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Sep-16-05

08:32am

T-616

From-

P.DU2/DID

F-891

ENGINEERING BULLETIN

OPERATION & MAINTENANCE

JOB NAME:

HAT CREEK RADIO OBSERVA-

TORY
HAT CREEK, CA
FOR: PO# PTS 066988
Model PCP-1 00-1 OA-WP-HA-SSC-LAC-HGBP-CTC

Serial No. 6406/95

Sep-16-D5 08:32am From7
.,'iltri lie Mmmfacturing
IS Kit Street
Kcent', NH 03431
Pbone: (}(}3.352-5500
F~IX: hO~.]''i2-(HJO

T-618
.:-:~~~

. ,-'" :, ;

P.DOI/OID F-89\

Make pi umbing connc<. After all electricalconnecNmsarc made.J PCP. 5.. 15 41. Fillunlil coolanl is visible at least 3/4 of the way up the liquid level sight glass.ned to pump a coolant (water or water and ethylene glycol solution) from the cooling tank through a dosed cooling loop Zlnd buck to the cooling lank. chiller funclions before operating. -High Pres. B.~switch seHings ilrc dependent upon application ot' equipment C.CLOSED LOOP CHI LLJt:RS: PCP I. Cut In RZZ Cut Out 22 275 350 PIISS.lkc repairs necessary. controls from direct exposure Inclcmcnts and allows outdoor installatiDIl.WP.:tioTl ti I11Cdelay pmgl1ll11 mcnu..Sep-lii-05 08:33am' 1-61B Frcm- P.:is IIsually not under pressure.WIJ. PCP.:hillers are de-sig. Check conlant level periodically by shuuing 011pump and thcnnpcning air vent. 7. 2. If recirculating pump is supplied with a bleed plug in pump housing. Open fil I port Oll'lOp of cabi net and air vent. Add more liqujd <ISnecessary to rill sight gi<. turn on pump and pump liquid through complete cooling loop. 6406/95 A.C1~C Serial No. The cooling L. loosen plug umil water begins to dripollt. OIYfIONS: This dullcr js supplied \Vilh the following oplions. OPERATIl\G PRESSURES: freon pressure: Your Filtrinc chiller is set at the factory lO operate at the following IU2 OpcratinlZ Pressure I~O.' 12.WCt:llher-ProorJLow-AmbienlConlrols .hten.."{\ltGIiI I . FiJI up cooling tmk through fill port u~ing a hose ('II'bucket and funnel. o. then retig.'. 3. Coolanl flow will be out or the' Discharge' connection.1 (pump down! I IAWll'ress(snfety) I I "':< I -' 35-45 PressuJ'(. 10. Close air vent and replace plug in rill porI.~ti()nsto pipe connechons ulgged 'Discharge' and 'Return'. 8. Close air vent and fill pon. Open air vent and fill port.Weatherproof' Je~ign protect!) s\viwhes.35e Compr~~ssorDiscllargt~ ."Ol{ MODEI.. 11.l00. <). Be slire 10 understand hm\! the .003/010 F-S91 INSTALLA110N INS1'RUCllONS . J . J. Add more coolant "'" necessary.mi.lSS. mnl()p. Tum off' pump.IIW Compressor *'" SUI~!eClIO Sut.10A. 4.HA-SSC-IJAC-HGBP. Check all piping for 1Ci:1ks and m.

