AEC A0551794 RS Series User manual

RS Series
Screw Compressor Central Chiller
Part Number: A0551794
Bulletin Number: AE3-635.2
Effective: 10/1/07
Write Down Your Serial Numbers Here For Future Reference:
_________________________ _________________________
_________________________ _________________________
_________________________ _________________________
We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.
DCN No. ____________
© Copyright 2008
All rights reserved.

Screw Compressor Central Chillers Chapter 1: Safety ii
Shipping Information
Unpacking and Inspection
You should inspect your Screw Compressor Central Chiller for possible shipping damage.
Thoroughly check the equipment for any damage that might have occurred in transit, such as
broken or loose wiring and components, loose hardware and mounting screws, etc.
In the Event of Shipping Damage
According to the contract terms and conditions of the Carrier, the responsibility of the
Shipper ends at the time and place of shipment.
Notify the transportation company’s local agent if you discover damage.
Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization.
File a claim with the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.
Advise customer service regarding your wish for assistance and to obtain an RMA (return
material authorization) number.
If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on it. You should have:
Screw Compressor Central Chiller
Bill of lading
Packing list
Operating and Installation packet
Electrical schematic and panel layout drawings
Component instruction manuals
Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.
If the Shipment is Not Correct
If the shipment is not what you ordered, contact the parts and service department
immediately at [phone]. Have the order number and item number available.
Hold the items until you receive shipping instructions.
Returns
Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.

Screw Compressor Central Chillers Chapter 1: Safety iii
Table of Contents
CHAPTER 1: SAFETY ...............................................................VI
1-1 How to Use This Manual ............................................................................................ vi
Safety Symbols Used in this Manual.................................................................... vi
1-2 Warnings and Precautions .........................................................................................vii
1-3 Responsibility ............................................................................................................viii
General Responsibility.........................................................................................viii
Operator Responsibility ........................................................................................ ix
Maintenance Responsibility................................................................................... x
Reporting a Safety Defect ..................................................................................... x
CHAPTER 2: FUNCTIONAL DESCRIPTION............................ 11
2-1 Models Covered in This Manual................................................................................ 11
2-2 General Description................................................................................................... 11
2-3 Standard Features..................................................................................................... 11
Mechanical Features ...........................................................................................11
Electrical Features...............................................................................................12
Controller Features..............................................................................................12
Standard Features on Remote Condensers........................................................12
2-4 Options ...................................................................................................................... 13
2-5 Safety Devices and Interlocks ................................................................................... 13
CHAPTER 3: INSTALLATION .................................................. 15
3-1 Uncrating the Equipment........................................................................................... 15
3-2 Rigging and Placing the Chiller ................................................................................. 15
3-3 Making Electrical Connections .................................................................................. 16
3-4 Setup Procedures...................................................................................................... 17
Piping Considerations .........................................................................................17
Making Process Water Connections ...................................................................18
Making Tank Piping Connections........................................................................19
Water Connection Sizing Considerations............................................................21
Galvanic Corrosion Considerations.....................................................................21
Water Treatment Considerations.........................................................................21
Making Water-Cooled Condenser Connections ..................................................21
Installing the Remote Air-Cooled Central Chiller Condensers.............................23
Checking Motor Direction ....................................................................................28
Changing fan rotation direction............................................................................28
3-5 Initial Start-up ............................................................................................................ 28
Pre-Startup Checks .............................................................................................28
Determining Chilled Water Flow Rate .................................................................32
CHAPTER 4: OPERATION ....................................................... 33
4-1 Start-up...................................................................................................................... 33
Water & Remote Air-Cooled Central Chiller Startup............................................33
4-2 Controller Description................................................................................................ 34

