clw quad series 60 to 140 tons clw quad series chiller ...clw quad series chiller installation...

IM1900WW 11/13

Installation Information

Water Piping Connections

Electrical Data

Microprocessor Control

Startup Procedures

Preventive Maintenance

CLW

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Commercial Chiller - 60 Hz

CLW Quad Series 60 to 140 Tons

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

Table of ContentsModel Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Field Connected Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

System Cleaning and Flushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

Field Wiring and Control Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-16

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Reference Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Unit Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Heat of Extraction/Rejection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Heating and Cooling Cycle Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Startup and Troubleshooting Form. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Revision Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4


Model Nomenclature

CLW

1-3 4 5-7 8 9 10

Model Type CLW – Quad R-410A Series

Operation C – Chiller R – Heat Recovery H – Heat Pump

Unit Capacity (Tons) 060, 080, 100, 120, 140

Compressor Series V – Standard Series

Compressor Quantity Q – Quad

Voltage 2 – 208-230/60/3 3 – 380/60/3 4 – 460/60/3 5 – 575/60/3

Chassis S – Standard

Water SD – Standard NC – Non-Modular with Isolation Valves NH – Non-Modular with Isolation Valves and Head Pressure Control

Refrigeration 0N – EEV Optimized 1N – TEV 0H – EEV with Hot Gas Bypass 1H – TEV with Hot Gas Bypass

Electrical 0 – No Disconnect 1 – Non-Fused Disconnect 3 – Breaker 4 – Separate 120VAC Connection

Controls S – Standard N – No Local Interface P – Primary E – Enhanced Interface W – Local Workstation Present

Rev.: 23 July 2013D

11 12 13

C 060 V Q 4 S S 1 1N

14-15

SD

15-16

5


Safety ConsiderationsInstalling and servicing air conditioning and heating

equipment can be hazardous due to system pressure and

electrical components. Only trained and qualified service

personnel should install, repair or service heating and air

conditioning equipment. When working on heating and

air conditioning equipment, observe precautions in the

literature, tags and labels attached to the unit and other

safety precautions that may apply.

Follow all safety codes. Wear safety glasses and work

gloves. Use quenching cloth for brazing operations. Have

fire extinguisher available for all brazing operations.

NOTE: Before installing, check voltage of unit(s) to ensure

proper voltage.

WARNING: Before performing service or maintenance operations on the system, turn off main power switches to the unit. Electrical shock could cause serious personal injury.

ApplicationUnits are not intended for heating domestic (potable water)

by direct coupling. If used for this type of application, a

secondary heat exchanger must be used.

Moving and StorageMove units in the normal “Up” orientation as indicated by

the labels on the unit packaging. When the equipment

is received, all items should be carefully checked against

the bill of lading to ensure that all crates and cartons

have been received in good condition. Examine units for

shipping damage, removing unit packaging if necessary

to properly inspect unit. Units in question should also

be internally inspected. If any damage is observed, the

carrier should make the proper notation on delivery receipt

acknowledging the damage. Units are to be stored in a

location that provides adequate protection from dirt, debris

and moisture.

Units are setup to be side picked using a fork lift. Some

units include pick bars allowing for picking from the end

with required fork lengths. Note unit labels and markings

for safe picking points. Do not pick the unit up from points

not specified and keep the unit level during transport and

handling. Using improper equipment handling methods can

result in damage and/or void the warranty.

General Installation InformationWARNING: To avoid equipment damage, do not leave the system filled in a building without heat during cold weather, unless adequate freeze protection levels of antifreeze are used. Heat exchangers do not fully drain and will freeze unless protected, causing permanent damage.

Unit LocationProvide sufficient room to make water and electrical

connections. If the unit is located in a confined space,

provisions must be made for unit servicing. Locate the

unit in an indoor area that allows easy removal of the

access panels and has enough space for service personnel

to perform maintenance or repair. These units are not

approved for outdoor installation and, therefore, must be

installed inside the structure being conditioned. Do not

locate units in areas subject to freezing conditions.

WARNING: Do not store or install units in corrosive environments or in locations subject to temperature or humidity extremes (e.g. attics, garages, rooftops, etc.). Corrosive conditions and high temperature or humidity can significantly reduce performance, reliability, and service life. WARNING: To avoid equipment damage and possible voiding of warranty, be sure that properly sized strainers are installed upstream of both brazed plate heat exchangers to protect them against particles in the fluid.

Unpacking the UnitRemove the stretch warp and protective cardboard from

the unit. Where applicable, remove any additional crating or

bracketing and discard.

6


Physical Dimensions With Enclosure

Dimensional Data and Physical Data

ModelA

LengthB

WidthC

HeightWeightlbs [kg]

Charge(per Circuit)

lbs [kg]

060in. 96 36 76 2976 22

cm. 243.8 91.4 193.0 1349.9 10.0

080in. 96 36 76 3174 24

cm. 243.8 91.4 193.0 1439.7 10.9

100in. 96 36 76 3352 24

cm. 243.8 91.4 193.0 1520.4 10.9

120in. 100 36 76 3540 26

cm. 254.0 91.4 193.0 1605.7 11.8

140in. 100 36 76 3642 28

cm. 254.0 91.4 193.0 1652.0 12.7

All dimensions in inches, [mm]

All water connections are 4 in. Victaulic

17.00

12.00

A ?

Low Voltage Elec PanelHigh Voltage

Elec Panel

HWS(Outlet)

HWR(Inlet)

CWR(Inlet)

CWS(Outlet)

B

Electrical Connection

C

4'' Victaulic(standard)

7


General

System piping should be kept as simple as possible to

minimize the pressure drop, but hand valves should be field

installed to facilitate unit servicing. The piping installation

should provide service personnel with the ability to measure

and/or monitor water temperatures and pressures.

Source and load fluid connections are provided with 4-inch

[10.2cm] Victaulic grooved nipples. Each nipple will also

have a PT port installed for test and balance purposes.

It will be the installing contractor’s responsibility to

adequately support incoming piping to avoid damage to the

unit’s piping or heat exchangers. The water lines should be

routed so as not to interfere with access to the unit.

Field Connected Water PipingFor any installation where the transmission of vibration

through the piping connections could cause unacceptable

noise levels in occupied spaces it is important to provide

adequate vibration damping. One method is to use the

optional Adapter Hose Kit (kit number TKC16S-4). This Kit

consists of four pieces of a braided stainless steel flexible

hose with a 4” Victaulic connection on one end and a 4”

MPT connection with pipe union on the other. Overall length

of each piece is 18”.

NOTE: Units are factory run-tested using propylene

glycol. Prior to connecting piping to unit, thoroughly flush

heat exchangers.

8


Field Connected Water Piping cont.Before final connection to the unit, the supply and return

hose kits must be connected to each other, bypassing

the unit, and the system flushed to remove dirt, piping

chips and other foreign material. Normally, a combination

balancing and close-off (ball) valve is installed at the return,

and a rated gate or ball valve is installed at the supply. The

return valve can be adjusted to obtain the proper water

flow. The valves allow the unit to be removed for servicing.

The proper water flow must be delivered to each unit

whenever the unit heats or cools. The proper flow rate

cannot be accurately set without measuring the water

pressure drop through the refrigerant-to-water heat

exchanger. A 3 GPM flow rate per ton [0.054 LPS per kW] of cooling capacity (2.25 GPM per ton [0.0404 LPS per kW] minimum) is required.

NOTE: The placement and connection of the water

circulating pump(s) must be taken into consideration prior

to designing the final water piping systems.

Closed Loop Tower/Boiler SystemsThe water loop is usually maintained between 60°F [15.5°C]

and 90°F [32.2°C] for proper heating and cooling operation.

This is accomplished with a cooling tower and a boiler.

To reject excess heat from the condenser water loop, the

use of a closed-circuit evaporative cooler or an open type

cooling tower with a secondary heat exchanger between

the tower and the condenser water loop is recommended.

If an open type cooling tower is used without a secondary

heat exchanger, continuous chemical treatment and filtering

of the water must be performed to ensure the water is free

from damaging materials.

CAUTION: Water piping exposed to outside temperature may be subject to freezing.

Open Loop Well Water SystemsInstallation of an open loop system is not recommended

without using a secondary heat exchanger unless water

quality guidelines are met.

Earth Coupled SystemsAll supply and return water piping should be insulated to

prevent excess condensation from forming on the water

lines. Ensure pumping system is capable of providing

adequate flow rate at the system pressure drop, 3.0 GPM

per ton [0.054 LPS per kW] (source side) is recommended.

Antifreeze in the loop is strongly recommended.

9


GeneralCommercial chiller systems may be successfully applied in a wide range of commercial and industrial applications. It is the responsibility of the system designer and installing contractor to ensure that acceptable water quality is present and that all applicable codes have been met in these installations.

Water TreatmentDo not use untreated or improperly treated water. Equipment damage may occur. The use of improperly treated or untreated water in this equipment may result in scaling, erosion, corrosion, algae or slime. The services of a qualified water treatment specialist should be engaged to determine what treatment, if any, is required. The product warranty specifically excludes liability for corrosion, erosion or deterioration of equipment.

The heat exchangers in the units are 316 stainless steel plates with copper brazing. The water piping in the heat exchanger is steel. There may be other materials in the building’s piping system that the designer may need to take into consideration when deciding the parameters of the water quality.

