DHR_Modular_Chiller_O&M_-_1_of_2.pdf

O&M Library London, United Kingdom NEC

Tab D

Manufacturer Product & Technical Data

Table of Contents Section Page

Multistack Service Manual

Variable Flow Application Product Data

Multistack IOM Manual

Virtual Moveable End Cap for Heat Pumps Installation Supplement pCO3 Controller User Manual

Dedicated Heat Recovery Chiller Product Data

Brass Socket Guages Product Data

Actuator Valves Product Data

Building Automation Site Survey

Multistack Preventative Maintenance

Multistack Heat Exchanger Cleaning Procedures

Multistack Customer Witness Test Report

Information for Spec Section

Tab D

SERVICE MANUAL

for

1065 Maple Avenue PO Box 510

Sparta, WI 54656 Phone: (608)366-2400

Fax: (608)366-2450 www.multistack.com

12-827-82 - VME

202-N030

(5) MS070XC5E2H2AAC-410A,

(2) MS050XC5E2H2AAC-410A,

(7) VME2E8A5 Valve modules

400 Volt

Specification 236422 - Page 1 of 159

Date: December 12, 2013

From: Brad Snodgrass / Mike Orlikowski Multistack

To: Juan Bazan BL Harbert International

Subj: Responses to Submittal Review Comments for 236422, Dedicated Heat Recovery Chillers (GSHP)

Dear Juan, Please see below for our responses to the submittal review comments:

Comment: For record, provide certification indicating compliance with ASHRAE 15 and ANSI/ASHRAE Guideline 147. (Refer to Section 1.6-B.)

Response: Please see page 6 of 89 for ASHRAE 15 and 147 certification letter.

Comment: For record, confirm that the submitted evaporators and condensers comply with the ASME Boiler and Pressure Vessel Code, Section VIII, Division 1. Provide an ASME label on each evaporator and condenser. (Refer to Section 1.6-C.)

Response: The brazed plate heat exchangers are rated and stamped in accordance with UL 1995.

Comment: Provide interface for full BMS integration with the heat pumps’ controllers. Coordinate BMS protocol with the approved BMS shop drawings.

Response: Please provide the completed BMS protocol survey (page 89 of 89).

Comment: Coordinate all VME II controller inputs, outputs, and sequences with the controls contractor in order to satisfy the intent of the control sequences listed in the design documents. Refer to the controls drawings, and in particular, NOB MC9.1.2, MC9.1.3, NOB MC9.1.4, NOB MC9.2.3, and NOB MC9.2.4 for details.

Response:

• NOB MC9.1.2

o MIV03, MIV04, & FCV01 are provided by others, but operated by the Multistack Water to Water Heat Pump. All other points and devices on the 9.1.2 list on sheet NOB MC9.1.2 are by the BAS Contractor.

• NOB MC9.1.3

o MIV03, MIV04, & FCV01 are provided by others, but operated by the Multistack Water to Water Heat Pump. All other points and devices on the 9.1.2 list on sheet NOB MC9.1.2 are by the BAS Contractor.

Specification 236422 - Page 2 of 159

• NOB MC9.1.4

o In order to provide the points list, we will need the completed BMS protocol survey.

Please provide the completed BMS protocol survey (page 89 of 89)

• NOB MC9.2.3

o In order to provide the points list, we will need the completed BMS protocol survey.

Please provide the completed BMS protocol survey (page 89 of 89)

• NOB MC9.2.4

o In order to provide the points list, we will need the completed BMS protocol survey.

Please provide the completed BMS protocol survey (page 89 of 89)

Comment: The bypass valves at the heat pump CHW, HHW, and source water loop hook-ups (refer to “VMEII Piping Schematic,” page 8 of submittal) are by others but shall be controlled by Multistack.

Response: Multistack concurs with this comment.

Comment: Coordinate heat pump dimensions with all other trades. Heat pumps shall be accessible for maintenance and inspection. Coordinate installation of submitted heat pumps with heat pump manufacturer’s recommended service clearances.

Response: Please let us know what additional information is needed to assist in this coordination effort.

Comment: Coordinate all control valves, control wiring, and sensors with the design drawings and the controls contractor.

Response: Please let us know what additional information is needed to assist in this coordination effort.

Comment: Coordinate all power wiring with the design drawings and the electrical contractor.

Response: Please let us know what additional information is needed to assist in this coordination effort.

Comment: Coordinate all piping hook-ups with the design drawings and the chiller manufacturer’s recommendations.

Response: Please let us know what additional information is needed to assist in this coordination effort.

Comment: Coordinate refrigerant leak detector and alarm with design drawings and the mechanical and controls contractors.

Response: Please let us know what additional information is needed to assist in this coordination effort.

Comment: Coordinate all balance-of-system components (pumps, strainers, isolation valves, etc.) with the design drawings and the mechanical contractor.

Responses: Please let us know what additional information is needed to assist in this coordination effort.

Comment: Provide factory-witness test per the mechanical specifications. Coordinate with Owner and CM at time of test.

Response: Multistack will provide notification of the witness test date within 14 days of the test (we will make every effort to give additional notice).

Comment: Coordinate housekeeping pad requirements with the design drawings and the mechanical contractor.

Specification 236422 - Page 3 of 159

Response: Please let us know what additional information is needed to assist in this coordination effort.

Comment: Base isolation is not required. Direct, non-isolated base mounting is acceptable from an acoustic and vibration transmission standpoint.

Response: Multistack is not providing this item – to be coordinated by others.

Comment: Provide startup service, training, toolkit, and O&M data per the specification.

Response:

• We will provide start up services as outlined in specification 236422 Paragraph 3.6.A

• Training will be provided during the onsite start up visit as required by 3.6.A

• Specification 236422 Paragraph 2.9.C requires any special tools that are not readily available.

