Gulf+western Acwc-sc User manual

MODEL

ACWC-SC

Screw Type

AIR

COOLED

PACKAGED

CHILLERS

SERVICE

MANUAL

I & 0 6500A

INSTALLATION,

OPERATION

&

MAINTENANCE

INSTRUCTIONS

TABLE OF

CONTENTS

DESCRIPTION PAGE NO.

Inspection

&

Handling

...........................................................................................

2

Location

&

Mounting

.

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.

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2

Wiring

..............................................................................................................

2

Chiller

Piping

.....................................................................................................

2

Start-Up

........................................................................................................

2 & 3

Maintenance

....

.

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.

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.

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.

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3

Slide Valve

Unloading

System

..................................................................................

4

Low

Ambient

Operation

.........................................................................................

5

Control

Settings

..................................................................................................

5

Unit

Operating

Limitations

......................................................................................

5

Sequence

of

Operation

......................................................................................

6 & 7

Models ACWC-160SC

Thru

200SC

Sequence

of

Operation

......................................................................................

8 & 9

Model

ACWC-215SC

Control

Wiring

Diagram

..................................................................................

10 &

11

Models ACWC-160SC

Thru

200SC

Control

Wiring

Diagram

....................................................................................

12-15

Model ACWC-215SC

Power Wiring Diagram

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16

Across-The-Line

Start

Power

Wiring

Diagram

..........................................................................................

17

Star-Delta

Electrical Data

...................................................................................................

18

Cooler

Pressure

Drops

..........................................................................................

18

Unit

Loading/Suspension

Points

..............................................................................

18

Troubleshooting

Guide

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.19

Causes & Prevention

of

Freeze-Up

............................................................................

19

Start-Up

Check

List

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.

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20

Operating

Data

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.. 20

BOHN

HEAT TRANSFER

A Gulf+Western

Company

Danville,

Illinois

61832•{217)446-3710

..

!

I

INSPECTION

&

HANDLING

When

unit

is received,

it

should

be

checked

for

visible

or

concealed

damage

. If

damage

has

occurred

it

should

be reported

to

the carrier

imm

e

diately

.

o.nd

clo.im

filed

.

Models

ACWC

160SC

thru

215SC are

factory

mounted

on

two

(2)

permanent

angle beam,

carbon

steel skids. Ei

ght

(8) 2W'

lifting

eyes

are

provided

in the

skids

to

allow

rigging.

Spreader bars

must

be

used between

rigging

lines

to

prevent

damage

to

the

unit. Rollers

may be used

under

the

skids

to

facilitate

moving

the

unit

a

short

distance

. Physical damage to the unit, after acceptance,

Is

not the

responsibility of the factory.

LOCATION

&

MOUNTING

Model

ACWC

Air

Cooled

Packaged Water

Chillers

are

designed

for

outdoor

application

and

may

be

mounted

on

roof

or

at

ground

level.

Air

flow

through

the

condenser

is vertical and the

unit

may be

located

adjacent

to

outside

of

building

or

on

roof

without

regard

for

prevailing

wind

direction.

Since

these

units

are

air

cooled,

the

flow

of

air

to

and

from

the

condenser

coil

must

not

be impeded.

There

must

be

no

obstruction

above the

unit

that

would

tend

to

deflect

discharge

air

downward

where

it

could

be

recirculated

back

to the

inlet

of

the unit. The

required

overhead

air

space

should

be a

minimum

of

eight

(8) feet.

Ductwork

must

not

be applied

to

the fan

outlets

.

The

unit

must

be

installed

with

sufficient

clearance

for

air

entrance

to

the

condenser

coil

and

for

servicing

access. The

unit

should

be

located

no

closerthan

four

(4) feet

from

any wall

or

other

obstruction

.

Clearance

must

be

provided

at

either

end

of

the

unit

to

permit

removal

of

tubes

from

the

chiller

.

Unit

must be set on a

solid

and level

foundation

.

On

roof

installations

the

unit

should

be

mounted

on

support

beams

which

span

load-bearing

walls

to

prevent excessive

vibration

.

On

ground

level

installations,

the

unit

should

be

mounted

on a

substantial

base

that

will

not

settle. A

one-piece

concrete

slab

with

footings

extended

below

the

frost

line is recommended. A space

should

be left between the

slab

and

the

building

to

prevent

the

transmission

of

sound

and

vibration

.

Vibration

mounts

may

be used

for

roof

mounted

units

or

other

locations

where noise

might

be

objectionable.

WIRING

A

unit

wiring

diagram

showing

the required

power

supply

character-

istics

and all

factory

supplied

wiring

details is

provided

with

unit.

Separate, field

supplied,

disconnects

must be installed in the

power

supply

and

should

be

within

the

sight

of

the unit.

Separate 115

volt

power

source

must be field

supplied

to

provide

power

for

control

and heater

circuits

.

2

CHILLER

PIPING

The

chiller

inlet

(return)

water

pipe

should

be

connected

to the water

connection

closest

to

the

control

panel end

of

the

unit

and the

outlet

(:.upply)

vvdte• 1-'ifJt::

<..v""""'t"'u

tv

u,.,

wat.,r

<,;urrrr.,<,;llun

on

the

opposite

end

of

the cooler(s).

A

flow

switch

must

be installed in a

straight

horizontal

section

of

the

chilled

water

piping

.

Gauges

should

be installed in

the

piping

to

and

from

the

chiller

to

measure

the

pressure

drop

and to

insure

the

proper

(GPM)

flow

rate

in

accordance

with

submittal

data. A

strainer

should

be

installed

in

the

piping

on the

inlet

side

of

the

chiller

and

vibration

eliminators

should

be

employed

on both the inlet and

outlet

pipes.

Air

vents

should

be located at all high

points

in the

piping

system. Vents

should

be located

to

be accessible

to

servicing

.Drain

connections

should

be

provided

at all

low

points

to

permit

complete

drainage

of

chiller

and

piping

system.

The

chilled

water

piping

should

be

insulated

to

reduce heat

pickup

and

to

prevent

condensation

.

If

the system is

for

year-round

operation

or

if

it

will

not

be

drained

in the winter,

the

chilled

water

piping

should

be protected againstfreezing by

electric

heating cable

or

other

suitable means.

Upon

completion

of

chiller

piping,

start

the

system water

pump

and

purge

air

from

the

system.

Air

purging

should

be

done

from

the

high

points

in

the

water

circuit.

Purging

of

the

chiller

barrel may be

accomplished

through

the

vent

pipe

located

on

the

top

of

the

chiller

compartment.

Failure

to

purge

air

from

the

water

circuit

will

result in

inadequate

waterflow

and maycause the

unit

to

cutout

on

low

water

flow

freeze

protection.

START-UP

Refer

to

start, test, and

check

list

included

with

this

manual.

Check

all

electrical

and

mechanical

connections

for

shipping

looseness and

tighten

all screws on electrical

terminals

.

Activate the 115

volt

chiller

and crankcase heater

circuit

24

hours

prior

to

unit

start-up

.

Rotateeach fan

prior

to

start-up

. Fans

should

turn

freely.

Check

belt

tension

and

pulley

alignment.

After

two

(2) weeks

of

operation,

readjust

belt

tension

to

accommodate

for

belt stretching.

Check

all

control

settings

as

specified in Table

1.

Check

the

compressor

oil level

through

the

crankcase

sight

glass.

The

oil

level

should

be

to

the

top

of

the glass. If

the

level is low, add

oil in

accordance

with

the

directions

in the

maintenance

instruction

(page 3).

