McQuay MPC-HPC200 Installation Manual

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Installation, Operation and Maintenance Manual

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IM 856-1

Aftermarket Products

Field Installation Procedure For PureCharge - Oil, Acid, Moisture Removal Unit

2008 McQuay International

Part Number: IM 856-1 Date: January 2009 Supersedes: IM 856 dated April 2007

For Models: MPC-LPC200-11/113 MPC-LPC200-123 MPC-HPC200

Table Of Contents

Hazardous Identification Information............................3

Installation......................................................................4

PureCharge Specifications .............................................4

Average refrigerant/oil mixture in tank per distillation..4

Contents of the PureCharge Installation Kit..................4

Field-Provided Items......................................................4

Preliminary Inspection ...................................................4

PureCharge Unit Operational Overview.........................5

How It Works.................................................................5

How the PureCharge Unit Transfers Oil to the Chiller’s

Oil Sump ........................................................................5

Operating Parameters.....................................................5

Operational LED Indicators ...........................................6

Diagnostic LED indicators.............................................6

Fault LED indicators......................................................6

Installing the PureCharge Unit.......................................8

Location and Mounting ..................................................8

Plumbing the PureCharge Unit.......................................8

Liquid Refrigerant Fill Line (with Strainer)...................9

Vapor Return Line..........................................................9

Oil Return Line and Oil Filter-Drier installation............9

Option 1 Oil Line Piping Instructions..........................11

Option 2 Oil Line Piping Instructions..........................11

Electrical Connection...................................................13

Power Requirement......................................................13

Optional Chiller Run Signal.........................................13

Connecting Power........................................................ 13

Initial Start-Up............................................................. 14

Start-Up Procedure ...................................................... 14

Description Of PureCharge Components..................... 15

Safety Features............................................................. 16

Electrical Control Box.................................................16

Logic Board Relays and Dip Switches ........................ 17

Switches (SW1) & (SW2) (Dip Switches)...................17

Maintenance................................................................. 21

EZ-Change Refrigerant Filter Drier Replacement

Instructions .................................................................. 21

Steps for Changing EZ Change Filter Drier................. 21

Periodic Maintenance .................................................. 22

Control Calibration...................................................... 22

Leak Testing Procedures.............................................. 22

PureCharge Evacuation Procedure .............................. 23

Troubleshooting........................................................... 24

Using Switch SW2 Dip Switches as a diagnostic aid.. 24

Troubleshooting Chart.................................................24

Switch light defective. ................................................. 24

Replace switch............................................................. 24

Troubleshooting the Liquid Level Sensor.................... 28

Liquid Level Sensor Replacement Instructions........... 28

Replacing Level Sensor Switch Electronic Module.....28

Procedure to Clear Oil Logged Distillation Tank ........ 29

2 IM 856-1

Introduction

The McQuay PureCharge unit is designed to remove oil, acid & moisture from the refrigerant charge of a centrifugal chiller and automatically return the oil to the chiller’s oil sump. The PureCharge unit may be used with centrifugal chillers using the following refrigerants: R-11. R-113, R-114, R-123, R-12, R-22 and R-134a.

Hazardous Identification Information

! DANGER

Dangers indicate a hazardous situation which will result in death or serious injury if not avoided.

! WARNING

Warnings indicate potentially hazardous situations which can result in property damage, severe personal injury, or death if not avoided.

! CAUTION

Cautions indicate potentially hazardous situations, which can result in personal injury or equipment damage if not avoided.

IM 856-1 3

Installation

! WARNING

Installing or servicing refrigerant support equipment can be hazardous due to system pressures and dangerous voltages. Only qualified service personnel should work on such equipment.

PureCharge Specifications

Electrical power requirements:

Remote alarm relay (rly) contact rating

Operating environment: 70°F to 105°F, 5% to 80% relative

Storage environment: 0°F to 120°F, 5% to 80% relative

Dimensions (approximate):

Weight (approximate): 60 pounds Shipping weight

(approximate): Operating distillation

temperature: Operating pressures: 30 to 250 psi Distillation tank factory

pressure tested at: Average refrigerant/oil

mixture in tank per distillation

(varies depending upon installation and refrigerant level in chiller):

Average rate of refrigerant/oil mixture processed (depends upon installation, refrigerant level in chiller, and whether chiller is Running or Off):

Note: The PureCharge unit comes

equipped with a remote alarm capability.

Contents of the PureCharge Installation Kit

Each kit includes:



One Installation, Operation and Maintenance Manual. One PureCharge unit with EZ-Change refrigerant



filter attached. One oil filter/drier (for use in oil return line).



One liquid-line strainer (for use in refrigerant fill line).



120 VAC, 50/60 Hz., 1-Phase, 15amp fused circuit

Actual current draw approximately 4 Amps

120 VAC; 15 Amp

humidity, non condensing

humidity, non condensing 33" height x 16" length x 12" depth

95 pounds

155 F degrees

350 psig

10 to 20 lbs

850 to 1250 lbs. per week 44000 to 65000 lbs per year

One 1/4’ sweat check valve (with spring) (for use in



oil return line). One 3/8” charging valve adapter with copper ferrules



and cap. One 1/2” charging valve adapter with copper ferrules



and cap. Two 5/8” charging valve adapters with copper ferrules



and cap. One 3/4” to 5/8” reducing flare union (for use with



charging valve adapter if necessary). One 5/8” to 1/2” reducing flare union (for use with



charging valve adapter if necessary). One 1/2” to 3/8” reducing flare union (for use with



charging valve adapter if necessary). One 1/4” NPT run brass fitting (fitting with Schrader



valve for use with oil adapter fitting for leak testing.) One plastic tool for inserting power line into electrical



terminal block. One brass three-way internal branch tee and copper



ferrule. Two 1/4” NPT to 1/4” brass flare fittings.

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Two 1/4” NPT to 1/4” brass 90-degree flare fittings.

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Two 1/4” NPT pipe plugs

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Twelve 1/4” flare nuts



One six feet length of 3/8” ID 3/4” line insulation

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One ten feet length of 1/8” adhesive-backed insulation



tape. One 18” x 24”x 1/2” sheet of adhesive-backed



insulation

Field-Provided Items

To be furnished by the installer:

PureCharge unit mounting hardware.



Electrical conduit and wiring materials.



1/4-inch copper refrigerant tubing.

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Refrigerant cylinder (for collection of excess oil if

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excess oil is not initially returned directly to the chiller’s oil sump.

Preliminary Inspection

Before installing the PureCharge unit, check the data on the unit nameplate and verify that it is the appropriate model for the refrigerant in the chiller it is to be installed on. Make sure the voltage is correct for the application. Visually inspect all components for damage in shipment before installing. Pay particular attention to the Temperature Sensor (TS-1) capillary tube.

4 IM 856-1

PureCharge Unit Operational Overview

The PureCharge unit is designed to remove oil, acids and moisture from a centrifugal chiller’s refrigerant. However, its main purpose is to remove oil from the refrigerant and return it to the chiller’s lubrication circuit (oil sump) where it belongs. Initial oil stripping is accomplished in two phases. The first phase, or initial oil stripping process, occurs at initial start-up of the PureCharge unit. This is when all the excess oil that has been added to the system over time is removed from the oil sump and discarded. Often times the initial stripping process can yield several gallons to multiple tens of gallons, depending on how severely the refrigerant is saturated with oil.

The second phase begins when all excess oil has been removed from the refrigerant. The PureCharge unit will, from that point on, maintain the system in lubrication balance. Lubrication balance meaning virtually 100 percent of the compressor’s lubricating oil is kept in the oil sump.

Operation of the PureCharge unit is accomplished by a patented process utilizing gravity, heat and pressure in conjunction with special high capacity desiccants to completely remove oil, acids and moisture from a chiller’s refrigerant charg e.

The PureCharge unit works by repeatedly drawing 10 to 20 pounds (depending upon the refrigerant level available in the chiller evaporator) of refrigerant for processing from the chiller for each extract cycle. The oil-contaminated refrigerant is heated by means of a flexible band electric heater and the liquid refrigerant is vaporized off. As the refrigerant vaporizes it passes through the special E-Z Change high capacity moisture/acid filter-drier where it is cleaned before returning to the chiller evaporator.

At the end of the distillation phase, any distilled oil is automatically returned to the chiller’s oil sump through an in-line high acid capacity filter-drier where any residual acids are removed.

The PureCharge unit is able to process between 850 and 1250 pounds of refrigerant per week.

Three Operational Phases:

1. Fill Phase (Phase 1): Refrigerant contaminated with

oil, acid and moisture flows by gravity from the chiller’s evaporator into the PureCharge distillation tank. The Fill Cycle terminates automatically when liquid refrigerant is sensed by the optical level sensor, or after 75 minutes fill time, whichever comes first. At the end of the Fill Phase, Distillation (Phase 2) is initiated.

2. Distillation (Phase 2): During the distillation phase the

distillation heater is energized, heating the refrigerantoil mixture and causing the liquid refrigerant to vaporize. The vaporized refrigerant vapor flows from the distillation tank to the chiller evaporator through an integral high capacity moisture/acid filter-drier.

Once all refrigerant is vaporized, any distilled oil remaining accumulates at the bottom of the PureCharge distillation tank where it is further heated. Upon reaching 155 F degrees an Oil Return Phase (Phase 3) is initiated. Average duration of a typical Distillation Phase is approximately 1-1/2 to 2-1/4 hours, depending upon the refrigerant level in the distillation tank at the start of the distillation phase.

3. Oil Transfer (Phase 3): During the oil return phase

distilled oil is automatically transferred from the Distillation Tank to the chiller’s oil sump. The returning oil flows through an in-line high acid capacity filter where residual acids are removed before entering the oil sump.

How the PureCharge Unit Transfers Oil to the Chiller’s Oil Sump

During the Distillation Phase, vaporized refrigerant is returned to the chiller evaporator through a 10-psid check valve. Therefore, at the conclusion of the distillation phase, the vapor pressure in the distillation tank will be at a pressure 10 psi higher than the chiller evaporator / oil sump pressure. This pressure is used to push accumulated oil from the tank back to the oil sump.

