side of
compressor contactor
THREE PHASE VOLTAGE MONITOR
190-630 VAC 50-60 Hz
6 5 4 3 1
CONTROL
VOLTAGE
19-240-
VAC
RED
COMALARMRUN
LOAD
ENERGIZED
RED
CONNECT FOR
OPTIONAL ALARM
FUSE BLOCK
FU1
FUSES 1 AMP
FU3
FU2
SETUP FAULTREAD
SHORT PINS WHEN USING 24
VAC CONTROL VOLTAGE
LOAD1A
LOAD2B
CLOAD3
LINE1
A
LINE2
LINE3
B
C
CONTROLS
P/N ICM450
ICM
TO CHILLER
OFF/ON SWITCH
24V FROM
TRANSFORMER
AUTO or number of times the load can be re-engerized after a load side
fault before a manual reset is necessary. Note: when monitoring line side
only, the reset mode will always be AUTO
With control mode set to OFF, the load will energize if no 3- phase fault
conditions exist; with control mode ON, the load will energize if no fault
conditions exist and control voltage is present at 1 and 3 of the ICM450
*Non-critical fault are faults such as High/Low Voltage and Phase Unbalance. Critical faults, such as Phase Loss and Phase Reversal have a fault
interrogation of under 2 seconds and it is not user adjustable.
ICM 450C; Parameter Settings and Wiring Diagram For 230-460 Volt Units, 24Volt Control
Parameters
Minimum phase to phase average voltage% Under Voltage 2-25% 13% 10%
NOTES:
FAULT- PRESS TO READ FAULTS.HOLD FOR 5 SECONDS TO
CLEAR AND RESET MEMORY.
READ- HOLD FOR VOLTAGE DISPLAY
SETUP-PRESS TO ENTER SETUP MODE AND SELECT USER
PARAMETERS.
PRESS ARROWS TO SCROLL THROUGH AND SELECT USERPARAMETER SETTINGS IN SET UP MODE. HOLD DOWN FOR
FAST EDIT.FILE:
ICM450C 3ph voltage monitor0413.vsd
8/10/2019 Chiller Installation Instructions
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Marrone & Co., Inc.14020 Interdrive West, Houston, Texas 77032 Phone (800) 473-9178, (281) 227-8400
Fax (800) 473-9175, (281) 227-8404 www.waterchillers.com
MNL_ICM450-Insert_(0313).docx - 1 -
ICM450Three Phase Voltage MonitorsProgrammable, 25-Fault Memory, Protects motors from premature failure and burnouts
MODE OF OPERATIONAt power up, the ICM450 evaluates the incoming power for proper phase sequence, amplitude, and symmetry (voltage
unbalance). If the three phase input at the line side connections is within user-set parameters, the load energize LED is turned on
and the internal relay is energized. Continuity will be across terminals 4 and 6. If connections are made to the load side terminals,
the ICM450 will transfer monitoring over to the load side only.
When a critical fault condition (phase loss or phase reversal) is present, the relay will immediately de-energize, the load
energized LED will turn off, the fault LED will flash, and the fault is written to memory. Continuity will be across terminals 4 and 5.
If a non-critical fault condition (unbalance, high or low voltage) is present, the ICM450 will ignore it during the interrogation
delay time. If it is still present following the interrogation delay time, the relay will de-energize, the load-energized LED will turn off,
the fault LED will flash, and the fault is written to memory. Continuity will be across terminals 4 and 5.
The ICM450 will store the last 25 faults in memory. The relay will not energize if any fault conditions exist. The integral
adjustable delay on break timer will prevent short cycling.
SETTING THE PARAMETERS
1.Press the green SETUP button to enter Setup mode. Setup LED will light.
2.Use the and arrows to change user parameters.
3.
Scroll through setup by pressing and releasing the SETUP button.
4.When the last parameter has been set, the phase average will be displayed and the Setup LED will automatically turn OFF.
BUTTON FUNCTIONS
Press arrows to scroll through and select user
parameter settings in Setup mode.
HOLD down for fast edit.
Press to enter Setup mode
and select user parameters.
Hold for voltage display
a->b, b->c, a->c
(simultaneously).
Press to read faults.
Hold for 5 seconds to clear
faults and reset memory.
Parameters (See Wiring Diagram for Factory Settings)
Parameter Description Range
Line Voltage Average phase to phase line voltage 190-630
Delay On Break Amount of time between the load de-energizing and re-energizing 0-10 mins
Fault Interrogation Amount of time before the load de-energizes due to a non-critical fault* 0-15 secs
% Over/Under Voltage Maximum/minimum phase to phase average voltage, respectively 2-25%
% Phase Unbalance Amount of allowable voltage unbalance 2-20%
Reset Mode AUTO or number of times the load can be re-energized after a load side fault before a
manual reset is necessary. Note: When monitoring line side only, the reset mode will
always be AUTO
AUTO,
0-10
Control Mode With control mode set to OFF, the load will energize if no 3- phase fault conditions
exist; with control mode ON, the load will energize if no fault conditions exist and
control voltage is present at terminals 1 and 3 of the ICM450
ON or OFF
*Non-critical faults are faults such as High/Low Voltage and Phase Unbalance. Critical faults, such as Phase Loss and Phase Reversal,
have a fault interrogation of under 2 seconds and it is not user adjustable.
