Ref. Charge - Koolant Koolers
Contents
1. 17 Trouble Shoting t m 18 Trouble Shaoatirig Part2 ore 19 i e EE 20 Limited Warranty cos so oio dd toe er Rv stt srt 21 A WARNING A ELECTRICAL HAZARDS 1 TURN OFF MAIN POWER DISCONNECT SWITCH ON THIS MACHINE BEFORE ATTEMPTING TO SERVICE THIS EQUIPMENT 2 THIS MACHINE IS PORTABLE DISCONNECT ALL POWER SOURCES BEFORE REMOVING CONTROL COVERS 3 USER IS RESPONSIBLE FOR LOSS OF OR FAILURE TO USE AND MAINTAIN ANTI HAZARD PROTECTIVE COVERS FOR ELECTRICAL EQUIPMENT AS FURNISHED BY THE MANUFACTURER OF THIS MACHINE 4 SHOULD YOU FIND IT NECESSARY TO MAKE ANY REPAIRS TO THE REFRIGERATION BECAUSE REPAIR CAN BE HAZARDOUS READ THE UNIT MANUAL UNDER REFRIGERATION OR CALL THE MANUFACTURER AND SELLER PLEASE NOTE THE DANGER OF OVER CHARGING THE REFRIGERATION SYSTEM Failure to read and observe above precautionary warnings are serious offenses under Public Law 91 596 All employees are hereby notified that the employer and owner of this equipment under OSHA must take immediate disciplinary action up to and including dismissal for failure to read and comply with this notice To Comply With OSHA All Warning Signs Must Not Be Removed From This Water Chilling Equipment Specifications REFRIGERATIO Max rated ambient temp 90 F Min Chilled water temp 60 F Max Water Temp 85 F Compressor HP Refrigerant R134A2. 230 Marks LOVE Electronic Controller Type Air Water Cooled Chiller Notes All motors have internal overload protection unless otherwise shown Je Black L3 Red i ng 562 926 3855 1211 Park St Cerritos CA 90703 562 926 0960 Fax Schreiber Engineering Air Cooled Water Chiller Model MICRO MAX series This unit is pre wired for 230 1 To test unit as follows NOTE Make sure the switch on the panel is at OFF position Connect the water system loop as follows The discharge from chiller water pump to heat exchanger being cooled then connect the return water to the chiller return as marked These discharge and return fittings 1 2 The connecting hose can be rubber or plastic However using rubber hose will require make adaptor at the chiller s discharge and return for connection The pump is factory set to discharge water 4 4 gpm gallon per minute at 60psi Adjusting the relief valve located at pump discharge can modify this flow condition Be sure you use a non contaminate hose Fill the reservoir through the fill pipe on top of the unit Be sure you replace the cap when the reservoir s filled The water sight glass is marked at the reservoir proper fill level The unit is equipped with a 220v female power plug A male power plug is supplied with the unit Proper wire connection is required with a certified electrical technician With input power 220 1 voltages supplied to the unit the controll
3. Charge 3 Ibs 1 HP Pump Specifications ELECTRICAL Voltage 230 1 Full Load Amps 13 8 AMPS 5 5 g p m 60 p s i Nominal Flow Rate 4 0 g p m Nominal Pressure 60 p s 1 Pump Horsepower V Pump Type Positive Displacement Pump Material PHYSICAL Overall Dimensions Brass 21 500Wx 26 500Dx30 750H Reservoir Capacity 8 Gallons Weight 350 lbs Discharge Return Connections NPT Tank Fill Y NPT Tank Drain 3 8 NPT Ball Valve STARTUP CHECKLIST POWER SUPPLY Verify that the power supplying to the chiller matches the requirements as stated on the nameplate Connecting chiller to the wrong power supply will damage system components and void the warranty FILL THE RESERVOIR Using the fill port on the top of the chiller to add water until the level reaches the red line marked on the sight glass DO NOT USE DEIONIZED WATER Connect Discharge and Return Piping Connect your piping to the two female fitting on the front of the chiller Rubber Hose PVC and copper are acceptable piping materials Do not use any ferrous piping material as they will damage the chiller s water loop system Doing so will cause damage to the chiller that is not covered by warranty Check for proper rotation Not applicable for this model Temp Sensor 230 1 Power Supply 1000 Ohms 25 Degrees Celsius 5 WPRC Water Pump 1 5 DTE poire Voltage
