Download Screw Type Air-Cooled Packaged Chillers ACWC-SC
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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 .! I INSPECTION & HANDLING CHILLER PIPING When unit is received, it should be checked for visible or concealed damage . If damage has occurred it should be reported to the carrier 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 imm e diately .o.nd clo.im filed . (:.upply) vvdte• 1-'ifJt:: <..v""""'t"'u tv u,., wat.,r <,;urrrr.,<,;llun on the 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. 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 . 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. 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. 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. 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. 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 . START-UP 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 . 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. Vibration mounts may be used for roof mounted units or other locations where noise might be objectionable. 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. 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. 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) . Separate 115 volt power source must be field supplied to provide power for control and heater circuits. .--..,_ 2 . CAUTION: 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 uil level Is to the tOP Of the sight glass . 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 tightness . u,., 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 operational temperature setting and allow unit to return to normal operation . MAINTENANCE CONDENSER Units equipped with belt drive fans have inherently protected motors. Fan belts , fan bearings and motor bearings require periodic maintenance as follows: 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) oil 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 . 1. Fan Belts -After two (2) weeks operation , the belts w ill 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. 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. 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. 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 . The air inlet of the condenser coil should be kept clean through a regular preventative maintenance program . HIGH PRESSURE PORT 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. 3 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. 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 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. 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. 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. 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. 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 r Hydraulic Piston Load Unload c::> ¢::J Oil Pressure Vent to Suction Slide Valve ~ Oil Pressure Lines Screw Rotor UL-1 Oil Return Oil Supply The following table lists solenoid valve position for all three operating modes. Starting Loading Unloading UL-1 Close Open Close UL-2 Close Close Open UL-3 Open Close Close '-...../' 4 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: 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. FAN CYCLING MEDIUM AMBIENT CONTROL TO 30° F. (STANDARD EQUIPMENT -FACTORY INSTALLED) 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 . A fan cycling control is standard on all Air Cooled Packaged Water Chillers to prov1de prop er 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. 