APPENDIX B - Fenton Courthouse - Multitask Chiller O M Manual~1.pdf

MASSACHUSETTS TRIAL COURT | REGION 3 CHILLER

SERVICE AGREEMENT

Region 3 Chiller Service Agreement RFP | Page 12 of 30

COMMONWEALTH OF MASSACHUSETTS

MASSACHUSETTS TRIAL COURT

REQUEST FOR PROPOSALS

Region 3 Chiller and Associated HVAC Equipment Preventive Maintenance and Repair Service Agreement

APPENDIX B

Fenton Courthouse - Multistack Chiller O&M Manual

This appendix is incorporated by reference into the Region 3 Chiller Service Agreement Request for Proposals.

Facilities Management & Capital Planning

Modular Water-Cooled Chillers

Installation, Operation, Maintenance

MS010XC, MS015XC, MS020XC, MS030XC,

MS040XC, MS050XC, MS070XC, MS085XC

Standard and Total Access™ Modules

Contents

Safety Information Nameplate and Model Number Nomenclature Chiller Arrangement and Components, Standard and Total Access™ Modules...............................................................5-7 General Data Shipping Information..........................................................................................................................................................................9-10 Clearances and Dimensions............................................................................................................................................................11-16 Piping, Flow Protection Pressure Relief Piping, Water Treatment Specifications, Pipe Flushing Module Assembly, Standard Modules........................................................................................................................................19-21 Module Assembly, Total Access™ Modules Multiflush Assembly, Leak Testing Electrical Installation, Wiring, Electrical Data............................................................................................................................24-28 Frame and Enclosure Panel Installation Installation Checklist Start-Up Data Log...............................................................................................................................................................................31-32 Operation...............................................................................................................................................................................................33-34 Maintenance.........................................................................................................................................................................................34-36 Troubleshooting Daily Log................................................................................................................................................................................................38-39

This Multistack installation and operation manual will assist in the proper installation and operation of Multistack modular chillers. Review this manual carefully.

• The information and illustrations contained in this manual are generalized. Consult with a Multistack representative to address specific installation and operating details not covered in this manual.

to the Multistack Service Department at: (608) 366-2400 or via e-mail to info@multistack.com

Planning Ahead To ensure all warranties and a successful installation, a Factory Authorized Technician is required to perform start-up of the Multistack Chiller. If start-up is to be performed directly by Multistack, a minimum of two weeks notice is required. Please call the Multistack Service Department at (608) 366-2400 to schedule.

Multistack has a policy of continual improvement and reserves the right to change product design, literature and specifications without notice.

© 2016 Multistack

This manual provides information on the proper installation, operation and maintenance requirements for Multistack water-cooled modular chillers. Follow these instructions to help ensure that the chiller performs properly. Failure to follow these in-structions can significantly affect the chiller’s performance and reliability and may adversely affect the equipment warranty.

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 weld-ing, an “R” stamp is required.

CAUTION: Working with HVAC 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 strip-ping threads or breaking screws and bolts. Use accurate refrigerant and electrical meters to properly maintain and diagnose HVAC equipment.

MS 050 X C or N 2 H 1 W 0 A A -410A

Series Module Nominal Capacity (10 - 160 tons)

Compressor Type1

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

Configuration2

Voltage3

Module Number ( 1 - single, 2 - multiple) Application4

AHRI Version - if applicable Evaporator5

Condenser6

Refrigerant

1 B: Bristol, C: Trane Cornerstone, R: Bitzer Screw, S: Trane Scroll, T: Danfoss Turbocor, Z: Copeland scroll (old elec), X: Copeland Scroll (ZP), A: Copeland Scroll (ZR) 2 1- Standard, 2- Total Access, 3 - Evap extended headers, 4 - Cond extended headers, 5 - Both extended headers, V - others 3 A - 208/3/60, L - 230/3/60, H - 460/3/60, C - 575/3/60, D - 200/3/50, E - 400/3/50, F - 380/3/60, S - 220/230/1/60, V - other 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, V - Other 6 A - Brazed SS, B - Brazed SMO, C- S&T copper, D - S&T cu-Ni, E - Double wall brazed, V - Other

Model Number Nomenclature

Unit Nameplate The chiller nameplate is located on the front of the control panel.

Use the unit model number nomenclature to identify specific features and options of an Multistack chiller module.

Multistack Water-Cooled Modular Chillers Multistack invented the modular chiller. Multistack modular chillers are available in a wide range of capacities, and with two independent scroll compressors. Modules can be mix-matched and combined to create up to 15-module arrays and 1,275 tons of cooling capacity using environmentally friendly R-410A. Multistack modular chillers can help owners qualify for USGBC LEED points and significant utility rebates. Multistack’s innovative modular design makes adding more capacity as easy as purchasing and installing more modules.