Our chiller does not require any non-standard tools.

• O&M data will be provided at the time of shipment.

Specification 236422 - Page 4 of 159

Please see below for exceptions – clarifications related to the review of the specification.

Modular Water to Water Heat Pump

• Comments on Schedule Notes o Note 1: Housekeeping Pad by Others – Powder Coated Lifting Frame Included

• Specification 236422 Notes o Seismic & Vibration Isolation (Neoprene & Springs) by Others o Table 2.2-1

Pumps not included in this submittal o 3.3.D & E Evaporator and Condenser Connections by Others o 3.3.F Clarification: Circuit Charge likely below level that requires venting o 3.7.A Occupancy Adjustments, Not Included - Available on a T&M basis

Common Items Included:

• Freight from our Factory in Sparta, Wisconsin to First Destination Contiguous United States

• Warranties as Required in Specifications.

• Factory Witness Tests.

• A single 10 Day Job Site Visit by our TS Cleared Technician for Start Up, Commissioning, and Owner Training is included for both this chiller and the two Water Cooled Chillers presented in a separate submittal. Additional Visits to satisfy construction schedule requirements are available on a T&M basis, $15,000 per 5 day trip.

Common Items Excluded:

• Seismic Isolators

• Pumps and Auxiliary Items (e.g. Expansion Tanks, 30 Mesh Dual Basket Strainers, etc.)

Notes:

• Chilled Water and Hot Water Plant Building Automation System Interfaces with the Master Controllers for the items proposed above via either Bacnet MSTP, Bacnet IP, or Modbus RTU are included.

Specification 236422 - Page 5 of 159

MULTISTACK

1065 Maple Ave, Sparta, WI 54656

PHONE: (608) 366-2400 ▌▌▌FAX: (608) 366-2450

Subject: Compliance with ASHRAE Standard 15

The signature below certifies that Multistack, LLC is compliant with the manufacturer requirements of ASHRAE 15 “Safety Code for Mechanical Refrigeration” and manufacturer requirements of ANSI/ASHRAE Guideline 147 “Reducing Release of Halogenated Refrigerants from Refrigeration and Air-Conditioning Equipment and Systems” for refrigerant leaks, recovery, and handling and storage requirements.

Signed:

Michael S. Orlikowski Multistack Key Accounts Manager

Specification 236422 - Page 6 of 159

P.O. Box 510 - Sparta, WI 54656 - (608)366-2400 / Fax (608)366-2450 www.multistack.com - www.airstack.com

Specification 236422 - Page 7 of 159 http://www.multistack.com/� http://www.airstack.com/�

III MULTISTACK Submittal Information

JOB NAME: ENGINEER: Arup -- Dow Irons

LOCATION: ARCHITECT:

CUSTOMER: CONTRACTORB.L. Harbert

Multistack Order Number: Submitted by:

Customer P.O. Number: Quote #: QMO05242013-11

Sales Representative: Approved by: Date:

GENERAL INFORMATION WATER-COOLED CHILLER FEATURES

Chiller I.D. (5) MS070XC5E2H2AAC-410A & (2) MS050XC5E2H2AAC-410A

Other (7) VME2E8A5 Valve Modules • Stainless steel evaporator and condenser

• Lead compressor sequencing every 24 hours

Length: • Automatic internal rescheduling if fault occurs

Width: • Multiple, independent refrigeration systems

Height: • Automatic logging of any fault conditions

• Electronic chilled water control

CHILLED WATER DESIGN • Modules fit through single width doors and into

Entering Temperature: 57.2 °F passenger elevators

Leaving Temperature: 44.0 °F • Filters in condenser and evaporator supply headers

Evaporator Flow Rate: 360.9 GPM • Stainless steel evaporator & condenser inlet headers

Evaporator Pressure Drop: 10.4 Feet • Quick interconnect modular design

• R-410A Refrigerant

HEATING WATER DESIGN • Warranty: Compressor Parts (5 Year)

Entering Temperature: 130.0 °F • Dedicated Heat Recovery Controls

Leaving Temperature: 140.0 °F • VMEII Controls

Condenser Flow Rate: 687.0 GPM • Total Access Design w/ Var. Flow (Evap. & Cond.) C-Steel Valves (2"-up to 30, 2.5"-50&70)

Condenser Pressure Drop: 10.3 Feet • 8" Headers on Evaporator and Condenser

• Acoustical Cabinet Insulation

VMEII HEAT PUMP PERF. (AT FULL SIMULTANEOUS LOAD) • Refrigerant Pressure Gauges

Cooling Capacity: 699.2 KW • Two Point Power( Each with Disc Sw & PPM)

Power Input: 309 KW • Interoperability Web Portal (BACnet or Modbus)

HEATING CAPACITY: 1007 KW Heating COP: 3.3 • 6" Conduit Passage Incorporated in Module Frame

Cooling COP: 2.3 Heating & Cooling COP: 5.5 • Extra Materials: Control Circuit Board & PPM

Performance Based on 1-50 & 4-70 ton module(s) operating • Extra Materials: 2 Circuit Breakers

• NEMA 4X Variable Flow Actuators

• Factory Witness Test

• Lifting Frame

ELECTRICAL DATA CHILLER BUSBAR SCHEMATIC

MAIN POWER SUPPLY 400 / 50 / 3 - LOCATION OF JUNCTION BOX(S) = J

- ROUTING OF BUSBARS: _ _ _

ELECTRICAL CIRCUIT(S) CAPACITY

LEFT RIGHT

CIRCUIT CIRCUIT V 1 V 2 V 3 V 4 V 5 V 6 7 V

Minimum Circuit Ampacity (amps) 477 351 M 50 M 70 M 70 M 70 M 70 M 70 50 M

Maximum Over Current Protection (MOP) 600 450 J E E E E E E E J

PLAN VIEW

IMPORTANT: To assure full equipment design performance, life and reliability, the MULTISTACK chiller must be piped in accordance with Installation Manual unless specifically authorized otherwise by MULTISTACK in writing.

