ClimaCool UCW-H 30, UCW-H 50, UCW-H 70, UCW-H 85 User Manual
Water Cooled Ulmate Chiller Soluon
Model UCW/H 30, 50, 70, 85
Installaon, Operaon & Maintenance Manual
Table of Contents
Introduction .........................................1
Pre-Installation .......................................2
Unit Installation ......................................3
Model Key ...........................................4
Physical Data .........................................5
Dimensional Data and Drawings ........................6
Rigging and Lifting Procedures ........................7
Mounting Rail and Vibration Isolation ...................8
Recommended Service Clearances ......................9
Water Piping ......................................10-11
Water Piping Congurations ..........................12
Hydronic Refrigeration ...............................13
Filling the Water System ..............................14
Water Treatment ....................................15
Water Temperature Requirements ....................16
Condenser and Evaporator Water Pressure
Drop Charts ......................................... 17
Glycol Performance Adjustment Factors Charts .........18-19
Electrical Connection .................................20
Voltage/Phase Monitor Wiring ......................... 21
Pre-Startup .........................................22
Pre-Startup Check List ................................23
Startup .......................................... 24-25
Superheat & Subcooling Flowchart ....................26
Startup and Warranty Form ........................ 27-29
Chiller Operation and Maintenance ....................30
Heat Exchangers ....................................31
Cleaning Arrangment ................................32
Operational Limitations ..............................33
Compressor Information .............................34
Refrigeration Circuit Diagram ......................35-36
Refrigeration System Re-Processing and Charging .......37
Options and Accessories ..............................38
Stainless Steel Strainer Option .....................39-43
Y Type and Basket Type Strainers ......................44
Electrical Data ....................................45-46
Power Distribution Drawing ...........................47
Wiring Diagrams ..................................48-57
Troubleshooting Guide ............................58-59
Warranty Certicate .................................60
Introduction
CAUTION
!
ATTENTION INSTALLER
3 Phase Scroll Compressor Units
• If this unit uses a 3 Phase Scroll Compressor, the following
instructions MUST BE followed:
- Unit power supply MUST BE wired in the proper sequence to avoid
damage to the 3 Phase Scroll Compressor;
- Scroll Compressors with INCORRECT rotation show the following
characteristics:
1.) High sound level;
2.) High suction pressure and low dischage pressure;
3.) Low current draw.
- If any of the three above characteristics exist, swap two of the
three supply wires at the disconnect and recheck compressor for
incorrect rotation.
General Description
ClimaCool’s dedication to energy and environmental
leadership led to the Ultimate Chiller Solution design.
Available in 30, 50, 70 and 85 tons, each module is compact,
redundant, maneuverable, ecient, reliable and serviceable.
Combined tonnages can obtain specic project turndown
and capacity requirements from 30 to 1,000 tons per bank
while having the ability to accommodate future growth and
expansion needs.
The UCW/H model can oer hot gas bypass, heat pump and
heat recovery options utilizing environmentally friendly
R-410A refrigerant for Green building designs.
WARNING
This unit contains HFC-(R410A), an azeotropic mixture of R-32 (Difluoromethane) and R-125 (Pentafluoroethane).
DO NOT VENT HFC-(R410A) to the atmosphere. The U.S. Clean Air Act requires the recovery of any residual
refrigerant. Do not use R-22 service equipment or components on R410A systems.
Safety
Throughout this manual warning, danger, caution and
attention notices appear. Read these items carefully before
attempting any installation, service or troubleshooting of
the equipment. All labels on unit access panels must
be observed.
DANGER: Immediate hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING: Potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION: Potentially hazardous situation or an unsafe
practice which, if not avoided, could result in minor or
moderate injury or product or property damage.
ATTENTION: Notication of installed, operation or
maintenance information which is important, but not
hazard related.
High voltage is used to operate this equipment. Failure to observe standard electrical safety procedures may result
in serious injury. Only persons qualified and / or properly trained should attempt to install, operate and maintain this
equipment. These chillers come fully charged with refrigerant. Installation, and start – up should be accomplished by
technicians who are fully certified to handle refrigerants, as required by 40 CRF Part 82, subpart F of the Recycling
and Emissions Reduction Act. Scroll compressors are used in this equipment. Phase verification is required for proper
rotation direction. Incorrect rotation will result in elevated sound and internal overload trip failure.
SAFETY WARNING
• Excessive Chlorine, Undissolved Solids and
other improper water quality conditions
WILL DAMAGE the internal heat exchanger and
WILL VOID YOUR WARRANTY!
WARNING
To avoid the release of refrigerant into the atmosphere,
the refrigerant circuit of this unit must be serviced only by
technicians who meet local, state and federal prociency
requirements.
All refrigerant discharged from this unit must be recovered
WITHOUT EXCEPTION. Technicians must follow industry
accepted guidelines and all local, state and federal statutes for
the recovery and disposal of refrigerants.