If an antifreeze or water treatment solution is to be used, the designer should confirm it does not have a detrimental effect on the materials in the system.

Contaminated WaterIn applications where the water quality cannot be held to prescribed limits, the use of a secondary or intermediate heat exchanger is recommended to separate the unit from the contaminated water.

Material Copper 90/10 Cupronickel 316 Stainless SteelpH Acidity/Alkalinity 7 - 9 7 - 9 7 - 9

ScalingCalcium and

Magnesium Carbonate(Total Hardness)

less than 350 ppm(Total Hardness)

less than 350 ppm(Total Hardness)

less than 350 ppm

Corrosion

Hydrogen SulfideLess than 0.5 ppm (rotten egg

smell appears at 0.5 ppm)10 - 50 ppm Less than 1 ppm

Sulfates Less than 125 ppm Less than 125 ppm Less than 200 ppm

Chlorine Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Chlorides Less than 20 ppm Less than 125 ppm Less than 300 ppm

Carbon Dioxide Less than 50 ppm 10 - 50 ppm 10 - 50 ppm

Ammonia Less than 2 ppm Less than 2 ppm Less than 20 ppm

Ammonia Chloride Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Ammonia Nitrate Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Ammonia Hydroxide Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Ammonia Sulfate Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Total Dissolved Solids (TDS) Less than 1000 ppm 1000 - 1500 ppm 1000 - 1500 ppm

LSI Index +0.5 to -0.5 +0.5 to -0.5 +0.5 to -0.5

Iron Fouling(Biological Growth)

Iron, FE2+ (Ferrous)Bacterial Iron Potential

< 0.2 ppm < 0.2 ppm < 0.2 ppm

Iron OxideLess than 1 ppm, above this level deposition will occur

Less than 1 ppm, above this level deposition will occur

Less than 1 ppm, above this level deposition will occur

ErosionSuspended Solids

Less than 10 ppm and filtered for max. of 600 micron size



Threshold Velocity(Fresh Water)

< 6 ft/sec < 6 ft/sec < 6 ft/sec

NOTES: Grains = ppm divided by 17mg/L is equivalent to ppm

2/22/12

Water QualityThe following table outlines the water quality guidelines for unit heat exchangers. If these conditions are exceeded, a secondary heat exchanger is required. Failure to supply a secondary heat exchanger where needed will result in a warranty exclusion for primary heat exchanger corrosion or failure.

StrainersThese units must have properly sized strainers upstream of both brazed plate heat exchangers to protect them against particles in the fluid. Failure to install proper stainers and perform regular service can result in serious damage to the unit, and cause degraded performance, reduced operating life and failed compressors. Improper installation of the unit (which includes not having proper strainers to protect the heat exchangers) can also result in voiding the warranty.

Field supplied strainers with 20-40 mesh (530-1060 microns) are recommended, with 30 mesh (800 microns) being the optimum choice. The strainers selected should have a mesh open area of at least 6 square inches (39 square centimeters) for each unit being serviced by the strainer. Using strainers with a smaller amount of open area will result in the need for more frequent cleaning.

Strainers should be selected on the basis of acceptable pressure drop, and not on pipe diameter. The strainers selected should have a pressure drop at the nominal flow rate of the units; low enough to be within the pumping capacity of the pump being used.

WARNING: Must have intermediate heat exchanger when used in pool applications.

Water Quality Guidelines

10


System Cleaning and Flushing

Cleaning and FlushingPrior to start up of any heat pump, the water circulating

system must be cleaned and flushed of all dirt and debris.

If the system is equipped with water shutoff valves, the

supply and return runouts must be connected together

at each unit location (This will prevent the introduction of

dirt into the unit, see Flushing with Water Shutoff Valve

Equipped Systems illustration). The system should be filled

at the water make-up connection with all air vents open.

After filling, vents should be closed.

The contractor should start the main circulator with the

pressure reducing valve makeup open. Vents should be

checked in sequence to bleed off any trapped air and to

verify circulation through all components of the system.

As water circulates through the system, the contractor

should check and repair any leaks found in the piping

system. Drain(s) at the lowest point(s) in the system should

be opened for initial flush and blowdown, making sure

water fill valves are set at the same rate. Check the pressure

gauge at the pump suction and manually adjust the make-

up water valve to hold the same positive pressure both

before and after opening the drain valves. Flushing should

continue for at least two hours, or longer if required, until

drain water is clean and clear.

The supplemental heater and/or circulator pump, if used,

should be shut off. All drains and vents should be opened

to completely drain the system. Short-circuited supply and

return runouts should now be connected to the unit supply

and return connections.

Refill the system with clean water. Test the system water

for acidity and treat as required to leave the water slightly

alkaline (pH 7.5 to 8.5). The specified percentage of

antifreeze may also be added at this time. Use commercial

grade antifreeze designed for HVAC systems only.

Environol™ brand antifreeze is recommended.

Once the system has been filled with clean water and

antifreeze (if used), precautions should be taken to protect

the system from dirty water conditions. Dirty water will

result in system-wide degradation of performance, and

solids may clog valves, strainers, flow regulators, etc.

Additionally, the heat exchanger may become clogged

which reduces compressor service life and can cause

premature unit failure.

In boiler/tower application, set the loop control panel

set points to desired temperatures. Supply power to all

motors and start the circulating pumps. After full flow has

been established through all components including the

heat rejector (regardless of season), air vented and loop

temperatures stabilized, each of the units will be ready for

check, test and start up and for air and water balancing.

Ground Source Loop System CheckoutOnce piping is completed between the unit pumping

system and ground loop, final purging and charging of

the loop is needed. A high pressure pump is needed to

achieve adequate flow velocity in the loop to purge air

and dirt particles from the loop itself. Antifreeze solution

is used in most areas to prevent freezing. Flush the

system adequately to remove as much air as possible;

then pressurize the loop to a static pressure of 40-50

PSI (summer) or 50-75 PSI (winter). This is normally

adequate for good system operation. Loop static pressure

may decrease soon after initial installation, due to pipe

expansion and loop temperature change. Running the

unit for at least 30 minutes after the system has been

completely purged of air will allow for the “break-in”

period. It may be necessary to adjust static loop pressure

(by adding water) after the unit has run for the first time.

Loop static pressure will also fluctuate with the seasons.

Pressures will be higher in the winter months than during

the cooling season. This fluctuation is normal and should be

considered when charging the system initially.

Ensure the pump provides adequate flow through the unit

by checking pressure drop across the heat exchanger.

Usually 2.25-3.0 GPM of flow per ton of cooling capacity is

recommended in earth loop applications.

Return Runout

Supply Runout

Mains

Rubber Hose

Runouts InitiallyConnected Together

Flushing with Water Shutoff Valve Equipped Systems

11


Electrical Data

MCA (Maximum Current Rating) is a calculation based off the RLA of the compressor on the electrical connection and is used to properly size the wire. Please refer to NEC for additional information.

MOCP (Maximum Over Current Protection) is a calculation based off the RLA of the compressor on the electrical connection and is used to fuses and breakers. Please refer to NEC for additional information.

Notes:1. Where RLA1 is equal to the largest compressor in the system and the others RLA's are all subsequent

motors present in the system. 2. Total unit MCA shall not exceed 500A or a second connection will be required.

ModelRated

VoltageVoltageMin/Max

HPCompressor Unit

MCC RLA1 MOA MCA HP MOCP

060

208-230/60/3 187/253

15

89.9 57.6 77.3 244.8

60

302.4

460/60/3 414/506 43.0 27.6 35.0 117.3 144.9

575/60/3 517/633 34.4 22.0 28.0 93.5 115.5

080

208-230/60/3 187/253

20

110.7 70.9 108.0 301.3

80

372.2

460/60/3 414/506 54.1 34.7 48.8 147.5 182.2

575/60/3 517/633 43.3 27.8 39.1 118.2 146.0

100

208-230/60/3 187/253

25

132.8 85.1 117.7 361.7

100

446.8

460/60/3 414/506 63.5 40.7 53.2 173.0 213.7

575/60/3 517/633 50.8 32.6 42.6 138.6 171.2

120

208-230/60/3 187/253

30

165.6 106.2 145.1 451.4

120

557.6

460/60/3 414/506 82.8 53.1 65.6 225.7 278.8

575/60/3 517/633 66.3 42.5 52.5 180.6 223.1

140

208-230/60/3 187/253

35

160.4 102.8 165.8 436.9

140

539.7

460/60/3 414/506 80.2 51.4 75.0 218.5 269.9

575/60/3 517/633 64.2 41.1 60.0 174.7 215.8

11/05/13

12


Low Voltage WiringWIRE LEGEND

(TB-

P7):

120V

AC P

ower

(Com

p 3&

4)

(TB-

P12)

: 24

VAC

Pow

er (C

ircui

t 1 &

2)

(TB-

P5):

120

VAC

switc

h po

wer

(TB-

P11)

: 24

VAC

switc

h po

wer

(TB-

P16)

:24V

DC

switc

h po

wer

(TB-

P13)

: 24

VAC

Pow

er (C

ircui

t 3 &

4)

(TB-

P8):

120

VAC

Neu

tral

(Com

p 1&

2)(T

B-P9

): 12

0VAC

Neu

tral

(Com

p 3&

4)

(TB-

P14)

: 24

VAC

Neu

tral

(Circ

uit 1

& 2

)(T

B-P1

5): 2

4 VA

C N

eutr

al (C

ircui

t 3 &

4)

