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Installation, Operations and Maintenance Manual COMPAX MODULAR CHILLER MODELS: CMS/CMM 045-900 www.compaxchiller.com
Installation, Operations and Maintenance Manual
COMPAX MODULAR CHILLERMODELS: CMS/CMM 045-900
www.compaxchiller.com
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TABLE OF CONTACT
1. INFORMATION ............................................................................................................................. 3 MODEL NUMBER NOMENCLATURE .......................................................................................................... 3 ATTENTION NEEDED FOR THE FOLLOWING STATEMENTS ....................................................................... 4 INSPECTION ............................................................................................................................................... 5 HANDLING ................................................................................................................................................. 5 STORAGE ................................................................................................................................................... 5 WEIGHT ..................................................................................................................................................... 6 UNIT DIMENSIONS AND CONNECTIONS ................................................................................................... 7 UNIT CLEARANCES ..................................................................................................................................... 9
2. INSTALLATION ............................................................................................................................ 10 INSTALLATION GUIDELINES ..................................................................................................................... 10 ELECTRICAL SUPPLY WIRING ................................................................................................................... 14
3. OPERATIONS .............................................................................................................................. 15 COMPAX CONTROLLERS .......................................................................................................................... 15 LCD DISPLAY MODULE............................................................................................................................. 17 CONTROLLER INPUTS & OUTPUTS .......................................................................................................... 19 HEATING & COOLING OPERATION .......................................................................................................... 20 CONTROLLER ALARMS ............................................................................................................................ 21 REFRIGERANT CHARGE............................................................................................................................ 22 SYSTEM PREPARATION FOR STARTUP .................................................................................................... 23 VERIFY CORRECT COMPRESSOR OPERATION (3-PHASE) ........................................................................ 24
4. MAINTENANCE ........................................................................................................................... 26 ANNUAL MAINTENANCE ......................................................................................................................... 26
APPENDIX A ....................................................................................................................................... 28 ANNUAL MAINTENANCE LOG ................................................................................................................. 29 COMPAX START UP RECORD ................................................................................................................... 30 SAMPLE GENERIC WIRING DIAGRAM ..................................................................................................... 31
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For Technical Support: 1-647-210-3819 Notice: Before calling technical support, please have the model and serial number of the unit ready.
For Parts: For replacement parts, please call your local Compax Representative with the model and serial number of the unit.
REVISION HISTORY June 2017 Updated pictures of piping parts, page 12.
July 2017 Reformatted layout, nameplate ID, unit picture, unit clearances, new maintenance log, updated start up record, and updated generic wiring diagrams.
CGC Group of Companies, Inc. 150 Britannia Rd East, Unit 1 Mississauga, Ontario, Canada L4Z 2A4 COPYRIGHT This document or any portion thereof are property of the CGC Group of Companies, Inc., and may not be reproduced or used in any manner whatsoever without the express written permission. CGC Group of Companies, Inc. reserves the right to revise this document at any time without obligation to notify of such change.
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1. INFORMATION MODEL NUMBER NOMENCLATURE
UNIT NAMEPLATE This sticker identifies the unit’s model number and is located next to the control panel door. Refer to this information when ordering parts.
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ATTENTION NEEDED FOR THE FOLLOWING STATEMENTS
WARNING: Indicates a potentially hazardous situation which if not avoided could result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury. It also indicates unsafe practice that could cause product or property damage.
NOTICE: Notes intended to clarify unit installation, operation or maintenance information.
WARNING: Installation and servicing of this equipment can be hazardous due to system pressure and electrical components. ONLY trained and qualified personnel should install, repair, or service the equipment.
WARNING: The installation of Compax Modular Chillers and all associated components, parts and accessories that make up the installation shall be in accordance with the regulations of authorities having jurisdiction and MUST conform to all applicable codes. It is the responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations.
WARNING: Disconnect all electrical power including remote disconnect and discharge all energy storing devices before servicing. Follow proper lock out/tag out procedures to ensure that power cannot be turned “ON”. When working with live electrical components, have a qualified licensed electrician or other individual who has been trained in handling live electrical components perform these tasks. Failure to follow this warning could result in death or serious injury.
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INSPECTION Upon receipt of the equipment, the cargo should be checked against the bill of lading to verify that all equipment’s have been received.