Total Access™ Modular Chillers With Total Access, heat exchangers are located on the outer edges of the chiller frame to provide easy serviceability with a small equip-ment room footprint. Total Access options include 10- through 85-ton modular chillers.

Unit Nameplate

High Pressure Transducer

High Voltage Panel

Isolation/Disconnect Switch

Buss Bar Duct

Entering Chilled Water Header

Leaving Chilled Water Header

Evaporator

Filter/Strainers

Leaving Condenser

Water Header

Entering Condenser

Water Header

Scroll Compressors

Condenser Expansion Valve

Liquid Line Sight Glass

Low Pressure Transducer

Low Voltage Panel

Standard Modular Chiller Arrangement

Total Access™ Modular Chiller Arrangement Multistack’s Total Access option makes maintenance and serviceability even easier by placing heat exchangers at the outside of the module frame. Manual isolation valves are factory-installed (Total Access units only) between the heat exchangers and water supply mains for heat exchanger isolation and removal without the need to remove a module or shut down the entire chiller while allowing access to all serviceable components.

High Voltage Panel

High Pressure Transducer

Evaporator

Expansion Valve

Low Voltage Panel Isolation/Disconnect

Switch

Buss Bar Duct

Condenser Filter/Strainers

Scroll Compressors

Low Pressure Transducer

Isolation Valve

Condenser

Chiller Components

Master Control Panel Each chiller has a master control panel that can be mounted on top of any of the module panels using provided knockouts. Sensors, cables and wiring connect through the bottom of the master control. The master control box includes built-in terminal strip inputs for flow switches, start/stop signal, alarm output, and power phase monitor. As shipped, the Master Control also contains the pLAN communication wire to be field installed by the start-up technician.

Four temperature sensors and sensor wells are supplied by Multistack: entering chilled water, leaving chilled water, entering condenser water, and leaving condenser water. The sensors are to be installed in customer’s piping system.

Module Control Boards and Low Voltage Panel The module control boards communicate individual module temperatures and pressures to the master control. Each module has a switch labeled Auto/ Off/ Manual. Normal operation is in the Auto mode. If there is a problem with the master control, the selector switch can be changed to Manual to provide individual module leaving chilled water temperature control that was pre-set at the master control.

Module High Voltage Panel The high voltage panel contains each compressor’s contactor, circuit breaker, control relay and transformer. External to the panel is the single-module isola-tion switch to isolate the that module from high voltage supply power.

Compressors, Sensors, Switches

• Standard modules use two scroll compressors with separate refrigeration circuits.

• Each refrigerant circuit has a high pressure (HP) and low pressure (LP) transducer that sends pressure signals to the module slave controller board. Each compressor also includes an HP switch with a manual reset button.

full during operation.

• Each circuit has its own leaving chilled water temperature sensor and refrigerant suction temperature sensor.

• Compressor crankcase heaters are not standard on Multistack MS chiller modules.

Chilled and Condenser Water Connections

• Water connections to the chilled and condenser side are standard 6-inch grooved pipes on MS010X through 070X, and 8-inch on MS085X units.

• The upper header on the chilled water side is entering water to the module.

mesh filter strainer to prevent debris from entering the brazed plate heat exchangers. This strainer should only be used as a final filter stage.

• Proper filtration before the module should be installed for easy access to cleaning, such as a ‘Y’ or a basket type of strainer.

High Voltage Panel

A Compressor Isolation Switch

Control Relay Transformer

High Voltage Circuit Breaker Control

Relay

B Compressor Isolation Switch

A Compressor Contactor

B Compressor Contactor

Single Circuit

Breaker

Master Controller

AUTO/OFF/MANUAL

Switch

Module Slave Controller

Low Voltage Terminal Strips

Low Voltage Circuit Breaker

Low Voltage Panel

Optional Manual Isolation Valves Standard modules are not supplied with isolation valves. Manual or electrically actuated valves may be ordered as an option from Multistack. Total Access modules are supplied with manual isolation valves from the factory and may be upgraded to electrically actuated valves as an option. Multistack recommends exercising the isolation valves as part of annual maintenance.

Optional Hot Gas Bypass As an option, hot gas bypass valves (Sporlan HGBE-8) can be provided for each circuit. The valve is adjustable from 75 to 150 psi with a standard setting of 120 psig. A screw on the pilot valve handles the adjustment. Turning clockwise increases the valve setting; counter-clockwise rotation decreases the valve setting.

Hot Gas Bypass Valve

Expansion Valves and Liquid Line Sight Glasses (Standard unit.)

