Spec - Chiller Lắp Đặt Chiller

MOTIVAIR COOLING SOLUTIONS
AIR COOLED CHILLERS
MODELS: MPCA0005 – MPCA0150

INSTALLATION, OPERATION, AND MAINTENANCE
MANUAL
This chiller has been factory run tested to the specified

water pressure
*****DO NOT OVER PRESSURIZE CHILLER WHEN LEAK
CHECKING PIPING OR FILLING HYDRAULIC SYSTEM*****
*Isolate chiller from piping if higher test pressure is
required for leak checking*
*Chiller damaged caused by over pressurization is NOT
covered by warranty*
85 Woodridge Dr. Amherst, NY 14228 – Phone# 716-691-9222 – Fax# 716-691-9229

www.motivaircorp.com
INDEX – TABLE OF CONTENTS
PAGE
• LEGAL PROVISIONS & SAFETY INSTRUCTIONS 1
• TRANSPORTING & SITE HANDLING 2-3
• CHILLER INSTALLATION 4-13
• PIPING INSTALLATION 14-18
• MAIN ELECTRICAL INSTALLATION 19
• WATER/GLYCOL INSTRUCTIONS 20
• CHILLER SEQUENCE OF OPERATION 21
• MPCA0005 – MPCA0150 PROGRAMMING AND ALARM CODES 22-25
• MPCA0005 – MPCA0150 STANDARD CONTROLLER LAYOUT 26
• COMMISIONING AND STARTUP INSTRUCTIONS 27-28
• TROUBLESHOOTING 29-32
• PREVENTIVE MAINTENANCE 33-35
• CHILLER REPAIR INFORMATION 36-37
• CLEANING THE PLATE EXCHANGER (EVAPORATOR) 38
• REFRIGERANT INFORMATION 39
• TERMS AND CONDITIONS OF SALE 40

MPCA0005 - MPCA0150 MANUAL
PROVISIONS AND SAFETY
WARNING
Operation of these systems involves potentially Iethal dangers (high
voltage and high pressures). Therefore, all safety precautions and
warnings described in this manual must be precisely observed.
Otherwise, severe or fatal injury may be caused.
Operator's Responsibility This chiller MUST be installed, maintained and operated by a person(s)
qualified for this equipment. This chiller contains refrigeration, water
circulation and electrical components. The person(s) most suited for this
equipment is a qualified licenced refrigeration technician. Intervention by
unauthorized or unqualified parties may void the warranty.
SAFETY INSTRUCTIONS
The installation, start-up and maintenance of the chillers are
dangerous, Due to:
• High pressures is generated in the equipment
• Electrical parts are energized
• The equipment contains hot pipes (Refrigeration system)
• Rotating parts (fans and or pumps) can cause injury the chillers
themselves may be installed in a dangerous position (roof, high
built frame etc.)
For these reasons, the chiller must be installed and connected to the
electricity/water installations by qualified companies only. Startup and
maintenance must be conducted by a qualified refrigeration company
only.
Simple maintenance operations on the equipment without opening

them may be performed by the operator. All other work must be
performed by specially qualified personnel.
1
TRANSPORT AND HANDLING
LIFTING - UNLOADING – POSITIONING MANUFACTURER'S NOTE

Notices (symbols) –on device packing must be The machine may be damaged by:
observed. Dropping or tipping it on the ground.
Check the center of gravity of the chiller. Pulling the chiller by cords, straps, etc.
Use appropriate unloading equipment. Lifting the chiller by its piping system.
Remove protective film from chiller and cardboard. Excessive shaking by cranes.
behind condenser before use. Damage of this type is not covered by warranty.
EC A
ECA
MAX 45°
EC A
ECA
2
LIFTING - UNLOADING – POSITIONING MANUFACTURER'S NOTE

Notices (symbols) –on device packing must be The machine may be damaged by:
observed. Dropping it or tipping it on the ground.
Check the center of gravity of the chiller. Pulling the chiller by cords, straps etc….
Use appropriate unloading equipment. Lifting the chiller by its piping system.
Remove protective film from metal panels before Excessive shaking by crane.
use. Damage of this type is not covered by warranty.
Installing with a fork lift truck

Use the forks to lift with: they must be as long
as the chiller. Use of fork extensions if
required, OR SERIOUS DAMAGE MAY RESULT.
LIFTING WITH A CRANE

Use the holes in the bottom framework for lifting. To
distribute the weight evenly place a strong L-shaped section
between the belts and structure work. INSERT SPREADER
BARS TO PREVENT CRUSHING
HOOKING TO THE STRUCTURE

Hook only to the points indicated by the lifting
labels.
Make sure there is no possibility that the hooks
can slip out due to swinging or movements from
the crane
3
CHILLER INSTALLATION
Foundation All chillers must be mounted on a solid, horizontal surface, suitable for the
weight of the chiller.* Note the chiller weight is incresed by filling with
glycol/water mixture.
Site Installation Observe all local regulations.
Must be dry and protected against freezing. The room temperature must not
be colder than 410F. The system must be installed horizontally. The
components are not suitable for exterior installation, without factory
modification and approval. Consult Motivair if chiller will be installed
outdoors
Installation Compliance with the following basic rules for the erection of devices with
radial fans wiIl ensure problem-free operation and the rated refrigeration
capacity.
Basic rules:
1. The condenser air is blown out vertically or horizontally.
2. Do not install the device close to heat sources. Heated air intake must be
avoided.
3. The condenser fans are rated for ZERO external static pressure. The fan
do not have the capacity to push air through ducting, which means that
NO DUCTS OR MUFFLERS may be used on the inlet ot outlet of the
chillers.
4. No air short-circuit is permitted, i.e. the heated discharge air from the
condenser fans must never be drawn back into the condenser inlet. This
will occur if the chiller is too close to a wall, or a low ceiling or other
obstructions.
5. In the case of shaft or trench mounting, contact the manufacturer for
advice on the installation site.
Structure-borne noise It is possible that noise or vibration may be transmitted through the ground,
or building structure. If this occurs, it may be necessary to install a vibration
elimination device. The construction specifications of the
customer/engineering contractor regarding structure transmitted noise or
vibration must be observed.
Vibrations May be transmitted through the chilled water piping. This can be avoided by
the use of flexible piping connections.
Clearances Must be maintained for servicing and ventilation purposes. All removable
side panels must be available service.
A minimum of 3 feet on all sides is required. Consult Motivair for irregular