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 by pass around the low pressure freezestat to prevent nuisance tnp-out during cold start-up. ACWC-SC CONTROL SETTINGS PRESSURE ACTUATED High Pressure Control (Manual Reset) Pumpdown Control (Auto Reset) Fan Cycling Pressure Control (Adjustable) Low Pressure Freeze Control (Manual Reset) -- TEMPERATURE ACTUATED Chiller Low Water Temperature Thermostat Chiller Water Cycling Thermostat (Adjustable) Chiller Heater Thermostat (Non-Adjustable Oil Temperature Safety Control (Adjustable) Manual Reset Capacity Control Thermostat (Adj.) Mode Control Position - (."'-._./ 1. 2. 3. 4. 5. LEGEND HP-1 HP2 & HP3 PD1 PD2 & PD3 2 Fan Cell FCP 1 FCP 2 3 Fan Cell FCP 1 FCP 2 FCP 3 4 Fan Cell FCP 1 FCP 2 FCP3 FCP4 LPF 1 LPF 2 & LPF-3 FACTORY SETTING Cut-In 300 PISG Cut-Out 365 PSIG Cut-In 55 PSIG Cut-Out 35 PSIG Cut-In (PSIG) Cut-Out 280 170 295 180 LEGEND T2 T1 Included With CBH1 Heater FACTORY SETTING Cut-Out 37° F. Dial Set At 55° F. Cut- In 40° F. Cut-Out 45° F. OTS 1 OTS 2 OTS3 T3 260 275 290 160 175 215 260 275 285 295 Cut-Out 160 175 210 235 54 PSIG Cut-Out 240° F. Dial Set At 44° F. UNIT OPERATING LIMITATIONS Maximum ambient air to condenser is 115° F. (60 Hertz operation). Maximum allowable cooler water pressure is 150 PSI G. Maximum allowable water temperature to cooler is 75° F. Units must not have leaving water temperatures of 42° F. or lower unless used with a glycol solution. Unit must be allowed to pumpdown at the end of each operating cycle (except on safety control shutdown). 5 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 - & Note number line number location EXAMPLE 30 ~ §] §] @@& ~ 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. SEQUENCE OF OPERATION MODELS ACWC 160 To 200 SC 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. 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. 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) . Control Identification Symbol 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. 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 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 ). 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, 10] (optional), and the low ambient crankcase heaters (SCH1, 2, 3) [3, 5, 7] (optional). , -~ NOTE: ALL FAN MOTORS ARE CONTROLELD BY THEIR OWN FAN CYCLING CONTROL AND WILL CUT IN AT DIFFERENT HEAD PRESSURES. 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! 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. 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] 6 \....__./ Relay (R14) (19] contact 7-4 [62] closes, which completes the interlock circuit for the water circulating pump. ~TAGE! 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). 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) . 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 . 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. 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. 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 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). 