If a compressor is removed from this unit, system refrigerant
circuit oil will remain in the compressor. To avoid leakage of
compressor oil, the refrigerant lines of the compressor must
be sealed after it is removed.
!
• Electric shock hazard!
• May result in injury or death!
• Disconnect power supply(ies)
before servicing!
• Refer servicing to qualified
service personnel.
• Unit to be serviced by qualified
personnel only.
• Refrigerant system under
pressure.
• Relieve pressure before using
tourch.
• Recover refrigerant and store or
dispose of properly.
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DANGER
! !
CAUTION ATTENTION
WARNING! To avoid possible injury or death due to electrical
shock, open the power supply disconnect switch and secure it
in an open position during installation.
CAUTION!
CAUTION! Use only copper conductors for field installed
electrical wiring. Unit terminals are not designed to accept
other types of conductors.
!
WARNING!
DANGER
RECOVER
REFRIGERANT
• Risque de choc électrique!
• Résultat de mai dans dommages
ou la mort!
• Debrancher avant d’entreprendre
le dépannage de l’appareil!
• Consulter un réparateur qualifie
pour le dépannage.
• Confier la maintenance á un
technicien qualifie.
• Le systéme frigorifique sous
pression.
• Décomprimer avant d’exposer á
la flamme.
• Récuperér le frigorigene et le
stocker ou le détrire
correctement.
1
Pre-Installation
Inspection
Upon receipt of equipment, carefully check the shipment
against the bill of lading and inspect each chiller for any
damage incurred during shipment. Thoroughly check for
any visible damage of control panels and electrical
and/or refrigeration components or broken copper lines.
The carrier must make proper notation of any damages or
shortages on all copies of the bill of lading and complete
a common carrier inspection report prior to your nal
acceptance of the shipment. Note: It is the responsibility
of the purchaser to le all necessary claims with the
carrier. In addition, please notify the ClimaCool Customer
Service Department at 405.815.3000 or customerservice@
climacoolcorp.com of all damage immediately.
Storage
Chillers should be stored in an upright position and kept in a
clean, dry area.
Handling of Modules
Carefully remove the module’s packaging. The chiller’s steel
base cutouts provide maneuverability by forklift or pallet
jack into its nal position (See Rigging and Lifting Procedures
on page 7). Verify that all header grooved couplings and
mounting hardware kits are on site prior to connecting
the modules. Note: Consult factory for handling other than in
the upright position.
Rigging and Lifting
Each module should be lifted using a pallet jack or fork
lift. If it is necessary to utilize a crane for rigging or lifting,
each module shall be lifted using lifting straps and spreader
bars using rigging points identied on Rigging and Lifting
Procedures on page 7.
Warranty
To ensure proper equipment longevity, design performance
and reliability, all ClimaCool chillers must be installed,
operated and maintained in accordance with ClimaCool IO&M
manuals. Water quality is of the utmost importance for the
proper care and maintenance of your modular chiller system.
Regular treatment of the water will increase longevity of your
system. Failure to provide adequate ltration or treatment
of evaporator and condenser water will void the ClimaCool
module’s warranty. A factory authorized technician is
required to perform the startup of your ClimaCool chiller.
Please contact the ClimaCool Customer Service Department
at 405-815-3000 or customerservice@climacoolcorp.com to
schedule. There is a minimum of 3 weeks’ notice required to
schedule your factory startup.
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Unit Installation
Unit Placement
ClimaCool modular chillers must be installed in a conditioned
and dehumidied space. The minimum foundation
requirement for the chiller is a level surface capable of
bearing the combined operating weight of the modules
(See Physical Data on page 5).
Service Access
The recommended service clearances are 36” for front
access, 18” height clearance for 30, 50 and 70 ton modules,
and 24” height clearance for 85 ton module, 30” for rear
access and at least 12” for side clearance or as required
for eld piping (see Recommended Service Clearances
and Bank Dimensions on page 9). Local building or electrical
codes may require additional clearance – please consult
applicable codes.
Draining
When performing standard maintenance procedures such
as ushing a heat exchanger, it will be necessary to isolate
either heat exchanger. ClimaCool modular chillers oer
optional water isolation valves for this purpose. Access
to a oor drain is helpful when performing standard
maintenance procedures. Warning: Water valves must be
reopened after ushing is complete.
Assembling Modules
ClimaCool recommends locking down the chiller to a
concrete base or to three (3) 4” base mounting rails using
the six (6) bolt holes provided in each base pan. Although
the compressors are installed on anti-vibration mountings,
further isolation of the chiller from the structure is
recommended by installing vibration-eliminating springs
or pads under the base rails on which the chiller will rest
(See page 8 – Mounting Rail and Vibration Isolation). One
module should be chosen as the reference module and
carefully located.
Field installed mounting accessories are provided for
adjoining each module.
