MODEL ACWC-SC Screw Type

AIR COOLED PACKAGED CHILLERS

SERVICE MANUAL I & 0 6500A

INSTALLATION, OPERATION &

MAINTENANCE INSTRUCTIONS TABLE OF CONTENTS

DESCRIPTION PAGE NO.

Inspection & Handling ........................................................................................... 2 Location & Mounting . ....... ... ...... ............................................... ................... . ..... .... 2 Wiring .............................................................................................................. 2 Chiller Piping ..................................................................................................... 2 Start-Up ........................................................................................................ 2 & 3 Maintenance .... . .... . ....... ..... ........... . ........ . ............. ... .... .... ........ .. ......................... 3 Slide Valve Unloading System .................................................................................. 4 Low Ambient Operation ......................................................................................... 5 Control Settings .................................................................................................. 5 Unit Operating Limitations ...................................................................................... 5 Sequence of Operation ...................................................................................... 6 & 7

Models ACWC-160SC Thru 200SC Sequence of Operation ...................................................................................... 8 & 9

Model ACWC-215SC Control Wiring Diagram .................................................................................. 10 & 11

Models ACWC-160SC Thru 200SC Control Wiring Diagram .................................................................................... 12-15

Model ACWC-215SC Power Wiring Diagram ............. .... . . .. ... . . ... .... .. ..... . ... .. .... .. ....... ...................... . ........ 16

Across-The-Line Start Power Wiring Diagram .......................................................................................... 17

Star-Delta Electrical Data ................................................................................................... 18 Cooler Pressure Drops .......................................................................................... 18 Unit Loading/Suspension Points .............................................................................. 18 Troubleshooting Guide .... .. ........... .... ........... ... .......... . ........... ..... ..... .. .... ... ............ . 19 Causes & Prevention of Freeze-Up ............................................................................ 19 Start-Up Check List ..................................... . ..... .. .. ... . .......................................... 20 Operating Data ... ..... ........... .... . ... .... ..... .. ................ . ...... ........................... ... ...... .. 20

BOHN HEAT TRANSFER A Gulf+Western Company

Danville, Illinois 61832•{217)446-371 0

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INSPECTION & HANDLING When unit is received, it should be checked for visible or concealed damage. If damage has occurred it should be reported to the carrier imme diately .o.nd clo.im filed .

Models ACWC 160SC thru 215SC are factory mounted on two (2) permanent angle beam, carbon steel skids. Eight (8) 2W' lifting eyes are provided in the skids to allow rigging. Spreader bars must be used between rigging lines to prevent damage to the unit. Rollers may be used under the skids to facilitate moving the unit a short distance. Physical damage to the unit, after acceptance, Is not the responsibility of the factory.

LOCATION & MOUNTING Model ACWC Air Cooled Packaged Water Chillers are designed for outdoor application and may be mounted on roof or at ground level. Air flow through the condenser is vertical and the unit may be located adjacent to outside of building or on roof without regard for prevailing wind direction.

Since these units are air cooled, the flow of air to and from the condenser coil must not be impeded. There must be no obstruction above the unit that would tend to deflect discharge air downward where it could be recirculated back to the inlet of the unit. The required overhead air space should be a minimum of eight (8) feet. Ductwork must not be applied to the fan outlets.

The unit must be installed with sufficient clearance for air entrance to the condenser coil and for servicing access. The unit should be located no closer than four (4) feet from any wall or other obstruction. Clearance must be provided at either end of the unit to permit removal of tubes from the chiller.

Unit must be set on a solid and level foundation .

On roof installations the unit should be mounted on support beams which span load-bearing walls to prevent excessive vibration .

On ground level installations, the unit should be mounted on a substantial base that will not settle . A one-piece concrete slab with footings extended below the frost line is recommended. A space should be left between the slab and the building to prevent the transmission of sound and vibration .

Vibration mounts may be used for roof mounted units or other locations where noise might be objectionable.

WIRING A unit wiring diagram showing the required power supply character­istics and all factory supplied wiring details is provided with unit. Separate, field supplied, disconnects must be installed in the power supply and should be within the sight of the unit.

Separate 115 volt power source must be field supplied to provide power for control and heater circuits.

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CHILLER PIPING The chiller inlet (return) water pipe should be connected to the water connection closest to the control panel end of the unit and the outlet (:.upply) vvdte• 1-'ifJt:: <..v""""'t"'u tv u,., wat.,r <,;urrrr.,<,;llun on the opposite end of the cooler(s) .

A flow switch must be installed in a straight horizontal section of the chilled water piping.

Gauges should be installed in the piping to and from the chiller to measure the pressure drop and to insure the proper (GPM) flow rate in accordance with submittal data. A strainer should be installed in the piping on the inlet side of the chiller and vibration eliminators should be employed on both the inlet and outlet pipes . Air vents should be located at all high points in the piping system . Vents should be located to be accessible to servicing . Drain connections should be provided at all low points to permit complete drainage of chiller and piping system.

The chilled water piping should be insulated to reduce heat pickup and to prevent condensation . If the system is for year-round operation or if it will not be drained in the winter, the chilled water piping should be protected against freezing by electric heating cable or other suitable means.

Upon completion of chiller piping, start the system water pump and purge air from the system . Air purging should be done from the high points in the water circuit. Purging of the chiller barrel may be accomplished through the vent pipe located on the top of the chiller compartment. Failure to purge air from the water circuit will result in inadequate waterflow and may cause the unit to cutout on low water flow freeze protection.

START-UP Refer to start, test, and check list included with this manual.

Check all electrical and mechanical connections for shipping looseness and tighten all screws on electrical terminals.

Activate the 115 volt chiller and crankcase heater circuit 24 hours prior to unit start-up.

Rotate each fan prior to start-up. Fans should turn freely. Check belt tension and pulley alignment. After two (2) weeks of operation, readjust belt tension to accommodate for belt stretching.

Check all control settings as specified in Table 1.

Check the compressor oil level through the crankcase sight glass. The oil level should be to the top of the glass. If the level is low, add oil in accordance with the directions in the maintenance instruction (page 3) .