** For best recommendations, consult manufacturer of equipment.
FAULTREAD
SETUP
8/10/2019 Chiller Installation Instructions
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MNL_ICM450-Insert_(0313).docx
- 2 -
Fault Conditions
Press and release fault button to scroll through all saved faults.
Note: For initial setup, press and hold FAULTfor 5 seconds to remove any previously stored faults.
Fault Problem Corrective Action
Back Phase
Loss
Not all three of the phases
on the load side are
present
1. Re-energize the contactor.
2. If the fault reappears after the load energizes:
a. Turn all power OFF
b. Check all load side connections
c. Check the contacts of the contactor for debris or excess carbon.Back Phase
Rev
Loads 1, 2, or 3 are not in
sequence
(not 120 phase shifted)
1. Turn OFF all power.
2. Swap any 2 phases on the load side of the unit only (example: swap load 1 and load 2) *
3. Re-apply power.
Back Phase
Unbal
A voltage unbalance
between the three load
phases exceeds the
unbalance setpoint
1. Press the READ button to observe the present load voltages. Check system for
unbalance cause.
2. Increase the fault interrogation time if necessary.
3. Increase the percent unbalance setting if necessary.
Front Over
Volt
Average phase-phase
voltage exceeds the
maximum percentage
1. Check system for over-voltage cause.
2. Increase the percent over-voltage setting if necessary.
3. Increase the fault interrogation time if necessary.
Front Phase
Loss
Not all three of the phases
on the line side are present
1. Press and hold the READ button on the phase monitor or use an AC voltmeter to
carefully measure all three phase-phase line voltages
(example: Line 1 Line 2, Line 2 Line 3, Line 3 Line 1).2. Repair the missing phase.
Front Phase
Rev
Lines 1, 2, or 3 are not in
sequence (not 120 phase
shifted)
1. Turn OFF all power.
2. Swap any 2 phases on the line side of the unit. For example: swap load 1 and load 2*.
3. Re-apply power.
Front Phase
Unbal
A voltage unbalance
between the three line
phases exceeds the
unbalance setpoint
1. Press the READ button to observe the present load voltages. Check system for
unbalance cause.
2. Increase the fault interrogation time if necessary.
3. Increase the percent unbalance setting if necessary.
Front Under
Volt
Average phase-phase
voltage is below the
minimum percentage
1. Check system for under-voltage cause.
2. Increase the percent under-voltage setting if necessary.
3. Increase the fault interrogation time if necessary.
* Onlyswap phases during initial setup, notafter unit has been in operation without errors.
Troubleshooting
Problem LCD Readout LED Status Corrective Action
Load will not energize Phase
Avg.
All LEDs Off Confirm that the control input is properly connected and
configured
Load will not energize Phase
Avg.
Load LED Off,
Fault LED Blinking
Press FAULT to observe the current fault; correct the
condition of the first fault that appears (see Fault Conditions,
Page 6 for a list of corrective actions)
Fault LED blinks repeatedly
while load is energized
Phase
Avg.
Fault LED Blinking,
Load LED On
Indicates there are faults saved in the memory, press FAULT
rapidly to scroll through saved faults; to clear the faults,
press and hold FAULT for more than 5 seconds
Load will not de-energize
when control voltage is OFF
Phase
Avg.
Load LED On,
Control LED Off
The control mode setting is OFF; press SETUP to get to the
control mode. Press to set the control mode ON
Setup LED is on while load is
being energized
Anything Other
Than PhaseAvg.
