ASP X Chiller Modules - The Sustainability Initiative
Contents
1. 150 F Change the oil after 500 hours of operation break in then every 6 months or 2500 hours of operation which ever happens first Since this gear box has only a small amount of oil proper oil change frequency is the key to longevity 13 28 0 Troubleshooting Air Cooled Packaged Modules ASPX modules use the Carel PCO3 master control The user manual for the PCO3 controller is located in section 6 of the submittal package The user manual details the different status screens and explanations of system or module faults The following guide is for troubleshooting ASPX modules and the PC03 FAULT No Display on Master Module EX 1 2 Interlock EX 4 Interlock Waiting For Chilled Water Flow Low Chilled Water Temp No Demand 100 Demand all the time 100 Demand won t load Excessive Cycling High Discharge Pressure HP Low Suction Pressure LP Low Suction Temperature Communication Error Circuit Fault P Lan Error SOLUTION Check main disconnect for power Check circuit breakers in module Check transformer in modules Check for 24V at J1 on board Check appropriate interlock component Check jumpers on TS2 in master module Check for proper rotation phasing Check PPM device Check CHW pump Check flow switch operation Check filter strainers Check TS2 inputs 3 5 Check LCHW sensor Check setpoints in system variables Check for flow restriction Check entering ECHW sensor Check setpoints in2. 0 System Water Volume Chilled water systems remove the thermal gain from the process of cooling A properly sized chilled water system will have enough time to properly control respond to changes in load and prevent short cycling of the chiller To ensure the system water volume is adequate a general rule of thumb is 7 10 gallons of water per ton or Acceptable Chilled Water Volume Chilled Water Design GPM X 3 In the event the system components can t hold the necessary chilled water volume a properly sized chilled water storage tank should be added 6 0 Electrical Data Field wiring should be done in accordance with all federal state and local regulations Breakers fuses wire and wire size must be sized and installed per the National Electric Code NEC Applied voltage to all Multistack chillers must be 10 of the unit s nameplate voltage The voltage imbalance between phases must not exceed 2 According to NEMA Standard MG 1 1998 a 2 voltage imbalance will cause a current imbalance of 6 to 10 times the voltage imbalance It is very important to keep the unbalance between electrical phases to a minimum There will always be one module in the bank that is the Master Module This module contains the Master Control Board far left as well as the module Slave Board right of the master Condenser fan control will either be by on off pressure control or VFDs Compressors use contactors as starters and circuit breakers for high and low
3. Charge the circuit with virgin refrigerant Charge with liquid into the discharge side See refrigerant charge on nameplate data of unit 7 Run the system with a burnout filter core for two to three weeks then replace it with a standard core drier 20 0 Heat Exchangers Multistack uses brazed plate stainless steel heat exchangers on the evaporator side of our modules These heat exchangers are made of 316L stainless steel and 99 9 pure copper Condenser side heat exchangers are made from direct expansion copper tube and aluminum fin Without proper water treatment or due to abuse the evaporator side heat exchangers can corrode and eventually develop an internal leak In such an event it would become necessary to replace the heat exchanger Following are the steps for field replacement of a failed evaporator side heat exchanger 1 If the refrigerant has not been lost on the failed circuit you should first do a standard refrigerant recovery 2 Begin by isolating the module and draining the water glycol from the loop 3 Remove the 4 8 round header pipes that attach to brazed plate heat exchanger if you have a front module For rear module s remove the crossover pipes from the front module 4 Cut the refrigerant lines below the elbows and sweat off remaining pipe 5 Remove old heat exchanger and replace with new one 6 Fit in copper connections and braze Purge with Nitrogen while brazing 7 After brazing do a leak check and evacuate to
4. ECTRICAL RATINGS 460 VAC 3PH 60 HZ COMPRESSOR AMPS oy ORLA JTI LRA 447 HP C2 3 RLA 173 LRA _ I HP FAN MOTOR AMPS Sou AS FLA _ 37 5 LRA i NON SCORE MAX FUSE SIZE 100 MAX CE SIZE 400 REFRIGERANT R410A CHARGE FACTORY TEST PRESSURE 595 PSI HI SIDE 235 PSI LO SIDE SERIAL NUMBER _ 8 0 Factory Setup Commissioning Information By going to the System Variables Menu and selecting Factory Settings you can access the program type as well as other settings To change these settings you must enter a password that is available to Authorized Service Technicians by calling Multistack tech support at 608 366 2400 The Standard program should be used on applications where no glycol is present in the chilled water loop In this mode the chilled water temp cut out is 34 F The Low Temp program should be used in applications that have a minimum of 25 glycol in the chilled water loop Cut out on water temp in this mode is 20 F The Low Ambient program should be used for applications when the module s will be operating below 45 F ambient temperatures but no glycol is present If operating below 45 F and glycol is used on the load side the Low Temp program should be used Refrigerant Type Choose refrigerant type used in the modules R410a Suction Superheat Cut Out Adjustable from 0 15 F Variable Flow Select Enable if doing variable flow on the chilled water side or Disable if not To do variable flow water control valves