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. CAUTION: The discharge line valve must be open before starting the compres­sor. Liquid line valves must also be open for sustained operation . All compressors are soli a mountea on 1sopads, therefore, compressor hold-down bolts must not be loosened . Loosening these bolts will cause excessive vibration of the compressor and may result in refrigerant line breakage. Prior to start-up check all compressor hold-down bolts for t ightness.

MAINTENANCE CONDENSER Units equipped with belt drive fans have inherently protected motors. Fan belts , fan bearings and motor bearings require periodic maintenance as follows:

1. Fan Belts -After two (2) weeks operat ion , the belts wi ll have nearly reached their permanent stretch , therefore, each belt should be checked again and proper adjustments made. To maintain good fan and motor operation , the belt tension should be checked at three (3) month intervals.

2. Fan Bearings- Each fan shaft is provided with ball bearings of the relubricatable type. Each bearing is provided with grease fittings, accessible through the individual motor access panels . It is recommended the bearings be greased by adding 4 to 5 shots with a hand gun . The suggested greasing interval is indicated on a sticker attached to the unit.

3. Motor Bearings- Each motor is equipped with ball bearings. Ball bearings consume a very small amount of lubricant, but enough must be present at all time to prevent motor injury. The length of time a bearing can run without having grease added or replaced will depend upon the operating conditions . Under normal operating conditions, the motor bearings should be lubricated at 2000 hour operating intervals . The lubricant should be from a clean closed container and should be an anti-friction type bearing grease-free from solid fillers or other harmful ingredients. Lubricant should have a safe operating temperature of 2000° F.

The air inlet of the condenser coil should be kept clean through a regular preventative maintenance program .

COMPRESSOR 1. OIL LEVEL - The oil level in the compressor(s) should be

checked periodically, with the compressor either running or stopped . If the oil level is below one-half ( '12 ) the sight glass, oil must be added.

Oil should be added only with the compressor shut off. To do so, turn the return water thermostat (T1) to a higher temperature setting , and wait for the unit to pumpdown and shutoff. Place the system "ON-OFF" switch in the "OFF" position . Close the line valve in the discharge line between compressor and condenser.

Refrigerant pressure inside of the compressor will now be approximately 80 to 90 PSI G. The low pressure cut-out setting is 35 PSIG, but the residual discharge pressure (upstream of the discharge check valve) will equalize back into the suction side after the compressor stops.

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Locate the discharge pressure port adjacent to solenoid valve UL-3 (see drawing below) ; remove the cap and release the residual pressure by pushing in on the pressure port fitting itself. Pump oil into this flU' t u11til u,., uil level Is to the tOP Of the sight glass.

Replace the discharge port cap. Re-open the discharge line valve. Do not allow compressor to run with discharge valve closed. Place the system "ON-OFF" switch in the "ON" position . Using a jumper wire, make a "short" for five (5) seconds between terminal #4 on terminal block TER5 and the switched terminal of a solenoid valve feeding the circuit you have just "blown" (e .g . terminal #121 on TER4 to energize SOL 1 ). Reset return water thermostat (~1) to the operat ional temperature setting and allow unit to return to normal operation .

2. RECOMMENDED OIL- The unit is factory-charged with BOHN SR-30 refrigeration oil.

Do not add any other type of oil to this factory charge.

Do not operate compressor If oil level is below one-half ('h) sight glass. If the oil level is below the minimum specified above, and BOHN SR-30 is not on hand, you may drain the entire factory oil charge, then refill with SUN ISO 4GS refrigeration oil. The factory (BOHN) oi l is of the synthetic type and will not mix with SUN ISO 4GS. Do not attempt to operate the screw compressor with any oil other than these two specified above.

It is suggested that a gallon or more of BOHN SR-30 oil be obtained and kept on hand at the job site. The substitution of SUNISO 4GS oil, as outlined above, will result in a 2% to 4% capacity loss, and no reduction in input K.W.

3. COMPRESSOR REPAIRS (Internal) - Contact factory or an authorized BOHN Service Agency if a compressor malfunction is suspected .

4. COMPRESSOR REPAIRS (External) - Proper operation of unloaded start , loading, and unloading is controlled by solenoid valves UL-1 , UL-2 and UL-3. Any of these three (3) solenoid valves may be repaired or replaced in the field , as required .

HIGH PRESSURE PORT

SLIDE VALVE UNLOADING SYSTEM

1 ne tlonn screw compressor capacity control system for infinite modulation consists of a slide valve and hydraulic piston/ cylinder operator internal to the compressor; plus three hydraulic solenoid valves (UL-1, UL-2 & UL-3) piped externally.

The slide valve forms a portion of the chamber wall in which the rotors turn; thus, its position with respect to the rotors determines the effective rotor length and thereby the percent of full load capacity.

Upon compressor start-up, UL-3 is opened. This allows oil pressure to act upon the hydraulic piston, holding it in the fully unloaded position . After 30 seconds, during which time full oil flow is established to all bearings surfaces, UL-3 is closed . At this point, the temperature controller is free to open and close UL-1 or UL-2 in response to the supply water temperature.

The slide valve will move to the left (loading) by force of discharge pressure, whenever UL-1 opens to permit flow to the oil return (low

Load Unload

¢::J c::> Oil Pressure

Slide Valve

Oil Pressure Lines

Screw Rotor

pressure) line. The slide valve will move to the right (unloading) whenever UL-2 opens the oil supply (high pressure) line, since the force of the oil exceeds that of the discharge gas.

The temperature controller sends a series of power (energizing) " pulses" to the appropriate solenoid to adjust to load conditions. The further the supply water temperature is from the controller set point, the longer is the duration of the pulses. The series of pulses will continue until the controller is satisfied. As the water temperature approaches the set point, the pulses become quite brief to prevent overshooting the set point.

This method of compressor unloading in conjunction with supply water sensing minimizes action/ reaction lag time and overshoot resulting in an exceptionally precise and stable control of supply water temperature.