..

~·

.

--..,_

. CAUTION:

The

discharge

line valve

must

be open

before

starting

the

compres-

sor

.

Liquid

line valves

must

also be open

for

sustained

operation

.

All compressorsare solia mountea on 1sopads,therefore,

compressor

hold-down

bolts

must

not

be loosened.

Loosening

these

bolts

will

cause excessive

vibration

of

the

compressor

and may result in

refrigerant

line breakage.

Prior

to

start-up

check

all

compressor

hold-down

bolts

for

tightness.

MAINTENANCE

CONDENSER

Units

equipped

with belt drive fans have

inherently

protected

motors

. Fan belts,fan

bearings

and

motor

bearings

require

periodic

maintenance

as

follows:

1. Fan Belts

-After

two

(2) weeks

operat

i

on

,

the

belts will have

nearly

reached

their

permanent

stretch,

therefore

, each belt

should

be

checked

again and

proper

adjustments

made.

To

maintain

good

fan and

motor

operation

,the belt tension

should

be

checked at three (3)

month

intervals.

2.

Fan

Bearings-

Each fan shaft is

prov

i

ded

with

ball

bearings

of

the

relubricatable

type

. Each bearing is provided

with

grease

fittings,

accessible

through

the

individual

motor

access panels. It

is

recommended

the bearings be greased

by

adding

4

to

5 shots

with

a hand

gun

.The suggested greasing interval is

indicated

on a

sticker

attached to the unit.

3.

Motor

Bearings-

Each

motor

is

equipped

with

ball bearings. Ball

bearings

consume

a very small

amount

of

lubricant

,

but

enough

must

be

present

at all

time

to prevent

motor

injury.

The

length

of

time

a bearing can run

without

having grease added

or

replaced

will

depend

upon

the

operating

conditions

.

Under

normal

operating

conditions

,the

motor

bearings

should

be

lubricated

at

2000

hour

operating

intervals

.

The

lubricant

should

be

from

a

clean closed

container

and

should

be an

anti-friction

type

bearing

grease-free

from

solid

fillers

or

other

harmful

ingredients

.

Lubricant

should

have a safe

operating

temperature

of

2000° F.

The

air

inlet

of

the

condenser

coil

should

be

kept

clean

through

a

regular

preventative

maintenance

program

.

COMPRESSOR

1.

OIL LEVEL -

The

oil

level in the

compressor(s)

should

be

checked

periodically,

with

the

compressor

either

running

or

stopped

. If

the

oil

level is

below

one-half

(

'12

) the

sight

glass, oil

must be added.

Oil

should

be added

only

with

the

compressor

shut

off

.

To

do

so,

turn

the

return

water

thermostat

(T1) to a

higher

temperature

setting

, and

wait

for

the

unit

to

pumpdown

and

shutoff.

Place the

system "

ON-OFF

"

switch

in the "OFF"

position

. Close

the

line

valve in the

discharge

line between

compressor

and

condenser

.

Refrigerant

pressure

inside

of

the

compressor

will

now

be

approximately

80 to 90 PSIG.

The

low

pressure

cut-out

setting is

35 PSIG,

but

the residual

discharge

pressure (upstream

of

the

discharge

check

valve)

will

equalize

back

into

the

suction

side

after

the

compressor

stops.

3

Locate

the

discharge

pressure

port

adjacent

to

solenoid

valve

UL-3

(see

drawing

below)

; remove

the

cap and release the

residual pressure

by

pushing

in on the pressure

port

fitting

itself.

Pump

oil

into

this

flU'

t

u11til

u,.,

uil

level

Is

to the

tOP

Of

the

sight

glass.

Replacethe

discharge

port

cap

. Re-open the discharge line valve.

Do not allow compressor to run with discharge valve closed.

Place

the

system

"ON-OFF"

switch

in

the

"

ON

"

position

.

Using

a

jumper

wire, makea

"short

"

for

five (5)

seconds

between

terminal

#4

on

terminal

block

TER5 and the

switched

terminal

of

a

solenoid

valve

feeding

the

circuit

you

have

just

"blown

" (e.g.

terminal

#121

on TER4 to energize

SOL

1).Reset return

water

thermostat

(~1)

to

the

operat

ional

temperature

setting and

allow

unit

to

return

to

normal

operation

.

2.

RECOMMENDED

OIL-

The

unit

is

factory-charged

with

BOHN

SR-30

refrigeration

oil.

Do not add any other type of oil

to

this factory charge.

Do not operate compressor

If

oil level

is

below one-half

('h)

sight

glass.

If

the

oil

level is

below

the

minimum

specified

above, and

BOHN

SR-30 is

not

on hand, you may drain the entire factory oil charge,

then refill

with

SUNISO 4GS

refrigeration

oil. The

factory

(BOHN)

oil is

of

the

synthetic

type

and will not mix

with

SUN

ISO 4GS. Do

not

attempt

to

operate

the

screw

compressor

with

any

oil

other

than these

two

specified above.

It

is

suggested

that

a

gallon

or

more

of

BOHN

SR-30

oil

be

obtained

and kept on

hand

at the

job

site. The

substitution

of

SUNISO

4GS oil, as

outlined

above,

will

result

in a

2%

to

4%

capacity

loss, and

no

reduction

in

input

K.W.

3.

COMPRESSOR REPAIRS (Internal) -

Contact

factory

or

an

authorized

BOHN

Service

Agency

if a

compressor

malfunction

is

suspected.

4. COMPRESSOR REPAIRS (External) -

Proper

operation

of

unloaded

start,

loading

, and

unloading

is

controlled

by solenoid

valves UL-1 ,

UL-2

and UL-3.

Any

of

thesethree (3) solenoid valves

may be repaired

or

replaced in the field,

as

required.

HIGH

PRESSURE

PORT

SLIDE

VALVE

UNLOADING

SYSTEM

1ne

tlonn

screw

compressor

capacity

control

system

for

infinite

modulation

consists

of

a

slide

valve and

hydraulic

piston

/

cylinder

operator

internal

to

the

compressor;

plus

three

hydraulic

solenoid

valves (UL-1,

UL-2

&

UL-3)

piped

externally.

The

slide

valve

forms

a

portion

of

the

chamber

wall in

which

the

rotors

turn;

thus,

its

position

with

respect

to

the

rotors

determines

the

effective

rotor

length

and

thereby

the

percent

of

full load

capacity

.

Upon

compressor

start-up

,

UL-3

is opened.

This

allows

oil pressure

to

act

upon

the

hydraulic

piston,

holding

it in

the

fully

unloaded

position

.

After

30 seconds,

during

which

time

full

oil

flow

is

established

to

all

bearings

surfaces,

UL-3

is

closed

.

At

this

point,

the

temperature

controller

is free

to

open

and close UL-1

or

UL-2

in

response

to

the

supply

water

temperature

.

The

slide

valve

will

move

to

the

left

(loading)

by

force

of

discharge

pressure

,

whenever

UL-1

opens

to

permit

flow

to

the

oil

return

(low

Load Unload

¢::J

c::>

Oil Pressure

Slide Valve

Oil

Pressure Lines

Screw

Rotor

pressure) line.

The

slide

valve

will

move

to

the

right

(unloading)

whenever

UL-2

opens

the

oil

supply

(high

pressure) line,

since

the

force

of

the

oil

exceeds

that

of

the

discharge

gas.

The

temperature

controller

sends a series

of

power

(energizing)

"

pulses

"

to

the

appropriate

solenoid

to

adjust

to

load

conditions

.