5. II MULTISTACK Originators Innovators Never the Imitators ASP X Chiller Modules Operation and Maintenance Manual Table of Contents 1 0 Chiller Identification soci 6666166601616 s0x 15646601600 0161211050400025562461160nx1191502015611 00 3 2 0 Theory of Operation icssicsnscsssccssecdcacrsotscssecsunssnncdsessbaccvssdendvsuesauscscanssuustsdeccontebuctveussvensseuvennciuss 3 3 0 Water Meane Misno rane aeara NaO Eea esi SA EER Ea 3 AO FIOW PrO OCOT oinor E E si 4 5 0 System Water VolUMe sssesseesecesocssoesscesocesocescesocesocesocsscescocesocesossscessocesoesscesoeesocssoesseesocesoses 4 GO Elec rical Data riren N E NE na 4 7 0 Identification and Explanation of CompOonennfS oo co s s29 5599555585566855668558855 4 8 0 Factory Setup Commissioning lInformatiOIn c lt s s99 953995558555895886568655885566 7 20 Dany LOG NOOTE ORAR RO SE PSA ABR ae 7 10 0 Pressure Readings se decob te 60i0x6020160044066 05615e98 8608350968900 g900301spxsa829698990561893 g101602ss8 7 FRO Strainer CICAnIn Alana sacana 002010101200220200106 n6 00622001020 11220 0 xi0 71stsessrgeei 8 1220 Compressor Oil LEVO Pasce s c oE EEEE 8 13 0 Refrigerant Charge Evacuation ssessesseeseesoesoesscesocsscesoesoesoesscesoesoesoeescesoesossoeeseesoesoesoeese 8 TO Filter DC S e E E EE EE EEE 8 15 0 Condenser Fan Control esseessessoesscesocesocesoesccesocesocesocesocesocsscesocesocesoesscssoces
6. a maximum of 500 microns Charge the circuit according to the name plate specification If the brazed plate heat exchanger failure has caused water to enter into the refrigerant side the compressor and condenser side heat exchanger should also be checked for possible contamination If water has entered into the compressor it is recommended the compressor be replaced as removing all the moisture from the oil is very difficult Replacement of the condenser side heat exchanger the expansion valve and installation of a liquid line filter drier with a water core cartridge is also recommended Evacuate the circuit to a maximum of 500 microns and let stand for 20 minutes Charge the circuit and run two to three weeks with the high water core cartridge and then replace with a standard core The condenser side heat exchangers on ASPX modules require periodic cleaning of the fins to keep airborne debris from plugging up the fins and causing high pressure conditions A coil cleaner suitable for copper and aluminum can be used for this 21 0 Optional Low Ambient Package The standard operating range for ASPX modules is 95 F through 20 F For operation from 20 F to negative 20 F modules should be ordered with the Low Ambient Package This includes the flooded head pressure control valve properly sized liquid receiver tank to handle both summer and winter charge liquid line check valve and setting the chiller into the Low Ambient or Low Temperature mode Note o
7. aster Module are referred to as Slave Modules The only difference between these modules and the master is they do not have the master board or the master input terminals 7 3 Compressors Sensors and Switches Standard modules use two scroll compressors piped in tandem Each compressor has an HP and LP transducer that sends pressures to the module slave board as well as an HP switch with a manual reset button Compressors have an oil level sight glass that should be at 1 4 1 8 full during operation Each module will have its own Leaving Chilled Water Sensor as well as Refrigerant Suction Temperature sensors In addition the Master Module has and Entering Chilled Water Sensor A System Leaving Chilled Water Sensor is shipped in the electrical panel of the Master Module and should be field installed 2 10 after the first module on the take off side Heaters on compressors will also be energized whenever power is on the module Heaters should always be on at least 24 hours before starting the compressors 7 4 Crossover Pipes Electrical Feeds Modules ordered with single point power are shipped with main power wiring to the system power junction box cut to size and wire tied in the module For rear modules that do not include the water header pipes and connect back to back with front modules crossover pipes that connect the front module headers to the rear modules heat exchangers are supplied The rear module Leaving Chilled Water sensor should plu