(TB-

P17)

: 24

VDC

Pow

er (C

ircui

t 1 &

2)

(TB-

P20)

: 24

VDC

Neu

tral

(Circ

uit 3

& 4

)

(TB-

P10)

: 120

VAC

Gro

und

(TB-

P2):

120

VAC

Pow

er (O

utle

ts &

Hea

ters

)(T

B-P1

): 12

0 VA

C sw

itch

pow

er

(TB-

P3):

120

VAC

Neu

tral

(Out

lets

& H

eate

rs)

(TB-

P4):

120

VAC

Gro

und

(Out

lets

)

(TB -

P 6)

(TB-

P6):

120

VAC

Pow

er (C

omp

1&2)

(TB-

P19)

: 24

VDC

Neu

tral

(Circ

uit 1

& 2

)

(Out

lets

)

(TB-

P2)

(RIB

-2.1

& O

utle

ts)

(R-3

.13,

TB-

B22)

(RIB

-7.1

)(R

IB-1

.1)

INPUT/OUTPUT SIGNAL

INPUT/OUTPUT COMMON

120VAC, 24VAC

120VAC (+) / 24VDC (-)

GROUND

24VAC & 24VDC (+)

BLACK

WHITE

GREEN

RED

BLUE

GRAY

(R-9

.13,

TB-

Y22)

(KM

C-U

1,2,

3 )

(KM

C-U

4,5,

6 &

TB-

O19

)(K

MC-

U1,

2,3)

(KM

C-U

4,5,

6 &

TB-

B20)

(U2 -

C-5,

U3-

C-5)

(U5-

C-5,

U6-

C-5)

(TB-

O4)

ETHERNET WIRE

(TB-

P18)

: 24

VDC

Pow

er (C

ircui

t 3 &

4)10A 10A 5A 1A

120 VAC POWER 24 VAC POWER 24 VDC POWER COMPRESSOR 2 SENSORSWATER TEMP SENSORS & CONTROL VALVES

(120

VA

CTr

ansf

orm

er)

(24

VA

CTr

ansf

orm

er)

(24

VD

CTr

ansf

orm

er)

(120

VA

CTr

ansf

orm

er)

120VAC 15A Duplex Receptacle

(TB-

G4)

COMPRESSOR 1 SENSORS

(TB-

P12)

(TB-

P17)

LOW VOLTAGE PANEL LAYOUTUNIT TYPE:UNIT MODEL:SERIAL NUMBER:

Touch Screen IP: ________________________ (Assigned)Master Controller IP: _____________________ (Assigned)Chipkin Field Server IP:___________________ (Assigned)

START-UP DATE:START-UP TECHNICIAN:

CHILLIT CHILLERS LLC PH: (574) 970-3035Rev: E 08/01/13 CPM © CHILLIT CHILLERS 2013

(TB-

B19)

:Isol

atio

n Va

lves

(24V

AC)

(TB-

B20)

:Isol

atio

n Va

lve

(com

mon

)(T

B-B1

0) +

24 V

AC(T

B -B1

1 , U

1-G

-16 )

(TB-

B1):

Evap

orat

or In

let C

1&C2

(TB-

B2):

Com

mon

TBG

1 &

3

(TB-

B3):

Evap

orat

or O

utle

t Tem

p C1

&C2

(U1-

IN1-

1)(U

1-C-

2)

(U1-

IN2-

3)

(TB-

B9):

Evap

orat

or O

utle

t Tem

p C3

&C4

(TB-

B8):

Com

mon

TBG

8&10

(TB-

B21)

:C1&

2 Is

olat

ion

Valv

es S

igna

l(T

B-B2

2): C

3&4

Isol

atio

n Va

lve

Sign

al

(TB-

B18)

: Con

dens

er H

eade

r Out

let T

emp

(TB-

B17)

: Com

mon

TBG

20

(TB-

O1)

: C1-

Cond

ense

r Liq

uid

Tem

p(T

B-O

2): C

omm

on T

BG1

& 3

(T

B-O

3): C

1-Ev

apor

ator

Gas

Tem

p(T

B-O

4): C

1-D

isch

arge

Pre

ssur

e(T

B-O

5): C

1-D

isch

arge

Pre

ssur

e

(TB-

O10

): C1

- Mot

or P

rote

ct A

larm

(TB-

O12

): C1

-Hig

h Pr

essu

re A

larm

(TB-

O13

): C1

-Low

Pre

ssur

e AL

arm

(TB-

O6)

: C1-

Suct

ion

Pres

sure

(TB-

O8)

: C1-

Curr

ent T

rans

duce

r(T

B-O

9): C

1-Cu

rren

t Tra

nsdu

cer

(TB-

O7)

: C1-

Suct

ion

Pres

sure

(R-1

.14)

(R-3

.14)

(R-4

.14)

(U2-

IN1-

1)

(U2-

IN2-

3)

(U1-

IN3-

4)

(U2-

IN4-

6)

(TB-

P17)

+24

vDc

(TB-

O4)

+24

vDc

(TB-

Y1):

C2-C

onde

nser

Liq

uid

Tem

p(T

B-Y2

): Co

mm

on T

BG1

& 3

(T

B-Y3

): C2

-Eva

pora

tor G

as T

emp

(TB-

Y4):

C2-D

isch

arge

Pre

ssur

e(T

B-Y5

): C2

-Dis

char

ge P

ress

ure

(TB-

Y10)

: C2-

Mot

or P

rote

ct

(TB-

Y12)

: C2-

Hig

h Pr

essu

re A

larm

(TB-

Y13)

: C2-

Low

Pre

ssur

e Al

arm

(TB-

Y6):

C2-S

uctio

n Pr

essu

re

(TB-

Y8):

C2-C

urre

nt T

rans

duce

r(T

B-Y9

): C2

-Cur

rent

Tra

nsdu

cer

(TB-

Y7):

C2-S

uctio

n Pr

essu

re

(R-5

.14)

(R-7

.14)

(R-8

.14)

(U3-

IN1-

1)(U

3-C-

2)(U

3-IN

2-3)

(U3-

IN3-

4)

(U3-

IN4-

6)

(TB-

O8)

+24

vDc

(TB-

Y4) +

24vD

c

(U2-

IN5-

7)(T

B-O

6) +

24vD

c

(U3-

IN5-

7)(T

B-Y6

) +24

vDc

(TB-

Y11)

: C2-

Ther

mal

Ove

rload

Ala

rm

(TB-

O11

): C1

- The

rmal

Ove

rload

Ala

rm(R

-2.1

4)

(R-6

.14)

COMPRESSOR 4 SENSORSCOMPRESSOR 3 SENSORS

(TB-

G1)

: C3-

Cond

ense

r Liq

uid

Tem

p(T

B-G

2): C

omm

on T

BG1

& 3

(T

B-G

3): C

3-Ev

apor

ator

Gas

Tem

p(T

B-G

4): C

3-D

isch

arge

Pre

ssur

e(T

B-G

3): C

3-D

isch

arge

Pre

ssur

e

(TB-

G10

): C3

- Mot

or P

rote

ct A

larm

(TB-

G12

): C3

-Hig

h Pr

essu

re A

larm

(TB-

G13

): C3

-Low

Pre

ssur

e AL

arm

(TB-

G6)

: C3-

Suct

ion

Pres

sure

(TB-

G8)

: C3-

Curr

ent T

rans

duce

r(T

B-G

9): C

3-Cu

rren

t Tra

nsdu

cer

(TB-

G7)

: C3-

Suct

ion

Pres

sure

(R-9

.14)

(R-1

1.14

) (R

-12.

14)

(U5-

IN1-

1)(U

5-C-

2)(U

5-IN

2-3)

(U5-

IN3-

4)

(U5-

IN4-

6)

(TB-

P18)

+24

vDc

(TB-

G4)

+24

vDc

(TB-

N1)

: C4-

Cond

ense

r Liq

uid

Tem

p(T

B-N

2): C

omm

on T

BG1

& 3

(T

B-N

3): C

4-Ev

apor

ator

Gas

Tem

p(T

B-N

4): C

4-D

isch

arge

Pre

ssur

e(T

B-N

5): C

4-D

isch

arge

Pre

ssur

e

(TB-

N10

): C4

-Mot

or P

rote

ct

(TB-

N12

): C4

-Hig

h Pr

essu

re A

larm

(TB-

N13

): C4

-Low

Pre

ssur

e Al

arm

(TB-

N6)

: C4-

Suct

ion

Pres

sure

(TB-

N8)

: C4-

Curr

ent T

rans

duce

r(T

B-N

9): C

4-Cu

rren

t Tra

nsdu

cer

(TB-

N7)

: C4-

Suct

ion

Pres

sure

(R-1

3.14

)

(R-1

5.14

) (R

-16.

14)

(U6-

IN1-

1)(U

6-C-

2)(U

6-IN

2-3)

(U6-

IN3-

4)

(U6-

IN4-

6)

(TB-

G8)

+24

vDc

(TB-

N4)

+24

vDc

(U5-

IN5-

7)(T

B-G

6) +

24vD

c

(U6-

IN5-

7)(T

B-N

6) +

24vD

c

(TB-

N11

): C4

-The

rmal

Ove

rload

Ala

rm

(TB-

G11

): C3

- The

rmal

Ove

rload

Ala

rm(R

-10.