• Header grooved coupling kits containing four (4)
grooved couplings with gaskets
• Mounting hardware kit containing necessary bolts,
spacers, nuts and washers
• Header bank end cap kit containing four (4) grooved
couplings with gaskets and four (4) end caps
Field installing the mounting hardware kit will assist with
alignment of the modules in a bank and eliminate oset
inconsistencies. The 1/2” mounting holes are provided on
sides of the unit base pan. First module should be set, set
adjacent unit on mounting surface roughly aligned
1 ½ inches away from the rst unit. While holding spacer
in place work through rst modules front base cutout to
place a washer and insert bolt through front mounting hole
and spacer. Repeat the process for the rear mounting hole.
Line up mounting hole of adjacent module with bolt from
previous module and working through adjacent modules
front base cutout place a washer, split lock washer and nut.
Using the appropriate tools tighten hardware assembly
until seated.
Inspect the pipe ends to ensure they are free from any
indentations, projections, roll marks or other harmful
surface defects such as loose paint, scale, dirt, chips,
grease and rust. Inspect the grooved coupling gasket for
any defects. Apply a thin layer of silicone or other
non-petroleum lubricant to the sealing lips of the gasket
as well as to the exterior of the gasket. Install gaskets on
the pipe ends of one of the two modules to be mated.
Be sure the gasket is completely on the pipe to avoid
damage in the next step. Move the second module into
position and line up the piping. Ensure you are maintaining
alignment for any additional modules to be added. When
pipe ends are aligned, slide the gasket over the ends and
center it between the grooves. No part of the gasket
should protrude into the groove of either pipe end. Place
the coupling halves over the gasket and make sure that
the coupling keys (the part that goes into the groove) are
engaged into the grooves. Insert the bolts and install nuts
to hand tight. Ensure the oval neck of the bolt engages into
the bolt hole of the housing. Tighten nuts alternately and
equally until the bolt pads meet and make metal to metal
contact. Tighten nuts by another ¼ to ½ turn to make sure
the nuts and bolts are snug and secure; the use of a torque
wrench is usually not required. Uneven tightening of bolts
may cause the gasket to be pinched resulting in immediate
or delayed leaks.
Header Insulation
Chilled water piping is pre-insulated on each module at
the factory with ¾” closed cell insulation. After bolting
all modules together and leak testing, the entire coupling
connection will need to be insulated by the installing
contractor.
Sound Attenuation Panels and Gasket
Attenuation panels are enclosures made of 18 gauge
galvanized steel with powder coat paint nish and berglass
insulation. Panel package includes one (1) upper panel made
out of four (4) sections and one (1) lower panel for each side
of bank (eld installed), four (4) panels for each module
in the bank (factory installed) and gasket sealant tape for
installation between modules. Install panels by setting in
place and locking down with the half turn latches or self
tapping screws. Note: Panel package includes a compressed
1” x 1” gasket sealant tape for installation between
modules. Install the tape on the outer frame on the side
of one module prior to installing the adjacent modules.
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3
r
Model Key
RejectionMeans
W=Water ModelConfiguration
H=HighTemperature S=Standard
NominalTons
070 B=HotGasBypass‐BothCircuits
030 RefrigerantOptions
050 0=(None)
DesignSeries X=SpecialOptions
085 (NotavailablewithHeatPumpapplication)
S=Scroll
X=SpecialOptions
CompressorType
Controls&Electrical Application
A=StandardControls C=Cooling
X=SpecialOptions H=HeatRecovery
U=380/3/50 X=SpecialOptions
N=575/03/60 M=ManualValvesforEvap&Conds
F=460/3/60 B=Evap&CondsrMotorizedValves
H=208‐230/3/60 E=Evap.MotorizedValves&ManualCondsrValves
Voltage
A
UC F S
₁₂
W ASACA
₃ ₁₃ ₁₄
030
UltimateChillerSolutionModelKey
₈₄₅₆ ₇ ₉ ₁₀
A=R‐410A
X=SpecialOptions
Refrigerant
R=ReverseCycle(HeatPump)
X=SpecialOptions
0=(None)
WaterIsolationValves
R=PressureReliefValves
P=HotGasBypasswithPressureReliefValves
₁₂₁₁
M0
₁₅
X=SpecialOptions
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Physical Data
Model UCW/H Module and Compressor
30 50 70 85
Capacity (tons) ¹
31.7 51.5 67.2 82.8
kW/Ton
0.738 0.746 0.744 0.740
Full-Load EER
2
16.3 16.1 16.1 16.2
Refrigerant Circuits (quantity)
2 2 2 2
Compressor Type
Scroll Scroll Scroll Scroll
Compressor Quantity
2 2 2 2
Compressor Nominal Hp (per circuit)
15 25 35 40
Refrigerant Charge (per circuit) R-410A (lbs)
15 32 34 40
Module Operating Weight w/Water (lbs)
3
1480 2200 2450 2855
Module Shipping Weight (lbs)
4
1290 1880 2130 2390
30 50 70 85
Heat Exchanger (type) Brazed Plate Brazed Plate Brazed Plate Brazed Plate
Independent Refrigerant Circuits (quantity)
2 2 2 2
Water Storage Volume HX Only (gals)
3.2 6.1 7.3 11.4
Water Storage Volume HX Plus Main Headers (gals)
13.1 16.7 17.9 26.2
Min
30 50 70 85
Max
165 250 250 485
Maximum Design Working Pressure - Water Side (psi)
300 300 300 300
Header Water Connections - Inlet/Outlet (inches)
6
6 6 6 8
30 50 70 85
Heat Exchanger (type) Brazed Plate Brazed Plate Brazed Plate Brazed Plate
Independent Refrigerant Circuits (quantity)
2 2 2 2
Water Storage Volume HX Only (gals)
2.8 5.1 6.5 9.7
Water Storage Volume HX Plus 6" Main Headers (gals)
12.8 15.7 17.1 24.5
Min
40 65 85 100
Max
165 250 250 350
System Volume (gals)
8
Min
180 300 420 510
Maximum Design Working Pressure - Water Side (psi)
300 300 300 300
Header Water Connections - Inlet/Outlet (inches)
6
6 6 6 8
Notes:
1.