How It Works

PureCharge operation is cyclic and non-stop as long as power is applied. Each complete extract cycle comprises three operational phases and is approximately 2-1/2 to 31/2 hours in duration.

IM 856-1 5

Operating Parameters

1. Fill Phase: 75 minutes maximum. (Controlled by

either programmed time or liquid level sensor.)

2. Distillation Phase: Duration of the Distillation Phase

is dependant upon the amount of refrigerant in the tank at the conclusion of the Fill Phase and will vary from approximately 1-1/2 to 2-1/4 hours.

3. Oil Transfer Phase: The Oil Transfer Phase is a six-

minute timed cycle.

4. Oil Temperature: The temperature of the distilled oil

is limited to 155 F degrees by Temperature Sensor (TS-1). This setting can be calibrated in the field when necessary. However, do not change the factory setting unless calibration is absolutely necessary. Refer to the Maintenance section for calibration instructions.

5. Refrigerant Process Capacity: The PureCharge unit ,

on average, processes approximately 850 to 1250 pounds of refrigerant per week. The chiller’s total refrigerant charg e is processed and made progressively cleaner until all oil, acids and moisture have been removed. To completely clean the refrigerant, the chiller’s total refrigerant charge must be processed several times (at least 4 or 5 times).

6. Oil-Refrigerant Separation Efficiency: The amount of

refrigerant and oil being returned to the oil sump at the completion each cycle is proportionate to the level of oil concentration in the refrigerant. The higher the oil concentration, the more refrigerant will be returned with the oil to the oil sump. However, under any condition, the amount of refrigerant reaching the oil sump is insignificant. For example, a chiller with a 500-pound charge containing an average of 12% oil by weight means that the PureCharge unit will return approximately one pound of oil and approximately two ounces of refrigerant to the chiller oil sump on any given cycle. This is only during the initial cleanup period.

7. Once the excess oil is removed, only trace amounts of

refrigerant (if any) will ever reach the oil sump because only a small amount of oil will be returned during each return cycle (again that is once the excess oil has been removed). The approximately two ounces of refrigerant that does reach the chiller oil sump every 2-1/2 to 3-1/2 hours is inconsequential and will have no bearing on chiller operation if the chiller’s oil sump heater is on. If on, the chiller’s oil sump heater will quickly vaporize such a miniscule amount of refrigerant long before the next PureCharge unit’s oil transfer cycle occurs.

8. Power Consumption: Distillation is accomplished by

means of a 350-watt electric heater. However, because the heater is only energized approximately 60% of the time, power consumption is approximately that of a 250-watt light bulb.

Operational LED Indicators

A series of six LED indicators located on the upper right side of the solid state logic board are provided as a means of monitoring unit operation. See Figure 6 o n page

Operation LED indicators

D1, D2, D3, D4, D5 Green LED Blinking Indicates 5 second delay before program starts.

D1 Green LED Blinking Indicates unit is in Fill Phase 1 and the distillation tank is currently being filled from the chiller evaporator. The Fill Phase is either a 75minute timed period

6 IM 856-1

or until a liquid level high signal is

18.

received from the optical level sensor of the PureCharge unit, whichever comes first.

D2 Green LED Blinking Indicates the cycle has advanced to Distillation Phase 2 and is currently in the process of vaporizing the refrigerant from the refrigerant/oil mixture.

D3 Green LED Blinking Indicates the liquid refrigerant has vaporized, distilled oil temperature has reached 155 F degrees and is currently in the Oil Transfer Phase 3.

D4 Green LED ON Solid Anytime the heater is on, the green LED D5 will be on solid. This is simply for informational purposes.

D5 Green LED On Solid Anytime the liquid level high sensor senses a liquid level the green D5 LED is on solid. This is simply for information.

Diagnostic LED indicators

When diagnosing unit problems it is helpful to be able to verify various system components for proper operation. (See the section titled Using Switch SW2 Dip Switches as Diagnostic Aid on page

24.)

Fault LED indicators

The LED indicators are also used to indicate certain Fault conditions. (Refer to the Troubleshooting Section starting on page fault conditions:

D6 Red LED Blinking with D1 Green LED ON Solid: Indicates temperature in the distillation tank did not

drop below 155 F degrees within a pre-programmed time limit of 20 minutes after initiating a Fill Phase. Refer to Troubleshooting Section starting on page cause.

D6 Red LED Blinking with D2 Green LED ON Solid: Indicates temperature failed to reach 155 degrees F.

within a pre-programmed 6 hour time limit after initiation of the Distillation Phase. Refer to Troubleshooting Section starting on page

D6 Red LED Blinking with D3 Green LED ON Solid: Indicates that the unit prematurely reached a

temperature of 155 F degrees during the distillation phase. This would indicate that the distillation tank is not filling with refrigerant properly or is losing the distillation charge prior to proper distillation. Refer to Troubleshooting Section on page

D6 Red LED Blinking with D4 Green LED ON Solid: Logic board received a signal from the Liquid

Level High Optical sensor for a period of 2 hours straight indicating a problem Refer to Troubleshooting Section on page

24.) The following is a description of the possible

24 for probable

24 for probable cause.

Recording the LED Lights During a Fault

When you see the red FAULT light ON, do not immediately turn the power switch OFF. First, remove the cover from the control box and observe and record which of the LED light(s) are ON. This will tell you the kind of fault that has occurred. Turning the switch OFF resets the logic board, terminating the Fault indicator. Record the type of fault. Examine the unit for any apparent problems, and check the troubleshooting section for possible causes of the fault. If there is no readily apparent problem, reset the unit. After reset, allow unit to operate normally to see if the fault repeats.

IM 856-1 7

Installing the PureCharge Unit

3. The unit

(vertical) position.

must be installed standing in an upright

Location and Mounting

The PureCharge unit comes mounted on its own integral base sufficient for proper support. Unit piping normally provides adequate support to stabilize the unit. Additional support may be provided as deemed necessary.

1. The unit

chiller’s refrigerant charging valve or other appropriate valve located near the bottom of the evaporator. The liquid refrigerant Fill Line is to be connected at this point.

2. The unit should be mounted directly on the flo or so

the liquid refrigerant Fill inlet port is as low as possible relative to the refrigerant level in the evaporator. When the chiller is mounted on a pad, the unit still should sit on the floor. The extra height of the pad provides additional liquid head to aid in gravity flow of liquid refrigerant from the chiller. The unit cannot overfill because of a Liquid Level High optical sensor. When the sensor is reached, the fill phase is terminated.

During a Fill Phase, if the refrigerant level in the distillation tank does not reach at minimum the middle sight glass, the PureCharge unit is not filling to an acceptable operating level.

Figure 1 – PureCharge Unit Hook-up

must be located within four (4) feet of the

! WARNING

Plumbing the Unit

To facilitate connection of the refrigerant Fill line and the Oil Return line, to their respective chiller valves, special brass valve adapter fittings and copper ferrules have been provided in the Installation Kit. These special adapters allow hook-up to the chiller’s valves without interfering with normal service access.

Determining Which Side Port to Use

Each valve adapter has opposing 1/4-inch FNPT side ports. To determine which of the ports to use, temporarily screw the valve adapter onto the charging valve hand tight. Usually only one of these ports will be accessible. This is the port you will use. The other port will be plugged. Select the appropriate fitting from the Kit, as called for in the piping instructions, and install in this port. Then, using a 1/4-inch pipe plug from the Kit, plug the unused side port. Each valve adapter comes with flare cap and ferrule to cap off the adapter’s charging access port. Be sure to always use a ferrule when installing the valve adapter and cap.

! CAUTION

Complete Fill Line and fittings from evaporator to the PureCharge unit must be completely insulated to avoid vapor locking, which will prevent filling.

1/4" Vapor Return Line

(Equalization Line)

Equalization Solenoid Valve (SOL-2)

Valve Adapter

1/4" Fitting

Refrigerant Charging Valve

1/4" Refrigerant "Fill" Line

Cap

Inlet Strainer

Evaporator Gauge Line

1/4" Internal Flare Branch Tee

Insulation

Fill Solenoid Valve (SOL-1)

EVAPORATOR

Oil Return Solenoid Valve (SOL-3)

"High Acid Capacity"

Oil Filter

1/4" Oil Return Line

Oil Sump

Oil Charging

Valve

Adapter

Valve

Shrader Fitting

Cap

Oil Line Check Valve

8 IM 856-1

Liquid Refrigerant Fill Line (with Strainer)

Although the following instructs you to connect the Liquid Refrigerant Fill Line to the chiller’s refrigerant charging valve, this is not always best. Some chillers have the charging valve located very close to where liquid refrigerant from the condenser enters the evaporator.

Usually, when this is the case, the chiller manufacturer provides an alternate access valve elsewhere near the bottom of evaporator. When this is the case, you should connect to the alternate valve. If the chiller currently has an oil recovery eductor system, it probably will be necessary to disconnect the eductor and make the connection there. Wherever the connection is made, as long as sufficient refrigerant from the evaporator is available to the unit, it will function and remove oil from the refrigerant. However, connecting to the optimum location assures optimal oil removal.

Carrier Series D™ Centrifugal Chiller Instructions

On some Carrier Series D centrifugal chillers, the refrigerant charging valve is located about even with the refrigerant level in the cooler. Therefore, for the unit to fill by gravity, it will be necessary to cut into the horizontal section of the refrigerant charging line where it exits the bottom of the cooler and add a fitting and valve for connection of the unit Fill Line.

1. Select the appropriate size valve adapter from the

Installation Kit that fits the chiller’s refrigerant charging valve. Depending on how the Fill Line is to run, select either a straight (U1-4B) or 90 degree (E14B) brass 1/4” NPT x 1/4” flare fitting from the Kit and install in the appropriate side port. Install a 1/4” pipe plug from the Kit into the opposite side port.