14)

(R-1

4.14

)

(TB-

Z1):

Enab

le C

ompr

esso

r 1

(TB-

Z3):

120

VAC

Neu

tral

(TB-

Z5):

Enab

le C

ompr

esso

r 2

(RIB

-1.2

)(R

IB-2

.2)

(TB-

Z2):

Enab

le H

eat C

omp1

(TB-

Z6):

120

VAC

Neu

tral

(TB-

Z7):

Enab

le H

eat C

omp2

(RIB

-3.2

)(R

IB-4

.2)

(TB-

Z4):

Rese

t Com

pres

sor 1

(TB-

Z9):

120

VAC

Neu

tral

(TB-

Z8):

Rese

t Com

pres

sor 2

(RIB

-5.2

)(R

IB-6

.2)

(TB-

P9)

(TB-

Z3)

(TB-

Z6)

(TB-

Z19)

: G

roun

d

(TB-

Z10)

: Ena

ble

Com

pres

sor 3

(TB-

Z12)

: 120

VAC

Neu

tral

(TB-

Z14)

: Ena

ble

Com

pres

sor 4

(TB-

Z11)

: Ena

ble

Hea

t Com

p3

(TB-

Z15)

: 120

VAC

Neu

tral

(TB-

Z16)

: Ena

ble

Hea

t Com

p4

(TB-

Z13)

: Res

et C

ompr

esso

r 3

(TB-

Z18)

: 120

VAC

Neu

tral

(TB-

Z17)

: Res

et C

ompr

esso

r 4

ENABLE COMPRESSORS & RESET

RIB-2Heater C1

RIB-5Heater C2

RIB-3Reset C1

RIB-6Reset C2

(TB-

P2_1

20V+

)

(RIB

-2.1

_120

V+)

(TB-

Z8)

(TB-

Z4)

(TB-

Z7)

(TB-

Z2)

RIB-1Enable C1

RIB-4Enable C2

(TB-

P6)

(TB-

Z5)

(TB-

Z1)

(RIB

-4.1

_120

V+)

(RIB

-1.1

_120

V+)

(RIB

-3.1

_120

V+)

(U2-

G-4

& R

IB-2

.5)

(U2-

OU

T1-1

)

(U3-

G-4

)

(U3-

OU

T1-1

)

(RIB

-1.5

)

(U2-

OU

T2-3

)

(U3-

G-4

)

(U3-

OU

T2-3

)

(U2-

G-8

)

(U2-

OU

T4-7

)

(U3-

G-8

)

(U3-

OU

T4-7

)

RIB-8Heater C3

RIB-11Heater C4

RIB-9Reset C3

RIB-12Reset C4

(RIB

-5.1

_120

V+)

(RIB

-8.1

_120

V+)

(TB-

Z8)

(TB-

Z4)

(TB-

Z7)

(TB-

Z2)

RIB-7Enable C3

RIB-10Enable C4

(TB-

P7)

(TB-

Z5)

(TB-

Z1)

(RIB

-10.

1_12

0V+)

(RIB

-7.1

_120

V+)

(RIB

-9.1

_120

V+)

(U5-

G-4

)

(U5-

OU

T1-1

)

(U6-

G-4

)

(U6-

OU

T1-1

)

(U5-

G-4

)

(U5-

OU

T2-3

)

(U6-

G-4

)

(U6-

OU

T2-3

)

(U5-

G-8

)

(U5-

OU

T4-7

)

(U6-

G-8

)

(U6-

OU

T4-7

)

1

(TB-Y10)

(R-4.13)

(TB-Y12)

(R-6.13)

(TB-Y13)

(R-7.13)

R-5

[120

VA

C]

Com

p-2

Mot

orP

rote

ctA

larm

R-7

[120

VA

C]

Com

p-2

Hig

hP

ress

ure

Ala

rm

R-8

[120

VA

C]

Com

p-2

Low

Pre

ssur

eA

larm

(TB-O10)

(TB-P11)

(TB-O12)

(R-2.13)

(U2-IN6-9)

(U2-IN7-10)

(TB-O13)

(R-3.13)(U2-IN8-12)

5(N

O)

13(-

)

9

1(N

C)

14(+

)R-1

[120

VA

C]

Com

p-1

Mot

orP

rote

ctA

larm

R-3

[120

VA

C]

Com

p-1

Hig

hP

ress

ure

Ala

rm

R-4

[120

VA

C]

Com

p-1

Low

Pre

ssur

eA

larm

(U2-C-11)

(R-2.5)

(R-3.5)

(U3-IN6-9)

(U3-IN7-10)

(U3-IN8-12)

(U3-C-11)

(R-6.5)

(R-7.5)

R-6

[120

VA

C]

Com

p-2

Ther

mal

Ove

rload

Ala

rm

(TB-O11)

(R-1.13)(U2-IN6-9)

R-2

[120

VA

C]

Com

p-1

Ther

mal

Ove

rload

Ala

rm

(R-1.5)

(TB-Y11)

(R-5.13)

(U3-IN6-9)

(TB-B1)(TB-B2)

(eSC-1)(eSC-3)

(eSC-2)

(TB-B3)(TB-B4)(TB-B5)(TB-B6)

(TB-B13)

(TB-B14)

NOTE: Pressure sensors & CT’s require resistors and DIP switches

(TB-P14)(TB-P12)

(TB-P19)

(U1-IN1-1)(U1-C-2)(U1-IN2-3)(U1-IN3-4)(U1-C-5)(U1-IN4-6)


Evap Inlet (Return) Temp C1 C2Common IN1 & IN2Evap Outlet (Supply) Temp C1 C2Cond Inlet (Return) Temp C1 C2Common IN3 & IN4

Cond Outlet (Supply) Temp C1 C2

Evap/Cond Flow Switch C1 C2Common IN5 & IN6[A][A]Common IN7 & IN8

[A]

Input ID

U1 -AU1 +BU1 ϛ

U1 24Vac cU1 24Vac -U1 24Vac +

[A]

[A]

Common Out1 & Out2

[A]

[A]

Common Out3 & Out4

Output ID

[A]

Evap/Cond Iso 2-Way C1 C2Common Out5 & Out6

[A]

[A]

U1-OUT1-1

U1-OUT2-3

U1-G-4

U1-OUT3-5

U1-OUT4-7

U1-G-8U1-OUT5-9

U1-OUT6-11

U1-G-12U1-OUT7-13

U1-OUT8-15

Common Out5 & Out6 U1-G-16

U1 – MASTER TEMPS C1 & C2


C1-Condenser Liquid TempCommon IN1 & IN2

C1-Evaporator Gas Temp

C1- Discharge PressureCommon IN3 & IN4

Input ID

C1-Suction Pressure


C1-Current Transducer (CT)Common IN5 & IN6C1-Motor+ Thermal AlarmC1-High Pressure AlarmCommon IN7 & IN8

C1- Low Pressure Alarm

C1 – Enable Compressor

C1 – Crank Heater

Common Out1 & Out2

Not Used

C1 – Momentary Reset

Common Out3 & Out4

Output ID

Not Used

Not Used

Common Out5 & Out6

Not Used

Not Used

U2-OUT1-1

U2-OUT2-3

U2-G-4

U2-OUT3-5

U2-OUT4-7

U2-G-8U2-OUT5-9

U2-OUT6-11

U2-G-12U2-OUT7-13

U2-OUT8-15


U2 - COMPRESSOR 1

(TB-P14)(TB-P12)

(TB-Z19)U2 24Vac cU2 24Vac -U2 24Vac +

(U1 +B)(U1 ϛ)

(U1 -A) U2 -AU2 +BU2 ϛ




C2-Discharge PressureCommon IN3 & IN4

Input ID

C2-Suction Pressure


C2-Current Transducer (CT)Common IN5 & IN6C2- Motor + Thermal AlarmC2-High Pressure AlarmCommon IN7 & IN8

C2-Low Pressure Alarm


C2- Crank Heater

Common Out1 & Out2

Not Used


Common Out3 & Out4

Output ID

Not Used

Not Used

Common Out5 & Out6

Not Used

Not Used

U3-OUT1-1

U3-OUT2-3

U3-G-4

U3-OUT3-5

U3-OUT4-7

U3-G-8U3-OUT5-9

U3-OUT6-11

U3-G-12U3-OUT7-13

U3-OUT8-15


U3 - COMPRESSOR 2

(TB-P14)(TB-P12)

(TB-Z19)U3 24Vac cU3 24Vac -U3 24Vac +

U3 -AU3 +BU3 ϛ

250Ω

250Ω

250Ω

250Ω

250Ω

250Ω

(U2 +B)(U2 ϛ)

(U2 -A)

-

-

-

-

-

R-

NOTE: Pressure sensors & CT’s require resistors and DIP switches



Evap Inlet (Return) Temp C3 C4Common IN1 & IN2Evap Outlet (Supply) TempC3 C4

Cond Inlet (Return) Temp C3 C4

Common IN3 & IN4Cond Outlet (Supply) Temp C3 C4

Evap/Cond Flow Switch C3 C4Common IN5 & IN6[A]Evap Header Outlet TempCommon IN7 & IN8

Cond Header Outlet Temp

Input ID

U4 -AU4 +BU4 ϛ


[A]

[A]

Common Out1 & Out2

[A]

[A]

Common Out3 & Out4

Output ID

[A]

Evaporator Iso 2-Way C3 C4Common Out5 & Out6

Condenser Iso 2-way C3 C4

[A]