The

further

the

supply

water

temperature

is

from

the

controller

set

point,

the

longer

is

the

duration

of

the

pulses.

The

series

of

pulses

will

continue

until

the

controller

is satisfied. As

the

water

temperature

approaches

the

set

point

,

the

pulses

become

quite

brief

to

prevent

overshooting

the

set

point.

This

method

of

compressor

unloading

in

conjunction

with

supply

water

sensing

minimizes

action

/

reaction

lag

time

and

overshoot

resulting

in an

exceptionally

precise

and

stable

control

of

supply

water

temperature

.

UL-1

Oil

Return

Hydraulic

Piston

Oil

Supply

Vent

to

Suction

The

following

table

lists

solenoid

valve

position

for

all

three

operating

modes.

UL-1 UL-2 UL-3

Starting

Close Close

Open

Loading

Open

Close

Unloading

Close Open Close

4

r

~

'-...../'

-

(.

"'-._./

LOW

AMBIENT

OPERATION

Due

to

the

wide

range

of

applications,

it

is

sometimes

necessary

to

operate

the

Air

Cooled

Packaged

Water

Chillers

at

ambients

below

summer

conditions.

Without

proper

control,

when

ambients

drop

below

60°

F.

the

pressure

differential

between

the

condenser

and

the

evaporator

is

below

the

level

to

insure

proper

thermal

expansion

valve

operation

. As a

result,

the

unit

may

cycle

on

low

pressure

control

with

the

possibility

of

evaporator

freezing.

Three

types

of

system

control

are

available

allowing

the

units

to

operate

at

the

ambients

indicated:

FAN

CYCLING

MEDIUM

AMBIENT

CONTROL

TO

30°

F.

(STANDARD

EQUIPMENT

-FACTORY

INSTALLED)

A

fan

cycling

control

is

standard

on

all

Air

Cooled

Packaged

Water

Chillers

to prov1de

prop

er

operating

head pressures, in

ambient

conditions

to 30° F.

This

is an

automatic

operation

in

which

the

condenser

fans

are

cycled

on

and

off

, as

required,

in

response

to

head

pressure.

With

two

compressors

running

,

three

fans

are

cycled

(in

sequence)

on

five-fan

units;

four

fans

on

six-fan

units

; and five

fans

on

seven-fan

units.

With

one

compressor

running,

all

but

the lead fan are

cycled

in

sequence, in

response

to head pressure.

This

arrangement

provides

positive

start-up

control

down

to

+30°

F.

by

delaying

the

condenser

fan

operation

until

a

predetermined

head

pressure

is

obtained.

GRAVITY

(Discharge) DAMPERS

LOW

AMBIENT

CONTROL

TO

oo

F.

(OPTIONAL

EQUIPMENT-

FACTORY

INSTALLED)

All

condenser

fans

are

equipped

with

gravity

dampers

mounted

on

the

fan

discharge

to

minimize

the

effect

of

prevailing

winds;

and

to

prevent

convection

drafts

up

through

the

condenser

coil

in

still

air.

All

compressors

are

enclosed

in

individual

insulated

housings.

An

auxiliary

heater

is

included

to

supplement

the

standard

crankcase

heater

;

the

temperature

within

the

compressor

compartment

is

thermostatically

controlled

.

The

standard

condenser

fan

cycling

package,

operating

in

con-

junction

with

the

discharge

dampers

,

will

maintain

suitable

head

pressure

down

to

oo F.

ambient.

A

90-second

time

delay

relay

provides

an

electrical

bypass

around

the

low

pressure

freezestat

to

prevent

nuisance

tnp-out

during

cold

start-up.

ACWC-SC

CONTROL

SETTINGS

PRESSURE

ACTUATED

LEGEND

FACTORY

SETTING

High

Pressure

Control

HP-1

Cut-In

300 PISG

(Manual

Reset) HP2 & HP3

Cut-Out

365 PSIG

Pumpdown

Control

PD1

Cut-In

55 PSIG

(Auto

Reset) PD2 & PD3

Cut-Out

35 PSIG

Fan

Cycling

Pressure

Control

2 Fan

Cell

Cut-In

(PSIG)

Cut-Out

(Adjustable)

FCP 1 280 170

FCP 2 295 180

3 Fan

Cell

FCP 1 260 160

FCP 2 275 175

FCP 3 290 215

4 Fan Cell

FCP 1 260 160

FCP 2 275 175

FCP3

285 210

FCP4

295 235

Low

Pressure Freeze

Control

LPF 1

Cut-Out

54 PSIG

(Manual

Reset)

--

LPF 2 & LPF-3

TEMPERATURE

ACTUATED

LEGEND

FACTORY

SETTING

Chiller

Low

Water

Temperature

Thermostat

T2

Cut-Out

37°

F.

Chiller

Water

Cycling

Thermostat

(Adjustable)

T1

Dial Set

At

55°

F.

Chiller

Heater

Thermostat

Included

With

Cut

-In 40°

F.

(Non-Adjustable

CBH1

Heater

Cut-Out

45°

F.

Oil

Temperature

Safety

Control

OTS

1

(Adjustable)

OTS

2

Cut-Out

240°

F.

Manual

Reset

OTS3

Capacity

Control

Thermostat

(Adj.)

Mode

Control

Position

T3

Dial Set

At

44°

F.

UNIT

OPERATING

LIMITATIONS

1.

Maximum

ambient

air

to

condenser

is 115° F. (60

Hertz

operation).

2.

Maximum

allowable

cooler

water

pressure

is 150 PSIG.

3.

Maximum

allowable

water

temperature

to

cooler

is 75°

F.

4.

Units

must

not

have leaving

water

temperatures

of

42°

F.

or

lower

unless

used

with

a

glycol

solution.

5.

Unit

must

be

allowed

to

pumpdown

at the

end

of

each

operating

cycle

(except

on

safety

control

shutdown).

5

KEY

TO

WIRING

DIAGRAM

INDEXING

SYSTEM

The

wiring

diagrams

and

sequence

instructions

on

the

following

pages have been devised

to

simplify

the

understanding

and

tracing

of

circuit

theory.

The

following

key

shows

how

the

indexing

system can be used.

12

Line

number

on

wiring

diagram

[12]

Line

number

in

text

(RS)

Component

identification

symbol

in

text

(Relay #5)

~

Normally

open

contact-

line

number

location

~

Normally

closed

contact-

line

number

location

@

Holding

coil

-

line

number

location

&

Note

number

EXAMPLE

30

~

§] §]

SEQUENCE

OF

OPERATION

MODELS

ACWC

160

To

200

SC

The

following

sequence

of

operation

is

typical

for

the

ACWC

160

to

200

SC

(see Pages 10

and

11

for

typical

wiring

diagram).

Refer

to

the

wiring

diagram

furnished

with

unit

for

specific

information.

Control

Identification

Symbol

Circuit

Line

Number

Important Notel

The

compressor

crankcase

heater

must

be

energized

and remain

active

for

a

minimum

fa

24

hours

prior

to

unit

start-up.

PRELIMINARY

SEQUENCE

Place

control

circuit

"ON-OFF"

switches

(SW1

thru

SW4) in

the

"OFF"

position,

and set

the

staging

thermostat

(T1)

to

its

highest

temperature.

Activate

the

115

volt

electrical

service

to

terminals

#2 and #4

[1

and

3] on

terminal

board

(TEAS)

to

distribute

power

to

the

control

circuit

up

to

the

control

circuit

switches.