2. Using the appropriate copper ferrule, permanently

install the valve adapter onto the chiller’s refrigerant charging valve. (See Figure 1, page

3. Using 1/4” O.D. copper tubing, run a 1/4” copper line

to the Fill Solenoid Valve (SOL-1) from the valve adapter fitting. (See Figure 1, page

4. Be absolutely sure to keep the Fill Line lower than the

Liquid Fill Inlet connection on the distillation tank. If any part of the Fill Line rises higher than the Fill Inlet, liquid refrigerant may not flow by gravity from the chiller into the distillation tank.

5. Next, from the Installation Kit select the Fill line

strainer and two 1/4” flare nuts and install anywhere in the Fill Line. Make certain the connections to the strainer are leak tight.

6. Before making final connection to the unit, insulate

the entire refrigerant fill line and strainer. Insulation materials have been included in the Installation Kit.

IM 856-1 9

8.)

The entire Fill Line, Strainer, the refrigerant charging valve and all interconnecting piping up to the evaporator shell must be insulated. Failure to properly insulate these items may cause vapor lock preventing the PureCharge unit from functioning. (See Figure 1, on page

7. Do not open the refrigerant charging valve at this

time.

Vapor Return Line

Note: When connecting the vapor return line to a Schrader valve fitting, the valve stem

1. Close the evaporator gauge stop valve.

2. Disconnect the gauge line from valve.

3. From the Installation Kit, select the1/4”brass T6-4

three-way internal branch tee and copper ferrule. Connect the tee to the gauge stop valve 1/4” port. (See Figure 1, page

4. Re-connect gauge line to one end of tee.

5. From the other end of the tee, run a 1/4” copper line

to the Equalization Solenoid Valve (SOL-2). (See Figure 1, page

Avoid sagging or traps in the Vapor Return (Equalization) Line where vapor can condense and accumulate causing a blockage

6. Do Not re-open evaporator gauge valve at this time.

Oil Return Line and Oil Filter-Drier installation

Based on the severity of oil contamination in your system, the amount of oil that will be removed by the PureCharge unit on initial start-up could be several gallons more (excess oil) than the capacity of your chiller’s oil sump. For example, a 500-pound refrigerant charge with 12% oil by weight will contain approximately 8.5 gallons of excess oil. Until the chiller’s refrigerant is free of oil, you must decide how you are going to deal with the excess oil before the initial start-up of the PureCharge unit.

The above example is for illustrative purposes only. A smaller refrigerant charge with a higher percent oil concentration, or a larger refrigerant charge with a lower percentage, may yield much more than 8.5 gallons of excess oil. Before proceeding, estimate how much excess oil you will accumulate. To estimate the excess oil you are likely to accumulate, refer to the most recent refrigerant analysis for your chiller. You will also need to know the weight of your chiller’s refrigerant charge. Then refer to Chart 1, Percent of Oil, on page approximately how much excess oil you will be dealing with, you have the following two options as described.

! WARNING

8.)

must be removed.

8.)

10. Once you know

! CAUTION

It is important to note that the percentage of oil in a sample can vary by as much as 10 percent depending upon where the oil sample is taken from the chiller. For example, if the sample is taken from a location near where the refrigerant is returned from the condenser, mostly pure refrigerant is being returned to the evaporator at that location and the sample will indicate a lower percentage of oil contamination than actually exists in the chiller.

Option 1: Plumb the Oil Return Line per Option 1 piping instructions on page

11. This option allows the excess oil, as it is being stripped from the refrigerant, to flow direct to the chiller’s oil sump where it can accumulate. With Option 1, it will be necessary to periodically monitor the sump’s oil level and remove excess oil as it accumulates. Once the initial oil stripping process is complete and all excess oil has been removed from the oil sump, further monitoring will no longer be necessary.

Advantage: once the initial oil stripping process is complete, no further action is required.

Disadvantage: the main disadvantage to Option 1 is the necessity for someone to periodically monitor and drainoff oil from the oil sump. This may be inconvenient, as the oil-stripping process may take days or weeks to complete.

Option 2: Plumb the Oil Return Line per Option 2 piping instructions on page 11. As determined by previous calculation, install sufficient containment capacity, such as a single 50, 100, 200, etc., pound refrigerant recovery cylinder, in the Oil Return line between the PureCharge unit and the chiller’s oil sump. The cylinder will retain and hold the excess oil as it is stripped from the refrigerant, preventing it from accumulating in the oil sump.

Note that the rated capacity of a refrigerant recovery cylinder is for refrigerant which is heavier than oil; therefore a refrigerant recovery cylinder will not hold the same weight of oil as the rated refrigerant capacity. (See Figures 2 and 3 on page 11 which includes approxi mate oil holding capacities of various size refrigerant recovery cylinders.) Once the stripping process is complete the cylinder and excess oil must be removed from the system.

Advantage: does not require periodic monitoring and draining of oil in order to maintain proper oil level in the oil sump. (Good practice is still to periodically monitor the accumulation of oil in the recovery cylinder in the event that there is more oil recovered than anticipated.)

Disadvantage

: requires temporary installation of a

containment vessel. Also, once the oil stripping process is complete and the excess oil is collected, the containment vessel must be removed from the system.

Use the chart below to estimate the amount of excess oil in the chiller’s refrigerant charge. According to ASHRAE Study 601-TRP, the average chiller has 12% oil by weight in its refrigerant charge. A 500–pound refrigerant charge at 12% by weight contains 60 lbs, or 8.5 gallons of oil.

Chart 1 – Refrigerant-Oil Contamination Chart

100 200 300 400 500 600 700 800 900 1000 1100 1200

% OIL Lbs. Of Oil in Refrigerant Charge based on % by weight

1% 2% 3% 4% 5% 6% 7% 8%

9% 10% 11% 12% 13% 14% 15% 16% 17% 18% 19% 20% 21% 22% 23% 24% 25%

1 2 3 4 2 4 6 8 3 6 9 12 4 8 12 16 5 10 15 20 6 12 18 24 7 14 21 28 8 16 24 32

9 18 27 36 10 20 30 40 11 22 33 44 12 24 36 48 60 72 84 96 108 120 132 144 13 26 39 52 65 78 91 104 117 130 143 156 14 28 42 56 70 84 98 112 126 140 154 168 15 30 45 60 75 90 105 120 135 150 165 180 16 32 48 64 80 96 112 128 144 160 176 192 17 34 51 68 85 102 119 136 153 170 187 204 18 36 54 72 90 108 126 144 162 180 198 216 19 38 57 76 95 114 133 152 171 190 209 228 20 40 60 80 100 120 140 160 180 200 220 240 21 42 63 84 105 126 147 168 189 210 231 252 22 44 66 88 110 132 154 176 198 220 242 264 23 46 69 92 115 138 161 184 207 230 253 276 24 48 72 96 120 144 168 192 216 240 264 288 25 50 75 100 125 150 175 200 225 250 275 300

CHILLER REFRIGERANT CHARGE BY WEIGHT IN Lbs.

5 6 7 8 9 10 11 12 10 12 14 16 18 20 22 24 15 18 21 24 27 30 33 36 20 24 28 32 36 40 44 48 25 30 35 40 45 50 55 60 30 36 42 48 54 60 66 72 35 42 49 56 63 70 77 84 40 48 56 64 72 80 88 96 45 54 63 72 81 90 99 108 50 60 70 80 90 100 110 120 55 66 77 88 99 110 121 132

Oil weighs approximately 7 lbs per gallon

60 Lbs = approximately 8.5 gallons

10 IM 856-1

Option 1 Oil Line Piping Instructions

1. From the Installation Kit select the appropriate valve

adapter that fits the chiller’s oil charging valve. Depending on how the line is to be run, select either a straight (U1-4B) or a 90-degree (E1-4B) brass 1/4” NPT x 1/4” flare fitting and install in the appropriate adapter side port. Then, using a 1/4” NPT pipe plug from the Installation Kit, plug the unused side port.

2. Screw the valve adapter permanently onto the

chiller’s oil charging valve. Select the mating flare cap and copper ferrule from the Installation Kit and install on the adapter’s larger access port.

3. Next run a 1/4-inch copper line from the valve adapter

fitting to the 1/4-inch flare outlet fitting on the PureCharge Oil Return Solenoid Valve (SOL-3). From the installation kit you will find a 1/4-inch MPT Run (fitting with a Schrader valve) that must be installed in the adapter fitting. It will be use later in the leak testing. (See Figure 1, page 7.) Also a 1/4inch check valve with a spring (provided in the installation kit) must be installed in the line near the adapter fitting you just installed on the chiller’s oil charging valve. Make sure the flow direction arrow is pointing toward the oil sump.

4. Do not open the oil-charging valve at this time.

Option 2 Oil Line Piping Instructions

! CAUTION

This method is intended to be a temporary arrangement only and should be replaced once the excess oil has been removed and the refrigerant is oil free.

If you choose option 2



Be aware that during the initial oil stripping process about 10 to 15% by weight of the oil accumulated in the temporary collection cylinder will be refrigerant. Therefore, because of this refrigerant and the volume of the oil recovered be prepared to add make-up refrigerant to the chiller once the initial stripping process is complete.

All of the refrigerant in the temporary collection



cylinder may be recovered by applying a low wattage electric band heater to the recovery tank during the stripping process. It also helps to allow the tank to set with the heater energized for a day or two once the process is complete.

After the initial oil stripping process, and once the



PureCharge unit’s oil return line is connected permanently to the chiller’s oil sump, any refrigerant still entrained in the oil will be returned to the oil sump and be evaporated there.

1. Option 2 installation is identical to Option 1

! CAUTION

Do not connect multiple cylinders in series. The excess oil collection hook-up must be limited to a single cylinder: i.e., a single 50, 100, or 200 lb., etc. cylinder, and must not be filled to more than 80% of its rated capacity. Note that the rated capacity of a refrigerant recovery cylinder is for refrigerant which is heavier than oil; therefore a refrigerant recovery cylinder will not hold the same weight of Oil as the rated refrigerant capacity. (See Figures 2 and 3 on page 12 which indicates the approximate oil holding capacities of various size refrigerant recovery cylinders.)