space requirements.
4
INSTALLATION GUIDE
Location:
Locate the unit to provide proper airflow to the condenser (see Figure 1 page 2)
Due to the placement of the condenser coils on the MPCA0005-0150 chillers, it is desirable to orient the
unit so that prevailing winds blow parallel to the unit length, thus minimizing the wind effect on
condensing pressure performance. If low ambient temperature operation is expected, it is
recommended that optional fan VFD system be factory installed.
Using less clearance than shown in “Addendum A” can cause discharge air recirculation to the
condenser and could have a significant negative effect on unit performance.
See Restricted Airflow beginning on page 3 for further information. For pad-mounted units, it is
recommended that the unit be raised a few inches with suitable supports, located at least under the
mounting locations, to allow water to drain from under the unit to facilitate cleaning under it.
Service Access:
The main control box contains either the microprocessor or PLC (Programmable Logic Controller) for
optimum chiller control. The solid state compressor starter, fan control and other power equipment are
located in the main control box. Condenser fan VFD’s and overloads are either located in an
independent box on the side of the chiller or in the main cabinet. The side clearance required for
airflow provides sufficient service clearance.
_____________________________________________________________________________
CAUTION
Disconnect all power to the chiller while servicing condenser fan motors or compressors.
Failure to do so can cause bodily injury or death.
______________________________________________________________________________
Do not obstruct access to the sides or ends of the chiller with piping or conduit. These areas must be
open for service access. Do not obstruct any access to the control panel(s) with field mounted
disconnect switches. Make sure that the power conduit to control panel(s) does not restrict access to
removable panels.
4
Clearance Requirements:
Figure 1
AIR FLOW
NO OBSTRUCTIONS
ALLOWED ABOVE UNIT
AT ANY HEIGHT SEE NOTES 2&4
PERTAINING TO WALL
HEIGHT AT UNIT SIDES
Notes:
1. Minimum side clearance between units is 6 feet (1.8 meters) with no perimeter obstructions
within 10 feet of the units.
2. Unit must not be installed in a pit or enclosure that is deeper or taller than the height of the unit
unless extra clearance is provided per note 4.
3. Minimum clearance on each side is 8 feet (2.4 meters) when installed in a pit no deeper than the
unit height.
4. Minimum side clearance to a side wall or building taller than the unit height is 7 (2.1 meters)
feet provided no solid wall above 7 (2.1 meters) feet is closer than 12 (3.7 meters) feet to the
opposite side of the unit.
5. Do not mount electrical conduits where they can block service access to compressor controls,
refrigerant driers or valves.
6. There must be no obstruction of the fan discharge.
7. Field installed switches must not interfere with service access or airflow.
8. MPCA chillers use axial fans and are NOT suitable for ducted applications.
9. See the following pages if the airflow clearance cannot be met.
6
Restricted Airflow:
General
The clearances required for design operation of MPCA air-cooled condensers are described in the
previous section. Occasionally, these clearances cannot be maintained due to site restrictions such as
units being too close together or a fence or wall restricting airflow, or both.
The Motivair MPCA chillers have several features that can mitigate the problems attributable to
restricted airflow.
• The single side of the condenser formation allows inlet air for the coil(s) to come in from that
side and allows for smaller distances between the opposite side and encroaching obstructions
to allow for maximum air flow to the condenser side. Facing the chiller control cabinet, the
right-side of the unit is generally where the condenser(s) are located. NOTE: This is not
exclusive as Motivair reserves the right to change chiller design without notice.
• The VFD option allows for optimum air flow at multiple year round conditions. This is best
utilized when units are placed parallel to prevailing winds.
Figure 2
The following sections discuss the most common situations of condenser air restriction and give capacity
adjustment factors for each.
CAUTION
The unit capacity adjustment charts in this engineering bulletin serve only as a guide, and DO NOT
take into account prevailing site conditions.
_____________________________________________________________________________________
7
Case 1, Building or Wall on One side of One Unit:
The presence of a screening wall or the wall of a building, in close proximity to an air-cooled chiller is
common in both rooftop and ground level applications. Hot air recirculation on the coils adjoining the
wall increases compressor discharge pressure, decreasing capacity and increasing power consumption.
When close to a wall, it is desirable to place chillers on the north or east side of them (to minimize solar
effect). It is also desirable to have prevailing winds blowing parallel to the unit’s long axis. The worst
scenario is having wind blowing hot discharge air into the wall.
Figure 3
D
H
Figure 4, Adjustment Factor
8
Case 2, Two Units Side By Side:
Two or more chillers positioned side by side are common. If spaced closer than 6 feet it is necessary to
adjust the performance of each unit; circuits adjoining each other are affected. If one of the two units
also has a wall adjoining it, see Case 1. Add the two adjustment factors together (Figure 4 and Figure 6)
and apply to the unit between the wall and the other unit.
Mounting units end to end will not require adjusting performance. Depending on the actual
arrangement, sufficient space must be left between the units for access to the control panel door
opening. See “Clearance” section of this guide for requirements for specific units.
Pit or solid wall surrounds should not be used where the ambient air temperature exceeds 95°F.
Figure 5, Two Chillers Side by Side
9
Case 3, Three or More Units Side By Side:
When designs call for three or more units to be side by side; contact Motivair with the desired
placements of the units for approval. Capacity reduction is dependent on multiple possible orientations
of the units.
Figure 7, three or more chillers
D D D
10
Case 4, Open Screening Walls:
Decorative screening walls are common to help conceal a chiller either on grade or on a rooftop. These
walls should be designed such that the combination of their open area and distance from the chiller do
not require performance adjustment. It is assumed that the wall height is equal to, or less than the
chiller height when mounted on its base support. This is usually acceptable for concealment. If the wall
height is greater than the unit height, see Case 5 (Pit Installation).
The distance from the sides of the unit to the side walls should be sufficient for service and opening
control panel doors.
If each side wall is a different distance from the unit, the distances can be averaged, providing either
wall is not less than 8 feet from the unit. For example, do not average 4 feet and 20 feet to equal 12
feet.
Figure 9, Open Screening Walls
D D
Figure 10, Wall Free Area Graph
11
Case 5, Pit/Solid Wall Installation:
Pit installations can cause operating problems and great care should be exercised if they are to be used
on any installation. Recirculation and restriction are probable. A solid wall surrounding a unit is
effectively the same as a pit and the data given in Case 5 should be used.
Steel grating is sometimes used to cover a pit to prevent accidental falls or trips into the pit. The grating
material and installation design must be strong enough to prevent such accidents, yet provide abundant
open area or serious recirculation problems will occur. Have any pit installation reviewed by Motivair
application engineers prior to installation to discuss whether it has sufficient airflow characteristics. The
installation design engineer must approve the work and is responsible for design criteria.
Figure 11, Pit Installation
D
H
D=10Ft
12
Addendum: A
40” 40”
40”
40”
40”
40”
Control Panel
Control Panel
40” 40”
MIN. CLEARANCE FOR MPC-A 0005-0010 MIN. CLEARANCE FOR MPC-A 0150
13
14
NOTE: VENTS ARE REQUIRED AT ALL "LOCAL" HIGH POINTS IN SUPPLY AND RETURN
15
PIPING INSTALLATION
This section is intended as a guide for the correct installation of the chilled water piping system,
including this chiller. However, the chiller manufacturer accepts no responsibility what so ever for the
installation of the chiller or the associated piping.
All piping must be installed only by a licensed plumbing contractor, and in compliance with local codes.
DO NOT USE GALVANIZED PIPING IF GLYCOL IS TO BE USED IN THE CHILLED WATER SYSTEM. Chemical
reaction between the glycol and the galvanized piping can be detrimental to the cooling system, the
glycol and chiller. Piping material may be copper, plastic, carbon or stainless steel depending on the
requirements of each installation.
It is the responsibility of the engineer and/or the piping contractor to insure that the piping is correctly
sized in relation to the installation, and the available dynamic head of the pump installed inside the
chiller. The chilled water pipe connections on the chiller are not necessarily the appropriate size for the
system piping. As a general guide, the chiller pipe connections should be considered as the minimum
pipe size required for the installation. Drastic reduction in pipe sizing (small hoses, etc.) will reduce the
chilled water flow and may cause a low flow alarm, or freezing damage to the evaporator. Note:
Installation with low water flow/high water temperature rise should always have a full-ported by-pass
installed between the chiller inlet and outlet connections, with a manually adjustable gate valve in the
by-pass line. Correctly adjusted, this blended return water will maintain an adequate flow through the
chiller, at an acceptable return temperature.
ALWAYS install a filter/strainer on the inlet off the chiller, in order to prevent particulates (rust, dirt
and installation debris) from blocking the evaporator. Blockage will severely impair chiller
performance and is not covered by warranty.
Always install a pressure gauge in the return piping close to the chiller. This is essential for monitoring
system pressure and pump performance.
It is good piping practice, especially on systems with short piping runs and/or low system pressure loss,
to install a gate valve in the DISCHARGE line from the chiller for throttling purposes. This allows the
operator to maintain optimum pump performance by adding resistance to the system. NEVER throttle
the water flow on the return line to the chiller. This will cause cavitations and over-heating of the pump.
AUTOMATIC WATER MAKE-UP
If the chilled water cooling system is expected to lose water during normal operation an automatic
water make-up system should be installed, or can be supplied as a factory option. The auto make-up
system must include a water pressure regulator and pressure gauge. CAUTION: The tank inside the
chiller has a maximum pressure rating of 15 PSIG. Do not discharge city water (which can be 60-80psig)
directly into the chiller. Instantaneous pressurization can cause the tank to rupture before the pressure
relief valve opens. NOTE: Do not use an automatic water make-up system if glycol is installed for anti-
freeze protection. The glycol will become diluted and the freeze protection point will be higher (less
protection from freezing). Some critical applications require the installation of emergency city water and
drain solenoid valves, in the event of a chiller failure. In this case, the chiller MUST be isolated from the
city water pressure to avoid damage. After operation of the emergency city water system, the glycol
concentration must be carefully checked using a spectrometer. Add glycol to maintain the correct
antifreeze concentration if required.
NOTE: Vertical piping immediately connected to and from the chiller will impose a static (or standing)
head pressure, which can be read on the pump discharge gauge of the chiller, and the gauge installed on
the return line to the chiller, when the system is not operating. For example, if the supply and/or return
piping from the chiller rises 15 feet before running above a ceiling, etc. this will show a gauge static
16
pressure of approximately 6-7psig on the gauges (feet x .424 = psig). This is simply the weight of water in
the vertical piping at that location, and does not indicate an overall system pressure.
SYSTEM VENTING
The single most common problem in chiller piping installations is lack of chilled water flow caused by
poor piping practices and/or inadequate venting of the system. The symptom is a repeated flow alarm,
when the flow switch installed in the return line inside the chiller contacts open which in turns triggers
the flow alarm on the control panel.
The 0005-0150 size chillers are EKdCLOSED CIRCUIT system and is open to atmosphere. This means that air
will remain in all local high points above chiller of the system when it is initially filled with water.
NOTE: A local high point is any point in the piping, which can be described as an inverted “U” section.
More clearly defined, if the piping rises vertically ANYWHERE, AND AT ANY ELEVATION IN THE SYSTEM,
travels horizontally, then drops again vertically, this inverted “U” section of piping IS A PERMANENT AIR
LOCK AND MUST BE VENTED. Venting is required AT ALL LOCAL HIGH POINTS, and is required on both
the supply and return pipes. Vents can be either manual, or automatic. Automatic vents should always
be installed with an isolation valve for future service access, repair or replacement. Automatic vents are
particularly susceptible to drawing air into the return chilled water piping if this line is allowed to fall
into a vacuum.
NOTE: The expansion tank should not normally be pressurized to more than 15 psig, measured when the
system is not operating. The final discharge pump pressure should NEVER be allowed to exceed the
maximum pump rating pressure (normally around 35-50psig).
CAUTION: Supercharging the pump with city water pressure higher than nominal rating of the pump,
can damage the mechanical pump seal(s), or cause damage to the chiller, piping system or customer
equipment. This damage is not covered by the chiller warranty.
17
WATER/GLYCOL FILLING
If glycol is required for antifreeze protection, ALWAYS use an industrial inhibited ethylene glycol, or
propylene (food grade) glycol. DO NOT use automobile antifreeze. Suitable glycols are manufactured by
the Dow Chemical Company for this purpose, and available nationwide. There are other glycol suppliers
available, but always exercise great caution in the selection of a glycol supplier, and always confirm the
freeze protection after installation, using a spectrometer. Damage caused by freezing is not covered
under warranty.
Glycol can be pre-mixed with water to the correct concentration, then pumped into the system, or
pumped in separately from the water, provided the system capacity is calculated accurately. The most
common method for filling the system is to pump the water glycol into the fill or drain connection of the
chiller, with all system vents open. There is a manual vent located at the back of the chiller for initial
filling/venting purposes, in addition to the high point piping vents. NOTE: The system should be filled
slowly and carefully, allowing all the air to escape. The system can only be filled as fast as the air can
escape. Be patient, and do not over-pressurize the system. After initial operation, check all air is vented
from the system.
GLYCOL CHART
Ethylene Glycol Propylene Glycol
% of Glycol Freeze Point % of Glycol Freeze Point

0% 32F 0% 32F
10% 26F 10% 26F
20% 16F 20% 19F
30% 4F 30% 8F
40% -12F 40% -7F
50% -34F 50% -28F
60% -60F 60% -60F
18
MAIN ELECTRICAL INSTALLATION

WIRING DIAGRAM INSPECTION
The manufacturer of the supplied chiller accepts
NO LIABILITY Check that the wiring diagram supplied with the
for the work supplied by the customer or civil chiller is correct and complete:
engineering contractor.
MODEL INFORMATION:
MAIN ELECTRICAL CONNECTION REFER TO DATA ON SERIAL STICKER FOR
EACH MODEL
The connection of the device to the main electrical
power supply must only be carried out by an licensed
electrician, and in strict accordance with local electrical
codes and safety standards.
WARNING – MANUFACTURER’S NOTICE
ELECTRICAL COMPONENTS The main disconnect switch on the chiller must be

FuIIy wired electrical panel switched off before carrying out any wiring work.
The electrical panel is mounted in the chiller and
contains all necessary controls for the chiller. Do not switch on the microprocessor until startup
and commissioning has been successfully
Additional wiring in the electrical panel Additional completed.
wiring is permitted but must not modify the original
condition of the factory-installed wiring. All changes
must be recorded in the original wiring diagram and
must be available to the manufacturer.
MAIN VOLTAGE SUPPLY