See Drawing

See Drawing

DESIGN NOTE: All loops (heating, cooling and source/sink) must be designed for the same fluid solution and loop pressure.

202-N030

ALS-15-0067

Brad Snodgrass

See Drawing

Tuesday, February 11, 2014

12-827-82 (VME)-- MWHP-1 (PEAK SIMULTANEOUS)

12-827-82

DoS

Specification 236422 - Page 8 of 159

LOCATION: ARCHITECT:

CUSTOMER: CONTRACTOR:B.L. Harbert

Multistack Order Number: Submitted by:

Customer P.O. Number: Quote #: QMO05242013-11

Sales Representative: Approved by: Date:

GENERAL INFORMATION WATER-COOLED CHILLER FEATURES

Chiller I.D. (5) MS070XC5E2H2AAC-410A & (2) MS050XC5E2H2AAC-410A

Other (7) VME2E8A5 Valve Modules • Stainless steel evaporator and condenser

• Lead compressor sequencing every 24 hours

Length: • Automatic internal rescheduling if fault occurs

Width: • Multiple, independent refrigeration systems

Height: • Automatic logging of any fault conditions

• Electronic chilled water control

SOURCE/SINK WATER DESIGN • Modules fit through single width doors and into

Entering Temperature: 46.0 °F passenger elevators

Leaving Temperature: 40.0 °F • Filters in condenser and evaporator supply headers

Evaporator Flow Rate: 954.5 GPM • Stainless steel evaporator & condenser inlet headers

Evaporator Pressure Drop: 18.6 Feet • Quick interconnect modular design

• R-410A Refrigerant

HEATING WATER DESIGN • Warranty: Compressor Parts (5 Year)

Entering Temperature: 130.0 °F • Dedicated Heat Recovery Controls

Leaving Temperature: 140.0 °F • VMEII Controls

Condenser Flow Rate: 860.4 GPM • Total Access Design w/ Var. Flow (Evap. & Cond.) C-Steel Valves (2"-up to 30, 2.5"-50&70)

Condenser Pressure Drop: 10.3 Feet • 8" Headers on Evaporator and Condenser

• Acoustical Cabinet Insulation

VMEII HEAT PUMP PERF. (AT FULL HEATING LOAD) • Refrigerant Pressure Gauges

Heat Extracted: 840.6 KW • Two Point Power( Each with Disc Sw & PPM)

Power Input: 421.9 KW • Interoperability Web Portal (BACnet or Modbus)

HEATING CAPACITY: 1261.1 KW Heating COP: 3.0 • 6" Conduit Passage Incorporated in Module Frame

Cooling EER: 6.8 Heating & Cooling COP: 5.0 • Extra Materials: Control Circuit Board & PPM

Performance Based on 2-50 & 5-70 ton module(s) operating • Extra Materials: 2 Circuit Breakers

• NEMA 4X Variable Flow Actuators

• Factory Witness Test

• Lifting Frame

ELECTRICAL DATA CHILLER BUSBAR SCHEMATIC

MAIN POWER SUPPLY 400 / 50 / 3 - LOCATION OF JUNCTION BOX(S) = J

- ROUTING OF BUSBARS: _ _ _

ELECTRICAL CIRCUIT(S) CAPACITY

LEFT RIGHT

CIRCUIT CIRCUIT V 1 V 2 V 3 V 4 V 5 V 6 7 V

Minimum Circuit Ampacity (amps) 477 351 M 50 M 70 M 70 M 70 M 70 M 70 50 M

Maximum Over Current Protection (MOP) 600 450 J E E E E E E E J

PLAN VIEW

IMPORTANT: To assure full equipment design performance, life and reliability, the MULTISTACK chiller must be piped in accordance with Installation Manual unless specifically authorized otherwise by MULTISTACK in writing.

See Drawing

See Drawing

DESIGN NOTE: All loops (heating, cooling and source/sink) must be designed for the same fluid solution and loop pressure.

202-N030

ALS-15-0067

Brad Snodgrass

See Drawing

Tuesday, February 11, 2014

12-827-82 (VME) -- MWHP-1 (PEAK HEATING)LSW

12-827-82

DoS

Specification 236422 - Page 9 of 159

LOCATION: ARCHITECT:

CUSTOMER: CONTRACTORB.L. Harbert

Multistack Order Number: Submitted by:

Customer P.O. Number: Quote #: QMO05242013-11

Sales Representative: Approved by: Date:

GENERAL INFORMATION WATER-COOLED CHILLER FEATURES

Chiller I.D. (5) MS070XC5E2H2AAC-410A & (2) MS050XC5E2H2AAC-410A

Other (7) VME2E8A5 Valve Modules • Stainless steel evaporator and condenser

• Lead compressor sequencing every 24 hours

Length: • Automatic internal rescheduling if fault occurs

Width: • Multiple, independent refrigeration systems

Height: • Automatic logging of any fault conditions

• Electronic chilled water control

CHILLED WATER DESIGN • Modules fit through single width doors and into

Entering Temperature: 57.2 °F passenger elevators

Leaving Temperature: 44.0 °F • Filters in condenser and evaporator supply headers

Evaporator Flow Rate: 450.6 GPM • Stainless steel evaporator & condenser inlet headers