2.
3.
4. Unit shipping weight includes refrigerant charge, compressor oil and packaging.
5.
6.
7.
8. Required to provide stable operation. Storage/buffer tanks in return piping may be utilized to meet the minimum volume requirements.
Main header water/fluid connections are 6" grooved coupling for the 30, 50 and 70 ton modules. The 85 ton module uses 8" grooved couplings.
85 ton module cannot be directly coupled with 30, 50 or 70 ton modules due to a difference in header and frame size.
Module operational weight includes water, compressor oil, and refrigerant charge. Multiply times the number of modules for a total system
operational weight.
Tonnage ratings conditions: 44°F leaving chilled water temperature, 85°F entering condenser water temperature, flow rates are 3 gpm per ton
through the condenser with a fouling factor of .00025 hr-ft2-°F/Btu and 2.4 gpm per ton through the evaporator with a .0001 hr-ft2-°F/Btu fouling
factor.
Ratings in accordance with AHRI Standard 550/590.
The minimum/maximum flow rates are based on an approximate temperature differential of 5°F to 20°F through the evaporator and 5°F to 30°F
through the condenser. Flow rates vary based on application; verify with selection software.
Model UCW/H Condenser
Flow Rate (gpm)
5
Model UCW/H Evaporator
Flow Rate (gpm)
5
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Dimensional Data and Drawings
P5
Chiller Type Header A Header B
UCW Chilled Water Outlet Chilled Water Inlet
UCH Heat Recovery Chilled Water Outlet Chilled Water Inlet
UCH Heat Pump (Cooling Priority) Chilled Water Outlet Chilled Water Inlet
UCH Heat Pump (Heating Priority) Load Water Inlet Load Water Outlet
Load Water Piping Configuration Arrangement
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Rigging and Lifting Procedures
Rigging
Each module should be lifted using lift straps threaded through the steel base cutouts and a spreader bar.
Note: If no spreader bar is used, damage to the module may occur.
Figure 1 Figure 2
Figure 1 Figure 2
Lifting Strap Lifting Strap
Spreader BarSpreader Bar
Spreader Bar
Lifting and Transporting Modules
Pallet jacks or forklifts are required for lifting and transporting the module. Each module has base cutouts provided
for ease of maneuverability. 60” forks are recommended to prevent damage to chiller base.
Figure 3
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Mounting Rail and Vibration Isolation
4” Rail Minimum
Recommended
(by others)
4” Rail Minimum
Recommended
(by others)
Spring Vibration
Isolators (by others)
ClimaCool recommends locking down the chiller to a concrete base or to three (3) 4” base mounting rails using the six
(6) bolt holes provided in each base pan. Due to the low vibration of the modules, the application of spring isolators or
pads is not required. Should isolators or pads be desired install in accordance with Figures 4 and 5.
Figure 4 - Spring Vibration Isolators Option
4” Rail Minimum
Recommended
(by others)
Spring Vibration
Isolators (by others)
Figure 5 – Vibration Isolation Pads Option
4” Rail Minimum
Recommended
(by others)
Note: Size and weight distribution is to be determined by a qualied structural engineer per individual job requirements.
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Recommended Service Clearances
Top View
30”
Rear Service Access
12”
36”
Notes:
1. Allow 36" clearance for electrical panels and 30" clearance for rear service access to modules.
2. Allow a minimum of 18" height clearance for 30, 50 and 70 ton modules. Allow a minimum of 24” height clearance for 85 ton modules.