NOTICE: The receiver is responsible to check for damages, visible or concealed on the cargo and report it to the carrier immediately. The carrier should make proper notation of the damages on the way bill and fill out a carrier inspection form.
HANDLING Care must be taken in handling the Compax modular chiller units and other accessories to ensure that this equipment does not sustain any damage. It is recommended that the units be transported individually if they are not already mounted onto a common base, and that a header be pre-installed on the units.
The protective shipping packaging should remain on the unit until it is ready for installation. The unit(s) must not be run during construction, and shall be sheltered from contaminants and debris.
STORAGE The Compax unit(s) must be stored in an upright position at all times. Failure to maintain the unit(s) in an upright position may result in permanent damage to the Compax device. Dropping the unit, or exposing it to shock or vibration may also result in permanent damage to the interior components and piping.
The unit shall be stored in a non-corrosive environment, sheltered from conditions of extreme temperature or humidity. Subjecting the unit to conditions of this nature may result in significantly reduced performance, reliability, and operational life.
The unit is intended for interior use only and should be stored indoors at all times to protect it from the elements.
If indoor storage is not possible, the equipment may be stored outdoors during the summer months only, if the following provisions are met:
The equipment must be placed on a dry surface, or raised off the ground in a manner which allows for air-circulation beneath the unit.
A waterproof tarp must be used to cover the equipment in a manner which provides protection from the elements.
Continuous ventilation to the units must be provided to help prevent moisture accumulation on the interior and exterior surfaces. Moisture buildup on, or within the unit’s insulation may result in microbial growth that can lead to odors and health-related problems.
The units must be stored in their original packaging.
The individual units shall not be stacked on top of one another.
If the unit was previously in use, ensure that all water in the system has been blown out, and that all pipe connections are plugged during storage.
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CAUTION: Sheet metal parts may have sharp edges. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing units.
WEIGHT Model Weight (lb)
CMS/CMM 045 250 CMS/CMM 060 265 CMS/CMM 075 280 CMS/CMM 085 300 CMS/CMM 110 535 CMS/CMM 135 535 CMS/CMM 150 535 CMS/CMM 175 545 CMS/CMM 210 950 CMS/CMM 230 970 CMS/CMM 260 1000 CMS/CMM 300 1025 CMS/CMM 350 1175 CMS/CMM 450 1200 CMS/CMM 600 1800 CMS/CMM 700 1900 CMS/CMM 900 2000
Electrical Box
Acoustically Insulated Panels
Flex Controller Display
Forklift Access
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UNIT DIMENSIONS AND CONNECTIONS
CMS/CMM 045 – 085
Reversing Non Reversing T1 OUT
Load (heating or cooling) Condenser/Heating T2 IN T3 OUT
Source/Sink Evaporator/cooling T4 IN
All Connections – 1” NPT coupling
CMS/CMM 110-175
Reversing Non Reversing T1 OUT
Load (heating or cooling) Condenser/Heating T2 IN T3 OUT
Source/Sink Evaporator/Cooling T4 IN
All Connections – 1.50” Groove Mechanical Fittings
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CMS/CMM 210-450
Reversing Non Reversing T1 OUT
Load (heating or cooling) Condenser/Heating T2 IN T3 OUT
Source/Sink Evaporator/cooling T4 In
All Connections – 2.0” Groove Mechanical Fittings
CMS/CMM 600-900
Reversing Non Reversing T1 OUT
Load (heating or cooling) Condenser/Heating T2 IN T3 OUT
Source/Sink Evaporator/cooling T4 In
All Connections – 3.0” Groove Mechanical Fittings
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UNIT CLEARANCES
Note: All four cabinet sizes require the same clearances along the front, back, and sides of the unit. Generic cabinet shown.
Allow Clearance for Pipe Rack for units 210-900.
40”
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2. INSTALLATION INSTALLATION GUIDELINES The installation of Compax modular chillers and all associated components, parts and accessories that make up the installation shall be in accordance with the regulations of authorities having jurisdiction and must conform to all applicable codes. It is the responsibility of the installing contractor to determine and comply with all applicable codes and regulations.
LOCATION
Locate the unit in an indoor area. The ambient temperature surrounding the unit must not be less than 45°F (7°C). Do not locate the unit in areas that are subject to freezing.