UL-1

Oil Return

Hydraulic Piston

Oil Supply

Vent to

Suction

The following table lists solenoid valve position for all three operating modes.

UL-1 UL-2 UL-3 Starting Close Close Open

Loading Open Close Close

Unloading Close Open Close

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LOW AMBIENT OPERATION Due to the wide range of applications, it is sometimes necessary to operate the Air Cooled Packaged Water Chillers at ambients below summer conditions. Without proper control, when ambients drop below 60° F. the pressure differential between the condenser and the evaporator is below the level to insure proper thermal expansion valve operation . As a result, the unit may cycle on low pressure control with the possibility of evaporator freezing. Three types of system control are available allowing the units to operate at the ambients indicated:

FAN CYCLING MEDIUM AMBIENT CONTROL TO 30° F.

(STANDARD EQUIPMENT -FACTORY INSTALLED)

A fan cycling control is standard on all Air Cooled Packaged Water Chillers to prov1de proper operating head pressures, in ambient conditions to 30° F.

This is an automatic operation in which the condenser fans are cycled on and off, as required, in response to head pressure. With two compressors running , three fans are cycled (in sequence) on five-fan units; four fans on six-fan units; and five fans on seven-fan units. With one compressor running, all but the lead fan are cycled in sequence, in response to head pressure.

This arrangement provides positive start-up control down to +30° F. by delaying the condenser fan operation until a predetermined head pressure is obtained.

GRAVITY (Discharge) DAMPERS LOW AMBIENT CONTROL TO oo F.

(OPTIONAL EQUIPMENT- FACTORY INSTALLED)

All condenser fans are equipped with gravity dampers mounted on the fan discharge to minimize the effect of prevailing winds; and to prevent convection drafts up through the condenser coil in still air.

All compressors are enclosed in individual insulated housings. An auxiliary heater is included to supplement the standard crankcase heater; the temperature within the compressor compartment is thermostatically controlled .

The standard condenser fan cycling package, operating in con­junction with the discharge dampers, will maintain suitable head pressure down to oo F. ambient. A 90-second time delay relay provides an electrical bypass around the low pressure freezestat to prevent nuisance tnp-out during cold start-up.

ACWC-SC CONTROL SETTINGS

PRESSURE ACTUATED LEGEND FACTORY SETTING High Pressure Control HP-1 Cut-In 300 PISG (Manual Reset) HP2 & HP3 Cut-Out 365 PSIG Pumpdown Control PD1 Cut-In 55 PSIG (Auto Reset) PD2 & PD3 Cut-Out 35 PSIG Fan Cycling Pressure Control 2 Fan Cell Cut-In (PSIG) Cut-Out (Adjustable) FCP 1 280 170

FCP 2 295 180 3 Fan Cell

FCP 1 260 160 FCP 2 275 175 FCP 3 290 215

4 Fan Cell FCP 1 260 160 FCP 2 275 175 FCP3 285 210 FCP4 295 235

Low Pressure Freeze Control LPF 1 Cut-Out 54 PSIG (Manual Reset)

--LPF 2 & LPF-3

TEMPERATURE ACTUATED LEGEND FACTORY SETTING

Chiller Low Water Temperature Thermostat T2 Cut-Out 37° F.

Chiller Water Cycling Thermostat (Adjustable) T1 Dial Set At 55° F.

Chiller Heater Thermostat Included With Cut- In 40° F. (Non-Adjustable CBH1 Heater Cut-Out 45° F.

Oil Temperature Safety Control OTS 1 (Adjustable) OTS 2 Cut-Out 240° F. Manual Reset OTS3 Capacity Control Thermostat (Adj.) Mode Control Position T3 Dial Set At 44° F.

UNIT OPERATING LIMITATIONS 1. Maximum ambient air to condenser is 115° F. (60 Hertz operation). 2. Maximum allowable cooler water pressure is 150 PSI G. 3. Maximum allowable water temperature to cooler is 75° F. 4. Units must not have leaving water temperatures of 42° F. or lower unless used with a glycol solution. 5. Unit must be allowed to pumpdown at the end of each operating cycle (except on safety control shutdown).

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KEY TO WIRING DIAGRAM INDEXING SYSTEM The wiring diagrams and sequence instructions on the following pages have been devised to simplify the understanding and tracing of circuit theory. The following key shows how the indexing system can be used.

12 Line number on wiring diagram

[12] Line number in text

(RS) Component identification symbol in text (Relay #5)

~ Normally open contact- line number location

~ Normally closed contact- line number location

@ Holding coil - line number location

& Note number

EXAMPLE

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SEQUENCE OF OPERATION MODELS ACWC 160 To 200 SC

The following sequence of operation is typical for the ACWC 160 to 200 SC (see Pages 10 and 11 for typical wiring diagram). Refer to the wiring diagram furnished with unit for specific information.

Control Identification Symbol

Circuit Line Number

Important Notel The compressor crankcase heater must be energized and remain active for a minimum fa 24 hours prior to unit start-up.

PRELIMINARY SEQUENCE

Place control circuit "ON-OFF" switches (SW1 thru SW4) in the "OFF" position, and set the staging thermostat (T1) to its highest temperature.

Activate the 115 volt electrical service to terminals #2 and #4 [1 and 3] on terminal board (TEAS) to distribute power to the control circuit up to the control circuit switches. Crankcase heater relay contacts (R19) (3]. (R20) [5]. and (R21) [7] are closed and are supplying power to the compressor crankcase heaters. Power is also supplied to the chiller barrel heater (CBH1) (11]. the receiver heaters (RH1, 2, 3) (8, 9, 1 0] (optional), and the low ambient crankcase heaters (SCH1, 2, 3) [3, 5, 7] (optional).

Close the main power disconnect switch. Check to see that the red indicating light on the phase loss monitor (PLM1) is lit (NOTE: There will be two phase loss monitors, (PLM1) and (PLM2), on 208-230 volt models). This light must be on to indicate proper phase rotation for the compressor(s) . If the light is not on, the main control circuit to the compressors will not be energized. Reverse any two phase legs at the Main Incoming Power Terminal Block. DO NOT reverse the leads on the phase loss monitor, for this will allow the compressor to run backwards, causing severe damage, and WILL VOID THE COMPRESSOR WARRANTEE!