4. 162 BP C Evaporator Brazed plate MM100 150AC 1 R184 High Pressure Switch MM50AC only v 1 R185 Low Pressure Switch MM50AC only v 1 Electrical E108 Contactors 30 Amp 240V coil v 1 E104 4 Point Terminal Block A 1 E109 Fuse Block 30 Amp v 1 E109 F25 25 Amp Fuse 3 E109 F 12 12 Amp Fuse v 3 E170 1 Relay Base v 1 E170 Relay 240v coil DP DT 1 E115 Grounding Screw A 1 E122 Switch 1 400 Love Control 4 1 Plumbing P132 Pump assembly 1 132 Pump Motor v 1 132 1 E136 30 Water Pressure Gauge 1 P146 Water Relief Valve 1 P149 wsga Water Level 1 Accessories C101 Casters v 4 CA100MM Cabinet x 1 C100 Crate v 1 Note Some water connection parts are not listed Schreiber Limited Warranty Schreiber warrants the product described herein against defective material or workmanship for one year from the date of purchase If any part is found to be defective within the war ranty period Schreiber or its authorized service agent will replace or at Schreiber s options re pair the part free of charge for materials and labor This warranty does not cover damage caused by misuse accident abuse incorrect installation or operation In addition it does not cover damage occurring during transit or damage caused by or resulting from repair or modifications carried out by anyone other than Schreiber or its Authorized Service Agent 562 926 3855 2
5. INSTALLATION OPERATION amp MAINTENANCE OWNERS MANUAL Aim cie ndr lt The Finest Chiller in America e 2 Af QURLITS 5 SINCE 1958 MAX 74 1 AND 1 1 2 TON Serial No Voltage 230 1 Ref Charge R134A SCHREIBER ENGINEERING Division of DovaTech 12111 E Park Street Cerritos CA 90703 Tel 562 926 3855 Fax 562 926 0969 TABLE CONTENTS iere EUER 1 Table of Contents AME 2 CAUMOM 3 Specifications isi CONCRA QOO D DUE REX HUE ER OR AKTE Sq DOCE DOR LEX Se 4 staring Check io ae d qn AI E E d s Ae 5 Wiring Rc 6 Instruction INOrmAatOn P DTE 7 Installation Operation TL 8 Electrical Controller Setting ucciso cutis Hush on ped deck hte e vie odd ene 9 Isetrigeratiori System Soe Experte ream SEM ees e dinh eR s 10 Chilled Water recidere hiekei E Em FEDERE 10 Special Features CL 12 Service ET CRI E Bp E n CM EE bu 13 Maintenance Information lt
6. PROTECTIVE COVER by adhering to the following service procedures 1 If the branch circuit short circuit and ground fault protective device i e fuse or circuit breaker is open this is a strong indication that an electrical problem exists and must be found and corrected The circuit protective device rating must first be checked as required by the National Electrical Code and its maximum rating should coincide with that marked on the equipment nameplate and or on the unit wiring diagram and or instructions This breaker or fuse rating should be as low as practical A rule of thumb is 175 times the motor compressor RLA FLA on older units as shown on the unit nameplate It is acceptable to first replace the fuse or reset the circuit breaker ONE TIME to determine if it was just a nuisance opening WARNING The terminal PROTECTIVE COVER must be securely in place 2 If the fuse or circuit breaker again opens DO NOT continue to replace or reset as the equipment obviously has an electrical problem CAUTION Continual resetting may cause the terminal to vent 3 DISCONNECT all power to the unit making sure all power legs are open 4 Without removing the terminal PROTECTIVE COVER disconnect the three leads going to the compressor terminals at the nearest point to the compressor and identify them as Common C Start S and Run R Identification can generally be made through the unit wiring diagram DO NOT disconnect at the compres
7. ace Replace Repair or replace Repair or replace Replace Replace Repair Repair leak and recharge Replace expansion valve Repair or replace motor Clean condenser Install service panel Replace expansion valve Repair leak Re adjust or replace Replace Check controls circuit Repair or replace Out of adjustment Not circulating water TROUBLE SHOOTING PART II REFRIGERATION SYSTEM INTERNAL PRESSURE USING REFRIGERANT R 134A High Pressure Switch Manual Reset Cut out at 425 P S I Low Pressure Switch Automatic Reset Cut out at 15 P S I WORKING REFRIGERANT PRESSURES R 134A High Pressure 185 to 325 P S I Low Pressure 45 to 70 P S I These pressures are under normal ambient temperatures and chilled water temperatures 19 PARTS LIST Micro Max Series 230 1 If this unit has special feature s installed see appendix for part number s Part Number Description Refrigeration R100C cu Condensing unit MM50AC 1 R102C cu Condensing Unit MM100AC ud 1 R114C Condensing Unit MM150AC R146 5 Refrigeration Sight Glass 1 4 for MM50AC 1 R146 1 Refrigeration Sight Glass 3 8 for MM100 150AC 1 R150 Drier 74 for MM50AC 1 R152 Drier 3 8 for MM100 150AC 1 R140 5 Expansion Valve x 3 8 for MM50AC 1 R140 1 Expansion Valve 3 8 x 7 for MM100AC 1 R140 2 Expansion Valve 3 8 gt for MM150AC 1 R160 BP Evaporator Brazed Plate MM50AC 1 R