Butterfly Valve Actuator for Variable Flow shown on standard module with extended headers.

Power Actuated Butterfly Valve

Expansion Valve, Subcooling, Liquid Line Sight Glass

• Each circuit on a module has a thermal expansion valve located between the water header pipes on the condenser side. During factory run testing the valves are adjusted to maintain 10-12 degrees superheat. Check the superheat periodically to maintain this range. Subcooling should normally be in a 10-15 degree range. No external subcooler is used.

• The liquid line sight glass shows green on the indicator bulb if no moisture is present in the refrigerant circuit. Yellow indicates potential moisture.

circuit.

• Refer to the unit nameplate for refrigerant charge information.

Variable Flow and Power Actuated Butterfly Valves For variable flow on the chilled or condenser water side, chiller mod-ules must be ordered with power actuated butterfly valves.

Note: The footprint of an array of standard modules will increase as the valves add length. Total Access™ module footprint will not change.

1. Multistack recommends controlling the chiller pumps to maintain pressure differential across the chiller, not the system. Control based on system pressure will provide erratic results.

2. Chiller minimum flow bypass for the system can be programmed in the master controller.

Heat Exchanger Isolation Valves on Total Access™ Modular Chiller

Expansion Valves

Sight Glasses

General Data Table

MS010X MS015X MS020X MS030X MS040X MS050X MS070X MS085X

Compressor Type Scroll

Dry Weight (lbs. each) 89 135 135 146 280 293 390 419

Normal Capacity (tons each) 5 7.5 10 15 20 25 30 40

Compressor Quantity/Module 2 2 2 2 2 2 2 2

Oil Charge (pints per compressor) 3.5 6.9 6.9 6.9 9.5 9.5 13.3 13.3

Evaporator (Brazed Plate) Brazed Plate

Weight (lbs.) 50 70 70 90 180 180 220 300

Water Storage (gal.) 1.0 1.6 1.6 2.2 5.5 5.5 7.3 10.1

Circuit Configuration Dual Dual Dual Dual Dual Dual Dual Dual

Quantity 1 1 1 1 1 1 1 1

Header System (gal.) 7 7 7 7 7 7 7 14

Condenser Brazed Plate

Weight (lbs. each) 50 80 80 100 200 200 290 340

Water Storage (gal.) 1.1 2.2 2.2 2.9 6.6 6.6 10.1 12.3

Circuit Configuration Dual Dual Dual Dual Dual Dual Dual Dual

Quantity 1 1 1 1 1 1 1 1

Header System (gal.) 7 7 7 7 7 7 7 14

Refrigerant Type R410A

Charge (lbs./circuit) 6.5 6.5 6.5 10 18 20 23 28

Number of Circuits 2 2 2 2 2 2 2 2

Total Water Volume - gal./module 16.1 17.8 17.8 19.1 26.1 26.1 31.4 50.3

Operating Weight (lbs.) 1,490 (1,620) 1,500 (1,630) 1,510 (1,640) 1,610 (1,740) 1,790 (1,920) 1,970 (2,100) 2,060 ( 2,210 ) 2,350 (2,680)

Shipping Weight (lbs.) 1,330 (1,470) 1,340 (1,480) 1,350 (1,490) 1,450 (1,590) 1,630 (1,770) 1,950 (1,990) 1,890 ( 2,060) 2,380 (2,630)

NOTES: Figures in parentheses ( ) apply to Total Access™ configuration chillers.

Add 75 lbs. per module if equipped with enclosure panels.

Multistack has a policy of continual improvement and reserves the right to change product design, literature and specifica-tions without notice.

Module Shipment Package

Pallet #1 — Typical Cabinetry Package (Optional)

Pallet #2 — Buss Connections

NOTE: Before accepting delivery of the Multistack chiller, check the overall condition of the equipment for damage such as broken copper lines, oil leaks, damaged controls and/or electrical component housing, or any major component torn loose from its mounting. If the Multistack modular chiller is damaged during shipping by the transportation company or its agent, the installing contractor MUST promptly file a claim with the transportation company and advise Multistack. Any discrepancy or damage must be noted on the bill of lading.

Multistack has a policy of continual improvement and reserves the right to change product design, literature and specifica-

Pallet #3 — Typical Piping & Electrical Package

* May be shipped separately to sales office or job site.

** Shipped inside #19 - Junction Box

25 26

30 31

39 40

Module on Fork Lift Module on Pallet Jack

Caution: Modules Are Top Heavy

Moving Chiller Modules

Multistack chiller modules MS010 through MS085 may be moved using a fork lift truck, pallet jack or similar equipment. Optional spreader bars for lifting and factory-installed wheels are available from Multistack. Contact your Multistack representative. For unit weights see the table on Page 8 and the job-specific as-built submittal drawings.