At thIs tllTle.linproper receiver pres:.~dvcr.004/Jl0 F-8~1 - HA I.surc operating control.anbe: seriousl y damagcJ. If there has been a loss of refrigeram.ondenscr~ (3) lCl. the receivcr pressure falls until it approache~ the control point of the ambient' control. the ambieni control will UlItOlllllticallymodulale. The chiller also utilizes a lime delay low prc\. will actually calise Ihew.:hargeand the refrigeranl wilJ back up int. Sufficient ~harge of refligeram means Ihallherc must be t~nough liquid rcfligemm in the rccc!vcr Juring lowestamhient conditions. regardless of outside temperature.hout of stainlcs.tife control 80 that the chiller will rur. At the same time the other side {)f the valve will start to bypass hot gas to the re.scalell valve that will maintain a nearly U'lllstan~ rc('civerpressure for normalsystem operation.. If it is hot.ntetingthe evaporalor. This pressure t:ontwl has a 90 second'delay nil funcLJon. it ISbetter to com plctel y emply lhe charge and recharge lOthe original amounl on the nameplate of the chiller..the valvc starf£ to throttle.there is sufficient pressure in the receiver for proper expansion valve. If the compressor is allowed In fun under ulow charge condition wIth tlw ambient conlrol.r.Cabinet and frame constructed throug. Bectluse it may be difficult to teli by looking at.(J) hot gas.cliofl satisfactorily during periods of low ambient. the rcfrigerantl10w to maim..a few other things should te checked to make sure that it is liquid: (1) Suctjon and head pressures will be h'!Wwith high superheat. up andrnaking sure. \l/ani1tng il.operation.cd t:om.lterin the. As long as r. During periods of low ambient iempemture.. The hot gase. The pressure control keeps Lh(~compressor running for 90 seconds before trippin~ oul . steel.hereis suffidcnt rerrigerant charge in the system.. temperature. Too Jilllc refngerant and the chiller and the chiner won't operate properly in low ambient condiLi()n~..!c islnw. thus reducing the acu"e condenser surface.lenser lo permil c()rnpreS~ollo run at norlllal head and suction pressures in high ambient conditions. The bypui>s hot gas mixes with the cold liquid from the condenser. (2) liquid drain from (. Too mu<...the site glass whether it is full of liquid or JUS!hot !~as. (2) Check outlet of t"xpa!1~ionvalve. I Stainless Steel Cabinet.ure.The chiller is outhltcd with a refrigerant side head pres!. The valve has three connectil)nS on 1t-.o the ~onJens{. thcn hot gas can cnter the liquid line and the cxpan. there there is hot gas in the liquid line amI the char/.Sep-IS-05 Q8:33am. The charge is very clitical. II' there is tun liule refrigerant and there is no liquid seal. restri<:l1ngthe liquid now from the condenser. This headpressure control is a nOJ1~adjuslabJe.:hI. to maintain a liquid seal for the liquid line.lank to heat up. LAC-LOW AMBIENT CONTROL-. through the expansionvalve. ir .jol1valve and cooling \\'ill stop.This is done to eliminate8hol1cyclingon low pressure on stan-up during low ambienls. Frcrn- 1-618 P. causing high pre~suJ'c In high ambient conditions.'civ(~r. This will raIse the ~()ndenser pres~urc.flgh ambient Condenser ~ OvcIsjl'. causin~ liquid refrigcrant to back up in the condenser.