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 (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) . 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. SAFETY CONTROLS Each refrigerant circuit is protected by seven standard safety controls, and one optional safety control. 1. 2. 3. 4. 5. 6. 7. 8. Relay (R7) contact 9-6 [70] closes, energizing solenoid valve (UL 11). 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. High Pressure (HP) Low Pressure Freeze (LPF) High Discharge Temperature (OTS) Low Oil Temperature (LOT) Compressor Solid State Module (CSTM) Low Water Temperature (T2) Low Pressure (LP) 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 . Compressor #1 is fully loaded. Compressors #2 and #3 are being capacity-modulated. ,.-......__/ 7 SEQUENCE OF OPERATION MODEL ACWC 215 SC 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. The following sequence of operation is typica l for the ACWC 215 SC (see pages 12 to 15 for typical w iring diagram ). Refer to the wiring diagram furnished with un it for specific information. ( ) Control Identification Symbol [ ] Circuit Line Number Important Notel The compressor crankcase heate r 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. ~ \ 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 w iring diagrams) . Fan motor#4 will start as soon as the head pressure reaches the " cut-in " setting of (FCP7) . 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, 10] (optional) . 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], unload ing the compressor. 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 w ill allow the compressor to run backwards, causing seve re damage , and WILL VOID THE COMPRESSOR WARRANTEE! STAGE 3 LOADING Upon a further inc rease 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. 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 . 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. Set the staging thermostat (T1) to the design range of operation (e.g. 54° F. return water). Set the capacity contro l thermostat (T3) to the design range of operation (e.g . 44° F. supply water) . \....__/ Relay (R9) contact 9-6 [1 05] closes, energizing solenoid valve (UL 11), 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. 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. 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. 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. Compressor #1 is full loaded . Compressors #2 and #3 are being capacity-modulated . 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 ). 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. 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. 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. 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 8 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 control solenoid valves. ~~ '-.._/ 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 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 (116]. Thio o.llowo tho capacity control thormootat (T'l) to .. norgi:zo nf thA condAn!':Ar !':lab. solenoid valve (UL 1-4) [11 OJ, loading the compressor; or to energize solenoid (UL2-4) [115) , unloading the compressor. 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. 