CAUTION: Do not install units in location subject to temperature or humidity extremes. These conditions can significantly reduce performance, reliability and service life of the unit.
PLACEMENT
Place the units in their final resting position and make certain that clearance requirements are met before proceeding with installation. Plumb the units with a level, and shim where necessary.
PIPING
Before making the final fluid connections, flush and clean the piping system in accordance with the instructions set forth in section – System Preparation for Startup, page 25. If applicable, please also follow the instructions of any fluid treatment specialist associated with the site location.
Install shut-off/balancing valves and couplings at each unit as specified below, to allow for easy removal and servicing.
Recommendation: Install a micron filter across the pumps on both loop systems.
WARNING: Piping must comply with all applicable codes.
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Figure 1 – Recommended Valves and Couplings
When installing the Compax units, the manufacturer recommends that each branch line off of the main fluid header be equipped with shutoff valves, check valves, and mechanical grooved connections as shown in Figure 1. Each branch header shall also have a drain valve installed at its base to enable system flushing at start-up and during routine servicing.
For more detail on unit types (reversing and non-reversing) and control points, see Figure 2 in section 3.0 – Operation, of this guide.
WATER PIPE CONNECTIONS (T1 - T4) Compax CMS/CMM machines sized 045 - 085 come equipped with 1” NPT (female) pipe connections.
Compax CMS/CMM machines sized 110 – 175 come equipped with 1.5” grooved mechanical connections. These machines are shipped with their water connection pipes (T1 – T4) pre-grooved, and include four pre-grooved extension pipes, as well as four grooved mechanical couplings (see pictures below).
Compax CMS/CMM machines sized 210 – 450 come equipped with 2.0” grooved mechanical connections. These machines are shipped with their water connection pipes (T1 – T4) pre-grooved, and include four pre-grooved extension pipes, as well as four grooved mechanical couplings.
Compax CMS/CMM machines sized 600 – 900 come equipped with 3.0” grooved mechanical connections. These machines are shipped with their water connection pipes (T1 – T4) pre-grooved, and include four pre-grooved extension pipes, as well as four grooved mechanical couplings.
NOTICE: Figure 1 must only be used as reference and is not meant for design purposes. For piping designations (T1, T2, T3, T4) and descriptions, see page 13.
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Figure 2 Copper Connecting Tube
Figure 3 Grooved Coupling
Figure 4 Copper Connecting Tube with Coupling Figure 5 Complete Assembly with Ball Valve
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COMPAX CONNECTION DETAILS
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ELECTRICAL SUPPLY WIRING
WARNING: To avoid possible injury or death due to electrical shock or contact with moving part, open the power supply disconnect switch and secure it in the “OFF” position for the complete duration of the installation. Follow proper lock out/ tag out procedures to ensure the power cannot be inadvertently energized.
CAUTION: Use only copper conductors for field installed electrical wiring. Unit terminals are not designed to accept other types of conductors.
All field-installed wiring, including the electrical ground, must comply with the National Electrical Code (henceforth referred to as NEC) as well as all other applicable local codes. In addition, all field wiring must conform to Class II temperature limitations described in the NEC.
The installing electrical contractor must make the field connections as described in the separate wiring and controls documents that is provided with the heat pump. A generic wiring diagram is provided at the end of this manual for reference.
COMPAX OPERATING VOLTAGE RANGES Specified Minimum Maximum
208/230/60/1 197 V 252 V 208/230/60/3 187 V 252 V
460/60/3 432 V 504 V 575/60/3 545 V 630 V
To avoid fouled machinery, extensive unit clean up, and voiding the warranty, do not operate units before ALL necessary system preparations (fluid loop cleaning, filling, and flushing, etc.) outlined in this document are made.
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3. OPERATIONS COMPAX CONTROLLERS
Each Compax unit will ship with a Microprocessor controller, which is compatible with Modbus RTU open communication protocol. Each controller is equipped with a LCD display device, as well as several push buttons that allow the user to navigate through the control menus in order to view, and modify system parameters such as temperature set points.
For detailed information on the Control Sequencing Panel that coordinates the operation of several Compax units, please refer to additional documentation accompanying the manual.