Crankcase

heater relay

contacts

(R19) (3]. (R20)

[5].

and

(R21) [7] are

closed

and are

supplying

power

to

the

compressor

crankcase

heaters.

Power

is also

supplied

to

the

chiller

barrel

heater

(CBH1)

(11].

the

receiver heaters (RH1,

2,

3) (8,

9,

10]

(optional),

and

the

low

ambient

crankcase

heaters

(SCH1,

2,

3)

[3,

5,

7]

(optional).

Close

the

main

power

disconnect

switch.

Check

to

see

that

the

red

indicating

light

on

the

phase loss

monitor

(PLM1) is

lit

(NOTE: There

will be two phase loss monitors, (PLM1) and (PLM2),

on

208-230 volt

models).

This

light

must

be on

to

indicate

proper

phase

rotation

for

the

compressor(s)

. If

the

light

is

not

on,

the

main

control

circuit

to

the

compressors

will

not

be

energized.

Reverse

any

two

phase legs

at

the

Main Incoming Power Terminal Block.

DO

NOT

reverse

the

leads on

the

phase loss

monitor,

for

this

will

allow

the

compressor

to

run

backwards,

causing

severe damage, and WILL VOID

THE

COMPRESSOR WARRANTEE!

Start-up

the

chilled

water

pump.

The

water

flow

is

confirmed

when

the

water

flow

switch

completes

an

electrical

circuit

across

terminals

#12 (58] and #13 [60]

of

terminal

board (TEAS).

Terminals

#14 [61]

6

@@&

~

See

Note

Number

3

The

holding

coil

for

the

first

contact

shown

on

this

line

(reading

from

left

to

right)

can

be

found

on

line

#44;

the

holding

coil

for

the

second

contact

can be

found

on

line #74.

The

contacts

for

the

holding

coil

shown

on

this

line

can

be

found

on

lines 66, 23, and 54.

The

contact

on

line

23 is

normally

closed

.

This

is

the

number

which

identifies

the

line

of

wiring

shown

at

the

left.

and #15 [63]

provide

an

interlock

for

the

water

pump

starter(s);

either

contact

(R14). (R16),

or

(R18) [62]

will

close

any

time

a

compressor

is

running.

Set

the

staging

thermostat

(T1)

to

the

design range

of

operation

(e.g.

54°

F.

return

water). Set

the

capacity

control

thermostat

(T3)

to

the

design

range

of

operation

(e.g. 44°

F.

supply

water).

Place

the

four

(4)

control

circuit

switches

(SW1-SW4) in

the

"ON"

position

,

thus

energizing

the

balance

of

the

control

circuit.

The

system will

be

In

the "Time-In" mode for five minutes before any

compressor will start.

STAGE 1

LOADING

Upon

demand

for

cooling,

the

first

step

of

the

staging

thermostat

(T1)

will

close

,

energizing

relay (TD10) (63] and

staging

relay (R1)

[62].

closing

(R1)

contacts

7-4 [22]. 8-5 [25].

and

9-6 (16]. If

the

safety

controls

and

switches

are closed,

the

control

circuit

[16]

for

compressor

No.1

and

liquid

line

solenoid

(SOL

1) (25]

will

energize,

allowing

the

compressor

to

start. Fan

contactor

(C13) (21]

will

also

close,

bringing

power

to

the

line

side

of

fan

cycling

pressure

controls

(FCP1) and (FCP2) (see

Power

Wiring

Diagram-

Pages 16

and 17). Fan

motor

#1

will

start

as

soon

as

the

head

pressure

reaches

the

"cut-in"

setting

of

(FCP1

).

NOTE: ALL FAN

MOTORS

ARE

CONTROLELD

BY

THEIR OWN

FAN

CYCLING

CONTROL

AND

WILL

CUT

IN

AT

DIFFERENT HEAD PRESSURES.

Relay (R19) [20]

contact

7-1

[3] opens,

de-energizing

compressor#1

crankcase

heater(s). Relay (R14) (19]

contact

8-5 (24] closes,

energizing

(TD7) [23].

This

will

force

compressor

#1

to

run

for

five

minutes.

COMPRESSOR

#2

CANNOT

BE

STARTED

UNTIL

(TD7)

TIMES

OUT.

Time

delay relay (TD1 0) [63]

contact

C-NC

(26]

holds

the

compressor

in an

unloaded

condition

for

30 seconds. When relay (TD10)

times

out,

it

will

energize

relay (R4) [27].

closing

contacts

9-6 [71] and 7-4

[74].

This

allows

the

capacity

control

thermostat

(T3)

to

energize

solenoid

valve

(UL

1-1) [71].

loading

the

compressor;

or

to

energize

solenoid

valve (UL2-1) [74].

unloading

the

compressor.

,

-~

\....__./

,.

-......__/

Relay (R14) (19]

contact

7-4 [62] closes,

which

completes

the

interlock

circuit

for

the

water

circulating

pump.

~TAGE! Z

LOADINu

Upon

a

further

increase in return watertemperature, the second step

of

the

staging

thermostat

(T1) will close. If the

lock-out

timer

(TD5)

and

the

lock-in

timer

(TD7) [64] have

timed

out, relays (R2) [64] and

(TD11) [65]

will

be energized,

closing

(R2)

contacts

9-6 [32]. 8-5

[40]. and 7-4 [37]. If the safety

controls

and switches are closed,

the

control

circuit

[32]

for

compressor

#2

and

liquid

line

solenoid

(SOL2) [40] will energize,

allowing

the

compressor

to start.

Relay (R20) [36]

contact

7-1

[5] opens,

de-energizing

crankcase

heater(s).

Contact

9-6 [44] closes,

energizing

fan

contactor

(C14)

(44].

bringing

power

to

the

line

side

of

the

balance

of

the

fan

cycling

pressure

controls

(see

power

wiring

diagrams)

. Fan

motor

#3

will

start

as

soon as

the

head pressure reaches

the

"cut-in"

setting

of

(FCP3).

Relay (R16) [35]

contact

8-5 [39] closes,

energizing

(TD8) (38].

This

will

force

compressor

#2

to run

for

five minutes. Compressor

#3

cannot be started until (TDS) times out.

Time

delay

relay (TD11) [65]

contact

C-NC

(41]

holds

compressor#2

in an

unloaded

condition

for

30 seconds. When (TD11) times out,

it

will energize (R5) (42].

closing

contacts

9-6 (72] and 7-4 (75].

This

allows

the

capacity

control

thermostat

(T3)

to

energize

solenoid

valve

(UL

1-2) [72].

loading

the

compressor;

or

to

energize

solenoid

valve (UL2-2) [75].

unloading

the compressor.

STAGE 3

LOADING

Upon

a

further

increase in return watertemperature, the

third

step

of

the

staging

thermostat

(T1)

will

close. Ifthe

lock-out

timer

(TD6) and

the

lock-in

timer

(TD8) (66] have

timed

out

, relays (R3) (66]. (R7)

(68].

and

(TD12) [67] will be energized. Relay (R3)

contacts

9-6 [48].

7-4 [53]. and 8-5 [56] close. If

the

safety

controls

and

switches

are

closed, the

control

circuit

[48]

for

compressor

#3

and

liquid

line

solenoid

(SOL3) [56] will energize,

allowing

the

compressor

to

start.

Relay (R21) [52] energizes,

opening

contact

7-1

[7],

de-energizing

compressor

#3

crankcase

heater(s). Relay (R18) (51]

contact

8-5

[55] closes,

energizing

(TD9) [54].

This

will

force

compressor

#3

to

run

for

five minutes.