Screw Compressor Central Chillers Chapter 1: Safety iv
Identifying Control Panel Indicator Lights and Switches for the Standard and
Advanced Controllers ..........................................................................................34
4-3 Controller Operation (Standard Controller) ............................................................... 36
Using the Standard Touchscreen Interface.........................................................36
Main Menu Screen ..............................................................................................37
Compressor Status Screen .................................................................................37
Process and Recirculation Pump Status Screens...............................................39
Active Alarm List and Alarm History Screens......................................................40
Configuration Menu Screen.................................................................................41
Viewing and Setting System Temperatures ........................................................45
Hourmeters Screen .............................................................................................46
4-4 Controller Operation (Advanced Controller) .............................................................. 48
Using the Advanced Touchscreen Interface........................................................48
Accessing the Main Menu Screen.......................................................................49
Viewing Compressor Status ................................................................................51
Viewing Chiller Pump Status ...............................................................................53
Viewing Active Alarms and Alarm History Screens .............................................54
Configuration Menu Screen.................................................................................56
Viewing and Setting System Temperatures ........................................................58
Viewing Compressor Run Times.........................................................................60
Viewing Pump Run Times ...................................................................................62
4-5 Operation Procedures ............................................................................................... 63
4-6 Shutdown................................................................................................................... 63
CHAPTER 5: MAINTENANCE .................................................. 64
5-1 Maintenance Schedule.............................................................................................. 64
5-2 Preventative Maintenance......................................................................................... 65
Lubrication...........................................................................................................65
Condenser Maintenance .....................................................................................65
5-3 Corrective Maintenance ............................................................................................ 66
Evaporator Maintenance .....................................................................................66
Miscellaneous Maintenance ................................................................................66
CHAPTER 6: TROUBLESHOOTING ........................................ 67
6-1 Introduction................................................................................................................ 67
CHAPTER 7: APPENDIX .......................................................... 70
7-1 Optional Components................................................................................................ 70
7-2 Technical Specifications............................................................................................ 70
Model Number Nomeclature................................................................................70
Typical Two-Circuit 60-195 Ton Remote Water Cooled Chiller Specifications....71
Typical Two-Circuit 60-195 Ton Remote Air Cooled Chiller Specifications.........72
RSR Series Remote Condenser Models .............................................................73
7-3 Drawings & Diagrams................................................................................................73
7-4 Spare Parts List......................................................................................................... 74
7-5 Returned Material Policy ........................................................................................... 75
Credit Returns .....................................................................................................75
Warranty Returns ................................................................................................75
7-6 Safety Tag Information .............................................................................................. 75
Central Chiller Safety Tags .................................................................................75

Screw Compressor Central Chillers Chapter 1: Safety v
7-7 Central Chiller Identification (Serial Number) Tag..................................................... 76
7-8 Technical Assistance................................................................................................. 77
Parts Department ................................................................................................77
Service Department.............................................................................................77
Sales Department................................................................................................77
Contract Department ...........................................................................................77

Screw Compressor Central Chillers Chapter 1: Safety vi of 77
Chapter 1: Safety
1-1 How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining your
screw compressor central chiller. The purpose is to assist you in applying efficient, proven
techniques that enhance equipment productivity.
This manual covers only light corrective maintenance. No other maintenance should be
undertaken without first contacting a service engineer.
The Functional Description section outlines models covered, standard features, and safety
features. Additional sections within the manual provide instructions for installation, pre-
operational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the screw compressor central chiller. We can also provide the assistance of a factory-
trained technician to help train your operator(s) for a nominal charge. This section includes
instructions, checks, and adjustments that should be followed before commencing with
operation of the Central Chiller. These instructions are intended to supplement standard
shop procedures performed at shift, daily, and weekly intervals.
The Operation chapter includes a description of electrical and mechanical controls, in
addition to information for operating the Central Chiller safely and efficiently.
The Maintenance chapter is intended to serve as a source of detailed assembly and
disassembly instructions for those areas of the equipment requiring service. Preventive
maintenance sections are included to ensure that your Central Chiller provides excellent, long
service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, parts lists, and
available options. A spare parts list with part numbers specific to your machine is provided
with your shipping paperwork package. Refer to this section for a listing of spare parts for
purchase. Have your serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
DANGER! DANGER indicates an imminently hazardous situation that, if not avoided,
will result in death or serious injury.
WARNING! WARNING indicates a potentially hazardous situation or practice that, if
not avoided, could result in death or serious injury.
Caution! CAUTION indicates a potentially hazardous situation or practice that, if
not avoided, may result in minor or moderate injury or in property damage.