MPCA0005-0010 230V/60Hz/1~
MPCA0150 230V/60Hz/1~
The permissible voltage tolerance is ±5%. These values

are BINDING and COMPULSORY.
INFORMATION ON EXTERNAL WIRING

Main power feed
Note:
If for local code or other reasons the cable size of the
power supply line is larger than the terminal size on the
main disconnect or power block:
1. A junction box must be fitted to the chiller in

compliance with local codes in order to reduce the
cable size
Or
2. The main disconnect switch or power block of the

chiller must be replaced (prior approval of the
manufacturer is required).
19
WATER/GLYCOL INSTRUCTIONS
COLD WATER PIPING CONT.
MANUFACTURER'S SPECIFICATIONS
The chiller circuit must be 100% filled with 6. Ensure that the water circuit is maintained at the
water/glycol for operation. If the cooling process correct pressure by installing an appropriate sized
causes a loss of water/glycol in the circuit a diaphragm expansion tank close to the inlet of the
automatic water make-up vavle must be installed. chiller. The return side of the chiller must be 5-10psig
Insufficient fluid in the water/glycol circuit wiIl lead to when the pump is running.
failure of chiller 7. Install temperature and pressure gauges at the inlet
1. Safety devices and outlet of the chiller and the heat load to ensure
2. Controls,due to compressor fluctuations/ hunting easy inspection and maintenance.
(frequent switching). And compressor starts. 8. All chilled water lines should be insulated. Only
3. Cooling Capacity insulate pipes AFTER the circuit was tested for leaks.
These can be avoided by adding a reservoir on the GLYCOL IN CIRCUIT

inlet side of the chiller. Glycol mixture
The following basic rules must be followed:
OnIy operate the chiller with a flow switch 1. The freezing point of the mixture must be lower than
(supplied) that switches off the chiller in the event the minimum evaporation temperature. Or the
of insufficient water or a faulty pump. lowest outside piping temperature, whichever is the
If this condition is not satisfied: lower of the two.
ALL WARRANTY CLAIMS SHALL BE VOIDED
2. See correction factors for glycol concentration on
Flow meter and a automatic water make-up system
back page of the MPCA chiller brochure.
can be purchased from the factory.
3. Use only an industrial grade inhibited ethylene glycol
or food grade propylene glycol solution. DO NOT use
COLD WATER PIPING automotive antifreeze.
4. Check the pH-value of the solution. lt should be
Water piping and connection to the chiller must about 9 and must never be less than 7.5.
conform with all generally accepted piping practices
5. Check the pH-value regularly (maintenance).
and local codes. All piping should be performed by a
6. DO NOT use galvanized piping or fittings
qaulified person(s) or company.
The following specifications are intended to prevent
Operating the devices with a glycol mixture
damage to the chiller.
Check the extemal cold water network and pumps:
1. Avoid unnecessary pressure drop by ensuring • sufficient pressure for increased water volume
correct pipe sizes and routing. • pumps suitable for glycol operation
2. Connect the chiller with vibration eliminators to • bleed valves (rapid bleeder unsuitable)
avoid transmission of noise and vibrations.
3. Shut-off valves should be installed at the inlet and IMPORTANT: NEVER change the antifreeze alarm
outlet of the chiller so that maintenance and parameter on chiller without written authorization from
repair work can be performed without draining factory. If parameter is changed withour factory consent
the piping system. WARRANTY WILL BE VOIDED.
4. Y-Strainer (40 mesh) should be installed on the
inlet piping to the chiller to ensure no foreign
particles enter the evaporator and or !!!WARNING!!!
pump.*Without a Y-Strainer installed blockage The glycol/water mixture must not be discharged into
of the evaporator will occur the normal water drainage system. lt must be
5. Automatic vents should be installed at all local collected in suitable containers and disposed of in
high points of the piping system to eliminate air accordance with legal regulations.
locks. See chilled water system diagram for
location(s).
20
MPCA0005 – MPCA0150
Mechanical cooling – inlet control
On a call for cooling set point = 50*F + diff = 7*F entering temperature = 57*F glycol pump
running the compressor starts. The controller reads the Inlet temperature
and the compressor operates to pull down to set point. As the loop temp falls 0.1*F below set
point the compressor shuts off glycol pump remains running. Compressor will turn back on
when set point + differential is exceeded.
21
dIXEL Installing and Operating Instructions 1592020030
4. FRONT PANEL COMMANDS
Digital controller with off cycle defrost and AUX relay
XR30CX
CONTENTS
1. GENERAL WARNING ___________________________________________________ 1
2. GENERAL DESCRIPTION _______________________________________________ 1
3. CONTROLLING LOADS _________________________________________________ 1
4. FRONT PANEL COMMANDS _____________________________________________ 1
5. MAX & MIN TEMPERATURE MEMORIZATION _______________________________ 1
6. MAIN FUNCTIONS _____________________________________________________ 1 : To display target set point; in programming mode it selects a parameter or confirm
7. PARAMETERS ________________________________________________________ 2 an operation.
8. DIGITAL INPUT (ENABLED WITH P3P = N) _________________________________ 3
(DEF) To start a manual defrost
9. TTL SERIAL LINE – FOR MONITORING SYSTEMS ___________________________ 3
10. X-REP OUTPUT – OPTIONAL ____________________________________________ 3
11. INSTALLATION AND MOUNTING _________________________________________ 3 (UP): To see the max. stored temperature; in programming mode it browses the
12. ELECTRICAL CONNECTIONS ____________________________________________ 3 parameter codes or increases the displayed value.
13. HOW TO USE THE HOT KEY_____________________________________________ 3 (DOWN) To see the min stored temperature; in programming mode it browses the
14. ALARM SIGNALS ______________________________________________________ 3 parameter codes or decreases the displayed value.
15. TECHNICAL DATA _____________________________________________________ 4
To switch the instrument off, if onF = oFF.
16. CONNECTIONS _______________________________________________________ 4
17. DEFAULT SETTING VALUES_____________________________________________ 4 To switch the light, if oA1 = Lig
1. GENERAL WARNING KEY COMBINATIONS:
+ To lock & unlock the keyboard.
1.1 PLEASE READ BEFORE USING THIS MANUAL
• This manual is part of the product and should be kept near the instrument for easy and
+ To enter in programming mode.
quick reference. + To return to the room temperature display.
• The instrument shall not be used for purposes different from those described hereunder.
It cannot be used as a safety device. 4.1 USE OF LEDS
• Check the application limits before proceeding. Each LED function is described in the following table.
LED MODE FUNCTION
1.2 SAFETY PRECAUTIONS ON Compressor enabled
• Check the supply voltage is correct before connecting the instrument.
Flashing Anti-short cycle delay enabled
• Do not expose to water or moisture: use the controller only within the operating limits
avoiding sudden temperature changes with high atmospheric humidity to prevent ON Defrost enabled
formation of condensation ON An alarm is occurring
• Warning: disconnect all electrical connections before any kind of maintenance.
ON Continuous cycle is running
• Fit the probe where it is not accessible by the End User. The instrument must not be
opened. ON Energy saving enabled
• In case of failure or faulty operation send the instrument back to the distributor or to ON Light on
“Dixell S.p.A.” (see address) with a detailed description of the fault. ON Auxiliary relay on
• Consider the maximum current which can be applied to each relay (see Technical Data). °C/°F ON Measurement unit
• Ensure that the wires for probes, loads and the power supply are separated and far
°C/°F Flashing Programming phase
enough from each other, without crossing or intertwining.
• In case of applications in industrial environments, the use of mains filters (our mod. FT1) 5. MAX & MIN TEMPERATURE MEMORIZATION
in parallel with inductive loads could be useful.
2. GENERAL DESCRIPTION 5.1 HOW TO SEE THE MIN TEMPERATURE

Model XR30CX, format 32 x 74 mm, is a digital thermostat with off cycle defrost designed for 1. Press and release the n key.
refrigeration applications at normal temperature. It provides two relay outputs, one for the 2. The “Lo” message will be displayed followed by the minimum temperature recorded.
compressor, the other one can be used as light, for alarm signalling or as auxiliary output.. It 3. By pressing the n key again or by waiting 5s the normal display will be restored.
is also provided with 2 NTC or PTC probe inputs, the first one for temperature control, the
second one, optional, to connect to the HOT KEY terminals to signal the condenser 5.2 HOW TO SEE THE MAX TEMPERATURE
temperature alarm or to display a temperature. The digital input can operate as third 1. Press and release the o key.
temperature probe. 2. The “Hi” message will be displayed followed by the maximum temperature recorded.
The HOT KEY output allows to connect the unit, by means of the external module XJ485-CX, 3. By pressing the o key again or by waiting 5s the normal display will be restored.
to a network line ModBUS-RTU compatible such as the dIXEL monitoring units of X-WEB
family. It allows to program the controller by means the HOT KEY programming keyboard. 5.3 HOW TO RESET THE MAX AND MIN TEMPERATURE RECORDED
The instrument is fully configurable through special parameters that can be easily 1. Hold press the SET key for more than 3s, while the max. or min temperature is
programmed through the keyboard. displayed. (rSt message will be displayed)
2. To confirm the operation the “rSt” message starts blinking and the normal temperature
3. CONTROLLING LOADS will be displayed.
3.1 COMPRESSOR 6. MAIN FUNCTIONS

The regulation is performed Temper.
according to the temperature 6.1 HOW TO SEE THE SETPOINT
measured by the thermostat probe SET 1. Push and immediately release the SET key: the display will show
with a positive differential from the the Set point value;
set point: if the temperature Time 2. Push and immediately release the SET key or wait for 5 seconds to
increases and reaches set point plus Compr. display the probe value again.
differential the compressor is started ON
and then turned off when the 6.2 HOW TO CHANGE THE SETPOINT
temperature reaches the set point 1. Push the SET key for more than 2 seconds to change the Set point value;
value again. 2. The value of the set point will be displayed and the “°C” or “°F” LED starts blinking;
In case of fault in the thermostat probe the start and stop of the compressor are timed through
3. To change the Set value push the o or n arrows within 10s.
parameters “COn” and “COF”.
4. To memorise the new set point value push the SET key again or wait 10s.
3.2 DEFROST 6.3 HOW TO START A MANUAL DEFROST
Defrost is performed through a simple stop of the compressor. Parameter “IdF” controls the
Push the DEF key for more than 2 seconds and a manual defrost will
interval between defrost cycles, while its length is controlled by parameter “MdF”.
start.
1592020030 XR30CX GB m&M r1.1 05.03.2007.doc XR30CX 1/4