U4-OUT1-1

U4-OUT2-3

U4-G-4

U1-2-OUT3-5

U4-OUT4-7

U4-G-8U4-OUT5-9

U4-OUT6-11

U4-G-12U4-OUT7-13

U4-OUT8-15


U4 – MASTER TEMPS C3 & C4




C3- Discharge PressureCommon IN3 & IN4

Input ID

C3-Suction Pressure


C3-Current Transducer (CT)Common IN5 & IN6C3-Motor+ Thermal AlarmC3-High Pressure AlarmCommon IN7 & IN8

C3- Low Pressure Alarm


C3 – Crank Heater

Common Out1 & Out2

Not Used


Common Out3 & Out4

Output ID

Not Used

Not Used

Common Out5 & Out6

Not Used

Not Used

U5-OUT1-1

U5-OUT2-3

U5-G-4

U5-OUT3-5

U5-OUT4-7

U5-G-8U5-OUT5-9

U5-OUT6-11

U5-G-12U5-OUT7-13

U5-OUT8-15


U5 - COMPRESSOR 3


U5 -AU5 +BU5 ϛ




C4-Discharge PressureCommon IN3 & IN4

Input ID

C4-Suction Pressure


C4-Current Transducer (CT)Common IN5 & IN6C4- Motor + Thermal AlarmC4-High Pressure AlarmCommon IN7 & IN8

C4-Low Pressure Alarm


C4- Crank Heater

Common Out1 & Out2

Not Used


Common Out3 & Out4

Output ID

Not Used

Not Used

Common Out5 & Out6

Not Used

Not Used

U6-OUT1-1

U6-OUT2-3

U6-G-4

U6-OUT3-5

U6-OUT4-7

U6-G-8U6-OUT5-9

U6-OUT6-11

U6-G-12U6-OUT7-13

U6-OUT8-15


U6 - COMPRESSOR 4


U6 -AU6 +BU6 ϛ

250Ω

250Ω

250Ω

250Ω

250Ω

250Ω

(TB-N10)

(R-12.13)

(TB-N12)

(R-14.13)

(TB-N13)

(R-15.13)

R-1

3[1

20V

AC

]C

omp-

4M

otor

Pro

tect

Ala

rm

R-1

5[1

20V

AC

]C

omp-

4H

igh

Pre

ssur

eA

larm

R-1

6[1

20V

AC

]C

omp-

4Lo

wP

ress

ure

Ala

rm

(TB-G10)

(R-8.13)

(TB-G12)

(R-10.13)

(U5-IN6-9)

(U5-IN7-10)

(TB-G13)

(R-11.13)

(U5-IN8-12)

R-9

[120

VA

C]

Com

p-3

Mot

orP

rote

ctA

larm

R-1

1[1

20V

AC

]C

omp-

3H

igh

Pre

ssur

eA

larm

R-1

2[1

20V

AC

]C

omp-

3Lo

wP

ress

ure

Ala

rm

(U5-C-11)

(R-10.5)

(R-11.5)

(U6-IN6-9)

(U6-IN7-10)

(U6-IN8-12)

(U6-C-11)

(R-14.5)

(R-15.5)

R-1

4[1

20V

AC

]C

omp-

4Th

erm

alO

verlo

adA

larm

(TB-G11)

(R-9.13)(U5-IN6-9)R

-10

[120

VA

C]

Com

p-3

Ther

mal

Ove

rload

Ala

rm

(R-9.5)

(TB-N11)

(R-13.13)

(U6-IN6-9)

(TB-

B10)

: Con

dens

er In

let (

Retu

rn) C

1&C2

(TB-

B4):

Cond

ense

r Inl

et (R

etur

n) C

1&C2

(TB-

B5):

Com

mon

TBG

4,5

& 7

(T

B-B6

): Co

nd O

utle

t (Su

pply

) Tem

p C1

&C2

(U1-

IN3-

1)(U

1-C-

5)

(U1-

IN4-

6)(T

B-B7

): Ev

apor

ator

Inle

t C3&

C4

(TB-

B12)

: Con

d O

utle

t (Su

pply

) Tem

p C1

&C2

(TB-

B13)

: Eva

p &

Con

d Fl

ow S

witc

h C1

&C2

(TB-

B15)

: Eva

p &

Con

d Fl

ow S

witc

h C3

&C4

(TB-

B16)

: Eva

pora

tor H

eade

r Out

let T

emp

(TB-

B14)

: Com

mon

TBG

11,1

2,14

,15

TB

TB2

2R

TB2-R

TB2R

T

R

T

R

3

T

R

3-

T3-

TB5R

TB5R

TB5

R-

TB

R-

TB

R-

6

TB

6

TB6-

R

TB6-

R-

(RIB

-7.2

)(R

IB-8

.2)

(RIB

-9.2

)(R

IB-1

0.2)

(RIB

-11.

2)(R

IB-1

2.2)

(TB-

Z9)

(TB-

Z12)

(TB-

Z15)

(TB-

B11)

: Com

mon

TBG

11,1

2,14

,15

(U4-

IN1-

1)(U

4-C-

2)

(U4-

IN2-

3)(U

4-IN

3-1)

(U4-

C-5)

(U4-

IN4-

6)

21 21 21 21 21 21 21 21 21 21 21 2

3 4 5 3 4 5 3 4 5 3 4 5 3 4 5 3 4 5 3 4 5 3 4 5 3 4 5 3 4 5 3 4 5 3 4 5

13(-

)

9

14(+

)13

(-)

9

14(+

)13

(-)

9

14(+

)13

(-)

9

14(+

)13

(-)

9

14(+

)13

(-)

9

14(+

)13

(-)

9

14(+

)13

(-)

9

14(+

)13

(-)

9

14(+

)13

(-)

9

14(+

)13

(-)

9

14(+

)13

(-)

9

14(+

)13

(-)

9

14(+

)13

(-)

9

14(+

)13

(-)

9

14(+

)

5(N

O)

1(N

C)5(

NO

)1(

NC)

5(N

O)

1(N

C)5(

NO

)1(

NC)

5(N

O)

1(N

C)5(

NO

)1(

NC)

5(N

O)

1(N

C)5(

NO

)1(

NC)

5(N

O)

1(N

C)5(

NO

)1(

NC)

5(N

O)

1(N

C)5(

NO

)1(

NC)

5(N

O)

1(N

C)5(

NO

)1(

NC)

5(N

O)

1(N

C)

(R-5.1)

(R-13.5)

(TB-O1)(TB-O2)(TB-O3)(TB-O5)

TB-P19(24VDC-)

(TB-O7)

(TB-O9)

(U2-C-5)

(R-1 & 2.9)

(R-4.9)

(R-1.5)(R-3.9)

(TB-Y1)(TB-Y2)(TB-Y3)(TB-Y5)

TB-P19(24VDC-)

(TB-Y7)

(TB-Y9)

(U3-C-5)

(R-5 & 6.9)

(R-8.9)

(R-5.5)(R-7.9)

(TB-B7)(TB-B8)(TB-B9)

(TB-B10)(TB-B11)(TB-B12)

(TB-B15)

(TB-B14)

(TB-B18)

(TB-B17)

(U4 +B)(U4 ϛ)

(U4 -A)

(U5 +B)(U5 ϛ)

(U5 -A)

(TB-B16)

(TB-G1)(TB-G2)(TB-G3)(TB-G5)

TB-P20(24VDC-)

(TB-G7)

(TB-G9)

(U5-C-5)

(R-9 & 10.9)

(R-12.9)

(R-9.5)(R-11.9)

(TB-N1)(TB-N2)(TB-N3)(TB-N5)

TB-P20(24VDC-)

(TB-N7)

(TB-N9)

(U6-C-5)

(R-13 & 14.9)

(R-16.9)

(R-13.5)(R-15.9)

EOL - ON

EOL – OFF

EOL – OFFEOL – OFF

EOL – OFF

EOL – OFF

(U1-

IN5-

7)(U

1-C-

8 &

U4-

C-8)

(U4-

IN5-

7)(U

4-IN

7-10

)(U

4-C-

11)

(U4-

IN8-

12)

(RIB-1.4)

(RIB-1.5)

(RIB-2.4)

(RIB-3.5)

(RIB-3.4)

(TB-B21)

(TB-B20)

(RIB-4.4)

(RIB-4.5)

(RIB-5.4)

(RIB-6.5)

(RIB-6.4)

(TB-P15)(TB-P13)

(TB-Z19)

(TB-P15)(TB-P13)

(TB-Z19)

(RIB-7.4)

(RIB-7.5)

(RIB-8.4)

(RIB-9.5)

(RIB-9.4)

(TB-B22)

(U1-G-16)

(RIB-10.4)

(RIB-10.5)

(RIB-11.4)

(RIB-12.5)

(RIB-12.4)

(TB-P15)(TB-P13)

(TB-Z19)

(U3 +B)(U3 ϛ)

(U3 -A)

(U1-

OU

T7-1

3)(U

4-O

UT7

-13)

13


Wiring Schematics

L1

L2

L3

1

2

L 11

N 12 14

L1L2L3

F1

F1 Main FuseF2 Compressor FuseK1 Motor ContactorT/O Thermal Overload RelayM Compressor MotorF3 Control Circuit FuseRIB1 Enable Compressor Relay (HOA)RIB2 Enable Crank Heater (HOA)RIB3 Fault Reset (HOA)BO1 Binary Controller Output (Enable Compressor)BO2 Binary Controller Output (Crank Heater)BO4 Binary Controller Output (Fault Reset)

LEGEND

MainSwitch

F2

K1

T/O

120V AC

M1

2

3

F3

RIB3N/C

RIB1N/O

BO4COM

BO1COM

R1 Motor Protect Alarm Monitor RelayR2 Thermal Overload Alarm Monitor RelayR3 High Pressure Alarm Monitor RelayR4 Low Pressure Alarm Monitor RelayBI6 Binary Control Input 6 (Motor Protect & Thermal Overload)BI7 Binary Control Input 7 (High Pressure Alarm)BI8 Binary Control Input 8 (Low Pressure Alarm)CK HTR Crankcase Heater

Note 1: Many different power connection configurations are available, refer to specifications.