8. ct Multistack for more information if heat exchanger cleaning is needed Be sure to use only chemicals compatible with 316L stainless steel and copper Do not use bleach or hydrochloric or sulfuric acids 18 4 Condenser Coils The condenser side coils should be cleaned periodically of air born debris to maximize efficiency and heat exchange Coil cleaner compatible with aluminum and copper can be used Coils can be washed with a garden hose or if careful a pressure washer Be sure to wash the debris out from the backside of the coils in order to avoid further compacting debris into the coils 18 5 Cabinet and Related Hardware a Dry clean electrical panels remove debris b Apply protective coatings or wax if required 19 0 Compressors With any chiller system there is always the chance of compressor failure In the event of a failure proper steps should be taken to determine the cause of the failure 1 A motor burn due to a fault in the motor insulation is quite rare Most burnouts are actually caused by a mechanical condition or lubrication problems In the event of a burnout proper clean up procedures should be followed 2 Check all electrical components of the circuit contactors fuses wires etc 3 If necessary do a system clean up Nu Calgon RX 11 Flush or Sporlan System Cleaner work well 4 Replace the liquid line filter drier with burnout core 5 Evacuate the system to a minimum of 500 microns and hold for 20 minutes 6
9. e pump make sure the ball valve to the system is closed 11 Basic Operational Sequence e With the breakers within the control panel of the glycol feeder module off apply the correct voltage 10 to the module e Fill the feeder tank with a 25 to 50 mixture of glycol and water e Set the Control Mixing Valve to the Mix Purge position e Turn on the breakers within the control panel If there is enough solution the pump will start and will purge air from the hoses within the feeder tank assembly e Turn the Control Mixing Valve to the Normal position The reading on the gauge will now start rising Turn the regulator screw in until the gauge on the regulator reads slightly above the pressure at the suction side of the pumps e Open the main ball valve to the system The glycol feeder is now in full operation It will pump the glycol solution into the system to maintain a constant pressure at the suction side of the pumps Glycol Feeder Module Control Components Control Mixing Valve The control mixing valve on the side of the green cover of the tank is a two position valve The first of the two positions is the normal Operation position In this position the pump inside the tank cover will pressurize the internal pressure of the glycol feeder The second position is the Mix Purge operation position where the pump will pull the glycol mixture from the bottom of the tank and pour it back into the tank in a different location mixin
10. ed by a low flow condition or set points in the master control that are too low If these possibilities are eliminated the Chilled Water heat exchangers may need cleaning Steps to remove the strainers for cleaning 1 Stop Chilled water pump and shut down chiller 2 Close inlet and outlet water valves to the chilled water 3 Drain the water glycol from the top header in the end module so the strainers can be removed 4 Remove the 4 8 Victaulic end cap on last module 5 Remove strainers and clean You may need to make a tool to hook the other strainers for removal 6 Re install clean strainers 7 Open the bottom water isolation valve and fill unit from the bottom up to prevent air from being trapped 8 Restart Chilled Water pump bleed any air and start Chiller 12 0 Compressor Oil Level Compressors used on ASPX modules are oil charged by the compressor manufacturer The standard tandem Copeland compressors do have an oil equalizer line and oil level sight glass indicator Oil level should be maintained at Ya 1 4 full To ensure no liquid is present in the oil the crankcase heaters should be on 24 hours before starting of the compressors Factory oil charge volume for each compressor can be found in section 13 0 13 0 Refrigerant Charge Evacuation All ASPX modules are factory charged with the recommended refrigerant volume Prior to charging each circuit is evacuated to a maximum of 150 microns and held 15 minutes The proper ref
11. g the solution Pressure Gauge The pressure gauge shows the pressure that the chilled water loop is operating at It is also showing what the Pressure Regulator is allowing into the chilled water loop Pressure Regulator The pressure regulator limits the amount of pressure going into the system from the glycol feeder When the desired system pressure is reached this regulator closes down Once the regulator closes down the internal pressure of the glycol feeder raises until the internal pressure switch shuts off the pump Pressure Switch The pressure switch shuts off the pump that is internal to the glycol feeder Once the pressure regulator closes down and the pressure inside the glycol feeder rises this component turns the pump off This component is an internal part to the pump inside the feeder itself Float Switch The float switch will shut off the glycol feeders internal pump when there is not enough solution in the tank to maintain pressure in the system This prevents the pump from running without any fluid in it 25 0 Optional Water Storage Tank Modules As mentioned above under System Water Volume if low water volume is a problem a Tank module can be supplied with an optional mini glycol feeder instead of the full module glycol feeder The tank would be rated at 150 psig and standard volume of 180 gallons and would connect directly to the mechanical and or free cool and pump modules 12 26 0 Optional Variable Flow CHW Val