2. Plumb the selected excess oil containment vessel in the oil return line precisely as illustrated in Figure 2 on page

12. Remember to install the check valve (provided in the PureCharge unit Installation Kit) in the oil return line between the containment vessel and the oil sump, as shown in Figure 2, on page

12. The check valve must be installed it prevents back flow of oil from the oil sump into the oil containment vessel.

! WARNING

Failure to install the check valve may result in oil draining from the oil sump into the temporary oil containment vessel, causing the chiller to shut down because of low oil level.

! WARNING

The PureCharge unit will not function and also will not transfer oil to the oil containment vessel unless the vessel is properly connected to the chiller’s oil charging valve and the valve is open.

Unless the excess oil that is collected is intended for reuse later, do not install the oil filter-dryer at this time. Wait until the oil stripping process is finished before installing the oil filter-dryer.

! CAUTION

Option (2) is intended only as a convenient method of dealing with excess oil. You MUST still occasionally monitor the oil sump for excessive oil accumulation since there may be more excess oil than anticipated. Refer to approximate oil holding capacities of the refrigerant recovery cylinders unde r Fi g ure 2 on page

12.

On initial start-up the PureCharge distillation tank will accumulate and retain approximately two pounds of recovered oil. Therefore, depending upon the level of oil contamination, a number of cycles may be required before actual oil transfer to the chiller oil sump begins.

3. Once all excess oil has been stripped from the chiller’s

refrigerant, remove the temporary containment vessel (with excess oil).

except you will temporarily install one, and only one, containment vessel in the oil return line. The size of the containment vessel (determined by previous calculation) should be of sufficient

4. Using ¼-inch copper tubing, reconnect the

PureCharge unit to the chiller’s oil sump per Option 1 piping instructions. Be sure to install the oil filter at this time.

capacity to collect and hold all excess oil.

5. Do not open valve at this time.

IM 856-1 11

6. Properly dispose of the accumulated excess waste oil.

Figure 2 – CORRECT Optional Oil Collection Cylinder Hook-up

EVAPORATOR

Oil Return Solenoid Valve (SOL-3)

Approximate oil holding capacities at 80% full of various size refrigerant recovery cylinders .50 lb. Cylinder…….. 23 pounds / 3.3 gallons

Temporary

Excess Oil Collection Cylinder

(Do Not fill cylinder more than 80% full)

Approximate oil-holding capacities at 80% full of various size refrigerant recovery cylinders: 50 lb. Cylinder…… 23 pounds / 3.3 gallons 100 lb. Cylinder…… 46.4 pounds / 6.6 gallons 200 lb. Cylinder…… 92.8 pounds / 13.2 gallons

Oil Sump

Oil Charging

Valve

Adapter

Valve

Shrader Fitting

Cap

Oil Line Check Valve

Figure 3 – WRONG Optional Oil Collection Cylinder Hook-up

EVAPORATOR

Oil Return Solenoid Valve (SOL-3)

1 2

Oil Sump

Oil Charging

Valve

Adapter

Valve

Shrader Fitting

Cap

Oil Line Check Valve

12 IM 856-1

Electrical Connection

! DANGER

Be sure to open and lockout all electrical disconnects to prevent possible injury or death caused by electrical shock during installation

Use Class 1, 14 AWG copper wire and metal conduit. All field-installed wiring must comply with applicable NEC and local electrical codes.

Power Requirement

The PureCharge unit requires one power connection to the chiller's fused control panel. The electrical requirement is 120-VAC, 50/60 Hz, 1-phase 15 amp fused circuit. Actual current draw is approximately 4 amps.

Optional Chiller Run Signal

The PureCharge Logic Board is provided with an optional Chiller Run Signal input terminal designated as IN6. In most instances it will not be necessary to provide a Chiller Run Signal to the PureCharge unit. However, the option is available should there be a need.

When the Chiller Run Signal option (activation of which requires turning ON Dip Switch 6 of SW1, (see Figure 6

18) is used, the PureCharge unit will be active only

page while the chiller is running (while unit receives a Chiller Run Signal). When the chiller shuts down, the PureCharge unit will suspend operation. PureCharge operation resumes when the chiller re-starts.

For an application requiring use of the Chiller Run Signal option proceed with installation as follows:

1. Connect a Chiller Run Signal from an appropriate 120VAC source in the chiller control panel to input IN-6 on the PureCharge logic board and turn ON dip switch 6 on SW1, see Figure 6, page switch 6 location. See Wiring Diagram Figure 8, Page 30, and Figure 6, page 18, for l ogi c board for “Input 6” terminal location.

2. Now you must connect a neutral for the Run Signal from the chiller control circuit to the terminal J22 on the control logic board. See Wiring Diagram Figure 8 on Page board for J22 terminal location.

30, and Figure 6 on page 18 , on the logic

18 for Switch SW1 Dip

Connecting Power

The picture to the right shows how to make electrical connections to Terminal Block TB-1. Strip 5/16” of the insulation on each wire. Insert the tool provided with the Installation Kit (or a small screwdriver) into the space above the place you are going to insert the stripped wire. Slightly pry the tool or screwdriver toward the center of the block until you hear a click. This opens the spring clip where the wire is to be inserted. Insert the wire, and then remove the screwdriver. The wire should be held in place. Test by pulling on wire to make sure connection is firm.

Figure 4 – Electrical Control Box Field Wiring

1. Connect the line voltage wire to the common

terminal of the Pressure Disconnect switch.

2. Connect the neutral lead to Terminal-4 slot of

TB-1.

3. Connect the ground wire to the ground lug.

Ground Lug Neutral

(High) Pressure Disconnect Switch Common Terminal

IM 856-1 13

Initial Start-Up

! CAUTION

Before starting the PureCharge unit for the first time, be sure you have considered how you will be handling the excess oil that will be removed. You have two options: see Oil Return Line installation instructions starting on page 8. Removal of excess oil from system is essential.

! CAUTION

The chiller’s oil sump heater must be on anytime the PureCharge unit is on. Should the chiller’s oil sump heater be off for any reason, the PureCharge unit must be off.

Start-Up Procedure

Even though each PureCharge unit is completely leak tested at the factory before shipment, it is possible for a fitting or line, etc. to become loosened during shipment. It is absolutely imperative that there be no leaks anywhere in the PureCharge system. A leak can either result in air entering the chiller, or the loss of refrigerant. Instructions on how to locate the leak testing procedure that must be followed is described in Step 3 below.

! CAUTION

It may be necessary to add refrigerant to the system during the initial oil stripping process. Every pound of oil removed from the refrigerant is equivalent to a volumetric reduction of two pounds of refrigerant from the system. Therefore when significant quantities of oil are removed from the system, it may be necessary to compensate for this volumetric loss by adding refrigerant. If the refrigerant level in the evaporator is not at least 2 inches above the inlet Fill port, then nuisance PureCharge unit faults may result.

1. Check all fittings and piping connection to make

absolutely sure all are tight.

2. Verify that the EZ-Change Filter on top of the unit’s

distillation tank is tight.

3. The PureCharge unit must be leak tested.

Low pressure refrigerants - See page



PureCharge leak test procedure on a chiller using low pressure refrigerants.

High pressure refrigerants - See page 23 for



PureCharge leak test procedure on a chiller using high pressure refrigerants.

22 for

4. When you have completed the leak testing procedure,

proceed to Step 5.

5. The D1 green LED indicator (see Figure 6, page

18) should now be blinking, indicating the unit is in Fill Phase and the distillation tank is being filled by gravity with refrigerant from the chiller. Filling of the distillation tank can be observed by viewing the three (3) sight glasses on the right side of the distillation tank.

After 75 minutes, (or if the Liquid Level High sensor senses a level indicating that the tank has filled with an appropriate amount of refrigera nt ) t he D1 Green LED indicator will de-energize and D2 green LED indicator will energize and blink, indicating the unit is in the Distillation Phase.

After the distillation cycle (approximately 1-1/2 to 21/4 hours) the Oil Return phase will begin. It is a timed six-minute period. The D3 green LED should begin blinking. This is good indication that the PureCharge unit is functioning properly. After about a day of operation, either the oil level in the oil sump should begin rising, or the temporary collection cylinder should begin accumulating oil. The oil removal rate will depend on several things: the percentage of oil in the chiller’s refrigerant charge, the amount of refrigerant processed in each cycle, and the location from which the refrigerant was removed from the chiller.

6. Initial start-up is now complete.

7. Replace control box cover. The PureCharge unit can remove several gallons of oil per

day from a chiller during the initial first few days of operation, when properly installed and with a refrigerant charge that has a high percentage of oil, and then gradually decrease in amount day-by-day until all oil is eventually removed from the chiller’s refrigerant.

14 IM 856-1

Description Of PureCharge Components

To view photographs of components, see Fi gu re 5 o n page 16, Figure 6 on page 18, and Figure 7on page 19.

250 PSIG Pressure Cut-Out Switch (HPC-1)

High Pressure Cut Out Switch (HPC-1) turns PureCharge unit off when pressure reaches 250 psi.

Distillation Heater

The Distillation Heater is a 350-watt flexible band heater attached around the bottom of the Distillation Tank and supplies the heat to distill the liquid refrigerant from the oil. The heater temperature is regulated by Temperature Sensor (TS-1) to a maximum of 155 F degrees.

Distillation Tan

The Distillation Tank is where the refrigerant is distilled and separated from the oil by heat.

Electrical Control Box

The Electrical Control Box contains the solid state logic board, temperature sensor (TS-1) and terminal strip and the 250-psig pressure cut out switch (HPC-1). On top of the control box are the ON-OFF lighted rocker switch and the red “fault” light.