RIB2N/O

BO2COM

R1BI6 COM

DualPressureSwitch

Low Pressure

High PressureR4BI8 COM

R3BI7 COM

CK HTR

R2

BI6

COM

120V

-

+

SE-E1

See Note 1 See Note 1 CHILLIT CHILLERS(CLW SCROLL SERIES BASIC WIRING DIAGRAM)

14


Field Wiring and Control Setup

Line VoltageHigh Voltage Connections

Connect power wiring as shown in the line voltage wiring

schematic on page 13.

Low Voltage OperationThermostat/Controller (Aquastat)A two-stage 24 VAC thermostat or liquid controller (field

supplied) must be used to turn the commercial chiller on

or off, and to switch it from cooling to heating if

necessary. Multiple chillers in the same bank must be

controlled from one thermostat/controller (must be

isolation relays for multiple unit applications).

Low Voltage Connections

Connect low voltage thermostat wiring as shown in the low

voltage wiring schematic on page 12. Connections shown

are for typical thermostat. Actual connections may vary

with specific device used.

NOTE: If a separate transformer is used to supply a Y1, Y2, or

B signal to the unit controls, isolation relays must be used.

CAUTION: Use only copper conductors for field installed wiring. Terminals in the unit are not designed for other types of conductors.

WARNING: All wiring must comply with local and state codes. Disconnect the power supply before beginning to wire to prevent electrical shock or equipment damage.

15


The CLW’s microprocessor based control not only monitors

and controls the heat pump but also can communicate any

of this information back to the building automation system

(BAS) clearly putting the CLW Quad Series in a class of

its own. The control will enumerate all fault and warning

conditions which can be read over a BAS as well as display

on a local user interface. An enhanced local interface is

invaluable as a service tool for the building service team

and is used to aid in diagnosing issues and the initial setup,

startup, and commissioning.

The Control Provides:

• Operational sequencing

• High and low-pressure safety switch monitoring

• Monitoring motor rotation, oil temperature, and motor

windings overheating

• Monitors for electrical thermal overloading

• Lockouts and mode control

▶ The unit can be commanded to run from the local

display, BAS or HOA switches (manual hand-off-auto

switch) located in the low voltage panel.

▶ An alarm history can be viewed through the local

user interface.

▶ Trending of key inputs and variables are stored in the

controller and available to viewed and graphed.

▶ The Controller has unused analog and digital inputs and

outputs for field installed items such as additional water

temperature or status switches

Standard Features

• Operational sequencing and compressor and

unit staging

• High and low-pressure safety switch monitoring

• Monitoring motor rotation, oil temperature, and

motor overheating

• Monitors for electrical thermal overloading

• Monitors for high and low saturation temperatures

• Proves Flow prior to starting

• Short cycle warnings

• Lockout and mode control

DDC Operation & Connection

The controller is a native BACnet controller. Other optional

network protocols are supported via a protocol Gateway.

• Johnson Control N2

• LonWorks

• Modbus

• And many more

Control Features

Control and Safety Feature Details

User Shutdown

• The shutdown mode can be activated by a command

from a facility management system or the local user

interface. When the unit is shut down any isolation

valves are close and any compressor heaters are

powered. Additionally the shutdown can be complete

and no outputs are active.

Alarm Shutdown

• Alarm Shutdown occurs when ever an alarm condition

is present from any physical safety: refrigerant system

high pressure, refrigerant system low pressure, motor

thermal overload, motor rotation direction incorrect,

electrical thermal overload, no flow, or freeze detection.

• Alarm Shutdown occurs when ever an alarm condition

is present from any software safety: High Sat, Low

Sat, trying to start a compressor too quickly. Other

software condition can trigger an alarm shut down

like approaching or exceeding the application range

of the compressor.

• When any valid fault signal remains continuously

active for the length of its recognition delay, the

controller will go into fault retry mode, which will

turn off compressors. If the safety is auto resetting,

after the compressor delay time for that alarm, the

compressors will attempt to operate once again. If

four consecutive faults occur in 2 hours, the unit will

go into lockout mode.

Alarm Lockout Mode

• Lockout mode is activated when a physical safety

requires a manual reset or a software safety with an

auto resetting safety is configured to lockout after

a number of repeated alarms in a period of time

described above.

• The lockout condition can be reset by powering down

the controller, by a commanding the unit off from the

local display or the BAS, or by the pushing the alarm

reset button on the local display.

Refrigerant System Low Pressure

• The low-pressure switch is a normally closed (NC)

switch that monitors the systems refrigerant pressure.

• This safety requires a manual reset.

Refrigerant System High Pressure

• The high-pressure switch is a normally closed (NC)

switch that monitors the systems refrigerant pressure.

• This safety requires a manual reset.

16


Control FeaturesAlarm Outputs

• The control has 18-enumerated status variable for each

compressor and the unit.

• Compressor Lockout

• Any compressor can be locked out from the local

display or using the HOA switch.

Motor & Oil Thermal Overload

• The motor thermal overload switch is a normally

closed (NC) switch that monitors the temperature of

the motor.

• This safety can be configured to auto reset or manual

reset (factory default).

Motor Rotation Direction

• The motor rotation direction switch is a normally

closed (NC) switch that monitors the rotation direction

of the motor.

Electrical Thermal Overload

• The electrical thermal overload switch is a normally

closed (NC) switch that monitors the electrical thermal

conditions of the wires leaving the main contactor.

• This safety can be configured to auto reset or manual

reset (factor default).

Flow Switches

• The optional flow switches are normally closed (NC)

switch that monitors the flow in the pipes into the

evaporator and condenser.

• This safety clears when flow is present.

Freeze Protection

• The optional freeze protection switch is a normally

closed (NC) switch that monitors the temperature of

the water in the pipe coming out of the evaporator for

freeze conditions.

• This safety can be configured to auto reset or

manual reset.

Low Refrigerant Saturation Temperatures

• The controller monitors the refrigerant saturation

temperatures for low saturation temperatures. Without

glycol, it is recommend to set the low saturation

temperature to 34°F and consider it an alarm condition

it the saturation temperature continuously remains

below that temperature for 90 seconds.

• The compressor will not restart until the low saturation

compressor delay time delay has been satisfied.

High Refrigerant Saturation Temperatures

• The controller monitors the refrigerant saturation

temperatures for high saturation temperatures. An

alarm condition occurs if the saturation temperature

exceeds the high limit.

• The compressor will not restart until the high saturation

compressor delay time delay has been satisfied.

17


Power Fail Restart

• When the controller is first powered up, the outputs will

be disabled and delay timers reset to avoid a random

start or multiple compressors staring simultaneously.

Lead Compressor Start Delay Time

• The lead compressor Fixed-On-Delay-Time that will

ensure that the lead compressor output is not enabled

for 120 seconds after the control receives a call to start

the unit and the lead compressor.

• This delay is not adjustable.

Lag Compressor Start Delay Time

• The lag compressor Fixed-On-Delay-Time will ensure

that the lead compressor output is not enabled for 5

minutes after the control receives a call to start the

lead compressor.

• This delay is adjustable from 60 – 3600 seconds over a

BAS or a local display.

Compressor Minimum On Delay

• There is no compressor minimum on time safety but in

adjusting the on off dead band for any given site no

compressor should never be enabled for less than two

(2) minutes each time the compressor output is enabled.

Compressor Minimum Off Delay Time

• The compressor minimum time delay will ensure

that the compressor output will not be enabled for a

minimum of ten (10) minutes after it is disabled.

• This allows for the system refrigerant pressures to

equalize after the compressor is disabled.

• This delay is adjustable from 480 - 1200 over a BAS or

a local display.

Compressor Lead/Lag

• Compressor lead/lag is a standard part of the

system. The unit is shipped from the factory with lead/

lag disabled.

• Lead/lag can be activated through the unit from the

user interface.

Modes

• The flowing modes are supported. Optional dual 6-pipe

rack* or local valves are required to implement many of

the modes

• Heating Only Cycle

• Cooling Only Cycle

• Simultaneous Heating and Cooling*

• Fixed Building Heating and Cooling*

• Primary Heating Secondary Cooling*

• Primary Cooling Secondary Heating*

• Free Cooling*

Fault History

• If a fault occurs the fault will be recorded and

displayed on the local display and an enumerated

status is available for the BAS.

• Optional trending and archiving solutions are available.