Start-up the chilled water pump. The water flow is confirmed when the water flow switch completes an electrical circuit across terminals #12 (58] and #13 [60] of terminal board (TEAS). Terminals #14 [61]

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~ See Note Number 3

The holding coil for the first contact shown on this line (reading from left to right) can be found on line #44; the holding coil for the second contact can be

found on line #74.

The contacts for the holding coil shown on this line can be found on lines 66, 23, and 54. The contact on line 23 is normally closed .

This is the number which identifies the line of wiring shown at the left.

and #15 [63] provide an interlock for the water pump starter(s); either contact (R14). (R16), or (R18) [62] will close any time a compressor is running.

Set the staging thermostat (T1) to the design range of operation (e.g . 54° F. return water) . Set the capacity control thermostat (T3) to the design range of operation (e.g. 44° F. supply water) .

Place the four (4) control circuit switches (SW1-SW4) in the "ON" position , thus energizing the balance of the control circuit. The system will be In the "Time-In" mode for five minutes before any compressor will start.

STAGE 1 LOADING Upon demand for cooling, the first step of the staging thermostat (T1) will close, energizing relay (TD10) (63] and staging relay (R1) [62]. closing (R1) contacts 7-4 [22]. 8-5 [25]. and 9-6 (16] . If the safety controls and switches are closed, the control circuit [16] for compressor No.1 and liquid line solenoid (SOL 1) (25] will energize, allowing the compressor to start. Fan contactor (C13) (21] will also close, bringing power to the line side of fan cycling pressure controls (FCP1) and (FCP2) (see Power Wiring Diagram- Pages 16 and 17). Fan motor #1 will start as soon as the head pressure reaches the "cut-in" setting of (FCP1 ).

NOTE: ALL FAN MOTORS ARE CONTROLELD BY THEIR OWN FAN CYCLING CONTROL AND WILL CUT IN AT

DIFFERENT HEAD PRESSURES.

Relay (R19) [20] contact 7-1 [3] opens, de-energizing compressor#1 crankcase heater(s). Relay (R14) (19] contact 8-5 (24] closes, energizing (TD7) [23]. This will force compressor #1 to run for five minutes. COMPRESSOR #2 CANNOT BE STARTED UNTIL (TD7) TIMES OUT.

Time delay relay (TD1 0) [63] contact C-NC (26] holds the compressor in an unloaded condition for 30 seconds. When relay (TD10) times out, it will energize relay (R4) [27]. closing contacts 9-6 [71] and 7-4 [74] . This allows the capacity control thermostat (T3) to energize solenoid valve (UL 1-1) [71]. loading the compressor; or to energize solenoid valve (UL2-1) [74]. unloading the compressor.

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Relay (R14) (19] contact 7-4 [62] closes, which completes the interlock circuit for the water circulating pump.

~TAGE! Z LOADINu

Upon a further increase in return water temperature, the second step of the staging thermostat (T1) will close. If the lock-out timer (TD5) and the lock-in timer (TD7) [64] have timed out, relays (R2) [64] and (TD11) [65] will be energized, closing (R2) contacts 9-6 [32]. 8-5 [40]. and 7-4 [37]. If the safety controls and switches are closed, the control circuit [32] for compressor #2 and liquid line solenoid (SOL2) [ 40] will energize, allowing the compressor to start.

Relay (R20) [36] contact 7-1 [5] opens, de-energizing crankcase heater(s). Contact 9-6 [44] closes, energizing fan contactor (C14) (44]. bringing power to the line side of the balance of the fan cycling pressure controls (see power wiring diagrams) . Fan motor #3 will start as soon as the head pressure reaches the "cut-in" setting of (FCP3) .

Relay (R16) [35] contact 8-5 [39] closes , energizing (TD8) (38]. This will force compressor #2 to run for five minutes. Compressor #3 cannot be started until (TDS) times out.

Time delay relay (TD11) [65] contact C-NC (41] holds compressor#2 in an unloaded condition for 30 seconds. When (TD11) times out, it will energize (R5) (42]. closing contacts 9-6 (72] and 7-4 (75] . This allows the capacity control thermostat (T3) to energize solenoid valve (UL 1-2) [72]. loading the compressor; or to energize solenoid valve (UL2-2) [75]. unloading the compressor.

STAGE 3 LOADING Upon a further increase in return water temperature, the third step of the staging thermostat (T1) will close. If the lock-out timer (TD6) and the lock-in timer (TD8) (66] have timed out , relays (R3) (66]. (R7) (68]. and (TD12) [67] will be energized . Relay (R3) contacts 9-6 [48]. 7-4 [53]. and 8-5 [56] close. If the safety controls and switches are closed, the control circuit [ 48] for compressor #3 and liquid line solenoid (SOL3) [56] will energize, allowing the compressor to start.

Relay (R21) [52] energizes , opening contact 7-1 [7], de-energizing compressor #3 crankcase heater(s). Relay (R18) (51] contact 8-5 [55] closes, energizing (TD9) [54] . This will force compressor #3 to run for five minutes.

Relay (R7) contact 9-6 [70] closes, energizing solenoid valve (UL 1-1). thus locking compressor #1 in the fully loaded position. Relay (R7) contacts 8-2 [71] and 7-1 [74] open to disconnect the capacity control thermostat (T3) from compressor #1 capacity control solenoid valves.

Time delay relay (TD12) [67] contact C-NC [57] holds compressor #3 in an unloaded condition for 30 seconds. When (TD12) times out, it will energize relay (R6) [58]. closing contacts 9-6 [73] and 7-4 [76]. This allows the capacity control thermostat (T3) to energize solenoid valve (UL 1-3) [73]. loading the compressor; or to energize solenoid valve (UL2-3) [76]. unloading the compressor.

Compressor #1 is fully loaded.

Compressors #2 and #3 are being capacity-modulated.

