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Form No: MM0463A Products that perform...By people who care R 134a AFHX Series INSTALLATION, OPERATION & MAINTENANCE MANUAL INSTALLATION, OPERATION & MAINTENANCE MANUAL MODEL: AIR COOLED FLOODED CHILLERS SCREW COMPRESSOR 60Hz

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  • Form No: MM0463A

    Products that perform...By people who care

    R134aAFHX Series

    INSTALLATION,OPERATION &MAINTENANCE

    MANUAL

    INSTALLATION,OPERATION &MAINTENANCE

    MANUAL

    MODEL:

    AIRCOOLED

    FLOODEDCHILLERS

    SCREWCOMPRESSOR

    60Hz

  • - 2 -

    AFHX Standard R134a 60Hz IOM Manual

    TABLE OF CONTENTS DESCRIPTION PAGE NO DESCRIPTION PAGE NO 1.0 INTRODUCTION 1.1 Product Identification. ......................................................... 3 2.0 INSTALLATION 2.1 General................................................................................... 6

    2.1.1 Application Precautions ............................................ 6 2.1.2 Chilled Water Flow ................................................... 6

    2.2 Inspection. ............................................................................. 6 2.3 Rigging ................................................................................... 6

    2.3.1 General ...................................................................... 6 2.3.2 Rigging & Moving .................................................... 6

    2.4 Space Requirements and Clearance ................................... 8 2.4.1 General ...................................................................... 8 2.4.2 AFHX ........................................................................ 8

    2.5 Foundation .......................................................................... 13 2.6 Vibration Isolation .............................................................. 13 2.7 Piping connections. ............................................................. 13 2.8 Electrical Wiring. ............................................................... 13 2.9 Controls ............................................................................... 16

    2.9.1 Connections ............................................................. 16 2.9.2 Settings .................................................................... 16

    2.10 Request For Start-Up Representative .............................. 16 3.0 OPERATION 3.1 General................................................................................. 17 3.2 Unit piping ........................................................................... 17 3.3 System Water Flow Rate ................................................... 17 3.4 Unit Operation Including Overnight Shut Down and

    Morning Restart ................................................................. 17 3.4.1 Air Cooled Package Chiller Start-Up ..................... 17

    3.5 System Start Up .................................................................. 17 3.6 Shut-Down (Overnight Or Weekend) .............................. 22 3.7 Seasonal Shut-Down Procedure ........................................ 22 3.8 Seasonal Start-up Procedure ............................................. 22 3.9 Safety Relief Valves ............................................................ 22 3.10 Refrigeration Cycle- Multiple Compressor AFHX ......... 22 3.11 Fan Cycling ......................................................................... 23 3.12 Liquid Injection .................................................................. 23 3.13 Hydraulic Capacity Control System ................................. 23

    4.0 ELECTRICAL 4.1 Electrical Data..................................................................... 24 4.2 Wiring Diagram .................................................................. 24 4.3 Typical Operation ............................................................... 24 4.4 Vision 2020i Controller and Terminal ............................. 29

    4.4.1 Operator Keypad ....................................................... 29 4.4.1.1 The fifteen polycarbonate buttons ............... 29

    4.4.2 Status Reading ........................................................... 29 4.4.2.1 Input status key ............................................ 29 4.4.2.2 Output status key ......................................... 30 4.4.2.3 Compressor status key ................................. 30 4.4.2.4 Setpoint key ................................................. 31 4.4.2.5 Clock key ..................................................... 31 4.4.2.6 Alarm history key ........................................ 31

    4.4.3 Authorization ............................................................. 32 4.4.3.1 Authorization key ........................................ 32

    4.4.4 Advanced user key and menu ................................... 32 4.4.4.1 User key ....................................................... 32

    4.4.5 Technician Key and Menu ...................................... 32 4.4.5.1 Technician status key .............................. 32