Figure 6 – Compax Flex Control Panel
CONTROL SEQUENCES
Figure 7 – Modes of Operation (Compax Reversing and Non-Reversing units)
CMS/CMM 045 – 175: Single compressor - single stage units.
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CMS/CMM 210 – 900: Dual compressor set - two stage units with two compressors in a dual refrigerant circuit.
For the compressor(s) to be activated, a series of conditions must first be met. Fault conditions can be viewed on the LCD display. The compressor is activated during a HEAT or COOL call only when the high pressure and low pressure switch conditions are met, and when a series of temperature conditions are satisfied. In addition, the FLOW switch input must be closed.
The temperature limits for return water T2 and T4, and supply water T1 and T3, are determined by the model type - CMS (non-reversing) or CMM (reversing) - as well as the temperature range selected (Normal, low source temperature). A set of the four possible operating cycles is listed below with required temperature conditions.
Low Source temperature conditions are displayed in parentheses. ‘Control Range’ indicates the minimum and maximum allowable set-points for the operating condition.
Cycle 1: Non-Reversing units (CMS) Cooling Temperature Limits
Source: T1 Max. 145°F T2 Max. 140°F
Load: T3 Min. 35°F (20°F) T4 Min. 40°F (25°F) Setpoint Range: 45° - 60°F, maintained at T4 (load return water temperature).
Cycle 2: Non-Reversing units (CMS) Heating Temperature Limits
Load: T1 Max. 145°F T2 Max. 140°F
Source: T3 Min. 35°F (20°F) T4 Min. 40°F (25°F) Setpoint Range: 80° - 135°F, maintained at T2 (load return water temperature).
Cycle 3: Reversing units (CMM) Cooling Temperature Limits
Load: T1 Min. 35°F T2 Min. 40°F Source: T3 Max. 145°F
T4 Max. 140°F Setpoint Range: 45° - 60°F, maintained at T2 (load return water temperature).
Cycle 4: Reversing units (CMM) Heating Temperature Limits
Load: T1 Max. 145°F T2 Max. 140°F
Source: T3 Min. 35°F (20°F) T4 Min. 40°F (25°F) Setpoint Range: 80° - 135°F, maintained at T2 (load return water temperature).
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LCD DISPLAY MODULE Each Compax unit is equipped with an LCD display module that provides information on the unit’s operation. Each display module has four pushbuttons that allow the user to scroll through the various menu screens and make adjustments where applicable.
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MENU SCREENS Menu Screen 1: This menu screen shows both the current alarm status, as well as the most previous alarm.
The UP, DOWN, and ENTER buttons have no function on this screen. Pressing the MENU button will cause the display to scroll to menu screen 2.
Menu Screen 2: This menu screen shows the current temperature readings (F). TH1 = Load Leaving Fluid (Condenser on CMS) TH2 = Load Entering Fluid (Condenser on CMS) TH3 = Source Leaving Fluid (Evaporator on CMS) TH4 = Source Entering Fluid (Evaporator on CMS) TH5 = Discharge Gas, Circuit 1 TH6 = Discharge Gas, Circuit 2
The UP, DOWN, and ENTER buttons have no function on this screen. Pressing the MENU button will cause the display to scroll to menu screen 3.
Menu Screen 3: This menu screen shows the current status of the digital inputs (1 = closed). HEAT = Heat Call COOL = Cool Call FLOW = Flow Switch AUX = Aux Alarm Contact (Used for electronic expansion valves on CMM units) HP1 = High Pressure Switch, Circuit 1 HP2 = High Pressure Switch, Circuit 2 LP1 = Low Pressure Switch, Circuit 1 LP2 = Low Pressure Switch, Circuit 2
The UP, DOWN, and ENTER buttons have no function on this screen. Pressing the MENU button will cause the display to scroll to menu screen 4.
Menu Screen 4: This menu screen shows the current heating and cooling setpoints (°F).
Pressing the DOWN button will decrease the heating or cooling setpoint. Pressing the ENTER button will change the selected setpoint between heating a cooling. Pressing the MENU button will cause the display to scroll to menu screen 5.
Menu Screen 5: This menu screen shows the current network address assigned to the unit.
Pressing the UP button will increase the address number. Pressing the DOWN button will decrease the address number. Pressing the MENU button will cause the display to scroll to menu screen 6. The ENTER button has no function.