3. Local building and/or electrical codes may require additional clearance. Consult applicable codes.
Front Service Access
36”
30”
CoolLogic
Control Panel
(Wall Mounted)
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Water Piping
HEADER BYPASS
REVERSE RETURN
HEADER BYPASS
REVERSE RETURN
No. 29 Reducing Tee
w/Thd. Branch
6 x 6 x 2
END VIEW
No.10
2" 90°
Elbow
No.50 Reducer
6 x 2
Hose Kit
2"Belimo
Ball Valve &
Actuator
2"
Grooved
Coupling
HEADER BYPASS
DIRECT RETURN &
HEADER BYPASS
DIRECT RETURN &
No. 25 Grooved Branch
6 x 6 x 2
No. 29 Reducing Tee
w/Thd. Branch
6 x 6 x 2
END VIEW
Hose Kit
2"Belimo
Ball Valve &
Actuator
2"
Grooved
Coupling
As with any water system, it is important that the system
be clean. The pipe work installer must remove weld scale,
rust and contamination during pipe work fabrication.
The system water piping must be ushed thoroughly
with recommended alkaline ush or other chemicals that
are compatible with 316 stainless steel, prior to making
connections to the ClimaCool chiller. There are certain
necessary components that should always be installed in
both the chilled water and condenser water systems. (See
Water Piping Conguration Figures 9 and 10 on page 12).
Piping congurations on multiple modules may also be
found on pages 12. All water piping must be installed in
accordance with applicable codes and standards.
Temperature Sensor and Wells
ClimaCool provides four (4) temperature sensors and wells
with each chiller system congured by the CoolLogic Control
System. They must be eld installed 36” - 60” away from
the bank and before the strainer on the chilled water inlet,
chilled water outlet, condenser water inlet and condenser
water outlet (See Water Piping Congurations – page 12).
Note: Sensors must be fully inserted into the well to obtain
proper readings.
Pressure Dierential Flow Sensor
It is imperative that minimum and maximum water ow
rates, as dened in the Physical Data tables on page 5, are
not exceeded. To prevent operation of the chiller without
sucient water ow to the evaporator and condenser, it
is required to install pressure dierential ow sensors in
both the chilled and condenser water circuits. Place one
on each side, downstream of the strainers on the inlet and
outlet of a straight pipe, as close to the module as possible.
Do not put in an elbow on the outlet. (See Water Piping
Congurations – page 12). Note: Evaporator and condenser
sides both require sensors of equal pressure ranges.
Strainers – Minimum 60 Mesh Screen Required
ClimaCool chillers utilize brazed plate heat exchangers
which are extremely sensitive to debris. Therefore, it is
mandatory that all condenser and chilled water systems
include a strainer with a minimum of 60 mesh screen for
proper ltration. The strainers must be installed as shown in
the Water Piping Congurations on page 12 and be in place
at all times when the chiller(s) is/are in operation.
ClimaCool’s warranty does not cover and does not apply to
products which have defects or damages due to freezing
of the water supply, an inadequate or interrupted water
supply, corrosives or abrasives in the water supply, or
improper or inadequate ltration or treatment of the
water supply.
Chiller/Heater System Water Header Bypass
A bypass is required for any chilled water/evaporator, hot
water/condenser (heating load) and source water side
(geothermal, cooling tower or closed circuit cooler) with
variable pumping. The bypass must be piped in such a way
that the temperature and dierential pressure sensors are
still sensing active ow. See Water Piping Conguration
Figures 9 and 10 on page 12 The purpose of the chiller/heater
system bypass is to prevent deadheading of the pumps
when all of the internal unit valves go closed as well as allow
temperature and dierential pressure sensors to sense
active ow. The bypass should be sized for an absolute
minimum of one module’s worth of design ow. (Please
refer to selection submittals for design ow rates).
Modules can be designated for xed bypass for heating,
cooling and source ow, however, this limits the number of
modules remaining for that duty. Also, with a module acting
as a bypass increased wear of heat exchangers may be
caused by abrasion from bypass ow.
Pressure Taps
The installing contractor must provide access ports for
connecting both the pressure dierential ow sensor and
pressure gauges for both the condenser and chilled water
systems. A ¼” pressure tap is required on the inlet and the
outlet of both water systems for a total of eight (8) taps. If a
port is shared by the pressure dierential ow sensor and the
pressure gauge, it will require four (4) ½” taps. (See Water
Piping Congurations – page 12).
Water Isolation Valves
It is recommended to provide bank water isolation valves
for proper isolation and maintenance of the chiller, pump
and strainer (See Water Piping Congurations – page 12).