Setup LED On,
Load LED On
To exit the setup mode, press either READ or FAULT
Load will not energize Reset Fault LED Blinking Unit in lockout; maximum number of retries in manual reset
mode has been reached; to reset unit, press FAULT and hold
for more than 5 seconds
Load turns ON and OFF
repeatedly
Readout is
Irrelevant
Fault LED Blinking Fix load side fault; press FAULT to observe condition; the
delay on break period may be too short; press SETUP to
enter the delay on break mode; press to lengthen the delay
8/10/2019 Chiller Installation Instructions
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COLD SHOT CHILLERS
DRAWN ENGINEERING
ISSUED
SIZE FSCM NO DWG NO
ACHILL WATER CIRC
E - Portable with
04/2011 SCALE NA DWG-CHW_AllFlowDesigns_0411d.vsd
CHILLER
PUMP
MANUAL
BYPASS
STRAINER
FS
FLOW SWITCH
DRAIN
STAINLESS STEEL/COPPER BRAZED
PLATE EVAPORATOR
STAINLESS STEEL
TANK WITH SHOE BOX
LID
TEMPERATURE
SENSOR
(Temperature
Controller)
8/10/2019 Chiller Installation Instructions
31/36
COLD SHOT CHILLERS
DRAWN ENGINEERING
ISSUED
SIZE FSCM NO CHILL WATER
Chiller M
ACWC-90
(TYPICA
0210 SCALE 8 CONNECTIONS
NOTES
ALL PIPING IS TO BE INSULATED
CHILL
WATER IN
WATER
OUT TO
CHILLER
65.5
CITYWATER IN
TO
DRAIN
TO MACHINES
FROM MACHINES
60.0
1 BALL
VALVE
1 BALL
VALVE
3/4 BALL
VALVE
3/4 CHECK
VALVE
1 CHECK
VALVE
3/4 BALL
VALVE
8/10/2019 Chiller Installation Instructions
32/36
Marrone & Co., Inc.14020 Interdrive West, Houston, Texas 77032 Phone (800) 473-9178, (281) 227-8400
Fax (800) 473- 9175, (281) 227-8404 www.waterchillers.com
Pump/Motor Assembly ASP-SSPC
Exploded View and Cross Section of Pump and Motor Assembly
CSC_ASP-TechnicalInfo_0511.doc
Item
No. Part Description
Standard
Materials
100 Casing 304 SS
200 Impeller (Enclosed) 304 SS
300
Mechanical Seal - Type 6 (std.)
(Other seal types available)
Car/Cer/Buna
N/316 SS
400 Seal Plate 304 SS
500 Casing O-Ring Buna N
510 Impeller O-Ring Buna N
600 Motor Adapter Plate 304 SS
7CS Casing Screw - 1/4-20 (3/16 Allen)
Nickel Plated
Steel
7DP Drain Plug - 1/8" NPT 304 SS
7MB Motor Bolt - 3/8-16 (7/32 Allen) 304 SS
7SC
Impeller Screw - 10-32LH (1/8
Allen) (Standard on 3-Ph motors
1-hp or larger) 304 SS
800
Pump Base (not supplied with
footed motors) 304 SS
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PUOD-000-015-0-0.docx
Performance Curve Data Sheet - PUOD-000-015-0-0
(Pump with Motor, 1-1/2Hp, ODP, 208-230/460V/3ph/60Hz)
Performance Curve Data Sheet
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CKL_StartupChecklist-2-20ton_0312.docx
START-UP CHECK LIST
2 thru 20-TON
EQUIPMENT MODEL#: SERIAL#:
OWNER NAMEADDRESS
CITY STATE ZIP
INSTALLING CONTRACTOR
ADDRESS PHONE#
START-UP PERFORMED BY
1. Manual referred to for details on installation and startup. Yes No
2. Add additional information and notes on back of form. Yes No
3. Is there any physical damage? Yes No
a.
Will this prevent start-up? Yes NoDescription:
4. Unit is installed level as per the installation instructions. Yes No
5. Power supply agrees with the unit nameplate. V Yes No
6. Control voltage is appropriate per electrical drawing. V Yes No
7. Electrical power wiring is installed properly. Yes No
8. Unit is grounded properly. Yes No
9. Electrical circuit protection has been sized & installed properly. Yes No
10.
All terminals are tight. Yes No11.All plug assemblies are tight. Yes No
12.Crankcase heaters energized for 24 hours before start-up. Yes No
13.All chilled water valves are open. Yes No
14.All piping is connected properly. Yes No
15.All air has been purged from the system. Yes No
16.Chilled water pump is operating with the correct rotation. Yes No
17.Water loop volume greater than 6gal/ton. Yes No18.Proper loop freeze protection provided to F
i. Freeze Protection Fluid Type /ii. Concentration / %
19.
Outdoor piping wrapped with electric heater tape. Yes No20.Check the pump seals for any signs of leaking.
Chiller pump(s) free of leaks? Yes No
Process pump(s) free of leaks? Yes No21.Measure the following under full load with clear refrigerant sight glass.
Discharge Pressure: PSI
Suction Pressure: PSI
Suction Line Temp: F
Entering Fluid Temp: F
Leaving Fluid Temp: F
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"ECONOMICALLY
PRICED DEPENDABILITY"
1 YEAR
COMPLETE PARTS
PRODUCT WARRANTY
LIMITED
EFFECTIVE
WITH
PRODUCT MANUFACTURED
BEGINNING
JANUARY
1995
Dear Consumer:
Congratulations on your purchase of this new Water Chiller.