8. compressor the overload is located between the common terminal of the compressor and the common motor lead inside the compressor If the resistance reading between Common and Start or Common and Run is open infinity and the resistance reading between Start and Run indicates winding Resistance Values in the Tecumseh Hermetic Compressor Service Data Book then the internal protector is open and time must be allowed for it to reset Any Common and Start Common and Run and Start and Run resistance reading must be within the values shown in Tecumseh Hermetic Compressor Service Data Book Three phase internal overloads open all three phases Therefore allow time for reset For external overload protected motor compressors the continuity of the overload may be checked The resistance of all winding may also be checked 1 e C S C R and S R Any lack of continuity other than test indicating an open internal protector or improper resistance indicates a faulty or damaged motor and the compressor must be properly replaced as it has failed and cannot be repaired If the above indicates no problem with the compressor then carefully reconnect the leads to the proper compressor terminals C S amp R correctly replace the terminal PROTECTIVE COVER gasket if required and the bale strap Then proceed to conduct similar ground and continuity test from the three lead connection points which you previously disconnected forward towar
9. d the incoming power connections to find the electrical problem DO NOT reset the ground fault 15 protective device until you have located and corrected the problem Refer to the Unit Wiring Diagram and Service Manual for the proper procedure and wiring checkout The text of step by step procedures uses language and symbols which refer to the electrical supply as single phase Three phase equipment should be given equally cautious consideration when service is necessary Again we want to stress that it is essential that WHENEVER ELECTRIC POWER is applied to the motor compressor the terminal PROTECTIVE COVER must be properly in place Servicing refrigeration and air conditioning systems can be dangerous and extreme caution in all respects should be exercised by the personnel servicing such equipment The precautions discussed in this bulletin deal only with those dangers associated with VENTING TERMINALS 16 MAINTENANCE INFORMATION There are no lubrication points on the chiller All motors have permanent lubrication in the bearings The water that is used in the chilled water circuit has no special requirements except that deionized water cannot be used The water should be clean and some type of water conditioner can be used Nothing should be used in the chilled water circuit that could damage the all copper Heat Exchanger THIS INCLUDES THE USE OF DEIONIZED WATER The air cooled condenser should be cleaned on a regu
10. ed water system The chilled water reservoir is not pressurized Do not plumb two chillers in series The MICRO MAX chiller is installed with a strainer on the return line to keep foreign particles out of the system 11 SPECIAL FEATURES SERVICE BULLETIN HERMETIC COMPRESSOR ELECTRICAL TERMINAL VENTING CAN BE DANGEROUS 3K 2K 2K K K K When the insulating material which supports a hermetic compressor electrical terminal suddenly disintegrates due to physical abuse or as a result of an electrical short between the terminal and the compressor housing the terminal may be expelled venting the vaporous and liquid contents of the compressor housing and system If the hermetic compressor terminal PROTECTIVE COVER is not properly in place with its weatherproofing gasket if required and bale strap fastening device secured there is a remote possibility if a terminal vents that the vaporous and liquid discharge can be ignited spouting flames several feet causing potentially severe or fatal injury to anyone in its path The discharge from a venting terminal can be ignited external to the compressor if the terminal PROTECTIVE COVER is not properly in place and if the discharge impinges on a sufficient heat source such as but not limited to an open flame electric heater or an electrical spark Ignition of the discharge can also occur at the venting terminal or inside the motor compressor enclosure if there is sufficient contaminant air