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PUMPDOWN SEQUENCE STAGE 3 PUMPDOWN A dccrca:>e in return water temperature will t;iiU>Se the third step or the staging thermostat (T1) to open, thereby de-energizing staging relay (R3) , opening contacts 8-5, 9-6, and 7-4. Liquid line solenoid (SOL3) will de-energize, stopping the flow of refrigerant to chiller circuit #3. The compressor will continue to run until the chiller circuit has been cleared of refrigerant and the suction pressure is approximately 35 PSIG. Low pressure control (LP3) contact will then open, de-energizing compressor contactors (C5) (49] and (C6) [50]. stopping compressor #3; and de-energizing relays (R18) and (R21 ). Relay (R18) N.C. (normally closed) contact 2-8 (54] energizes lock-out timer (TD6). preventing compressor #3 re-start for . five minutes. Relay (R21) energizes the compressor crankcase heater(s).

Staging thermostat (T1) also de-energizes relay (R7). opening contact 9-6, releasing compressor #1 from continuous full-load operation. Relay (R7) contacts 8-2 and 7-1 close, allowing the capacity control thermostat (T3) to operate capacity control solenoid valves (UL1-1) and (UL2-1) as required .

STAGE 2 PUMPDOWN A further decrease in return water temperature will de-energize staging relay (R2), closing liquid line solenoid (SOL2) . When chiller circuit #2 has pumped out, low pressure control (LP2) opens, stopping compressor #2; and de-energizing relays (R16) and (R20) . Relay (R16) N.C. contact (8-2) [38] energizes lock-out timer (TD5), preventing compressor #2 re-start for five minutes. Relay (R20) (36] energizes compressor#2 crankcase heater(s); and also de-energizes fan contactor (C14) (44]. stopping the fan motor(s) servicing the two-circuit condenser slab.

STAGE 1 PUMPDOWN Step 1 of the staging thermostat (T1) will open when the return water temperature is reduced to the set point . This de-energizes staging relay (R1 ), closing liquid line solenoid (SOL 1 ), stopping refrigerant flow to chiller circuit #1. Compressor#1 continues to run until chiller circuit #1 pressure is down to the low pressure control (LP1) set point. The (LP1) contact opens, de-energizing compressor contac­tors (C1) (17]. (C2) (18], and fan contactor (C13) [21]. stopping compressor #1 and the remaining fan motor(s).

Relay (R14) N.C. contact 8-2 (23] energizes lock-out timer (TD4), preventing compressor #1 re-start for five minutes; relay (R14) contact 7-4 (62] opens, removing the circulating pump starter interlock . Relay (R19) de-energizes, closing contacts 7-1 [3]. energizing compressor #1 crankcase heater(s) .

SAFETY CONTROLS Each refrigerant circuit is protected by seven standard safety controls, and one optional safety control.

1. High Pressure (HP) 2. Low Pressure Freeze (LPF) 3. High Discharge Temperature (OTS) 4. Low Oil Temperature (LOT) 5. Compressor Solid State Module (CSTM) 6. Low Water Temperature (T2) 7. Low Pressure (LP) 8. Compressor Starter Overloads (OLH) (Optional)

If any of these devices should open due to abnormal conditions, the compressor will automatically stop. All controls must be manually reset , except Low Oil Temperature (LOT), Low Pressure (LP) and Compressor Solid State Module (CSTM), which resets itself after a two minute bleed-down period. The compressor motor windings are also equipped with a thermal protector, automatic reset , which is not shown on the wiring diagram.

SEQUENCE OF OPERATION MODEL ACWC 215 SC

The following sequence of operation is typical for the ACWC 215 SC (see pages 12 to 15 for typical wiring diagram). Refer to the wiring diagram furnished with un it for specific information.

( ) Control Identification Symbol

[ ] Circuit Line Number

Important Notel The compressor crankcase heater must be energized and remain active a minimum of 24 hours prior to unit start.

PRELIMINARY SEQUENCE Place control circuit " ON-OFF" switches (SW1 thru SW5) in the " OFF" position , and set the staging thermostat (T1 ) to its highest temperature.

Activate the 115 volt electrical service to terminals #2 and #4 [ 1 and 3] on terminal board (TER5) to distribute power to the control circu it up to the control c ircuit switches. Crankcase heater relays (R20) [3], (R21) (5], (R22) [8], and (R23) (10] are closed and are supp ly ing power to the compressor crankcase heaters. Power is also supplied to the chiller barrel heaters (CBH1) [17] and (CBH2) [20], the receiver heaters (RH1 , 2, 3, 4) (12, 13, 15, 16] (optional) , and the low ambient crankcase heaters (SCH1 , 2, 3, 4) [3, 5, 8, 1 0] (optional) .

Close the main power disconnect switch. Check to see that the red indicating lights on the phase loss monitors (PLM1 ) and (PLM2) are lit. These lights must be on to indicate proper phase rotation for the compressor(s). If the lights are not on , the main control circuit to the compressors will not be energized. Reverse any two phase legs at the main Incoming power terminal block. DO NOT reverse the leads of the phase loss monitor, fo r this wi ll allow the compressor to run backwards, causing seve re damage , and WILL VOID THE COMPRESSOR WARRANTEE!

Start-up the chilled water pump. The water flow is confirmed when the waterflow switch completes an electrical circuit across terminals #12 [89] and #13 [91] of terminal board (TER5) . Terminals #14 [92] and #15 (94] provide an interlock for the water pump starter(s) ; either contact (R11 ), (R12) , (R13) , or (R14) [95] will close any time a compressor is running .

Set the staging thermostat (T1) to the design range of operation (e.g. 54° F. return water). Set the capacity control thermostat (T3) to the design range of operation (e.g . 44° F. supply water) .

Place the five control circuit switches (SW1 thru SW5) in the " ON" position , thus energizing the balance of the control circuit. The system will be in the "time-In" mode for five minutes before any compressor will start.