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. r SAFETY CONTROLS 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) . Each refrigerant circuit is protected by seven standard safety controls, and one optional safety control. 1. 2. 3. 4. 5. 6. 7. 8. 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 . High Pressure (HPO) Low Pressure Freeze (LPF) High Discharge Temperature (OTS) Low Oil Temperature (LOT) Compressor Solid State Module (CSTM) Low Water Temperature (T2) Low Pressure (LP) 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 . 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), 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, 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 . 9 0 NOTE WITH LINE NO. LINE NO. CONTACTS WITH LINE NO. CONTACTS WITH CLOSED NORIIIALL'f Of>EN NORMALLY HOLDING COILS WITH LINE NO. !I SEC DETAIL "B" - ) !!iSEC STAR DELTA STARTING DETAIL "A" STAR DELTA STARTING (NOT SUPPLIED WITH BELL OPTION.) I CIRCUIT 2 ' I I I I I I :vuu OPTIONAL 207 1 1 L- ~ 21.3 M ~ GFI ~PfiO"HAL [ 123 L- c; N R ~- Ml ~~ 226 8 Rl9 5 GF 2 SW3 OPTiONAL ' COMPRESSOR CIRCUIT 2 BLUE R ~~ ~ SJ,._ itt 4 2 5 5 ! TO - 0LH4 R2 5 6 rlJ"': 8 B 30 SEC Tl NO Ml tl2 NC 244 N~NT TDB 229 128 NO 8 5 230 R20 OLH6 ~30 SEC 5 7 OLH5 WHEN SUPPLIED 228 zoow ~ !lOW I~ . I II ===::::J IH WHITE 12GA ~H~:E I 12 GA 1!31 ""~ = 225 9 6 Tl ~ SOLI A TOT 8 L--e- UL3-I ~TI-o2 HGS I r l C). ~ WHITE -e- ~-'-----~ OETAIL"AMQ ~ r S~~;.N 12ovl LPFI HTR ~SEE T2 c;7 ~ 121 6 120 i·d· RI4 2 ':L7~ Rl f~I!Jr : I : -------"l OPTIONAL or~ LEir "cd ! I r--r==e- CBH I RH 3 RH2 RH I ~;~~OPT. ~-;--~0~ .-=---~oPT I~ !lOW I~ . PCH2 ~~ =I WHITE 142 WHITE 9 245 BLUE R2 6 r ~~~ r 9~~~6 235 y :::E ~ R LP2 227 RED ~ Nl "=Z._ S~~.:N 129 SEE 8 UL3-2 w;;: ~ R5J-----..J SOL 2 A T0 5 Q ~ Co::\'-----~ ~ LPF 2 ~81:::":\ HTR DETAIL Tl ~ [ ~ T2 120vl ~OPTIONAL i9oSEc wmE ~ 128 127 - R4 } - - - - - - ' 0 ~ - 122 IO>~H$)C'-------------:<!?;-------<>-1...o--1 ~ 5111~N1 I ~IRED Y R 8 1/S v 9 W - R LPI 224 7 T07 1 OLH2 ..., 211...,212 J 119 RED 8f1 J: -~g- R- c:!r.- 8 _ ~3 M2 WIRED WHEN SUPPLIED 8 ~HI -....,-2 10 C:, 11 ,... _ TH zoow ..::=--~oPT PCHI 148 147 146 145 R22\+--------------_. 116 ''' 114 113 112 Ill 4 7lJI 216 Tl CST• . Co ~--;~ 206 20!1 204 61 I ,I I r-c=-~_j ~22 OPTIONAL RHT3 .. ::. RHTZ RHTI I ~222 t I I : I cSTw' -,-,-,.Jy J25-UiT-,-,-,-0-iS~Y~34 11 -:i LP'Il: 2 :I OPTIONAL r:;- 215 ors1 1----Q 117 COMPRESSOR CIRCUIT I '--,~,~,--+<,_,., [ BLUE R Lon r-~sr- R- .0. 8 118 y --- --- ..__ __.!R~E£_0----<,::SW;:._;,' 273 f"'T. A-LPFI 2 14 HPI J BLACK 110 BlACk RZO ) Rl9 R.z2~ OPPrfiOfll 7 7 R21 7 7 J,J! I 203 RHPC YELLOW.~ 201 YEUOW BLUE 202 ~ -,,PC 1...---o~ I: _R;_I BLUE -109 REO 108- I o- RED C8FI I t::tl.) ~- OPTIONAL ~ L _ y_ ____j 1 OPTIOHAlr---- ..--..... CB2 rT l ~:·o 1J Iii..J! i L 1 ':JT _j=PUoll 8 CBI 4 BLACK 12GA 1----l.-- _~.- [ I 9 10- I I : I l 0-r-- 4 2 1~~ I ALARM CIRCUIIIT r • POWER SUPPLY 115V/60'\,/IIf TYPICAL. FOR UGHT OPTION ON ALARM CIRCUITS 1,2 8 3. 0 6 0 0 DESIGNATIONS : .. Rrt- ~ ~ ~ 1!3 ~'i!il·~ 13*91821 ~ ETI!3 ~ §] ~ li!m ~ ~ @ 00 ®§ 8 @) l9 ® @).§) €X§ @) @ @ @ ® ® ® ® ® @ ® ~ 8 & & &, & & & & &6 & J I ~ u " l J ~ z . " ~ u - j § u .