11. er will display the discharge water temperature Turning the main panel switch to ON position will starts the system This switch activates the control to turn on the pump and the refrigeration system The unit leaves the factory with discharge temperature setting at 60 F 10 second delay is programmed to the controller to start the refrigeration unit The minimum temperature is set 40 F and the maximum temperature set is 90 F Refer to the control setting page for changing discharge temperature With the controller set at the proper temperature it will control this temperature within 1 F The unit is equipped with a low pressure switch and high pressure switch These switches are inter connected to the controller These switches are there to protect the refrigeration system from leaking or overload The low pressure switch is set at 25 PSI and the high pressure switch is set at 425 PSI If any of the situations is occurring the controller will automatically turn off the condensing unit The controller will display LI or H1 which indicate the refrigeration system is being shut off due to pressure If the system is off at low pressure display 1 1 fix the leak and recharging the system will reset the switch If the system is off at high pressure correct the problem and press the red button to reset the switch NOTE OF CAUTION Always keep the fluid in the reservoir at its proper level If the unit condenser becomes cl
12. lar basis depending on the environment the chiller is installed in check often The water level should be maintained as close to the level as marked on the water sight glass You can damage the refrigeration system by the water being at a low level and will affect the efficiency of the unit Caution The compressor receivers and water pump could be hot enough to injure one touching these components The dial thermometer is reading the temperature of the discharge chilled water Please note This is a hermetically sealed compressor There are no necessary maintenance requirements Please read the service bulletins before making any repairs 17 Compressor won t run Compressor runs No refrigeration High pressure trips Low pressure switch Cutting out Temperature too high Temperature too cold Check Power supply Electrical circuit Check Line load voltage Temperature control Compressor overload Low pressure switch High pressure switch Manual switch Compressor control circuit Refrigerant leak Stuck expansion valve Condenser motor Air over condenser restricted Service panel not in place Defective expansion valve Refrigerant leak Dial thermometer Temperature controller Water pump off Temperature controller Dial thermometer Water pump 18 TROUBLE SHOOTING PART I SYMPTOM DIAGNOSIS REMEDY Correct circuit breaker Repair or replace bad circuit Correct voltage condition Repair or repl
13. ller shut off at he refrigerant high pressure due to a dirty condenser excessive ambient temperature or a blockage in the refrigerant line The high pressure switch is set at 425 psi Pressing the red button on the switch will reset the circuit This is a medium temperature chiller The temperature range is 45 to 90 F The chiller will not operate to its full capacity outside of this temperature range Chilled Water System A 265 GPH Gallons per Hour positive displacement pump is equipped with this chiller Because of its design the flow rate is not adjustable The pressure can be adjusted by throttling the discharge If the discharge is throttled too much the internal pressure relief valve will open and bypass water back through the tank The pressure relief valve is factory set at 60 psi The water used to fill the chiller must be absolutely free of any particulate matter If any particles or sediment is run through the pump it will score the inside 10 resulting a marked decrease in pump performance This failure is not covered by warranty A filter is available as an option to install to the chiller However the water initially placed in the reservoir must be clean The reservoir level must be maintained to the level marked on the sight glass Damage to the evaporator can result due to low water level Plumbing must be rubber hose PVC or copper Use of any other material will increase the chance of contamination in the chill
14. ogged it must be cleaned Be sure you check the condenser often Does not take much dirt in condenser to cause a problem The refrigeration system is a medium temperature Never set the controller below 45 F INSTALLATION 1 Place chiller on level ground 2 Allow 3 in of clearance in the front and in the back of the unit This clearance is necessary for air circulation through to the unit If the airflow in and out of the chiller is restricted the chiller s cooling capacity is reduced 3 Connect chiller to power supply Refer to the nameplate for electrical circuit requirements 4 Connect chilled water piping 5 Fill tank with water to proper level at the fill port Note the when the chiller is started the water level will drop slightly as the pipes are filled Add more water after the unit is started OPERATION 1 After all electrical and plumbing connections are made and the reservoir is filled You are ready to start the unit 2 Turn the main power switch to the position 3 The temperature displayed is the chiller discharge temperature Refer to controller page to modify the setting Do not set the temperature less than 40 F You will damage the unit TEMPERATURE DISPLAY ET POINT BUTTON INSIDE YOUR CHILLER Electrical System This chiller requires a power input of 220 volt single phase The power supplier to the controller is 24 VAC through a step down transformer The chiller can ope