Evaporator Pressure Drop: 10.4 Feet • Quick interconnect modular design

• R-410A Refrigerant

SOURCE/SINK WATER DESIGN • Warranty: Compressor Parts (5 Year)

Entering Temperature: 62.0 °F • Dedicated Heat Recovery Controls

Leaving Temperature: 71.0 °F • VMEII Controls

Condenser Flow Rate: 753.1 GPM • Total Access Design w/ Var. Flow (Evap. & Cond.) C-Steel Valves (2"-up to 30, 2.5"-5

Condenser Pressure Drop: 18.6 Feet • 8" Headers on Evaporator and Condenser

• Acoustical Cabinet Insulation

VMEII HEAT PUMP PERF. (AT FULL COOLING LOAD) • Refrigerant Pressure Gauges

Cooling Capacity: 873 KW • Two Point Power( Each with Disc Sw & PPM)

Power Input: 121.8 KW • Interoperability Web Portal (BACnet or Modbus)

Total Heat of Rejection: 993.6 KW Heating COP: 8.2 • 6" Conduit Passage Incorporated in Module Frame

Cooling COP: 7.1 Heating & Cooling COP: 15.3 • Extra Materials: Control Circuit Board & PPM

Performance Based on 1-50 & 3-70 ton module(s) operating • Extra Materials: 2 Spare Circuit Breakers

• NEMA 4X Variable Flow Actuators

• Factory Witness Test

• Lifting Frame

ELECTRICAL DATA CHILLER BUSBAR SCHEMATIC

MAIN POWER SUPPLY 400 / 50 / 3 - LOCATION OF JUNCTION BOX(S) = J

- ROUTING OF BUSBARS: _ _ _

ELECTRICAL CIRCUIT(S) CAPACITY

LEFT RIGHT

CIRCUIT CIRCUIT V 1 V 2 V 3 V 4 V 5 V 6 7 V

Minimum Circuit Ampacity (amps) 477 351 M 50 M 70 M 70 M 70 M 70 M 70 50 M

Maximum Over Current Protection (MOP) 600 450 J E E E E E E E J

PLAN VIEW

202-N030

ALS-15-0067

Brad Snodgrass

See Drawing

Tuesday, February 11, 2014

12-827-82 (VME) -- MWHP-1 (PEAK COOLING)

12-827-82

DoS

IMPORTANT: To assure full equipment design performance, life and reliability, the MULTISTACK chiller must be piped in accordance with Installation Manual unless specifically authorized otherwise by MULTISTACK in writing.

See Drawing

See Drawing

DESIGN NOTE: All loops (heating, cooling and source/sink) must be designed for the same fluid solution and loop pressure.

Specification 236422 - Page 10 of 159

Specification 236422 - Page 11 of 159

MULTISTACK

12-827-82 202-N030

Wiring 202-N030.E01 202-N030.E02 202-N030.E03 202-N030.E04 202-N030.E05 202-N030.E06 202-N030.E07 202-N030.E08 202-N030.E09 202-N030.E10 202-N030.E11 202-N030.E12

III MULTISTACK

1065 Maple Ave.

Phone #: (608) 366-2400 Fax #: (608) 366-2450 E-mail: info@multistack.com

Web Site: www.multistack.com

Specification 236422 - Page 12 of 159

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Specification 236422 - Page 24 of 159

T

T

VME II Piping Schematic

T

T

T T

Temperature sensors provided by Multistack, installed by others.

DP Transmitters for VFD control supplied and installed by others.

Bypass valves supplied and installed by others.

Minimum 30 mesh strainers required on load and source inlets, supplied and installed by others.

T

DP

Specification 236422 - Page 25 of 159

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CVSP =COO

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Specification 236422 - Page 26 of 159

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Specification 236422 - Page 27 of 159

Variable Flow Application Engineering Bulletin sm

For:

Multistack Modular Scroll Only Applications

Specification 236422 - Page 28 of 159

Variable Flow Application Engineering Bulletin Product Information

MultIStAck MOdulAr chIllErS Or hEAt PuMPS And VArIABlE PrIMAry FlOw PuMPIng SyStEMS The Multistack Modular Chiller and Heat Pump design offers some unique advantages when used in a variable primary flow system. These advantages include precise temperature control while providing infinite flow modulation with minimum flows significantly lower than traditional chillers. The Multistack Modular Chiller, however, has some subtle differences from a conventional system. These differences must be understood to properly design a variable primary flow system. This document will outline the basic requirements for a variable primary flow application utilizing the Multistack Modular System. The following three factors must be considered:

1. Pump VFD Control

2. System Bypass Sizing and Control (Minimum flow requirement at full load)

3. Minimum Chiller Flow – (Minimum flow requirement at low load)

PuMP VFd cOntrOl The application of the Multistack Chiller or Heat Pump in a variable flow system requires a different control approach when compared to conventional systems. In place of a single machine with one heat exchanger, the Multistack system incorporates multiple heat exchangers, each with its own motorized, fully modulating isolation valve. The internal header system of a Multistack Modular Chiller manifolds all modules’ evaporators and condensers in a parallel flow arrangement and provides proper flow distribution to each active heat exchanger. As a result the differential pressure across the MULTISTACK MODULAR CHILLER or HEAT PUMP can be directly correlated to the flow across all active heat exchangers.

Proper water flow to each operating heat exchanger must be maintained at all load conditions. This can be accomplished one of two ways:

1. The variable speed drive of the pump is controlled directly by a differential pressure transmitter installed at the inlet and outlet of the Multistack Modular System. The pump will modulate to maintain the required pressure differential across the Multistack Modular System. (Drawing 1).