Multistack has a policy of continual improvement and reserves the right to change product design, literature and specifica-

Clearances Diagram shows typical dimensions and the recommended clearances around the modular chiller. There must be a minimum of six inches clearance over the top of the chiller, including the top of master controller if installed on top of the module.

For specific unit dimensions, refer to as-built submittal drawings.

St an da rd

M od ul es

(C on st an t F lo w D es ig

n) *S tan da rd ize d d raw ing of sa m ple cu sto m er ins tal lat ion

En clo su re pa ne ls are op tio na l

M od ul e

D im en si on s

(N o

Pa ne ls

W idt h (A

De pt h

(B

He igh t (C

St an da rd

5/8

To ta l A cc es s (

M S0

--0

To ta l A cc es s (

M S0

Ex te nd ed

H ea de rs

1/8

Ex te nd ed

H ea de rs

5/8

A

B

C

V ar ia bl e Fl ow D es ig n fo r C hi lle d an d

H ot

W at er St an da rd M od ul es w ith E xt en de d

H ea de rs o n

Ev ap or at or s an d

Co nd en se rs

M od ul e

D im en si on s

(N o

Pa ne ls

W idt h (A

De pt h

(B

He igh t (C

St an da rd

5/8

To ta l A cc es s (

M S0

--0

To ta l A cc es s (

M S0

Ex te nd ed

H ea de rs

1/8

Ex te nd ed

H ea de rs

5/8

*S tan da rd ize d d raw ing of sa m ple cu sto m er ins tal lat ion

En clo su re pa ne ls are op tio na l

A ar ia bl e Fl ow D es ig n fo r H ot

W at er , C on st an t F lo w fo r C hi lle d W at er

St an da rd

M od ul es w ith

E xt en de d H ea de rs o n Co nd en se rs

M od ul e

D im en si on s

(N o

Pa ne ls

W idt h (A

De pt h

(B

He igh t (C

St an da rd

5/8

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M S0

--0

To ta l A cc es s (

M S0

Ex te nd ed

H ea de rs

1/8

Ex te nd ed

H ea de rs

5/8

*S tan da rd ize d d raw ing of sa m ple cu sto m er ins tal lat ion

En clo su re pa ne ls are op tio na l

M od ul e

D im en si on s

(N o

Pa ne ls

W idt h (A

De pt h

(B

He igh t (C

St an da rd

5/8

To ta l A cc es s (

M S0

--0

To ta l A cc es s (

M S0

Ex te nd ed

H ea de rs

1/8

Ex te nd ed

H ea de rs

5/8

B

B

A ar ia bl e Fl ow D es ig n fo r C hi lle d

W at er , C on st an t F lo w fo r C on de ns er

W at er St an da rd M od ul es w ith E xt en de d

H ea de rs o n

Ev ap or at or s

M od ul e

D im en si on s

(N o

Pa ne ls

W idt h (A

De pt h

(B

He igh t (C

St an da rd

5/8

To ta l A cc es s (

M S0

--0

To ta l A cc es s (

M S0

Ex te nd ed

H ea de rs

1/8

Ex te nd ed

H ea de rs

5/8

B

*S tan da rd ize d d raw ing of sa m ple cu sto m er ins tal lat ion

En clo su re pa ne ls are op tio na l

C

To ta l A cc es s

M od ul es

W ith o r W ith ou t V ar ia bl e Fl ow

M od ul e

D im en si on s

(N o

Pa ne ls

W idt h (A

De pt h

(B

He igh t (C

St an da rd

5/8

To ta l A cc es s (

M S0

--0

To ta l A cc es s (

M S0

Ex te nd ed

H ea de rs

1/8

Ex te nd ed

H ea de rs

5/8

*S tan da rd ize d d raw ing of sa m ple cu sto m er ins tal lat ion

En clo su re pa ne ls are op tio na l

C

Recommended Piping All piping must be properly and adequately supported at coupling connections and 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 use of a 30-mesh system strainer, Y-type basket or equal, in each condenser and evaporator inlet header.

It is the installing contractor’s responsibility to make sure the water systems have been flushed and the strainers are clean and clear of debris before starting the chiller. Do not flush piping so as to push debris into or through the through the chiller heat exchangers.

Typical Sensor Wells

Important Be sure to install the supplied sensor wells in the system piping. The wells should be installed a few feet from the chiller in the entering and leaving chilled water and entering and leaving condenser water pipes.