~ l 0 C/) 0 0 N c ~ -1 :I: 0 ~ en ~ 0 > 0 G) z ~ 0 r ~ ~ -4 z 0 0 > r 0 -4 .,< CIRCUIT BREAKER- CONTROL CIRCUIT CIRCUIT BREAKER- HEATERS CB l, 4 LOW OIL TEMPERATURE LOW PRESSURE CONTROL I LOW PRESSURE I OIL TEMPERATURE SAFETY I PHASE LOSS MONITOR !RELAY-STAG ING RELAY - CAPACITY CONTROL LOT 1-3 LPI - 3 LPF I · 3 OTS I· 3 PLM 1 Rl -3 SWl - 4 I TINE DELAY- CYCLING TRANSITION CONTACTOR TI N E DELAY - TRANSITION CONTACTOR TC 1-3 TO 1-3 VOLT LOSS MONITOR STARTER - COMPRESSOR TO 13 - 15 I TINE DELAY- LOCI<· OUT LPF SECONDARY CRA NI<CASE HEATER SCH I· 3 CIRCUIT BREAI<[R- RtC. HEATER RECEIVER HEAT ER THERMOSTAT RELAY- SECONDARY HEATERS PILOT LIGHTS RECE IVER HEATER RECEIVER HEATER PRESSURE CONTROL R 22 RH 1·3 PL I· 9 PR IMARY COMPRESSOR HEATER THERMOSTAT OVERLOAD HEATERS - STARTERS OLH 1-9 LOW AMBIENT HOT GAS SOLENOID I GROUND FAULT PROTECTION AMBIENT HIGH TEMPERATURE THEA"'. PCH I · 3 GF 1- 3 OPTIONAL Q TERMINAL BOARD-FACTORY WIRING UNLOADERS-SOLENOIO COMPRESSOR 0 TERMINAL BOARD-CUSTOMER WIRING ~~ ;o~~2 ~:=~ ~~~:~ ~ ~A~~~~~~c~~:TROL TO 4-8 THERMOSTAT- CAPACITY CONTROLLER ] THERMOSTAT- LOW TEMPERATURE THERMOSTAT - SEQUENCER I SWITCH- COMPR. CIRCUITS SOLI · 3 TZ I RELAY-CRANI<CASE I SOLENOID-LIQUID LINE R 19 -21 Rl4, 16, IB I RELAY - TNTEIIILOCK SWITCH- MASTER RELAY - LOCK IN I HIGH PRESSURE CONTROL HPI -3 FREEZE ! COMPRESSOR SOLID STATE NODULE CSTMI ·3 CHILLER BARREL HEATER CONTACTOR - CONDENSER FAN CBI "c" Cl3-14 CONTACTOR - COioiPRESSOR STA NDARD LEGEND DETAIL SSEC I STA R DELTA STARTI NG QI I YELLOW · r;== I T2 AND T3 TEMP. SENSORS LOCATED IN WATER OUTLET, Tl IN WATER INLET. 2. WHEN TO 13,14 a IS ARE SUPPLIED , WIRE S FROM 120,127 a 133 TO T2 BE CO JojE 218, 236 8 255 RESPECTIVELY. l. WHEN LATI IS NOT SUPPLIED, WIRE 265 BECOMES 13. 4. WHEN GF!,GF2 8 GF3 ARE NOT SUPPLIED, WIRES 213, 231 8 250 BECOME 117, 124 8 130 RESPECTIVELY. 5 FOR CONTACTOR COILS Cl THRU C6, Cl3 8 C 14, SEE MAIN POWER DIAGRAM FOR CONTACTS 6. ALARM LIGHT OPTION AND ALARM BELL OPTION ARE NOT SUPPLIED SIMULTANEOUSLY. 7. WHEN VLN I IS NOT SUPPLIED, WIRE 209 8ECOio4ES 272 . NOTES TO PUMP MOTOR INTERLOCK. REMOTE SWITCHES! TO 8£ WIRED IN SERIES ALARM CIRcunl 1 CIRCUIT3 ' I NO WHITE ,., .. '" ... 140 UL2-3 UL2 ·2 UL2· 1 ULI -3 UL I-1 .•• 1 WHITE R6}-----_j " 77 76 " H " 72 70 .. " 60 ,. ~ ® 00 00 @ ® @ &/!::,. & & & &. & €€.> 1701~1~ ~ ® ® @@ ® @ 00 & @ ~@§> @) \32137149 ~ \1s\22\z5l ~ 58@ ~ ~ L:.J..I•~ §ol>ol<•l ~ @ @ @ ~ u "5 ~ l { 0 en 0 0 N c: ::D :I: -t 0 0) ~ :e0 0 z C) )> ::D :e 0 r ::D -t z r 0 0 )> 0 -t .,< "' ~ NOTE WITH LtNE NO, \ ' DETAIL "A " STAR DELTA STARTIN G (NOT SUPPLIED WITH BELL OPTIOfrll . ) 4 . .. 0-f---. 2 "v :b Lfop!T N RED 1 m!"" ,. ·lT PLM I I 12GA BLACK ce0 4 7f LUlL ALARM CIRCUIT CIRCUIT I a II~V/60 '\.1 / I fll PO WER SUPPLY CIRCUITS 11 2,3 NORMALLY OPEN CONTACTS WITH LINE NO NO~ hi ALLY CLOSED CONTAC TS WITH LINE NC'. I-IOLDING COILS WIT H :..I NE NO. TYPICAL fOR LIGHT OPTION ON ALARM 6 :J J 0 T:~ @]•• C B 3~ -- ~ CB YELLOW BLUE RE D ~LOW 11 2 -- RED 218 BLACK 211 ( BLACK 209 BLACK L:~ I I~ "+~ ~ OPTIONAL L_ I I - ~2~ I R~ ' . ~ CBH2 I~ '" 10--- AHT2 212 CSTMI OL"' 121 OFTi"ONAL ~ OFTIC'NAL []3-;-o::J 0 -fiiONAL ~ oinoHAC l~9 WHITE O<.H3 OPTIONAL T ~ R ~ 90 SEC I ::j_ __ _ j T D20 _ _ -L__ W"'TE ~ I I _O>TIOHAC R31 )--i-'-------""=""--------~ ~--~ I r-------~ \rt" l fc£0 WHEN SUPPLIED 0'"1 1 '8----=:::J ~ 6NAL ~ 7 R,2~ 1 "' ! OPTIONAL ~" 1 70J'r )i 7 " " ' 200W ~ "' I ~ ,,. ~~ T~ ~~0 [, f-- I I :•.,']'~' I 30 ~217 -- ~ - ~ ~~o----!.Q9 - I I -'"·~ [!E) 1 27 1 33 1 9~ 1 30 L:J 3513sl 29 27 26 2 2 23~ 2 21~ 20 (0 9 @ @ @ @ e (0 e @ @ @ • ~ il & ~ & & 11. l ,---------.._~ < )> 0 (/) (II ..... 