Screw Compressor Central Chillers Chapter 1: Safety vii
1-2 Warnings and Precautions
Our equipment is designed to provide safe and reliable operation when installed and operated
within design specifications, following national and local safety codes. This may include, but
is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international
regulations.
To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this equipment, use good judgment and follow these safe practices:
Read and follow these operation and installation instructions when installing,
operating, and maintaining this equipment. If these instructions become
damaged or unreadable, additional copies are available from the manufacturer.
Follow all SAFETY CODES.
Wear SAFETY GLASSES and WORK GLOVES.
Work only with approved tools and devices.
Disconnect and/or lock out power before servicing or maintaining the equipment.
Use care when LOADING, UNLOADING, RIGGING, or MOVING this
equipment.
Operate this equipment within design specifications.
OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.
You should remove the fuses and carry them with you.
Make sure the equipment and components are properly GROUNDED before you
switch on power.
When welding or brazing in or around this equipment, make sure VENTILATION is
ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with
sheet metal. An approved FIRE EXTINGUISHER should be close at hand and
ready for use if needed.
Do not restore power until you remove all tools, test equipment, etc., and the
equipment and related components are fully reassembled.
Only PROPERLY TRAINED personnel familiar with the information in this manual
should work on this equipment.
We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide
by the foregoing recommendations in order to make operator safety a reality.

Screw Compressor Central Chillers Chapter 1: Safety viii
1-3 Responsibility
These machines are constructed for maximum operator safety when used under standard
operating conditions and when recommended instructions are followed in the maintenance
and operation of the machine.
All personnel engaged in the use of the machine should become familiar with its operation as
described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its
vicinity.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All warning and danger signs must be observed and obeyed. All actual or potential danger
areas must be reported to your immediate supervisor.
General Responsibility
No mater who you are, safety is important. Owners, operators and maintenance personnel
must realize that every day, safety is a vital part of their jobs.
If your main concern is loss of productivity, remember that production is always affected in a
negative way following an accident. The following are some of the ways that accidents can
affect your production:
Loss of a skilled operator (temporarily or permanently)
Breakdown of shop morale
Costly damage to equipment
Downtime
An effective safety program is responsible and economically sound.
Organize a safety committee or group, and hold regular meetings. Promote this group from
the management level. Through this group, the safety program can be continually reviewed,
maintained, and improved. Keep minutes or a record of the meetings.
Hold daily equipment inspections in addition to regular maintenance checks. You will keep
your equipment safe for production and exhibit your commitment to safety.
Please read and use this manual as a guide to equipment safety. This manual contains safety
warnings throughout, specific to each function and point of operation.

Screw Compressor Central Chillers Chapter 1: Safety ix
Operator Responsibility
The operator’s responsibility does not end with efficient production. The operator usually has
the most daily contact with the equipment and intimately knows its capabilities and
limitations.
Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates, or
through a casual attitude toward machinery formed over a period of months or years. Your
employer probably has established a set of safety rules in your workplace. Those rules, this
manual, or any other safety information will not keep you from being injured while operating
your equipment.
Learn and always use safe operation procedures. Cooperate with co-workers to promote safe
practices. Immediately report any potentially dangerous situation to your supervisor or
appropriate person.
REMEMBER:
NEVER place your hands or any part of your body in any dangerous location.
NEVER operate, service, or adjust the chiller without appropriate training and first
reading and understanding this manual.
Before you start the chiller check the following:
Remove all tools from the chiller;
Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the
chillers operating area;
If your chiller has been inoperative or unattended, check all settings before starting the
unit.
At the beginning of your shift and after breaks, verify that the controls and other
auxiliary equipment are functioning properly.
Keep all safety guards in place and in good repair. NEVER attempt to bypass, modify,
or remove safety guards. Such alteration is not only unsafe, but will void the warranty
on your equipment.
When changing control settings to perform a different mode of operation, be sure
selector switches are correctly positioned. Locking selector switches should only be
adjusted by authorized personnel and the keys removed after setting.
Report the following occurrences IMMEDIATELY:
unsafe operation or condition
unusual chiller action
leakage
improper maintenance
NEVER stand or sit where you could slip or stumble into the chiller
while working on it.
DO NOT wear loose clothing or jewelry, which can be caught while working on a
chiller. In addition, cover or tie back long hair.