2. The variable speed drive of the pump is controlled directly to a pressure transmitter installed in the building piping. The pump will modulate to control system pressure at the point of measurement (Drawing 2).

Design Note: To maintain acceptable temperature variance and avoid nuisance faults Multistack incorporates fast acting modulating valves with a stroke times less than 30 seconds. As a result it is critical that there is no delay associated with the Pump VFD control or the System bypass valve. The system bypass valve must be a pressure dependent valve with a similar stroke time to the Multistack onboard valve.

MInIMuM FlOw rEQuIrEMEnt At Full lOAd and SyStEM ByPASS SIZIng and cOntrOl One reality of a variable primary flow system, regardless of which of the above pump control methods is utilized (based on the chiller ΔP or the system pressure), is that there will be some control lag between the load seen by the chilled water distribution system and the Multistack chiller or heat pump.

Because of this, it is possible for the chiller to temporarily have a different flow requirement than the air handler (or other terminal device) . To avoid potential operational issues due to this phenomenon the system must incorporate a bypass valve. One example of how this operational issue could occur is:

The chiller is operating at full load (perhaps in a pull down situation). The air handlers gain control of their load and all simultaneously drive their chilled water control valves closed (this can happen quite abruptly in some variable primary flow systems). At this point the system has a very low water flow requirement to the air handlers. Simultaneously, the chiller (whose capacity is being controlled by chilled water temperature) has not yet seen a drop in required capacity at its system sensors due to the system water volume (which creates a time lag between a change in leaving temperature at the air handlers and a change in entering temperature at the Multistack Chiller). As a result of this lag, the MULTISTACK MODULAR CHILLER or HEAT PUMP would require more flow than the rest of the system until the chiller controls can unload the chiller/heater to match the system load condition. Without a system bypass valve in place the result of this condition would be to either provide too much flow to the air handlers or not enough flow to the MULTISTACK MODULAR CHILLER or HEAT PUMP.

When controlled properly the system bypass valve ensures each system component receives the proper flow at all times (including the potential lag period).

There are two control methods for the system bypass valve (which directly correlate to the control of the pump as described above):

1. When using the first pump control method (differential pressure drop across the chiller controlling the pump speed) the system bypass valve is controlled directly to a differential pressure transmitter installed in the building piping. The system bypass valve will modulate to control pressure differential as shown in (Drawing 1).

2. When using the second pump control method (system pressure controlling the pump speed) the system bypass valve is controlled directly to a differential pressure transmitter installed at the inlet and outlet of the Multistack Modular System. The system bypass will modulate to maintain the required differential pressure across the MULTISTACK MODULAR CHILLER or HEAT PUMP.(Drawing 2)

When sizing the system bypass all load conditions must be taken into account. For this reason the system bypass is not sized to the minimum system flow, rather it is sized to provide minimum flow at full load of the chiller. Contact your local Multistack sales representative for proper bypass sizing.

Design Note: The minimum flow bypass should be located on the load side of the piping system and is typically accomplished by installing the valve as an end-of-loop bypass. Some systems may not allow for an end-of-loop bypass. In these situations the valve may be installed closer to the chiller, however, a minimum system volume equaling a minimum of a 2-minute loop time must be maintained to ensure proper operation.

Specification 236422 - Page 29 of 159

Product Information

MInIMuM chIllEr FlOw (MInIMuM FlOw rEQuIrEMEnt At lIght lOAd) The Multistack control system together with the modulating valves at each evaporator and or condenser allows for maximum flow turndown. The MULTISTACK MODULAR CHILLER or HEAT PUMP can have a minimum flow at light load equivalent to the flow required for one circuit. Often the pumping system has a higher flow requirment than the Multistack Chiller. Additionally, by keeping the lead circuit’s modulating valve open (which is rotated each day to follow the lead circuit) the pumping system will not be “dead‐headed” by the chiller under a no‐load condition. If the pumps minimum turndown is more than one circuit of flow, the MULTISTACK MODULAR CHILLER or HEAT PUMP can be programmed to set the number of open valves to satisfy the minimum flow of the pump, eliminating the need for an external chiller bypass.

Design Note: This is the minimum operating point for MULTISTACK MODULAR CHILLER or HEAT PUMP only. It does not determine the system’s minimum flow requirement or the system bypass valve sizing.

In summary, the Multistack Variable Flow Chiller or Heat Pump can offer significant control and turn‐down advantages in variable primary flow pumping systems that will improve the energy profile of the system. Please contact us with any questions or concerns that you may have. We will listen, and do our best to support you in making your system the best it can be.

Specification 236422 - Page 30 of 159 drawing 1

D P

A H

U -4

A H

U -3

A H

U -2

A H

U -1

D P

Tr an sm itt er xx xx xx x

M ul tis ta ck C hi lle r

M ul tis ta ck R ec om m en de d

Va ria bl e

Fl ow

C hi lle r S ch em at ic en d of lo op b yp as s m ay b e co nt ro lle d di re ct ly b y en d of lo op p re ss ur e w ith a pr es su re tr an sm itt er

D ra w in g O ne

M ul ti st ac k re co m m en de d Va ri ab le F lo w c hi lle r S ch em at ic

En d of l oo p

Sy st em B yp as s w it h ch ill er d iff er en ti al P re ss ur e co nt ro l

*L es s th an se co nd s tr ok e tim e re qu ire d.