12. g in the program of the module The LP cut out for modules with R 410A is 50 psig If circuits are faulting on HP faults you should first check to see that the fans are operating If both fans are working check the cleanliness of the condenser coil ALP fault is an indication of low refrigerant charge in the system Ifa circuit is going out on an LP fault check the static pressure of the system while the circuit is in the off mode If pressures are low check the circuit for possible leaks The circuit can be pressurized to 15 psig with refrigerant and topped to 160 psig with dry Nitrogen 11 0 Strainer Cleaning All ASPX modules have a 30 mesh filter strainer in the Chilled Water inlet header The purpose for the filter strainer is to keep debris from entering the heat exchanger An external Y or basket type system strainer should also be installed as a pre filter to the factory supplied strainers There is no set time for cleaning the filter strainers The frequency of this process is dependant on the water quality in the Chilled Water loop Normally debris in a water loop is going to take the path of least resistance and build up on the last modules to receive water If circuits are faulting on Low Suction Temperature or Low Chilled Water Temperature the Chilled Water inlet filter cartridge should be checked The strainers are located in the top header on the Chilled Water side If the strainers are clean the fault is most likely being caus
13. g into the well supplied in the crossover pipe 7 5 Chilled Water Connections Water connections for the evaporator side are 4 8 grooved pipe The upper header is for Entering Chilled Water to the module The bottom header is for Leaving Chilled Water from the module The entering header contains a 30 mesh filter strainer to prevent debris from entering the brazed plate heat exchanger This filter should be used as a last means of defense Proper filtration before the module should be installed for easy access to cleaning 7 6 Expansion Valve Liquid Line Solenoid Liquid Receiver Chiller Modules use a mechanical expansion valve for refrigerant control to the evaporator Superheat should be set to approximately 10 12 F The Liquid Line Solenoid is used to prevent refrigerant migration into the evaporator during the OFF cycle A properly sized liquid receiver is used to store excess refrigerant needed in the refrigerant circuit for different ambient temperatures When the module is designed for Low Ambient Operation to 20 F a larger receiver than Standard is used 7 7 Nameplate Module nameplate s are located on the electrical control box door Nameplates include phone and address for Multistack model and serial number important to supply when calling for service parts or technical support refrigerant type and charge and electrical data As seei CERTIFIED Master tre fry WU DESTA T MAPLE AVEL SPAT A NT LS o fa ji qu MODEL EL
14. has dropped below the set point compressors will begin to cycle off 3 0 Water Treatment Proper water treatment is essential to ensure the peak efficiency and performance of the Chiller The evaporator side water quality should be kept within the following parameters to prevent any damage to the heat exchangers The use of hydrochloric sulfuric and muriatic acids as well as household bleach can cause stress corrosion to the stainless steel in the heat exchangers Use of these or any other unapproved chemicals is not covered under the Multistack warranty Multistack Water Guidelines PH gt l lt 9 TDS lt 1000 ppm if glycol used this parameter will be exceeded Hardness 30 500 ppm Alkalinity 30 500 ppm if glycol used this parameter will be exceeded Chlorides lt 200 ppm Sulphates lt 200 ppm 4 0 Flow Protection Proof of chilled water and condenser water flow is required by the Master Control inputs Paddle type or Differential Pressure DP switches may be used Switches are a Multistack option otherwise they are to field supplied and installed Chillers purchased with chilled or condenser water pump modules have a DP switch installed across the pump to verify it is running Multistack recommends a paddle type switch be installed in the leaving water piping of the chiller or if using a differential pressure switch install it across the inlet and outlet water connections to the chilled and or condenser water piping connections 5