Screw Compressor Central Chillers Chapter 1: Safety x
Clean the chiller and surrounding area DAILY, and inspect the machine for loose,
missing or broken parts.
Shut off power to the chiller when it is not in use. Turn the switch to the OFF
position, or unplug it from the power source.
Maintenance Responsibility
Proper maintenance is essential to safety. If you are a maintenance worker, you must make
safety a priority to effectively repair and maintain equipment.
Before removing, adjusting, or replacing parts on a machine, remember to turn off all electric
supplies and all accessory equipment at the machine, and disconnect and lockout electrical
power. Attach warning tags to the disconnect switch.
When you need to perform maintenance or repair work on equipment above floor level, use a
solid platform or a hydraulic elevator. If there is a permanently installed catwalk on your
equipment, use it. The work platform should have secure footing and a place for tools and
parts. DO NOT climb on equipment, machines, or work from ladders.
If you need to repair a large component, use appropriate handling equipment. Before you use
handling equipment (portable “A” frames, electric boom trucks, fork trucks, overhead cranes)
be sure the load does not exceed the capacity of the handling equipment or cause it to become
unstable.
Carefully test the condition of lifting cables, chains, ropes, slings, and hooks before using
them to lift a load.
Be sure that all non-current carrying parts are correctly connected to earth ground with an
electrical conductor that complies with current codes. Install in accordance with national and
local codes.
When you have completed the repair or maintenance procedure, check your work and remove
your tools, rigging, and handling equipment.
Do not restore power to the equipment until all persons are clear of the area. DO NOT start
and run the machine until you are sure all parts are functioning correctly.
BEFORE you turn the machine over to the operator for production, verify all equipment
enclosure panels, guards and safety devices are in place and functioning properly.
Reporting a Safety Defect
If you believe that your equipment has a defect that could cause injury, you should
immediately discontinue its use and inform the manufacturer.
The principle factors that can result in injury are failure to follow proper operating procedures
(i.e. lockout/tagout), or failure to maintain a clean and safe working environment.

Screw Compressor Central Chiller Chapter 2: Functional Description 11
Chapter 2: Functional Description
2-1 Models Covered in This Manual
This manual provides operation, installation, and maintenance instructions for Screw
Compressor Central Chillers. Model numbers are listed on the serial tag. Make sure you
know the model and serial number of your equipment before contacting the manufacturer for
parts or service.
Our screw compressor central chillers are designed to generate cooled water at carefully
controlled temperatures for use in plastic processing systems. Screw Compressor Central
chilling systems are sized to meet the specific requirements stated by the Customer at the
time of purchase.
2-2 General Description
Screw compressor central water chilling stations are available in water-cooled and remote air-
cooled designs. They differ only in the condensing media used. These units are configured
with two independent circuits using multiple compressors for each circuit. This manual lists
information specific to these units.
Screw Compressor central chilling stations may be configured with stainless steel pump tanks
for use as reservoirs for chilled water processes. These dual-well models hold hot and cold
water before and after it is pumped through the chiller. Tanks have recirculation pump(s) to
send return water to the chiller and process pump(s) to pump cooled water directly to process.
Standby pumps may be utilized to distribute pump service or to allow uninterrupted chiller
operation during pump maintenance.
Properly installed, operated, and maintained Screw Compressor Central chilling stations
provide many years of reliable operation. To get the most satisfaction from your new
chiller, read and follow the instructions in this manual.
2-3 Standard Features
Mechanical Features
Two independent refrigeration circuits
High-efficiency screw compressors
Stainless steel brazed plate (60 & 75) Shell & Tube (90-195) evaporators
Cleanable shell and tube condensers (water-cooled models)
High and low refrigerant pressure safeties
Evaporator water piping manifold (Condenser manifold optional)
R-134a refrigerant
1 year warranty on parts and labor

Screw Compressor Central Chiller Chapter 2: Functional Description 12
Electrical Features
Electronic expansion valve
2 remote single circuit condensers with variable speed lead fans and fan cycling (air-
cooled models)
NEMA 12 electrical enclosure
Touch-safe branch circuit fusing
Liquid line solenoid and shut-off valves
Chilled water flow switches
Controller Features
Allen Bradley Micrologix 1500 PLC control with PanelView 300 Micro
monochrome/key pad interface
Digital low temperature freezestat
3 year warranty on controller
Standard Features on Remote Condensers
Direct-drive 3-phase fan motors with ball bearings and internal overload protection
Electronic variable-speed control of lead fan and fan cycling for constant condenser
head pressure control
Fans are 30” (76 cm) in diameter and have PVC-coated steel fan guards; 1½hp (1.12
kW) variable-speed fans are 26” (66 cm) in diameter
Internal baffles between fan cells
UL listed in the United States and Canada
Patented floating tube coil to eliminate tube sheet leaks
Copper tube condenser coils have corrugated aluminum fins
Weather-proof control panel with factory-mounted door interrupt switch
High-efficiency condenser coil, designed for optimum performance
Aluminum housing provides corrosion protection for outdoor applications

