MOTIVAIR COOLING SOLUTIONS

85 Woodridge Dr. Amherst, NY 14228 – Phone# 716-691-9222 – Fax# 716-691-9229 www.motivaircorp.com

AIR COOLED CHILLERS

MODELS: MPCA0005 – MPCA0150

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

This chiller has been factory run tested to the specified water pressure

*****DO NOT OVER PRESSURIZE CHILLER WHEN LEAK CHECKING PIPING OR FILLING HYDRAULIC SYSTEM*****

*Isolate chiller from piping if higher test pressure is required for leak checking*

*Chiller damaged caused by over pressurization is NOT covered by warranty*

INDEX – TABLE OF CONTENTS

PAGE

• LEGAL PROVISIONS & SAFETY INSTRUCTIONS 1

• TRANSPORTING & SITE HANDLING 2-3

• CHILLER INSTALLATION 4-13

• PIPING INSTALLATION 14-18

• MAIN ELECTRICAL INSTALLATION 19

• WATER/GLYCOL INSTRUCTIONS 20

• CHILLER SEQUENCE OF OPERATION 21

• MPCA0005 – MPCA0150 PROGRAMMING AND ALARM CODES 22-25

• MPCA0005 – MPCA0150 STANDARD CONTROLLER LAYOUT 26

• COMMISIONING AND STARTUP INSTRUCTIONS 27-28

• TROUBLESHOOTING 29-32

• PREVENTIVE MAINTENANCE 33-35

• CHILLER REPAIR INFORMATION 36-37

• CLEANING THE PLATE EXCHANGER (EVAPORATOR) 38

• REFRIGERANT INFORMATION 39

• TERMS AND CONDITIONS OF SALE 40

PROVISIONS AND SAFETY

Operator's Responsibility

This chiller MUST be installed, maintained and operated by a person(s) qualified for this equipment. This chiller contains refrigeration, water circulation and electrical components. The person(s) most suited for this equipment is a qualified licenced refrigeration technician. Intervention by unauthorized or unqualified parties may void the warranty.

WARNING Operation of these systems involves potentially Iethal dangers (high voltage and high pressures). Therefore, all safety precautions and warnings described in this manual must be precisely observed. Otherwise, severe or fatal injury may be caused.

SAFETY INSTRUCTIONS

The installation, start-up and maintenance of the chillers are dangerous, Due to: • High pressures is generated in the equipment

• Electrical parts are energized

• The equipment contains hot pipes (Refrigeration system)

• Rotating parts (fans and or pumps) can cause injury the chillers themselves may be installed in a dangerous position (roof, high built frame etc.)

For these reasons, the chiller must be installed and connected to the electricity/water installations by qualified companies only. Startup and maintenance must be conducted by a qualified refrigeration company only. Simple maintenance operations on the equipment without opening them may be performed by the operator. All other work must be performed by specially qualified personnel.

MPCA0005 - MPCA0150 MANUAL

TRANSPORT AND HANDLING

LIFTING - UNLOADING – POSITIONING

Notices (symbols) –on device packing must be observed. Check the center of gravity of the chiller. Use appropriate unloading equipment. Remove protective film from chiller and cardboard. behind condenser before use.

MANUFACTURER'S NOTE The machine may be damaged by: Dropping or tipping it on the ground. Pulling the chiller by cords, straps, etc. Lifting the chiller by its piping system. Excessive shaking by cranes. Damage of this type is not covered by warranty.

ECA ECA

MAX 45°

ECA

EC

A

MPCA0005 - MPCA0150 MANUAL

LIFTING - UNLOADING – POSITIONING Notices (symbols) –on device packing must be observed. Check the center of gravity of the chiller. Use appropriate unloading equipment. Remove protective film from metal panels before use.

MANUFACTURER'S NOTE The machine may be damaged by: Dropping it or tipping it on the ground. Pulling the chiller by cords, straps etc…. Lifting the chiller by its piping system. Excessive shaking by crane. Damage of this type is not covered by warranty.

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IInnssttaalllliinngg wwiitthh aa ffoorrkk lliifftt ttrruucckk Use the forks to lift with: they must be as long as the chiller. Use of fork extensions if required, OR SERIOUS DAMAGE MAY RESULT.

MPCA0005 - MPCA0150 MANUAL

CHILLER INSTALLATION Foundation Site Installation Installation Structure-borne noise Vibrations Clearances

All chillers must be mounted on a solid, horizontal surface, suitable for the weight of the chiller.* Note the chiller weight is incresed by filling with glycol/water mixture. Observe all local regulations. Must be dry and protected against freezing. The room temperature must not be colder than 410F. The system must be installed horizontally. The components are not suitable for exterior installation, without factory modification and approval. Consult Motivair if chiller will be installed outdoors Compliance with the following basic rules for the erection of devices with radial fans wiIl ensure problem-free operation and the rated refrigeration capacity. Basic rules: 1. The condenser air is blown out vertically or horizontally. 2. Do not install the device close to heat sources. Heated air intake must be

avoided. 3. The condenser fans are rated for ZERO external static pressure. The fan

do not have the capacity to push air through ducting, which means that NO DUCTS OR MUFFLERS may be used on the inlet ot outlet of the chillers.

4. No air short-circuit is permitted, i.e. the heated discharge air from the condenser fans must never be drawn back into the condenser inlet. This will occur if the chiller is too close to a wall, or a low ceiling or other obstructions.

5. In the case of shaft or trench mounting, contact the manufacturer for advice on the installation site.

It is possible that noise or vibration may be transmitted through the ground, or building structure. If this occurs, it may be necessary to install a vibration elimination device. The construction specifications of the customer/engineering contractor regarding structure transmitted noise or vibration must be observed. May be transmitted through the chilled water piping. This can be avoided by the use of flexible piping connections. Must be maintained for servicing and ventilation purposes. All removable side panels must be available service. A minimum of 3 feet on all sides is required. Consult Motivair for irregular space requirements.

INSTALLATION GUIDE

Location:

Locate the unit to provide proper airflow to the condenser (see Figure 1 page 2)

Due to the placement of the condenser coils on the MPCA0005-0150 chillers, it is desirable to orient the unit so that prevailing winds blow parallel to the unit length, thus minimizing the wind effect on condensing pressure performance. If low ambient temperature operation is expected, it is recommended that optional fan VFD system be factory installed.

Using less clearance than shown in “Addendum A” can cause discharge air recirculation to the condenser and could have a significant negative effect on unit performance.

See Restricted Airflow beginning on page 3 for further information. For pad-mounted units, it is recommended that the unit be raised a few inches with suitable supports, located at least under the mounting locations, to allow water to drain from under the unit to facilitate cleaning under it.

Service Access:

The main control box contains either the microprocessor or PLC (Programmable Logic Controller) for optimum chiller control. The solid state compressor starter, fan control and other power equipment are located in the main control box. Condenser fan VFD’s and overloads are either located in an independent box on the side of the chiller or in the main cabinet. The side clearance required for airflow provides sufficient service clearance.

_____________________________________________________________________________

CAUTION

Disconnect all power to the chiller while servicing condenser fan motors or compressors. Failure to do so can cause bodily injury or death.

______________________________________________________________________________

Do not obstruct access to the sides or ends of the chiller with piping or conduit. These areas must be open for service access. Do not obstruct any access to the control panel(s) with field mounted disconnect switches. Make sure that the power conduit to control panel(s) does not restrict access to removable panels.

Clearance Requirements:

Figure 1

Notes:

1. Minimum side clearance between units is 6 feet (1.8 meters) with no perimeter obstructions within 10 feet of the units.

2. Unit must not be installed in a pit or enclosure that is deeper or taller than the height of the unit unless extra clearance is provided per note 4.

3. Minimum clearance on each side is 8 feet (2.4 meters) when installed in a pit no deeper than the unit height.

4. Minimum side clearance to a side wall or building taller than the unit height is 7 (2.1 meters) feet provided no solid wall above 7 (2.1 meters) feet is closer than 12 (3.7 meters) feet to the opposite side of the unit.

5. Do not mount electrical conduits where they can block service access to compressor controls, refrigerant driers or valves.

6. There must be no obstruction of the fan discharge. 7. Field installed switches must not interfere with service access or airflow. 8. MPCA chillers use axial fans and are NOT suitable for ducted applications. 9. See the following pages if the airflow clearance cannot be met.

SEE NOTES 2&4

PERTAINING TO WALL

HEIGHT AT UNIT SIDES

AIR FLOW NO OBSTRUCTIONS

ALLOWED ABOVE UNIT

AT ANY HEIGHT

Restricted Airflow:

General

The clearances required for design operation of MPCA air-cooled condensers are described in the previous section. Occasionally, these clearances cannot be maintained due to site restrictions such as units being too close together or a fence or wall restricting airflow, or both.

The Motivair MPCA chillers have several features that can mitigate the problems attributable to restricted airflow.

• The single side of the condenser formation allows inlet air for the coil(s) to come in from that side and allows for smaller distances between the opposite side and encroaching obstructions to allow for maximum air flow to the condenser side. Facing the chiller control cabinet, the right-side of the unit is generally where the condenser(s) are located. NOTE: This is not exclusive as Motivair reserves the right to change chiller design without notice.

• The VFD option allows for optimum air flow at multiple year round conditions. This is best utilized when units are placed parallel to prevailing winds.

Figure 2

The following sections discuss the most common situations of condenser air restriction and give capacity adjustment factors for each.

CAUTION

The unit capacity adjustment charts in this engineering bulletin serve only as a guide, and DO NOT take into account prevailing site conditions.

_____________________________________________________________________________________

Case 1, Building or Wall on One side of One Unit:

The presence of a screening wall or the wall of a building, in close proximity to an air-cooled chiller is common in both rooftop and ground level applications. Hot air recirculation on the coils adjoining the wall increases compressor discharge pressure, decreasing capacity and increasing power consumption.

When close to a wall, it is desirable to place chillers on the north or east side of them (to minimize solar effect). It is also desirable to have prevailing winds blowing parallel to the unit’s long axis. The worst scenario is having wind blowing hot discharge air into the wall.

Figure 3

Figure 4, Adjustment Factor

H D

Case 2, Two Units Side By Side:

Two or more chillers positioned side by side are common. If spaced closer than 6 feet it is necessary to adjust the performance of each unit; circuits adjoining each other are affected. If one of the two units also has a wall adjoining it, see Case 1. Add the two adjustment factors together (Figure 4 and Figure 6) and apply to the unit between the wall and the other unit.

Mounting units end to end will not require adjusting performance. Depending on the actual arrangement, sufficient space must be left between the units for access to the control panel door opening. See “Clearance” section of this guide for requirements for specific units.

