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Emerson Fluid Chiller User Manual

Emerson Fluid Chiller
64 pages
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Precision Cooling
For Business-Critical Continuity
Liebert Process Fluid Chiller
User Manual - 1.5 - 10 Tons, 50 & 60 Hz
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Emerson Fluid Chiller Specifications

General IconGeneral
BrandEmerson
ModelFluid Chiller
CategoryChiller
LanguageEnglish

Summary

1.0 INTRODUCTION

1.1 Product Description

Detailed overview of the Liebert Process Fluid Chiller's components and system features.

1.2 Optional Equipment

Lists and describes optional components available for the chiller system.

1.2.1 Refrigerant Gauges and Reservoir Heater

Details the optional factory-installed refrigerant gauges and reservoir heater for the fluid reservoir.

1.3 Accessory Equipment (Ship with Kits)

Lists and describes accessory equipment shipped separately for customization and indoor installation.

1.3.1 Emergency Water Source Module

Explains the function, features, and application of the emergency water source module.

1.3.2 Water Level Control and Alarm System

Describes the multi-point level switch, solenoid valve, and RCM4 monitor accessory.

1.3.3 Fluid Pressure Gauge

Details the analog fluid pressure gauge for panel mounting and monitoring supply or return pressure.

1.3.4 Check Valve

Describes the brass body swing check valve used in fluid piping to prevent backflow.

1.3.5 Dial Thermometer

Details the 2-1/2 inch dial thermometer for panel mounting and fluid temperature measurement.

1.3.6 Relief Valve

Explains the brass body relief valve, set at 50 PSI, for installation in fluid piping.

1.3.7 Circuit Setter

Describes the bronze body balancing valve for flow balance, metering, and shut off.

1.3.8 Ball Valve

Details the brass body 1/4 turn ball valve used for isolation of fluid piping components.

1.3.9 High Temperature Thermostat

Explains the remote bulb thermostat for alarming when fluid temperature rises above design limit.

1.3.10 Low Flow Switch

Describes the brass body flow switch that provides alarm contact when fluid flow falls below design limit.

1.3.11 RCM8 Monitor

Details the eight-point dry contact monitoring system used for remote monitoring and alarming.

2.0 INSTALLATION

2.1 Equipment Inspection

Instructions for inspecting the unit for visible or concealed damage upon arrival.

2.2 Location Considerations

Guidance on selecting an optimal location for the air-cooled chiller, considering security and airflow.

2.3 Piping Connections

Instructions for connecting the chiller to the coolant loop, including valve and insulation requirements.

2.4 Electrical Connections

Steps for connecting the unit to the AC power source and field wiring according to codes.

2.5 Preparation of Glycol Solution

Guidance on preparing and using ethylene or propylene glycol solutions for freezing protection.

2.6 Start-up

Refers to the Operation section for the start-up checklist and procedure.

3.0 OPERATION

3.1 Pre-Startup Checklist

A comprehensive checklist of items to verify before starting the chiller unit.

3.2 Startup Procedure

Step-by-step instructions for safely energizing and starting the chiller unit.

3.3 Overview of Operation

Explains the general operational principles, system responses, and fan motor regulation.

3.4 Transformer

Describes the transformer's role in providing 24 VAC for control circuit relays and contacts.

3.5 Low Pressure Switch Adjustment

Details how to adjust the low pressure switch cut-out and cut-in settings for different fluids.

3.6 Temperature Adjustment

Instructions for setting the temperature control (thermostat) setpoint and differential.

3.7 High Pressure Switch

Information on the non-adjustable high pressure switch that limits maximum discharge pressure.

3.8 Positive Start Kit

Explains the function of the non-adjustable time delay relay that bypasses the low pressure switch.

3.9 Short Cycle Prevent Relay

Describes the function of the non-adjustable time delay relay preventing rapid compressor cycling.

4.0 MAINTENANCE

4.1 Refrigeration System

Covers periodic inspections and maintenance of the refrigeration system components.

4.1.1 Suction Pressure

Details suction pressure variations, low pressure switch settings, and maximum operating pressures.

4.1.2 Discharge Pressure

Discusses discharge pressure variations and the high pressure switch cut-out setting.

4.1.3 Superheat

Explains how to determine and adjust superheat using the thermostatic expansion valve.

4.1.4 Thermostatic Expansion Valve Operation

Explains TEV function and provides steps for adjusting superheat setting.