Screw Compressor Central Chiller Chapter 2: Functional Description 13
2-4 Options
Options marked with “*” indicate options that can be factory installed or retrofitted in the
field.
Advanced control package including: AB SLC 5/04 PLC with PanelView 1000 color
touch screen, control of up to nine additional chillers, cooling tower system, water
treatment system, and DH+ communication capabilities
General Fault audible/visual alarm with elevated light stack
Non-fused rotary thru-the-door disconnect switches
Electrical operation available in 208, 460, and 575 volts, 60 Hz; 200, 380, and 415
volts, 50 Hz
UL/CUL-listed electrical subpanel
Water cooled condenser manifold
Onsite startup
2-5 Safety Devices and Interlocks
This section includes information on safety devices and procedures that are inherent to the
Chiller. This manual is not intended to supersede or alter safety standards established by the
user of this equipment. Instead, the material contained in this section is recommended to
supplement these procedures in order to provide a safer working environment.
At the completion of this section, the operator and maintenance personnel will be able to do
the following:
Identify and locate specific safety devices.
Understand the proper use of the safety devices provided.
Describe the function of the safety device.
Safety Circuit Standards
Safety circuits used in industrial systems protect the operator and maintenance personnel
from dangerous energy. They also provide a means of locking out or isolating the energy for
servicing equipment.
Various agencies have contributed to the establishment of safety standards that apply to the
design and manufacture of automated equipment. The Occupational Safety and Health
Administration (OSHA) and the Joint Industrial council (JIC) are just a few of the
organizations that have joined with the plastics industry to develop safety standards.
Every effort has been made to incorporate these standards into the design of the chiller;
however, it is the responsibility of the personnel operating and maintaining the equipment to
familiarize themselves with the safety procedures and the proper use of any safety devices.

Screw Compressor Central Chiller Chapter 2: Functional Description 14
Fail Safe Operation
If a safety device or circuit should fail, the design must be such that the failure causes a
“Safe” condition. As an example, a safety switch must be a normally open switch. The switch
must be held closed with the device it is to protect. If the switch fails, it will go to the open
condition, tripping out the safety circuit.
At no time should the safety device fail and allow the operation to continue. For
example, if a safety switch is guarding a motor, and the safety switch fails, the motor should
not be able to run.
Safety Device Lock-Outs
Some safety devices disconnect electrical energy from a circuit. The safety devices that are
used on these chillers are primarily concerned with electrical power disconnection and the
disabling of moving parts that may need to be accessed during the normal operation of the
machine.
Some of the safety devices utilize a manual activator. This is the method of initiating the
safety lock out. This may be in the form of a plug, lever or a handle. Within this lockable
handle, there may be a location for a padlock. Personnel servicing the equipment should
place a padlock in the lockout handle.
In addition to the safety devices listed above, these chillers are equipped with a line cord
plug. This allows the operator or maintenance personnel to unplug the chiller from its power
source and tag it out. The plug can then be tagged with any number of approved electrical
lockout tags available at most electrical supply stores.
WARNING!Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)
sources prior to servicing or cleaning the chiller. Failure to do so may result in serious
injury. No one but the person who installed the lockout may remove it.

Screw Compressor Central Chiller Chapter 3: Installation 15
Chapter 3: Installation
3-1 Uncrating the Equipment
WARNING!Due to the size and weight of the Screw Compressor Chiller, the manufacturer
recommends using bonded professional millwrights to unload and move the chiller.
1. Rig the chiller from the frame only, using spreader bars to prevent load transfer to
any chiller components.
2. Rig the frame from at least four points and balance the load before lifting to clear the
skid.
3. Use a forklift of adequate size when lifting the chiller by the fork pockets.
4. Insert the forks all the way into the pockets and be sure to balance the load before
lifting the chiller to clear the skid. Lift only as high as necessary.
5. Use a pry bar to free the skid if necessary.
6. Lower slowly.
Caution! Due to the weight of these units, use extrme caution when moving and
placing Screw Compressor Central Chilling Stations.
3-2 Rigging and Placing the Chiller
As with all equipment installations, follow all applicable codes and regulations.
1. Locate close to the process to reduce piping expense.
2. Locate adjacent to drain and city water sources.
3. Consult a structural engineer to assure that the floor, mounting pad or structural steel
support is of adequate strength.
4. Allow for required service clearances necessary for condenser maintenance and easy
access to all components. See page ?? in the Appendix for specific information.