22
6.4 HOW TO CHANGE A PARAMETER VALUE CCS Set point for continuous cycle: (-50÷150°C) it sets the set point used during the
continuous cycle.
To change the parameter’s value operate as follows:
COn Compressor ON time with faulty probe: (0÷255 min) time during which the
1. Enter the Programming mode by pressing the Set + n keys for 3s (the “°C” or “°F” LED
compressor is active in case of faulty thermostat probe. With COn=0 compressor is always
starts blinking).
OFF.
2. Select the required parameter. Press the “SET” key to display its value
COF Compressor OFF time with faulty probe: (0÷255 min) time during which the
3. Use “UP” or “DOWN” to change its value.
compressor is OFF in case of faulty thermostat probe. With COF=0 compressor is always
4. Press “SET” to store the new value and move to the following parameter.
active.
To exit: Press SET + UP or wait 15s without pressing a key.
CH Type of action: CL = cooling; Ht = heating.
NOTE: the set value is stored even when the procedure is exited by waiting the time-out to
expire. DISPLAY
CF Temperature measurement unit: °C=Celsius; °F=Fahrenheit. WARNING: When the
6.5 THE HIDDEN MENU measurement unit is changed the SET point and the values of the parameters Hy, LS,
The hidden menu Includes all the parameters of the instrument. US, Ot, ALU and ALL have to be checked and modified if necessary).
rES Resolution (for °C): (in = 1°C; dE = 0.1 °C) allows decimal point display.
6.5.1 HOW TO ENTER THE HIDDEN MENU dLy Display delay: (0 ÷20.0m; risul. 10s) when the temperature increases, the display is
1. Enter the Programming mode by pressing the Set + n keys for 3s (the “°C” or “°F” LED updated of 1 °C/1°F after this time.
starts blinking).
DEFROST
2. Released the keys, then push again the Set+n keys for more than 7s. The Pr2 label will
be displayed immediately followed from the HY parameter. IdF Interval between defrost cycles: (0÷120h) Determines the time interval between the
NOW YOU ARE IN THE HIDDEN MENU. beginning of two defrost cycles.
3. Select the required parameter. MdF (Maximum) length for defrost: (0÷255min) When P2P = n, (not evaporator probe:
4. Press the “SET” key to display its value timed defrost) it sets the defrost duration, when P2P = y (defrost end based on
5. Use o or n to change its value. temperature) it sets the maximum length for defrost.
6. Press “SET” to store the new value and move to the following parameter. dFd Temperature displayed during defrost: (rt = real temperature; it = temperature at
To exit: Press SET + o or wait 15s without pressing a key. defrost start; SEt = set point; dEF = “dEF” label)
NOTE1: if none parameter is present in Pr1, after 3s the “noP” message is displayed. Keep dAd MAX display delay after defrost: (0÷255min). Sets the maximum time between the end
the keys pushed till the Pr2 message is displayed. of defrost and the restarting of the real room temperature display.
NOTE2: the set value is stored even when the procedure is exited by waiting the time-out to ALARMS
expire. ALC Temperature alarms configuration: (Ab; rE)
6.5.2 HOW TO MOVE A PARAMETER FROM THE HIDDEN MENU TO Ab= absolute temperature: alarm temperature is given by the ALL or ALU values. rE =
THE FIRST LEVEL AND VICEVERSA. temperature alarms are referred to the set point. Temperature alarm is enabled when the
Each parameter present in the HIDDEN MENU can be removed or put into “THE FIRST temperature exceeds the “SET+ALU” or “SET-ALL” values.
LEVEL” (user level) by pressing “SET + n”. ALU MAXIMUM temperature alarm: (SET÷110°C; SET÷230°F) when this temperature is
In HIDDEN MENU when a parameter is present in First Level the decimal point is on. reached the alarm is enabled, after the “ALd” delay time.
ALL Minimum temperature alarm: (-50.0 ÷ SET°C; -58÷230°F when this temperature is
6.6 HOW TO LOCK THE KEYBOARD reached the alarm is enabled, after the “ALd” delay time.
AFH Differential for temperature alarm recovery: (0,1÷25,5°C; 1÷45°F) Intervention
1. Keep pressed for more than 3 s the UP + DOWN keys. differential for recovery of temperature alarm.
2. The “POF” message will be displayed and the keyboard will be locked. At this point it will ALd Temperature alarm delay: (0÷255 min) time interval between the detection of an alarm
be possible only to see the set point or the MAX o Min temperature stored condition and alarm signalling.
3. If a key is pressed more than 3s the “POF” message will be displayed. dAO Exclusion of temperature alarm at startup: (from 0.0 min to 23.5h) time interval
between the detection of the temperature alarm condition after instrument power on and
6.7 TO UNLOCK THE KEYBOARD alarm signalling.
Keep pressed together for more than 3s the o and n keys, till the “Pon” message will be CONDENSER TEMPERATURE ALARM (detected by the fourth probe)
displayed.
AP2 Probe selection for temperature alarm of condenser: nP = no probe; P1 =thermostat
probe; P2 = evaporator probe; P3 =configurable probe; P4 = Probe on Hot Key plug.
6.8 THE CONTINUOUS CYCLE
AL2 Low temperature alarm of condenser: (-55÷150°C) when this temperature is reached
When defrost is not in progress, it can be activated by holding the “o” key pressed for about the LA2 alarm is signalled, possibly after the Ad2 delay.
3 seconds. The compressor operates to maintain the “ccS” set point for the time set through Au2 High temperature alarm of condenser: (-55÷150°C) when this temperature is reached
the “CCt” parameter. The cycle can be terminated before the end of the set time using the the HA2 alarm is signalled, possibly after the Ad2 delay.
same activation key “o” for 3 seconds. AH2 Differential for temperature condenser alarm recovery: (0,1÷25,5°C; 1÷45°F)
Ad2 Condenser temperature alarm delay: (0÷255 min) time interval between the detection
6.9 THE ON/OFF FUNCTION of the condenser alarm condition and alarm signalling.
With “onF = oFF”, pushing the ON/OFF key, the instrument is switched off. The dA2 Condenser temperature alarm exclusion at start up: (from 0.0 min to 23.5h, res.
“OFF” message is displayed. In this configuration, the regulation is disabled. 10min)
To switch the instrument on, push again the ON/OFF key. bLL Compressor off with low temperature alarm of condenser: n = no: compressor
keeps on working; Y = yes, compressor is switched off till the alarm is present, in any
WARNING: Loads connected to the normally closed contacts of the relays are always case regulation restarts after AC time at minimum.
supplied and under voltage, even if the instrument is in stand by mode. AC2 Compressor off with high temperature alarm of condenser: n = no: compressor
keeps on working; Y = yes, compressor is switched off till the alarm is present, in any
7. PARAMETERS case regulation restarts after AC time at minimum.
REGULATION SECOND RELAY
Hy Differential: (0,1 ÷ 25,5°C / 1÷255 °F) Intervention differential for set point. Compressor tbA Alarm relay silencing (with oA1=ALr):
Cut IN is Set Point + differential (Hy). Compressor Cut OUT is when the temperature (n= silencing disabled: alarm relay stays on till alarm condition lasts, y =silencing
reaches the set point. enabled: alarm relay is switched OFF by pressing a key during an alarm).
LS Minimum set point: (- 50°C÷SET/-58°F÷SET): Sets the minimum value for the set point. oA1 Second relay configuration: ALr: alarm; Lig: light; AuS: Auxiliary relay; onF: always
US Maximum set point: (SET÷110°C/ SET÷230°F). Set the maximum value for set point. on with instrument on; db = do not select it; dEF: do not select it!.; FAn: do not select
Ot Thermostat probe calibration: (-12.0÷12.0°C; -120÷120°F) allows to adjust possible it!.; dF2: do not select it.
offset of the thermostat probe. AoP Alarm relay polarity: it set if the alarm relay is open or closed when an alarm happens.
P3P Third probe presence (P3): n= not present:, the terminal operates as digital input.; y= CL= terminals 1-2 closed during an alarm; oP = terminals 1-2 open during an alarm
present:, the terminal operates as third probe. DIGITAL INPUT
O3 Third probe calibration (P3): (-12.0÷12.0°C; -120÷120°F). allows to adjust possible
i1P Digital input polarity: oP: the digital input is activated by opening the contact; CL: the
offset of the third probe.
digital input is activated by closing the contact.
P4P Fourth probe presence: (n = Not present; y = present).
i1F Digital input configuration: EAL = external alarm: “EA” message is displayed; bAL =
o4 Fourth probe calibration: (-12.0÷12.0°C) allows to adjust possible offset of the fourth serious alarm “CA” message is displayed. PAL = pressure switch alarm, “CA” message
probe. is displayed; dor = door switch function; dEF = activation of a defrost cycle; AUS =to
OdS Outputs activation delay at start up: (0÷255min) This function is enabled at the initial switch on the second relay if oA1 = AUS; Htr = kind of action inversion (cooling –
start up of the instrument and inhibits any output activation for the period of time set in heating); FAn = not set it; ES = Energy saving.
the parameter.
did: (0÷255 min) with i1F= EAL or i1F = bAL digital input alarm delay: delay between the
AC Anti-short cycle delay: (0÷50 min) minimum interval between the compressor stop and
detection of the external alarm condition and its signalling.
the following restart. with i1F= dor: door open signalling delay
CCt Compressor ON time during continuous cycle: (0.0÷24.0h; res. 10min) Allows to set with i1F = PAL: time for pressure switch function: time interval to calculate the
the length of the continuous cycle: compressor stays on without interruption for the CCt number of the pressure switch activation.
time. Can be used, for instance, when the room is filled with new products.