Flow Protection Proof of chilled water and condenser water flow is required by the Master Controller inputs. Paddle-type or Differential Pressure (DP) switches may be used. Switches can be supplied by Multistack as an option, otherwise they are to be field supplied and installed. Chillers purchased with chilled or condenser water pump modules have a DP switch installed across the pump to verify operation. Multistack recommends a paddle-type switch be installed in the leaving chilled water piping using a differential pressure switch. Install it across the inlet and outlet water connections to the chilled and/or condenser water piping connections.

System Water Volume A properly sized chilled water system must have enough time (at least three minutes) to properly control and respond to changes in load and to prevent short cycling of the chiller. To ensure the system water volume is adequate, a general rule of thumb is:

7-10 gallons of water per ton or Acceptable Chilled Water Volume = Chilled Water Design GPM X 3

If the system heat exchangers, piping and components cannot hold the necessary chilled water volume, a properly sized chilled water storage tank should be added.

Condenser Water Temperature Control For installations where entering condenser water temperature could be lower than 65°F Multistack recommends installing a three-way tower bypass valve to maintain a minimum of 65°F entering condenser water temperature. This is based on a 10°F Delta-T system.

CONDENSER SIDE EVAPORATOR SIDE

Items in This Area Included with Chiller

To Cooling Tower or Fluid Cooler

Flow/DP Switch Isolation

Valves

Sensor Pockets, Sensors Supplied by Multistack, installed by others.

Pressure

Taps

Pressure Taps

Sensor Pockets, Sensors Supplied by Multistack, installed by others.

Isolation Valves

Flow/DP SwitchStrainer

Condenser Pump

3-Way Bypass Valve

CW In

CW Out

Strainer

Chilled Water Pump

CHW In

CHW Out

Pressure Taps

Pipe System Flushing Procedure Before connecting the chiller to the condenser and chilled water loop, the piping loops must be flushed with a detergent and hot water (110-130º F) mix-ture to remove any dirt and organic residue. After removing residue, continue flushing with a dilute phosphoric acid, sulfamic acid or citric acid and water mixture to remove inorganic scale in the pipe. Cleaning chemicals such as Nu-Calgon “Imperial Grade” Scale Remover part number 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).

Caution: The use of unapproved chemicals in the chilled or condenser water supplies may damage the heat exchangers. These chemicals in-clude, but are not limited to, hydrochloric acid, sulfuric acid, muriatic acid, and household bleach. Damage caused by the use of these and other unapproved chemicals is not covered by warranty. The only approved chemicals for heat exchanger cleaning are phosphoric or sulfamic acids in concentrations of 10 percent or less by volume. For more information contact your Multistack representative.

While flushing, 30-mesh Y-strainers (or equivalent) must be in place in the system piping and examined periodically as needed to remove collected residue.

The flushing process shall take no less than six hours, or until the strainers are clean after flushing. Old pipe systems with heavy encrustation shall be flushed a minimum of 24 hours and may require as much as 48 hours before the filters run clean. Detergent and acid concentrations shall be used in strict accordance with the respective chemical manufacturers instructions. After flushing with the detergent and/or dilute acid concentrations, the system loop shall be purged with clean water for at least an hour to flush out all residual cleaning chemicals.

Pressure Relief Piping and Refrigerant Monitoring Multistack chiller modules use a small refrigerant charge (typically 0.6 lbs. per ton) and are often exempt from many requirements of ASHRAE 15 Standard.

Pressure relief valves are not standard on water-cooled modules and must be special ordered if required by local codes.

Water Treatment / Specifications Supply water for both the chilled water and condenser water circuits must be analyzed and treated by a professional water treatment specialist familiar with the operating conditions and construction materials used in Multistack modular chiller heat exchangers, headers and associated piping. Water quality for modular chillers using 316 stainless steel brazed plate heat exchangers and carbon steel headers must be maintained within the following parameters:

Sulfates < 200 ppm

Module Assembly Multistack chiller modules and multiple module chiller arrays are designed to be mounted on steel rails.

1. Determine the entering and leaving evaporator and condenser connection arrangement before setting mounting rails and mod-ules modules in place. Connections may be at the same end or opposite ends, depending upon jobsite requirements.

2. Chiller modules are to be mounted on 4- x 4- x 4-inch steel rails or equivalent , 21 inches center-to-center.

3. Place 4- x 4- x 3/8-inch waffle type vibration pads every 22 inches under rails. 50 PSI maximum loading.

Note: Seismic restraint information available from Multistack.