Pit or solid wall surrounds should not be used where the ambient air temperature exceeds 95°F.

Figure 5, Two Chillers Side by Side

Figure 6, Adjustment Factor

D

Case 3, Three or More Units Side By Side:

When designs call for three or more units to be side by side; contact Motivair with the desired placements of the units for approval. Capacity reduction is dependent on multiple possible orientations of the units.

Figure 7, three or more chillers

D

D D

Case 4, Open Screening Walls:

Decorative screening walls are common to help conceal a chiller either on grade or on a rooftop. These walls should be designed such that the combination of their open area and distance from the chiller do not require performance adjustment. It is assumed that the wall height is equal to, or less than the chiller height when mounted on its base support. This is usually acceptable for concealment. If the wall height is greater than the unit height, see Case 5 (Pit Installation).

The distance from the sides of the unit to the side walls should be sufficient for service and opening control panel doors.

If each side wall is a different distance from the unit, the distances can be averaged, providing either wall is not less than 8 feet from the unit. For example, do not average 4 feet and 20 feet to equal 12 feet.

Figure 9, Open Screening Walls

Figure 10, Wall Free Area Graph

D D

Case 5, Pit/Solid Wall Installation:

Pit installations can cause operating problems and great care should be exercised if they are to be used on any installation. Recirculation and restriction are probable. A solid wall surrounding a unit is effectively the same as a pit and the data given in Case 5 should be used.

Steel grating is sometimes used to cover a pit to prevent accidental falls or trips into the pit. The grating material and installation design must be strong enough to prevent such accidents, yet provide abundant open area or serious recirculation problems will occur. Have any pit installation reviewed by Motivair application engineers prior to installation to discuss whether it has sufficient airflow characteristics. The installation design engineer must approve the work and is responsible for design criteria.

Figure 11, Pit Installation

Figure 12, Adjustment Factor

D=10Ft

H D

Addendum: A

40”

40” 4

0”

40”

MIN. CLEARANCE FOR MPC-A 0005-0010

Control Panel

40”

40”

MIN. CLEARANCE FOR MPC-A 0150

40” 4

0”

Control Panel

MPCA0005 - MPCA0150 MANUAL

NOTE: VENTS ARE REQUIRED AT ALL "LOCAL" HIGH POINTS IN SUPPLY AND RETURN

MPCA0005 - MPCA0150 MANUAL

PIPING INSTALLATION

This section is intended as a guide for the correct installation of the chilled water piping system, including this chiller. However, the chiller manufacturer accepts no responsibility what so ever for the installation of the chiller or the associated piping. All piping must be installed only by a licensed plumbing contractor, and in compliance with local codes. DO NOT USE GALVANIZED PIPING IF GLYCOL IS TO BE USED IN THE CHILLED WATER SYSTEM. Chemical reaction between the glycol and the galvanized piping can be detrimental to the cooling system, the glycol and chiller. Piping material may be copper, plastic, carbon or stainless steel depending on the requirements of each installation. It is the responsibility of the engineer and/or the piping contractor to insure that the piping is correctly sized in relation to the installation, and the available dynamic head of the pump installed inside the chiller. The chilled water pipe connections on the chiller are not necessarily the appropriate size for the system piping. As a general guide, the chiller pipe connections should be considered as the minimum pipe size required for the installation. Drastic reduction in pipe sizing (small hoses, etc.) will reduce the chilled water flow and may cause a low flow alarm, or freezing damage to the evaporator. Note: Installation with low water flow/high water temperature rise should always have a full-ported by-pass installed between the chiller inlet and outlet connections, with a manually adjustable gate valve in the by-pass line. Correctly adjusted, this blended return water will maintain an adequate flow through the chiller, at an acceptable return temperature. ALWAYS install a filter/strainer on the inlet off the chiller, in order to prevent particulates (rust, dirt and installation debris) from blocking the evaporator. Blockage will severely impair chiller performance and is not covered by warranty. Always install a pressure gauge in the return piping close to the chiller. This is essential for monitoring system pressure and pump performance. It is good piping practice, especially on systems with short piping runs and/or low system pressure loss, to install a gate valve in the DISCHARGE line from the chiller for throttling purposes. This allows the operator to maintain optimum pump performance by adding resistance to the system. NEVER throttle the water flow on the return line to the chiller. This will cause cavitations and over-heating of the pump. AUTOMATIC WATER MAKE-UP If the chilled water cooling system is expected to lose water during normal operation an automatic water make-up system should be installed, or can be supplied as a factory option. The auto make-up system must include a water pressure regulator and pressure gauge. CAUTION: The tank inside the chiller has a maximum pressure rating of 15 PSIG. Do not discharge city water (which can be 60-80psig) directly into the chiller. Instantaneous pressurization can cause the tank to rupture before the pressure relief valve opens. NOTE: Do not use an automatic water make-up system if glycol is installed for anti-freeze protection. The glycol will become diluted and the freeze protection point will be higher (less protection from freezing). Some critical applications require the installation of emergency city water and drain solenoid valves, in the event of a chiller failure. In this case, the chiller MUST be isolated from the city water pressure to avoid damage. After operation of the emergency city water system, the glycol concentration must be carefully checked using a spectrometer. Add glycol to maintain the correct antifreeze concentration if required. NOTE: Vertical piping immediately connected to and from the chiller will impose a static (or standing) head pressure, which can be read on the pump discharge gauge of the chiller, and the gauge installed on the return line to the chiller, when the system is not operating. For example, if the supply and/or return piping from the chiller rises 15 feet before running above a ceiling, etc. this will show a gauge static

MPCA0005 - MPCA0150 MANUAL

pressure of approximately 6-7psig on the gauges (feet x .424 = psig). This is simply the weight of water in the vertical piping at that location, and does not indicate an overall system pressure. SYSTEM VENTING The single most common problem in chiller piping installations is lack of chilled water flow caused by poor piping practices and/or inadequate venting of the system. The symptom is a repeated flow alarm, when the flow switch installed in the return line inside the chiller contacts open which in turns triggers the flow alarm on the control panel. The 0005-0150 size chillers are bh¢ ! CLOSED CIRCUIT system and is open to atmosphere. This means that air will remain in all local high points above chiller of the system when it is initially filled with water. NOTE: A local high point is any point in the piping, which can be described as an inverted “U” section. More clearly defined, if the piping rises vertically ANYWHERE, AND AT ANY ELEVATION IN THE SYSTEM, travels horizontally, then drops again vertically, this inverted “U” section of piping IS A PERMANENT AIR LOCK AND MUST BE VENTED. Venting is required AT ALL LOCAL HIGH POINTS, and is required on both the supply and return pipes. Vents can be either manual, or automatic. Automatic vents should always be installed with an isolation valve for future service access, repair or replacement. Automatic vents are particularly susceptible to drawing air into the return chilled water piping if this line is allowed to fall into a vacuum. NOTE: The expansion tank should not normally be pressurized to more than 15 psig, measured when the system is not operating. The final discharge pump pressure should NEVER be allowed to exceed the maximum pump rating pressure (normally around 35-50psig). CAUTION: Supercharging the pump with city water pressure higher than nominal rating of the pump, can damage the mechanical pump seal(s), or cause damage to the chiller, piping system or customer equipment. This damage is not covered by the chiller warranty.

MPCA0005 - MPCA0150 MANUAL

WATER/GLYCOL FILLING If glycol is required for antifreeze protection, ALWAYS use an industrial inhibited ethylene glycol, or propylene (food grade) glycol. DO NOT use automobile antifreeze. Suitable glycols are manufactured by the Dow Chemical Company for this purpose, and available nationwide. There are other glycol suppliers available, but always exercise great caution in the selection of a glycol supplier, and always confirm the freeze protection after installation, using a spectrometer. Damage caused by freezing is not covered under warranty. Glycol can be pre-mixed with water to the correct concentration, then pumped into the system, or pumped in separately from the water, provided the system capacity is calculated accurately. The most common method for filling the system is to pump the water glycol into the fill or drain connection of the chiller, with all system vents open. There is a manual vent located at the back of the chiller for initial filling/venting purposes, in addition to the high point piping vents. NOTE: The system should be filled slowly and carefully, allowing all the air to escape. The system can only be filled as fast as the air can escape. Be patient, and do not over-pressurize the system. After initial operation, check all air is vented from the system. GLYCOL CHART

Ethylene Glycol Propylene Glycol

% of Glycol Freeze Point % of Glycol Freeze Point 0% 32F 0% 32F 10% 26F 10% 26F 20% 16F 20% 19F 30% 4F 30% 8F 40% -12F 40% -7F 50% -34F 50% -28F 60% -60F 60% -60F

MPCA0005 - MPCA0150 MANUAL

MAIN ELECTRICAL INSTALLATION

The manufacturer of the supplied chiller accepts NO LIABILITY

for the work supplied by the customer or civil engineering contractor.

MAIN ELECTRICAL CONNECTION The connection of the device to the main electrical power supply must only be carried out by an licensed electrician, and in strict accordance with local electrical codes and safety standards.

ELECTRICAL COMPONENTS

FuIIy wired electrical panel The electrical panel is mounted in the chiller and contains all necessary controls for the chiller. Additional wiring in the electrical panel Additional wiring is permitted but must not modify the original condition of the factory-installed wiring. All changes must be recorded in the original wiring diagram and must be available to the manufacturer.

MAIN VOLTAGE SUPPLY

MPCA0005-0010 230V/60Hz/1~ MPCA0150 230V/60Hz/1~ The permissible voltage tolerance is ±5%. These values are BINDING and COMPULSORY.

INFORMATION ON EXTERNAL WIRING

Main power feed Note: If for local code or other reasons the cable size of the power supply line is larger than the terminal size on the main disconnect or power block: 1. A junction box must be fitted to the chiller in

compliance with local codes in order to reduce the cable size

Or

2. The main disconnect switch or power block of the chiller must be replaced (prior approval of the manufacturer is required).

WIRING DIAGRAM INSPECTION Check that the wiring diagram supplied with the chiller is correct and complete:

WARNING – MANUFACTURER’S NOTICE

The main disconnect switch on the chiller must be switched off before carrying out any wiring work. Do not switch on the microprocessor until startup and commissioning has been successfully completed.