Relay (R7)

contact

9-6 [70] closes,

energizing

solenoid

valve

(UL

1-

1).

thus

locking

compressor

#1

in

the

fully

loaded position. Relay

(R7)

contacts

8-2 [71] and 7-1 [74]

open

to

disconnect

the

capacity

control

thermostat

(T3)

from

compressor

#1

capacity

control

solenoid valves.

Time

delay relay (TD12) [67]

contact

C-NC

[57]

holds

compressor

#3

in an

unloaded

condition

for

30 seconds. When (TD12)

times

out

,

it

will

energize relay (R6) [58].

closing

contacts

9-6 [73] and 7-4 [76].

This allowsthe

capacity

control

thermostat

(T3) to energizesolenoid

valve

(UL

1-3) [73].

loading

the

compressor

;

or

to energize solenoid

valve (UL2-3) [76].

unloading

the compressor.

Compressor

#1

is

fully

loaded.

Compressors

#2

and

#3

are being

capacity-modulated.

7

PUMPDOWN

SEQUENCE

STAGE 3

PUMPDOWN

A

dccrca:>e

in

return

water

temperature

will

t;iiU>Se

the

third

step

or

the

staging

thermostat

(T1)

to

open,

thereby

de-energizing

staging

relay (R3),

opening

contacts

8-5, 9-6, and 7-4.

Liquid

line

solenoid

(SOL3)

will

de-energize,

stopping

the

flow

of

refrigerant

to

chiller

circuit

#3. The

compressor

will

continue

to

run

until

the

chiller

circuit

has been cleared

of

refrigerant

and the

suction

pressure is

approximately

35 PSIG.

Low

pressure

control

(LP3)

contact

will

then

open,

de-energizing

compressor

contactors

(C5) (49] and (C6)

[50].

stopping

compressor

#3; and

de-energizing

relays (R18) and

(R21

).Relay (R18)

N.C

.

(normally

closed)

contact

2-8 (54] energizes

lock-out

timer

(TD6).

preventing

compressor

#3

re-start

for

.five

minutes. Relay (R21) energizes

the

compressor

crankcase heater(s).

Staging

thermostat

(T1) also de-energizes relay (R7).

opening

contact

9-6, releasing

compressor

#1

from

continuous

full-load

operation.

Relay (R7)

contacts

8-2 and

7-1

close,

allowing

the

capacity

control

thermostat

(T3) to operate

capacity

control

solenoid

valves (UL1-1) and (UL2-1)

as

required.

STAGE 2

PUMPDOWN

A

further

decrease in return

water

temperature

will

de-energize

staging

relay (R2),

closing

liquid

line

solenoid

(SOL2). When

chiller

circuit

#2

has

pumped

out,

low

pressure

control

(LP2) opens,

stopping

compressor

#2

; and

de-energizing

relays (R16) and (R20).

Relay (R16) N.C.

contact

(8-2) [38] energizes

lock-out

timer

(TD5),

preventing

compressor

#2

re-start

for

five minutes. Relay (R20) (36]

energizes

compressor#2

crankcaseheater(s); and also de-energizes

fan

contactor

(C14) (44].

stopping

the

fan

motor(s)

servicing the

two-circuit

condenser

slab.

STAGE 1

PUMPDOWN

Step 1

of

the staging

thermostat

(T1) will

open

when

the

return

water

temperature

is reduced to

the

set

point

.

This

de-energizes

staging

relay

(R1

),

closing

liquid

line

solenoid

(SOL

1),

stopping

refrigerant

flow

to

chiller

circuit

#1.

Compressor#1

continues

to

run

until

chiller

circuit

#1

pressure is

down

to

the

low pressure

control

(LP1) set

point.

The

(LP1)

contact

opens

,

de-energizing

compressor

contac

-

tors

(C1) (17]. (C2) (18],

and

fan

contactor

(C13) [21].

stopping

compressor

#1

and the remaining fan

motor(s).

Relay (R14) N.C.

contact

8-2 (23] energizes

lock-out

timer

(TD4),

preventing

compressor

#1

re-start

for

five

minutes

; relay (R14)

contact

7-4 (62] opens,

removing

the

circulating

pump

starter

interlock

. Relay (R19)

de-energizes,

closing

contacts

7-1

[3].

energizing

compressor

#1

crankcase heater(s).

SAFETY

CONTROLS

Each

refrigerant

circuit

is

protected

by seven standard safety

controls,

and one

optional

safety

control.

1.

High Pressure (HP)

2.

Low

Pressure Freeze (LPF)

3. High

Discharge

Temperature

(OTS)

4.

Low

Oil

Temperature

(LOT)

5.

Compressor

Solid

State

Module

(CSTM)

6.

Low

Water

Temperature

(T2)

7.

Low

Pressure (LP)

8.

Compressor

Starter Overloads (OLH)

(Optional)

If any

of

these devices

should

open

due

to

abnormal

conditions,

the

compressor

will

automatically

stop. All

controls

must

be

manually

reset,

except

Low

Oil

Temperature

(LOT),

Low

Pressure (LP) and

Compressor

Solid

State

Module

(CSTM),

which

resets itself

after

a

two

minute

bleed-down

period. The

compressor

motor

windings

are

also

equipped

with

a

thermal

protector,

automatic

reset,

which

is

not

shown

on the

wiring

diagram.

SEQUENCE

OF

OPERATION

MODEL

ACWC

215 SC

The

following

sequence

of

operation

is

typica

l

for

the

ACWC

215 SC

(see pages 12

to

15

for

typical

wiring

diagram

).

Refer

to

the

wiring

diagram

furnished

with

unit

for

specific

information.

( )

Control

Identification

Symbol

[ ]

Circuit

Line

Number

Important Notel

The

compressor

crankcase

heater

must

be

energized

and remain

active

a

minimum

of

24

hours

prior

to

unit

start.

PRELIMINARY SEQUENCE

Place

control

circuit

"

ON-OFF

"

switches

(

SW1

thru

SW5) in

the

"OFF"

position

, and set

the

staging

thermostat

(T1

)

to

its

highest

temperature.

Activate

the

115

volt

electrical

service

to

terminals

#2 and #4 [1 and

3] on

terminal

board

(TER5)

to

distribute

power

to

the

control

circu

it

up

to

the

control

ci

rcuit

switches.

Crankcase

heater

relays (R20) [3],

(R21) (5], (R22)

[8],

and

(R23) (10] are

closed

and are

supp

lying

power

to

the

compressor

crankcase

heaters.

Power

is also

supplied

to

the

chiller

barrel

heaters

(CBH1)

[17] and

(CBH2)

[20],

the

receiver heaters (RH1 , 2, 3,

4)

(12, 13, 15, 16]

(optional)

,and

the

low

ambient

crankcase

heaters (SCH1 , 2, 3, 4) [3,

5,

8, 10]

(optional)

.

Close

the

main

power

disconnect

switch.

Check

to

see

that

the

red

indicating

lights

on

the

phase loss

monitors

(PLM1 ) and (PLM2) are

lit. These

lights

must

be on

to

indicate

proper

phase

rotation

for

the

compressor(s).

If

the

lights

are

not

on,

the

main

control

circuit

to

the

compressors

will

not

be

energized

. Reverse

any

two

phase legs at

the

main Incoming power terminal block. DO

NOT

reverse

the

leads

of

the

phase loss

monitor

,

fo

r

this

will

allow

the

compressor

to

run

backwards,

causing

seve

re

damage

,

and

WILL

VOID

THE

COMPRESSOR WARRANTEE!