STAGE 1 LOADING Upon demand for cooling , the first step of the staging thermostat (T1) will close, energizing relay (TD15) [94] and staging relay (R1) (93], closing (R1) contacts 7-4 [32], 8-5 [35], and 9-6 [26] . If the safety controls and switches are closed , the control circuit [26] for compressor #1 and liquid line solenoid (SOL 1) (35] will energize, allowing the compressor to start.

Relay (R20) (30] contact 9-6 (39] closes, energizing fan contactor (C13) (39], bringing power to the line side of fan cycling pressure controls (FCP1) thru (FCP6) (see Power Wiring Wiring Diagram on Pages 16 and 17) . Fan motor #1 will start as soon as the head pressure reaches the "cut-in " setting of (FCP1 ).

NOTE: ALL FAN MOTORS ARE CONTROLLED BY THEIR OWN FAN CYCLING CONTROL AND WILL CUT IN AT

DIFFERENT HEAD PRESSURES.

Relay (R20) contact 7-1 (3] opens, de-energizing compressor #1 crankcase heater(s) . Relay (R11) [29] contact 8-5 [34] closes , energizing (TD9) [33]. This will force compressor #1 to run for five minutes. COMPRESSOR #3 (Stage 2) CANNOT BE STARTED UNTIL (TD9) TIMES OUT.

Time delay relay (TD15) ]94] contact C-NC [36] holds the compressor in an unloaded condition for 30 seconds. When relay (TD15) times out, it will energize relay (R5) (37], closing contacts 9-6 [1 06] and 7-4 (112]. This allows the capacity control thermostat (T3) to energize solenoid valve (UL 1-1) [1 06], loading the compressor; or to energize

solenoid valve (UL2-1) [1 12], unloading the compressor. Relay (R11 ) [29] contact 7-4 [95] closes , wh ich completes the interlock circuit for the water c irculating pump.

STAGING 2 LOADING Upon a further increase in return water temperature, the second step of the staging thermostat (T1) will close. If the lock-in timer (TD9) [95] and lock-out timer (TD7) [95] have timed out , relays (R2) [95] and (TD16) [96] will be energized, closing (R2) contacts 9-6 [62], 7-4 (67], and 8-5 [70] . If the safety controls and switches are closed , the control circuit [62] for compressor #3 and liquid line solenoid (SOL3) [70] will energize, allowing the compressorto start.

Relay (R22) [66] contact 7-1 [8] opens, de-energizing crankcase heater(s). Contact 9-6 [74] closes , energizing fan contactor (C14) [74], bringing power to the line side of fan cycling pressure controls (FCP7) thru (FCP12) (see power wiring diagrams) . Fan motor#4 will start as soon as the head pressure reaches the "cut-in " setting of (FCP7) .

Relay (R13) [65] contact 8-5 [69] closes, energizing (TD11) [68] . This will fo rce compressor #3 to run fo r five minutes. Compressor#2 cannot be started until TD11) times out.

Time delay relay (TD16) [96] contact C-NC [71] holds compressor #3 in an unloaded condition for 30 seconds. When (TD16) times out, it will energize (R7) [72], closing contacts 9-6 [1 08] and 7-4 [113] . This allows the capacity control thermostat (T3) to energize solenoid valve (UL 1-3) [108], loading the compressor; or to energize solenoid valve (UL2-3) [113], unloading the compressor.

STAGE 3 LOADING Upon a further increase in return water temperature, the th ird step of the staging thermostat (T1) will close. If lock-in timer (TD11) and lock-out timer (TD6) [66] have timed out, relays (R3) [97], (R9) [99], and (TD17) (98] wil l be energized. Relay (R3) contacts 9-6 [45], 8-5 and 7-4 [50] close . If the safety controls and switches are closed , the control circuit [45] for compressor #2 and liquid line solenoid (SOL2) [53] will energize, allowing the compressor to start.

Relay (R21) [49] energizes , opening contact 7-1 [5], de-energizing compressor #2 crankcase heater(s) . Relay (R12) [48] contact 8-5 [52] closes , energizing (TD1 0) [51] . This will force compressor#2 to run for f ive minutes. Compressor #4 cannot be started until (TD10) times out.

Relay (R9) contact 9-6 [1 05] closes, energizing solenoid valve (UL 1-1), thus locking compressor #1 in the fully loaded position . Relay (R9) contacts 8-2 [106] and 7-1 [112] open to disconnect the capacity control thermostat (T3) from compressor #1 capacity control solenoid valves.

Time delay relay (TD17) [98] contact [54] holds compressor#2 in an unloaded condition for 30 seconds. When (TD17) times out, it will energize relay (R6) [55], closing contacts 9-6 [109] and 7-4 [114] . This allows the capacity control thermostat (T3) to energize solenoid valve (UL 1·2) (1 09], load ing the compressor; or to energize solenoid valve (UL2-2) (114], unloading the compressor.

Compressor #1 is full loaded.

Compressors #2 and #3 are being capacity-modulated .

STAGE 4 LOADING Upon a further increase in return water temperature, the fourth step of the staging thermostat (T1) will close. If the lock-in timer (TD1 0) and the lock-out timer (TD8) [1 00] have timed out, relays (R4) [1 00], (R1 0) (1 02], and (TD18) [1 01] will be energized. Relay (R4) contacts 9-6 [79], 7-4 (84], and 8-5 [87] close. If the safety controls and switches are closed , the control circuit [79] for compressor #4 and liquid line solenoid (SOL4) [87] will energize , allowing the com pres­so r to start.

Relay (R23) [83] energizes, opening contact 7-1 (7], de-energizing compressor #4 crankcase heater(s). Relay (R14) [82] contact 8-5 (86] closes, energizing (TD12). This will force compressor #4 to run for five minutes.

Relay (R1 0) contact 9-6 [1 07] closes, energizing solenoid valve (UL1-3 , thus locking compressor #3 in the fully loaded position . Relay (R1 0) contacts 8-2 (1 08] and 7-1 [113] open to disconnect the capacity control thermostat (T3) from compressor #3 capacity

8 control solenoid valves.