MODEL INFORMATION: REFER TO DATA ON SERIAL STICKER FOR

EACH MODEL

MPCA0005 - MPCA0150 MANUAL

WATER/GLYCOL INSTRUCTIONS

MANUFACTURER'S SPECIFICATIONS The chiller circuit must be 100% filled with water/glycol for operation. If the cooling process causes a loss of water/glycol in the circuit a automatic water make-up vavle must be installed. Insufficient fluid in the water/glycol circuit wiIl lead to failure of chiller

1. Safety devices 2. Controls,due to compressor fluctuations/ hunting

(frequent switching). And compressor starts. 3. Cooling Capacity These can be avoided by adding a reservoir on the inlet side of the chiller.

COLD WATER PIPING CONT. 6. Ensure that the water circuit is maintained at the

correct pressure by installing an appropriate sized diaphragm expansion tank close to the inlet of the chiller. The return side of the chiller must be 5-10psig when the pump is running.

7. Install temperature and pressure gauges at the inlet and outlet of the chiller and the heat load to ensure easy inspection and maintenance.

8. All chilled water lines should be insulated. Only insulate pipes AFTER the circuit was tested for leaks.

GLYCOL IN CIRCUIT

Glycol mixture The following basic rules must be followed: 1. The freezing point of the mixture must be lower than

the minimum evaporation temperature. Or the lowest outside piping temperature, whichever is the lower of the two.

2. See correction factors for glycol concentration on back page of the MPCA chiller brochure.

3. Use only an industrial grade inhibited ethylene glycol or food grade propylene glycol solution. DO NOT use automotive antifreeze.

4. Check the pH-value of the solution. lt should be about 9 and must never be less than 7.5.

5. Check the pH-value regularly (maintenance). 6. DO NOT use galvanized piping or fittings Operating the devices with a glycol mixture Check the extemal cold water network and pumps: • sufficient pressure for increased water volume • pumps suitable for glycol operation • bleed valves (rapid bleeder unsuitable) IMPORTANT: NEVER change the antifreeze alarm parameter on chiller without written authorization from factory. If parameter is changed withour factory consent WARRANTY WILL BE VOIDED.

!!!WARNING!!! The glycol/water mixture must not be discharged into

the normal water drainage system. lt must be collected in suitable containers and disposed of in

accordance with legal regulations.

OnIy operate the chiller with a flow switch (supplied) that switches off the chiller in the event

of insufficient water or a faulty pump. If this condition is not satisfied:

ALL WARRANTY CLAIMS SHALL BE VOIDED Flow meter and a automatic water make-up system

can be purchased from the factory.

COLD WATER PIPING Water piping and connection to the chiller must conform with all generally accepted piping practices and local codes. All piping should be performed by a qaulified person(s) or company. The following specifications are intended to prevent damage to the chiller. 1. Avoid unnecessary pressure drop by ensuring

correct pipe sizes and routing. 2. Connect the chiller with vibration eliminators to

avoid transmission of noise and vibrations. 3. Shut-off valves should be installed at the inlet and

outlet of the chiller so that maintenance and repair work can be performed without draining the piping system.

4. Y-Strainer (40 mesh) should be installed on the inlet piping to the chiller to ensure no foreign particles enter the evaporator and or pump.*Without a Y-Strainer installed blockage of the evaporator will occur

5. Automatic vents should be installed at all local high points of the piping system to eliminate air locks. See chilled water system diagram for location(s).

MPCA0005 - MPCA0150 MANUAL

MPCA0005 – MPCA0150

Mechanical cooling – inlet control

On a call for cooling set point = 50*F + diff = 7*F entering temperature = 57*F glycol pump running the compressor starts. The controller reads the Inlet temperature and the compressor operates to pull down to set point. As the loop temp falls 0.1*F below set point the compressor shuts off glycol pump remains running. Compressor will turn back on when set point + differential is exceeded.

MPCA0005 - MPCA0150 MANUAL

dIXEL Installing and Operating Instructions 1592020030

1592020030 XR30CX GB m&M r1.1 05.03.2007.doc XR30CX 1/4

Digital controller with off cycle defrost and AUX relay XR30CX

CONTENTS 1. GENERAL WARNING ___________________________________________________1 2. GENERAL DESCRIPTION _______________________________________________1 3. CONTROLLING LOADS _________________________________________________1 4. FRONT PANEL COMMANDS _____________________________________________1 5. MAX & MIN TEMPERATURE MEMORIZATION_______________________________1 6. MAIN FUNCTIONS _____________________________________________________1 7. PARAMETERS ________________________________________________________2 8. DIGITAL INPUT (ENABLED WITH P3P = N) _________________________________3 9. TTL SERIAL LINE – FOR MONITORING SYSTEMS ___________________________3 10. X-REP OUTPUT – OPTIONAL ____________________________________________3 11. INSTALLATION AND MOUNTING _________________________________________3 12. ELECTRICAL CONNECTIONS ____________________________________________3 13. HOW TO USE THE HOT KEY_____________________________________________3 14. ALARM SIGNALS ______________________________________________________3 15. TECHNICAL DATA _____________________________________________________4 16. CONNECTIONS _______________________________________________________4 17. DEFAULT SETTING VALUES_____________________________________________4 1. GENERAL WARNING

1.1 PLEASE READ BEFORE USING THIS MANUAL • This manual is part of the product and should be kept near the instrument for easy and

quick reference. • The instrument shall not be used for purposes different from those described hereunder.

It cannot be used as a safety device. • Check the application limits before proceeding.

1.2 SAFETY PRECAUTIONS • Check the supply voltage is correct before connecting the instrument. • Do not expose to water or moisture: use the controller only within the operating limits

avoiding sudden temperature changes with high atmospheric humidity to prevent formation of condensation

• Warning: disconnect all electrical connections before any kind of maintenance. • Fit the probe where it is not accessible by the End User. The instrument must not be

opened. • In case of failure or faulty operation send the instrument back to the distributor or to

“Dixell S.p.A.” (see address) with a detailed description of the fault. • Consider the maximum current which can be applied to each relay (see Technical Data). • Ensure that the wires for probes, loads and the power supply are separated and far

enough from each other, without crossing or intertwining. • In case of applications in industrial environments, the use of mains filters (our mod. FT1)

in parallel with inductive loads could be useful.

2. GENERAL DESCRIPTION Model XR30CX, format 32 x 74 mm, is a digital thermostat with off cycle defrost designed for refrigeration applications at normal temperature. It provides two relay outputs, one for the compressor, the other one can be used as light, for alarm signalling or as auxiliary output.. It is also provided with 2 NTC or PTC probe inputs, the first one for temperature control, the second one, optional, to connect to the HOT KEY terminals to signal the condenser temperature alarm or to display a temperature. The digital input can operate as third temperature probe. The HOT KEY output allows to connect the unit, by means of the external module XJ485-CX, to a network line ModBUS-RTU compatible such as the dIXEL monitoring units of X-WEB family. It allows to program the controller by means the HOT KEY programming keyboard. The instrument is fully configurable through special parameters that can be easily programmed through the keyboard.

3. CONTROLLING LOADS

3.1 COMPRESSOR The regulation is performed according to the temperature measured by the thermostat probe with a positive differential from the set point: if the temperature increases and reaches set point plus differential the compressor is started and then turned off when the temperature reaches the set point value again.

Time

Temper.

Compr.

SET

ON

In case of fault in the thermostat probe the start and stop of the compressor are timed through parameters “COn” and “COF”.

3.2 DEFROST Defrost is performed through a simple stop of the compressor. Parameter “IdF” controls the interval between defrost cycles, while its length is controlled by parameter “MdF”.

4. FRONT PANEL COMMANDS

: To display target set point; in programming mode it selects a parameter or confirm an operation.

(DEF) To start a manual defrost

(UP): To see the max. stored temperature; in programming mode it browses the parameter codes or increases the displayed value. (DOWN) To see the min stored temperature; in programming mode it browses the parameter codes or decreases the displayed value.

To switch the instrument off, if onF = oFF.

To switch the light, if oA1 = Lig KEY COMBINATIONS:

+ To lock & unlock the keyboard. + To enter in programming mode. + To return to the room temperature display.

4.1 USE OF LEDS Each LED function is described in the following table.

LED MODE FUNCTION

ON Compressor enabled

Flashing Anti-short cycle delay enabled

ON Defrost enabled

ON An alarm is occurring

ON Continuous cycle is running

ON Energy saving enabled

ON Light on

ON Auxiliary relay on °C/°F ON Measurement unit °C/°F Flashing Programming phase

5. MAX & MIN TEMPERATURE MEMORIZATION

5.1 HOW TO SEE THE MIN TEMPERATURE 1. Press and release the n key. 2. The “Lo” message will be displayed followed by the minimum temperature recorded. 3. By pressing the n key again or by waiting 5s the normal display will be restored.

5.2 HOW TO SEE THE MAX TEMPERATURE 1. Press and release the o key. 2. The “Hi” message will be displayed followed by the maximum temperature recorded. 3. By pressing the o key again or by waiting 5s the normal display will be restored.

5.3 HOW TO RESET THE MAX AND MIN TEMPERATURE RECORDED 1. Hold press the SET key for more than 3s, while the max. or min temperature is

displayed. (rSt message will be displayed) 2. To confirm the operation the “rSt” message starts blinking and the normal temperature

will be displayed.

6. MAIN FUNCTIONS

6.1 HOW TO SEE THE SETPOINT

1. Push and immediately release the SET key: the display will show the Set point value;

2. Push and immediately release the SET key or wait for 5 seconds to display the probe value again.

6.2 HOW TO CHANGE THE SETPOINT 1. Push the SET key for more than 2 seconds to change the Set point value; 2. The value of the set point will be displayed and the “°C” or “°F” LED starts blinking; 3. To change the Set value push the o or n arrows within 10s. 4. To memorise the new set point value push the SET key again or wait 10s.

6.3 HOW TO START A MANUAL DEFROST

Push the DEF key for more than 2 seconds and a manual defrost will start.

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6.4 HOW TO CHANGE A PARAMETER VALUE To change the parameter’s value operate as follows: 1. Enter the Programming mode by pressing the Set + n keys for 3s (the “°C” or “°F” LED

starts blinking). 2. Select the required parameter. Press the “SET” key to display its value 3. Use “UP” or “DOWN” to change its value. 4. Press “SET” to store the new value and move to the following parameter. To exit: Press SET + UP or wait 15s without pressing a key. NOTE: the set value is stored even when the procedure is exited by waiting the time-out to expire.

6.5 THE HIDDEN MENU The hidden menu Includes all the parameters of the instrument. 6.5.1 HOW TO ENTER THE HIDDEN MENU 1. Enter the Programming mode by pressing the Set + n keys for 3s (the “°C” or “°F” LED

starts blinking). 2. Released the keys, then push again the Set+n keys for more than 7s. The Pr2 label will

be displayed immediately followed from the HY parameter. NOW YOU ARE IN THE HIDDEN MENU.