4.1.5 Hot Gas Bypass Valve Operation

Details the function and adjustment procedure for the hot gas bypass valve.

4.1.6 Air Cooled Condenser

Guidance on cleaning and maintaining the air-cooled condenser for optimal efficiency.

4.1.7 Compressor Replacement

Information and procedures for replacing a faulty compressor unit.

Mechanical Failure

Describes symptoms and causes of mechanical compressor failure, indicating motor attempt to run.

Electrical Failure

Discusses symptoms and causes of electrical compressor failure, indicating pungent odor and black oil.

Compressor Replacement Procedure

Step-by-step procedure for replacing a compressor, including safety and recovery steps.

4.2 Chilled Fluid Pump

Information regarding the chilled fluid pump, including differential and suction pressure.

4.2.1 Pump Differential Pressure

Explains pump differential pressure requirements and measurement for preventing motor overload.

4.2.2 Pump Suction Pressure

Details minimum pump suction pressure requirements and checks for low pressure.

4.3 Refrigerant Gauges

Information on the optional refrigerant gauges located in the unit exterior panels.

4.4 Reservoir Heater

Describes the optional reservoir heater for maintaining fluid temperature during low ambient startups.

4.5 Reservoir Tank

Explains the function of the coolant reservoir tank for reducing temperature fluctuations and expansion.

4A.0 8- AND 10-TON PROCESS CHILLER USER MANUAL SUPPLEMENT

4A.1 Product Description

Describes the 8- and 10-ton chiller features, including dual compressors and heat exchangers.

4A.1.1 Additional Equipment

Lists the eight gauges included with the 8- and 10-ton chillers for monitoring various parameters.

4A.2 Temperature Control for 8- and 10-Ton Process Chiller

Explains the electronic hot gas bypass valve and controller for precise capacity control.

4A.3 Temperature Setpoint for Chiller

Instructions for setting the chiller temperature setpoint via potentiometer using a voltmeter.

4A.4 Flow Control

Explains the circuit setter and ball valve for setting the desired system flow rate.

5.0 TROUBLESHOOTING

Chilled Fluid Pump Troubleshooting

Table of symptoms, possible causes, and remedies for chilled fluid pump operational issues.

Compressor Troubleshooting

Table of symptoms, possible causes, and remedies for compressor operational issues.

Refrigeration System Troubleshooting

Table of symptoms, possible causes, and remedies for refrigeration system operational issues.

Condenser Fan Troubleshooting

Table of symptoms, possible causes, and remedies for condenser fan operational issues.

6.0 SEMI-Annual MAINTENANCE INSPECTION CHECKLIST

Air Cooled Condenser

Checklist items for inspecting the air-cooled condenser's cleanliness, motor, and bearings.

Chilled Water Pump

Checklist items for inspecting the chilled water pump for leaks and proper operation.

Compressor

Checklist item for inspecting the compressor for leaks.

Electrical Panel

Checklist items for inspecting electrical connections and operation sequence.

Refrigeration Cycle/Section

Checklist items for inspecting refrigerant lines, pressures, and valves.

7.0 PARTS

7.1 Parts List

List of fans and motors with part numbers and applicability across different ton models.

8.0 APPENDIX A: EMERGENCY WATER SOURCE MODULE

8.1 Model Numbers

Lists model numbers for the emergency water source module based on chiller ton capacity.

8.2 Typical Application

Shows a typical system configuration diagram for the emergency water bypass module.

8.3 Sequence of Operation

Details the normal operation and switchover sequence triggered by loss of flow or high temperature.

8.4 System Components

Lists and describes the key components of the emergency water source module, including RCM4 monitor.

8.5 Installation

Provides instructions for installing the module, including clearance and secure fastening.

8.6 Maintenance

Outlines periodic maintenance for the module, emphasizing monthly manual switchover verification.

9.0 APPENDIX B: THE WATER LEVEL CONTROL MODULE

9.1 Model Number

Specifies the model number for the water level control module for 1.5 and 5 ton units.

9.2 Typical Application

Illustrates a typical system configuration diagram for the water level control module.

9.3 Sequence of Operation

Explains the normal operation, fill sequence, and alarms for the water level control module.

9.4 System Components

Lists and describes the components of the water level control module, including RCM4 monitor and solenoid valve.

9.5 Installation

Provides instructions for installing the module, including reservoir switch and air vent.

9.6 Maintenance

Outlines periodic maintenance for the module, focusing on electrical system verification and supply line.

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