Thermal Care NQ Series User Manual

Installation & Operation Manual
NQ Series Portable and Remote Condenser Chillers

Thermal Care NQ Series Specifications

General

Brand	Thermal Care
Model	NQ Series
Category	Chiller
Language	English

Summary

Foreword

Safety Guidelines

Warning Symbols and Precautions

Explains safety symbols, warnings, and cautions for safe operation.

General Data

Air Cooled Chiller Specifications (Table 1)

Provides detailed specifications for air-cooled chiller models.

Water Cooled Chiller Specifications (Table 2)

Provides detailed specifications for water-cooled chiller models.

Remote Condenser Data

Remote Air Cooled Condenser Specs (Table 3)

Lists specifications for remote air-cooled condenser chiller models.

Remote Condenser Electrical Data (Table 4)

Details electrical data for remote air-cooled condenser units.

Pre-Installation Procedures

Receiving and Inspecting the Unit

Instructions for verifying unit correctness, condition, and documenting damage.

Unit Storage Guidelines

Recommendations for proper storage of the chiller to prevent damage.

Chiller Mechanical Installation

Foundation and Location Requirements

Guidelines for chiller placement, mounting, and clearance for serviceability.

Rigging and Lifting Procedures

Safe methods for moving and positioning the chiller unit.

Chilled Water Piping Installation

Best practices for installing chilled water piping to prevent condensation.

Pump Performance Curves

Recommended Overhead Piping Diagram (Figure 1)

Illustrates recommended overhead piping configuration with a vacuum break.

4-Ton Chiller Net Pump Performance (Figure 2)

Graph showing pump discharge pressure vs. flow for 4-ton chillers.

4-Ton High Flow Chiller Pump Performance (Figure 3)

Graph showing pump performance for 4-ton high-flow chillers.

5-Ton Standard Chiller Pump Performance (Figure 4)

Graph showing pump discharge pressure vs. flow for 5-ton chillers.

Chiller Pump Performance Data

5-Ton High Flow Chiller Pump Performance (Figure 5)

Graph showing pump performance for 5-ton high-flow chillers.

7¹⁄₂-Ton Standard Chiller Pump Performance (Figure 6)

Graph showing pump discharge pressure vs. flow for 7¹⁄₂-ton chillers.

7¹⁄₂-Ton High Flow Chiller Pump Performance (Figure 7)

Graph showing pump performance for 7¹⁄₂-ton high-flow chillers.

10-Ton Standard Chiller Pump Performance (Figure 8)

Graph showing pump discharge pressure vs. flow for 10-ton chillers.

Chiller Pump Performance Data (Continued)

10-Ton High Flow Chiller Pump Performance (Figure 9)

Graph showing pump performance for 10-ton high-flow chillers.

13-Ton Standard Chiller Pump Performance (Figure 10)

Graph showing pump discharge pressure vs. flow for 13-ton chillers.

13-Ton High Flow Chiller Pump Performance (Figure 11)

Graph showing pump performance for 13-ton high-flow chillers.

15-Ton Standard Chiller Pump Performance (Figure 12)

Graph showing pump discharge pressure vs. flow for 15-ton chillers.

Chiller Pump Performance Data (Continued)

15-Ton High Flow Chiller Pump Performance (Figure 13)

Graph showing pump performance for 15-ton high-flow chillers.

20-Ton Standard Chiller Pump Performance (Figure 14)

Graph showing pump discharge pressure vs. flow for 20-ton chillers.

20-Ton High Flow Chiller Pump Performance (Figure 15)

Graph showing pump performance for 20-ton high-flow chillers.

25-Ton Standard Chiller Pump Performance (Figure 16)

Graph showing pump discharge pressure vs. flow for 25-ton chillers.

Chiller Pump Performance Data (Continued)

25-Ton High Flow Chiller Pump Performance (Figure 17)

Graph showing pump performance for 25-ton high-flow chillers.