3. Select the required parameter. 4. Press the “SET” key to display its value 5. Use o or n to change its value. 6. Press “SET” to store the new value and move to the following parameter. To exit: Press SET + o or wait 15s without pressing a key. NOTE1: if none parameter is present in Pr1, after 3s the “noP” message is displayed. Keep the keys pushed till the Pr2 message is displayed. NOTE2: the set value is stored even when the procedure is exited by waiting the time-out to expire. 6.5.2 HOW TO MOVE A PARAMETER FROM THE HIDDEN MENU TO THE FIRST LEVEL AND VICEVERSA. Each parameter present in the HIDDEN MENU can be removed or put into “THE FIRST LEVEL” (user level) by pressing “SET + n”. In HIDDEN MENU when a parameter is present in First Level the decimal point is on.

6.6 HOW TO LOCK THE KEYBOARD 1. Keep pressed for more than 3 s the UP + DOWN keys. 2. The “POF” message will be displayed and the keyboard will be locked. At this point it will

be possible only to see the set point or the MAX o Min temperature stored 3. If a key is pressed more than 3s the “POF” message will be displayed.

6.7 TO UNLOCK THE KEYBOARD Keep pressed together for more than 3s the o and n keys, till the “Pon” message will be displayed.

6.8 THE CONTINUOUS CYCLE When defrost is not in progress, it can be activated by holding the “o” key pressed for about 3 seconds. The compressor operates to maintain the “ccS” set point for the time set through the “CCt” parameter. The cycle can be terminated before the end of the set time using the same activation key “o” for 3 seconds.

6.9 THE ON/OFF FUNCTION

With “onF = oFF”, pushing the ON/OFF key, the instrument is switched off. The “OFF” message is displayed. In this configuration, the regulation is disabled. To switch the instrument on, push again the ON/OFF key.

WARNING: Loads connected to the normally closed contacts of the relays are always supplied and under voltage, even if the instrument is in stand by mode.

7. PARAMETERS REGULATION Hy Differential: (0,1 ÷ 25,5°C / 1÷255 °F) Intervention differential for set point. Compressor

Cut IN is Set Point + differential (Hy). Compressor Cut OUT is when the temperature reaches the set point.

LS Minimum set point: (- 50°C÷SET/-58°F÷SET): Sets the minimum value for the set point. US Maximum set point: (SET÷110°C/ SET÷230°F). Set the maximum value for set point. Ot Thermostat probe calibration: (-12.0÷12.0°C; -120÷120°F) allows to adjust possible

offset of the thermostat probe. P3P Third probe presence (P3): n= not present:, the terminal operates as digital input.; y=

present:, the terminal operates as third probe. O3 Third probe calibration (P3): (-12.0÷12.0°C; -120÷120°F). allows to adjust possible

offset of the third probe. P4P Fourth probe presence: (n = Not present; y = present). o4 Fourth probe calibration: (-12.0÷12.0°C) allows to adjust possible offset of the fourth

probe. OdS Outputs activation delay at start up: (0÷255min) This function is enabled at the initial

start up of the instrument and inhibits any output activation for the period of time set in the parameter.

AC Anti-short cycle delay: (0÷50 min) minimum interval between the compressor stop and the following restart.

CCt Compressor ON time during continuous cycle: (0.0÷24.0h; res. 10min) Allows to set the length of the continuous cycle: compressor stays on without interruption for the CCt time. Can be used, for instance, when the room is filled with new products.

CCS Set point for continuous cycle: (-50÷150°C) it sets the set point used during the continuous cycle.

COn Compressor ON time with faulty probe: (0÷255 min) time during which the compressor is active in case of faulty thermostat probe. With COn=0 compressor is always OFF.

COF Compressor OFF time with faulty probe: (0÷255 min) time during which the compressor is OFF in case of faulty thermostat probe. With COF=0 compressor is always active.

CH Type of action: CL = cooling; Ht = heating. DISPLAY CF Temperature measurement unit: °C=Celsius; °F=Fahrenheit. WARNING: When the

measurement unit is changed the SET point and the values of the parameters Hy, LS, US, Ot, ALU and ALL have to be checked and modified if necessary).

rES Resolution (for °C): (in = 1°C; dE = 0.1 °C) allows decimal point display. dLy Display delay: (0 ÷20.0m; risul. 10s) when the temperature increases, the display is

updated of 1 °C/1°F after this time. DEFROST IdF Interval between defrost cycles: (0÷120h) Determines the time interval between the

beginning of two defrost cycles. MdF (Maximum) length for defrost: (0÷255min) When P2P = n, (not evaporator probe:

timed defrost) it sets the defrost duration, when P2P = y (defrost end based on temperature) it sets the maximum length for defrost.

dFd Temperature displayed during defrost: (rt = real temperature; it = temperature at defrost start; SEt = set point; dEF = “dEF” label)

dAd MAX display delay after defrost: (0÷255min). Sets the maximum time between the end of defrost and the restarting of the real room temperature display.

ALARMS ALC Temperature alarms configuration: (Ab; rE) Ab= absolute temperature: alarm temperature is given by the ALL or ALU values. rE =

temperature alarms are referred to the set point. Temperature alarm is enabled when the temperature exceeds the “SET+ALU” or “SET-ALL” values.

ALU MAXIMUM temperature alarm: (SET÷110°C; SET÷230°F) when this temperature is reached the alarm is enabled, after the “ALd” delay time.

ALL Minimum temperature alarm: (-50.0 ÷ SET°C; -58÷230°F when this temperature is reached the alarm is enabled, after the “ALd” delay time.

AFH Differential for temperature alarm recovery: (0,1÷25,5°C; 1÷45°F) Intervention differential for recovery of temperature alarm.

ALd Temperature alarm delay: (0÷255 min) time interval between the detection of an alarm condition and alarm signalling.

dAO Exclusion of temperature alarm at startup: (from 0.0 min to 23.5h) time interval between the detection of the temperature alarm condition after instrument power on and alarm signalling.

CONDENSER TEMPERATURE ALARM (detected by the fourth probe) AP2 Probe selection for temperature alarm of condenser: nP = no probe; P1 =thermostat

probe; P2 = evaporator probe; P3 =configurable probe; P4 = Probe on Hot Key plug. AL2 Low temperature alarm of condenser: (-55÷150°C) when this temperature is reached

the LA2 alarm is signalled, possibly after the Ad2 delay. Au2 High temperature alarm of condenser: (-55÷150°C) when this temperature is reached

the HA2 alarm is signalled, possibly after the Ad2 delay. AH2 Differential for temperature condenser alarm recovery: (0,1÷25,5°C; 1÷45°F) Ad2 Condenser temperature alarm delay: (0÷255 min) time interval between the detection

of the condenser alarm condition and alarm signalling. dA2 Condenser temperature alarm exclusion at start up: (from 0.0 min to 23.5h, res.

10min) bLL Compressor off with low temperature alarm of condenser: n = no: compressor

keeps on working; Y = yes, compressor is switched off till the alarm is present, in any case regulation restarts after AC time at minimum.

AC2 Compressor off with high temperature alarm of condenser: n = no: compressor keeps on working; Y = yes, compressor is switched off till the alarm is present, in any case regulation restarts after AC time at minimum.

SECOND RELAY tbA Alarm relay silencing (with oA1=ALr):

(n= silencing disabled: alarm relay stays on till alarm condition lasts, y =silencing enabled: alarm relay is switched OFF by pressing a key during an alarm).

oA1 Second relay configuration: ALr: alarm; Lig: light; AuS: Auxiliary relay; onF: always on with instrument on; db = do not select it; dEF: do not select it!.; FAn: do not select it!.; dF2: do not select it.

AoP Alarm relay polarity: it set if the alarm relay is open or closed when an alarm happens. CL= terminals 1-2 closed during an alarm; oP = terminals 1-2 open during an alarm

DIGITAL INPUT i1P Digital input polarity: oP: the digital input is activated by opening the contact; CL: the

digital input is activated by closing the contact. i1F Digital input configuration: EAL = external alarm: “EA” message is displayed; bAL =

serious alarm “CA” message is displayed. PAL = pressure switch alarm, “CA” message is displayed; dor = door switch function; dEF = activation of a defrost cycle; AUS =to switch on the second relay if oA1 = AUS; Htr = kind of action inversion (cooling – heating); FAn = not set it; ES = Energy saving.

did: (0÷255 min) with i1F= EAL or i1F = bAL digital input alarm delay: delay between the detection of the external alarm condition and its signalling. with i1F= dor: door open signalling delay with i1F = PAL: time for pressure switch function: time interval to calculate the number of the pressure switch activation.

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1592020030 XR30CX GB m&M r1.1 05.03.2007.doc XR30CX 3/4

nPS Pressure switch number: (0 ÷15) Number of activation of the pressure switch, during the “did” interval, before signalling the alarm event (I2F= PAL). If the nPS activation in the did time is reached, switch off and on the instrument to restart normal regulation.

odc Compressor status with door open: no, Fan = normal; CPr; F_C = Compressor OFF. rrd Outputs restart after doA alarm: no = outputs not affected by the doA alarm; yES =

outputs restart with the doA alarm; HES Temperature increase during the Energy Saving cycle : (-30,0°C÷30,0°C/-22÷86°F)

it sets the increasing value of the set point during the Energy Saving cycle. OTHER Adr Serial address (1÷244): Identifies the instrument address when connected to a

ModBUS compatible monitoring system. PbC Type of probe: it allows to set the kind of probe used by the instrument: PbC = PBC

probe, ntc = NTC probe. onF on/off key enabling: nu = disabled; oFF = enabled; ES = not set it. dP1 Thermostat probe display dP3 Third probe display- optional. dP4 Fourth probe display. rSE Real set point: (readable only), it shows the set point used during the energy saving

cycle or during the continuous cycle. rEL Software release for internal use. Ptb Parameter table code: readable only.

8. DIGITAL INPUT (ENABLED WITH P3P = N) The free voltage digital input is programmable in different configurations by the “i1F” parameter.

8.1 DOOR SWITCH INPUT (i1F = dor) It signals the door status and the corresponding relay output status through the “odc” parameter: no, Fan = normal (any change); CPr, F_C = Compressor OFF. Since the door is opened, after the delay time set through parameter “did”, the door alarm is enabled, the display shows the message “dA” and the regulation restarts is rtr = yES. The alarm stops as soon as the external digital input is disabled again. With the door open, the high and low temperature alarms are disabled.

