Sep-16-05 08:32am From- T-616 P.DU2/DID F-891

ENGINEERING BULLETIN

OPERATION & MAINTENANCE

JOB NAME: HAT CREEK RADIO OBSERVA-TORYHAT CREEK, CAFOR: PO# PTS 066988

Model PCP-1 00-1 OA-WP-HA-SSC-LAC-HGBP-CTC

Serial No. 6406/95

Sep-16-D5 08:32am From7

.,'iltri lie MmmfacturingIS Kit Street

Kcent', NH 03431Pbone: (}(}3.352-5500

F~IX:hO~.]''i2-(HJO

T-618 P.DOI/OID F-89\

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Sep-lii-05 08:33am' Frcm- 1-61B P.003/010 F-S91

INSTALLA110N INS1'RUCllONS ."Ol{MODEI.J PCP.l00..10A- WIJ..HA-SSC-IJAC-HGBP..C1~C

Serial No. 6406/95

A. PCP.CLOSED LOOP CHI LLJt:RS: PCP I.:hillers are de-sig.ned to pump a coolant (water or waterand ethylene glycol solution) from the cooling tank through a dosed cooling loop Zlnd buck to thecooling lank. The cooling L,mi.:is IIsually not under pressure.

J. Open fil I port Oll'lOp of cabi net and air vent.2. Make pi umbing connc<.~ti()nsto pipe connechons ulgged 'Discharge' and 'Return'. Coolanl

flow will be out or the' Discharge' connection.3. FiJI up cooling tmk through fill port u~ing a hose ('II'bucket and funnel. Fillunlil coolanl is

visible at least 3/4 of the way up the liquid level sight glass.

4. If recirculating pump is supplied with a bleed plug in pump housing, loosen plug umil water

begins to dripollt, then retig.hten.5. Check all piping for 1Ci:1ksand m.lkc repairs necessary.o. Close air vent and replace plug in rill porI.7. After all electricalconnecNmsarc made, turn on pump and pump liquid through complete

cooling loop.8. Tum off' pump.<). Open air vent and fill port.

10. Add more liqujd<ISnecessaryto rill sight gi<.lSS.11. Close air vent and fill pon.'12. Check conlant level periodically by shuuing 011pump and thcnnpcning air vent. Add more

coolant "'" necessary.

B. OPERATIl\G PRESSURES: Your Filtrinc chiller is set at the factory lO operate at the followingfreon pressure:

OpcratinlZ Pressure IU2 ,',

Compr~~ssorDiscllargt~ I~O.35e

Compressor Sut.:tioTl

*'" SUI~!eClIO ti I11Cdelay pmgl1ll11 mcnu,

PressuJ'(;~switch seHings ilrc dependent upon application ot' equipment

C. OIYfIONS: This dullcr js supplied \Vilh the following oplions. Be slire 10 understand hm\! thechiller funclions before operating.

,WP- WCt:llher-ProorJLow-AmbienlConlrols - Weatherproof' Je~ign protect!) s\viwhes, mnl()p;,controls from direct exposure Inclcmcntsandallows outdoor installatiDIl.

Cut In RZZ Cut Out 22

HighPres."{\ltGIiI 275 350-I .IIW PIISS.

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I(pump down!15

-'IAWll'ress(snfety) I "':< I 35-45 J

Sep-IS-05 Q8:33am. Frcrn- 1-618 P.004/Jl0 F-8~1

HA - I..flghambient Condenser ~ OvcIsjl'.cd t:om.lenser lo permil c()rnpreS~ollo run at norlllal headand suction pressures in high ambient conditions. I

Stainless Steel Cabinet- Cabinet and frame constructed throug.hout of stainlcs.. steel.

LAC-LOW AMBIENT CONTROL-- The chiller is outhltcd with a refrigerant side head pres!;tife

control 80 that the chiller will rur.cliofl satisfactorily during periods of low ambient, temperature.

This headpressure control is a nOJ1~adjuslabJe,scalell valve that will maintain a nearly U'lllstan~rc('civerpressurefor normalsystemoperation.

The valve has three connectil)nS on 1t-- (J) hot gas; (2) liquid drain from (;ondenscr~ (3) lCl.'civ(~r.

During periods of low ambient iempemture, the receivcr pressure falls until it approache~ the controlpoint of the ambient' control. At thIs tllTle.the valvc starf£ to throttle; restri<:l1ngthe liquid now from

the condenser, causin~ liquid refrigcrant to back up in the condenser, thus reducing the acu"e con-denser surface. This will raIse the ~()ndenser pres~urc. At the same time the other side {)f the valvewill start to bypass hot gas to the re.~dvcr. The bypui>s hot gas mixes with the cold liquid from thecondenser, \l/ani1tng il.up andrnaking sure.there is sufficientpressure in the receiver for properexpansion valve.operation. As long as r.hereis suffidcnt rerrigerant charge in the system, the ambi-eni control will UlItOlllllticallymodulale. the rcfrigerantl10w to maim..linproper receiver pres:;.ure,regardless of outside temperature.