Start-up

the

chilled

water

pump.

The

water

flow

is

confirmed

when

the

waterflow

switch

completes

an

electrical

circuit

across

terminals

#12 [89] and #13 [91]

of

terminal

board (TER5).

Terminals

#14 [92]

and #15 (94]

provide

an

interlock

for

the

water

pump

starter(s);

either

contact

(R11 ), (R12), (R13),

or

(R14) [95]

will

close

any

time

a

compressor

is

running

.

Set

the

staging

thermostat

(T1)

to

the

design

range

of

operation

(e

.g.

54° F.

return

water).

Set

the

capacity

contro

l

thermostat

(T3)

to

the

design

range

of

operation

(e.g. 44° F.

supply

water).

Place

the

five

control

circuit

switches

(SW1

thru

SW5) in

the

"

ON

"

position

,

thus

energizing

the

balance

of

the

control

circuit.

The

system will

be

in

the "time-In" mode for five minutes before any

compressor will start.

STAGE 1 LOADING

Upon

demand

for

cooling

,

the

first

step

of

the

staging

thermostat

(T1)

will

close,

energizing

relay (TD15) [94] and

staging

relay (R1)

(93],

closing

(R1)

contacts

7-4 [32], 8-5 [35], and 9-6 [26].

If

the

safety

controls

and

switches

are

closed

,

the

control

circuit

[26]

for

compressor

#1

and

liquid

line

solenoid

(SOL

1) (35]

will

energize

,

allowing

the

compressor

to

start.

Relay (R20) (30]

contact

9-6 (39] closes,

energizing

fan

contactor

(C13) (39],

bringing

power

to

the

line

side

of

fan

cycling

pressure

controls

(FCP1)

thru

(FCP6) (see

Power

Wiring

Diagram

on

Pages 16

and

17). Fan

motor

#1

will

start

as

soon

as

the

head

pressure reaches

the

"

cut-in

"

setting

of

(FCP1 ).

NOTE: ALL FAN

MOTORS

ARE CONTROLLED

BY

THEIR OWN

FAN

CYCLING

CONTROL

AND

WILL

CUT

IN

AT

DIFFERENT HEAD PRESSURES.

Relay (R20)

contact

7-1

(3] opens,

de-energizing

compressor

#1

crankcase

heater(s). Relay (R11) [29]

contact

8-5 [34] closes,

energizing

(TD9) [33].

This

will

force

compressor

#1

to

run

for

five

minutes.

COMPRESSOR #3 (Stage 2)

CANNOT

BE

STARTED

UNTIL

(TD9) TIMES OUT.

Time

delay relay (TD15) ]94]

contact

C-NC

[36]

holds

the

compressor

in an

unloaded

condition

for

30

seconds

. When relay (TD15)

times

out,

it

will

energize

relay (R5) (37],

closing

contacts

9-6

[1

06] and 7-4

(112].

This

allows

the

capacity

control

thermostat

(T3)

to

energize

solenoid

valve

(UL

1-1)

[1

06],

loading

the

compressor

;

or

to

energize

solenoid

valve (UL2-1)

[1

12],

unloading

the

compressor.

Relay (R11 ) [29]

contact

7-4

[95]

closes,

wh

i

ch

completes

the

interlock

circuit

for

the

water

ci

rculating

pump

.

STAGING

2 LOADING

Upon

a

further

increase in return

water

temperature

,

the

second

step

of

the

staging

thermostat

(T1)

will

close. If

the

lock-in

timer

(TD9)

[95] and

lock

-

out

timer

(TD7) [95] have

timed

out

, relays (R2) [95]

and (TD16) [96]

will

beenergized,

closing

(R2)

contacts

9-6 [62], 7-4

(67], and 8-5 [70]. If

the

safety

controls

and

switches

are closed,

the

control

circuit

[62]

for

compressor

#3 and

liquid

line

solenoid

(SOL3) [70]

will

energize

,

allow

ing

the

compressorto

start.

Relay (R22) [66]

contact

7-1

[8]

opens

,

de-energizing

crankcase

heater

(s).

Contact

9-6 [74] closes,

energizing

fan

contactor

(C14)

[74],

bringing

power

to

the

line

side

of

fan

cycling

pressure

controls

(FCP7)

thru

(FCP12) (see

power

wiring

diagrams)

. Fan

motor#4

will

start

as

soon

as

the

head pressure reaches

the

"

cut-in

"

setting

of

(FCP7).

Relay (R13) [65]

contact

8-5 [69] closes,

energizing

(TD11) [68].

This

will

fo

rce

compressor

#3

to

run for five

minutes

.Compressor#2

cannot be started until TD11) times out.

Time

delay

relay (TD16) [96]

contact

C-NC

[71]

holds

compressor

#3 in an

unloaded

condition

for

30

seconds

.When (TD16)

times

out

,

it

will

energize

(R7) [72],

closing

contacts

9-6

[1

08] and 7-4 [113].

This

allows

the

capacity

control

thermostat

(T3)

to

energize

solenoid

valve

(UL

1-3) [108],

loading

the

compressor

;

or

to

energize

solenoid

valve (UL2-3) [113],

unload

ing

the

compressor.

STAGE 3 LOADING

Upon

a

further

inc

rease in

return

water

temperature,

the

th

ird step

of

the

staging

thermostat

(T1)

will

close

. If

lock-in

timer

(TD11) and

lock-out

timer

(TD6) [66] have

timed

out

, relays (R3) [97], (R9) [99],

and (TD17) (98]

wil

l be

energized

. Relay (R3)

contacts

9-6 [45], 8-5

and 7-4 [50]

close

. If

the

safety

controls

and

switches

are

closed

,

the

control

circuit

[45]

for

compressor

#2 and

liquid

line

solenoid

(SOL2) [53]

will

energize

,

allowing

the

compressor

to

start.

Relay (R21) [49] energizes,

opening

contact

7-1

[5],

de-energizing

compressor

#2

crankcase

heater(s). Relay (R12) [48]

contact

8-5

[52] closes,

energizing

(TD1

0)

[51].

This

will

force

compressor#2

to

run

for

five

minutes

. Compressor #4 cannot be started until (TD10)

times out.

Relay (R9)

contact

9-6

[1

05] closes,

energizing

solenoid

valve

(UL

1-

1),

thus

locking

compressor

#1

in

the

fully

loaded

position

. Relay

(R9)

contacts

8-2 [106] and

7-1

[112]

open

to

disconnect

the

capacity

control

thermostat

(T3)

from

compressor

#1

capacity

control

solenoid

valves.

Time

delay

relay (TD17) [98]

contact

[54]

holds

compressor#2

in an

unloaded

condition

for

30

seconds.

When (TD17)

times

out,

it

will

energize

relay (R6) [55],

closing

contacts

9-6 [109] and 7-4 [114].

This

allows

the

capacity

control

thermostat

(T3)

to

energize

solenoid

valve

(UL

1·2)

(1

09], loading

the

compressor;

or

to

energize

solenoid

valve (UL2-2) (114],

unloading

the

compressor.

Compressor

#1

is

full

loaded

.

Compressors

#2 and #3 are

being

capacity-modulated

.

STAGE 4 LOADING

Upon

a

further

increase in return

water

temperature,

the

fourth

step

of

the

staging

thermostat

(T1)

will

close.