Same End

Opposite End

Vibration Pads

4. Lubricate rails with vegetable shortening or other non-petroleum lubricant to facilitate installation.

5. Place first module on the rails. 6. Slide module into position.

7. Place subsequent modules onto rails. 8. Leave sufficient space between modules to install coupling gaskets.

9. Lubricate gaskets with solid vegetable shortening or other non-petroleum based lubricant.

10. Slide modules together lining up footing holes. Install bottom joining bolts.

11. Install top joining bolts.

12. Starting with the lower header, install pipe couplings. Position cou-pling bolts at one and seven o’clock positions as shown for proper frame installation. Note: Assure proper strainer placement.

13. If adjustment is needed when tightening bolts, loosen the center header bolt.

14. The grooved heat exchanger couplings may also be loosened if adjustment is required.

15. Install the header blank ends, starting at bottom, then move to the top blank that includes drain valves (evaporator shown).

16. Install filter stop rings on module closest to piping take-off. The 9-inch long pipe stubs supplied by Multistack are to be installed at the take-off ends of the chiller.

A

B

17. The 3/4-inch drain valve (A), should be located on bottom header and petcock valve (B) installed in each contractor pipe stub.

Module Assembly - Total Access™ Modules

Evaporator side view of Multistack Total Access™ modules. (Optional enclosure panels not shown.)

Multistack Total Access modular chillers are assembled into chiller arrays in the same manner as non-Total Access modules as shown on Pgs. 19-21.

Grooved flange water connections on Total Access chiller modules joined into a chiller array.

Condenser side view of Total Access chiller modules assem-bled into a chiller array. .

NOTE: See Pallet #3 for Multiflush components, Page 10.

1. Attach Multiflush pipe to module header pipe. 2. Insert 30-mesh filter into header.

3. Install large grooved pipe couplings. Leave loose - do not tighten. 4. Attach Multiflush pipe fittings using grooved couplings as shown.

5. Install manual or solenoid valve at end of Multiflush header.

6. Tighten all fittings.

Multiflush System Assembly The following procedure describes installation of the Multiflush automatic debris removal system. This system is used periodically to remove dirt and debris from the from the chiller heat exchangers.

Leak Testing

After all piping connections are complete, make a static leak pressure test and seal any leaks. When the leak test has proved satisfactory, start the chiller system pumps and purge any air from the system. Seal any remaining leaks before proceeding.

NOTE: Before leak testing make sure the four sensor wells have been installed.

Electrical Installation Field wiring must comply with all federal, state and local regulations. Circuit breakers, fuses, wiring and wire size must be installed per the National Electric Code (NEC). Voltage applied to Multistack chillers must be within plus/minus 10 percent of nameplate voltage. Voltage imbalance between phases may not exceed two percent. According to NEMA Standard MG-1-1998, a two percent voltage imbalance will cause a current imbalance of six to 10 times the voltage imbalance. Voltage imbalance between electrical phases must be kept to a minimum. Most Multistack chillers come with a single point of electrical connection (up to 500 amps) to simplify installation. The main electrical conduit feeding the power junction box may enter from either the top, bottom, or left side of the panel when facing the panel. Chillers requiring more than 500 amps will have multiple electrical connection points (per the 500 amp requirement).

Optional Single Module Field Connection For single module installations, the power junction box can be deleted, but a power phase monitor must be installed. The main electrical feed can connect directly to the module circuit breaker.

Junction Box Support Electrical Junction Box Junction Box Support Leg

1. Attach the electrical junction box support. Line up the orange posts to ensure support is not backwards. The threaded plate slides in between frame.

2. The electrical junction box may be installed on either end of the chiller module.

3. Remove cover plate on appropriate end of the junction box, then bolt junction box to the support.

4. Cut the junction box support leg to length and fasten to the bottom of box and then to the floor, if necessary.

5. Three-phase wire and the ground wire, sized according to the nameplate rating, should be run through the junction box.

Buss bar Installation

NOTE: Contact the local Multistack representative before installing the buss bar. Depending on the start-up representative’s policy, the attachment of the buss bar system, and power phase monitor to the electrician’s wire and lugs may be the responsibility of the electrician or the Multistack autho-rized start-up technician.

1. Remove the buss duct covers. 2. Remove the isolation switch cover

NOTE: There is a dedicated chiller ground in this panel that must connect to a true earth ground.

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

3. Install the three buss bar connector wires to the isolation switch at each module. The wires are shipped with each module.

4. Remove the orange insulation and install the buss bar for Line 3 (back). Connect lug for Line 3 on each module.

5. After connecting the Line 3 lugs for all modules, cut the orange insulation to fit between the lugs. Install the lug cover and snap the buss bar into the plastic holders.

6. Single-phase power for the modules should be taken off two lines of the buss bar. Multistack recommends using Lines 1 and 3.