15. if you have 10 compressors and flow at a true 10 F Delta T with setpoints of 55 Up and 45 Lo and VSP at 50 your no load point would be 50 F The last module running would be producing water at 50 in and 40 out and mixing with those not ON producing the same temp as system entering 50 The system LCHW temps would then range between 45 50 F depending on the number of circuits ON and number OFF With motorized butterfly valves on each module we do not have to take into effect the mixed temperature as those heat exchangers are isolated Since the CHW pump will be speeding up and down based on a constant chilled water DP we should always be producing the same Delta T through modules as we are with the system temps So if we kept the VSP at 50 the last module would be on at 50 F entering water temp and producing both module and system leaving temp at 40 F If we raise the VSP to 80 with the same 55 and 45 setpoints the last module would be on at about 53 5 entering and then produce both module and system leaving temp at 43 5 So basically when doing variable flow a higher VSP is desired to maintain closer leaving water temps 27 0 Optional Gear Driven Condenser Fan low sound Service recommendations for ASP modules using the Right Angle Gear Drive for condenser fan motor The gear drive has an oil level sight glass that should be checked regularly The model 65 requires 50 gallons of ISO grade 220 synthetic oil for applications from 20
16. must be installed on each module between the water header pipe and heat exchanger Bypass Select enable to leave the valve on the lead module open for minimum flow bypass If no valves are installed on the module keep this variable in the disable mode For information on basic control setup of the modules see the ASPX Chiller User Manual 9 0 Daily Log Sheet On the back page of this manual is an information log sheet for the chiller The log sheet can be used daily weekly or as desired to record operation characteristics of the chiller The information recorded on the log sheet can also be very helpful for diagnosing potential problems in the system 10 0 Pressure Readings The operating suction and discharge pressures in the system are directly related to water flow condenser temperatures chilled water set points and the cleanliness of the system Standard operating conditions at 95 F ambient with 45 F leaving chilled water should be 450 psig 125 F saturated for discharge pressure and 114 psig 38 saturated suction pressure All ASPX modules have a high pressure cut out safety device Each circuit will cut out on HP when the programmed set limit in the master control is met Standard setting on this is 585 psig In addition a backup HP cut out switch is installed on each module The standard HP cut switch is set at 585 psig for R 410A Each ASPX module also has a low pressure safety cut out The LP cut out is controlled by a settin
17. n modules large than 15 tons two head pressure control valves will be used in parallel When doing low ambient applications it is also suggested to use VFDs for condenser fan control Evaporator Valve Liquid Line TF Drier Condenser Receiver E 22 0 Optional Pump Modules To provide water flow to the chiller bank Pump Modules can be provided in various sizes and configurations to connect directly to the mechanical or free cooling modules The standard pump would be built in the same frame size as the cooling modules and come with a Series 4382 dual arm with 1 primary pump and the 2nd as back up Pumps can be manually rotated for equal run time or special ordered with auto lead lag capability 10 23 0 Optional Free Cool Modules Modules for free cooling can connect directly to mechanical or pump modules to utilize the outside air temperature for cooling the water temperature Anytime a free cool module is used a minimum of 25 glycol concentration should be used The water glycol in these modules use the fin tube coils for heat exchange Free cool modules can work as stand alone or connect via a three pipe header system to mechanical modules to supplement the cooling A three way diverting valve which opens and closes based on ambient temperature will either send water through the free cool module or divert water directly to the mechanical modules The middle header of the free cool module should be the inlet connection fr
18. ocesoesscesocesoeesoses 8 16 0 Superheat Subcooling seeessesssesscesocesocesoesscesocesocesoesscesocesocesoesscesocesocesscesocesoesseesocesoeesosss 8 17 0 Pressure Relief u siga aid DDS Teia 9 18 0 Annual Maintenance c 6046461 101164661401019 263046E210266633092446111110443900933g614034400s40peexSosfssri 9 I 0 0000165 0n 9 20 0 Heat 1E 2000022 4 10 21 0 Optional Low Ambient Package G6 lt 9 9 999 895 08899688956889508895088950869996 10 22 0 Optional Pump MOGUICS sudodddditidsiiiiediciitaxsft6g163606631445056364612g06g616636001601639446963066 10 23 0 Optional Free Cool Modules esseeesseessocessocesocessocesocessocesocesocessoeesoeessocessoeesocessocesoeessoeesoe 11 24 0 Optional Glycol Feeder Module lt 6 G5 999 999 96984998989989845588959889598895 86 11 25 0 Optional Water Storage Tank Modules G5 G 6 2 99 95895958955895866568865 56 12 26 0 Optional Variable Flow CHW Valves GGG G0 0099558995589955665556695568896 13 27 0 Optional Gear Driven Condenser Fan csscccsssccssssccssssccssscccsssccesssscsessscsesssecesssceesnss 13 28 0 Troubleshooting Air Cooled Packaged Modules lt lt lt 5 se s5556 5953 14 1 0 Chiller Identification The module information data plate is located inside the electrical box com