1\) :e0 0 G') )> z ::D :e r 0 -t ::D z r 0 0 0 "tt -t (..) 1 _TOZ 242 (' ~1 I I ···-· IN r.c.z DETAIL "B' 2 .. ~~ STAR DELTA STARTING ,;;, ,.......,.. I I ~~R~R0~ c~RCUITI I I I I I I VLioll I T 2 [ I I I I BLUE 237 "" CIRCUIT 2 LPFZ , , . BLUE COMPRESSOR 181 ~· C0"'4 PRESSOR CIRCUIT I LOT 2 ,,Q OTS 2 )> I I TOI!I NO I 30 SEC NC z~~t ~ 250 129 R LP2 v ~~·. m ~2.0 ""' . , BLUE BLUE Q R3 BLUE ... REO ... l "' ~I"==" NTR (o2i) I 12ovl 0 0) :'-r: t 4 37~ ,." I @ e @ e @ @X§) e @ @ @ [4e[~•[tol~l ,. 55~ ,." e 51~ @ 00 @ @ so§"] "9l.:J4o[s,[ 411 47 .. ., u@J " j" • [!i] 33~ 32 ,., " I l1es I Ss-------J 8 A ~ llOl ,."' TOO & & & &. & j 8 i ~ ~ "" 1 j ~~ ~ ...... en 0 (11 1\) 0 0 )> C) lJ -z ~ r 0 lJ -t z 0 0 )> r 0 ,-t< -1>- ~ ~~~- DETAIL " D" STAR DELTA STARTING DETA I L "C" 5SEC 5 SEC STAR DELTA START I NG - I I I I I I ~~~Ru~Tc~currl I SWI I I I I I18ll I I I t I ..... ..., .... I BROWN BR OW N YELLOW c c R<t 139 c nPTinN.I.I ·~~ - 7 ·~ s~ T O 18 T DI6 SEC NO !0 SEC NC NO ~30 g • 6 ...., ..... BROW N YELLOW "' BROWN c.:::..__l___ ,., e Cl4 ; ·~ I 8 ~rOIH ! 144 z @) 00 J z 0 en ...... 0 0 @> @ @ & & t~J r5 j er \ e ;:; I\) =e 0 C) )> U1 ~ .&.: 6l =e :lJ ~ 9 @ e @ r 0 :lJ -i z 0 r 0 )> 0 -i .,-< leo\e5 \951 u ffi " 07 j e 0 EX3 0 . & & z & ~ ;:; ..~ .. l & & & @ e e e @ e .. EJ ~ 85 ~ 84 76 " 14 73 7Z 71 70 •• 68 ~ u s' js3jse \95 \ " 1 59~ ~ . I e: El 0 138 ~ ~~- ~ ... R22 :t23 6 .. , I ~ (}1 TER5 SWITCH TIME DELAY- 5 MIN, LOCK ·IN TIME DELAY- CAPACITY CONTROL TERWINAL 80ARO·CUSTONER WIRING TO 15-18 TER 5 COHTACTOR \ILt.tt-2 IVOLT LOSS NONITOR STAI!:TE"- COMPRESSOR TlloiE DELAY- TRANSITION CONTACTOR TO 20-23 I TINE DELAY - LOCK OUT LPF ITRAHSITION SECONDAI!:Y CRANKCASE HEATER I CIRCUIT BREAKER- REC . HEATER CB 5-6 TC 1-4 RECEIVER HU.TER PRESSURE CONTROL RECEIVER HEATEA THUMOSTAT RECEIVER HEATER RH 1-4 RHT 1-4 PL 1-12 R 30 ·31 AHPC 1- 4 IPRIWARY COloiPRESSOR HEATER PILOT LIGHTS RELAY- SECONDARY HEATERS I OLH 1-12 PCHI-4 LOW ANBIENT THERWOSTAT OVERLOAD HE4TERS - STARTERS I HOT GAS SOLENOID GROUND FAULT PROTECTION BOX FANS CONTROL CBF 1-2 HGS I AMBIENT HIGH TEWPERATURE THERN. AHT 1-2 OPTIONAL TERWINAL BOARD- FACTORY WIRING Ul I THRU4 llhll . 040FR~- ~01 FhiOIO COt.IPti~~!IOR 0 0 TIME DELAY TO ·-12 CYCLING THERMOSTAT- LOW TEMPERATURE T3 TO 5·8 THE t•»OSTAT - SEQUENCER THERMOSTAT- CAPACITY CONTROLLER T2 " SWITCH- COMPRESSOR CIRCUITS SOLENOID- LIQUID LINE RELAY- INTERLOCK REU.Y- CRANkCASE R 20-23 CONTROL SOL 1-4 sw 2-5 Rll-14 RELAY- LOCK IN R 9·10 SW I WASTER RELAY - STAGING RELAY - CAPACITY R!S - 8 !5 MIN LOAD UL2-3 176 1 96 ~ ~ ~ 7 WHEN VLM 1-2 ARE NOT SUPPLIED, WIRES 213 a 270 8ECOWE 214 8 12 RESPECTIVELY. I ... "' '" "' '" 110 109 ~ ~ @ @ e @ ®3 108 @ 00 e 6 ALARM LIGHT OPTION AND ALARM BELL OPTION ARE NOT SUPPLIED SIWULTANEOUSL't". 106 100 10< 102!1oij~ 101 <E:€) ~lso/ss/ @€) ~ 100 179/84/871 97 6. FOR CONTACTOR COILS C 1- 8, 13 8 14, SEE WAIN POWER DIAGRAM FOR CONTACTS. 4. WHEH Gfl-4 ARE NOT SUPPLIED, WIRES 218,237,254 ll 274 r.ECOME 121,128, 134 6 140 RESPECTIVELY. 