8.2 GENERIC ALARM (i1F = EAL) As soon as the digital input is activated the unit will wait for “did” time delay before signalling the “EAL” alarm message. The outputs status don’t change. The alarm stops just after the digital input is de-activated.

8.3 SERIOUS ALARM MODE (i1F = bAL) When the digital input is activated, the unit will wait for “did” delay before signalling the “CA” alarm message. The relay outputs are switched OFF. The alarm will stop as soon as the digital input is de-activated.

8.4 PRESSURE SWITCH (i1F = PAL) If during the interval time set by “did” parameter, the pressure switch has reached the number of activation of the “nPS” parameter, the “CA” pressure alarm message will be displayed. The compressor and the regulation are stopped. When the digital input is ON the compressor is always OFF. If the nPS activation in the did time is reached, switch off and on the instrument to restart normal regulation.

8.5 START DEFROST (i1F = dFr) It starts a defrost if there are the right conditions. After the defrost is finished, the normal regulation will restart only if the digital input is disabled otherwise the instrument will wait until the “MdF” safety time is expired.

8.6 INVERSION OF THE KIND OF ACTION: HEATING-COOLING (i1F = Htr) This function allows to invert the regulation of the controller: from cooling to heating and viceversa.

8.7 ENERGY SAVING (i1F = ES) The Energy Saving function allows to change the set point value as the result of the SET+ HES (parameter) sum. This function is enabled until the digital input is activated.

8.8 DIGITAL INPUTS POLARITY The digital input polarity depends on the “i1P” parameter. i1P=CL: the input is activated by closing the contact. i1P=OP: the input is activated by opening the contact

9. TTL SERIAL LINE – FOR MONITORING SYSTEMS The TTL serial line, available through the HOT KEY connector, allows by means of the external TTL/RS485 converter, XJ485-CX, to connect the instrument to a monitoring system ModBUS-RTU compatible such as the X-WEB500/3000/300.

10. X-REP OUTPUT – OPTIONAL As optional, an X-REP can be connected to the instrument, trough the HOY KEY connector. The X-REP output EXCLUDES the serial connection.

To connect the X-REP to the instrument the following connectors must be used CAB-51F(1m), CAB-52F(2m), CAB-55F(5m),

11. INSTALLATION AND MOUNTING

Instrument XR30CX shall be mounted on vertical panel, in a 29x71 mm hole, and fixed using the special bracket supplied. The temperature range allowed for correct operation is 0÷60 °C. Avoid places subject to strong vibrations, corrosive gases, excessive dirt or humidity. The same recommendations apply to probes. Let air circulate by the cooling holes.

12. ELECTRICAL CONNECTIONS The instrument is provided with screw terminal block to connect cables with a cross section up to 2,5 mm2. Before connecting cables make sure the power supply complies with the instrument’s requirements. Separate the probe cables from the power supply cables, from the outputs and the power connections. Do not exceed the maximum current allowed on each relay, in case of heavier loads use a suitable external relay.

12.1 PROBE CONNECTION The probes shall be mounted with the bulb upwards to prevent damages due to casual liquid infiltration. It is recommended to place the thermostat probe away from air streams to correctly measure the average room temperature. Place the defrost termination probe among the evaporator fins in the coldest place, where most ice is formed, far from heaters or from the warmest place during defrost, to prevent premature defrost termination.

13. HOW TO USE THE HOT KEY

13.1 HOW TO PROGRAM A HOT KEY FROM THE INSTRUMENT (UPLOAD) 1. Program one controller with the front keypad. 2. When the controller is ON, insert the “Hot key” and push o key; the "uPL" message

appears followed a by flashing “End” 3. Push “SET” key and the End will stop flashing. 4. Turn OFF the instrument remove the “Hot Key”, then turn it ON again. NOTE: the “Err” message is displayed for failed programming. In this case push again o key if you want to restart the upload again or remove the “Hot key” to abort the operation.

13.2 HOW TO PROGRAM AN INSTRUMENT USING A HOT KEY (DOWNLOAD) 1. Turn OFF the instrument. 2. Insert a programmed “Hot Key” into the 5 PIN receptacle and then turn the

Controller ON. 3. Automatically the parameter list of the “Hot Key” is downloaded into the Controller

memory, the “doL” message is blinking followed a by flashing “End”. 4. After 10 seconds the instrument will restart working with the new parameters. 5. Remove the “Hot Key”.. NOTE the message “Err” is displayed for failed programming. In this case turn the unit off and then on if you want to restart the download again or remove the “Hot key” to abort the operation.

14. ALARM SIGNALS Message Cause Outputs

“P1” Room probe failure Compressor output acc. to par. “Con” and “COF”

“P3” Third probe failure Outputs unchanged “P4” Fourth probe failure Outputs unchanged “HA” Maximum temperature alarm Outputs unchanged. “LA” Minimum temperature alarm Outputs unchanged. "HA2" Condenser high temperature It depends on the “Ac2” parameter "LA2" Condenser low temperature It depends on the “bLL” parameter “dA” Door open Compressor according to rrd “EA” External alarm Output unchanged. “CA” Serious external alarm

(i1F=bAL) All outputs OFF.

“CA” Pressure switch alarm (i1F=PAL)

All outputs OFF

14.1 ALARM RECOVERY Probe alarms P1”, “P3” and “P4” start some seconds after the fault in the related probe; they automatically stop some seconds after the probe restarts normal operation. Check connections before replacing the probe. Temperature alarms “HA”, “LA” “HA2” and “LA2” automatically stop as soon as the temperature returns to normal values. Alarms “EA” and “CA” (with i1F=bAL) recover as soon as the digital input is disabled. Alarm “CA” (with i1F=PAL) recovers only by switching off and on the instrument.

14.2 OTHER MESSAGES Pon Keyboard unlocked. PoF Keyboard locked noP In programming mode: none parameter is present in Pr1

On the display or in dP2, dP3, dP4: the selected probe is nor enabled noA None alarm is recorded.

dIXEL Installing and Operating Instructions 1592020030

1592020030 XR30CX GB m&M r1.1 05.03.2007.doc XR30CX 4/4

15. TECHNICAL DATA Housing: self extinguishing ABS. Case: XR30CX frontal 32x74 mm; depth 60mm; Mounting: XR30CX panel mounting in a 71x29mm panel cut-out Protection: IP20; Frontal protection: XR30CX IP65 Connections: Screw terminal block ≤ 2,5 mm2 wiring. Power supply: according to the model: 12Vac/dc, ±10%; 24Vac/dc, ±10%; 230Vac ±10%, 50/60Hz, 110Vac ±10%, 50/60Hz Power absorption: 3VA max Display: 3 digits, red LED, 14,2 mm high; Inputs: Up to 4 NTC or PTC probes. Digital input: free voltage contact Relay outputs: compressor SPST 8(3) A, 250Vac; or 20(8)A 250Vac AUX: SPDT 8(3) A, 250Vac Data storing: on the non-volatile memory (EEPROM). Kind of action: 1B; Pollution grade: 2;Software class: A.; Rated impulsive voltage: 2500V; Overvoltage Category: II Operating temperature: 0÷60 °C;Storage temperature: -30÷85 °C. Relative humidity: 20÷85% (no condensing) Measuring and regulation range: NTC probe: -40÷110°C (-40÷230°F);

PTC probe: -50÷150°C (-58÷302°F) Resolution: 0,1 °C or 1°C or 1 °F (selectable); Accuracy (ambient temp. 25°C): ±0,7 °C ±1 digit

16. CONNECTIONS The X-REP output excludes the TTL output.. It’s present in the following codes: XR30CX- xx2xx, XR30CX –xx3xx;

16.1 XR30CX – 8A COMPRESSOR

N.C.

1 2 3 4 5 6 7

9 10 11 12

CompLight/Alarm

Room

8Hot Key/IV probe

TTL or X-REP output

8(3)A250V 8(3)A250V

Line 12Vac/dc supply: connect to the terminals 7 and 8. 24Vac/dc supply: connect to the terminals 7 and 8. 120Vac supply: connect to the terminals 7 and 8.

16.2 XR30CX – 20A COMPRESSOR

N.C.

1 2 3 4 5 6 7

9 10 11 12

CompLight/Alarm

Room

8Hot Key/IV probe

TTL or X-REP output

8(3)A250V 20(8)A250V

Line 12Vac/dc supply: connect to the terminals 7 and 8. 24Vac/dc supply: connect to the terminals 7 and 8. 120Vac supply: connect to the terminals 7 and 8.

17. DEFAULT SETTING VALUES Labe Name Range °C/°F Set Set point LS÷US 3.0 - - - Hy Differential 0,1÷25.5°C/ 1÷ 255°F 2.0 Pr1 LS Minimum set point -50°C÷SET/-58°F÷SET -50.0 Pr2 US Maximum set point SET÷110°C/ SET ÷ 230°F 110 Pr2 Ot Thermostat probe calibration -12÷12°C /-120÷120°F 0.0 Pr1

P3P Third probe presence n=not present; Y=pres. n Pr2 O3 Third probe calibration -12÷12°C /-120÷120°F 0 Pr2 P4P Fourth probe presence n=not present; Y=pres. n Pr2 O4 Fourth probe calibration -12÷12°C /-120÷120°F 0 Pr2

OdS Outputs delay at start up 0÷255 min 0 Pr2 AC Anti-short cycle delay 0 ÷ 50 min 1 Pr1 CCt Continuos cycle duration 0.0÷24.0h 0.0 Pr2 CCS

Set point for continuous cycle (-55.0÷150,0°C) (-67÷302°F) 3 Pr2

COn

Compressor ON time with faulty probe 0 ÷ 255 min 15 Pr2

COF

Compressor OFF time with faulty probe

0 ÷ 255 min 30 Pr2

CH Kind of action CL=cooling; Ht= heating cL Pr1 CF Temperature measurement unit °C ÷ °F °C Pr2

rES Resolution in=integer; dE= dec.point dE Pr1 dLy Display temperature delay 0 ÷ 20.0 min (10 sec.) 0 Pr2 IdF Interval between defrost cycles 1 ÷ 120 ore 8 Pr1 MdF (Maximum) length for defrost 0 ÷ 255 min 20 Pr1 dFd Displaying during defrost rt, it, SEt, DEF it Pr2 dAd MAX display delay after defrost 0 ÷ 255 min 30 Pr2 ALc Temperat. alarms configuration rE= related to set;