If

the

lock-in

timer

(TD1 0)

and

the

lock-out

timer

(TD8)

[1

00] have

timed

out,

relays (R4)

[1

00],

(R1

0)

(1

02], and (TD18)

[1

01]

will

be

energized

. Relay (R4)

contacts

9-6 [79], 7-4 (84], and 8-5 [87] close. If

the

safety

controls

and

switches

are

closed

,

the

control

circuit

[79]

for

compressor

#4 and

liquid

line

solenoid

(SOL4) [87]

will

energize

,

allowing

the

com

pres-

sor

to

start.

Relay (R23) [83] energizes,

opening

contact

7-1

(7],

de-energizing

compressor

#4

crankcase

heater(s). Relay (R14) [82]

contact

8-5

(86] closes,

energizing

(TD12).

This

will

force

compressor

#4

to

run

for

five

minutes

.

Relay

(R1

0)

contact

9-6

[1

07] closes,

energizing

solenoid

valve

(UL1-3

,

thus

locking

compressor

#3 in

the

fully

loaded

position

.

Relay

(R1

0)

contacts

8-2

(1

08] and

7-1

[113]

open

to

disconnect

the

capacity

control

thermostat

(T3)

from

compressor

#3

capacity

8

control

solenoid

valves.

~

\

\....__/

~

'-.._/

r

~

Time

delay relay (TD18) (101]

contact

C-NC

(88]

holds

compressor

#4

in

an

unloaded

condition

for30

seconds.When (TD18)

times

out,

it

will

energize relay (R8) [89].

closing

contacts

9-6

[11

0) and 7:4

(116].

Thio

o.llowo

tho

capacity

control

thormootat

(T'l)

to

..

norgi:zo

solenoid

valve

(UL

1-4)

[11

OJ,

loading

the

compressor

;

or

to

energize

solenoid (UL2-4) [115),

unloading

the

compressor

.

Compressors

#1

and #3 are

fully

loaded.

Compressors

#2

and #4 are being capacity-modulated.

PUMPDOWN SEQUENCE

STAGE 4

PUMPDOWN

A decrease in return

water

temperature will cause the

fourth

step of

the staging

thermostat

(T1)

to

open,

thereby

de-energzing staging

relay (R4),

opening

contacts

8-5, 9-6, and 7-4.

Liquid

line solenoid

(SOL4) will de-energize,

stopping

the

flow

of refrigerant

to

chiller

circuit

#4.

The

compressor

will

continue

to

run

until

the

chiller

circuit

has been cleared

of

refrigerant and the suction pressure is

approximately

35

PSIG.

Low

pressure

control

(LP4)

contact

will

then open,

de-energizing

compressorcontactors

(C7) [80) and (C8)

[81),

stopping

compressor

#4

; and

de-energizing

relays (R14) and

(R23).Relay (R14) N.C.

(normally

closed)

contact

2-8 [85] energizes

lock-out

timer

(TD8), preventing

compressor

#4

re-start

for

five

minutes. Relay (R23) energizes

compressor#4

crankcase heater(s).

Staging

thermostat

(T1) also de-energizes relay (R10),

opening

contact

9-6, releasing

compressor

#3

from

continuous

full-load

operation. Relay

(R1

0)

contacts

8-2 and

7-1

close,

allowing

capacity

control

thermostat

(T3)

to

operate

capacity

control

solenoid

valves

(UL1-3) and (UL2-3)

as

required.

STAGE 3 PUMPDOWN

A

further

decrease in return

water

temperature

will

de-energize

staging relay (R3),

closing

liquid

line solenoid (SOL2). When

chiller

circuit

#2

low-side

has

pumped

out

,

low

pressure

control

(LP2)

opens,

stopping

compressor

#2;and de-energizing relays (R12) and

(R21

). Relay (R12) N.C.

contact

2-9 [51) energizes

lock-out

timer

(TD6), preventing

compressor

#2

re-start

for

five

minutes

. Relay

(R21) energizes

compressor

#2

crankcase heater(s).

Staging

thermostat

(T1) also de-energizes relay (R9),

opening

contact

9-6, releasing

compressor

#1

from

continuous

full-load

operation. Relay (R9)

contacts

8-2 and

7-1

close,

allowing

the

capacity

control

thermostat (T3)

to

operatecapacity

control

solenoid

valves

(UL

1-1) and (UL2-1)

as

required.

STAGE 2 PUMPDOWN

A

further

decrease in return

water

temperature

will

de-energize

staging relay (R2),

closing

liquid

line solenoid (SOL3). When

chiller

circuit

#3

has

pumped

out,

low

pressure

control

(LP3) opens,

stopping

compressor#3;

and de-energizing relays (R13) and (R22).

Relay (R13) N.C.

contact

2-8 [68) energizes

lock-out

timer

(TD7),

preventing

compressor

#3 re-start

for

five

minutes

. Relay (R22)

energizes

compressor

#3 crankcaseheater(s); and alsode-energizes

fan

contactor

(C14) [74).

stopping

the fan motor(s) on the

"lag"

half

nf

thA

condAn!':Ar

!':lab

.

STAGE 1 PUMPDOWN

Step1

of

the

staging

thermostat

(T1) will open when the return water

temperature

is reduced

to

the set

point

.

This

de-energizes staging

relay

(R1

),

closing

liquid

line

solenoid

(SOL

1

),

stopping

refrigerant

flow

to

chiller

circuit

#1

.Compressor#1

continues

to

run

until

chiller

circuit

#1

pressure is

down

to

the

low

pressure

control

(LP1) set

point.

The

(LP1)

contact

opens, de-energizing

compressor

contac-

tors

(C1) (27) and (C2) [28), and relay (R20),

stopping

compressor

#1

. Relay (R20) de-energizes fan

contactor

(C13),

stopping

the

remainingfan motor(s); and alsoenergizes compressor

#1

crankcase

heater(s).

The

(LP1)

contact

also de-energizes relay

(R11

).

Relay

(R11) N.

C.

contact

2-8 [33) energizes

lock-out

timer

(TDS), prevent-

ing

compressor

#1

re-start

for

five minutes. Relay (R11)

contact

7-4

[95) opens, removing the

circulating

pump

starter

interlock

.

SAFETY CONTROLS

Each

refrigerant

circuit

is protected

by

seven standard safety

controls

, and one

optional

safety control.

1.

High

Pressure

(HPO)

2.

Low

Pressure Freeze (LPF)

3.

High Discharge Temperature (OTS)

4.

Low

Oil Temperature (LOT)

5.

Compressor

Solid State

Module

(CSTM)

6.

Low

Water Temperature (T2)

7.

Low

Pressure (LP)

8.

Compressor

Starter Overloads (OLH) (optional)

If

any

of

these devices

should

open

due

to

abnormal

conditions

, the

compressor

will

automatically

stop. All

controls

must be

manually

reset,

except

Low

Oil

Temper-

ature (LOT),

Low

Pressure (LP) and

Compressor

Solid

State

Module

(CSTM),

which

resets itself

after

a

two

minute

bleed-down

period.

The

compressor

motor

wind-

ingsarealso

equipped

with

a

thermal

protector,

automatic

reset,

which

is

not

shown on the

wiring

diagram.

STAR-DELTA STARTING

OPEN

TRANSITION

·The

following

starting sequenceappliesto the

power

wiring diagrams

on Page 17

as

well

as

the

control

wiring

on Pages 10

thru

15

. Detail

"A"

on Page 10 is

typical

of

all screw

compressor

star-deltastart, and

will

be used

as

an example.

Staging

relay (R1)

contact

9-6 [16) closes,

energizing

star

contactor

(S1)

[168)

and the 5 second

transition

timer

(TD1) [16A). The (S1)

power

contacts

close,

tying

the

center

legs

of

the

motor

windings

together

into

the

"star"

(wye)

configuration.