30-Ton Standard Chiller Pump Performance (Figure 18)

Graph showing pump discharge pressure vs. flow for 30-ton chillers.

30-Ton High Flow Chiller Pump Performance (Figure 19)

Graph showing pump performance for 30-ton high-flow chillers.

35-Ton Standard Chiller Pump Performance (Figure 20)

Graph showing pump discharge pressure vs. flow for 35-ton chillers.

Chiller Pump Performance Data (Continued)

35-Ton High Flow Chiller Pump Performance (Figure 21)

Graph showing pump performance for 35-ton high-flow chillers.

40-Ton Standard Chiller Pump Performance (Figure 22)

Graph showing pump discharge pressure vs. flow for 40-ton chillers.

40-Ton High Flow Chiller Pump Performance (Figure 23)

Graph showing pump performance for 40-ton high-flow chillers.

Chiller Coolant Pressure Drop (4 & 5 Ton) (Figure 24)

Graphs showing coolant circuit pressure drop for 4 and 5-ton chillers.

Chiller Coolant Pressure Drop Data

Chiller Coolant Pressure Drop (7¹⁄₂ & 10 Ton) (Figure 25)

Graphs showing coolant circuit pressure drop for 7¹⁄₂ and 10-ton chillers.

Chiller Coolant Pressure Drop (13 & 15 Ton) (Figure 26)

Graphs showing coolant circuit pressure drop for 13 and 15-ton chillers.

Chiller Coolant Pressure Drop (20 & 25 Ton) (Figure 27)

Graphs showing coolant circuit pressure drop for 20 and 25-ton chillers.

Chiller Coolant Pressure Drop (30 & 35 Ton) (Figure 28)

Graphs showing coolant circuit pressure drop for 30 and 35-ton chillers.

Chiller Coolant Pressure Drop Data (Continued)

Chiller Coolant Pressure Drop (40 Ton) (Figure 29)

Graphs showing coolant circuit pressure drop for 40-ton chillers.

Condenser Water Piping Considerations

Discusses factors affecting condenser performance and water treatment.

Water Cooled Condenser Pressure Drop (5-15 Ton) (Figure 30)

Graph showing pressure drop for water-cooled condensers (5-15 ton).

Water Cooled Condenser Pressure Drop (20-40 Ton) (Figure 31)

Graph showing pressure drop for water-cooled condensers (20-40 ton).

Installation – Remote Air-Cooled Condenser

Location and Clearance Guidelines

Specifies requirements for outdoor condenser placement and clearances.

Mounting and Lifting (5-10 Ton Units)

Instructions for attaching legs and lifting smaller remote condensers.

Mounting and Lifting (15-40 Ton Units)

Instructions for attaching legs and lifting larger remote condensers.

Interconnecting Refrigerant Piping

Details on connecting chiller and remote condenser refrigerant lines.

Refrigerant Piping Design

General Refrigerant Piping Design Considerations

Key factors like distance, elevation, and drop legs for piping design.

Condenser Location Configurations (Figures 32-33)

Diagrams illustrating condenser placement relative to the chiller.

Condenser Location Below Chiller (Figure 34)

Diagram showing condenser placement below the chiller unit.

Determining Equivalent Line Length

Method for calculating equivalent pipe length for line sizing.

Liquid Line Sizing

Liquid Line Sizing Guidelines

Rules and considerations for sizing liquid refrigerant lines.

Liquid Line Sizes for R410A (5, 7¹⁄₂ Ton Circuits)

Table providing liquid line sizing based on equivalent length and riser height.

Liquid Line Sizes for R410A (20-35 Ton Circuits)

Table providing liquid line sizing for 20-35 ton circuits.

Liquid Line Sizes for R410A (40 Ton Circuit)

Table providing liquid line sizing for 40-ton circuits.

Discharge Line Sizing

Discharge (Hot Gas) Line Sizing

Guidance on sizing discharge lines for proper oil return and capacity.