EZ-Change High Moisture Capacity Filter-Drier

The EZ-Change Filter-Drier is an integral part of the PureCharge unit. Its function is to remove acids and moisture from the vaporized refrigerant on its return to the chiller evaporator. The EZ-Change Filter-Drier is connected to the PureCharge Distillation Tank via a “quick-connect” coupler with automatic flow shut-off. This permits quick and easy replacement of the EZChange Filter-Drier without the necessity of shutting down either the chiller or the PureCharge unit.

Fill Solenoid Valve (SOL-1)

The Fill Solenoid valve (SOL-1) controls the filling of the oil laden liquid refrigerant from the chiller’s evaporator.

Oil Transfer Solenoid Valve (SOL-3)

Oil Transfer Solenoid Valve (SOL-3) controls the transfer of distilled oil from the distillation tank to the chiller’s oil sump.

Oil Return Check Valve (CK-1)

The oil return check valve prevents inadvertent back-flow of oil from the chiller’s oil sump into the PureCharge distillation tank.

Oil Return Filter-High Acid Capacity

The high acid capacity oil filter removes acids from the distilled oil as it passes from the distillation tank to the chiller’s oil sump.

Power Switch (PS-1)

Power Switch (PS-1) controls input power to the control circuit and illuminates when switched ON. The switch also functions as the unit Fault Reset switch.

Pressure Equalization Check Valve (CK-2)

The Pressure Equalization Check Valve maintains 10 psid between the unit’s tank and the chiller evaporator during the distillation phase in order to maintain sufficient pressure differential to push accumulated oil to the oil sump during the oil transfer phase.

Pressure Equalization Solenoid Valve (SOL-2)

During the Fill Phase Pressure Equalization Solenoid Valve (SOL-2) is energized (opened) to allow the pressures in the distillation tank and the chiller evaporator to equalize. Once the pressures are equalized, the liquid refrigerant levels in the two vessels are free to seek a common level by gravity, thus allowing filling.

Safety Relief Valve (SRV-1)

300–psi atmospheric pressure relief valve protects PureCharge unit from over-pressurization.

Temperature Sensor (TS-1)

Temperature Sensor (TS-1) controls the distillation heater and limits oil temperature in the Distillation Tank to 155 F degrees.

Terminal Block (TB-1)

Terminal Block (TB-1) is used for convenient termination of unit wiring.

Solid State Logic Board –Switches SW1 and SW2 & Relays

(See Figure 6, page

Switches (SW1) & (SW2)

During normal operation all Dip Switches on SW1 & SW2 of the logic board must be in the OFF position. During diagnostics and leak testing procedures certain Dip Switches on Switch SW2 are placed in the ON position. (See Figure 6, page

Relay RLY-1 Controls the Fill Solenoid (SOL-1). Relay RLY-2 Controls Equalization Solenoid (SOL-2). Relay RLY-3 Controls Oil Transfer Solenoid (SOL-3). Relay RLY-4 Controls the Distillation Heater via

Temperature Sensor (TS-1). Relay RLY-5 Is a SPDT relay dedicated to Fault

indication. It can be utilized for remote fault indication. Relay RLY-6 Is not used.

During normal operation all Dip Switches of SW1 & SW2 must be set to the OFF position or the unit will not function correctly. Certain SW2 dip switches are used, but generally only during the leak testing procedures, or diagnostic procedures. See the section titled Using SW2 as Diagnostic Aid on page Leak Testing, on page

18 for further information.)

18.)

! WARNING

24 and Using SW2 During

22.

IM 856-1 15

(

)

(

)

(

)

Safety Features

Safety # 1 guarding against over pressurization.

A 250-psi High Pressure Cut-Out Switch turns PureCharge unit OFF when pressure reaches 250 psi to prevent safety relief pressure valve from activating at 300 psi.

Safety # 2 guarding against over pressurization.

A 300 psi atmospheric pressure relief valve is provided on the PureCharge Distillation Tank to protect against overpressurization.

Safety guarding against inadvertent closing of any isolation valve(s).

If any of the chiller’s isolation valves to which the PureCharge unit is connected are closed, the PureCharge unit will go into a fault condition to protect them and the PureCharge unit. The PureCharge unit will remain in the fault condition until power is removed and then reapplied.

Safety preventing transfer of undistilled refrigerant into chiller’s oil sump.

The PureCharge unit is designed so that if the oil transfer solenoid (SOL-3) fails in the open position, the PureCharge unit will not transfer refrigerant into the oil sump.

Safety guarding against Fill Solenoid (SOL-1) failing in the open, or closed position.

The PureCharge unit is programmed to determine if the Fill Solenoid Valve (SOL-1) fails in the open or closed position. If either occurs, the PureCharge unit will go into a fault condition to protect the chiller and the PureCharge unit. The PureCharge unit will remain in the fault condition until power is removed and then reapplied.

Safety guarding against Equalization Solenoid (SOL-2) failing in the open, or closed position.

The PureCharge unit is programmed to determine if the equalization solenoid (SOL-2) fails in the open or closed position. If either occurs, the PureCharge unit will go into a fault condition to protect the chiller and the PureCharge unit. The PureCharge unit will remain in the fault condition until power is removed and then reapplied.

Safety guarding against the Oil Transfer Solenoid (SOL-3) failing in the open position.

The PureCharge unit is programmed to determine if the oil transfer Solenoid (SOL-3) fails in the open position. If this occurs, the PureCharge unit will go into a fault condition to protect the Chiller and the PureCharge unit. The PureCharge unit will remain in the fault condition until power is removed and then reapplied.

Safety guarding against Temperature Sensor (TS-

1) failing.

The PureCharge unit is programmed to determine if the Temperature Sensor (TS-1) fails. If this occurs, the PureCharge unit will go into a fault condition to protect the chiller and the PureCharge unit. The PureCharge unit will remain in the fault condition until power is removed and then reapplied.

Safety guarding against Solid State Logic Board Relays sticking or not making.

The PureCharge unit is programmed to determine if the relays on the solid state logic board are either welded shut or if they fail to make. If this occurs, the PureCharge unit will go into a fault condition to protect the chiller and the PureCharge unit. The PureCharge unit will remain in the fault condition until power is removed and then reapplied.

Safety guarding against the heater failing in ON position or OFF position.

If the heater fails in the ON position, or if the heater does not work, the PureCharge unit will go into a fault condition to protect the chiller and the PureCharge unit. The PureCharge unit will remain in the fault condition until power is removed and then reapplied.

Electrical Control Box

The electrical control box contains the solid state logic board, temperature sensor (TS-1) and terminal strip and the 250-psig pressure cut-out switch (HPC-1). On top of the control box are the ON-OFF lighted rocker switch and the red Fault light.

Terminal Block (TB-1)

Terminal block (TB-1) is used for control wiring and for providing convenient termination for unit power wiring.

Temperature Sensor (TS-1)

Temperature sensor (TS-1) controls the distillation heater and limits oil temperature in the distillation tank to 155 F degrees.

250-psig Pressure Cut-out Switch (HPC-1)

High pressure cut-out switch terminates PureCharge unit operation when pressure in the PureCharge distillation tank exceeds 250 psi. Used to protect the PureCharge unit and the chiller from over pressurization.

Figure 5 – Major Electrical Components Box

Terminal Block

TB-1

250 Psi High Pressure Cut out Switch

HPC-1

Solid State

ic Board

Temperature Sensor

TS-1

16 IM 856-1

Logic Board Relays and Dip Switches

To view the location of all dip switches on the logic board, see Figure 6 on page

Relay RLY-1

Controls the Fill Solenoid Valve (SOL-1)

Relay RLY-2

Controls Equalization Solenoid Valve (SOL-2).

Relay RLY-3

Controls Oil Transfer Solenoid Valve (SOL-3).

Relay RLY-4

Controls the Distillation Heater via Temperature Sensor (TS-1).

Relay RLY-5

A SPDT relay dedicated to Fault indication. It can also be utilized for remote indication.

18.

Relay RLY-6

Not used.

Switches (SW1) & (SW2) (Dip Switches)

Switches (SW1) & (SW2) During normal operation all dip switches on SW1 & SW2 of the logic board must be in the OFF position. During diagnostics and leak testing procedures certain dip switches on Switch SW2 are placed in the ON position. (See Figure 6, page

! WARNING

During normal operation all Dip Switches of SW1 & SW2 must be set to the OFF position, or the unit will not function correctly. Certain SW2 dip switches are used, but generally only during the leak testing procedures, or for diagnostic aids. See the sections titled Using SW2 as Diagnostic Aid (page Testing, on page 22.

24) and Using SW2 During Leak

18.)

IM-856 17

(

Figure 6 – Solid State Logic Circuit Board

SWITCH SW2 Dip Switches 1, 2, 3 and 4 may be used for diagnostics. 1, 2 and 3 are be used during leak testing (See page 22 for explanation of when to use during leak testing.)

RLY-6

Relay

Not Used

RLY-5

Relay

Fault Indicator

SWITCH SW1 Dip

Switch 6 enables

Chiller “Run Signal”

uirement Option.