19. om the building load Once water leaves the free cool or if the valve to the free cool is closed the water goes to the top header The top header of the free cool connects to the first mechanical module so water will then flow to the mechanical modules Water leaves the mechanical module through the bottom header so the mechanical module bottom header will connect with the free cool module bottom header Leaving chilled water can the either exit the chiller through the free cool module bottom header or that header can be capped and water exits out the opposite ends mechanical modules bottom header Free cool module s do not communicate directly with mechanical modules They can be supplied with either fan cycling controls or VFDs that utilize a Carel controller for fan speed control Please see Free Cool User Manual for more information 24 0 Optional Glycol Feeder Module The Airstack Glycol Feeder Module is one section of a multi module chiller system Its purpose is to supply makeup glycol solution to the chilled water loop at the suction side of the pump Each glycol feeder module is composed of a storage tank and pump assembly expansion tank and related control components NOTE Do not use the glycol feeder to fill the chilled water loop The pump inside the glycol feeder is designed to move low volumes of solution at high pressures not high volumes of glycol solution Doing so could burn out the pump motor NOTE Before supplying power to th
20. partment of each module When ordering service parts or inquiring for technical assistance it is important to provide the model and serial number 1 1 Water Cooled Model Number ASP15X2H2A0 410a ASP 15 X 2 H 2 A 0 6 ASP Air Stack Packaged 15 tons 10 15 20 30 60 tons X or C X Copeland 410a Compressor C Trane Scroll 2 or 1 1 Dual Circuit Evaporator 1 Single Circuit Evaporator H 460V Or A 208V 1L 2300 C 575V V special 2 Multiple Module Power 1 Direct Connect Power A Water Cooled Or D DX unit R Heat Pump F Free Cool C Condenser L Fluid Cooler 0 ARI Version 410a Refrigerant 1 2 Serial Number Identification AJ 06 25 A Decade built 19905 J 2000 s A 2010 s J Year built A 01 B 02 03 J 10 06 June month built 01 Jan 02 Feb 25 25th module built 01 1st 02 2nd 2 0 Theory of Operation The Airstack ASPX chillers provide chilled water to an external load based off of the return water temperature calculated on the module Master Control When the Entering Chilled Water sensor sends the signal to the Master Control that Cooling is needed compressors will begin to start and produce Chilled Water The point at which the Entering Chilled Water temperature calls for compressors to start is determined by the Up Setpoint Lo Setpoint and the Variable Setpoint settings in the System Variables menu of the Master Control When the ECHW sensor is signaled that Chilled Water temperature
21. rigerant charge for each module can be found on the module data plate On air cooled packaged machines the proper charging procedure is calculated by the weigh in method Charging to a full sight glass on air cooled ma chines will likely result in over charging because the elbows in the liquid line as well as the liquid line solenoid valve still produce some flashing even with the correct charge As fans are cycling the sight glass will also display some bubbling Model Lbs R410a Lbs Low Ambient Total Tandem Compressor Oil Charge ASP10X 50 90 114 oz ASP15X 60 85 220 02 ASP20X 100 100 220 02 ASP30X 125 125 252 02 ASP60X 220 360 426 02 14 0 Filter Driers ASPX Chiller modules have a liquid line filter drier installed When doing a repair to the refrigerant side because of a compressor motor burn or moisture entering the system a proper replacement drier should be installed 15 0 Condenser Fan Control 10 15 and 20 ton modules can be ordered with standard pressure control cycling of fans or optional VFD control ASP30 and ASP60 modules come standard with VFD control 16 0 Superheat Subcooling ASPX modules use a mechanical expansion valve By turning the valve adjustment clockwise superheat is increased On each module superheat is set at the factory during the run test Superheat is set between 10 12 F during the test run Subcooling is necessary in the system to prevent flash gas when the refrigerant enters the expan