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Time delay relay (TD18) (101] contact C-NC (88] holds compressor #4 in an unloaded condition for30 seconds. When (TD18) times out, it will energize relay (R8) [89]. closing contacts 9-6 [11 0) and 7: 4 (116]. Thio o.llowo tho capacity control thormootat (T'l) to .. norgi:zo

solenoid valve (UL 1-4) [11 OJ, loading the compressor; or to energize solenoid (UL2-4) [115) , unloading the compressor.

Compressors #1 and #3 are fully loaded.

Compressors #2 and #4 are being capacity-modulated.

PUMPDOWN SEQUENCE STAGE 4 PUMPDOWN A decrease in return water temperature will cause the fourth step of the staging thermostat (T1) to open, thereby de-energzing staging relay (R4), opening contacts 8-5, 9-6, and 7-4. Liquid line solenoid (SOL4) will de-energize, stopping the flow of refrigerant to chiller circuit #4. The compressor will continue to run until the chiller circuit has been cleared of refrigerant and the suction pressure is approximately 35 PSIG. Low pressure control (LP4) contact will then open, de-energizing compressorcontactors (C7) [80) and (C8) [81), stopping compressor #4; and de-energizing relays (R14) and (R23) . Relay (R14) N.C. (normally closed) contact 2-8 [85] energizes lock-out timer (TD8), preventing compressor #4 re-start for five minutes. Relay (R23) energizes compressor#4 crankcase heater(s) .

Staging thermostat (T1) also de-energizes relay (R10) , opening contact 9-6, releasing compressor #3 from continuous full-load operation. Relay (R1 0) contacts 8-2 and 7-1 close, allowing capacity control thermostat (T3) to operate capacity control solenoid valves (UL1-3) and (UL2-3) as required.

STAGE 3 PUMPDOWN A further decrease in return water temperature will de-energize staging relay (R3), closing liquid line solenoid (SOL2) . When chiller circuit #2 low-side has pumped out, low pressure control (LP2) opens, stopping compressor #2; and de-energizing relays (R12) and (R21 ). Relay (R12) N.C. contact 2-9 [51) energizes lock-out timer (TD6), preventing compressor #2 re-start for five minutes. Relay (R21) energizes compressor #2 crankcase heater(s) .

Staging thermostat (T1) also de-energizes relay (R9), opening contact 9-6, releasing compressor #1 from continuous full-load operation. Relay (R9) contacts 8-2 and 7-1 close, allowing the capacity control thermostat (T3) to operate capacity control solenoid valves (UL 1-1) and (UL2-1) as required.

STAGE 2 PUMPDOWN A further decrease in return water temperature will de-energize staging relay (R2), closing liquid line solenoid (SOL3) . When chiller circuit #3 has pumped out, low pressure control (LP3) opens, stopping compressor#3; and de-energizing relays (R13) and (R22). Relay (R13) N.C. contact 2-8 [68) energizes lock-out timer (TD7),

preventing compressor #3 re-start for five minutes. Relay (R22) energizes compressor #3 crankcase heater(s); and also de-energizes fan contactor (C14) [74). stopping the fan motor(s) on the "lag" half nf thA condAn!':Ar !':lab.

STAGE 1 PUMPDOWN Step 1 of the staging thermostat (T1) will open when the return water temperature is reduced to the set point. This de-energizes staging relay (R1 ), closing liquid line solenoid (SOL 1 ), stopping refrigerant flow to chiller circuit #1 . Compressor#1 continues to run until chiller circuit #1 pressure is down to the low pressure control (LP1) set point. The (LP1) contact opens, de-energizing compressor contac­tors (C1) (27) and (C2) [28), and relay (R20), stopping compressor #1 . Relay (R20) de-energizes fan contactor (C13), stopping the remaining fan motor(s); and also energizes compressor #1 crankcase heater(s) . The (LP1) contact also de-energizes relay (R11 ). Relay (R11) N.C. contact 2-8 [33) energizes lock-out timer (TDS), prevent­ing compressor #1 re-start for five minutes. Relay (R11) contact 7-4 [95) opens, removing the circulating pump starter interlock.

SAFETY CONTROLS Each refrigerant circuit is protected by seven standard safety controls, and one optional safety control.

1. High Pressure (HPO) 2. Low Pressure Freeze (LPF) 3. High Discharge Temperature (OTS) 4. Low Oil Temperature (LOT) 5. Compressor Solid State Module (CSTM) 6. Low Water Temperature (T2) 7. Low Pressure (LP) 8. Compressor Starter Overloads (OLH) (optional)

If any of these devices should open due to abnormal conditions, the compressor will automatically stop. All controls must be manually reset , except Low Oil Temper­ature (LOT) , Low Pressure (LP) and Compressor Solid State Module (CSTM), which resets itself after a two minute bleed-down period. The compressor motor wind­ings are also equipped with a thermal protector, automatic reset, which is not shown on the wiring diagram.

STAR-DELTA STARTING OPEN TRANSITION

·The following starting sequence applies to the power wiring diagrams on Page 17 as well as the control wiring on Pages 10 thru 15. Detail "A" on Page 10 is typical of all screw compressor star-delta start, and will be used as an example. Staging relay (R1) contact 9-6 [16) closes, energizing star contactor (S1) [168) and the 5 second transition timer (TD1) [16A) . The (S1) power contacts close, tying the center legs of the motor windings together into the "star" (wye) configuration. The (S1) N.C. (normally closed) auxiliary contact [18] opens to prevent contactor (C2) from energizing. The (S1) N.O. (normally open) auxiliary contact [17) closes, energizing (C1) [17] . The (C1) power contacts close, applying power to the motor. The (C1) N.O. auxiliary contact closes,

9

locking (C1) in the energized position. The compressor operates in the star mode until (TD1) times out (5 seconds) at which time (TD1) contact (168) opens, de-energizing (S1 ). The (S1) N.C. contact [18) closes, energizing contactor (C2) [18), closing (C2) power contacts, thereby completing the Delta wiring configuration. (C2) N.C. auxiliary contact [16A] opens, preventing (S1) from energizing until the next starting sequence.