M ai nt ai n m in ut e lo op ti m e at a ll lo ad c on di tio ns

Specification 236422 - Page 31 of 159 drawing 2

D P

A H

U -4

A H

U -3

A H

U -2

A H

U -1

D P

Tr an sm itt er xx xx xx x

M ul tis ta ck C hi lle r

M ul tis ta ck R ec om m en de d

Va ria bl e

Fl ow

C hi lle r S ch em at ic en d of lo op b yp as s m ay b e co nt ro lle d di re ct ly b y en d of lo op p re ss ur e w ith a pr es su re tr an sm itt er

D ra w in g O ne

D P

P

D ra w in g Tw o

M ul ti st ac k

V ar ia bl e Fl ow c hi lle r S ch em at ic

*L es s th an se co nd s tr ok e tim e re qu ire d.

M ai nt ai n m in ut e lo op ti m e at a ll lo ad c on di tio ns

Specification 236422 - Page 32 of 159

F168_0812

Originators… Multistack invented the modular water chiller. It started with a radically simple idea: chiller modules that could be brought into the equipment room one at a time, through standard doorways and down elevators, to form a fully integrated chiller system. The idea launched a revolution and transformed Multistack into a leader in the commercial water-chiller industry.

Innovators… Multistack perfected the modular chiller and leads the industry in innovative and environmentally friendly modular solutions. Since founding in the late 1980s, Multistack has engineered, manufactured, and distributed an impressive array of modular air conditioning firsts: the first on-board strainer, the first modular automatic blow-down device, the first modular chiller for variable flow, the first modular chiller-heater (heat pump), the first modular heat-recovery chiller, the first modular air-to-water heat pump, the first modular chiller to utilize MagLev™ compressor technology, and the first modular chiller to utilize R-134a.

Never the Imitators… Multistack sets the standard in the industry for superior customer service, fast and on time shipment, superior product quality, and new product development. Our pioneering leadership in environmental issues is well documented. If you want the best, be sure to specify the original – Multistack®.

sm

1065 Maple Avenue P.O. Box 510 Sparta, WI 54656 Phone 608-366-2400 • Fax 608-366-2450 www.multistack.com

Specification 236422 - Page 33 of 159

Dedicated Heat Recovery Chiller® Installation, Operation, and Maintenance Manual

Specification 236422 - Page 34 of 159

Specification 236422 - Page 35 of 159

Safety Information

Model Number Nomenclature

INSTALLATION

Shipping Information

Chiller Location, Dimensions and Clearances

Installation Site Preparation

Recommended Water Piping Arrangement

Water Piping System Flushing Procedure

Chilled Water, Condenser Water Connections

System Water Volume

Water Treatment

Condenser Water Temperature Control

Pressure Relief Piping and Refrigerant Monitoring

Variable Flow and Power Actuated Butterfly Valves

Isolation Valves (Optional)

Hot Gas Bypass (Optional)

Module Mounting Base and Chiller Assembly

Chiller Assembly

Multiflush System Assembly

Water System Connections

Leak Testing

Flow Protection

Frame and Panel Installation

Buss Bar Installation

Electric Junction Box Installation

Field Electrical Connections

Field Electrical Connections

Optional Single Module Field Connection

Master Control Panel

Module Control Boards and Low Voltage Panel

High Voltage Panel

Compressors, Sensors, Switches

Controls Setup

Start-Up Data Log

OPERATIONS

Pressure Readings

Compressor Oil Level

Daily Log Sheet

Water Treatment

Dedicated Heat Recovery Chiller

MAINTENANCE

Multistack Water Guidelines

Strainer, Heat Exchanger Cleaning

Condenser Strainer Cleaning

Refrigerant Charge, System Evacuation

Filter Driers

Superheat/Subcooling

Pressure Relief Valve

Annual Maintenance

Maintenance Checks

Electrical Components

Refrigeration Circuits

Chilled and Condenser Water System

Cabinet and Related Hardware

Compressors

Heat Exchangers

Leak Testing a Condenser or Evaporator Heat Exchanger .. 40

Condenser or Evaporator Heat Exchanger Replacement ... 40

Troubleshooting DHRC Modules

Chiller Daily Log Sheet

Contents

Specification 236422 - Page 36 of 159

Multistack Dedicated Heat Recovery Chillers™

• Multistack Dedicated Heat Recovery Chillers (DHRC) give owners simultaneous, variable heating and cooling from a single system.

Available in 140, 160 and 180-degree modules while producing cold water for cooling. Ideal for concurrent heating and cooling load applications.

• DHRC units provide significant cost savings by capturing heat already available plus the heat generated in the cooling process.

• Heating COPs of 3.0 and combined heating and cooling COPs of more than 7.0. Typically three times more efficient than gas boilers.

Compatible with high-temp hot water systems.

• Like Multistack modular chillers, DHRC units use the latest in direct digital controls technology for efficient, precise temperature and humidity control with easy interface to BAS systems.

• Compact size requires minimal installation space freeing valuable floor space for core business operations.

This manual will assist in the proper installation, operation and maintenance of Multistack Dedicated Heat Recovery Chillers (DHRC). Review this manual carefully before installing, starting and operating th e DHRC chiller.

The information and illustrations contained in this manual are generalized. Each chiller installation may be customized to an extent that consultation with a Multistack representative may be necessary to cover details not included in this manual.

Be sure to read and follow the safety information found on Pages __ and __ throughout this manual. Good electrical and piping practices must be followed as described in this manual and in accordance with all applicable national and local codes. Do not install this equipment near an open flame per local codes and ASHRAE specifications.

Personnel servicing Multistack DHRC chillers must have a minimum Class II EPA certification.

Questions regarding the content of this manual and the installation, operation and maintenance of DHRC chillers should be directed to an authorized Multistack representative or to the Multistack Service Department at (608) 366-2400 or FAX (608) 366-2450.

Specification 236422 - Page 37 of 159

Safety Information

This manual includes warnings, cautions and notes.

DANGER conveys serious hazards for injury or death.

WARNING indicates risk of injury or death.