3. WHEH LATI IS NOT SUPPLIED, WIRE 289 BECOWES 13 . Z . WHEN TO 20·23 ARE SUPPLIED, WIRES FROt.t 124,131,137 6 143 TO T2 BECOME 223,241,259 & 279 RESPECTIVELY. WATER OUTLET, Tl IN WATER IHLET. I. T2 AND TJ TEMP SENSORS LOCATED IN NOTES PHASE LOSS MONITOR PL.M 1-2 R 1-4 95~ OTS 1-4 FREEZE OIL TEMPERATURE SAFETY PRESSURE LOW L.PI-4 LPF 1-4 94 90 lu/32/3sJ@ BLACK 8 14!5 COMPRESSOR SOLID STATE MOOULE BLACK HIGH PRESSURE CONTROL LOW OIL TEN PERATURE LOW PRESSURE CONTROL TO PUMF MOTOR IHTEALOCK 13 t BLACK CSTMI-4 CHILLER BARREL HEATER CB H 1-2 TO FLOW SWITCH. REMOTE SWITCHES TO BE WIRED IN SERIES. HPI-4 LOT 1·4 CIRCUIT MEAkER - CONTROL CIRCUIT CIRCUIT BREAKER- HEATERS C83-4,7 CONDENSER FAN CONTACTOA - "~~vw" v--· v~•••~wown LEGEND Cll-14 CBI- 2 ... STANDA RD ( 8 ::D I -~ 0 en c.n N .... 0 ~ l> 0 C) -z ~ ~i , i~ •! 0 r ~ ::D ~ z 0 l> r 0 0 ~ .,-< - ~I TYPICAL POWER WIRING ACROSS-THE-LINE START ACWC 160-200 SC USE COPP£R COHOUCTORS OHLT r-, Dl.SI 'A • L lti_jOf'fiOIU.L .. .. ' o,,., PC 8 7 ' ~~;,;L"m 9 l puu t 11 I9 1 9 -r·DI'TIDNAL ) TOCONTIIOLCI II CUrt ,..m fCPI lU$ LEGE ND r--~ I ~ j - I OV£11l.OolOIIUTU-SUIIT£11 CQNTACTOOI-CO'IPIIESSOII ~~~~~~) ~~:::~::"~C:~:S£11 FCPI·IO W.i~ ~ '::t FA~ UN CYClfi'IG PRESSURE COOITIIOL GilD GIIOUNOINGlltG III I I loi:Ov.JIII-COHD£NS£RFAN I'CII J CIRCUIT i!III£AK(III ·C00.1"111ESSOII I'C87·1 CIJICUITIIII[AK£11-FAII MOTOOI Pfll ·ll POWEll FUS£ ·T IIANSf OII MUI "'-MI·l DETAil FOR ONE TER'-IINAl BLOCK TAOOHS PHASE lOSS IIIONI!Ofl POWf~ l[lll·l l(II III IN .. LIIOARO· MAIN HIU. HRVI".I.l iiOAIIO·CONO[NSlll Hll~ TUI011NALI04110 CUSTOiol£11 ""IIH•G U~ • sni'<OTt, ,---NOT ES I I I 6FCP9 1 10 I 2 fOil Cl-14 ~" S~l - - All(~fii£0U111(00NIIOSC CONTROl CIRCUIT •tiii "'G - flllO - F• tTOIIT OIAG~A III WilliNG WIIIING i ACWC 215 SC US£ COPP[R CONDUCTORS ON LY REFER TO UNIT SPEC PLATE FOR VOLTAGE Fo~;l for~ •A 'A • LY.J I L_l,,_j .. ' '• .. I 1 , t PLiol l/ 19 \' lvc•• ~-TOPTIONAL I m. TOCONTI!OI.CIIICUIT II I II 19 1 ' g I PLM2/ ? lvcwz --..; - r O PTION.I.L ' e.-l!t. l t:l t:l t::i l Cl$·14 CONT.I.tTOIII·COND€NSEIIFAN CMI'I-4 tO WI'RESSOIIIIIPQTQII CIUI-2 00011 LATCHING $0\,_(N()IQ ftl'l·ll fA N tTCLINGI'RUSUIIECONTIIOL GilD IIII -I •• ~11·4 GIIOUHDI NG LUG flfOTOR·COND£NSIII,AN CIIICUIT PEAK(II-COioii'IIUSOII I'CI7•1 CIRCUIT I II!AKEII- n.JI WOTC)III Pf'!I•U I'O'IIIEIIFUSE-TIIAN!'OII IIIEII "-1111-2 .... ASI:LDSS IIIOJIITOIII T£1111-2 TERIII IN.U.IOAIIID-IIIAHoii'O'IIIU TEII! - 4 fEllS Tl:lllolllt.I.LIOAIIO•CONDENS£11F""" TEIIMINAliOAIID-CUSJOM[IIWIIIING NOTES 1. .. 4, WII.'CI'7,1,1S,IIlMNOTIIEQUIIIIEDD N 215SC. t.I'OR Cl-1 4 lEE CONTIIOl CIIICUIT WIII IIIO DIAGIIAIII - - - ,.IL O WIII INI - - ,ACTOIIITWI II INI 16 , TYPICAL POWER WIRING STAR-DELTA START N;t~t;"' I 1 1 1 1"1.1111/ A I t •( YLIII ACWC 160-200 SC ..... N~:E" r:-. : ,n I I _ ~~fiOtlll OI'T IOIIAL) o; I ~LIII/ • (YUI:I: OI'TIOIIAl} 11t 1 111111111 ' NOTES 1. 11 1 I ' t , I ,IO Ut lOOT U IIIII III:D 011 1 1 01 ~ . l,OII CI·C IOIII tOU IOOI.C•• tuiT • I• IM!Ho\&UII \....../ UKCOfi'NII ACWC215 SC COtiOUCTOM OtiLT lltEF£11 TO U"IT PlC 'LJ.Tt 'ClR VOLTAGE r+-h I A I : mull I C !1'\.11111/ ""' ...i rr.I n ~ l if ·t TO CI:*TIIQ. CMeurT rt-h n i ... 1 wu 1 I S3 & ;~: I II NOTES 17 _IIAII S4 :trtl e••• I l iiA,.II'a' T,I , IS ,II4111MI'tiiiOUIIICIOIINK J'' u :fW ; 1.