Menu Screen 6: This menu screen shows the current operating state of the unit. In Master mode, the unit will look to it’s digital inputs for heat/cool calls. In Slave mode, the heat and cool calls will come through the RS485 network port.
Pressing the UP button will set the unit to Master mode. Pressing the DOWN button will set the unit to Slave mode. Pressing the MENU button will cause the display to scroll to menu screen 1. The ENTER button has no function.
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CONTROLLER INPUTS & OUTPUTS
ANALOG INPUTS Each analog input (TH1-TH6) is connected to a 10kΩ thermistor, which is used to take temperature measurements (10°F – 254°F).
T1 - Load Supply Temperature (Condenser on CMS) T2 - Load Return Temperature (Condenser on CMS) T3 - Source Supply Temperature (Evaporator on CMS) T4 - Source Return Temperature (Evaporator on CMS) T5 - Compressor discharge gas temperature – refrigeration circuit 1. T6 - Compressor discharge gas temperature – refrigeration circuit 2.
DIGITAL INPUTS Each digital input (DI1-DI8) is configured to monitor the open/closed status of an external switch. When a particular switch is closed, the yellow LED below the corresponding input is illuminated. Screen 3 of the LCD menu also displays the current status of each digital input.
DI1 - Heat Call DI2 - Cool Call DI3 - Flow Status DI4 - Aux Alarm Contact (Used for electronic expansion valve on CMM units) DI5 - High Pressure Switch 1 DI6 - High Pressure Switch 2 DI7 - Low Pressure Switch 1 DI8 - Low Pressure Switch 2
ANALOG OUTPUTS Each analog output (AN1-AN4) is capable of providing a 0-10VDC output signal.
DIGITAL OUTPUTS Each digital output relay (K1-K8) provides a dry-contact; alternatively, each output can be configured to provide 24VAC by installing a jumper shunt across the associated J1-J8 pins. When a particular output is energized, the red LED above the corresponding output is illuminated.
K1 - Compressor 1 K2 - Compressor 2 K3 - Source Valve K4 - Load Valve K5 - N/A K6 - N/A K7 - System Lockout Relay K8 – N/A
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HEATING & COOLING OPERATION HEAT CALL
When the Compax unit is running in Master mode, closing the heat call input (DI1) will enable heating operation. In Slave mode, the heat call will come through the RS485 network. Upon receiving a heat call, both the load and source (evaporator and condenser on CMS) valves (K3, K4) will immediately be energized and will remain this way until the heat call is removed, and the compressors have been deactivated.
If the load entering temperature (T2) drops below the heat set point by 2°F or more, compressor 1 (K2) will be activated. Based on an internal PID controller, compressor 2 (K1) will be activated.
Compressor activation will be prevented if the load and source (evaporator or condenser valves) valves (K3, K4) have been open for less than two minutes.
If at any point the heat call input (DI1) is opened, both K1 and K2 will be deactivated, and the valves will be de-energized (K3, K4).Note: the compressor minimum run times must first expire before these actions are taken.
COOL CALL When the Compax unit is running in Master mode, closing the cool call input (DI2) will enable cooling operation. In Slave mode, the cool call will come through the RS485 network. Upon receiving a cool call, both the load and source (evaporator or condenser valves) valves (K3, K4) will immediately be energized and will remain this way until the cool call is removed, and the compressors have been deactivated.
If the source entering temperature (T4)) rises above the cool set point by 2°F or more, compressor 1 (K2) will be activated. Based on an internal PID controller, compressor 2 (K1) will be activated.
Compressor activation will be prevented if the load and source valves (K3, K4) have been open for less than two minutes.
If at any point the cool call input (DI2) is opened, both K1 and K2 will be deactivated, and the valves will be de-energized (K3, K4). Note: the compressor minimum run times must first expire before these actions are taken.
MINIMUM COMPRESSOR RUN-TIMES/STOP-TIMES. Each compressor will run for a minimum of 30 seconds before it is allowed to turn off. In the event that an alarm is tripped, the compressor(s) will be turned off immediately.
Each compressor will remain off for a minimum of 5 minutes between successive starts.
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CONTROLLER ALARMS
HIGH LOAD SUPPLY TEMPERATURE If the load supply (or condenser) temperature (T1) exceeds 140°F, an alarm will be activated and both compressors will immediately be turned off. Normal operation will resume only when the temperature falls below this value, and after the compressors’ minimum off time of 5 minutes has expired.