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Figure 6 Direct Return
Figure 7 Reverse Return
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Grooved
Coupling
No. 25 Grooved Branch
6 x 6 x 2
No.50 Reducer
No. 25 Grooved Branch
2"
Grooved
Coupling
6 x 6 x 2
Ball Valve &
No. 29 Reducing Tee
w/Thd. Branch
Hose Kit
SIDEVIEW
2"Belimo
Ball Valve &
Actuator
No. 29 Reducing Tee
6"
Grooved Coupling
Hose Kit
2"
Grooved
Coupling
No.10
2" 90°
2"Belimo
Actuator
SIDE VIEW
6 x 6 x 2
Module
w/Thd. Branch
6"
Header
6 x 6 x 2
Grooved Coupling
Module
Header
No.50
Module
Reducer
6"
2"
Header
Grooved
Coupling
6 x 2
Grooved Coupling
Module
6"
Header
Grooved Coupling
Hose Kit
END VIEW
2"Belimo
Ball Valve &
Hose Kit
END VIEW
Actuator
No. 29 Reducing Tee
w/Thd. Branch
6 x 6 x 2
No. 29 Reducing Tee
w/Thd. Branch
2"Belimo
Ball Valve &
Actuator
6 x 6 x 2
2"
2"
Grooved
Coupling
No.10
2" 90°
Elbow
6 x 2
ClimaCool oers two types of water header bypass kits, direct
LOAD 1
FROM CHILLER BANK
TYPICAL LOAD BYPASS VALVE ARRANGEMENT
TO CHILLER BANK
LOAD 2 LOAD 3 LOAD X
TYPICAL CHILLED AND HOT WATER
LOAD SIDE BYPASS VALVES
SIZE EQUIVALENT TO ONE MODULE
WORTH OF FLOW
return (Figure 6) and reverse return (Figure 7) as shown on
page 10. The bypass kits must be installed on each water source
loop and controls are integrated with the CoolLogic software.
Installation location can be found on page 12 – Water Piping
Conguration.
This bypass can also be created with eld supplied piping. The
design piping must accommodate one module’s worth of design
ow, and be positioned so that the temperature and dierential
ow sensors sense active ow in the bypass mode. See Figures
9 and 10 on page 12 - Water Piping Conguration. The eld
supplied piped chiller/heater system bypass must be controlled
by others. There are system communication delays, polling and
network conicts that strictly prohibit the use of ClimaCool
sensors and controls for control of eld supplied bypasses or
other eld supplied items. Recommended method is to control
via dierential pressure or gpm ow meters across the chilled
water/evaporator, hot water/condenser water systems.
Load Side System Bypass (Air Handlers, Fan
Coils, etc.)
A load system bypass is required for preventing pump
deadheading, allowing active ow system sensing and
preventing starving ow from the chiller/heater system.
Examples of an acceptable load side system bypass are:
•Utilize a quantity of 3-way control valves on the largest
loads farthest from the chiller/heater system.
•Field piping with a control valve to provide a bypass across
the larger system loads when their 2-way valves go closed.
Please refer to Figure 8 for a typical load bypass
valve arrangement. The load side system bypass should be
sized for an absolute minimum of one module’s worth of
design ow. (Please refer to selection submittals for design
ow rates). A minimum of (6) six gallons per nominal system
ton are also required to maintain proper system thermal
inertia. This is to avoid short cycling of compressors in the
chiller/heater system as well as prevent nuisance alarms.
Figure 8 - Typical Load Bypass Valve Arrangement
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Water Piping Congurations
Notes:
1. Figures 9 and 10 are required piping for proper water regulation and distribution through ClimaCool modular chillers.
2. Module order and incoming/outgoing water ow as shown in both Figure 9 and 10 can be set up as either a left-to-right or right-to-left conguration.
3. Condenser hydronic circuit shown. Piping congurations are similar for the chilled water hydronic circuit.
4. For condenser/heating and chilled water (evaporator) inlet/outlet location dimensions, refer to page 6 - Dimension Data.
5. A pressure dierential ow sensor is a required safety device for ClimaCool modular chillers on the chilled and condenser/heating water circuits.
6. A strainer with a minimum of 60 mesh stainless steel screen is a required safety to protect the brazed plate heat exchangers on both chilled and condenser/heating water sides of the system.
7. Maximum water ow rates for both evaporator and condenser/heating water header systems for 30, 50 and 70 ton modules in one bank is 1,000 gpm.
8. Maximum water ow rates for both evaporator and condenser/heating water header systems for 85 ton modules in one bank is 2,400 gpm.