7. Follow the procedure in Step 5 to complete installation of Lines 1 and 2.

8. Follow the procedure in Step 5 to complete installation of Lines 1 and 2.

9. With all three lines installed, use the provided overlap pieces to cover any open buss bar areas.

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 National Electric Code (NEC) and all applicable state/local codes.

10. The ground bar must be drilled, then attached to the module ground lug.

11. Reinstall the buss duct and isolation switch covers. Install the main power connectors as shown.

NOTE: IT IS THE ELECTRICIAN’S RESPONSIBILITY TO CONNECT

MAIN POWER TO THIS CONNECTOR.

12. Install the power phase monitor as shown. When correctly installed the lettering on the power phase monitor is inverted.

Wires are run to the normally open contact of the power phase monitor and connect to the master control.

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/tagouts.

Module wiring connections to the power junction box must be completed by a qualified electrician.

NOTE: Be sure to replace all protective covers after completing wiring connections.

On water cooled chillers with single point power, optional wire whips may be ordered and substituted for the standard buss bar. The conduit, wiring and junction box are shipped as part of the loose parts package. The wire and conduit are then connected to the junction box as the modules are installed. Each wire and circuit breaker is marked for correct connection.

Single Point Power

Each wire and circuit breaker is marked for correct connection.

Typical Interconnecting Wiring. Consult the Specific, As-Built Submittal Wiring Diagrams

Multistack has a policy of continual improvement and reserves the right to change product design, literature and specifica-tions without notice.

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/tagouts.

VOLTAGE 208 230 460 575

MS010X* 13.1/136 11.8/136 5.9/66.1 4.7/55.3

MS015X 24.8/240 22.4/240 11.9/130 9.1/93.7

MS020X 28.1/240 25.4/240 13.9/140 10.7/107.6

MS030X 49.8/340 45.0/340 22.5/173 18.0/132

MS040X 54.0/538 49.0/538 23.5/229 19.5/180

MS050X 67.0/605 60.0/605 30.0/272 24.0/215

MS070X 89.0/599 80.0/599 40.0/310 32.0/239

MS085X 112.8/943 102.0/943 51.0/408 37.6/375

MCA 3 CONDUCTORS

1 CONDUIT

6 CONDUCTORS

2 CONDUIT

50 8 — 65 6 — 85 4 — 100 3 — 115 2 — 130 1 — 150 1/0 — 175 2/0 — 200 3/0 — 230 4/0 —

255 250 MCM —

285 300 MCM 1/0

300 — 1/0 350 — 2/0 400 — 3/0 460 — 4/0

500 — 250 MCM

System Wire & Fuse Sizing Specifications Compressor Rated Load Amps (RLA) and Locked Rotor Amps (LRA) Data

Standard and Total Access™ Modules

RLA/LRA

MF= (2.25 x RLA1*) + RLA2 + RLA3 Where MF does not equal a standard size fuse, the next larger size fuse should be used.

NOTES:

A. *RLA1 = RLA of the largest compressor in the system. RLA2 & RLA3 = RLA of the other compres-sors in the system.

wires per conduit.

D. Wiring distance from branch circuit shall not exceed 100 feet.

* MS010X units are also available for single-phase power (230/1/60 ) applications and have an RLA of 19.5 amps and LRA of 178 amps.

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/tagouts.

(Applicable codes may require different wire sizing)

Frame & Panel Installation Attachment of the optional enclosure panels is the responsibility of the Multistack authorized start-up technician. Typical installation is shown.

1. Install panel clips and spindle posts on the outside four corners of module frame.

2. Attach panel supports on outside of end modules. 3. Attach front frame section on module (33-1⁄8 -inch pieces on bottom). Use “T” connectors in front middle. The four corner connectors go on top, front and rear.

4. Install two long frames over spindle posts vertically in rear (buss bar side). Attach top frames to corner joints (use special frames with seven holes for end modules only). At-tach 20-inch horizontal frames, two in front, one in rear.

5. Once the frame is assembled, attach the black fasteners and magnetic tape (or Velcro™ strips) to front of support panels.