LOW LOAD SUPPLY TEMPERATURE If the load supply temperature (T1) falls below 35°F, an alarm will be activated and both compressors will immediately be turned off. Normal operation will resume only when the temperature rises above this value, and after the compressors’ minimum off time of 5 minutes has expired.
HIGH SOURCE/SINK SUPPLY TEMPERATURE If the source supply temperature (T3) exceeds 140°F, an alarm will be activated and both compressors will immediately be turned off. Normal operation will resume only when the temperature falls below this value, and after the compressors’ minimum off time of 5 minutes has expired.
LOW SOURCE SUPPLY TEMPERATURE If the source supply temperature (T3) falls below 35°F (20°F for low source temperature option), an alarm will be activated and both compressors will immediately be turned off. Normal operation will resume only when the temperature rises above this value, and after the compressors’ minimum off time of 5 minutes has expired.
HIGH COMPRESSOR DISCHARGE GAS TEMPERATURE If the compressor discharge gas temperature (T5) or (T6) exceeds 250°F, an alarm will be activated and their specific compressor will immediately be turned off. Normal operation will resume only when the temperature falls below this value, and after the compressors’ minimum off time of 5 minutes has expired.
LOW FLOW In the event of low fluid flow, the flow status input (DI3) will open, an alarm will be activated and both compressors will immediately be turned off. Normal operation will resume only when the flow status input (DI3) closes, and after the compressors’ minimum off time of 5 minutes has expired.
AUX (EXV) ALARM If the EXV alarm contact input (DI4) opens, an alarm will be activated and both compressors will immediately be turned off. Normal operation will resume only when the EXV alarm input (DI4) closes, and after the compressors’ minimum off time of 5 minutes has expired.
LOW REFRIGERANT PRESSURE If the compressor has been running for 30 seconds or longer, and a low pressure switch input (DI7 or DI8) is opened, an alarm will be activated and the respective compressor will immediately be turned off. Normal operation will resume only when the low pressure input (DI7 or DI8) is closed, and after the compressors’ minimum off time of 5 minutes has expired.
If at any point a low pressure switch input (DI7 or DI8) is opened while the compressor is off, an alarm will immediately be activated and the compressor will be prevented from coming on until the appropriate low pressure switch input (DI7 or DI8) is closed.
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If there are 3 low pressure alarms activated by either of the low pressure switches (DI7 or DI8), an alarm will be activated, the respective compressor will immediately be turned off, and the system will go into a lockout condition causing the system lockout relay (K7) to energize. In order to clear the lockout condition, power must be cycled to the controller.
If a low pressure switch input (DI7 or DI8) is open for 10 minutes or longer, an alarm will be activated, and the respective compressor will immediately be turned off and the system will go into a lockout condition. In order to clear the lockout condition, power must be cycled to the controller.
HIGH REFRIGERANT PRESSURE If a high pressure switch input (DI5 or DI6) is opened, an alarm will be activated; the respective compressor will immediately be turned off. Normal operation will resume only when the high pressure input (DI5 or DI6) is closed, and after the compressors’ minimum off time of 5 minutes has expired.
If there are 3 high pressure alarms activated by either of the high pressure switches (DI5 or DI6), an alarm will be activated, and the respective compressor will immediately be turned off and the system will go into a lockout condition. In order to clear the lockout condition, power must be cycled to the controller.
If a high pressure switch input (DI5 or DI6) is open for 10 minutes or longer, an alarm will be activated, and the respective compressor will immediately be turned off and the system will go into a lockout condition. In order to clear the lockout condition, power must be cycled to the controller
REFRIGERANT CHARGE Model Charge limit (+/- 5%)
CMM/S 045 50 oz CMM/S 060 60 oz CMM/S 075 60 oz CMM/S 085 70 z CMM/S 110 120 oz CMM/S 135 135 oz CMM/S 150 140 oz CMM/S 175 160 oz CMM/S 210 120 oz (x2 circuits) CMM/S 230 135 oz (x2 circuits) CMM/S 260 135 oz (x2 circuits) CMM/S 300 155 oz (x2 circuits) CMM/S 350 170 oz (x2 circuits) CMM/S 400 185 oz (x2 circuits) CMM/S 450 200 oz (x2 circuits) CMM/S 600 280 oz (x2 circuits) CMM/S 700 320 oz (x2 circuits) CMM/S 900 360 oz (x2 circuits)
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SYSTEM PREPARATION FOR STARTUP
SYSTEM CLEANING AND FLUSHING Proper system cleaning and flushing is the most important aspect of the start-up procedure for water loop installations. Verify that the system has been flushed properly (refer to steps below) before making final piping connections and starting-up the units. Water used in the system must be clear city water or a glycol solution with no visible dirt, piping slag, or chemical cleaning agents.