Display D6

Red Led With

Green LED

Fault Indicator

Display D5

Liquid Level

High Sensor,

Activated

Indicator

Display D4

Heater On LED

or Fault indicator

Display D3 Oil Transfer LED or Fault Indicator

RLY-4

Relay Heater

RLY-3

Relay

Oil Transfer

Solenoid

Relay Pressure

Equalization

Solenoid

Fill Solenoid

Line voltage

SOL-3)

RLY-2

SOL-2)

RLY-1

Relay

SOL-1)

Wire L1

Neutral

Connection

Ground

Connecto

Display D2

Distillation

Phase LED or

Fault Indicato

Display D1

Fill Phase LED

Indicator

Temperature

Sensor TS-1

Input 1

Input 2 Liquid

Level switch &

bleed resistor

lead connection

Optional

Run Signal

Input 6

Terminal

J22

Isolated neutral

For Optional

Run signal

Logic Board

Fuse 1/2 am

18 IM 856-1

(

)

(

Figure 7 – Major Components of PureCharge

EZ Change

Refrigerant Filter

Pressure Equalization

Check Valve

Refrigerant Vapor Line

Connection to Chiller

Evaporator

Equalization Solenoid

SOL-2)

Liquid Level High

Optical Sensor

Line Connection to

Chiller Charging Valve

(Outlet of Fill Solenoid)

Refrigerant Fill

Solenoid

Line Connection to Oil

(Outlet of oil transfer

SOL-1)

Sump

Solenoid

Oil Transfer Solenoid

SOL-3)

Schrader Valve

Location

(Actual valve

Not visible)

Quick Change

Coupling with

Automatic Flow Shutoff

Valve

Safety Relief Valve

Location

(Actual valve

Not visible

High Pressure

Cut Out Switch

Sight Glasses

Electrical Box

Heater

Base

IM-856 19

(

)

(

Figure 7 – Major Components of PureCharge (continued)

Pressure Equalization

Check Valve

Refrigerant Vapor Line Connection to Chille

Equalization Solenoid

SOL-2)

Liquid Level High

Optical Sensor

Refrigerant Fill

Solenoid (SOL-1)

Temperature Sensor

(TS-1) Bulb,

Bulb Well & Capillary

Tube

Refrigerant Fill Line

Connection To Chiller

Charging Valve

Distillation Tank

Power and Reset

Switch

Fault

Warning Light

Oil Transfer

Solenoid

Line Connection

SOL-3

Oil Return

20 IM 856-1

Maintenance

This section discusses the PureCharge system maintenance requirements and procedures, electrical wiring diagram, basic PureCharge troubleshooting procedures and leak testing procedure. The following maintenance procedures are required to assure efficient and reliable operation of the PureCharge unit.

! WARNING

Certain servicing procedures may expose you to harmful materials and dangerous conditions. To minimize the possibility of injury, follow safety procedures and instructions described in this manual, on product labels and provided in material safety data sheets.

EZ-Change Refrigerant Filter Drier Replacement Instructions

Most centrifugal chillers have no means for removal of harmful oil, moisture and acids from the refrigerant. Typically oil, moisture and acids are allowed to accumulate in the refrigerant until a refrigerant analysis indicates they have reached dangerous levels and it is time to take corrective action. Usually this means either replacing the entire refrigerant charge or removing the charge and distilling it back into the chiller. Leaving moisture, acid and oil in the chiller’s refrigerant charge not only subjects the chiller to unnecessary harmful conditions, it is also not a very cost-effective way to maintain a centrifugal chiller.

The purpose of the PureCharge unit is not just to remove oil from the chiller’s refrigerant. It also removes moisture and acids as well. In fact, the PureCharge unit is the most effective means, if not the only means, of continually purging harmful moisture and acids from a centrifugal chiller.

The PureCharge unit will continue removing oil from the refrigerant after the filter-drier is saturated. However, the PureCharge unit can only remove moisture and acids as long as the EZ Change filter-drier is fresh and active. The EZ Change Refrigerant Filter Drier should be changed approximately every three months. A place has been provided on the filter-dryer label to record the date the filter-drier was installed.

Although three months may seem like a short time, remember that the PureCharge unit processes approximately between 850 and 1250 pounds of liquid refrigerant per week. This means that during each threemonth period the PureCharge unit will have processed (removed moisture and acids) from between 10,000 to 15,000 pounds of refrigera nt .

The PureCharge unit incorporates an integral self-sealing ball-check valve between the filter-drier and the distillation tank. When the filter-drier is unscrewed and removed, the ball-check valve closes off the flow path from the distillation tank preventing either refrigerant from escaping or air from being drawn in.

The EZ-Change Filter Drier requires much less time for change-out than a typical in-line filter-drier. Although the PureCharge unit self-seals when the EZ-Change Filter Drier is removed, a small amount (de minimus) of pressure release from dryer canister should be anticipated when removing

Steps for Changing EZ Change Filter Drier

1. Turn unit power

switch to OFF position.

2. Using appropriate

wrenches, loosen filter drier.

3. Slowly unscrew and remove spent filter drier.

4. Immediately install new filter-drier. (Use small

amount of O-ring lubricant on each O-ring.)

5. Using wrenches, gently tighten. Do not over-tighten.

6. Turn unit power switch back to ON position.

! WARNING

Always complete filter change-out. Never leave the PureCharge unit unattended with filter port open. Unit will not function with the filter drier removed.

Note that upon power-up, the PureCharge unit will always initiate operation in a Fill Phase of the operating cycle.

EZ Change Filter Drier

IM-856 21

Periodic Maintenance

Quarterly

1. Replace the EZ Change Refrigerant Filter Drier.

2. Visually inspect the entire unit.

Annually

1. Replace the EZ Change Filter-Drier if due (see last

replacement date indicated on label).

2. Replace the high

acid capacity oil filter. The oil filter also has a place on the label to record the replacement date.

High Acid Capacity Oil Filter

It is essential that the oil filter be replaced at least once a year. However, semi-annual replacement is preferred.

3. Visually inspect the entire unit.

Control Calibration

Temperature Sensor TS-1

General instructions on maintenance and adjustments.

  Avoid sharp bends or kinks in the capillary tube.

Do not allow capillary tube to rub and abrade against any moving surface. Avoid constant bending of the tubing to avoid work hardening effects.

Temperature Sensor Adjustments

The readings on the temperature sensor are a guide only. A separate thermometer must be used for exact adjustment of the set points. The temperature sensor in your PureCharge unit came adjusted by use of a separate thermometer. The setting as it appears on the temperature sensor may not exactly correspond to the actual setpoint of 155 F degrees.

1. Use a flat screwdriver or a 1/4” refrigeration (square) wrench to adjust setpoints.

2. Adjust the upper set point using the range spindle (the spindle to the left as you look at it).

Leak Testing Procedures

Dip Switch SW2 switches 1, 2 and 3 must be ON during leak testing procedure. (See Figure 6 on page location of Switch SW2.)

! WARNING

During the leak testing procedure all valves supplying the PURECHARGE UNIT must be closed.

Switching SW2’s Dip switches 1, 2 and 3 ON opens all the PureCharge’s solenoid valves so their respective lines can be tested for leaks.

1. Dip Switch 1 ON…energizes Fill Solenoid (SOL-1)

opens PureCharge tank and line up to the Chiller

and Charging Valve. (Green D1 LED on solid.)

2. Dip Switch 2 ON…energizes Equalization Solenoid

(SOL-2) and

opens PureCharge tank and line up to the

Evaporator Valve. (Green D2 LED on solid.)

3. Dip Switch 3 ON…energizes Oil Return Solenoid

(SOL-3) and

opens PureCharge unit tank and line up

to the Oil Sump valve. (Green D3 LED on solid.)

! WARNING

Be sure DIP Switches 1, 2 and 3 on SW2 are returned to the OFF position when finished with the leak test. If either of these DIP Switches are left in the ON position, the PureCharge unit will not function properly. (See Figure 6 on page

18 for location of Switch SW2.)

Leak Testing PureCharge unit when Installed on Chillers using Low Pressure Refrigerants

(See page 23 for leak test procedure on chillers using high pressure refrigerants.)

All chiller valves to PureCharge unit must remain CLOSED during this procedure exce pt when otherwise instructed as part this procedure.

To properly leak test the entire PureCharge system, you will have to pressurize the PureCharge unit, including all fittings and piping connections up to the chiller’s valves.

18 for

3. Adjust the lower setpoint by turning the differential spindle (the spindle to the right as you look at it).

Upper setpoint (minus) differential (equals) lower setpoint

1. Remove control box cover and flip Dip switches 1, 2

and 3 on SW2 to the ON position (See Figure 6 on

18 for location of SW2 and Dip Switches 1, 2

page and 3). This will energize all three unit solenoid valves allowing interconnecting lines to chiller to be pressurize.

22 IM 856-1

2. Connect a pressure source, such as nitrogen, to the Schrader port on the top of the unit filter drier. (See Figure 7, page

19 for location.)

3. Pressurize unit to approximately 40 psig.

4. Turn unit power switch to ON.

the system to approximately 40 psig and re-close valve. The entire system including the Fill line, Vapor Return line, Oil Return line (and the temporary oil recovery cylinder if installed) will be pressurized.

5. Using appropriate leak-testing method, leak test entire

system including all interconnecting lines, fittings, etc. Fix and repair any leaks.

5. Leak test entire PureCharge system.

6. Repair any leaks.

7. Once the leak test procedure is complete, bleed off test pressure and evacuate entire system. Because of the various check valves in the system, the only way the entire system can be evacuated is by connecting the vacuum pump to the oil charging valve adapter Schrader valve.

8. Once evacuation is complete, turn Unit Power Switch OFF.

9. Flip SW2 DIP switches 1, 2 and 3 back to the OFF position.

10. Open all Chiller Valves to PureCharge unit.

11. Turn PureCharge unit Power Switch back to the ON position. The PureCharge unit is now in operation.

NOTE: Any time unit power is applied or re-applied, (after

a 5-second delay, indicated by 5 green blinking LEDs) the unit always starts in a Fill Phase. After the 5-second programmed delay, the D1 green LED should begin flashing.

Leak Testing PureCharge unit when installed on Chillers using High Pressure Refrigerants

(See page 22 for leak test procedure on chillers using low pressure refrigerants.)

All chiller valves to PureCharge unit must remain CLOSED during this procedure exce pt when otherwise instructed as part this procedure.

1. Connect refrigeration manifold gauge to the1/4” Schrader valve. (See Figure 7, page

2. With power to the PureCharge unit OFF, remove cover from control panel. On the solid-state logic control board locate DIP-Switch SW2. (See Figure 6 on page

18 for dip-switch SW2 location.) Flip

switches 1, 2 and 3 to the ON position. This will energize all three PureCharge solenoid valves when power is applied.

3. Replace control panel cover and turn power switch ON. Solenoid valves (SOL-1), (SOL-2) and (SOL-3) should now be energized.

4. Now, while monitoring the refrigeration gauge, slowly and carefully crack open the refrigerant Fill Line valve on the chiller and allow chiller pressure to pressurize

19.)