6. With the first module frame and panels complete, install the additional enclosures.

INSTALLATION CHECKLIST & REQUEST FOR AUTHORIZED START-UP ENGINEER

CUSTOMER: _ _______________________________________

JOB NAME: _________________________________________

JOB LOCATION: _ _____________________________________

CUSTOMER ORDER NO.: _ ________________________________

CHILLED WATER Yes No N/A Piping complete and connected to Multistack Units. q q q Water system filled and vented. q q q Pumps installed (Rotation checked). q q q Recommended strainers installed. q q q Controls (3-way valves & by-pass valves, etc.) operable. q q q Water system operated and flow balanced to meet unit design requirements. q q q Strainers checked for unusual debris. q q q Flow or differential pressure switch installed. q q q

CONDENSER WATER Yes No N/A Piping complete and connected to Multistack Units. q q q Cooling tower flushed, filled and vented. q q q Pumps installed (Rotation checked). q q q Recommended strainers installed. q q q Controls (3-way valves and by-pass valves, etc.) operable. q q q Cooling tower fans wired and operable. q q q Condenser water system operated. q q q Condenser & evaporator strainers must be checked, cleaned and free of debris. q q q Flow or differential pressure switch installed. q q q

ELECTRICAL Yes No N/A Power wiring complete and in accordance with nameplate rating on Multistack unit and prepared for connec-tion in accordance with installation manual.

q q q

NOTE: No power is to be applied to unit prior to inspection by Multistack engineer.

All interlock wiring complete between control panel and complies with Multistack specifications and with applicable codes.

q q q

MISCELLANEOUS Yes No N/A Thermometer wells, thermometer gauges, control, etc. installed. q q q A minimum system load of 50% of total building load is available for testing and adjusting controls.

q q q

We understand that authorized representatives of the installing electrical and piping contractor must be available during the start-up period and that coordination is our responsibility.

We further understand that the services of Multistack Authorized Start-up Engineer will be furnished for a period of not more than sixteen (16) consecutive normal working hours and we agree that a charge for time and expenses will be made by Multistack if services are required for longer than sixteen (16) consecutive normal working hours or if repeat calls are required through no fault of Multistack.

Signed Title

Company Name, Company Location and Company Telephone

Job Location Telephone

START-UP DATA LOG

START-UP DATE:________________________________ SHIP DATE:_ _____________________________ JOB NAME:__________________________________JOB NUMBER:_ _____________________________

ADDRESS:_________________________________________________________________

MULTISTACK REPRESENTATIVE:_ ____________________________________________________

MODEL NUMBER:_ ____________________________________________________________

MODULE SERIAL NUMBERS

If yes, detail:_ ________________________________________

5. Flow or differential switches installed: CHILLED:_____ CONDENSER:_____

ELECTRICAL AND CONTROLS CHECKLIST

Start-up Service Technician Owner or Contractor Acceptance

DESIGN PARAMETERS

Start-Up Data Log, Cont’d

MODULE

CURRENT TEMPERATURE

HP LP

A B C Suct LoChw SYS LCHW ECHW

A B

A B

A B

A B

A B

A B

A B

A B

A B

A B

A B

A B

Actual Setpoints

*PC0 Program Version_ _________________ (Go to main menu screens then push PRG & UP but-tons)

Measured Readings

Factory Setup

1. Program Type___________________

2. Chiller Type_ ___________________

3. Refrigerant_ ___________________

4. Flow Faults: CHW_________________

CW__________________

5. Circuit Type_ ___________________

6. Variable Flow___________________

A. Valve Display_ ________________

B. CHW Output__________________

C. CHW Bypass__________________

D. CHW Min Output_ ______________

E. CW Output___________________

F. CW Bypass___________________

G. CW Set point_________________

H. CW Min Output_ _______________

I. CW PID_____________________

J. CHW PID_ ___________________

Operation The Multistack chiller provides chilled water to an external load, based on return water temperature to the Multistack Master Control. When the entering chilled water temperature sensor sends a signal to the master controller that cooling is needed, compressors will start and begin to produce chilled water.

A compressor start is determined by the entering chilled water (ECHW) upper set point and the variable set point setting in the Master Control System Variables menu. When the ECHW sensor senses that the chilled water temperature has dropped below the set point, compressors will begin to cycle off.

Chiller modules equipped with modulating butterfly valves on the chilled water side are controlled from the leaving chilled water set point (lower set point) in the System Variables menu. The module slave board(s) send a 2-10 VDC output to each actuator to modulate the water valve to maintain lower set point.

When a module is not running, valves close to prevent bypassing water at the operating chiller modules.

For variable flow applications one or more valves may remain open at all times to provide minimum flow through the chiller. The valve that stays open will always be the lead compressor for that day, eliminating the need for an external bypass installed at the chiller. If modulating butterfly valves are used on the condenser side of each module, the valves will control to a discharge pressure setting selected from the Factory Setup menu. This is also a 2-10 VDC output each module board sends to the valve actuator. If the condenser pump cycles off while no modules are running, minimum flow doesn’t need to be considered. If the condenser pump runs at minimum flow, the condenser bypass should be enabled in the Factory Setup menu.

Sequence of Operation, Leaving Chilled Water Temperature Control The Multistack chiller is equipped with a microprocessor based supply water temperature controller.