23
nPS Pressure switch number: (0 ÷15) Number of activation of the pressure switch, during 11. INSTALLATION AND MOUNTING
the “did” interval, before signalling the alarm event (I2F= PAL). Instrument XR30CX shall be mounted on vertical panel, in a
If the nPS activation in the did time is reached, switch off and on the instrument to 29x71 mm hole, and fixed using the special bracket supplied.
restart normal regulation.
The temperature range allowed for correct operation is 0÷60
odc Compressor status with door open: no, Fan = normal; CPr; F_C = Compressor OFF.
°C. Avoid places subject to strong vibrations, corrosive
rrd Outputs restart after doA alarm: no = outputs not affected by the doA alarm; yES =
gases, excessive dirt or humidity. The same
outputs restart with the doA alarm;
recommendations apply to probes. Let air circulate by the
HES Temperature increase during the Energy Saving cycle : (-30,0°C÷30,0°C/-22÷86°F)
cooling holes.
it sets the increasing value of the set point during the Energy Saving cycle.
OTHER
Adr Serial address (1÷244): Identifies the instrument address when connected to a 12. ELECTRICAL CONNECTIONS
ModBUS compatible monitoring system. The instrument is provided with screw terminal block to connect cables with a cross section up
PbC Type of probe: it allows to set the kind of probe used by the instrument: PbC = PBC to 2,5 mm2. Before connecting cables make sure the power supply complies with the
probe, ntc = NTC probe. instrument’s requirements. Separate the probe cables from the power supply cables, from the
onF on/off key enabling: nu = disabled; oFF = enabled; ES = not set it. outputs and the power connections. Do not exceed the maximum current allowed on each
dP1 Thermostat probe display relay, in case of heavier loads use a suitable external relay.
dP3 Third probe display- optional.
dP4 Fourth probe display. 12.1 PROBE CONNECTION
rSE Real set point: (readable only), it shows the set point used during the energy saving The probes shall be mounted with the bulb upwards to prevent damages due to casual liquid
cycle or during the continuous cycle. infiltration. It is recommended to place the thermostat probe away from air streams to correctly
rEL Software release for internal use. measure the average room temperature. Place the defrost termination probe among the
Ptb Parameter table code: readable only. evaporator fins in the coldest place, where most ice is formed, far from heaters or from the
warmest place during defrost, to prevent premature defrost termination.
8. DIGITAL INPUT (ENABLED WITH P3P = N)
The free voltage digital input is programmable in different configurations by the “i1F” 13. HOW TO USE THE HOT KEY
parameter.
13.1 HOW TO PROGRAM A HOT KEY FROM THE INSTRUMENT (UPLOAD)
8.1 DOOR SWITCH INPUT (i1F = dor)
1. Program one controller with the front keypad.
It signals the door status and the corresponding relay output status through the “odc” 2. When the controller is ON, insert the “Hot key” and push o key; the "uPL" message
parameter: no, Fan = normal (any change); CPr, F_C = Compressor OFF. appears followed a by flashing “End”
Since the door is opened, after the delay time set through parameter “did”, the door alarm is 3. Push “SET” key and the End will stop flashing.
enabled, the display shows the message “dA” and the regulation restarts is rtr = yES. The 4. Turn OFF the instrument remove the “Hot Key”, then turn it ON again.
alarm stops as soon as the external digital input is disabled again. With the door open, the
high and low temperature alarms are disabled. NOTE: the “Err” message is displayed for failed programming. In this case push again o key
if you want to restart the upload again or remove the “Hot key” to abort the operation.
8.2 GENERIC ALARM (i1F = EAL)
As soon as the digital input is activated the unit will wait for “did” time delay before signalling 13.2 HOW TO PROGRAM AN INSTRUMENT USING A HOT KEY
the “EAL” alarm message. The outputs status don’t change. The alarm stops just after the (DOWNLOAD)
digital input is de-activated.
1. Turn OFF the instrument.
2. Insert a programmed “Hot Key” into the 5 PIN receptacle and then turn the
8.3 SERIOUS ALARM MODE (i1F = bAL)
Controller ON.
When the digital input is activated, the unit will wait for “did” delay before signalling the “CA” 3. Automatically the parameter list of the “Hot Key” is downloaded into the Controller
alarm message. The relay outputs are switched OFF. The alarm will stop as soon as the memory, the “doL” message is blinking followed a by flashing “End”.
digital input is de-activated. 4. After 10 seconds the instrument will restart working with the new parameters.
5. Remove the “Hot Key”..
8.4 PRESSURE SWITCH (i1F = PAL)
If during the interval time set by “did” parameter, the pressure switch has reached the number NOTE the message “Err” is displayed for failed programming. In this case turn the unit off and
of activation of the “nPS” parameter, the “CA” pressure alarm message will be displayed. The then on if you want to restart the download again or remove the “Hot key” to abort the
compressor and the regulation are stopped. When the digital input is ON the compressor is operation.
always OFF.
If the nPS activation in the did time is reached, switch off and on the instrument to 14. ALARM SIGNALS
restart normal regulation.
Message Cause Outputs
“P1” Room probe failure Compressor output acc. to par. “Con” and
8.5 START DEFROST (i1F = dFr)
“COF”
It starts a defrost if there are the right conditions. After the defrost is finished, the normal
“P3” Third probe failure Outputs unchanged
regulation will restart only if the digital input is disabled otherwise the instrument will wait until
“P4” Fourth probe failure Outputs unchanged
the “MdF” safety time is expired.
“HA” Maximum temperature alarm Outputs unchanged.
8.6 INVERSION OF THE KIND OF ACTION: HEATING-COOLING (i1F = Htr) “LA” Minimum temperature alarm Outputs unchanged.
This function allows to invert the regulation of the controller: from cooling to heating and "HA2" Condenser high temperature It depends on the “Ac2” parameter
viceversa. "LA2" Condenser low temperature It depends on the “bLL” parameter
“dA” Door open Compressor according to rrd
8.7 ENERGY SAVING (i1F = ES) “EA” External alarm Output unchanged.
The Energy Saving function allows to change the set point value as the result of the SET+ “CA” Serious external alarm All outputs OFF.
HES (parameter) sum. This function is enabled until the digital input is activated. (i1F=bAL)
“CA” Pressure switch alarm All outputs OFF
8.8 DIGITAL INPUTS POLARITY (i1F=PAL)
The digital input polarity depends on the “i1P” parameter.
i1P=CL: the input is activated by closing the contact. 14.1 ALARM RECOVERY
i1P=OP: the input is activated by opening the contact Probe alarms P1”, “P3” and “P4” start some seconds after the fault in the related probe; they
9. TTL SERIAL LINE – FOR MONITORING SYSTEMS automatically stop some seconds after the probe restarts normal operation. Check
connections before replacing the probe.
The TTL serial line, available through the HOT KEY connector, allows by means of the Temperature alarms “HA”, “LA” “HA2” and “LA2” automatically stop as soon as the
external TTL/RS485 converter, XJ485-CX, to connect the instrument to a monitoring system temperature returns to normal values.
ModBUS-RTU compatible such as the X-WEB500/3000/300. Alarms “EA” and “CA” (with i1F=bAL) recover as soon as the digital input is disabled.
Alarm “CA” (with i1F=PAL) recovers only by switching off and on the instrument.
10. X-REP OUTPUT – OPTIONAL
As optional, an X-REP can be connected to the instrument, trough the HOY 14.2 OTHER MESSAGES
KEY connector. The X-REP output EXCLUDES the serial connection. Pon Keyboard unlocked.
To connect the X-REP to the PoF Keyboard locked
instrument the following
noP In programming mode: none parameter is present in Pr1
connectors must be used CAB-
On the display or in dP2, dP3, dP4: the selected probe is nor enabled
51F(1m), CAB-52F(2m), CAB-
55F(5m), noA None alarm is recorded.

24
15. TECHNICAL DATA rES Resolution in=integer; dE= dec.point dE Pr1
Housing: self extinguishing ABS. dLy Display temperature delay 0 ÷ 20.0 min (10 sec.) 0 Pr2
IdF Interval between defrost cycles 1 ÷ 120 ore 8 Pr1
Case: XR30CX frontal 32x74 mm; depth 60mm;
Mounting: XR30CX panel mounting in a 71x29mm panel cut-out MdF (Maximum) length for defrost 0 ÷ 255 min 20 Pr1
Protection: IP20; Frontal protection: XR30CX IP65 dFd Displaying during defrost rt, it, SEt, DEF it Pr2
Connections: Screw terminal block ≤ 2,5 mm2 wiring. dAd MAX display delay after defrost 0 ÷ 255 min 30 Pr2
Power supply: according to the model: 12Vac/dc, ±10%; 24Vac/dc, ±10%; 230Vac ±10%, ALc Temperat. alarms configuration rE= related to set;
Ab Pr2
50/60Hz, 110Vac ±10%, 50/60Hz Ab = absolute
Power absorption: 3VA max ALU MAXIMUM temperature alarm Set÷110.0°C; Set÷230°F 110 Pr1
Display: 3 digits, red LED, 14,2 mm high; Inputs: Up to 4 NTC or PTC probes. ALL Minimum temperature alarm -50.0°C÷Set/ -58°F÷Set -50.0 Pr1
Digital input: free voltage contact AFH Differential for temperat. alarm (0,1°C÷25,5°C) (1°F÷45°F)
1 Pr2
Relay outputs: compressor SPST 8(3) A, 250Vac; or 20(8)A 250Vac recovery
AUX: SPDT 8(3) A, 250Vac ALd Temperature alarm delay 0 ÷ 255 min 15 Pr2
Data storing: on the non-volatile memory (EEPROM). dAo Delay of temperature alarm at start up 0 ÷ 23h e 50’ 1.3 Pr2
Kind of action: 1B; Pollution grade: 2;Software class: A.; AP2 Probe for temperat. alarm of nP; P1; P2; P3; P4
Rated impulsive voltage: 2500V; Overvoltage Category: II P4 Pr2
condenser
Operating temperature: 0÷60 °C;Storage temperature: -30÷85 °C. AL2 Condenser for low temperat. alarm (-55 ÷ 150°C) (-67÷ 302°F) -40 Pr2
Relative humidity: 20÷85% (no condensing) AU2 Condenser for high temperat. alarm (-55 ÷ 150°C) (-67÷ 302°F) 110 Pr2
Measuring and regulation range: NTC probe: -40÷110°C (-40÷230°F);
Differ. for condenser temp. alar. [0,1°C ÷ 25,5°C] [1°F ÷
PTC probe: -50÷150°C (-58÷302°F) 5 Pr2
AH2 recovery 45°F]
Resolution: 0,1 °C or 1°C or 1 °F (selectable); Accuracy (ambient temp. 25°C): ±0,7 °C
±1 digit Ad2 Condenser temperature alarm delay 0 ÷ 254 (min.) , 255=nU 15 Pr2
Delay of cond. temper. alarm at start PARAMETERS ARE1,3 Pr2
16. CONNECTIONS dA2 up 0.0 ÷ 23h 50’
Compr. off for condenser low
NOT TO BE USE IN
The X-REP output excludes the TTL output.. It’s present in the following codes: n Pr2
XR30CX- xx2xx, XR30CX –xx3xx; bLL temperature alarm n(0) - Y(1) FOR
CHILLER
Compr. off for condenser high
16.1 XR30CX – 8A COMPRESSOR AC2 temperature alarm REFERANCE
n(0) - Y(1) ONLY n Pr2
tbA Alarm relay disabling n=no; y=yes y Pr2
Room
oA1 2nd relay configuration ALr = alarm; dEF = do not

select it; Lig =Light; AUS
9 10 11 12 =AUX; onF=always on; Fan= Lig Pr2
8(3)A250V 8(3)A250V do not select it; db = do not
select it; dF2 = do not select it
1 2 3 4 5 6 7 8 AoP Alarm relay polarity (oA1=ALr) oP; cL cL Pr2
Light/ Hot Key/IV probe i1P Digital input polarity oP=opening;CL=closing cL Pr1
Alarm N.C. Comp TTL or X-REP output i1F Digital input configuration EAL, bAL, PAL, dor; dEF; Htr,
dor Pr1
AUS
Line
did Digital input alarm delay 0÷255min 15 Pr1
12Vac/dc supply: connect to the terminals 7 and 8.
nPS Number of activation of pressure 0 ÷15
24Vac/dc supply: connect to the terminals 7 and 8. 15 Pr2
switch
120Vac supply: connect to the terminals 7 and 8.
odc Compress status when open door no; Fan; CPr; F_C no Pr2
16.2 XR30CX – 20A COMPRESSOR rrd Regulation restart with door open n–Y
y Pr2
alarm
HES Differential for Energy Saving (-30°C÷30°C) (-54°F÷54°F) 0 Pr2
Room
Adr Serial address 0÷247 1 Pr2

PbC Kind of probe Ptc; ntc ntc Pr1
9 10 11 12 onF on/off key enabling nu, oFF; ES nu Pr2
8(3)A250V 20(8)A250V dP1 Room probe display -- -- Pr2
dP3 Third probe display -- -- Pr1
1 2 3 4 5 6 7 8 dP4 Fourth probe display -- -- Pr1
Light/ N.C. Hot Key/IV probe rSE Real set point value actual set -- Pr2
Alarm Comp TTL or X-REP output rEL Software release -- -- Pr2
Line Ptb Map code -- -- Pr2
120Vac supply: connect to the terminals 7 and 8.
17. DEFAULT SETTING VALUES

Labe Name Range °C/°F
Set Set point LS÷US 3.0 ---
Hy Differential 0,1÷25.5°C/ 1÷ 255°F 2.0 Pr1
LS Minimum set point -50°C÷SET/-58°F÷SET -50.0 Pr2
US Maximum set point SET÷110°C/ SET ÷ 230°F 110 Pr2
Ot Thermostat probe calibration -12÷12°C /-120÷120°F 0.0 Pr1
P3P Third probe presence n=not present; Y=pres. n Pr2
O3 Third probe calibration -12÷12°C /-120÷120°F 0 Pr2
P4P Fourth probe presence n=not present; Y=pres.
O4 Fourth probe calibration
PARAMETERS AREn Pr2
-12÷12°C /-120÷120°F 0 Pr2
OdS Outputs delay at start up NOT TOminBE USE IN0
0÷255 Pr2
AC Anti-short cycle delay ÷ 50 min FOR 1
0CHILLER Pr1
CCt Continuos cycle duration 0.0÷24.0h 0.0 Pr2
CC Set point for continuous cycle REFERANCE
(-55.0÷150,0°C) ONLY
(-67÷302°F)
3 Pr2
S
CO Compressor ON time with faulty probe 0 ÷ 255 min
15 Pr2
n
Dixell S.p.A. Z.I. Via dell’Industria, 27
CO Compressor OFF time with faulty 0 ÷ 255 min
30 Pr2 32010 Pieve d’Alpago (BL) ITALY
F probe
tel. +39 - 0437 - 98 33 - fax +39 - 0437 - 98 93 13
CH Kind of action CL=cooling; Ht= heating cL Pr1 E-mail: dixell@dixell.com - http://www.dixell.com
CF Temperature measurement unit °C ÷ °F °C Pr2