Vertical Riser Traps (Figure 35)

Diagram illustrating vertical riser traps for hot gas lines.

Double Discharge Riser (Figure 36)

Diagram showing a double discharge riser configuration.

Discharge Line Sizing Tables (Tables 7 & 8)

Tables for horizontal/downflow and upflow discharge line sizing.

System Refrigerant and Oil Charge

Refrigerant Charge Tables (Tables 9 & 10)

Tables for calculating total and field piping refrigerant charges.

Oil Charge Determination

Procedure for determining the correct oil charge for the system.

Condenser Fan Control Settings (Table 11)

Table detailing fan pressure settings for condenser fan control.

Electrical Installation

Wiring, Voltage, and Phase Requirements

Guidelines for electrical wiring, voltage tolerance, and phase sequence.

Electrical Safety Precautions

Crucial safety warnings related to electrical hazards and components.

Air Cooled Chiller Electrical Data (Table 12)

Air Cooled Chiller Electrical Data (Table 12) - Cont.

Table providing electrical data for NQA15, NQA20, NQA25 models.

Air Cooled Chiller Electrical Data (Table 12) - Cont.

Table providing electrical data for NQA20, NQA25, NQA30 models.

Air Cooled Chiller Electrical Data (Table 12) - Cont.

Table providing electrical data for NQA30 models.

Water/Remote Air Cooled Chiller Electrical Data (Table 13)

Water/Remote Air Cooled Chiller Electrical Data (Table 13) - Cont.

Table for NQW10/NQR10, NQW15/NQR15 electrical data.

Water/Remote Air Cooled Chiller Electrical Data (Table 13) - Cont.

Table for NQW20/NQR20, NQW25/NQR25 electrical data.

Water/Remote Air Cooled Chiller Electrical Data (Table 13) - Cont.

Table for NQW30/NQR30, NQW35/NQR35, NQW40/NQR40 electrical data.

Remote Air Cooled Condenser Electrical Data

Remote Condenser Electrical Data (Table 14)

Table detailing electrical data for remote air-cooled condenser units.

Standard Controller Operation

Controller Interface Overview

Description of the controller's display, basic layout, and diagnostic lights.

Start and Stop Button Functions

How to use the Start and Stop buttons for chiller operation and cancellation.

Alarm and Hour Monitoring Buttons

Functionality of Alarm Silence/Reset and Compressor Running Hours buttons.

Pump Operation and Test Buttons

Operation of Pump Running Hours and Pump Test buttons.

Controller Operation Details

Display and Navigation Buttons

Functionality of Display/Program, Up, and Down arrow buttons.

Status Indicator LEDs

Explanation of Control Power and Autostart Signal LEDs.

Compressor Status LEDs

Meaning of Compressor #1 and #2 status LEDs and related parameters.

System Fault LEDs

Explanation of Temperature Limit, Phase Error, and Low Flow LEDs.

Controller Operation Details (Continued)

Chiller Protection LEDs

Explanation of Freezestat, Reservoir Level, Compressor Recycle, Refrigerant LEDs.

Temperature Display Functions

How the Set Point and Process displays show temperature and units.

Program Menu Overview

Introduction to accessing and using the controller's program menu.

Accessing and Navigating the Program Menu

Step-by-step guide to entering and navigating the program menu with password.

Program Menu Configuration

Master Reset Procedure

Instructions for performing a master reset to factory default settings.

Controller Program Menu Parameters (Table 15)

Table listing adjustable parameters, item codes, default values, and ranges.

Controller Control Fault Logic (Table 16)

Table detailing fault conditions, alarm indications, and reset requirements.

SPI Communications (Optional)

SPI Protocol Overview

Explanation of the SPI communication standard used for integration.

SPI Parameter Configuration (Table 17)

Table of SPI parameters, commands, poll/select values, and descriptions.

SPI Parameters (Continued)

Further SPI parameters including status, mode, and temperature readings.