9. Bypass is mandatory for systems utilizing motorized valves.
10. Header bypass valve may be installed at either end of bank.
11. For over seven (7) modules, please consult the factory.
Figure 10 - Field Piping Reverse Return
Figure 9 - Field Piping Direct Return
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Hydronic Refrigeration
Figure 11- Condenser Hydronic Circuit
Isolation Ball Valve (2, 2-1/2 or 3”)
To Cooling Tower
Header
From Cooling Tower
Header
Isolation Ball Valve (2, 2-1/2 or 3”)
Water Circuit
Figure 12 - Chilled Water Circuit
Pete’s Port
Service Port (3/4”)Pete’s Port
Service Port (3/4”)
Heat Exchanger
Refrigerant Circuit #1
Refrigerant Circuit #2
Refrigerant Circuit #1
Refrigerant Circuit #2
Header
Header
Isolation Ball Valve (2, 2-1/2 or 3”)
Chilled Water Inlet
Chilled Water Outlet
Isolation Ball Valve (2, 2-1/2 or 3”)
Pete’s Port
Cap Tube to Low Limit
Protection Thermostat
Service Port (3/4”)Pete’s Port
Service Port (3/4”)
Sensor Well (internal)
Heat Exchanger
Note: Figure 11 and 12 depict hydronic piping in each ClimaCool chiller module and are shown with water isolation valves.
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13
Filling the Water System
It is imperative that the water systems are free from
debris prior to initial operation. See Water Treatment for a
comprehensive list of precautions on page 15.
Filling, Purging and Leak Testing the System
After the water systems have been properly installed,
visually inspect all joints for tightness. If the chiller is to be
installed in an existing system, the cleanliness of the existing
system can be judged from the operating conditions of the
present machines. The cooling tower in particular, should
be inspected and cleaned, if required. It is good practice to
ush and, ideally, to acid wash the existing system before
connecting a new chiller.
The following method is recommended to ll and leak check
the water system for modules WITH Water Isolation Valves:
1. Close all water isolation valves inside each module
which isolate the individual heat exchangers.
2. Ensure that all drain valves are closed and that all water
main isolation valves are opened.
3. The system should be lled with clean water sent
through the strainers and the system checked for leaks.
4. Once the main water lines and the chiller headers are
lled with clean water, purge and repeat the lling
process at least three times.
5. All modules are equipped with ¾” ll and ush valves
with lines teed into the inlet and outlet connections into
and out of each heat exchanger. Ensure these ¾” valves
are CLOSED.
6. Open the water isolation valves inside each modular
chiller and repeat the lling process, this time also
checking for leaks inside each module.
7. Following the nal lling and leak checking procedure,
air should be purged from the system.
The following system is recommended to ll and leak check
the water system for modules WITHOUT Water Isolation
Valves:
1. Ensure that all drain valves are closed.
2. All modules are equipped with ¾” ll and ush valves
with lines teed into the inlet and outlet connections into
and out of each heat exchanger. Ensure these ¾” valves
are CLOSED.
3. The system should be lled with clean water sent
through the strainers and the system checked for leaks.
4. Once the main water lines and the chiller headers are
lled with clean water, purge and repeat the lling
process at least three times.
5. Following the nal lling and leak checking procedure,
air should be purged from the system.
Cleaning the System
The following method is recommended to properly clean
the water systems:
1. Before cleaning the system, install a temporary
bypass line between the main supply and return water
headers of both chilled and condenser water systems
when possible. Open the main header bypass lines to
divert the initial water ow around the module heat
exchangers until you are condent the circulating water
is mostly pure.
2. Provided main header bypass lines are installed, close all
water isolation valves inside all modular chillers equipped
with manual or automatic water isolation valves. If the
modules are NOT equipped with water isolation valves,
we recommend installing 3-way main header bypass
valves so the initial water ow bypasses all module
heat exchangers.
3. It is mandatory to run the pumps with the strainers in
place (see Starting the Pumps section below for proper
pump startup). All external hydronic branches should be
open to all devices in the system.
4. Pressure drop across the strainer must be observed
and as pressure change reaches 50% of the initial read,
strainers must be isolated and cleaned.
5. Open all water isolation valves inside each module
equipped with manual or automatic water isolation
valves (see step 6 for modules NOT equipped with water
valves). If bypass lines are not installed (described in step
1) it is recommended to drain out the initial ll of water
to help ush out debris. Close o the main header bypass
lines referred to in step 1 and open the ow to the main
water headers. Repeat steps 3 and 4 until there is no
more debris being collected by the strainers.
6. If bypass lines are not installed (described in step 1) and
the modules are NOT equipped with water isolation
valves, it is recommended to drain out the initial ll of
water to help ush out debris. Remove and clean the
strainers before relling and purging the system again.
Repeat steps 3 and 4 until there is no more debris being
collected by the strainers.
Starting the Pumps
Follow the manufacturer’s recommendations when starting
the pumps for the rst time. The system should be checked
for leaks and air purged with the pumps in operation. The
pressure drop across the heat exchangers will give a good
indication of ow through the system (See Condenser
and Evaporator Water Pressure Drop Charts on page 17).
This should be immediately checked against the expected
pressure drop for the ow rate required. If the pressure
drop begins to fall and the ow rate is falling, this could
indicate the need to clean the strainers.
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Water Treatment
CAUTION
Water quality is of the utmost importance for the proper
care and maintenance of the modular chiller system.