25
MPCA0005 - MPCA0010 STANDARD CONTROLLER LAYOUT

LEGEND:
SL=Working Probe
PV= Fan Cycling Switch
LP=Low Pressure Switch
HP=High Pressure Switch
EF=Liquid Line Solenoid
CC=Compressor Contactor
CP=Pump Contactor
CV=Fan Contactor
MPCA0150 STANDARD CONTROLLER LAYOUT
41
26
COMMISIONING AND STARTUP INSTRUCTIONS

COMMISSIONING ALWAYS OBEY SAFETY INSTRUCTIONS
WARNING - HIGH VOLTAGE
Check the water connections
RISK OF FATAL INJURY
1. Check the supply and retum connection Open the main fuse before reconnecting
2. If glycol solution:
Take a water sample to check the freeze protection Preparations at the switch cabinet
level. 1. Open the electrical cabinet (main switch OFF)
CHILLED WATER PUMPS
VisuaI inspection Inspection of chilled water circuit
Preparations with the electrical panel OPEN
1. Remove the access panels and check the condition of
the system, especially if chilled water pipes have 1. Switch main switch 0FF via extension.
been installed by the customer and or contractor. 2. OPEN both compressor overloads
2. Check the system visually for: (interrupt power supply to compressors)
Accessibility and servicing clearances 3. Switch main switch ON via extension
Has the system been modifled, e.g. by
fixing cable ducting or similar equipment? Check that Note: The chilled water pump must respond and start
there are no screws next to copper pipes or the air- after a short delay.
cooled condenser.
4. Bleed the system again
Note: Record any deviations on the commissioning 5. Check the chilled water piping in the entire system.
report.
Inspection of the cold water pumps
Inspect control panel and electrical work 1. Measure the running amps of the pump and compare
with the values in the wiring diagram.
WARNING! If the measured value is greater than the pump
Use only suitable tools and measuring equipment nameplate, the extemal pressure drop is incorrect.
when inspecting the electrical installation.
MANUFACTURER'S NOTE
The settings of the overloads must not be adjusted.
WARRANTY WILL BE VOIDED
1. Main switch to OFF - Open the electrical panel
2. Input terminal voltage? IF YES then open the main
Inspect the water system (check filters/strainers) and
fuse
remedy any faults.
3. Check the electrical connections. Although these
connections are well-tightened at the factory, they
INSPECTION OF COMPRESSOR(S)
may be Ioosened during transport. Retighten if
Check each chiller circuit as follows:
necessary.
1. Main switch OFF
4. Check the external connections against the wiring
2. Controller OFF by monitor pushbutton
diagram. Fit jumpers if necessary.
3. Close opened fuse of circuit
5. Check the customer's wiring up to the main
4. Main switch ON
disconnect for cable cross-section and correct
5. Controller ON by monitor pushbutton
grounding.
6. Clear alarm messages on monitor
6. Check the supply voltage: Close the main switch
System status:
and apply voltage to input terminals. +1-5% voltage
Chilled water pump running (otherwise compressor
tolerance
does not start)
Fan(s) running.
Inspection of chiller circuit
Note: Operate the compressor(s) at Ieast 15 minutes at
full Ioad.
27
Correct handover by the qualified company to the MAINTENANCE INTERVALS

operator or operator's personnel is a basic The Iist beIow contains recommendations based on
precondition for operation of the refrigeration practical experience.
system. These recommendations must be adapted to the actual
operating time of the chiller system, e.g. for continuous
Safety Instructions operation
The operator has been familiarised with the
specified safety instructions. Weekly
Inspections by operator
Operating Instructions
The operator has been: Every 3 months
− trained in chiller operation Maintenance by qualified company
− instructed in the function and operation of the
installed microprocessor. Once a year
− instructed in simple maintenance and General service by qualified chiller maintenance
inspection work. company
The following have been handed over If the system is shut down for a long period (winter
System documentation, consisting of: months), a complete inspection and service must be
(check where applicable) performed before switching on and restarting.
Handover Report including
commissioning data ____________
Instailation, Operating and MACHINE DATA
Maintenance Specifications ____________
Instructions for Use of the System type _____________
microprocessor ____________ Serial number _____________
Safety instructions ____________ Year of manufacture _____________

Refrigerant _____________
Electrical wiring diagram ____________
Certificates conforming to the
"Pressure Vessel Order" ____________ Qualified Company (Stamp) - Signature
"C.E." Certificate for export
conforming to EC standard ____________
Miscellaneous:
____________________ ____________
____________________ ____________ Operator (Stamp) – Signature
____________________ ____________
INSPECTION – MAINTENANCE
The operator has been informed in precise detail by the Date: ______________________
qualified company of the necessity for regular
inspection and maintenance.
Inspection and maintenance must be performed to
validate any warranty claim.
28
TROUBLESHOOTING
WARNING The table that follows lists a large proportion of
OBEY SAFETY INSTRUCTIONS the fault causes that can occur in practice. These
descriptions are intended for information only
and must not be considered as a repair manual.
Often, the cause of a failure is due to a variety of
WARNING factors. However, these factors can only be
Only qualified service and maintenance technicians evaluated by a qualified refrigeration company
may carry out repairs to the system. During with precise knowledge of the functional
operation, potentially fatal pressures and voltages
interactions.
are generated in the system. All safety precautions
and warnings contained in these documents must be
IMPORTANT
strictly observed.
A large proportion of the functions, faults and
operating states of the system are signalled by
Possible malfunctions to the chiller may occur due to the microprocessor.
the following factors: The microprocessor monitors all the function
areas of the system.
Therefore, this information is also essential in
1. Changes in operating conditions troubleshooting the faults.
2. lnsufficient maintenance and inspection
3. External environmental factors
4. Internal machine factors CHANGES IN OPERATING CONDITIONS
Significant changes in the operating conditions of
5. System factors
the chiller may cause faults, because individual
6. Operating errors components important to the operation of the
system wiII not be tuned to the new operating
mode.
CAUSES OF MALFUNCTIONS
Inform the MANUFACTURER of any intended
change and obtain prior consent.
These causes can be divided into three groups:
WARRANTY WILL BE VOIDED
1. Faults due to the water circuit.
The operator can generally remedy this type of
problem.
2. Electrical faults
With the aid of a qualified electrician, the operator
can partially remedy this type of fault.
3. Faults in the refrigerant circuit.

This type of problem can only be remedied by a
qualified refrigeration company.
29
A) FAULT: COMPRESSOR DOES NOT START

SYMPTOM CAUSE POSSIBLE SOLUTION
1. No voltage at power terminals of Power failure Check the fuses and wiring
motor starter
2. No voltage at power terminals of Overload tripped Determine the cause. lf all checks good
motor starter reset the overload.
3. Voltage on but not applied down Fuse Blown Change fuse – Identify the fault.
stream of the fuse
4. Main voltage too low Main power grid low Contact electric company
5. Correct voltage is coming to the Compressor failure Replace compressor

compressor terminals
6. Damaged contacts or burnt coil Defective starter contactor Repair or replace.
7. Compressor relay does not close Control circuit interupted ldentify the open safety switch and
determine cause
8. Compressor does not start Inlet water temperature does not exceed Check set point and differential
differential set point
B) FAULT: COMPRESSOR NOISE - TOO LOUD.

*STOP THE COMPRESSOR*
1. Compressor “knocking” Internal parts of compressor boken Compressor must be replaced
2. Suction line exceptionally cold Expansion valve not closing Check the expansion valve
Repair or replace
C) FAULT: COMPRESSOR LOSING OIL

*STOP THE COMPRESSOR*
1. Lack of oil in compressor Oil level too low Oil must be topped up
2. Oil level falling Clogged filter dryer Change the dryer
3. Compressor turning on/off too often Compressor hunting Readjust superheat. Check TXV sensor
position.
4. Reduced compressor capacity Possible bad compressor windings Replace compressor
30
D) FAULT: COMPRESSOR “HUNTING”

1. Low pressure switch keeps tripping and Chiller low on refrigerant Repair possible leak in the circuit
bubbles in sight glass during normal Top off with refrigerant.
operation
2. Compressor turning on/off to Loose contact in electrical panel Repair or replace the defective switch
frequently
Replace dryer
3. Suction pressure low, ice on top of Filter dryer plugged
compressor
Repair or replace
4. Noisy liquid line solenoid Liquid line solenoid leaking by
E) FAULT: INSUFFICIENT COOLING CAPACITY
1. TXV very noisy during operation Low on refrigerant or faulty TXV Top off refrigerant and or replace TXV
Replace dryer/LL solenoid

2. Temperature difference up/down Dryer or LL solenoid valve clogged
stream of filter dryer or LL solenoid
valve
Clean or replace
3. Frequent chiller cycling TXV seized or clogged
Ensure proper water flow. Check
4. High water temperature Low flow across evaporator. Excessive expansion valve superheat
pressure drop in evaporator
Check pump rotation, Remedy
5. Reduced water flow
Flow in water piping restricted or blocked obstruction
Superheat is out of adjustment Adjust TXV superheat

6. Chiller wont make set point
Overloading the chillers sized capacity Correct the overloading condition
7. Chiller wont make set point
F) FAULT: SUCTION PRESSURE TOO LOW
1. Bubbles in sight glass Low on refrigerant Possible leaks or insufficient refrigerant
2. Compressor hunting Compressor hunting See D) above: Compressor hunting
3. Temperature difference up/down Dryer or LL solenoid valve clogged Replace the dryer
stream of filter dryer or LL solenoid
4. No refrigerant flow through TXV TXV clogged or powerhed defective Clean/ replace TXV or powerhead
5. Water flow low Loss of water/glycol and or restriction Meassure GPM and or find and repair
restriction
31
G) FAULT: CONDENSING PRESSURE TOO HIGH