CAUTION warns of possible injury or damage.

NOTE calls out work practices that can result in optimal operations.

Warnings, cautions and notes include:

DANGER: To avoid the risk of electrical shock, personal injury or death, disconnect all electrical power to the unit before performing any maintenance or service. The unit may have more than one electrical power supply. Assume all electrical wires are live, energized wires. Use lockout/tag outs.

DANGER: Use extreme caution when working around electrical components, wiring and connections to avoid injury or death by electric shock.

DANGER: Never remove a lockout from equipment unless you placed it there. Each person shall place his/her own lock/tag when required to isolate an energy source. Do not start any adjustment, service or repair without verifying that the tag/lock out switch or control cannot be by-passed or over-ridden. Verify that the locked-out switch or control cannot be overridden. Test the equipment to be certain that the locked-out switch is de-energized and not simply malfunctioning. Press all start buttons to confirm that the equipment WILL NOT start.

Confirm that the system being serviced or repaired is the system that has been locked out. Before restarting equipment, verify all tools and other items have been removed, all machine guards are in place, all electric systems are reconnected, and personnel are clear of equipment.

DANGER: During installation, testing, servicing and troubleshooting this product, it may be necessary to work with live electrical components. Only qualified licensed electricians or other properly trained persons may perform these tasks. Failure to follow all electrical safety precautions can result in death or serious injury. All HVAC equipment must be installed per the National Electric Code (NEC) and/or all applicable state/local codes.

DANGER: Incorrect handling of HVAC equipment can result in explosions, electrical shock or fire, causing property damage, injury and/or fatality.

DANGER: HVAC liquids and chemicals can be dangerous if used incorrectly or if spills or accidents occur. Handle detergents and solvents with care to avoid spills and burns.

DANGER: Danger of explosion. Refrigerant cylinders can explode causing serious injury and/or death if not handled and stored properly.

WARNING: Only qualified, licensed electricians with proper personal protection equipment should wire Multistack chillers. Injury or death my result if not properly wired due to electric shock hazard

WARNING: Danger of electrical shock. Many types of HVAC equipment have switches and regulators with electrical current on even when other parts of the equipment appear to be turned off. Main circuit breakers must be turned off before servicing equipment to avoid injury, fatality.

WARNING: Be sure to use lifting slings with lifting capacity to safely handle unit weight. Consult the unit’s as-built submittal drawings for unit weight data.

WARNING: If welding on chiller water connections, use proper electrical grounding to avoid damaging the compressors or chiller controls.

Never weld directly on the heat exchanger shells. Only an authorized ASME-certified repair agency may weld directly on ASME-certified shells. After welding, an “R” stamp is required.

CAUTION: Working with HVAC (heating, ventilating and air conditioning) equipment can be hazardous due to electricity, moving parts, chemicals, combustion and other hazards. Use safe work habits including proper tools and personal protective equipment. Understand and heed all safety information, installation guidelines and operation and maintenance procedures.

CAUTION: Pressurized application of cleaning substances or refrigerants must be done with the correct procedures to ensure the safety of technicians and others, and avoid property damage.

NOTE: Use correct tools for HVAC equipment installation, maintenance and adjustment. Use the correct tools to make tight connections without stripping threads or breaking screws and bolts. Use accurate refrigerant and electrical meters to properly maintain and diagnose HVAC equipment.

NOTE: Use proper personal protective equipment when working with HVAC equipment. For example, shoes and boots that protect ankles and feet, safety glasses for eye protection, and gloves to protect hands are common protective items for HVAC technicians. Injuries and accidents can be prevented or minimized by using appropriate protective equipment.

NOTE: Understand and pay attention to all safety information including all equipment manufacturer safety instructions, labels and signs.

Always follow original equipment manufacturer’s instructions, and local building codes and ordinances.

NOTE: Do not begin work until barricades, warning signs or other protective devices have been installed to isolate the work area from local traffic.

Specification 236422 - Page 38 of 159

Chiller Identification

Nameplate

Module nameplates are located on module high voltage panel door. Nameplates include model and serial number, refrigerant type and charge, electrical data and Multistack contact information for service parts and technical support.

Model Number Nomenclature

MS 050 X C or N 1 H 1 W 0 A A C -410A

Series1

Module Nominal Capacity (10 - 165 tons)

Compressor Type2

AHRI Certified (C - certified, N - Not certified)

Configuration3

Voltage (see voltage codes)

Module Number ( 1 - single, 2 - multiple)

Application4

AHRI Version - if applicable

Evaporator5

Condenser6

Refrigerant (410A, 134a, 407c)

Controller Option7

1 MS - Multistack (non - reversing valve), MR - Multistack Heat pump (w/ reversing valve) 2A - Copeland Scroll (ZR), B - Bristol, C: Trane Cornerstone, D-Copeland Digital Scroll, H - Hanbell screw, N - none, R - Bitzer Screw, S - Trane Scroll, T - Danfoss Turbocor, Z - Copeland scroll (old elec), X - Copeland Scroll (ZP) 3 1- Standard, 2- Total access, 3 - Evap extended headers, 4 - Cond extended headers, 5 - Both extended headers, 6-Outdoor, V - others 4 A - Air Cooled split, C - Single module temp controller, D - Cond unit, F - Fluid cooler (high temp),H - Heat recovery, R - Heat pump, W - Water cooled 5 A - Brazed SS, B - Brazed SMO, C- S&T copper, D - S&T cu-Ni, O - remote by others, R - remote by MS, V - Other 6 A - Brazed SS, B - Brazed SMO, C- S&T copper, D - S&T cu-Ni, E - Double wall brazed, O - remote by others, R - remote by MS, V - Other 7 F - FlexSys base, G - FlexSys with options, C - Carel, V - Other

C 575/3/60

E 380 - 415/3/50

F 380/3/60

H 460/3/60

V OTHER

A 70

B 80

C 90

D 100

E 110

F 125

G 150

H 175

I 200

J 225

K 250

L 300

M 350

N 400

O 450

P 500

Q 600

R 700

S 800

T 350/500

U 400/500

V 450/500

W 450/600

X 500/600

Amperage Codes/MOP Voltage Codes

Specification 236422 - Page 39 of 159

Typical Multistack chiller module shown with optional removable wheels and standard strainers installed.