• Control Accessories and Options

• Local 7” user display

• Local 7” user display and Web pages

• Local 17” touch Screen and SQL Database

Sequence of Operation

18


HE

GPM x 500*

Legend

Abbreviations and Definitions

Reference CalculationsHeating Calculations: Cooling Calculations:

LWT = EWT + HR

GPM x 500*LWT = EWT -

NOTE: * When using water. Use 485 for 15% methanol/water or Environol solution.

ELT = entering load fluid temperature to heat pump

EER = cooling energy effciency (TC/KW)

LLT = leaving load fluid temperature from heat pump

PSI = pressure drop in pounds per square inch

LGPM = load flow in gallons per minuteFT HD = pressure drop in feet of head

LWPD = load heat exchanger water pressure dropKW = kilowatt

EST = entering source fluid temperature to heat pump

HR = heat rejected in MBTUH

LST = leaving source fluid temperature from heat pumpTC = total cooling capacity in MBTUH

SGPM = source flow in gallons per minuteCOP = coefficient of performance (HC/KW x 3.413)

SWPD = source heat exchanger water pressure dropHC = heating capacity in MBTUHHE = heat of extraction in MBTUH

Verify the following:• High voltage is correct and matches nameplate

• Fuses, breakers and wire size are correct

• Low voltage wiring is complete

• Piping is complete and the water system has been

cleaned and flushed

• Air is purged from closed loop system

• Isolation valves are open and water control valves or loop

pumps are wired

• Service/access panels are in place

• Transformer has been switched to lower voltage tap if

needed (208/230 volt units only)

• Unit controls are in “off” position

• Flow switches are installed and ready or wires

are jumpered

• Freeze detection setpoints have been set in

the microprocessor

WARNING: Verify ALL water controls are open and allow water flow PRIOR to engaging the compressor. Failure to do so can result in freezing the heat exchanger or water lines causing permanent damage to the unit.

Unit Startup

Startup Steps• Set thermostat control above cooling setpoint.

• Set thermostat control in cooling mode.

• Slowly reduce the control setting until both the

compressor and water control valve/loop pumps are

activated. Verify that the compressor is on and that

the water flow rate is correct by measuring pressure

drop through the heat exchanger and comparing to the

Pressure Drop table. Check for correct rotation of scroll

compressors. Switch any two power leads at the L1, L2,

and L3 line voltage termination block if incorrect.

• Perform a cooling capacity test by multiplying GPM x ΔT

x 485 (antifreeze/water). Use 500 for 100% water. Check

capacity against catalog data at same conditions.

• Set control to “OFF” position.

• Leave unit “OFF” for approximately five (5) minutes to

allow pressure to equalize.

• Adjust control below heating setpoint.

• Set control in “HEAT” position mode.

• Slowly increase the control setting until both compressor

and water control valve/loop pumps are activated. The

reversing valve should be heard changing over.

• Perform a heating capacity test by multiplying GPM x ΔT

x 485 (antifreeze/water). Use 500 for 100% water. Check

capacity against catalog data at same conditions.

• Check for vibrations, noise and water leaks.

• Set system to maintain desired setpoint.

• Instruct the owner/operator of correct control and

system operation.

19


Pressure Drop

EvaporatorCLW060 CLW080 CLW100 CLW120 CLW140

GPM PD GPM PD GPM PD GPM PD GPM PD

84.8 1.9 106.2 1.7 124.8 1.5 169.6 2.2 169.8 1.9

99.8 2.6 127.4 2.3 169.6 2.8 184.6 2.6 199.8 2.6

114.8 3.3 149.8 3.2 184.6 3.3 199.6 3.1 237.6 3.6

135.8 4.6 166.4 3.9 199.6 3.8 229.6 4.0 258.4 4.2

147.8 5.4 178.8 4.5 229.6 4.9 263.8 5.2 279.4 4.9

159.6 6.2 191.4 5.1 249.4 5.8 287.2 6.1 300.4 5.6

171.6 7.2 214.6 6.4 268.2 6.6 310.4 7.1 321.4 6.4

183.6 8.1 237.6 7.7 286.8 7.6 333.8 8.2 339.0 7.1

199.4 9.5 254.2 8.8 306.4 8.6 357.0 9.3 369.0 8.4

214.4 10.9 276.6 10.4 327.8 9.8 369.0 10.0 399.0 9.8

232.8 12.8 299.0 12.0 339.0 10.4 399.0 11.6 428.8 11.2

249.2 14.6 321.6 13.8 369.0 12.3 428.8 13.3 458.8 12.8

268.0 16.7 344.0 15.7 398.8 14.2 458.8 15.1 478.6 13.9

CondenserCLW060 CLW080 CLW100 CLW120 CLW140

GPM PD GPM PD GPM PD GPM PD GPM PD

82.0 2.0 114.4 2.3 124.4 1.9 143.0 1.7 191.2 2.0

101.0 2.9 124.4 2.7 144.6 2.5 168.2 2.3 208.0 2.4

114.4 3.7 134.6 3.1 171.4 3.4 205.8 3.3 213.4 2.9

124.4 4.4 144.6 3.6 186.6 4.0 224.0 3.9 232.2 3.4

134.6 5.1 160.0 4.3 201.6 4.7 242.0 4.5 251.2 4.0

143.8 5.9 174.0 5.1 216.8 5.4 260.2 5.2 270.0 4.6

156.4 6.9 188.2 5.9 232.0 6.1 274.2 5.8 288.8 5.2

165.8 7.5 202.2 6.8 248.6 7.0 298.4 6.8 320.0 6.3

179.2 8.7 216.4 7.7 268.8 8.1 322.6 7.9 348.2 7.5

182.8 9.1 239.8 9.4 289.0 9.3 346.8 9.1 376.4 8.7

199.0 10.6 261.0 11.0 309.0 10.6 371.0 10.3 404.6 9.9

215.0 12.3 282.2 12.8 335.6 12.4 376.8 10.7 432.8 11.3

231.2 14.2 303.2 14.6 362.8 14.4 410.0 12.5 443.4 11.9

247.4 16.1 324.4 16.6 390.0 16.5 443.4 14.5 476.6 13.6

20


Heat of Extraction Data

ModelSourceGPM

LoadGPM

EST Heat Of Extraction (HE)

ºF 105°F 110°F 115°F 120°F 125°F

060 180 180

50 864.6 847.6 837.4 827.6 823.8

55 920.0 910.6 901.2 889.2 877.4

60 992.4 978.4 962.6 955.6 941.6

65 1062.0 1046.0 1035.8 1021.0 1003.2

080 240 240

50 1145.4 1129.0 1116.4 1111.4 1098.4

55 1226.4 1219.6 1201.6 1185.4 1169.8

60 1323.0 1304.2 1283.4 1276.2 1255.2

65 1426.8 1405.0 1380.8 1361.6 1337.6

100 300 300

50 1366.0 1360.6 1343.2 1329.0 1312.4

55 1462.6 1455.4 1436.8 1418.4 1398.2

60 1577.8 1556.4 1546.0 1524.8 1503.2

65 1701.0 1676.4 1664.0 1639.0 1613.8

120 360 360

50 1762.6 1743.6 1723.0 1700.8 1693.8

55 1892.0 1867.4 1857.4 1833.2 1807.2

60 2043.6 2014.8 1986.6 1973.6 1945.8

65 2189.2 2156.8 2140.8 2108.6 2076.8

140 420 420

50 1937.4 1910.0 1885.8 1876.0 1850.0

55 2077.2 2065.0 2033.2 2004.8 1974.2

60 2244.2 2211.6 2179.0 2159.2 2126.4

65 2405.0 2387.0 2349.6 2312.0 2287.6

07/24/13

21


Heat of Rejection Data

ModelSourceGPM

LoadGPM

EST Heat Of Extraction (HR)

ºF 65°F 70°F 75°F 80°F 85°F 90°F 95°F

060 180 180

42 934.0 923.0 915.6 905.0 897.0 888.8 878.8

44 960.0 953.8 946.0 934.4 922.8 910.2 905.8

46 990.6 980.0 968.4 963.8 951.6 939.4 934.4

48 1023.4 1011.8 1000.0 992.0 982.0 968.0 960.0

50 1048.0 1042.0 1030.0 1018.0 1004.0 998.0 986.0

080 240 240

42 1248.0 1234.6 1224.6 1210.4 1199.8 1188.8 1175.2

44 1290.0 1271.2 1261.0 1253.8 1234.4 1217.4 1209.4

46 1327.0 1308.4 1291.4 1285.0 1268.8 1253.2 1249.4

48 1371.2 1348.8 1332.8 1326.8 1312.6 1294.4 1284.4

50 1413.4 1392.0 1374.8 1357.0 1343.4 1329.4 1315.2

100 300 300

42 1493.2 1474.8 1464.8 1448.0 1435.4 1417.4 1409.0

44 1542.6 1525.0 1512.4 1494.6 1482.6 1465.0 1446.6

46 1591.0 1577.0 1559.6 1544.6 1524.8 1506.2 1493.6

48 1642.0 1625.2 1601.6 1591.2 1572.4 1552.2 1532.0

50 1692.6 1672.2 1651.6 1638.8 1620.0 1599.2 1581.6

120 360 360

42 1934.0 1907.0 1890.0 1868.0 1846.6 1828.4 1807.8

44 1955.2 1967.4 1948.4 1925.8 1903.0 1880.6 1861.6

46 2054.0 2033.0 2008.8 1985.0 1964.2 1937.4 1917.2

48 2122.0 2093.0 2071.2 2048.2 2024.0 1995.8 1971.0

50 2184.2 2160.0 2129.6 2108.0 2084.0 2057.6 2030.8

140 420 420

42 2112.0 2092.8 2072.8 2055.2 2028.6 2009.6 1986.4

44 2172.4 2160.0 2140.0 2114.4 2095.2 2067.8 2046.4

46 2244.0 2228.8 2206.0 2182.4 2154.4 2133.6 2111.0

48 2317.6 2293.8 2274.0 2249.4 2224.2 2194.4 2170.4

50 2386.0 2367.6 2344.2 2318.2 2294.6 2262.6 2242.2

07/24/13

22


Should a major problem develop, refer to the following information for possible causes and corrective steps.