1. Normal operation high pressure switch Too much refrigerant in system Check subcooling
trips Remove refrigerant
Insufficant cooling air (ambient)
Clean the condenser
Ambient is high than 95F
Fan(s) do not delivery enough air
Check phase rotation
Defective fan motor
External air resistance too high.
2. High water temperature Heat load exceeded chillers capacity
Send proper load to chiller. Call factory
to see what the chiller was sized for
H) FAULT: CONDENSING PRESSURE TOO LOW
1. Suction and discharge pressure High pressure valves in compressor are Replace the compressor
equalize after pumpdown causing pressure to bleed by.
2. Bubbles in sight glass Low on refrigerant Insufficient rerigerant due to

refrigerant leak.
I) FAULT: CONDENSER FANS
1. Fan or fram vibration Fan out of balance Inspect the bearings and visually check
for damage. Is chiller level?
2. No air flow or some fans not running Fan fuse blown Check the voltage.
Check the VFD (if fitted) and measure
the values.
Check the fan motor(s)
L) FAULT: CHILLED WATER PUMP
1. Large delta T between inlet and Not enough flow through chiller Pressure drop in process cooling circuit
outlet temperatures is too high. Check the GPM
2. Water leaking from pump Mechanical seal defective Replace mechanical seal
3. Pump does not run although cooling Mechanically seal defective or Check amp draw of pump. External
is required overload tripped pressure loss may be too high causing
the amp draw to be higher than
normal
32
PREVENTATIVE MAINTENANCE
MAINTENANCE
Before carrying out any maintenance work, the service technician must be made thoroughly familiar with the
following safety precautions and provisions.
GENERAL WARNING
SAFETY PRECAUTIONS Avoid any skin contact with gas or refrigerating oiIs.
Severe bums may be caused. Always wear rubber
WARNING gloves when handling dirty parts.
High voltage - Risk of fatal injury
Disconnect the unit from the power supply before WARNING
opening the doors or removing the chiller panels. Risk of injury
If it is necessary to carry out work inside the system
WARNING with the fans running, make sure that no parts of the
High voltage - Risk of fatal injury body or clothing are caught in the fan blades or other
After opening the electrical panel, voltage is applied at moving parts.
input terminals L1, L2, L3
WARNING
Before carrying out any work in the electrical cabinet,
make sure that the main switch is set to the “0FF”
position.
WARNING
Use only the appropriate tools and measuring MANUFACTURER’S SPECIFICATION
equipment to check the electrical system.
The safety devices installed in the system
WARNING such as flow meters, pressure switches etc. must not
Risk of burns be bypassed.
Exposed copper pipes may be hot. WARRANTY WILL BE VOIDED
WARNING
Danger of suffocation when working with refrigerants, Microprocessor
make sure of good ventilation. Do not smoke. Changes to the programming domain protected by
password may only be made after checking with the
WARNING manufacturer.
Refrigerant must never be discharged into the WARRANTY WILL BE VOIDED
environment. It must be coIlected in a collecting
container for reuse or for return to the manufacturer. Modifications in the control panel
The panel wiring may only be changed with the
consent of the manufacturer.
WARNING Additional wiring is possible
Do not undo any refrigerant or hydraulic connections Any changes to the wiring must be marked in the
until the system is depressurised. wiring diagrams and made available to the operator.
WARNING
Protective goggles and rubber gloves must be worn
when handling refrigerant.
33
PREVENTIVE MAINTENANCE Servicing tasks required every 6 months

Maintenance Intervals
Note: The maintenance intervals specified here are 1. Repeat the 3-month service
based on experience. Depending on individual 2. Preventive maintenance – additional
conditions at any job site, required maintenance − Check superheat and subcooling
intervals may need to be performed more or less − Check the glycol/water mixture for good freeze
frequently than recommended within this manual. protection
3. Commissioning operations, as follows:
WARNING − Check the glycol water pumps
STRICTLY OBEY THE SAFETY INSTRUCTIONS − Check the flow meters for proper GPM
− Check all safety devices
WARNING
− Check the antifreeze protection (setting)
Maintenance must be carried out by qualified service
and maintenance technician. During operation,
Enter all repairs/changes in a maintenance log
potentially lethal high voltages and high pressures
are generated in the chiller system.
Note: The recommendations and specifications given
All safety precautions and wamings given in these
here are based on experience. The type and scope of
documents must be precisely observed. Otherwise,
maintenance depends on the actual application of the
severe or fatal injuries may be caused.
system. More frequent and more comprehensive
inspections may be necessary in the event of more
adverse conditions, e. g.:
− Higher or lower ambient temperatures
− Power fluctuations
MANUFACTURER’S NOTE
− Dusty/Dirty installation conditions
When gather running data on chiller readings must be
taken at full load and under the normal system
operating conditions.
Checking the glycol solution
Weekly tasks required
lf the system is operated with a water/glycol mixture, the
mixed percentage must be regularly checked.
1. A general inspection of the chiller operation.
2. Carry out weekly inspections.
Recommendation: every 6 months
− Only a correct mixture can guarantee correct
Servicing tasks required every 3 months:
operation. Check the percentage with a portable
spectrometer.
3. Check the settings of all safety devices against the
− Excess glycol concentration: reduces the cooling
Commissioning Report.
capacity
4. Preventive maintenance, as follows:
− Insufficient glycol concentration: risk of freezing.
− Check the fan(s) are running
− The water sample should also be checked for
− Check the refrigerant pipes for any signs of leaks
signs of corrosion.
− Check the water/glycol pipes for any signs of leaks
− Check the glycol water pump(s)
Note: Improper use of water treatment agents can cause
− Check the condenser for dirt build up
major problems. Obtain information from the
− Check the electrical cabinet manufacturer on suitable inhibitors.
− Check the compressor(s) amp draw
5. Carry out any maintenance issues once they are WARNING
found The glycol/water mixture must not be discharged into
the normal water drains. It must be collected in
Enter all repairs/changes in a maintenance log suitable containers and disposed of in accordance
with the local law specifications.
34
Preventive Maintenance
WARNING - RISK OF INJURY
IMPORTANT NOTE
Risk of cuts due to the condenser fins. Wear gloves if
The maintenance operations are described below. All
working on the condenser.
operations must be performed step by step and must
be completely finished. RISK OF INJURY
If it is necessary to carry out work inside the system
WARNING with the fans running, make sure that no parts of the
High voltage - Risk of fatal injury body or clothing are caught in the fan blades or other
Disconnect the unit from the power supply before moving parts.
opening the doors or removing the chiller panels.
Checking the air-cooled condenser
Risk of burns 1. Check the condenser coil and clean CAREFULLY.
Exposed copper pipes may be hot. Low PSI compressed air can be used. DO NOT USE
A BRUSH OR SCRAPER OR CODENSER COIL WILL
Checking the refrigerant pipes BE PERMANENTLY DAMAGED.
1. Check the refrigerant piping as far as possible for 2. Straighten bent fins with a fin comb set for the
cracks, damage and oil leaks. correct fin pitch.
2. Check the piping for chafing points, especially
where the pipes are routed very close to the frame
work or along internal components of the chiller. WARNING
3. Check the pipe insulation and repair/replace if After changing any components such as fan baldes,
necessary. etc., insure balance is correct.
4. Check the pipes for vibrations. Check the pipe
mounting clips and re-tighten the screws if 1. Check the fan mounting and, if necessary, tighten
necessary. the securing screws.
2. Check the electrical terminal box.
Checking the water/ glycol Iines 3. Check to make sure the rotation of fans are
1. Check all pipes for vibrations. correct
2. Check the mounting clips and tighten if necessary.
3. Check for leaks at screwed joints and weldings and After completing these operations, re-install any side
repair if necessary. or top panel that was removed. This is to ensure
4. Squeeze the insulation to determine whether it proper air flow is going through condenser
has filled with water. lf so:
Locate the leak and repair Record any repairs/changes on the maintenance log.
5. Check the insulations and repair/replace any
damaged points. WARNING
Note: Condensation may form due to inadequately If unit has shipped with a protective heat shrink wrap,
insulated chilled water pipes. the wrap , must be removed immediately so moisture
WARNING does not collect inside the wrap. Please contact Motivair
High voltage - risk of fatal injury for any long term storage requirements.
Disconnect the unit from the power supply
Checking the chilled water pumps

- when mounted in the chiller -
1. Check for leaks around the pump. If leaking,
tighten any flange fittings that might be leakingo
or the mechanical pump seal might need to be
changed.
2. Check on the motor electrical box for loose
electrical connections. lf necessary, retighten the
electrical connections. Reclose the terminal box.
3. Check the externally mounted Y-strainer and clean
if necessary.
35
MAINTENANCE/REPAIR 2. Connect refrigerant pressure gauges to the service

ports.
FAILURE OF A COMPRESSOR 3. Close the service valves by tuming them clockwise.
Occasionally, a fault in the motor insulation can cause Reclaim the refrigerant pressure from the
the motor to burn out. On a maintained system, this compressor.
type of failure is very rare. 4. Remove all mechanical and electrical connections
However, if it does occur, it wiII generally be caused by on the compressor, and then the remove the
mechanical or lubrication faults that result in burn-out. defective compressor.
Compressor damage can be Iargely prevented if the 5. Install the new compressor and connect up all
problems Ieading to motor burn-out are remedied. connections correctly.
6. Evacuate the refrigerant circuit to 500microns.
Regular service inspections - That identify fault 7. Open the service valves on the compressor.
conditions play an active role in ensuring operating 8. Start up the compressor. Check the refrigerant
safety and reducing maintenance costs. level and ensure the circuit is perfectly sealed.
9. Dispose of the defective compressor in accordance
Mechanical fault - The refrigerant gas from the service with local laws.
port does not smell burnt. The motor tries to start.
Compressor replacement after burn-out
Electrical fault - This type of fault is identified by a
characteristic smell when the coolant is removed from In the case of an electrical fault and compressor motor
the service port. After severe burn out, the oil is black burn-out, proceed very carefully.
and acidic. lf the motor burns out, the stator windings break
down, forming carbon, water and acid, which
Check all electrical components before replacing a contaminate the refrigerant system.
compressor assumed to be defective. These impurities must be completely removed from
1. Check the main disconnect switch and fuse the system in order to prevent repeated motor
2. Check all safety devices of the compressor. damage.
3. Check whether the mechanical or electrical fault
has damaged the compressor. WARNING!
4. Perform an acid test. lf the replacement compressor is damaged due to
inadequate system cleaning, warranty will be voided
WARNING - RISK OF BURNS 1. Carry out the acid test and send it with the
Do not undo any refrigerant connections until the compressor to the manufacturer for damage
system is depressurised. analysis.
2. Check: the power supply of the refrigerant circuit
WARNING
must be disconnected.
When working on the refrigerant circuit, open the
compressor breaker in the electrical cabinet.
CARE
High voltage - Risk of fatal injury
Disconnect the main current supply to the unit if the
Compressor replacement after mechanical fault power supply has to be maintained (to operate the
second circuit)
lf a mechanical fault is found, and the acid test is OBEY THE SAFETY INSTRUCTIONS
negative, replace the compressor as follows:
3. Check the electrical circuit in the electrical cabinet
1. Check: the power supply to the circuit must be for blown fuses, charred contacts, overload
disconnected. contacts and relays.
Check the input and output terminals of the
compressor circuit.
36
MAINTENANCE/REPAIR CONTINUED WARNING!

lf the replacement compressor is damaged due to
Compressor replacement after burn-out inadequate system cleaning, warranty will be voided.
4. Check the connection line of the compressor for

charred or damaged connectors, insulation and
short-circuited or grounded.
5. Meg the compressor.
6. Establish the cause of the electrical fault. Take all
necessary corrective action to ensure that the new
compressor does not experience the same result.
WARNING
Refrigerant must never be discharged into the
environment. It must be collected in a collecting
container for proper disposal
WARNING
Avoid any skin contact with gas or refrigeration oils.
Severe burns may be caused. Always wear rubber
gloves when handling dirty parts.
Removing the compressor
1. Reclaim the refrigerant circuit