Proper water treatment is a specialized industry and it is
recommended to consult an expert in this eld to analyze
the water for compliance with the water quality parameters
listed in Table 1. The materials exposed to the water are
type 316 stainless steel, pure copper and carbon steel.
Other materials may exist external to the ClimaCool chiller.
It is the user’s responsibility to ensure these materials are
compatible with the treated water. Regular treatment
of the water will increase longevity of your system.
Failure to provide adequate ltration or treatment of
evaporator and condenser water will void the ClimaCool
module’s warranty.
Heavy-Contaminated Water
In such instances whereby the particulates in the water are
excessive, it is recommended to install an intermediate plate
and frame heat exchanger to isolate the ClimaCool chiller
from the building water system.
Cooling Tower
The cooling tower should be located away from sources of
external contaminates such as trees, dust or grass cuttings.
Insect inltration can be reduced by eliminating lights near
the tower. A periodic visual inspection of the tower system
should be made and contaminates removed as required.
• Excessive Chlorine, Undissolved Solids and
other improper water quality conditions
WILL DAMAGE the internal heat exchanger and
WILL VOID YOUR WARRANTY!
Table 1 - Water Quality Parameters
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Water Temperature Requirements
Pressure Taps
Thermometer
Wells
Isolation Valves
Condenser Water
Flow Sensor or
Switch
Pressure Relief Valve
Flow to Tower Load
Flow from Tower
Cooling Tower
Bypass Valve
Strainer Isolation
Valve
Pump
Backflow
Preventer
Strainer
Drain
Valve
Backflow
Preventer
Pressure
Relief Valve
Condenser Water Temperature
The condensers are designed to operate most eciently
at lower entering water temperatures for lower power
consumption. The expansion valve, however, relies on
the pressure dierence across the valve to drive the liquid
refrigerant through. It is necessary to maintain a minimum
pressure dierential across the thermal expansion valve
(equivalent to a 30°F dierence between saturated
liquid temperature in the condenser and saturated vapor
temperature in the evaporator) to avoid loss of eciency
and system performance. This pressure dierential is most
commonly ensured by cycling the fans on the cooling tower
to maintain the entering condenser water temperature
above the minimum temperature of 60°F. An alternate
method to maintain the minimum entering condenser water
temperature above 60°F is to employ a bypass arrangement
as shown in Figure 13 below. This valve is an automatic
3-way bypass valve, which senses the temperature of the
mixed water entering the condenser. If this mixed water
temperature falls below 60°F the valve will re-circulate
the leaving condenser water and mix it into the entering
condenser water stream (bypassing the cooling tower).
The full range of entering condenser water is 60°F to 95°F
for standard applications and maximum leaving hot water
temperature of 135°F for high temperature applications.
For entering water less than 60°F refer to Options and
Accessories (page 38) - Motorized Water Isolation Valves.
Chilled Water Temperature
Modules are designed for a leaving water temperature
range from 40°F to 62°F. All cataloged modules can operate
safely in this range without the need of special controls or
glycol additives. Leaving water temperatures below 40°F
can result in evaporator suction temperatures below the
freezing point of water. Therefore, a glycol solution additive
is required that will protect the evaporator from freeze ups
at lower operating suction temperatures. The full range of
leaving chiller uid using glycol is 20°F to 62°F.
Figure 13– Condenser Water System
Note: Only required for equipment without motorized condenser valves.
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Condenser and Evaporator Water Pressure Drop Charts - 030, 050, 070, 085
100
43.3
t
10
4.3
s
Condenser Water Pressure Drop
30, 50, 70 & 85-Ton, UCW/UCH Series
Model# UCW/UCH030 Model# UCW/UCH050 Model# UCW/UCH070 Model# UCW/UCH085
80
60
50
45
40
35
30
25
20
18
16
. of Water)
14
12
10
8
6
4
Pressure Drop (F
2
1
10 1000
120
100
80604030
140
160
180
240
200
280
350
260 300
220
400
500
Flow (GPM)
Evaporator Water Pressure Drop
30, 50, 70 & 85-Ton, UCW/UCH Series
34.7
26.0
21.7
19.5
17.3
15.5
13
10.8
8.7
7.8
7.0
6.1
5.2
4.3
3.5
2.6
1.7
0.87
0.43
Drop (PSI)
Pressure
Model# UCW/UCH030 Model# UCW/UCH050 Model# UCW/UCH070 Model# UCW/UCH085
(Ft. of Water)
100
80
60
50
45
40
35
30
25
20
18
16
14
12
8
6
4
43.3
34.7
26.0
21.7
19.5
17.3
15.5
13
10.8
8.7
7.8
7.0
6.1
5.2
3.5
2.6
1.7
ure Drop (PSI)
Pres
Pressure Drop
2
1
10 1000
120
100
80604030
140
160
180
200
220
240
280
400 500
300
260
0.87
0.43
Flow (GPM)
17
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