Modbus RTU (Optional)

Overview of the Modbus RTU option for RS-485 communication.

Modbus RTU Parameters

Modbus RTU Parameters (Integral Values) (Table 18)

Table listing Modbus RTU parameters with integer values and notes.

Modbus RTU Parameters (Floating Point Values) (Table 19)

Table listing Modbus RTU parameters with floating point values and notes.

Optional Controller Operation

PLC and Touchscreen Interface

Introduction to the optional PLC and touchscreen interface for chiller control.

Start-Up Screen and Contact Info

Description of the initial screen and company contact details.

Main Navigation Screen

Overview of the primary screen for chiller control and navigation.

Start and Stop Button Functions

Explains the operation of Start and Stop buttons on the main screen.

Optional Controller Navigation

Alarm and Navigation Button Functions

Describes Alarms, Setup, Process, and Refrigeration diagnostic buttons.

Setup and Diagnostic Screens

Details on Compressor Setup, Process Setup, PID, and FreezeStat screens.

Hot Gas Bypass PID Tuning

Explanation and adjustment of PID parameters for hot gas bypass.

Freezestat Setup Screen

How to adjust Freezestat settings for freeze protection.

Controller Diagnostics

Process Diagnostic Screen

Displays operating status of coolant temp, pump, and HGBP valve.

I/O Status Screen and Navigation

Shows digital inputs/outputs and allows navigation to output designation.

Refrigeration Diagnostic Screen

Displays operating status of set point, actual temps, HGBP, compressor.

Preventive Maintenance

Maintenance Schedule Overview

Importance of preventive maintenance and suggested schedule.

Once a Week Maintenance

Tasks to perform weekly, including checks on condenser coils and temperatures.

Once a Month Maintenance

Tasks to perform monthly, including electrical connections and voltage checks.

Every Three Months Maintenance

Tasks to perform quarterly, including Y-strainer cleaning and technician inspection.

Preventive Maintenance Checklist

Preventive Maintenance Checklist

A checklist for tracking scheduled maintenance activities.

General Troubleshooting

Compressor and Pump Start Issues

Common causes and remedies for compressor and pump start failures.

Refrigerant Pressure Related Issues

Troubleshooting for high or low refrigerant pressure problems.

Freezestat and Flow Issues

Solutions for freezestat faults and low flow conditions.

Temperature Control and Cooling Issues

Troubleshooting for erratic temperature control and insufficient cooling.

Start-Up Procedures

Step 1: Connect Main Power

Instructions for connecting main power and checking phase sequence.

Step 2: Fill Coolant Circuit

Steps for filling the coolant reservoir with water or glycol solution.

System Fill Water Chemistry Requirements

Discusses water properties, potential issues, and necessary treatments.

Water Quality Requirements (Table 20)

Table listing water characteristics and their quality limitations.

Start-Up Procedures (Continued)

Recommended Glycol Solutions (Table 21)

Table recommending glycol concentrations for different chilled water temperatures.

Step 3: Check Condenser

Procedures for checking integral, water-cooled, and remote condensers.

Step 4: Check Refrigerant Valves

Verify that all refrigerant service valves are open.

Step 5: Verify Freezestat Setting

How to set the Freezestat appropriately for operating conditions.

Start-Up Procedures (Continued)

Step 6: Turn On Control Power

Instructions for turning on control power and resetting potential alarms.

Step 7: Establish Coolant Flow

How to establish coolant flow through the chiller before operation.

Step 8: Initial Unit Operation

Steps for setting temperature, checking pressures, and initial operation.

Warranty

Thermal Care Equipment Warranty

Details the standard warranty coverage for Thermal Care equipment.

Warranty Limitations and Exclusions

Specifies conditions that may void the warranty or are not covered.

Extended 5 Year Compressor Warranty (Optional)

Extended Compressor Warranty Terms

Details the terms and conditions for the optional extended compressor warranty.