Ab = absolute Ab Pr2 ALU MAXIMUM temperature alarm Set÷110.0°C; Set÷230°F 110 Pr1 ALL Minimum temperature alarm -50.0°C÷Set/ -58°F÷Set -50.0 Pr1 AFH Differential for temperat. alarm

recovery (0,1°C÷25,5°C) (1°F÷45°F) 1 Pr2

ALd Temperature alarm delay 0 ÷ 255 min 15 Pr2 dAo Delay of temperature alarm at start up 0 ÷ 23h e 50’ 1.3 Pr2 AP2 Probe for temperat. alarm of

condenser nP; P1; P2; P3; P4 P4 Pr2

AL2 Condenser for low temperat. alarm (-55 ÷ 150°C) (-67÷ 302°F) -40 Pr2 AU2 Condenser for high temperat. alarm (-55 ÷ 150°C) (-67÷ 302°F) 110 Pr2

AH2 Differ. for condenser temp. alar. recovery

[0,1°C ÷ 25,5°C] [1°F ÷ 45°F] 5 Pr2

Ad2 Condenser temperature alarm delay 0 ÷ 254 (min.) , 255=nU 15 Pr2

dA2 Delay of cond. temper. alarm at start up 0.0 ÷ 23h 50’ 1,3 Pr2

bLL Compr. off for condenser low temperature alarm n(0) - Y(1) n Pr2

AC2 Compr. off for condenser high temperature alarm n(0) - Y(1) n Pr2

tbA Alarm relay disabling n=no; y=yes y Pr2 oA1 2nd relay configuration ALr = alarm; dEF = do not

select it; Lig =Light; AUS =AUX; onF=always on; Fan= do not select it; db = do not

select it; dF2 = do not select it

Lig Pr2

AoP Alarm relay polarity (oA1=ALr) oP; cL cL Pr2 i1P Digital input polarity oP=opening;CL=closing cL Pr1 i1F Digital input configuration EAL, bAL, PAL, dor; dEF; Htr,

AUS dor Pr1

did Digital input alarm delay 0÷255min 15 Pr1 nPS Number of activation of pressure

switch 0 ÷15 15 Pr2

odc Compress status when open door no; Fan; CPr; F_C no Pr2 rrd Regulation restart with door open

alarm n – Y y Pr2

HES Differential for Energy Saving (-30°C÷30°C) (-54°F÷54°F) 0 Pr2 Adr Serial address 0÷247 1 Pr2 PbC Kind of probe Ptc; ntc ntc Pr1 onF on/off key enabling nu, oFF; ES nu Pr2 dP1 Room probe display -- -- Pr2 dP3 Third probe display -- -- Pr1 dP4 Fourth probe display -- -- Pr1 rSE Real set point value actual set -- Pr2 rEL Software release -- -- Pr2 Ptb Map code -- -- Pr2

Dixell S.p.A. Z.I. Via dell’Industria, 27 32010 Pieve d’Alpago (BL) ITALY tel. +39 - 0437 - 98 33 - fax +39 - 0437 - 98 93 13 E-mail: dixell@dixell.com - http://www.dixell.com

MPCA0150 STANDARD CONTROLLER LAYOUT

MPCA0005 - MPCA0010 STANDARD CONTROLLER LAYOUT

MPCA0005 - MPCA0150 MANUAL

COMMISIONING AND STARTUP INSTRUCTIONS

1. Main switch to OFF - Open the electrical panel 2. Input terminal voltage? IF YES then open the main

fuse 3. Check the electrical connections. Although these

connections are well-tightened at the factory, they may be Ioosened during transport. Retighten if necessary.

4. Check the external connections against the wiring diagram. Fit jumpers if necessary.

5. Check the customer's wiring up to the main disconnect for cable cross-section and correct grounding.

6. Check the supply voltage: Close the main switch and apply voltage to input terminals. +1-5% voltage tolerance

COMMISSIONING Check the water connections

1. Check the supply and retum connection 2. If glycol solution:

Take a water sample to check the freeze protection level.

VisuaI inspection

1. Remove the access panels and check the condition of the system, especially if chilled water pipes have been installed by the customer and or contractor.

2. Check the system visually for: Accessibility and servicing clearances Has the system been modifled, e.g. by fixing cable ducting or similar equipment? Check that there are no screws next to copper pipes or the air-cooled condenser.

Note: Record any deviations on the commissioning report. Inspect control panel and electrical work

Preparations at the switch cabinet 1. Open the electrical cabinet (main switch OFF) CHILLED WATER PUMPS Inspection of chilled water circuit Preparations with the electrical panel OPEN 1. Switch main switch 0FF via extension. 2. OPEN both compressor overloads

(interrupt power supply to compressors) 3. Switch main switch ON via extension Note: The chilled water pump must respond and start after a short delay. 4. Bleed the system again 5. Check the chilled water piping in the entire system. Inspection of the cold water pumps 1. Measure the running amps of the pump and compare

with the values in the wiring diagram. If the measured value is greater than the pump nameplate, the extemal pressure drop is incorrect.

ALWAYS OBEY SAFETY INSTRUCTIONS

WARNING! Use only suitable tools and measuring equipment when inspecting the electrical installation.

WARNING - HIGH VOLTAGE RISK OF FATAL INJURY

Open the main fuse before reconnecting

MANUFACTURER'S NOTE The settings of the overloads must not be adjusted. WARRANTY WILL BE VOIDED

Inspect the water system (check filters/strainers) and remedy any faults. INSPECTION OF COMPRESSOR(S) Check each chiller circuit as follows: 1. Main switch OFF 2. Controller OFF by monitor pushbutton 3. Close opened fuse of circuit 4. Main switch ON 5. Controller ON by monitor pushbutton 6. Clear alarm messages on monitor System status: Chilled water pump running (otherwise compressor does not start) Fan(s) running. Inspection of chiller circuit Note: Operate the compressor(s) at Ieast 15 minutes at full Ioad.

MPCA0005 - MPCA0150 MANUAL

Correct handover by the qualified company to the operator or operator's personnel is a basic precondition for operation of the refrigeration system. Safety Instructions The operator has been familiarised with the specified safety instructions. Operating Instructions The operator has been: − trained in chiller operation − instructed in the function and operation of the

installed microprocessor. − instructed in simple maintenance and

inspection work. The following have been handed over System documentation, consisting of: (check where applicable) Handover Report including commissioning data ____________ Instailation, Operating and Maintenance Specifications ____________ Instructions for Use of the microprocessor ____________ Safety instructions ____________ Electrical wiring diagram ____________ Certificates conforming to the "Pressure Vessel Order" ____________ "C.E." Certificate for export conforming to EC standard ____________ Miscellaneous: ____________________ ____________ ____________________ ____________ ____________________ ____________ INSPECTION – MAINTENANCE The operator has been informed in precise detail by the qualified company of the necessity for regular inspection and maintenance. Inspection and maintenance must be performed to validate any warranty claim.

MAINTENANCE INTERVALS

The Iist beIow contains recommendations based on practical experience. These recommendations must be adapted to the actual operating time of the chiller system, e.g. for continuous operation Weekly Inspections by operator Every 3 months Maintenance by qualified company Once a year General service by qualified chiller maintenance company

If the system is shut down for a long period (winter months), a complete inspection and service must be performed before switching on and restarting. MACHINE DATA

System type _____________

Serial number _____________

Year of manufacture _____________

Refrigerant _____________

Qualified Company (Stamp) - Signature Operator (Stamp) – Signature Date: ______________________

MPCA0005 - MPCA0150 MANUAL

TROUBLESHOOTING

WARNING OBEY SAFETY INSTRUCTIONS

The table that follows lists a large proportion of the fault causes that can occur in practice. These descriptions are intended for information only and must not be considered as a repair manual. Often, the cause of a failure is due to a variety of factors. However, these factors can only be evaluated by a qualified refrigeration company with precise knowledge of the functional interactions.

WARNING Only qualified service and maintenance technicians may carry out repairs to the system. During operation, potentially fatal pressures and voltages are generated in the system. All safety precautions and warnings contained in these documents must be strictly observed.

Possible malfunctions to the chiller may occur due to the following factors:

1. Changes in operating conditions

2. lnsufficient maintenance and inspection

3. External environmental factors

4. Internal machine factors

5. System factors

6. Operating errors

CAUSES OF MALFUNCTIONS These causes can be divided into three groups: 1. Faults due to the water circuit.

The operator can generally remedy this type of problem.

2. Electrical faults With the aid of a qualified electrician, the operator can partially remedy this type of fault.

3. Faults in the refrigerant circuit.

This type of problem can only be remedied by a qualified refrigeration company.

IMPORTANT A large proportion of the functions, faults and operating states of the system are signalled by the microprocessor. The microprocessor monitors all the function areas of the system. Therefore, this information is also essential in troubleshooting the faults.

CHANGES IN OPERATING CONDITIONS Significant changes in the operating conditions of

the chiller may cause faults, because individual components important to the operation of the system wiII not be tuned to the new operating

mode. Inform the MANUFACTURER of any intended

change and obtain prior consent. WARRANTY WILL BE VOIDED

MPCA0005 - MPCA0150 MANUAL

A) FAULT: COMPRESSOR DOES NOT START

SYMPTOM CAUSE POSSIBLE SOLUTION

1. No voltage at power terminals of motor starter 2. No voltage at power terminals of motor starter 3. Voltage on but not applied down

stream of the fuse 4. Main voltage too low 5. Correct voltage is coming to the

compressor terminals

6. Damaged contacts or burnt coil

7. Compressor relay does not close

8. Compressor does not start

Power failure Overload tripped Fuse Blown Main power grid low Compressor failure Defective starter contactor Control circuit interupted Inlet water temperature does not exceed differential set point

Check the fuses and wiring Determine the cause. lf all checks good reset the overload. Change fuse – Identify the fault. Contact electric company Replace compressor Repair or replace. ldentify the open safety switch and determine cause Check set point and differential

B) FAULT: COMPRESSOR NOISE - TOO LOUD.

