
16
PRE-START-UP
System Checkout — When the installation is complete,
follow the system checkout procedure outlined below before
starting up the system. Be sure:
1. Voltage is within the utilization range specifications of the
unit compressor and fan motor, and voltage is balanced
for 3-phase units.
2. Fuses, breakers and wire are correct size.
3. Low voltage wiring is complete.
4. Piping and system flushing is complete.
5. Air is purged from closed loop system.
6. System is balanced as required. Monitor if necessary.
7. Isolation valves are open.
8. Water control valves or loop pumps are wired.
9. Transformer switched to lower voltage tap if necessary.
10. Service/access panels are in place.
11. Control field-selected settings are correct.
FIELD SELECTABLE INPUTS
Jumpers and DIP (dual in-line package) switches on the
control board are used to customize unit operation and can be
configured in the field.
Safety Devices and the Complete C Control-
ler — Each unit is factory provided with a Complete C con-
troller that controls the compressor operation and monitors the
safety controls that protect the unit. See Fig. 11 for Complete C
sequence of operation.
Safety controls include the following:
• For single compressor models (025-071, 180 and 210),
Fig. 7 and Fig. 9
- High-pressure switch inputs are wired across the HPC ter-
minals on the control board
- Low-pressure switch inputs are wired across the LPC ter-
minals on the control board
- The standard source side freeze thermistor is wired across
the FREEZE 1 terminals on the control board. Cutting the
FREEZE 1 diode will change the freeze setting to 15 F for
the source sensor.
- The standard load side freeze thermistor is wired across
the FREEZE 2 terminals on the control board. Cutting the
FREEZE 2 diode will change the freeze setting to 15 F for
the load sensor.
• For dual compressor models (122, 240-420), Fig. 8 and
Fig. 10
- High-pressure switch inputs are wired across the HP1 and
HP2 terminals on the control board
- Low-pressure switch inputs are wired across the LP1 and
LP2 terminals on the control board
- The standard source side freeze thermister is wired across
the FREEZE 1 terminals on the control board. Cutting the
JP 1 diode will change the freeze setting to 15 F for the
source sensor.
- The standard load side freeze thermister is wired across the
FREEZE 2 terminals on the control board. Cutting the JP
2 diode will change the freeze setting to 15 F for the load
sensor.
• Optional freeze protection sensor, mounted close to con-
densing water coil, monitors refrigerant temperature
between condensing water coil and thermal expansion
valve. If temperature drops below or remains at freeze
limit trip for 30 seconds, the controller will shut down
the compressor and enter into a soft lockout condition.
The default freeze limit trip is 30 F, however this can be
changed to 15 F by cutting the R-42 resistor located on
top of DIP switch SW1.
• The optional condensate overflow protection sensor is
located in the drain pan of the unit and connected to the
‘COND’ terminal on the Complete C board.
NOTE: If freeze protection sensor is not installed, a jumper
between freeze contacts must be installed on the Complete C
board otherwise unit will not start.
The Complete C controller includes the following features:
ANTI-SHORT CYCLE TIMER — A 5-minute delay on
break timer prevents compressor short cycling.
RANDOM START — Each controller has a unique random
start delay ranging from 270 to 300 seconds to reduce the
chances of multiple units simultaneously starting after initial
power up or after a power interruption, creating a large electri-
cal spike.
LOW PRESSURE BYPASS TIMER — If the compressor is
running and the low-pressure switch opens, then the control
will keep the compressor on for 120 seconds. After 2 minutes if
the low-pressure switch remains open, the control will shut
down the compressor and enter a soft lockout. The compressor
will not be energized until the low-pressure switch closes and
the anti-short cycle time delay expires. If the low-pressure
switch opens 2 to 4 times in 1 hour, the unit will enter a hard
lockout and need to be reset.
BROWNOUT/SURGE/POWER INTERRUPTION PRO-
TECTION — The brownout protection in the Complete C
board will shut down the compressor if the incoming power
falls below 18 VAC. The compressor will remain off till the
voltage goes above 18 VAC and the anti-short cycle timer (300
seconds) times out. The unit will not go into a hard lockout.
MALFUNCTION OUTPUT — Alarm output is Normally
Open (NO) dry contact. If 24 VAC output is needed R must be
wired to the ALR-COM terminal; 24 VAC will be available on
the ALR-OUT terminal when the unit is in alarm condition. If
pulse is selected the alarm output will be pulsed. The fault out-
put will depend on the dip switch setting for “ALARM.” If it
set to “CONST,’ a constant signal will be produced to indicate
a fault has occurred and the unit requires inspection to deter-
mine the type of fault. If it is set to “PULSE,” a pulse signal is
produced and a fault code is detected by a remote device indi-
cating the fault. See LED Fault Indication below for blink code
explanations. The remote device must have a malfunction de-
tection capability when the Complete C board is set to
“PULSE.”
TEST DIP SWITCH — A test DIP switch is provided to re-
duce all time delay settings to 10 seconds during troubleshoot-
ing or verification of unit operation. Note that operation of the
unit while in test mode can lead to accelerated wear and prema-
ture failure of the unit. The “TEST” switch must be set back to
“NO” for normal operation.
FREEZE SENSOR — The freeze sensor input is active all the
time, if a freeze option is not selected the freeze terminals will
need a jumper. There are 2 configurable freeze points, 30 F and
15 F. The unit will enter a soft lockout until the temperature
climbs above the set point and the anti-short cycle time delay
has expired. The freeze sensor will shut the compressor output
down after 90 seconds of water flow loss and report a freeze
condition. It is recommended to have a flow switch to prevent
the unit from running if water flow is lost. See Fig. 12.
IMPORTANT: Jumpers and DIP switches should only
be clipped when power to control board has been turned
off.