Cleaning and flushing the unit is the single most important step to help ensure proper startup and efficient operation of the system. Follow the instructions below:
1. Verify that the electrical power to the unit is disconnected and that the pumps are turned OFF. Follow proper lock out/ tag out procedures to ensure power cannot be inadvertently energized.
2. Fill the system with water and drain to remove any debris in the system piping. 3. Again, fill the system with water while leaving the air vents open. Bleed all air from the system
but do not allow the system to overflow. Check the system for leaks and make any required repairs. Adjust the expansion tank (if applicable) to the appropriate settings.
4. With strainers in place, start the pumps. Systematically check each vent to ensure that all of the air is bled from the system.
5. Verify that make-up water is available and adjusted to properly replace any space remaining when air is evacuated.
6. Open the drain at the lowest point in the system. Verify that the make-up water replacement rate equals the rate of bleed. Continue to bleed the system until the water appears clean, or for at least three hours - whichever is longer.
7. Completely drain the system. 8. Refill the system with clean water or a glycol solution as required. Since water varies for each
locality, contact a local water treatment company for the correct cleaning chemicals to use in your area.
9. Circulate the solution for a minimum of 24 hours. At the end of this period, shut off the circulating pump(s) and again drain the system. Repeat system cleaning and circulate for a minimum of one week.
10. Test the system pH with litmus paper. The system water should be slightly alkaline (pH 7.5 to 8.5). Add chemicals as appropriate to maintain acidity levels. When the system is cleaned, flushed, refilled and bled, check the main system panels, safety cut-outs, and alarms. Set controls to properly maintain loop temperature.
SYSTEM FLUID: Ensure that the system fluid temperature is within an acceptable range to facilitate start-up (when conducting this check, also verify the proper heating and cooling set points).
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VOLTAGE CHECK: Ensure that voltage is within the utilization range (see “Compax Operating Voltage Ranges” in Installation section, page 14, of this guide).
SYSTEM WATER PH: Verify that system water exhibits an approximately neutral balance (i.e., a pH of 7.5 to 8.5).
FREEZE PROTECTION FROM WATER SYSTEM: Ensure that freeze protection is provided for the fluid loop system. Inadequate freeze protection can lead to permanent damage and expensive repairs.
REMOVE AIR FROM SYSTEM FLUID LOOP: Air in the system impairs unit operation and can cause erosion in the system piping.
CAUTION: A potentially damaging situation may occur during construction where the system fluid loop is drained after being cleaned, flushed and tested. Compax units will not completely drain and may hold fluid in the condenser and/or evaporator coil. Extensive damage may result to internal components if freeze prevention measures are not implemented (i.e. sufficient glycol).
NOTICE: In the following part of the procedure, it will be necessary to access the areas around the electrical wiring and the circuit board. Do not adjust or remove any board connections or wiring connections to other components without first powering down the unit. Disconnects are usually within reach of the unit. Exercise caution at all times.
VERIFY CORRECT COMPRESSOR OPERATION (3-PHASE) With the power OFF, remove the front panel and the electrical panel cover. Remove any thermostat block and turn power ON to the unit with the electrical disconnect.
Ensure that the correct standby protocol is in place - the following board lights will come on in standby: Power, HP, LP, and Alarm.
Inspect the fan section to ensure that it is clear of any debris and that the fan rotates freely. Compax Chiller units come equipped with a 3-phase fan and compressor, which are wired in-phase with each other. Although internal connections to the fan and compressor are made at the factory, variances in power supply in the field will require that the compressor be tested for correct operation. The fans used are not rotation sensitive. They are backward inclined and always turn correctly.