~agaill.~the chiller is hot gassing. raising the waicr temperature.:kcdwith refrigeration. When the waler temperature exceeds this set pOlllt. As the pressure drops. the hot gas pressure regulator will open and ~tart passing hot gas into the liquid sidc of the evaporaror. putting the chiller into its cooling mod(. liquid. 3. .g the liquid line solenoid and causing the suction pressure to drop. the low tempcnlture thermostat will de-energize the hot ga. the controller \"ill opcl1thc hot gas solenoid valvc which allows hot refrigcmnt gu. low temperature thennostat will shUt the compressor niT \lotil the load increases. When Ihe set point is reached.1suction pressure at the temperature being maintained.intcrJol. Set thesctpoinl thermostatat the desired tClilpcrature. the sc~p()intthermostat will open up. so it must be calling for cooling before the system can run. When the water temperature IS above [he setpoint..in.~l1r. 5.hechiller to maintain a smnller than nonmtltemperature. solenoid as \-vellas the .:ater temperature rises above the setpoint.c.. It involves the addition {?fa solid state tempcnllure controller rated typically ilt :!:. the.005/010 F-891 to help the build system up toopcraling pressure. allowing the flow of liquid rcfJigcrant to enter the cvaporntor.:onlrollcr. ThiS pressure wili be regulated at apprnxlITlBtely15. the tempcrature drops below the desired seLpoint eventhough thechiller is in hot gas bypass. . Whenthe \. The low tCIlIperature cutout thermostat is in serie~ with the setpoim thennostat. the chiller will be fully loaded and cooling.ssllfc to rise whkh closes the hot gas regulator.Sep-16-05 08:34am 1-618 From- P. There is also a low tempera{ure Ihcrmostat (usually mounted inside the cabmet) which should be set abollt 5° lower than the "ct rOlllt . Thi~ will cause the unit to pump down and turn oil untillhc temperature nses agmn. The hot gas gives the cOInpressor a false load and can a~tuaJly warm the watcr temperature back up.5°Fand a hot gas bypass solenoid.suction pre.:ofitrul\Vilhollt shol1-cycling the compressor.Close Temperature Control: This oplion is designed to allow i.20 psi lower than the norm. If under no-loud conditions. If under low load conditions the tcmperatnre continues to Jrop bcluw the sctp()int C'ie!1 whii<. rhe liquid linc solenoid is n>energizcd. the compressor will operate at full capacity to bril)g the temperature down. crc. 4. Set the solid state temperature controller <ltthe desired outlet water temperature. Set the low temperature culoutlhemloslat a few dc!:!reeslower than the sctpoint. differential without short-cycling the compressor..This in effect unloads the refrigcmtion without turning niT the c()mpres~. When the water temperature reaches sctpoint. ' 2. lme solenoid. Sequence or Operation I. Pump mllst be running . HOT GAS BYPASS OPERATION The hot gas bypass option is designed to help the chillcr maintain dose temperature I. de-cncrgil. This causes the. to bypass the condenser.

%Therrlli)stat 196-0406/95-*Compn:ssor starting rclHY 224-6406/95-* Fan m(Hor (air cooled models) 233-6406/95-*ComplCssor overload The above spare parts arc the major ~omponcnts for your chiller. please notify factory .)6/95."'"urc recolll- E. Compres::. F. J. I.:hcdis engineering bulletin 1'\>1' your lype of chiller.Sep-IG-05 08:35am T-618 From- P. Start-up by anyonemhcr t.'ing Bulletin: A tutc.1'this is not enclosed.. Selected Maintenance Manuals 1. Those with suffix mended to be kept in stock at all limes. Pump Manual . Wiring Diagl"am: Attachedis the wiring diagram for YOllrchiller. please notify Jaclory it' this is not enclosed.OOE/OIO F-g91 PART NUMBER I68-M06/95-* AlIhJi1KUk cxp~H1sionvalvc 176-64<.Be sure to have a qualif'ieJ rcfrigcral10n mechanic complete and n:~turn one copy LoHllrinc.Copeland KAR 1-0 HX)-TAC 2. . Refrigel"ation/Plumbing Schematic: Attached is the refrigeration/plumbing schcmatic for yuur chiller.t.AvailabJc upon request.hana qualified rerrigerationmcchaniL~ will void warranty. G.or Manuai . Chiller Wa'Tanty Form . Chiller 'I\~st RepOI.O&L 1ST . H. Engillec.

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..SSC-U\C-HGOP-CTC HAT CREEK RADIO OBSERVATORY. NH 03450 FlEFfilGERATION SCHEMATIC PCP-1(Jo-10A. /' . HAT CREEK. -ri i I Iq"J SERVICE VALVE T !-IIL PRESS SWITCH I i i ~_~ ~:~ I 04:-"'1 SE. . Halrisville.C SOLENOID EXPANSION VALVE \" / ./ j lANK WITH EVAPORATOR ~ ... .. CA. DRIER EYE N.009/Dl0 F-891 TO CONDENSEH (~) SOLENOID SERVIC:= VALVE SEIWICE VALVE RECEIVER HOT GAS REG. \ '.WP-HA.' FILTRINE MfG.RV:CE VALVE / _\. CO.. FOR: PO# PTS 066988 811 6406/95 ..Sep-16-05 08:36am Fram- 1-618 FROM CONDENSER P..