15. present in the system and an electrical arc occurs as the terminal vents Ignition cannot occur at the venting terminal without the presence of contaminant air and cannot occur externally from the venting terminal without the presence of an external ignition source It is therefore essential that any air in a refrigeration air conditioning or heat pump system be completely removed when the system is manufactured when the system is installed and whenever the system is field processed as a result of field service Field service includes but is not limited to leak repairs or compressor replacement Eliminating air within the system prevents ignition at or in the hermetic compressor if a terminal should vent thereby reducing the hazard potential To reduce the possibility of external ignition all open flame electrical power and other heat sources should be extinguished or turned off prior to servicing a system Before using a soldering or welding torch to remove or repair tubing make sure all the system refrigerant charge has safely been released A venting terminal presents no danger to servicing personnel or anyone else in the vicinity if the compressor terminal PROTECTIVE COVER is properly in place as shown 13 on Tecumseh Products Company drawings and diagrams using the parts as shown on Tecumseh Products Company bills of material Hermetic compressors can be properly serviced without unnecessarily removing the terminal
16. rate at both 60Hz and 50Hz however there is 12 reduction if cooling capacity and a 17 reduction in flow capacity at 50 Hz High voltage electrical components stored in the control box Take careful precaution when open the door Door must be secure in place when the unit is operating CONTROLLER SETTING Parameters overview Carel uchiller has many parameters available Only few will ever need to be adjusted Parameter Function R1 Cooling Set point R2 Cooling Differential R6 Return Temperature Reading Changing Set points Cooling Set point d Press the SEL key for 5 seconds R1 will appear on the screen 2 Press the SEL key and adjust the desire cooling value Press the SEL key to store the value 3 Hit the PRG key to return to normal operation Refrigeration System The refrigeration system is factory charged with R 134A If the refrigeration system has to be serviced and recharged with refrigerant do not use any other than R 134A The MICRO MAX series chiller is equipped with a refrigerant low pressure and high pressure refrigerant switches The low pressure switch is an automatic reset switch that will protect the compressor in the event of a refrigerant leak It is set at 25 psi The high pressure switch is a manually resetting switch The controller turns off the refrigeration unit when it detects a high pressure condition in the refrigeration system Chi
17. sor terminals at this time 5 With Megger Hi Potential Ground Tester or other suitable instruments which puts out a voltage between 300 and 1500 volts check for a ground separately between each of the three C S amp R leads and ground such as an unpainted tube on the compressor Do not use a low voltage output instrument such as a volt ohmmeter or other such continuity instruments as these will not detect a low level fault ground 6 If a ground is indicated then carefully remove the compressor terminal PROTECTIVE COVER and inspect for loose leads or insulation breaks in the lead wires T If 6 indicates no visible problem carefully remove the leads at the compressor terminals CAUTION Damage can occur to the glass embedded terminals at this 14 10 point if the leads not properly removed which can result in the terminal venting and hot oil discharging No ignition however can occur if all power is disconnected and no external ignition source is present Repeat 5 testing carefully checking for ground directly between each compressor terminal C S amp R and ground If once again a ground is indicated proceed to properly replace the compressor as it has failed and cannot be repaired It is important to note that a volt ohmmeter may be used only to check the resistance and or continuity of the motor windings This may be done as follows a b c For internal overload protected motor
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