Pallet #1 (Optional Cabinetry-not standard)

1. Top Front Panel

2. Bottom Front Panel

3. Rear Panel/End Panel

4. Side End Panel

5. Master Controller Top Panel

6. Frame Pieces

7. Frame Connectors, Fasteners, Clips & Magnetic Tape

Pallet #2 (Buss Connections)

8. Buss bar

9. Buss bar insulation

10. Ground strap

11. Junction Box leg

Installation

For best performance, reliability and chiller life, follow these installation instructions and guidelines. Be sure to observe all safety warnings and recommendations.

Shipping Information

NOTE: Before accepting delivery of the Multistack DHRC chiller modules, check for any visible damage including broken copper lines, oil leaks, damaged controls and/or electrical component housing, or any major component torn loose from its mounting.

If the DHRC chiller is damaged during transportation or handling by the transportation company or its agent, the installing contractor must promptly file a claim with the transportation company and advise Multistack. Any discrepancies must be noted on the bill of lading.

Specification 236422 - Page 40 of 159

Moving the Chiller Modules

Caution: Unit Top Heavy

Module on forklift. On pallet jack. On removable wheels.

WARNING: If lifting modules with a hoist, be sure to use lifting slings with lifting capacity to safely handle unit weight. Consult the unit’s as-built submittal drawings for unit weight data.

25 26

30 31

39 40

Pallet #3 (Piping & Electrical)

18. Master Control (*a)

19. Junction Box

20. Junction Box Cover

21. Sensors / Cables

22. Junction Box Connector (Throat)

23. Power Phase Monitor

24. Buss bar Connector

25. Power Phase Monitor Wire

26. Buss bar Insulation Overlap

27. Phase Monitor Wire

28. Buss bar End Caps

29. Drain Valves & Fittings

30. Module Joining Bolts

31. End Cap for DDRS-210A (upper)

32. End Caps (evaporator)

33. Couplings

34. DDRS-210A

35. Auto Solenoid for DDRS

36. Pipe Stubs

37. End Cap DDRS (lower)

38. Filter Stops

39. Pet Cock Valves

40. Drain Valves & Fittings

41. Sensor Wells

42. 30 Mesh Filter Strainer *a. Maybe shipped separately to sales office or job site.

*b. Shipped inside #19 - Junction Box

Specification 236422 - Page 41 of 159

Chiller Location, Dimensions and Clearances

Recommended clearance values for the modular chiller.

NOTE: There must be a minimum of six inches of clearance over the top ofchiller which includes the top of the master controller if installed on top of the chiller.

Determine piping location before chiller modules are set in place.

Specification 236422 - Page 42 of 159 susanw Rectangle

Installation Site Preparation

Recommended Water Piping Arrangement

All piping must be properly and adequately supported at coupling connections and other suitable intervals along the piping runs. Hanger design must provide for the weight of fluids in the piping system when the chiller is in operation.

MULTISTACK modules are equipped with brazed plate heat exchangers made of 316 stainless steel. MULTISTACK recommends a 1/8-inch basket “Y” type or similar system strainer. MULTISTACK supplies a serviceable 30 mesh strainer in each condenser and evaporator inlet header.

It is the contractor’s responsibility to make sure water systems are flushed and strainers are clean and clear of debris before starting the chiller.

Flushing should be done separately and not through the chiller.

Water Piping System Flushing Procedure

Before connecting the chiller to the condenser and chilled water loop, piping loops shall be flushed with detergent and hot water (110- 130 degrees F) mixture to remove previously accumulated dirt and organic residue. After removing residue, continue flushing with a dilute phosphoric, sulfamic or citric acid and water mixture to remove scale in the pipe. Cleaning chemicals such as Nu-Calgon “Imperial Grade” Scale Remover (Part no. 4360-84) or equivalent suitable for both organic residue and scale removal may be substituted. Otherwise detergents and acids shall not be combined unless approved by the chemical manufacturers.) Only chemicals compatible with 316 stainless steel, copper and carbon steel shall be used. Any concentrations of hydrochloric or sulfuric acid or chloride containing chemicals shall not be allowed to come in contact with copper brazed 316 stainless steel heat exchangers.

During flushing, 30 mesh (max.) Y-strainers (or acceptable equivalent) shall be in place in the system piping and examined periodically as needed to remove residue. The flushing process will require at least six hours or until the strainers are clean. Old water systems with heavy encrustation need to be flushed for at least 24 hours and may require as much as 48 hours before the filters run clean. Detergent and acid concentrations must be in strict accordance with the respective manufacturer’s instructions. After flushing with detergent and/or dilute acid concentrations, the water system must be purged with clean water for at least one hour to ensure that all residual cleaning chemicals are flushed out.

Before supplying water to the chiller, consult the Water Treatment Specifications on Page __ for water quality requirements during chiller operation.

Chilled Water, Condenser Water Connections

Chilled and condenser water connections are standard six-inch grooved fittings. On the evaporator side, the upper header is entering chilled water to the module; the bottom header is chilled water leaving the module. The condenser side is the opposite: Water enters at the bottom and exits on top.