I I'~ A'H VeNT i SiTE G!.10A..HAT CREEK.I VALVE .AS:3 I ~: ! (7'\ ~/ '..Sep-16-05 08:37am fill T-613 Frcrn- P. ---- I BYfAS:J _ 1 1 DISCHARGE RETUHN .9:98 S# 6406/95 ... CA. . POil PTS 06(. FOR... CO. DRAIN i FILTRINE MFG. Harrisville.WP.C-HG8P-ClC fiAT CF.EEK RADIO OBSERVATORY.HA-SSC-U.010/OIO F-&9) THERMOSTAT PORT L! i-tJANUA'L .. NH 03450 PLUMBING SCHEMATIC !''::P-10o..

If the needed heat is not available at the point of vaporization. there will be ~ substantial drop in the temperature of the vaporized fluid. and to release heat at some other point enabling re-use of the refrigerant. Both of these conditions require service by an experienced refrigeration techni- cian. Starting with the compressor. only gaseous refrigerant is pumped through the ressor. is pumped to a pressure. used to detect should be. If it is yellow. Freon R-12. This valve is controlled by a temperature sensing bulb fastened to the evaporator. thus no gas accumulation occurs. The trapped gas condenses as it cools further. properly operating system. should be completely filled with clear liquid. higher In a comp- The hot. From the solenoid valve. The process depends upon the property of fluids known as latent heat of vaporization. When the compressor is operating. From the sight glass. is caused to absorb heat at the point where cooling is desired. Its purpose is to prevent liquid freon from filling the low pressure portion of the refrigeration circuit during compressor off-periods. the liquid freon passes through an anti-migration solenoid valve. high pressure gas. Without this valve. After the compressor has been running for a short time. It opens on demand when the evaporator temperature rises above a preset temperature. causing the high pressure liquid to flow into an area of low pressure. a small amount of bubbling is normal. cooled. This causes the temperature to rise and if heat is allowed to dissipate from the system. however. the vapor will return to the liquid state. Pumping of liquid by the compressor is harmful and must be prevented. Fans draw air over the condenser coils to speed heat removal. The compression of the gas causes a sharp rise in temperature. the refrigerant.REFRIGERATION SYSTEM . the refrigerant is contaminated with quires service by an experienced refrigeration technician. High pressure liquid leaving the receiver passes through a drier cartridge which removes any water that may be trapped in the refrigerant system. If a fluid changes from the liquid to the vapor state. The process may be reversed by increasing the pressure of the vapor. the liquid freon passes to a thermostatically controlled expansion valve. the sight glass. Foaming indicates the presence of oil in the refrigerant. It then passes through a sight glass which includes an indicator excessive water contamination of the refrigerant. a heat exchanger. passing through the condenser. . resulting in immediate vaporization of most of the liquid and a sharp drop in refrigerant temperature. green water and re- The sight glass also indicates insufficient freon charge. the refrigerant.THEORY OF OPERATION A refrigeration system is a closed loop circuit in which a fluid. This valve closes whenever the compressor shuts off. The indicator in color. causing it to condense to liquid. it must absorb heat in order to maintain its original temperature. heat from the atmosphere would cause expansion of the gas in the receiver tank and resulting flow of liquid freon through the system to the compressor inlet. is The high pressure liquid collects in the receiver tank which also traps any remaining gas.

the ultimate purpose of the machine. The cold refrigerant gas in the evaporator coils removes heat from the chiller water reservoir before passing out of the evaporator. The pressure in these coils is thereby kept at a relatively low value so that the refrigerant in this area remains primarily in the gaseous state. This is. .Modulation of the expansion valve by the evaporator temperature sensing bulb assures that excessive refrigerant will not flow into the evaporator coils. The low pressure gas is then passed through a filter to remove any particulate contaminants before returning to the compressor inlet. of course.