Sufficient ~harge of refligeram means Ihallherc must be t~nough liquid rcfligemm in the rccc!vcrJuring lowestamhient conditions,to maintaina liquidseal for the liquid line. II' there is tun liulerefrigerant and there is no liquid seal, thcn hot gascan cnter the liquid line and the cxpan..jol1valveand cooling \\'ill stop.The hot gase.ntetingthe evaporalor,through the expansionvalve. will actuallycalise Ihew..lterin the.lank to heat up.

Bectluse it may be difficult to teli by looking at.the site glass whether it is full of liquid or JUS!hot!~as.a few other things should te checked to make sure that it is liquid:(1) Suctjon and head pressureswill be h'!Wwith high superheat.(2) Check outlet of t"xpa!1~ionvalve. If it is hot, there there is hot gas in the liquid line amI the char/,!cislnw.

If the compressor is allowed In fun under ulow charge condition wIth tlw ambient conlrol. ir ..;anbe:seriousl y damagcJ.

If there has been a loss of refrigeram. it ISbetter to com plctel y emply lhe charge and recharge lOtheoriginal amounl on the nameplate of the chiller.

The charge is very clitical. Too mu<.:hI.:hargeand the refrigeranl wilJ back up int.o the ~onJens{.r.causing high pre~suJ'c In high ambient conditions. Too Jilllc refngerant and the chiller and the chinerwon't operate properly in low ambient condiLi()n~.

The chiller also utilizes a lime delay low prc\;surc operating control. This pressure t:ontwl has a 90second'delay nil funcLJon.This is done to eliminate8hol1cyclingon low pressureon stan-up during

low ambienls. The pressurecontrol keeps Lh(~compressor running for 90 seconds before trippin~ oul

Sep-16-05 08:34am From- 1-618 P.005/010 F-891

to help the build system up toopcraling pressure.

HOT GAS BYPASS OPERATION

The hot gas bypass option is designed to help the chillcr maintain dose temperature I..:ofitrul\Vilholltshol1-cycling the compressor. .

Sequence or Operation

I. Pump mllst be running - intcrJol.:kcdwith refrigeration. '

2. Set thesctpoinl thermostatat the desired tClilpcrature.

3. Set the low temperature culoutlhemloslat a few dc!:!reeslower than the sctpoint. The low tCIlI-

perature cutout thermostat is in serie~with the setpoim thennostat. so it must be calling for coolingbefore the system can run.

4. When the water temperature ISabove [he setpoint, the chiller will be fully loaded and cooling.When the water temperature reaches sctpoint, the sc~p()intthermostat will open up. de-cncrgil.in.g theliquid line solenoid and causing the suction pressure to drop. As the pressure drops, the hot gaspressure regulator will open and ~tart passing hot gas into the liquid sidc of the evaporaror. ThiSpressure wili be regulated at apprnxlITlBtely15.20 psi lower than the norm..1suction pressure at thetemperature being maintained. The hot gas gives the cOInpressor a false load and can a~tuaJly warmthe watcr temperature back up. When the \,:ater temperature rises above the setpoint. rhe liquid lincsolenoid is n>energizcd. allowing the flow of liquid rcfJigcrant to enter the cvaporntor. This causesthe.suction pre.ssllfc to rise whkh closes the hot gas regulator. putting the chiller into its coolingmod(.~agaill.

5. If under low load conditions the tcmperatnre continues to Jrop bcluw the sctp()int C'ie!1 whii<.~the

chiller is hot gassing. the low tempcnlture thermostat will de-energize the hot ga, solenoid as \-vellasthe liquid lme solenoid. Thi~ will cause the unit to pump down and turn oil untillhc temperature. .nses agmn.

crc- CloseTemperatureControl: This oplion is designed to allow i.hechiller to maintain a smnllerthan nonmtltemperature. differential without short-cycling the compressor. It involves the addition{?fa solid state tempcnllure controller rated typically ilt :!:.5°Fand a hot gas bypass solenoid.

Set the solid state temperature controller <ltthe desired outlet water temperature. When the walertemperature exceeds this set pOlllt, the compressor will operate at full capacity to bril)g the tempera-ture down. When Ihe set point is reached. the controller \"ill opcl1thc hot gas solenoid valvc whichallows hot refrigcmnt gu.c;; to bypass the condenser.This in effect unloads the refrigcmtion withoutturning niT the c()mpres~.~l1r.

There is also a low tempera{ure Ihcrmostat (usually mounted inside the cabmet) which should be setabollt 5° lower than the "ct rOlllt ,:onlrollcr. If under no-loud conditions, the tempcrature dropsbelow the desired seLpoint eventhough thechiller is in hot gasbypass. the. low temperature thenno-stat will shUt the compressor niT \lotil the load increases. raising the waicr temperature.