Screw Compressor Central Chiller Chapter 3: Installation 16
3-3 Making Electrical Connections
Screw Compressor Central Chilling systems are designed for three-phase voltage operation.
Refer to the unit nameplate for proper voltage and amperage requirements.
Note: Make sure you provide a correctly sized and protected supply of electrical
power to the unit.
Refer to National Electric Code (NEC) Article 430-24 through 430-26 for
proper feeder conductor and supply disconnect sizing.
Maintain a safe ground and disconnect the power supply before servicing
the unit. A qualified electrician should make electrical connections, and
disconnect and lock out electricity using OSHA 29 CFR 1910.147
standards when you need to service the unit.
Check serial tag voltage and amperage requirements and make sure your electrical service
conforms before making any electrical connections. Total running amps for the Screw
Compressor Central Chilling systems are listed on the nameplate. Customer connections can
be run to the supply terminals from either side of the unit.
WARNING!Make sure that all three phases are wired correctly. If not wired properly, the compressor
will run backwards and cause severe damage to the compressor. Again, check the unit
nameplate for correct voltage and amperage. Compressors must be wired in sequence
(ABC). If not wired properly, the unit can be damaged if run backwards.
DANGER! Improper electrical connections can damage the unit and cause serious operator injury
or death! Compressor damage will occur if compressors are run backwards.
Bring properly sized power leads and ground from a fused disconnect (installed by your
electrician) to the unit. Provide external overcurrent protection to the unit, using circuit
breakers or fuses. If you use fuses, make sure that they are dual-element time-delay fuses,
sized according to your electrical code. Make sure that all electrical connections are tight.
Note: The following MUST be followed when making electrical connections for
your central chiller:
1. Electrical connections must comply with all applicable electrical
codes.
2. The chiller must be grounded in accordance with NEC Article
250.
3. Voltage must be within plus or minus ten percent (10%) of the
nameplate rating with 2% maximum imbalance between legs.
4. Make sure your installer provides external protection.
Caution! Check Compressor Rotation Before Starting Unit!
Connect a phase monitor and phase incoming power ABC.
Check the electrical wiring schematic
provided in your Customer Information packet
for additional information.

Screw Compressor Central Chiller Chapter 3: Installation 17
Note:
Never switch contactor leads or motor leads for reversing rotation.
Do not use contactor or motor leads for phase matching.
Compressor damage will occur if the compressor is run in reverse.
The compressor motor protector checks for correct phasing and will
not allow it to start in reverse.
If you discover that phasing is reversed, correct it by switching any
two main power leads into the disconnect switch or distribution
block on the unit.
Check your work and proceed to the next section.
3-4 Setup Procedures
This section provides the procedures necessary for configuring your Screw Compressor
Central Chiller.
Configuration of your chiller includes making process water connections, tank piping
connections, water-cooled condenser connections, and connecting the remote air-cooled
condenser. We recommend that you carry out these procedures in the order given here.
Note:Before carrying out these procedures, install all equipment as described in
this section.
Piping Considerations
Piping systems vary with process application and pump tank configuration. Typical system
configuration drawings are provided in this manual; the details may or may not apply to your
application. Piping systems must be designed by a person knowledgeable in piping system
design and configuration. Our Contracting Department can design and install a piping system
tailored to your process.
All piping returning to the pump tank must be equipped with an inverted trap with a
vacuum breaker at the high point of the system to prevent mains from siphoning into
the pump tank.
Run mains full size in order to reduce pressure drop in the system and provide
maximum pressures at the ends of the mains.