    4.4.5.2 Technician status key- main menu ......... 32 4.4.5.3 Compressor FLA calibration .................. 33 4.4.5.4 To perform sensor calibration ................. 33 4.4.5.5 Manual control ........................................ 33 4.4.5.6 Compressor control ................................. 34 4.4.5.7 Sensors Override ..................................... 35

    4.4.6 Control Functions ................................................... 35 4.4.6.1 Chilled water pump interlock and flow

    switch ..................................................... 35 4.4.6.2 Customer control interlock ..................... 35 4.4.6.3 Anti-recycle timer ................................... 36 4.4.6.4 On delay timer ......................................... 36 4.4.6.5 Load control ............................................ 36 4.4.6.6 Ramp control ........................................... 36 4.4.6.7 Staging control ........................................ 36 4.4.6.8 Modmotor setback control ...................... 36 4.4.6.9 Sump Heater Control .............................. 36 4.4.6.10 Suction/ Discharge Pressure Differential

    control ..................................................... 37 4.4.6.11 Evaporator Freeze Shutoff ...................... 37 4.4.6.12 Low pressure cut-off ............................... 37 4.4.6.13 High pressure cut-off .............................. 37 4.4.6.14 Optical oil level sensor ........................... 37 4.4.6.15 High oil temperature thermostat ............. 37 4.4.6.16 Overload protector .................................. 37 4.4.6.17 Phase control relay .................................. 37 4.4.6.18 Sensor alarm ............................................ 38 4.4.6.19 No-stop alarm .......................................... 38 4.4.6.20 Low differential pressure alarm .............. 38

    4.5 Condenser Fan Control Logic ........................................... 38 4.5.1 Air-Cooled Condenser Control Setpoints ............... 38 4.5.2 Increasing Condenser Pressure ............................... 39 4.5.3 Decreasing Condenser Pressure .............................. 39

    4.5.3.1 Adaptive Control Logic .......................... 39 4.6 Master/ Slave Control Sequence ....................................... 39

    4.6.1 Sensor Principle of Operation VIA DBLAN Communication Bus ............................................... 40

    4.6.2 Sequence of Operation ............................................ 41 4.7 Vision 2020i Local Area Network (DBLAN) ................... 41 4.8 Network Connection Diagram .......................................... 42 4.9 Hardware Setting ............................................................... 42

    4.9.1 Addressing the Vision 2020i Controller ................. 42 4.9.2 Addressing the Vision 2020i DBG1 Terminal ....... 43 4.9.3 Vision 2020i Controller LED Status ...................... 44

    5.0 MAINTENANCE 5.1 General ................................................................................ 45 5.2 Periodic Inspection ............................................................. 45 5.3 Monthly Inspection ............................................................. 45 5.4 Vessel Maintenance ............................................................ 45

    5.4.1 General .................................................................... 45 5.4.2 Water Side Cleaning Of Evaporator ....................... 45

    5.5 Air Cooled Condenser Cleaning ....................................... 45 5.6 Electrical Malfunction ....................................................... 47 5.7 Refrigerant Charge ............................................................ 47

    5.7.1 General .................................................................... 47 5.7.2 Air Cooled Packages ............................................... 47

    5.8 Oil Charge ........................................................................... 47 5.9 Troubleshooting .................................................................. 48 5.10 Sample Log Sheet ............................................................... 49

    SCHEMATIC DIAGRAM, GRAPH AND TABLE

    DESCRIPTION PAGE NO Figure 2.3.2 Typical Rigging ......................................................... 7 Figure 2.4.1 Typical Space Requirements ....................................... 8 Figure 2.4.2 Dimensional Data ...................................................... 10 Figure 2.5A Isolator Location ....................................................... 14 Figure 2.5B Isolator Point Load Data ........................................... 14 Figure 3.2 Typical Piping Schematic ......................................... 18 Figure 3.3 Evaporator Water Pressure Drop .............................. 21

    DESCRIPTION PAGE NO Figure 4.2 Typical Wiring Schematic ........................................ 25 Figure 4.3.1 Vision 2020i keypad ................................................ 29

    Table 1.1 Physical Specifications ....