This certificate is our warranty
to
you. Please ensure
that
you
have completed the reverse side of this certificate and mail
a copy back
to
us
.
COMPLETE
UNIT
WARRANTY
THE WATER CHILLER DESCRIBED ON THE
REVERSE
SIDE
OF THIS
CERTIFICATE
IS
WARRANTED
AGAINST
DEFECTS
N MATERIAL OR WORKMANSHIP
UNDER
NORMAL USE AND
MAINTENANCE
FOR
A PERIOD
OF ONE
(1) YEAR FROM THE
PURCHASE DATE
WE
WILL PROVIDE A REPLACEMENT
PART
FOR ANY
PART FOUND
TO
BE
DEFECTIVE.
THIS
WARRANTY
DOES NOT INCLUDE SERVICE OR LABOR CHARGES
CONNECTED
WITH THE DETERMINATION OR REPLACEMENT
OF
DEFECTIVE
PARTS OR
FREIGHT CHARGES
TO SHIP THESE
PARTS.
EXTENDED
PARTS WARRANTY
n
addition
to
the
above Complete Unit Warranty, the
following extended warranties may apply
to
your unit:
FOUR YEAR ADDITIONAL EXTENDED WARRANTY of
compressors. LIFETIME
WARRANTY of
tanks against
leakage, base frames against rust through (20 tons and
under) and casters.
Upon the expiration of the "Complete Unit Warranty", the
above listed components are warranted for an additional
term as listed above against defects in material or
workmanship under normal use and maintenance. We
will provide a replacement part
for
any part found to be
defective. This warranty does not include service or labor
charges connected with the determination or replacement
of defective parts
or freight
charges
to
ship these parts.
EXCLUSIONS
The foregoing provisions state the exclusive remedy for any
breach of warranty
or
any other claim in respect
to
the product
described on the reverse side
of
this certificate. THE
EXPRESS
WARRANTIES CONTAINED HEREIN
ARE
N LIEU OF ALL
OTHER
WARRANTIES. IMPLIED WARRANTIES, INCLUDING
WARRANTIES
OF
MERCHANTABILITY ARE LIMITED TO
THE
DURATION OF
THE
COMPLETE UNIT
WARRANTY DESCRIBED
ABOVE.
CONSEQUENTIAL
OR
INCIDENTAL
DAMAGES
FOR
BREACH OF ANY WARRANTY EXPRESS OR IMPLIED
ARE
EXCLUDED.
Some states do
not
allow limitations on how long an implied
warranty lasts or the exclusions of consequential or incidental
.
damages,
so
the above limitations and exclusions may not
apply
to
you. This warranty gives you speCific legal rights
and you may also have other rights which vary from state
to
state.
. .
This warranty shall be void if:
1. The unit is not installed, operated or serviced in
accordance with the installation and operation
instructions furnished, and with
the
recommendations
of the Air Conditioning Contractors of America (ACCA).
f you do not have a copy of
the
installation and
operation instructions, please write directly to
our
office
to receive one.
2. Components or other accessories not compatible with
the unit have been used with or attached to the unit.
3. The user has otherwise abused or failed to maintain the unit.
4. The unit is installed outside the United States
of
America,
Canada or Mexico.
5.
The defect or damage
is
not caused
by
the manufacturer
(see reverse side).
RETAIN
THIS CERTIFICATE WITH YOUR VALUABLE DOCUMENTS
SHOULD YOU REQUIRE IN-WARRAN1Y PARTS
UNDER
THE
TERMS
STATED
ABOVE,
CONTACT
US FOR
REPLACEMENT PARTS .
Marrone Co.,
Inc.
14020 Interdrive West Houston, TX 77032
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OWNER - PLEASE RETAIN A Opy OF THIS CERTIFICATE
WITH YOUR VALUABLE DOCUMENTS
EQUIPMENT DESCRIPTION & INSTALLATION DATA
MODEL NUMBER
INSTALLED BY (SERVICE AGENCY OR PERSON)
UNIT SERIAL
NO
.
ADDRESS STREET
PURCHASER
CITY STATE
ADDRESS STREET DATE INSTALLED
CITY STATE AIR CONDITIONING REFRIGERATION LICENSE
,
CLASS, STATE
IMPORTANT
The following are the responsibilities of the user. They are examples of defects or
damages that are not manufacturing defects, and are, therefore, not included in this
Limited Warranty.
1.
Damage to unit or unsatisfactory operation due to improper cleaning or use of unit in
corrosive atmosphere.
2.
Damage to unit from unsatisfactory operation due to blown fuses, inadequate or
interrupted electrical protective devices or operations of unit
on
power supply other
than covered by name plate rating of unit.
3. Damage due to transportation or handling prior to and during installation.
4. Damage due to accident or from alteration, improper installation, or tampering.