Screw Compressor Central Chiller Chapter 3: Installation 18
Making Process Water Connections
All Models
All central chilling stations have two chilled water connections per unit, and on water-cooled
models, one more set of water connections for condenser water:
The chilled water manifold allows one-point connections of Chilled Water piping. The Sch.
40 steel piping includes butterfly valves at each evaporator for flow balancing and circuit
isolation; optional pressure gauges can be installed.
To Process
The chilled water supply outlet should be piped to the cold side of the pump tank.
From Process
The chilled water return for water returning back to the chiller from the process to be cooled
and recirculated from the hot side of the pump tank.
Control Probe
This central chilling station is equipped with two control probes which sense temperatures.
One probe measures the temperature of the hot well and the other does the same for the cold
well of the reservoir. These temperatures are used by the PLC controller to sequence the
compressors, based on load.

Screw Compressor Central Chiller Chapter 3: Installation 19
Making Tank Piping Connections
If you have purchased the Screw Compressor central chilling station with the optional
integral pump tank, please proceed with this section.
Note: Thermocouplings for chillers must be installed on both the hot and cold
sides of the tank.
Freezestat Control
The unit can be equipped with a freezestat control which shuts down the compressor if the
chilled water temperature approaches the freezing point. The chilled water pump on the
system will continue to run. It is factory-set at 40°F (4ºC) or 10°F (6ºC) below the rated
capacity operating temperature of 50°F (10ºC).
If you want lower chilled water temperatures (minimum of 30°F (-1ºC), you’ll need to mix
process water with industrial- (not automotive) grade ethylene or propylene glycol with rust
inhibitor to provide protection down to 20°F (12ºC) below the operating temperature you
want. Figure 1 below shows the proper mixtures needed to provide protection to 20°F (12ºC)
below the operating temperature you want. You can then reset the freezestat cutout
temperature to a temperature 10°F (6ºC) below the operating temperature you selected.
Caution! Make sure all freezestat adjustments are performed by a qualified
refrigeration service technician.
The manufacturers product warranty does not cover system freeze-up!
Figure 1: Freezing Protection Curve
Example: Desired leaving temperature = 35°F (1.7ºC),
Glycol % by volume = 35%
This will provide protection to 15°F (-9.4ºC)
Ethylene glycol required for evaporator freeze protection
Ethylene
glycol
percent by
volume
Chilled water operating temperature ºF / ºC
60
50
40
30
20
10
0
-50ºF -40ºF
-40ºC
-30ºF -20ºF -10ºF 0ºF 10ºF 20ºF 30ºF 40ºF 50ºF 60ºF
16ºC10ºC4ºC-1ºC-7ºC-12ºC-18ºC-23ºC-29ºC-34ºC-46ºC

Screw Compressor Central Chiller Chapter 3: Installation 20
Return (From Process)
Bring the chilled water returning from the process to the pump tank warm (From Process)
side. This line is sized according to the flow rate from the process to the pump tank. See
Page 16 for more information on piping considerations.
Caution! Do not use the Screw Compressor Central Chiller to support piping.
Makeup
Connect a city water source to maintain water level in the pump tank. See page 21 for water
treatment considerations.
Note: If glycol is to be added to the system, DO NOT DO THIS!
Overflow
Connect the OVERFLOW outlet to an approved, trapped drain to permit excess water in the
pump tank to overflow to the drain. The overflow line is sized according to the size of the
pump tank.
Flow Switch
This central chiller station is equipped with a flow switch which shuts down the chiller if the
evaporator water flow falls below a safe operating gallons-per-minute (liters-per-minute)
flow rate.
Control Nozzle
All central chilling station evaporators have two control nozzles. The flow switch, freezestat,
and flush port are located in the control nozzle. Pressure gages are mounted in the control
nozzles to aid in achieving proper flow through the evaporator and balancing flows.
Pressure drop between evaporator entering water pressure and evaporator leaving water
pressure can be converted to gallons per minute using the pressure drop chart below.
Water Side Pressure Drop
Condenser (each) Evaporator (each)
Model
Number Flow (gpm) PD (psi) Flow (gpm) PD (psi)
RSW/R60 91 4.0 72 5.3
RSW/R75 102 4.7 90 4.5
RSW/R90 117 4.4 107 5.6
RSW/R100 150 5.5 123 3.9
RSW/R115 166 4.3 140 3.0
RSW/R145 196 4.1 175 4.8
RSW/R165 219 4.1 200 4.6
RSW/R195 278 4.7 232 6.0
To Drain
Connect to a 1½” line (approx. 63 mm) leading to an approved, trapped drain. You can drain
the pump tank if necessary.
Note:If glycol is added to the system, DO NOT DO THIS!