6. Once you are certain there are NO leaks, turn OFF

power and flip Dip switches 1, 2 and 3 back to the OFF position.

7. Re-open all chiller valves.

8. Turn power ON. The PureCharge unit is now in

operation.

PureCharge Evacuation Procedure

All chiller valves to PureCharge unit must remain CLOSED during this procedure exce pt when otherwise instructed as part this procedure.

1. Due to system check valves the only way the entire

system can be completely evacuated is by connecting the vacuum pump to oil sump valve adapter Schrader valve. (See Figure 1on page location).

2. Flip Dip switches 1, 2 and 3 on SW2 to the ON position.

3. Turn power ON to PureCharge unit and evacuate.

4. Once evacuation is complete, close valve on gauge manifold set and remove vacuum pump. Leave manifold gauges closed and connected to oil return Schrader valve.

5. Again, while monitoring the refrigeration gauge, slowly and carefully crack open the refrigerant Fill Line valve on the chiller and allow chiller pressure to pressurize the system to approximately 1/2 psig.

6. Now, disconnect refrigeration gauges and cap the Schrader valve.

7. Turn unit power switch OFF and flip switch SW2’s dip switches 1, 2 and 3 to the OFF position.

8. Re-open all three (3) chiller valves to the

PureCharge unit.

9. Turn unit power switch to ON position. The po wer switch green indicator light should no w be energized. The PureCharge unit is now in operation.

Any time power is applied or re-applied, (after a 5-second delay, indicated by 5 green blinking LEDs) the unit always starts in a Fill Phase. After the 5-second programmed delay, the D1 green LED should begin flashing.

8 for

IM-856 23

Troubleshooting

Should an operational difficulty or malfunction occur, the diagnostic chart and checkout procedures on the following pages should help to quickly determine the cause and corrective action. The Troubleshooting Chart has a Symptom column which describes what the unit is doing; a Possible Cause column which identifies possible sources of the problem; and a Solution column which describes what must be done to correct the problem.

Recording LED Status

Should the PureCharge unit shut down on a Fault condition, until you should first removed its electrical panel cover and recorded the status of the green indicator LED’s D1 through D5 located on the Logic Board. Knowing the particular LED(s) that are lighted will help you diagnose the cause of the problem. Once the unit is powered OFF, this information will be lost. Retain the record of the LED readings. Examine the unit for any apparent problems; check the Troubleshooting section for possible causes of the fault. Check to see if all appropriate Dip Switches on SW1 & SW2 are off (see pages

24 ), then if there is no apparent problem, reset power.

and See if the fault repeats.

Using Switch SW2 Dip Switches as a diagnostic aid

Switch SW2 Dip Switches can be used to activate the

15, 22,

solenoid valves and distillation heater for various procedures. This can be very helpful when diagnosing and/or correcting certain operational problems. By switching the appropriate Dip Switch to the ON position, the corresponding valve or heater will energize.

1. SW2 switching Dip Switch 1 ON…………energizes

Fill Solenoid (SOL-1), Green D1 LED

will be on solid.

2. SW2 switching Dip Switch 2 ON………….energizes

Equalization Solenoid (SOL-2), Green

D2 LED will be on solid.

3. SW2 switching Dip Switch 3 ON……. ……energizes

Oil Return Solenoid (SOL-3), Green D3

LED will be on solid.

4. SW2 switching Dip Switch 4 ON…………..energizes

the Distillation Heater and the Green

D4 LED will be on solid.

! WARNING

Be sure DIP Switches, 1, 2, 3 and 4 on Switch SW2 are returned to the OFF position when finished. If any of these DIP Switches are left in the ON position, the PureCharge unit will not function properly. (See Figure 6, page

18 for location of Switch SW2.)

Troubleshooting Chart

Symptom Possible Cause Solution

Power switch ON but switch Light is Off. Main power to unit Off.

Switch light defective. Power switch ON and lighted but Logic Board LED’s are all OFF

D5 green LED flashing Chiller Run Signal requirement enabled

Fault Red LED D6 flashing Green LED D1 ON solid

Logic Board fuse blown.

Logic Board defective.

and no Run signal received

Indicates distillation tank temperature did

not drop below 155 F degrees during the

first 20 minutes of the fill phase.

Restore main power.

Replace switch. Replace fuse.

Replace Logic Board. Restore Chiller Run Signal.

Distillation heater stuck on. RLY-1 contacts stuck. Replace Logic Board.

Temperature Sensor TS-1 defective. Replace sensor.

Chiller’s charging valve closed. Open valve.

Oil Return Solenoid Valve SOL-2 defective and the unit still has hot oil in it. Replace solenoid coil or valve. Check if Oil sump valve is closed. Check RLY-4 relay, if defective, Replace Logic Board.

Refer to “Distillation Tank will not fill” Symptom troubleshooting chart.

24 IM 856-1

Symptom Possible Cause Solution

Fault Red LED D6 flashing Green LED D2 ON solid

Fault Red LED D6 flashing Green LED D3 ON solid

Fault Red LED D6 flashing Green LED D4 ON solid

Indicates distillation temperature failed to

reach 155 F degrees within 6 hours after

starting Primary Distillation Phase.

Indicates the Logic Board detected that

the programmed distillation temperature

was reached prematurely, indicating the

PureCharge unit is not filling properly, or

is losing the PureCharge charge prior to

distillation.

Refer to “Distillation Tank will not fill”

Symptom below in troubleshooting

section.

Dip Switches on Switches SW1 or SW2

may be set improperly.

Fill Solenoid Valve (SOL-1) or Oil

Solenoid Valve (SOL-3) stuck open.

Indicates the Logic Board sees a signal

from the Liquid Level High Sensor for

longer than 2 hours straight.

PureCharge unit may be oil logged. See

the “Oil will not transfer from Distillation

Tank to oil sump” in Symptoms below in

this chart.

Distillation heater defective. Replace heater (see Maintenance Using

Switch SW2 dip switch 4 as a diagnostic aid on page 24).

Heater relay RLY-4 on Logic Board defective. Replace Logic Board.

Temperature Sensor TS-1 defective. Replace Sensor.

Fill Solenoid valve (SOL-1) fails open or shut. Replace valve

Refer to “Distillation Tank will not fill” Symptom below in Troubleshooting section.

Verify that all dip switches on SW1 and SW2 are in the Off position. Pay particular attention to the SW2 dip switches 6 and 8 and make sure they are definitely Off (sometimes they may appear to be off, but are t actually On).

(See pages SW2 information.)

Replace appropriate defective Solenoid Valve.

Check the Liquid Level Sensor for defect. See page for test procedure

Check Logic Board for loose connection to INPUT 2

Logic Board may be defective, Replace logic board

Bleed resister wire lead between IN2 and Neutral on logic board may be defective or disconnected

15, 22 and 24 for SW1 and

IM-856 25

Symptom Possible Cause Solution

Distillation Tank will not fill, or empties too soon during distillation phase

Heater fails to heat. Defective heater.

Chiller’s refrigerant charging valve

closed or obstructed.

Vapor return line stop valve closed.

Distillation heater stuck ON during Fill

Phase.

Equalization line, if connected to

Schrader valve, may not have valve

stem removed.

Fill line kinked or obstructed.

Fill line strainer clogged.

Fill Solenoid (SOL-1) fails to open.

Equalization Solenoid (SOL-2) failed to

open.

Unit may be mounted to high.

Fill line and connecting piping up to

evaporator shell may not be insulated

causing vapor lock.

Refrigerant Charge low.

Dip Switches on Switches SW1 or SW2

may be set improperly.

Logic Board may be defective

Liquid Level Sensor may be defective

Indications may be D6 Fault light and/or

D3 and/or D4 green LED activated.

Oil return Solenoid 3 stuck open causing

un-distilled refrigerant to be forced into

oil sump.

RLY-4 relay defective.

Disconnected lead.

Defective Temperature Sensor TS-1

Contacts stuck closed.

Open valve or replace valve.

Open valve. Defective TS-1, Replace. Or RLY-4

contacts stuck. Replace Logic Board. Remove Schrader valve stem.

Correct as needed. Replace Fill line Strainer. Replace Fill Solenoid (SOL-1). Replace Equalization Solenoid (SOL-2). See Installing the unit on page Insulate. (See page 9 for warning

information on insulating.)

Correct Refrigerant Charge. (See pages 17, 22, and 24 for SW1

and SW2 information.) Replace Logic Board. Check the Liquid Level Sensor for

defect. See page28 for test procedure. Also check Pressure Equalization Check Valve for leaking.

Replace oil return Solenoid 3.

Replace heater (See Maintenance Section on Using Switch SW2 DIP switch 4 as a diagnostic aid. See page 24 for SW2 information)

Replace Logic Board. Reconnect lead. Replace sensor.

Fill Solenoid Valve (SOL-1) fails to open or close

Defective Logic Board.

Solenoid coil defective.

SOL-1 Solenoid Valve defective.

RLY-1 relay defective.

Disconnected lead.

Solenoid seat may be contaminated.

Replace Logic Board. Replace coil. Replace valve. Replace Logic Board. Reconnect lead. Replace Solenoid.

26 IM 856-1

Symptom Possible Cause Solution

Equalization Solenoid Valve (SOL-2) fails to open or close.

Oil transfer Solenoid Valve (SOL-3) fails to open or close.

Oil will not transfer from Distillation Tank to oil sump.

Solenoid coil defective.

SOL-2 Solenoid Valve defective.

RLY-2 relay defective.

Disconnected lead.

Solenoid seat may be contaminated.

Solenoid coil defective.

SOL-3 Solenoid Valve defective.

RLY-3 relay defective.

Disconnected lead.

Solenoid seat may be contaminated.

Oil Return Solenoid Valve SOL-3

Solenoid coil defective.

SOL-3 Solenoid Valve defective.

Oil Sump valve closed.

Oil return line kinked or blocked.

Oil Filter blocked.