There is an instant of time (the "open transition ") between the opening of (S1) power contacts and the closing of (C2) power contacts, in which power across the motor windings is interrupted.

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NOTES

1. .. 4, WII.'CI'7,1,1S,IIlMNOTIIEQUIIIIEDD N 215SC.

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--- ,.ILO WIII INI

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16

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ACWC 160-200 SC

ACWC215 SC

TYPICAL POWER WIRING STAR-DELTA START

NOTES 1. 11 1 I 't,I,IO Ut lOOT U IIIII III:D 011 1 101~.

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17

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ELECTRICAL DATA 60HZ.

TOTAL UNIT CHARACTERISTICS COMPRESSORS CONDENSER FANS VOLTAC:E Min. Clroult Max. Fuoo &uggoatod Rated Locked Full

Amps' Size3 Wire Size• Load Rotor Load Model Name Circuit Circuit Circuit Circuit Circuit Circuit Qty. Type Amps Amps Amps ACWC Plate Range 1' 2' 1' 2' 1' 2' H.P. Start Each Each Phase Each

208-230 187-253 322 460 450 600 160SC 460 414-506 326 - 400 -

208-230 187-253 335 468 450 600

185SC 460 414-506 350 - 400 -

208-230 187-253 339 468 500 600 200SC 460 414-506 358 450 - -

208-230 187-253 501 501 700 700

215SC 460 414-506 222 222 300 300 4605 414-506 420 - 500 -

"ATL- Across The Line '208-230 voltage requires two field wiring supplies (circuits). ' Minimum circuit ampacity is per N.E.C. Section 430-24.

400 700 205 400 (3)60 ATL" 90 -

400 750 IJ.!.@_ 205 (2)75

ATL" 208

IJ.!.@_ 90 500 -(2)75 98

500 750 208

500 - (3)75 ATL" 98 900 v 900/ 205

0000 0000 (4)60 ATL" 90

600 - 90

3Use time delay (dual element) fuses only. Suggested fuse sizes based on N.E.C. Section 440-22. •Wire size based on copper conductors with 75° C. insulation per N.E.C. Table #31 0.16. 5 Single point power terminals

NOTE:

1228 491

1228

1415 491 562

1415

562

1228

491 491

Maximum inrush amps is L.R.A. of lag compressor+ R.L.A. of all other compressors+ F.L.A. of all fans. Lag Compressor: 75 H.P. on 185SC.

Model

ACWC 320 340

160SC 12.0 13.7

185SC - -

200SC - -

215SC ----

01

()2

COOLER WATER PRESSURE DROP (Feet of Water)

GALLONS PER MINUTE

360 380 400 420 440 460 480 500

15.4 17.1 18.8 20.6 - - - -

10.6 11.9 13.1 14.3 15.7 17.1 18.6 20.2

- - 13.1 14.3 15.7 17.1 18.6 20.2

- - - 11.1 12.2 13.3 14.4 15.5

Q3 Qs

1}4 Qs

520 540 560

- - -- - -

- - -16..Z_ _1_7 . ~ 19.4

13.2 3 6.6

13.2

3 6.6

13.2 3 6.6

13.2

3 6.6

6.6

580

-

-

-

20.8

7L51

slJl

6~~~- 138Y, ~ 8 + 107Y, ~

LOADING (LBS.)

Model LOCATION POINT NUMBER Dim.

ACWC 1 2 3 4 5 6 7 8 8

160SC 2120 2120 2120 2120 1830 1830 1510 1510 74

185SC 2280 2280 2280 2280 1960 1960 1630 1630 129

200SC 2340 2340 2340 2340 2010 2010 1670 1670 129

215SC 2330 2330 2330 2330 2150 2150 2150 2150 129

18

Locked

Rotor Amps Each 92.0 46.0

92.0

46.0

92.0 46.0

92.0

46.0

46.0

'

START-UP CHECK LIST

Equipment Inspection: a. Unit damaged on arrival

b. Material received agrees with sh ipping papers I

"" Setting Unit: a. Vibration isolator used

b. Spring isolator adjusted for equal height

c . If rubber-in-shear isolators are used, is unit leveled by shimming

Wiring: a. Power wiring complete

b. Control wiring complete

c. Electric service adequate for load

d. Power source voltage correct for motor(s) used

e. Motor circuit has proper size fusetrons

f. System wired per diagram

g. All lead connections tight

h. Wiring complies with local codes

Piping: a. Piping complies with applicable codes

b. External piping independently supported

c. Chilled water lines insulated

Alignment: a. All belts adjusted and checked for tension

b . All pulleys checked and adjusted for proper pitch , tightness and

alignment

Before Start-Up: a. Open compressor discharge service valve

b. Open liquid valve(s)

c . Open suction , and discharge valves to pressure gauges (if supplied)

d . Check rotation of all fan motors

e. All motors and bearings lubricated

g. Start auxiliary equipment (pumps, fans, etc.)

h. Is crankcase heater operating?

After Start-Up: a. Check high pressure control

b. Check oil temperature safety switch

c. Check and adjust low pressure or temperature freeze control -d. Check and adjust operating thermostat

e. Check and adjust low pressure operating control

f . Check and adjust expansion valve superheat

g. Check and adjust capacity control thermostat

OPERATING DATA

CHILLER Voltage: L-1 L-2 L-3 ___ _

Pressure Gauge Readings:

a. Suction psig b. Discharge psig

High pressure switch setting: (Cut-In) psig ---- psig (Out)

Checked Setting Yes No

Low Pressure Switch Setting: (Cut-In) psig ---- psig (Out)

Checked Setting Yes No

Low Pressure Freeze Control Cut In Cut Out

Oil Temperature Safety Switch Cut Out

If Star-Delta start, time delay is seconds.

Temperature of air entering condenser oF.

Temperature of air leaving condenser oF.

Temperature of chilled water entering chiller oF.

Temperature of water (chilled) leaving chiller oF.

Chilled water pressure entering chiller psig

Chilled water pressure leaving chiller psig

..,._._..

YES NO

i

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I'

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