The following checks will verify correct operation:
• The discharge from the compressor (top most line) will become hot almost immediately. • There will be a cloudy refrigerant surge visible in the sight glass. • The compressor noise will have a distinctive whirring sound and not be overly loud. • There will be no run-on, or idling-on of the compressor motor when you release the manual
button of the contactor.
If the above signs are not present, then power OFF the unit using the disconnect, and switch around two of the three wires at the incoming power to the unit. Power ON the unit and perform the check again.
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If the operation is correct, power OFF the unit and replace the electrical panel cover, and the front panel of the unit.
START UP: The large Compax operating range, as shown on page 16, affects the refrigerant charge listed on page 24. Verify the charge when operating the Compax unit at the application operating conditions. A clear sight glass and a sub cooling of 5 to 8°F are the best indicator of optimum charge. If the conditions at the time of startup are vastly different from the application operating conditions, a future check of the charge may be necessary.
Follow the Startup Check List found in the Appendix to test the Compax operating conditions in heating and cooling, as applicable. Report any anomalies and submit a copy of the completed checklist to the local representative or the Manufacturer to register the warranty.
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4. MAINTENANCE ANNUAL MAINTENANCE The following maintenance checks shall be carried out on an annual basis, and remedial action performed when applicable:
Step 1: Tighten all electrical connections.
Step 2: Inspect all wires for damage that may include, but is not limited to, discoloration, breakage or wearing in the insulation, charring, and melting. Also, all wires should be checked to ensure that they are properly tied in place and that they are not hanging loose and coming into contact with copper pipes. Vibration from copper pipes can cause the insulation on the wires to wear down which could result in electrical arcing.
Step 3: Verify the supply voltage is in accordance with the electrical labeling on the unit.
Step 4: Check all temperature sensors for proper readings annually or as required
Step 5: Check safety switches annually
Step 6: Verify proper operation of the crankcase heater, if equipped, Figure 8, by carefully checking the temperature of the heater. The compressor must be off for the heater to work properly and for checking.
Step 7: Ensure that the crankcase heater is tightly fastened to the base of the compressor and does not move or has not slipped down. Loose or improperly positioned heaters may fail prematurely.
Figure 8: Crankcase Heater
CAUTION: Do not touch the crankcase heater as injury could result.
If the crankcase heater is hot then it is operating properly. If the crankcase heater is at room temperature while the unit is powered and the compressor is off, check the wiring and auxiliary contactor connections. DO NOT operate the compressor until the crankcase heater has been inspected and is operating properly.
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NOTICE: If the unit has been unpowered for more than a day or the heater was not working properly, restore heater operation and power the unit for at least 24 hours before initiating a cooling or heating call.
Step 8: Inspect the oil sight glass, if equipped, located at the bottom of each compressor in the unit. The oil level should be between a quarter and half way up the sight as shown in Figure 9. If the oil level is low, below the bottom of the sight glass you may need to add oil. If it appears to be higher than the sight glass, as seen in Figure 10, allow the crankcase heater to warm up the compressor until the oil level is half way up the sight glass. DO NOT operate the compressor when the sight glass is either full or empty.
Figure 9: Proper Oil Level
Figure 10: Improper Oil Level
Step 9: Once the crankcase heater is operating properly and the compressor oil levels are half way up the sight glass, place a set of refrigerant gauges on the high and low pressure access ports. Measure the superheat and sub-cool temperatures to ensure that they are within design specifications. Also, measure the compressor discharge pipe temperature as close to the compressor discharge connection.
Step 10: Use the Annual Maintenance Check List, in Appendix A, to fill in the record information.
CAUTION: Do not restart units without inspection and remedy of faulting condition. Equipment damage may occur.
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APPENDIX A
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ANNUAL MAINTENANCE LOG This maintenance log must be kept with the unit for annual recording.
Checks Check if completed
Remedial action? Name and Date
Tighten all electrical connections Inspect all wires
Verify the supply voltage Check all temperature sensors for proper readings
Check safety switches
Verify proper operation of the crankcase heater Inspect oil glass
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COMPAX START UP RECORD
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SAMPLE GENERIC WIRING DIAGRAM
CGC Group of Companies, Inc.www.cgc-group.com
1-150 Britannia Rd East, Mississauga, Ontario, Canada L4Z 2A41-888-220-5551