Replace coil. Replace valve. Replace Logic Board. Reconnect lead. Replace Solenoid. Replace coil. Replace valve. Replace Logic Board. Reconnect lead. Replace Solenoid. Replace coil.

Replace valve. Open Valve. Correct as necessary.

Replace oil filter. RLY-3 relay defective. Equalization Solenoid Valve SOL-2

stuck open or leaking past valve seat. Pressure Equalization Check Valve is

defective and leaking. Oil Check Valve CK-1 stuck closed.

Replace Logic Board.

Replace valve.

Replace Pressure Equalization Check

Valve.

Replace Oil Check Valve, CK-1

IM-856 27

Troubleshooting the Liquid Level Sensor

Preliminary Test:

1. Turn unit power switch OFF.

2. While observing the LEDs on logic board; turn unit

power switch ON.

Normal Result (A)

LED D1 ON blinking; indicates the unit liquid level sensor is functioning properly and is operating in the Fill Mode (so long as liquid is not present in the upper sight glass).

Faulty Result (B)

LEDs D2 ON blinking, D4 and D5 ON solid; means either the liquid level sensor has erroneously detected a liquid level and is therefore defective, or the logic board is defective.

To determine which component is at fault, proceed with the following test:

1. Turn unit power switch OFF.

2. Disconnect the yellow level sensor wire and the blue

bleed resistor wire from Input Terminal IN2 on the logic board. This eliminates the level sensor from the circuit.

3. Turn unit power switch back ON.

Determination (1)

LED D1 ON blinking; indicates the logic board is responding correctly therefore the problem is the liquid level sensor. Proceed to liquid level sensor replacement instructions on page

Determination (2)

Any other result indicates a bad board. Board must be replaced. When replacing board, remember to reconnect the yellow level sensor wire and the blue bleed resistor wire to Input Terminal IN2 on the logic board.

28.

Liquid Level Sensor Replacement Instructions

Liquid level sensor malfunction can result from either a defective electronic module or a cracked or cloudy prism. A faulty electronic module is most likely causing the problem and therefore should be replaced first since it can be replaced quickly and easily without opening the refrigeration system.

However, if after replacing the electronic module the liquid level sensor still does not function properly then the prism is probably at fault. A cracked or cloudy prism can cause erratic response or no response at all to the presence of liquid.

It the prism is defective the complete liquid level sensor will have to be replaced. In order to replace the complete sensor it will be necessary to isolate and depressurize the distillation tank.

MODULE

PRISM

Replacing Level Sensor Switch Electronic Module

1. Turn unit power switch OFF.

2. Disconnect the white liquid level sensor wire from

TB-1 terminal 2, and the black sensor wire from TB-1 terminal 5.

3. Disconnect the yellow sensor wire from the bleed

resistor connected to Input terminal IN2 on the logic board

4. Remove sensor wiring and conduit from electrical

box.

5. Remove conduit and conduit connector from sensor.

6. Remove the retaining ring that holds the electronic

module in place in the sensor body. This will require a pair of IRR P-101 or equivalent snap ring pliers.

7. Remove the retainer

8. Using the module leads gently p ull the defective

module and O-ring from the sensor body, being careful not to loose the O-ring.

9. Insert the new replacement module with old O-ring

into the sensor body.

10. Insert retainer and re-install retaining ring.

11. Re-connect sensor wires.

Note: It is imperative that the white wire be connected to

TB-1 terminal 2 and the black wire be connected to TB-1 terminal 5. The yellow wire must be connected to the blue bleed resistor wire and both must be connected to logic board Input terminal IN2.

28 IM 856-1

Procedure to Clear Oil Logged Distillation Tank

The following conditions can cause “oil logging” of the PureCharge Distillation Tank:

1. The Oil Sump Oil Charging valve has been

inadvertently left closed.

2. The Oil Return Solenoid Valve (SOL-3) fails in the

closed position.

3. Relay (RLY-3) fails to energize Solenoid Valve

(SOL-3) preventing oil return to oil sump.

4. The Oil Return line is kinked, or obstructed,

preventing oil return to oil sump.

5. The Pressure Equalization Check Valve is defective,

preventing the unit from retaining pressure that is used to return oil to the oil sump during the oil return phase.

Should oil logging occur, clear the Distillation Tank using the following procedure:

1. Troubleshoot to determine which of the above

mentioned conditions has caused the oil logging problem.

2. Correct the problem. Only after the problem has been

corrected can you proceed to the next step.

3. Turn OFF power to unit.

4. Isolate from the chiller by closing all valves to unit:

Refrigerant Charging Valve, Oil Sump Charging Valve and the Evaporator Gauge Stop Valve.

5. Remove cover from Electrical Panel, on Switch SW2

flip Dip Switch 3 to the ON position. (This procedure allows the Oil Return Solenoid Valve (SOL-3) energize when power is reapplied.) See Figure 6, on page 18 for location of SW2.

6. Using a manifold gauge set, connect a pressure source,

such as nitrogen, to the Shrader Access Fitting located near the top of the Distillation Tank. Pressurize the tank to approximately 4 psig.

7. Now,

re-open the oil sump oil-charging valve.

8. Turn power to unit back ON.

9. The 4 psig pressure will now push the oil from the

Distillation Tank back to the chiller’s oil sump.

! CAUTION

only to

15. Place cover back on electrical panel.

16. Open ALL valves to unit.

17. Turn unit power back ON. The PureCharge unit

should now function properly.

Cautions indicate potentially hazardous situations, which can result in personal injury or equipment damage if not avoided.

10. When the manifold gauge indicates 2 psig pressure in

the Distillation Tank, enough oil has been transferred. Be sure to stop at 2 psig to prevent nitrogen from entering the chiller.

11. Remove manifold gauge set from unit.

12. Turn power to unit back OFF again.

13. Flip SW2, dip switch 3 back to the OFF position. See

Figure 6, on page 18 for location of SW2.

14. Use vacuum pump to evacuate the PureCharge unit. IM-856 29

Figure 8 – Electrical Wiring Diagram, PureCharge

115 VAC

BLK

HPC-1

COM

NEUTRAL

2 2B2A

BLK BLK WHT

BLK

TB1

BLK

1111

3 4

BLK

FAULT

COM

RLY-6

COM

RLY-5

NC NO

RLY-4

LOGIC BOARDLOGIC BOARD

D6 D5 D4 D3 D2 D1

IN1

IN2

GND

BLK

RED

TS-1

Optical Level Sensor

YEL

BLK

WHT

BLK

WHT

RLY-3

RLY-2

IN6

IN7

RLY-1

LINE

NEUTRAL

GND

WHT

Optional Chiller "Run Signal"

Run Signal Isolated Neutral

BLU

Bleed Resistor

BLU

BLK

WHT

SOL-1

Fill

Equalizer

Oil Return

Distillation Heater

SOL-2

SOL-3

BLK

WHT

BLK

WHT

30 IM 856-1

This document contains the most current product information as of this printing. For the most up-to-date product information, please go to Conditions of Sale and Limited Product Warrant

www.mcquay.com • 800-432-1342

www.mcquay.com. All McQuay equipment is sold pursuant to McQuay's Standard Terms and

IM-856 31

McQuay MPC-HPC200 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Hazardous Identification Information

Installation

PureCharge Specifications

Contents of the PureCharge Installation Kit

Each kit includes:

Field-Provided Items

To be furnished by the installer:

Preliminary Inspection

PureCharge Unit Operational Overview

Three Operational Phases:

How the PureCharge Unit Transfers Oil to the Chiller’s Oil Sump

How It Works

Operating Parameters

Operational LED Indicators

Operation LED indicators

Diagnostic LED indicators

Fault LED indicators

Recording the LED Lights During a Fault

Installing the PureCharge Unit

Location and Mounting

Plumbing the Unit

Determining Which Side Port to Use

Liquid Refrigerant Fill Line (with Strainer)

Carrier Series D™ Centrifugal Chiller Instructions

Vapor Return Line

Oil Return Line and Oil Filter-Drier installation

Option 1 Oil Line Piping Instructions

Option 2 Oil Line Piping Instructions

If you choose option 2

Electrical Connection

Power Requirement

Optional Chiller Run Signal

Connecting Power

Initial Start-Up

Start-Up Procedure

Description Of PureCharge Components

250 PSIG Pressure Cut-Out Switch (HPC-1)

Distillation Heater

Distillation Tan

Electrical Control Box

EZ-Change High Moisture Capacity Filter-Drier

Fill Solenoid Valve (SOL-1)

Oil Transfer Solenoid Valve (SOL-3)

Oil Return Check Valve (CK-1)

Oil Return Filter-High Acid Capacity

Power Switch (PS-1)

Pressure Equalization Check Valve (CK-2)

Pressure Equalization Solenoid Valve (SOL-2)

Safety Relief Valve (SRV-1)

Temperature Sensor (TS-1)

Terminal Block (TB-1)

Solid State Logic Board –Switches SW1 and SW2 & Relays

Safety Features

Safety # 1 guarding against over pressurization.

Safety # 2 guarding against over pressurization.

Safety guarding against inadvertent closing of any isolation valve(s).

Safety preventing transfer of undistilled refrigerant into chiller’s oil sump.

Safety guarding against Fill Solenoid (SOL-1) failing in the open, or closed position.

Safety guarding against Equalization Solenoid (SOL-2) failing in the open, or closed position.

Safety guarding against the Oil Transfer Solenoid (SOL-3) failing in the open position.

Safety guarding against Solid State Logic Board Relays sticking or not making.

Safety guarding against the heater failing in ON position or OFF position.

Electrical Control Box

Terminal Block (TB-1)

Temperature Sensor (TS-1)

250-psig Pressure Cut-out Switch (HPC-1)

Figure 5 – Major Electrical Components Box

Logic Board Relays and Dip Switches

Relay RLY-1

Relay RLY-2

Relay RLY-3

Relay RLY-4

Relay RLY-5

Switches (SW1) & (SW2) (Dip Switches)

Maintenance

Steps for Changing EZ Change Filter Drier