Sep-IG-05 08:35am From- T-618 P.OOE/OIO F-g91

PART NUMBER

I68-M06/95-* AlIhJi1KUk cxp~H1sionvalvc176-64<.)6/95.%Therrlli)stat

196-0406/95-*Compn:ssor starting rclHY224-6406/95-* Fan m(Hor (air cooled models)

233-6406/95-*ComplCssor overload

The above spare parts arc the major ~omponcnts for your chiller. Those with suffix .."'"urc recolll-

mended to be kept in stock at all limes.

E. Engillec.'ingBulletin: Atutc.:hcdis engineering bulletin 1'\>1'your lype of chiller.

F. Wiring Diagl"am: Attachedis the wiring diagram for YOllrchiller, please notify factory .1'this is notenclosed.

G. Refrigel"ation/Plumbing Schematic: Attached is the refrigeration/plumbing schcmatic for yuurchiller, please notify Jaclory it' this is not enclosed.

H. Chiller Wa'Tanty Form - Be sure to have a qualif'ieJ rcfrigcral10n mechanic complete and n:~turnone copy LoHllrinc. Start-up by anyonemhcr t.hana qualified rerrigerationmcchaniL~will voidwarranty.

I. Chiller 'I\~stRepOI.t-AvailabJc upon request.

J. Selected Maintenance Manuals

1. Compres::;or Manuai - Copeland KAR 1-0 HX)-TAC2. Pump Manual - O&L 1ST

Sep-16-05U8:35amFram- T-61B p.007/alO F-S9l

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Sep-16-05 08:36am Fram-

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FILTRINE MfG. CO.Halrisville. NH 03450

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HAT CREEK RADIO OBSERVATORY, HAT CREEK, CA; FOR: PO# PTS066988

811 6406/95

Sep-16-05 08:37am

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06(,9:98

S# 6406/95

REFRIGERATION SYSTEM - THEORY OF OPERATION

A refrigeration system is a closed loop circuit in which a fluid. the refrigerant.is caused to absorb heat at the point where cooling is desired, and to release

heat at some other point enabling re-use of the refrigerant.

The process depends upon the property of fluids known as latent heat of vapor-

ization. If a fluid changes from the liquid to the vapor state. it must absorbheat in order to maintain its original temperature. If the needed heat is not

available at the point of vaporization. there will be ~ substantial drop in the

temperature of the vaporized fluid. The process may be reversed by increasing

the pressure of the vapor. This causes the temperature to rise and if heat is

allowed to dissipate from the system, the vapor will return to the liquid state.

Starting with the compressor, the refrigerant, Freon R-12, is pumped to a

pressure. The compression of the gas causes a sharp rise in temperature.

properly operating system, only gaseous refrigerant is pumped through theressor.

higherIn acomp-

The hot. high pressure gas, passing through the condenser, a heat exchanger, iscooled, causing it to condense to liquid. Fans draw air over the condenser

coils to speed heat removal.

The high pressure liquid collects in the receiver tank which also traps any re-

maining gas. The trapped gas condenses as it cools further, thus no gas accumu-

lation occurs. High pressure liquid leaving the receiver passes through a drier

cartridge which removes any water that may be trapped in the refrigerant system.

It then passes through a sight glass which includes an indicator

excessive water contamination of the refrigerant. The indicator

in color. If it is yellow, the refrigerant is contaminated with

quires service by an experienced refrigeration technician.

used to detect

should be. greenwater and re-

The sight glass also indicates insufficient freon charge. When the compressor

is operating, the sight glass. should be completely filled with clear liquid.

After the compressor has been running for a short time. however, a small amount

of bubbling is normal. Foaming indicates the presence of oil in the refrigerant.

Both of these conditions require service by an experienced refrigeration techni-cian.

From the sight glass. the liquid freon passes through an anti-migration solenoid

valve. This valve closes whenever the compressor shuts off. Its purpose is to

prevent liquid freon from filling the low pressure portion of the refrigerationcircuit during compressor off-periods. Without this valve, heat from the atmos-

phere would cause expansion of the gas in the receiver tank and resulting flow

of liquid freon through the system to the compressor inlet. Pumping of liquid bythe compressor is harmful and must be prevented.

From the solenoid valve. the liquid freon passes to a thermostatically controlled

expansion valve. This valve is controlled by a temperature sensing bulb fastened

to the evaporator. It opens on demand when the evaporator temperature rises above

a preset temperature. causing the high pressure liquid to flow into an area of low

pressure. resulting in immediate vaporization of most of the liquid and a sharpdrop in refrigerant temperature.

Modulation of the expansion valve by the evaporator temperature sensing bulb

assures that excessive refrigerant will not flow into the evaporator coils.

The pressure in these coils is thereby kept at a relatively low value so that

the refrigerant in this area remains primarily in the gaseous state.

The cold refrigerant gas in the evaporator coils removes heat from the chiller

water reservoir before passing out of the evaporator. This is, of course, the

ultimate purpose of the machine. The low pressure gas is then passed through

a filter to remove any particulate contaminants before returning to the comp-ressor inlet.