*STOP THE COMPRESSOR* 1. Compressor “knocking” 2. Suction line exceptionally cold

Internal parts of compressor boken Expansion valve not closing

Compressor must be replaced Check the expansion valve Repair or replace

C) FAULT: COMPRESSOR LOSING OIL

*STOP THE COMPRESSOR*

1. Lack of oil in compressor 2. Oil level falling 3. Compressor turning on/off too often

4. Reduced compressor capacity

Oil level too low Clogged filter dryer Compressor hunting Possible bad compressor windings

Oil must be topped up Change the dryer Readjust superheat. Check TXV sensor position. Replace compressor

MPCA0005 - MPCA0150 MANUAL

D) FAULT: COMPRESSOR “HUNTING”

SYMPTOM CAUSE POSSIBLE SOLUTION

1. Low pressure switch keeps tripping and

bubbles in sight glass during normal operation

2. Compressor turning on/off to

frequently 3. Suction pressure low, ice on top of

compressor 4. Noisy liquid line solenoid

Chiller low on refrigerant Loose contact in electrical panel Filter dryer plugged Liquid line solenoid leaking by

Repair possible leak in the circuit Top off with refrigerant. Repair or replace the defective switch Replace dryer Repair or replace

E) FAULT: INSUFFICIENT COOLING CAPACITY

1. TXV very noisy during operation

2. Temperature difference up/down

stream of filter dryer or LL solenoid valve

3. Frequent chiller cycling 4. High water temperature 5. Reduced water flow 6. Chiller wont make set point 7. Chiller wont make set point

Low on refrigerant or faulty TXV Dryer or LL solenoid valve clogged TXV seized or clogged Low flow across evaporator. Excessive pressure drop in evaporator Flow in water piping restricted or blocked Superheat is out of adjustment Overloading the chillers sized capacity

Top off refrigerant and or replace TXV Replace dryer/LL solenoid Clean or replace Ensure proper water flow. Check expansion valve superheat Check pump rotation, Remedy obstruction Adjust TXV superheat Correct the overloading condition

F) FAULT: SUCTION PRESSURE TOO LOW

1. Bubbles in sight glass 2. Compressor hunting 3. Temperature difference up/down

stream of filter dryer or LL solenoid 4. No refrigerant flow through TXV 5. Water flow low

Low on refrigerant Compressor hunting Dryer or LL solenoid valve clogged TXV clogged or powerhed defective Loss of water/glycol and or restriction

Possible leaks or insufficient refrigerant See D) above: Compressor hunting Replace the dryer Clean/ replace TXV or powerhead Meassure GPM and or find and repair restriction

MPCA0005 - MPCA0150 MANUAL

G) FAULT: CONDENSING PRESSURE TOO HIGH

SYMPTOM CAUSE POSSIBLE SOLUTION

1. Normal operation high pressure switch

trips

2. High water temperature

Too much refrigerant in system Insufficant cooling air (ambient) Fan(s) do not delivery enough air Heat load exceeded chillers capacity

Check subcooling Remove refrigerant Clean the condenser Ambient is high than 95F Check phase rotation Defective fan motor External air resistance too high. Send proper load to chiller. Call factory to see what the chiller was sized for

H) FAULT: CONDENSING PRESSURE TOO LOW

1. Suction and discharge pressure

equalize after pumpdown 2. Bubbles in sight glass

High pressure valves in compressor are causing pressure to bleed by. Low on refrigerant

Replace the compressor Insufficient rerigerant due to refrigerant leak.

I) FAULT: CONDENSER FANS

1. Fan or fram vibration 2. No air flow or some fans not running

Fan out of balance Fan fuse blown

Inspect the bearings and visually check for damage. Is chiller level? Check the voltage. Check the VFD (if fitted) and measure the values. Check the fan motor(s)

L) FAULT: CHILLED WATER PUMP

1. Large delta T between inlet and

outlet temperatures 2. Water leaking from pump 3. Pump does not run although cooling

is required

Not enough flow through chiller Mechanical seal defective Mechanically seal defective or overload tripped

Pressure drop in process cooling circuit is too high. Check the GPM Replace mechanical seal Check amp draw of pump. External pressure loss may be too high causing the amp draw to be higher than normal

MPCA0005 - MPCA0150 MANUAL

PREVENTATIVE MAINTENANCE

MAINTENANCE Before carrying out any maintenance work, the service technician must be made thoroughly familiar with the

following safety precautions and provisions.

WARNING Do not undo any refrigerant or hydraulic connections until the system is depressurised.

GENERAL SAFETY PRECAUTIONS

WARNING

High voltage - Risk of fatal injury Disconnect the unit from the power supply before opening the doors or removing the chiller panels.

WARNING Protective goggles and rubber gloves must be worn when handling refrigerant.

WARNING Avoid any skin contact with gas or refrigerating oiIs. Severe bums may be caused. Always wear rubber gloves when handling dirty parts.

MANUFACTURER’S SPECIFICATION

WARNING High voltage - Risk of fatal injury

After opening the electrical panel, voltage is applied at input terminals L1, L2, L3

WARNING Before carrying out any work in the electrical cabinet, make sure that the main switch is set to the “0FF” position.

WARNING Use only the appropriate tools and measuring equipment to check the electrical system.

WARNING Risk of burns

Exposed copper pipes may be hot.

WARNING Danger of suffocation when working with refrigerants, make sure of good ventilation. Do not smoke.

WARNING Refrigerant must never be discharged into the environment. It must be coIlected in a collecting container for reuse or for return to the manufacturer.

WARNING Risk of injury

If it is necessary to carry out work inside the system with the fans running, make sure that no parts of the body or clothing are caught in the fan blades or other moving parts.

The safety devices installed in the system such as flow meters, pressure switches etc. must not be bypassed.

WARRANTY WILL BE VOIDED

Microprocessor Changes to the programming domain protected by password may only be made after checking with the manufacturer.

WARRANTY WILL BE VOIDED

Modifications in the control panel The panel wiring may only be changed with the consent of the manufacturer.

Additional wiring is possible Any changes to the wiring must be marked in the wiring diagrams and made available to the operator.

MPCA0005 - MPCA0150 MANUAL

Servicing tasks required every 6 months 1. Repeat the 3-month service 2. Preventive maintenance – additional − Check superheat and subcooling − Check the glycol/water mixture for good freeze

protection 3. Commissioning operations, as follows: − Check the glycol water pumps − Check the flow meters for proper GPM − Check all safety devices − Check the antifreeze protection (setting) Enter all repairs/changes in a maintenance log Note: The recommendations and specifications given here are based on experience. The type and scope of maintenance depends on the actual application of the system. More frequent and more comprehensive inspections may be necessary in the event of more adverse conditions, e. g.: − Higher or lower ambient temperatures − Power fluctuations − Dusty/Dirty installation conditions Checking the glycol solution lf the system is operated with a water/glycol mixture, the mixed percentage must be regularly checked. Recommendation: every 6 months

− Only a correct mixture can guarantee correct operation. Check the percentage with a portable spectrometer.

− Excess glycol concentration: reduces the cooling capacity

− Insufficient glycol concentration: risk of freezing. − The water sample should also be checked for

signs of corrosion. Note: Improper use of water treatment agents can cause major problems. Obtain information from the manufacturer on suitable inhibitors.

PREVENTIVE MAINTENANCE Maintenance Intervals Note: The maintenance intervals specified here are based on experience. Depending on individual conditions at any job site, required maintenance intervals may need to be performed more or less frequently than recommended within this manual.

WARNING

STRICTLY OBEY THE SAFETY INSTRUCTIONS

WARNING Maintenance must be carried out by qualified service and maintenance technician. During operation, potentially lethal high voltages and high pressures are generated in the chiller system. All safety precautions and wamings given in these documents must be precisely observed. Otherwise, severe or fatal injuries may be caused.

MANUFACTURER’S NOTE

When gather running data on chiller readings must be taken at full load and under the normal system operating conditions. Weekly tasks required 1. A general inspection of the chiller operation. 2. Carry out weekly inspections.

Servicing tasks required every 3 months: 3. Check the settings of all safety devices against the

Commissioning Report. 4. Preventive maintenance, as follows: − Check the fan(s) are running − Check the refrigerant pipes for any signs of leaks − Check the water/glycol pipes for any signs of leaks − Check the glycol water pump(s) − Check the condenser for dirt build up − Check the electrical cabinet − Check the compressor(s) amp draw 5. Carry out any maintenance issues once they are

found Enter all repairs/changes in a maintenance log

WARNING The glycol/water mixture must not be discharged into the normal water drains. It must be collected in suitable containers and disposed of in accordance with the local law specifications.

MPCA0005 - MPCA0150 MANUAL

WARNING - RISK OF INJURY Risk of cuts due to the condenser fins. Wear gloves if

working on the condenser.

Preventive Maintenance

IMPORTANT NOTE The maintenance operations are described below. All operations must be performed step by step and must be completely finished.

WARNING High voltage - Risk of fatal injury

Disconnect the unit from the power supply before opening the doors or removing the chiller panels.

Risk of burns Exposed copper pipes may be hot.

Checking the refrigerant pipes 1. Check the refrigerant piping as far as possible for

cracks, damage and oil leaks. 2. Check the piping for chafing points, especially

where the pipes are routed very close to the frame work or along internal components of the chiller.

3. Check the pipe insulation and repair/replace if necessary.

4. Check the pipes for vibrations. Check the pipe mounting clips and re-tighten the screws if necessary.

Checking the water/ glycol Iines

1. Check all pipes for vibrations. 2. Check the mounting clips and tighten if necessary. 3. Check for leaks at screwed joints and weldings and

repair if necessary. 4. Squeeze the insulation to determine whether it

has filled with water. lf so: Locate the leak and repair

5. Check the insulations and repair/replace any damaged points.

Note: Condensation may form due to inadequately insulated chilled water pipes.

WARNING High voltage - risk of fatal injury

Disconnect the unit from the power supply

Checking the chilled water pumps - when mounted in the chiller -

1. Check for leaks around the pump. If leaking, tighten any flange fittings that might be leakingo or the mechanical pump seal might need to be changed.

2. Check on the motor electrical box for loose electrical connections. lf necessary, retighten the electrical connections. Reclose the terminal box.

3. Check the externally mounted Y-strainer and clean if necessary.

RISK OF INJURY If it is necessary to carry out work inside the system with the fans running, make sure that no parts of the body or clothing are caught in the fan blades or other moving parts.

Checking the air-cooled condenser 1. Check the condenser coil and clean CAREFULLY.

Low PSI compressed air can be used. DO NOT USE A BRUSH OR SCRAPER OR CODENSER COIL WILL BE PERMANENTLY DAMAGED.

2. Straighten bent fins with a fin comb set for the correct fin pitch.

WARNING After changing any components such as fan baldes, etc., insure balance is correct.

1. Check the fan mounting and, if necessary, tighten the securing screws.

2. Check the electrical terminal box. 3. Check to make sure the rotation of fans are

correct After completing these operations, re-install any side or top panel that was removed. This is to ensure proper air flow is going through condenser Record any repairs/changes on the maintenance log.