The

(S1) N.

C.

(normally

closed)

auxiliary

contact

[18] opens

to

prevent

contactor

(C2)

from

energizing.

The

(S1) N.O.

(normally

open)

auxiliary

contact

[17)

closes,

energizing

(C1) [17].

The

(C1)

power

contacts

close,

applying

power

to

the

motor

.The (C1) N.O.

auxiliary

contact

closes,

9

locking

(C1) in the energized

position

.

The

compressor

operates in the star

mode

until

(TD1) times

out

(5

seconds) at

which

time

(TD1)

contact

(168) opens, de-energizing

(S1

).

The

(S1) N.C.

contact

[18) closes,

energizing

contactor

(C2)

[18),

closing

(C2)

power

contacts,

thereby

completing

the Delta

wiring

configuration.

(C2) N.

C.

auxiliary

contact

[16A] opens,

preventing (S1)

from

energizing

until

the next starting sequence.

There

is an

instant

of

time

(the

"open

transition") between the

opening

of

(S1)

power

contacts

and

the

closing

of

(C2)

power

contacts,

in

which

power

across the

motor

windings

is

interrupted

.

0

~

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ACWC

160-200 SC

ACWC215

SC

TYPICAL

POWER

WIRING

STAR-DELTA

START

NOTES

1.

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ELECTRICAL

DATA

60HZ.

TOTAL

UNIT

CHARACTERISTICS

COMPRESSORS

CONDENSER

FANS

VOLTAC:E

Min.

Clroult

Max.

Fuoo

&uggoatod

Rated

Locked

Full

Amps' Size3 Wire Size• Load Rotor Load

Model Name Circuit Circuit Circuit Circuit Circuit Circuit Qty. Type Amps Amps Amps

ACWC Plate Range 1' 2' 1' 2' 1' 2' H.P. Start Each Each Phase Each

208-230 187-253 322 460 450 600

160SC 460 414-506 326 -400 -

208-230 187-253 335 468 450 600

185SC 460 414-506 350 -400 -

208-230 187-253 339 468 500 600

200SC 460 414-506 358 450

--

208-230 187-253

501

700 700

215SC 460 414-506 222 222 300 300

4605 414-506 420 -500 -

"ATL-

Across

The

Line

'208-230 voltage

requires

two

field

wiring

supplies

(circuits).

'

Minimum

circuit

ampacity

is

per

N.E.C.

Section

430-24.

400 700 205

400 (3)60

ATL"

90

-

400 750

IJ.!.@_

205

(2)75

ATL"

208

IJ.!.@_

90

500 -(2)75 98

500 750 208

500 -(3)75

ATL

"

98

900 v 900/ 205

0000 0000 (4)60

ATL"

90

600 -90

3Use

time

delay (dual

element)

fuses

only

. Suggested fuse sizes based on N.E.C.

Section

440-22.

•Wire size based on

copper

conductors

with

75° C. in

sulation

per

N.E.C.

Table

#31

0.16.

5

Single

point

power

terminals

NOTE:

1228

491

1228

1415

491

562

1415

562

1228

491

Maximum

inrush

amps

is L.R.A.

of

lag

compressor+

R.L.A.

of

all

other

compressors+

F.L.A.

of

all fans.

Lag

Compressor:

75

H.P. on 185SC.

Model

ACWC 320 340

160SC 12.0 13.7

185SC - -

200SC - -

215SC -

---

01

()2

COOLER

WATER PRESSURE

DROP

(Feet of Water)

GALLONS PER

MINUTE

360 380 400 420 440 460 480 500

15.4 17.1 18.8 20.6 - - - -

10.6 11.9

13.1

14.3 15.7 17.1 18.6 20.2

- - 13.1

14

.3 15.7

17.1

18.6 20.2

---

11.1

12.2

13

.3 14.4 15.5

Q3

Qs

1}4

Qs

520 540 560

---

- - -

---

16..Z_

_1_7

.

~

19.4

13.2

3 6.6

13.2

3 6.6

13.2

3 6.6

13.2

3 6.6

6.6

580

-

20.8

7L51

slJl

6~~~-

138

Y,

~

8 + 107

Y,

~

LOADING

(LBS.)

Model

LOCATION

POINT

NUMBER Dim.

ACWC 1 2 3 4 5 6 7 8 8

160SC 2120 2120 2120 2120 1830 1830 1510 1510

74

185SC 2280 2280 2280 2280 1960 1960 1630 1630 129

200SC 2340 2340 2340 2340 2010 2010 1670 1670 129

215SC 2330 2330 2330 2330 2150 2150 2150 2150 129

18

Locked

Rotor

Amps

Each

92.0

46.0

92

.0

46.0

92

.0

46.0

92

.0

46.0

'

START-UP

CHECK

LIST

Equipment Inspection: a.

Unit

damaged on arrival

b.

Mater

i

al

received agrees

with

shi

pping

papers

I

""

Setting Unit: a.

Vibration

isolator

used

b.

Spring

isolator

adjusted

for

equal

height

c. If

rubber-in-shear

isolators

are used, is

unit

leveled by

shimming

Wiring:

a.

Power

wiring

complete

b.

Control

wiring

complete

c. Electric service adequate

for

load

d. Power

source

voltage

correct

for

motor(s)

used

e.

Motor

circuit

has

proper

size fusetrons

f.

System wired per

diagram

g. All lead

connections

tight

h.

Wiring

complies

with

local codes

Piping:

a.

Piping

complies

with

applicable

codes

b. External

piping

independently

supported

c.

Chilled

water lines insulated

Alignment: a. All belts adjusted and checked

for

tension

b.

All

pulleys

checked

and

adjusted

for

proper

pitch

,

tightness

and

alignment

Before Start-Up: a. Open

compressor

discharge

service valve

b. Open

liquid

valve(s)

c. Open

suction

, and

discharge

valves

to

pressure gauges

(if

supplied)

d.

Check

rotation

of

all fan

motors

e. All

motors

and bearings

lubricated

g. Start

auxiliary

equipment

(pumps, fans, etc.)

h. Is crankcase heater operating?

After Start-Up: a.

Check

high pressure

control

b.

Check

oil

temperature

safety

switch

c.

Check

and

adjust

low

pressure

or

temperature

freeze

control

-

d.

Check

and

adjust

operating

thermostat

e.

Check

and

adjust

low

pressure

operating

control

f.

Check

and

adjust

expansion

valve superheat

g.

Check

and adjust

capacity

control

thermostat

OPERATING

DATA

CHILLER

Voltage:

L-1

L-2 L-3

___

_

Pressure Gauge Readings:

a.

Suction

psig

b.

Discharge

psig

High pressure switch setting:

(Cut-In)

psig

----

psig (Out)

Checked Setting Yes No

Low Pressure Switch Setting:

(Cut-In)

psig

----

psig (Out)

Checked Setting Yes

No

Low

Pressure Freeze

Control

Cut

In

Cut

Out

Oil

Temperature

Safety

Switch

Cut

Out

If

Star-Delta start, time delay is seconds.

Temperature

of

air entering

condenser

oF.

Temperature

of

air

leaving

condenser

oF.

Temperature

of

chilled

water

entering

chiller

oF

.

Temperature

of

water (chilled) leaving

chiller

oF

.

Chilled

water

pressure entering

chiller

psig

Chilled

water pressure leaving

chiller

psig

..,._._..

YES

NO

i

~

I'

•. I

Gulf+Western ACWC-SC User manual

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