22. sion valve ASPX condensers are sized so that subcooling of the liquid refrigerant will take place without a separate subcooler The general range of subcooling seen is 7 15 F 17 0 Pressure Relief Valve Each module has a 650 psig pressure relief valve The relief valve is installed on the receiver of the module and has a 3 8 thread connection 18 0 Annual Maintenance 18 1 Electrical Components a Check all external interlocks b Inspect compressor terminals c Check compressor crankcase heater operation d Tighten all contactors relay and circuit breaker terminals e Check and calibrate all compressor safety controls f Check and record voltages and amperages for compressors g Check and record amperages for pumps and condenser fans h Check and calibrate low ambient fan cycling controls i Inspect relay contacts for damage or pitting 18 2 Refrigeration Circuits a Analyze refrigerant with tube type moisture acid analyzer b Check and record refrigerant subcooling and superheat c Check liquid solenoid valves d Check expansion valve and sensing bulb connections 18 3 Chilled Water System a Clean pump strainers and system strainers b Remove header caps and clean the ECHW strainers c Check glycol inhibitor content in system chilled water d In severe cases where the chilled side water is contaminated the heat exchangers may need to be backflushed Multistack has available a cleaning kit do to this task Please conta
23. system variables Check sensor location Check entering CHW sensors Check setpoints in system variables Command On at master Control Check sensors Check load limit setting in system variables Check VSP setting is system variables Check entering CHW sensor location Check fan operation Check coil condition Check fan settings in system variables Check refrigerant charge leaks Check expansion valve Check suction sensor Check setpoints in system variables Check for flow restriction Check settings in system variables Check cables at J11 comm ports Check dip switch settings Check components in control circuit Check wire crimps in control circuit Check the communication circuit J11 for loose connections Check for possible airwave interference M MULTISTACK Daily Chiller Log Sheet Status SuctPress HeadPress Suctlemp LochwTemp Fautt ifany mpm om PE com comta PE Omi omt omg comes po comso oo po comso po po compete oo po po comosa ln o m ww Demand Capacity Lm PP Comments HI MULTISTACK 1064 Maple Avenue Sparta WI P 608 366 2400 F 608 366 2450 www multistack com F162ASP O amp M 072610
24. ves To accomplish variable flow on the chilled water side modules must be special ordered with power actuated butterfly valves In some configurations this will change the footprint of the modules as valves will need to be installed between the heat exchanger and water header pipe of each module The valves on each module will open close and modulate as compressors cycle on or off The valves allow flow to go through only modules that are running Therefore pressure drop increases as modules cycle off closing valves and allowing the pump to slow down to maintain constant pressure drop across the chiller Control of the variable speed pump needs to be taken from the pressure differential between the inlet and outlet of the chilled water at the chiller Control based off of system pressure will result in erratic temperature control as well as likely faults with operating modules On the chilled water side a minimum flow needs to be supplied to the chiller In the factory setup menu of the master control you can select the number of valves to be open all of the time to maintain a minimum flow For further information on variable flow please see the Multistack Variable Flow Supplement The Variable Setpoint also works differently when doing variable flow Since valves are used to isolate each heat exchanger we do not need to account for the mixing effect of modules that are running with modules in the off mode On a normal application without water valves
25. voltage components The main power input block is located to the right of the circuit breakers A module Auto Off Manual Mode switch is also available for back up control if the master board would fail The master module also has the terminal strip inputs for flow switches start stop alarm output and phase monitor When shipped the master control panel will also contain the P Lan communication wire to be field installed and the system Leaving Chilled Water Sensor well to be field installed 7 0 Identification and Explanation of Components 7 1 Master Module Control Panel There will always be one module in the bank that is the Master Module This module contains the Master Control Board far left as well as the module Slave Board right of the master Condenser fan control will either be by on off pressure control or VFDs Compressors use contactors as starters and circuit breakers for high and low voltage components The main power input block is located to the right of the circuit breakers A module Auto Off Manual Mode switch is also available for back up control if the master board would fail The master module also has the terminal strip inputs for flow switches start stop alarm output and phase monitor When shipped the master control panel will also contain the P Lan communication wire to be field installed and the system Leaving Chilled Water Sensor well to be field installed 7 2 Slave Module Control Panel All modules except the M
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