MPCA0005 - MPCA0150 MANUAL

MAINTENANCE/REPAIR

FAILURE OF A COMPRESSOR

Occasionally, a fault in the motor insulation can cause the motor to burn out. On a maintained system, this type of failure is very rare. However, if it does occur, it wiII generally be caused by mechanical or lubrication faults that result in burn-out. Compressor damage can be Iargely prevented if the problems Ieading to motor burn-out are remedied. Regular service inspections - That identify fault conditions play an active role in ensuring operating safety and reducing maintenance costs. Mechanical fault - The refrigerant gas from the service port does not smell burnt. The motor tries to start. Electrical fault - This type of fault is identified by a characteristic smell when the coolant is removed from the service port. After severe burn out, the oil is black and acidic. Check all electrical components before replacing a compressor assumed to be defective. 1. Check the main disconnect switch and fuse 2. Check all safety devices of the compressor. 3. Check whether the mechanical or electrical fault

has damaged the compressor. 4. Perform an acid test.

Compressor replacement after mechanical fault lf a mechanical fault is found, and the acid test is negative, replace the compressor as follows: 1. Check: the power supply to the circuit must be

disconnected.

WARNING - RISK OF BURNS Do not undo any refrigerant connections until the system is depressurised.

WARNING When working on the refrigerant circuit, open the compressor breaker in the electrical cabinet.

2. Connect refrigerant pressure gauges to the service ports.

3. Close the service valves by tuming them clockwise. Reclaim the refrigerant pressure from the compressor.

4. Remove all mechanical and electrical connections on the compressor, and then the remove the defective compressor.

5. Install the new compressor and connect up all connections correctly.

6. Evacuate the refrigerant circuit to 500microns. 7. Open the service valves on the compressor. 8. Start up the compressor. Check the refrigerant

level and ensure the circuit is perfectly sealed. 9. Dispose of the defective compressor in accordance

with local laws.

Compressor replacement after burn-out In the case of an electrical fault and compressor motor burn-out, proceed very carefully. lf the motor burns out, the stator windings break down, forming carbon, water and acid, which contaminate the refrigerant system. These impurities must be completely removed from the system in order to prevent repeated motor damage.

WARNING! lf the replacement compressor is damaged due to inadequate system cleaning, warranty will be voided

1. Carry out the acid test and send it with the compressor to the manufacturer for damage analysis.

2. Check: the power supply of the refrigerant circuit must be disconnected.

CARE High voltage - Risk of fatal injury

Disconnect the main current supply to the unit if the power supply has to be maintained (to operate the second circuit)

OBEY THE SAFETY INSTRUCTIONS

3. Check the electrical circuit in the electrical cabinet for blown fuses, charred contacts, overload contacts and relays. Check the input and output terminals of the compressor circuit.

MPCA0005 - MPCA0150 MANUAL

MAINTENANCE/REPAIR CONTINUED Compressor replacement after burn-out 4. Check the connection line of the compressor for

charred or damaged connectors, insulation and short-circuited or grounded.

5. Meg the compressor. 6. Establish the cause of the electrical fault. Take all

necessary corrective action to ensure that the new compressor does not experience the same result.

Removing the compressor 1. Reclaim the refrigerant circuit 2. Close the compressor inlet and outlet service

valves. 3. Remove the burnt out compressor. Dispose of in

accordance to local laws Note: Check that the inlet and outlet valves are not fouled after the severe burn-out. Before connecting the new compressor, the valves must be carefully cleaned and/or replaced. Check the seals in the service valves . Cleaning the refrigerant circuit Clean the circuit with great care and in conformity with the manufacture.

WARNING Refrigerant must never be discharged into the environment. It must be collected in a collecting container for proper disposal

WARNING Avoid any skin contact with gas or refrigeration oils. Severe burns may be caused. Always wear rubber gloves when handling dirty parts.

WARNING! lf the replacement compressor is damaged due to inadequate system cleaning, warranty will be voided.

MPCA0005 - MPCA0150 MANUAL

CLEANING THE PLATE EXCHANGER (EVAPORATOR)

Clean exchangers subject to fouling (scale, sludge deposits, etc.) periodically, depending on specific conditions. A marked increase in pressure drop and/or reduction in performance usually indicate cleaning is necessary. Since the difficulty of cleaning increases rapidly as the scale thickens or deposits increase, the intervals between cleanings should not be excessive. Back flush with a high pressure stream of hot water to remove loose deposits. Circulating hot wash oil or light distillate will usually effectively remove sludge or similar soft deposits. In some applications the fouling tendency can be very high, e.g. when using extremely hard water at high temperatures. Use a tank with weak acid, 5% phosphoric acid or, if the exchanger is frequently cleaned, 5% oxalic acid. Pump the cleaning liquid through the exchanger. For optimum cleaning, the cleaning solution flow rate should be a minimum of 1.5 times the normal flow rate, preferably in a back-flush mode. After use, DO NOT to forget to rinse the heat exchanger carefully with clean water. A solution of 1-2% sodium hydroxide (NaOH) or sodium bicarbonate (NaHCO) before the last rinse ensures that all acid is neutralized. Clean at regular intervals. If the heat exchanger is excessively fouled and it cannot be cleaned by commercial cleaning methods, then replacement of the unit is suggested. It is recommended that the refrigerant circuit NOT be chemically cleaned.

MPCA0005 - MPCA0150 MANUAL

CHLORINE - FREE REFRIGERANTS The compressors designed for operation with chlorine-free refrigerants are factory-filled with ester oils approved by the compressor manufacturer and are marked accordingly. Compared to single-substance refrigerants and azeotropic and quasi-azeotropic mixtures, the zeotropic refrigerant mixtures are characterised by a wider temperature variation. Specific effects on system maintenance and repairs must therefore be taken into account. Due to the fact that zeotropic mixtures can have different compositions in the liquid and gas phases, it is especially important that these refrigerants are only ever poured into the system in the Iiquid state. Therefore: strictly follow the filling instructions of the refrigerant manufacturer. In the event of a Ieak, the change in mixture composition Ieads to reduced superheat at the thermostatic expansion valve and ultimately to liquid flood back in the compressor. Another aspect of the mixture change is sudden ‘hunting’ of the expansion valve. Tests by refrigerant manufacturers and the past experience of users have shown that this situation can be stabilized by filling the system with the original composition. Before replacing the entire refrigerant charge, a mixture concentration analysis is recommended.

The use of polyester oils ("POE"s) is necessary for operation with chlorine-free refrigerants. Compared to mineral oils, POEs have high hygroscopicity (moisture absorption). If POE is exposed for only a short time to the ambient air, it absorbs so much moisture that it is no longer acceptable for use in refrigeration circuits. Since a POE binds moisture more firmly than mineral oil, the moisture is more difficult to remove from the system by vacuum. Consequently, we recommend filling the system with a POE containing Iess than 50ppm moisture particles. With the use of appropriately sized filter dryers, the moisture content in the system can be kept below 50 ppm. lf the moisture level rises to unacceptable Ievels, corrosion and copper-plating can occur. By perfect evacuation, the residual moisture can be reduced to 10 ppm. The system is evacuated to 500 microns. In the event of any doubt regarding the moisture level in the system, an oil sample should be taken and analysed for water content. The installed indicator sight glasses can be used for the new refrigerants and oils, but they do not show the actual moisture content, which may be higher than shown in the sight glass due to the high hygroscopicity (moisture absorption). The display in the sight glass only gives the moisture content of the refrigerant. To determine the real moisture level, an oil sample must be taken from the system and analysed.

MPCA0005 - MPCA0150 MANUAL

Terms & Conditions of Sale

1) All orders are subject to approval & acceptance by the Seller. 2) Prices are quoted FOB point of shipment, and are subject to change without notice. All prices are exclusive of any sales, use, State, Federal, or local taxes. The collection & payment of such taxes are the responsibility of the Buyer. 3) Upon transfer of the equipment from the Seller to a common carrier, title shall pass to the Buyer. The Buyer assumes all risks of loss or damage during transit. The buyer must file claims for such loss or damage with the carrier, with assistance from the Seller. 4) Seller shall not be liable for any damages or consequential losses of any kind, arising out of its inability to deliver due to labor, suppliers, fire, flood, delays of any kind, acts of God, or any other cause whatsoever. 5) Seller warrants all equipment to be free from defects in materials and workmanship for a period of fourteen (14) months from the date of shipment or 12 months from the date of startup, provided the equipment is applied, installed and maintained in accordance with Seller’s recommendations. Seller’s liability is limited solely to repair or replacement of the defective item, at Sellers option, excluding labor or freight. Under no circumstances shall Seller be liable for any losses, rental equipment charges, or consequential damages of any kind, howsoever caused. All warranty interpretations and limitations are defined in the Motivair Standard Product Warranty, a copy of which is available to Buyer on request. 6) Seller makes no warranty or representation of any kind, expressed or implied, as to the merchantability, fitness or suitability for any particular purpose, with respect to the equipment. 7) Buyer must obtain written permission from Seller, prior to returning any equipment for warranty, credit, or any other reason whatsoever. The terms of any warranty returns or associated credits are in strict accordance with the above referenced Motivair Standard Product Warranty. All goods returned for reasons other than warranty shall be subject to a re-stocking charge of no less than 15%, not to exceed the full invoiced value of the equipment, to be determined at the sole discretion of the Seller. Return freight charges, plus the risk of loss or damage, whether or not it occurs during shipment back to Seller, will be borne solely by the Buyer. 8) Order changes must be submitted in writing by the Buyer and acknowledged in writing by the Seller, before such changes shall be deemed valid. Cancellations shall be subject to a charge not to exceed the value of the original order, at the sole discretion of the Seller. Buyer shall also be responsible for all freight costs associated with any order changes or cancellations. 9) Terms of payment shall be net 30 days to all credit-approved Buyers, from the date of shipment or consignment to a common carrier, for all standard or inventoried items. Seller will allow a cash discount of 1% for prompt payment received within ten (10) days of Sellers invoice date. 10) Terms of payment for large or custom orders shall be specified at the time of order acknowledgement. No contractor or performance payment retention is allowed for any reason whatsoever, beyond these payment terms. 11) A finance charge of 1.5% per month will be applied to all overdue accounts. In the event Seller utilizes a collection agency or legal proceedings to recover money due and payable to Seller under this agreement, Buyer agrees to pay for all costs directly associated with this collection. 12) This contract shall be governed in strict accordance with the laws of New York State. If any of these terms are held to be invalid by a prevailing court of law, the remainder of these terms shall remain in effect, and shall not be affected by the invalid portion. 13) This contract shall constitute the entire agreement between Buyer and Seller. All terms and conditions contained herein shall be deemed acceptable by the Buyer and shall prevail over any and all terms stipulated within the Buyer’s purchase order, unless specifically amended by the Buyer, and agreed by the Seller in writing. Customer Signature of Acceptance: ______________________________ Date: ____________________________

MPCA0005 - MPCA0150 MANUAL