- CI· CMKl~ el !tCUITWIR I . . C !PLII2:/ ""' · r.;~-j· ~ A I V Y ~~~ f J ~U4 1 •111111 1 ELECTRICAL DATA 60HZ. Model ACWC 160SC Wire Size• Size 3 Amps' Name Circuit Circuit Circuit Circuit Circuit Circuit Plate Range 1' 1' 1' 2' 2' 2' 208-230 187-253 400 322 700 460 450 600 460 414-506 400 400 326 208-230 187-253 335 468 450 400 600 414-506 - 350 400 - 500 Qty. H.P. Type Start (3)60 ATL" IJ.!.@_ (2)75 IJ.!.@_ 750 185SC 460 Full Locked Load Amps Each 13.2 6.6 Rotor Amps Each 92.0 46.0 13.2 92 .0 Rated Locked &uggoatod Max. Fuoo Min. Clroult CONDENSER FANS COMPRESSORS TOTAL UNIT CHARACTERISTICS VOLTAC:E - ATL" Rotor Amps Each 1228 491 Load Amps Each 205 90 205 208 90 98 208 98 205 90 90 Phase 3 1228 1415 491 562 1415 562 1228 491 491 (2)75 208-230 187-253 500 750 339 468 500 600 200SC (3)75 ATL " 460 414-506 500 358 450 208-230 187-253 501 700 900 v 900/ 501 700 460 414-506 222 222 300 300 0000 0000 (4)60 215SC ATL" 460 5 414-506 420 500 600 "ATL- Across The Line '208-230 voltage requires two field wiring supplies (circuits). ' Minimum circuit ampacity is per N.E.C. Section 430-24. 3 Use 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 6.6 46.0 13.2 6.6 13.2 6.6 6.6 92.0 46.0 92.0 46.0 46.0 3 3 3 ' NOTE: 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. COOLER WATER PRESSURE DROP (Feet of Water) Model GALLONS PER MINUTE ACWC 320 340 360 380 400 420 160SC 12.0 13.7 15.4 17.1 18.8 20.6 10.6 11.9 13.1 14.3 15.7 17.1 13.1 14.3 15.7 17.1 11.1 12.2 13.3 14.4 15.5 185SC 200SC 215SC --- - - - - - 440 - 460 480 500 520 - - - - - 18.6 20.2 - 18.6 20.2 - - 540 560 - - - - 16..Z_ _1_7 . ~ 580 19.4 20.8 01 Q3 Qs 7L51 ()2 1}4 Qs slJl 6~~~- ~ 138Y, + 8 ~ 107Y, LOADING (LBS.) Dim. LOCATION POINT NUMBER Model ACWC 1 2 3 4 5 6 7 8 160SC 2120 2120 2120 2120 1830 1830 1510 1510 74 185SC 2280 2280 2280 2280 1960 1960 1630 1630 129 8 200SC 2340 2340 2340 2340 2010 2010 1670 1670 129 215SC 2330 2330 2330 2330 2150 2150 2150 2150 129 18 START-UP CHECK LIST YES NO a. Unit damaged on arrival Equipment Inspection: ~ b. Material received agrees with sh ipping papers I "" a. Vibration isolator used Setting Unit: b. Spring isolator adjusted for equal height c . If rubber-in-shear isolators are used, is unit leveled by shimming Wiring: i 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 I' g. All lead connections tight h. Wiring complies with local codes •. a. Piping complies with applicable codes Piping: b. External piping independently supported c. Chilled water lines insulated a. All belts adjusted and checked for tension Alignment: b . All pulleys checked and adjusted for proper pitch , tightness and alignment a. Open compressor discharge service valve Before Start-Up: 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? a. Check high pressure control After Start-Up: 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 High pressure switch setting: (Cut-In) Checked Setting Yes Yes Low Pressure Freeze Control - - - - psig (Out) psig - - - - psig (Out) No Low Pressure Switch Setting: (Cut-In) Checked Setting psig psig No Cut In Cut Out Oil Temperature Safety Switch Cut Out If Star-Delta start, time delay is seconds. Temperature of air entering condenser Temperature of air leaving condenser oF. oF. Temperature of chilled water entering chiller oF. Temperature of water (chilled) leaving chiller Chilled water pressure entering chiller Chilled water pressure leaving chiller oF. psig psig ..,._._..