If compressor won’t run:

1. The fuse may be open or the circuit breaker is tripped. Check electrical circuits and motor windings for shorts or

grounds. Investigate for possible overloading. Replace fuse or reset circuit breakers after fault is corrected.

2. Supply voltage may be too low. Check it with a volt meter.

3. Control system may be faulty. Check control for correct wiring of thermostat or aquastat and check the 24 volt

transformer for proper voltage.

4. Wires may be loose or broken. Replace or tighten.

5. The low pressure switch may have tripped due to one or more of the following:

a) Heating

1) Plugged heat exchanger on source side

2) Water flow source side -(Low)

3) Water too cold source side

4) Low refrigerant

b) Cooling

1) Plugged heat exchanger on load side

2) Water flow load side - (Low)

3) Water too cold load side

4) Low refrigerant

6. The high pressure switch may have tripped due to one or more of the following:

a) Heating

1) Plugged heat exchanger on load side

2) Low water flow load side

3) Water too warm load side

b) Cooling

1) Plugged heat exchanger on source side

2) Low water flow on source side

3) Water too warm source side

7. The compressor overload protection may be open. Disconnect power. Remove S1 & S2 wires from the compressor

protection module. Measure the resistance between the S1 & S2 wires. If the resistance measures > 2750 ohms, then

the internal compressor resistance has tripped the compressor protection module. The compressor protection module

will reset after a 30 minute delay and the resistance measures < 2250 ohms. Cycling the power off for a minimum of 3

seconds will manually reset the compressor module. The internal compressor resistance must measure < 2250 ohms for

the compressor module to reset.

8. The internal winding of the compressor motor may be grounded to the compressor shell. If so, replace the compressor.

9. The compressor winding may be open or shorted. Disconnect power. Check continuity with ohm meter. If the winding is

open, replace the compressor.

If sufficient cooling or heating is not obtained:

1. Check control for improper location or setting.

2. Check for restriction in water flow.

3. Check refrigerant subcooling and superheat for proper refrigerant charge and expansion valve operation.

4. The reversing valve may be defective and creating a bypass of refrigerant. If the unit will not heat, check the reversing

valve coil.

If the unit operation is noisy:

1. Check compressor for loosened mounting bolts. Make sure compressor is floating free on its isolator mounts. Check for

tubing contact with the compressor or other surfaces. Readjust it by bending slightly.

2. Check screws on all panels.

3. Check for chattering or humming in the contactor or relays due to low voltage or a defective holding coil. Replace

the component.

4. Check for proper installation of vibration absorbing material under the unit.

5. Check for abnormally high discharge pressures.

6. Compressor rotation incorrect

Troubleshooting

23


Heating Cycle Analysis

Cooling Cycle Analysis

24


Check One Start up/Check-out for new installation Troubleshooting Problem:___________________________________

1. FLOW RATE IN GPM (SOURCE SIDE HEAT EXCHANGER)

Water In Pressure: a.______ PSIWater Out Pressure: b.______ PSIPressure Drop = a - b c.______ PSIConvert Pressure Drop to Flow Rate (refer to Pressure Drop table) d.______ GPM

2. TEMPERATURE RISE OR DROP ACROSS SOURCE SIDE HEAT EXCHANGER

COOLING HEATINGWater In Temperature: e.______ °F e.______ °FWater Out Temperature: f. ______ °F f. ______ °FTemperature Difference: g.______ °F g.______ °F

3. TEMPERATURE RISE OR DROP ACROSS LOAD SIDE HEAT EXCHANGER

COOLING HEATINGWater In Temperature: h.______ °F h.______ °FWater Out Temperature: i. ______ °F i. ______ °FTemperature Difference: j. ______ °F j. ______ °F

4. HEAT OF REJECTION (HR) / HEAT OF EXTRACTION (HE) CALCULATION

HR or HE = Flow Rate x Temperature Difference x Brine Factor* d. (above) x g. (above) x 485 for Methanol or Environol, 500 for water*Heat of Extraction (Heating Mode) = btu/hrHeat of Rejection (Cooling Mode) = btu/hrCompare results to Capacity Data Tables

Note: Steps 5 through 8 need only be completed if a problem is suspected

5. WATTSCOOLING HEATING HYDRONIC

Volts: m._____ VOLTS m.______ VOLTS m. ______ VOLTSTotal Amps (Comp. + Fan): n. _____ AMPS n. ______ AMPS n. ______ AMPSWatts = m. x n. x 0.85 o. _____ WATTS o. ______ WATTS o. ______ WATTS

6. CAPACITYCooling Capacity = HR. - (o. x 3.413) p. _____ btu/hrHeating Capacity= HE. + (o. x 3.413) p. _____ btu/hr

7. EFFICIENCYCooling EER = p. / o. q. _____ EERHeating COP = p. / (o. x 3.413) q. _____ COP

8. SUPERHEAT (S.H.) / SUBCOOLING (S.C.) COOLING HEATING HYDRONICSuction Pressure: r. ______ PSI r. ______ PSI r. ______ PSISuction Saturation Temperature: s. ______ °F s. ______ °F s. ______ °FSuction Line Temperature: t. ______ °F t. ______ °F t. ______ °FSuperheat = t. - s. u. _____ °F u. ______ °F u. ______ °F

Head Pressure: v. ______ PSI v. ______ PSI v. ______ PSIHigh Pressure Saturation Temp.: w. _____ °F w. _____ °F w. _____ °FLiquid Line Temperature*: x. ______ °F x. ______ °F x. ______ °FSubcooling = w. - x. y. ______ °F y. ______ °F y. ______ °F

* Note: Liquid line is between the source heat exchanger and the expansion valve in the cooling mode; between the load heat exchanger and the expansion valve in the heating mode.

Company Name: _________________________________Technician Name: ________________________________Model No: ______________________________________Owner’s Name: __________________________________Installation Address: ______________________________

Company Phone No: ______________________________Date: __________________________________________Serial No:_______________________________________Open or Closed Loop: _____________________________Installation Date: _________________________________

COOLING

CLW Quad Startup and Troubleshooting Form

25


Unit Heat Exchanger Maintenance1. Keep all air out of the water or antifreeze solution.

2. Keep the system under pressure at all times. Closed

loop systems must have positive static pressure or air

vents may draw air into the system.

NOTES: If the installation is in an area with a known high

mineral content in the water, it is best to establish with

the owner a periodic maintenance schedule for checking

the water-to-refrigerant heat exchanger on a regular

basis. Should periodic cleaning be necessary, use standard

cleaning procedures. Generally, the more water flowing

through the unit, the less chance there is for scaling. Low

GPM flow rates produce higher temperatures through the

heat exchanger. To avoid excessive pressure drop and the

possibility of metal erosion, do not exceed GPM flow rate as

shown on the specification sheets for each unit.

Quarterly Checks• Compressor oil levels

• Test and check all manual safeties

• Check strainers for debris

• Check water flow rates and pressure drops across

evaporators and condensers

• Verify graphical data and trending

• Properly document all data

Annual Checks• Remove and clean all waterside strainers

• Back washing of heat exchangers

• Perform leak tests on all refrigerant circuits

• Check all water flanged connections for wear or leaks

• Implement oil analysis if deemed necessary

• Verify all electrical connections

• Check and update all graphical interface items along

with main controller

• Check and test all safeties both mechanical and

software

• Verify sensor accuracy

• Do a system check to get overall overview

• Properly document all data

Preventive Maintenance

Replacement ProceduresWhen contacting the company for service or replacement

parts, refer to the model number and serial number of the

unit as stamped on the serial plate attached to the unit.

If replacement parts are required, mention the date of

installation of the unit and the date of failure, along with an

explanation of the malfunctions and a description of the

replacement parts required.

In-Warranty Material Return

Material may not be returned except by permission

of authorized warranty personnel. Contact your local

distributor for warranty return authorization and assistance.

26


Service Parts ListNot available at time of publication. See selection software for a full part list.

27


Pages: Description: Date: By:

11 Updated Electrical Data 14 Nov 2013 DS

All First Published 06 Sept 2013 DS

Revision Guide

Manufactured by

WaterFurnace International, Inc.

9000 Conservation Way

Fort Wayne, IN 46809

www.waterfurnace.com

©2013 WaterFurnace International, Inc., 9000 Conservation Way, Fort Wayne, IN 46809-9794. WaterFurnace has a policy of continual product research and development and

reserves the right to change design and specifi cations without notice.

Product: CLW Quad Series Chiller

Type: Commercial Chiller - 60 Hz

Size: 60-140 Tons

Document: Installation ManualIM1900WW 11/13

clw quad series 60 to 140 tons clw quad series chiller ...clw quad series chiller installation...

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