2. Close the compressor inlet and outlet service
valves.
3. Remove the burnt out compressor. Dispose of in
accordance to local laws
Note: Check that the inlet and outlet valves are not
fouled after the severe burn-out. Before connecting
the new compressor, the valves must be carefully
cleaned and/or replaced.
Check the seals in the service valves .
Cleaning the refrigerant circuit

Clean the circuit with great care and in conformity with
the manufacture.
37
CLEANING THE PLATE EXCHANGER (EVAPORATOR)
Clean exchangers subject to fouling (scale, sludge deposits, etc.) periodically, depending on
specific conditions. A marked increase in pressure drop and/or reduction in performance
usually indicate cleaning is necessary. Since the difficulty of cleaning increases rapidly as the
scale thickens or deposits increase, the intervals between cleanings should not be excessive.
Back flush with a high pressure stream of hot water to remove loose deposits. Circulating hot
wash oil or light distillate will usually effectively remove sludge or similar soft deposits.
In some applications the fouling tendency can be very high, e.g. when using extremely hard
water at high temperatures. Use a tank with weak acid, 5% phosphoric acid or, if the exchanger
is frequently cleaned, 5% oxalic acid. Pump the cleaning liquid through the exchanger.
For optimum cleaning, the cleaning solution flow rate should be a minimum of 1.5 times the
normal flow rate, preferably in a back-flush mode. After use, DO NOT to forget to rinse the heat
exchanger carefully with clean water. A solution of 1-2% sodium hydroxide (NaOH) or sodium
bicarbonate (NaHCO) before the last rinse ensures that all acid is neutralized. Clean at regular
intervals.
If the heat exchanger is excessively fouled and it cannot be cleaned by commercial cleaning
methods, then replacement of the unit is suggested.
It is recommended that the refrigerant circuit NOT be chemically cleaned.
38
CHLORINE - FREE REFRIGERANTS
The compressors designed for operation with chlorine- The use of polyester oils ("POE"s) is necessary for
free refrigerants are factory-filled with ester oils operation with chlorine-free refrigerants.
approved by the compressor manufacturer and are
marked accordingly. Compared to mineral oils, POEs have high hygroscopicity
(moisture absorption).
Compared to single-substance refrigerants and
azeotropic and quasi-azeotropic mixtures, the zeotropic If POE is exposed for only a short time to the ambient air,
refrigerant mixtures are characterised by a wider it absorbs so much moisture that it is no longer acceptable
temperature variation. Specific effects on system for use in refrigeration circuits.
maintenance and repairs must therefore be taken into
account. Since a POE binds moisture more firmly than mineral oil,
the moisture is more difficult to remove from the system
Due to the fact that zeotropic mixtures can have by vacuum.
different compositions in the liquid and gas phases, it is
especially important that these refrigerants are only Consequently, we recommend filling the system with a
ever poured into the system in the Iiquid state. POE containing Iess than 50ppm moisture particles.
Therefore: strictly follow the filling instructions of the With the use of appropriately sized filter dryers, the
refrigerant manufacturer. moisture content in the system can be kept below 50 ppm.
In the event of a Ieak, the change in mixture lf the moisture level rises to unacceptable Ievels, corrosion
composition Ieads to reduced superheat at the and copper-plating can occur.
thermostatic expansion valve and ultimately to liquid
flood back in the compressor. By perfect evacuation, the residual moisture can be
reduced to 10 ppm.
Another aspect of the mixture change is sudden
‘hunting’ of the expansion valve. The system is evacuated to 500 microns. In the event of
any doubt regarding the moisture level in the system, an
Tests by refrigerant manufacturers and the past oil sample should be taken and analysed for water
experience of users have shown that this situation can content.
be stabilized by filling the system with the original
composition. The installed indicator sight glasses can be used for the
new refrigerants and oils, but they do not show the actual
Before replacing the entire refrigerant charge, a mixture moisture content, which may be higher than shown in the
concentration analysis is recommended. sight glass due to the high hygroscopicity (moisture
absorption).
The display in the sight glass only gives the moisture

content of the refrigerant.
To determine the real moisture level, an oil sample must

be taken from the system and analysed.
39
Terms & Conditions of Sale
1) All orders are subject to approval & acceptance by the Seller.
2) Prices are quoted FOB point of shipment, and are subject to change without notice. All prices are exclusive of any sales, use,
State, Federal, or local taxes. The collection & payment of such taxes are the responsibility of the Buyer.
3) Upon transfer of the equipment from the Seller to a common carrier, title shall pass to the Buyer. The Buyer assumes all risks of
loss or damage during transit. The buyer must file claims for such loss or damage with the carrier, with assistance from the Seller.
4) Seller shall not be liable for any damages or consequential losses of any kind, arising out of its inability to deliver due to labor,
suppliers, fire, flood, delays of any kind, acts of God, or any other cause whatsoever.
5) Seller warrants all equipment to be free from defects in materials and workmanship for a period of fourteen (14) months from the
date of shipment or 12 months from the date of startup, provided the equipment is applied, installed and maintained in accordance
with Seller’s recommendations. Seller’s liability is limited solely to repair or replacement of the defective item, at Sellers option,
excluding labor or freight. Under no circumstances shall Seller be liable for any losses, rental equipment charges, or consequential
damages of any kind, howsoever caused. All warranty interpretations and limitations are defined in the Motivair Standard Product
Warranty, a copy of which is available to Buyer on request.
6) Seller makes no warranty or representation of any kind, expressed or implied, as to the merchantability, fitness or suitability for any
particular purpose, with respect to the equipment.
7) Buyer must obtain written permission from Seller, prior to returning any equipment for warranty, credit, or any other reason
whatsoever. The terms of any warranty returns or associated credits are in strict accordance with the above referenced Motivair
Standard Product Warranty. All goods returned for reasons other than warranty shall be subject to a re-stocking charge of no less
than 15%, not to exceed the full invoiced value of the equipment, to be determined at the sole discretion of the Seller. Return freight
charges, plus the risk of loss or damage, whether or not it occurs during shipment back to Seller, will be borne solely by the Buyer.
8) Order changes must be submitted in writing by the Buyer and acknowledged in writing by the Seller, before such changes shall be
deemed valid. Cancellations shall be subject to a charge not to exceed the value of the original order, at the sole discretion of the
Seller. Buyer shall also be responsible for all freight costs associated with any order changes or cancellations.
9) Terms of payment shall be net 30 days to all credit-approved Buyers, from the date of shipment or consignment to a common
carrier, for all standard or inventoried items. Seller will allow a cash discount of 1% for prompt payment received within ten (10) days
of Sellers invoice date.
10) Terms of payment for large or custom orders shall be specified at the time of order acknowledgement. No contractor or
performance payment retention is allowed for any reason whatsoever, beyond these payment terms.
11) A finance charge of 1.5% per month will be applied to all overdue accounts. In the event Seller utilizes a collection agency or
legal proceedings to recover money due and payable to Seller under this agreement, Buyer agrees to pay for all costs directly
associated with this collection.
12) This contract shall be governed in strict accordance with the laws of New York State. If any of these terms are held to be invalid
by a prevailing court of law, the remainder of these terms shall remain in effect, and shall not be affected by the invalid portion.
13) This contract shall constitute the entire agreement between Buyer and Seller. All terms and conditions contained herein shall be
deemed acceptable by the Buyer and shall prevail over any and all terms stipulated within the Buyer’s purchase order, unless
specifically amended by the Buyer, and agreed by the Seller in writing.
Customer Signature of Acceptance: ______________________________ Date: ____________________________
40

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Spec - Chiller Lắp Đặt Chiller

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MOTIVAIR COOLING SOLUTIONS

AIR COOLED CHILLERS

MODELS: MPCA0005 – MPCA0150

This chiller has been factory run tested to the specified

85 Woodridge Dr. Amherst, NY 14228 – Phone# 716-691-9222 – Fax# 716-691-9229

• LEGAL PROVISIONS & SAFETY INSTRUCTIONS 1

• TRANSPORTING & SITE HANDLING 2-3

• CHILLER INSTALLATION 4-13

• PIPING INSTALLATION 14-18

• MAIN ELECTRICAL INSTALLATION 19

• CHILLER SEQUENCE OF OPERATION 21

• MPCA0005 – MPCA0150 PROGRAMMING AND ALARM CODES 22-25

• MPCA0005 – MPCA0150 STANDARD CONTROLLER LAYOUT 26

• COMMISIONING AND STARTUP INSTRUCTIONS 27-28

• PREVENTIVE MAINTENANCE 33-35

• CHILLER REPAIR INFORMATION 36-37

• CLEANING THE PLATE EXCHANGER (EVAPORATOR) 38

• TERMS AND CONDITIONS OF SALE 40

PROVISIONS AND SAFETY

Simple maintenance operations on the equipment without opening

TRANSPORT AND HANDLING

LIFTING - UNLOADING – POSITIONING MANUFACTURER'S NOTE

LIFTING - UNLOADING – POSITIONING MANUFACTURER'S NOTE

Installing with a fork lift truck

LIFTING WITH A CRANE

HOOKING TO THE STRUCTURE

Site Installation Observe all local regulations.

A minimum of 3 feet on all sides is required. Consult Motivair for irregular

Figure 4, Adjustment Factor

Figure 5, Two Chillers Side by Side

Figure 6, Adjustment Factor

Figure 7, three or more chillers

Figure 9, Open Screening Walls

Figure 10, Wall Free Area Graph

Figure 11, Pit Installation

Figure 12, Adjustment Factor

AUTOMATIC WATER MAKE-UP

Ethylene Glycol Propylene Glycol

% of Glycol Freeze Point % of Glycol Freeze Point

MAIN ELECTRICAL INSTALLATION

ELECTRICAL COMPONENTS The main disconnect switch on the chiller must be

MAIN VOLTAGE SUPPLY

The permissible voltage tolerance is ±5%. These values

INFORMATION ON EXTERNAL WIRING

1. A junction box must be fitted to the chiller in

2. The main disconnect switch or power block of the

These can be avoided by adding a reservoir on the GLYCOL IN CIRCUIT

Mechanical cooling – inlet control

2. GENERAL DESCRIPTION 5.1 HOW TO SEE THE MIN TEMPERATURE

3.1 COMPRESSOR 6. MAIN FUNCTIONS

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oA1 2nd relay configuration ALr = alarm; dEF = do not

Adr Serial address 0÷247 1 Pr2

17. DEFAULT SETTING VALUES

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MPCA0005 - MPCA0010 STANDARD CONTROLLER LAYOUT

MPCA0150 STANDARD CONTROLLER LAYOUT

COMMISIONING AND STARTUP INSTRUCTIONS

Correct handover by the qualified company to the MAINTENANCE INTERVALS

Safety instructions ____________ Year of manufacture _____________

____________________ ____________ Operator (Stamp) – Signature

3. Faults in the refrigerant circuit.

Safety instructions Year of manufacture _

________ Operator (Stamp) – Signature

Customer Signature of Acceptance: __ Date: