Johnson Controls Quantech Millennium QCC3080CZE Owner's manual

QCC3080C – QCC3160C
Air-Cooled Scroll Condensing Units
Style A and B (60 Hz)
80 ton to 160 ton
281 kW to 522 kW
R-410A and R-454B
035-26917-000
Air-Cooled Scroll Condensing Units
Installation, Operation, Maintenance Supersedes QCC3-NM1 (1123) Form QCC3-NM1 (1223)
Issue Date:
December 19, 2023

Quantech
2
FORM QCC3-NM1
ISSUE DATE: 12/19/2023
This equipment is a relatively complicated apparatus.
During rigging, installation, operation, maintenance,
or service, individuals may be exposed to certain com-
ponents or conditions including, but not limited to:
heavy objects, refrigerants, materials under pressure,
rotating components, and both high and low voltage.
Each of these items has the potential, if misused or
handled improperly, to cause bodily injury or death. It
is the obligation and responsibility of rigging, instal-
lation, and operating/service personnel to identify and
recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure
to comply with any of these requirements could result
in serious damage to the equipment and the property in
Important!
Read before proceeding!
General safety guidelines
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
This document is intended for use by owner-authorized
rigging, installation, and operating/service personnel. It
is expected that these individuals possess independent
training that will enable them to perform their assigned
tasks properly and safely. It is essential that, prior to
performing any task on this equipment, this individual
shall have read and understood the on-product labels,
this document and any referenced materials. This in-
dividual shall also be familiar with and comply with
all applicable industry and governmental standards and
regulations pertaining to the task in question.
Safety symbols
The following symbols are used in this document to alert the reader to specific situations:
Indicates a possible hazardous situation
which will result in death or serious injury
if proper care is not taken.
Indicates a potentially hazardous situa-
tion which will result in possible injuries
or damage to equipment if proper care is
not taken.
Identies a hazard which could lead to
damage to the machine, damage to other
equipment and/or environmental pollu-
tion if proper care is not taken or instruc-
tions and are not followed.
Highlights additional information useful
to the technician in completing the work
being performed properly.
External wiring, unless specied as an optional connection in the manufacturer’s product line, is not
to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accor-
dance with Johnson Controls’ published specications and must be performed only by a qualied
electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper
connections to the controls or application of improper control signals. Failure to follow this warn-
ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

Quantech 3
FORM QCC3-NM1
ISSUE DATE: 12/19/2023
Changeability of this document
In complying with Johnson Controls’ policy for con-
tinuous product improvement, the information con-
tained in this document is subject to change without
notice. Johnson Controls makes no commitment to
update or provide current information automatically
to the manual or product owner. Updated manuals, if
applicable, can be obtained by contacting the nearest
Johnson Controls Service office or accessing the John-
son Controls Knowledge Exchange website at https://
docs.johnsoncontrols.com/chillers/.
It is the responsibility of rigging, lifting, and operating/
service personnel to verify the applicability of these
documents to the equipment. If there is any question
regarding the applicability of these documents, rig-
ging, lifting, and operating/service personnel should
verify whether the equipment has been modified and
if current literature is available from the owner of the
equipment prior to performing any work on the chiller.
AFFECTED PAGES DESCRIPTION
3 Refrigerant warning added to General safety guidelines
Revision notes
Revisions made to this document are indicated in the following table. These revisions are to technical information,
and any other changes in spelling, grammar, or formatting are not included.
Associated literature
MANUAL DESCRIPTION FORM NUMBER
Installation and Start-up Checklist QCC3-CL2
Limited Warranty Engineered Systems Equipment 50.05-NM2
Shipping Damage Claims 50.15-NM
Chiller A2L Refrigerant Application Data 160.00-AD10
Working with chiller vessels which are designed to contain contents under pressure must only be
conducted by fully qualied technicians who have been certied in accordance with EPA Section 608
of the Clean Air Act requirements for the US or equivalently the Federal Halocarbon Regulations
and the Refrigerant Code of Practice for Canada. This equipment is only intended for installation
in locations that are not accessible to the general public. Further, this equipment is not intended for
use by persons (including children) with reduced physical, sensory or mental capabilities, or lack
of experience and knowledge. Refrigerant R-454B is classied as an A2L refrigerant and must be
handled in accordance with all governing regulations. Failure to meet this requirement can result
in damage to equipment, release of refrigerant into the environment, contamination of the operating
space for the equipment and pose a risk of personal injury or death. It is the responsibility of any
service technician or operator to adhere to these requirements. See 160.00-AD10 for greater details
regarding the application and use of A2L refrigerants.

Quantech
4
FORM QCC3-NM1
ISSUE DATE: 12/19/2023
Nomenclature
See Nomenclature on page 23 for addi-
tional information on PIN.
Conditioned-based maintenance
Traditional chiller maintenance is based upon assumed
and generalized conditions. In lieu of the traditional
maintenance program, a Johnson Controls Quantech
Conditioned Based Maintenance (CBM) program can
be substituted. This CBM service plan is built around
the specific needs for the chiller, operating conditions,
and annualized impact realized by the chiller. Your lo-
cal Johnson Controls Branch can propose a customized
Planned Service Agreement that leverages real time
and historical data, delivering performance reporting,
corrective actions required and data enabled guidance
for optimal operation and lifecycle assurance. The pro-
gram will include fault detection diagnostics, operation
code statistics, performance based algorithms and ad-
vance rules based rationale delivered by the Johnson
Controls Connected Equipment Portal.
QC C3145C
E = R-410A
J = R-454B

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FORM QCC3-NM1
ISSUE DATE: 12/19/2023
Table of contents
Section 1: General equipment information and safety ...................................................................................... 11
Introduction..................................................................................................................................................... 11
Compressors .................................................................................................................................................. 11
Condenser...................................................................................................................................................... 11
Refrigerant circuit ........................................................................................................................................... 11
Warranty ......................................................................................................................................................... 11
Safety and quality...........................................................................................................................................12
About this manual...........................................................................................................................................12
Misuse of equipment ......................................................................................................................................13
Section 2: Product description ............................................................................................................................15
Introduction.....................................................................................................................................................15
General system description............................................................................................................................15
Refrigerant circuit ...........................................................................................................................................16
Microcomputer control center.........................................................................................................................16
High ambient kit..............................................................................................................................................17
Communications.............................................................................................................................................17
Power panel ...................................................................................................................................................17
Accessories and options ................................................................................................................................17
Unit components ...........................................................................................................................................20
Nomenclature (Pin) ........................................................................................................................................23
Refrigerant flow diagram ................................................................................................................................27
Process and instrumentation diagram............................................................................................................28
Section 3: Handling and storage..........................................................................................................................29
Delivery and storage ......................................................................................................................................29
Inspection .......................................................................................................................................................29
Unit rigging .....................................................................................................................................................29
Section 4: Installation ...........................................................................................................................................31
Installation checklist .......................................................................................................................................31
Handling .........................................................................................................................................................31
Location and clearances ................................................................................................................................31
Spring isolators: optional ................................................................................................................................32
Compressor mounting ....................................................................................................................................32
Pipework arrangement ...................................................................................................................................32
Ductwork connection .....................................................................................................................................32
Wiring .............................................................................................................................................................32
Compressor heaters.......................................................................................................................................33
Relief valves ...................................................................................................................................................33
High pressure cutout ......................................................................................................................................33
Electrical wiring ..............................................................................................................................................33
Compressor heaters.......................................................................................................................................35
Refrigerant piping ...........................................................................................................................................35
Oil traps ..........................................................................................................................................................38
Refrigerant charge..........................................................................................................................................38
Filter driers, sight glasses, and TXV’S............................................................................................................38
Refrigerant piping notes .................................................................................................................................39
Control wiring .................................................................................................................................................41

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FORM QCC3-NM1
ISSUE DATE: 12/19/2023
Section 5: Technical data......................................................................................................................................43
Operational limitations....................................................................................................................................43
Physical data ..................................................................................................................................................44
Electrical data.................................................................................................................................................45
Wiring Diagrams.............................................................................................................................................68
Power options connection diagram ................................................................................................................78
Wiring .............................................................................................................................................................84
Micro panel connections.................................................................................................................................86
Dimensions.....................................................................................................................................................92
Clearances .....................................................................................................................................................95
Weight distribution and isolator mounting positions .......................................................................................96
Isolator information.........................................................................................................................................97
Section 6: Commissioning .................................................................................................................................103
Commissioning.............................................................................................................................................103
Preparation: power off ..................................................................................................................................103
Preparation: power on ..................................................................................................................................104
Section 7: Unit controls ......................................................................................................................................109
Introduction...................................................................................................................................................109
Microprocessor board...................................................................................................................................109
Unit switch .................................................................................................................................................... 110
Display.......................................................................................................................................................... 110
Keypad ......................................................................................................................................................... 110
Battery back-up ............................................................................................................................................ 110
Transformer ................................................................................................................................................. 110
Single system select and programming number of compressors................................................................. 110
Status key..................................................................................................................................................... 111
Display/print keys ......................................................................................................................................... 117
Entry keys.....................................................................................................................................................125
Setpoints keys ..............................................................................................................................................126
Unit keys ......................................................................................................................................................133
Section 8: Unit operation....................................................................................................................................139
Capacity control............................................................................................................................................139
Suction pressure limit controls .....................................................................................................................139
Discharge pressure limit controls .................................................................................................................139
Discharge air temperature control ................................................................................................................139
Suction Pressure control ..............................................................................................................................141
System lead/lag............................................................................................................................................142
Compressor lead/lag ....................................................................................................................................142
Anti-recycle timer..........................................................................................................................................142
Anti-coincidence timer ..................................................................................................................................142
Evaporator blower control ............................................................................................................................142
Pumpdown control........................................................................................................................................142
Condenser fan control ..................................................................................................................................145
Load limiting .................................................................................................................................................147
Compressor run status .................................................................................................................................147
Alarm status .................................................................................................................................................147
BAS/EMS discharge air temperature reset using a voltage or current signal .............................................148
Table of contents (cont’d)

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FORM QCC3-NM1
ISSUE DATE: 12/19/2023
Section 9: Service and troubleshooting............................................................................................................149
Clearing history buffers.................................................................................................................................149
Service mode outputs...................................................................................................................................149
Service mode condensing unit configuration................................................................................................ 150
Service mode analog and digital inputs........................................................................................................150
Control inputs and outputs ...........................................................................................................................151
Checking inputs and outputs ........................................................................................................................153
Optional printer installation...........................................................................................................................157
Section 10: Maintenance.....................................................................................................................................161
Important ......................................................................................................................................................161
Compressors oil level check......................................................................................................................... 161
Oil analysis ...................................................................................................................................................161
Condenser fan motors..................................................................................................................................161
Condenser MCHX ........................................................................................................................................161
Microchannel coil cleaning ...........................................................................................................................161
Cleaning procedure required for standard and environment guard microchannel coils ...............................162
Cleaning procedure for environment guard premium microchannel coils .................................................... 162
Steps to touch-up small sections of finned coil surface................................................................................163
Steps to touch-up end (dead) tubes and condenser coil headers:...............................................................163
Materials required:........................................................................................................................................163
Chilled liquid system maintenance ...............................................................................................................164
Scheduled maintenance...............................................................................................................................164
Chiller / compressor operating log................................................................................................................ 164
Evaporator freeze damage...........................................................................................................................164
Glycol concentration.....................................................................................................................................164
Winterization.................................................................................................................................................164
Before applying power to the chiller, ensure the chilled liquid system is filled .............................................164
Removing water/glycol from the evaporator.................................................................................................165
Operating parameters ..................................................................................................................................165
On-board battery backup..............................................................................................................................165
Brazed plate heat exchanger (evaporator) heater........................................................................................165
Overall unit inspection ..................................................................................................................................165
BAS control ..................................................................................................................................................166
BACnet and Modbus data communication ...................................................................................................169
Table of contents (cont’d)

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FORM QCC3-NM1
ISSUE DATE: 12/19/2023
List of figures
Figure 1 - Compressors..........................................................................................................................................15
Figure 2 - Unit Components Front ..........................................................................................................................20
Figure 3 - Power Panel Components......................................................................................................................21
Figure 4 - Power Panel / Control Components.......................................................................................................22
Figure 5 - Refrigerant Flow Diagram ......................................................................................................................27
Figure 6 - Process and Instrumentation Diagram...................................................................................................28
Figure 7 - Unit Rigging............................................................................................................................................29
Figure 8 - Single-Point Supply Connection – Terminal Block, Non-Fused Disconnect Switch Or Circuit Breaker .40
Figure 9 - Discharge Air Sensor Field Wiring..........................................................................................................40
Figure 10 - Control Wiring.......................................................................................................................................41
Figure 11 - Elementary Wiring Diagram..................................................................................................................68
Figure 12 - Power Options Connection Diagram....................................................................................................78
Figure 13 - Single Point and Dual Point Wiring ......................................................................................................82
Figure 14 - Wiring ...................................................................................................................................................84
Figure 15 - Micro Panel Connections .....................................................................................................................86
Figure 16 - Elementary Diagram.............................................................................................................................88
Figure 17 - Unit Clearances – All Models ...............................................................................................................95
Figure 18 - Sample Printout Supplied in the Isolator Package and in the Chiller Panel Literature Packet.............96
Figure 19 - Status Key Messages Quick Reference List ...................................................................................... 116
Figure 20 - Operation Data...................................................................................................................................120
Figure 21 - Setpoints Quick Reference List..........................................................................................................132
Figure 22 - Unit Keys Programming Quick Reference List...................................................................................138
Figure 23 - Discharge Air Temperature Control ....................................................................................................140
Figure 24 - Suction Pressure Control ...................................................................................................................141
Figure 25 - QCC3080C – QCC3090C Fan Location (Typical).............................................................................. 143
Figure 26 - QCC3100C – QCC3130C Fan Location ............................................................................................145
Figure 27 - QCC3145C – QCC3160C Fan Location ............................................................................................146
Figure 28 - Microboard Layout..............................................................................................................................152
Figure 29 - I/O Board Relay Contact Architecture ................................................................................................156
Figure 30 - Printer to Microboard Electrical Connections .....................................................................................157

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FORM QCC3-NM1
ISSUE DATE: 12/19/2023
List of tables
Table 1 - Product identification number (Pin) .........................................................................................................23
Table 2 - Fitting Equivalent Lengths........................................................................................................................36
Table 3 - Refrigerant Piping Charges......................................................................................................................36
Table 4 - Miscellaneous Liquid Line Pressure Drops ..............................................................................................36
Table 5 - Refrigerant Line Connections...................................................................................................................37
Table 6 - Refrigerant Line Pressure Drops (Imperial) .............................................................................................39
Table 7 - Voltage Limitations ...................................................................................................................................43
Table 8 - Physical Data (Imperial) ...........................................................................................................................44
Table 9 - Micro Panel Power Supply .......................................................................................................................45
Table 10 - Voltage Range........................................................................................................................................45
Table 11 - Standard Efficiency Unit Electrical Data (4 compr) R-410A, single point ...............................................46
Table 12 - Standard Efficiency Unit Electrical Data (5 compr) R-410A, single point............................................... 47
Table 13 - Standard Efficiency Unit Electrical Data (6 compr) R-410A, single point............................................... 49
Table 14 - High Efficiency Unit Electrical Data (4 compr) R-410A, single point ......................................................49
Table 15 - High Efficiency Unit Electrical Data (5 compr) R-410A, single point ......................................................49
Table 16 - Standard Efficiency Unit Electrical Data (4 compr) R-454B, single point............................................... 50
Table 17 - Standard Efficiency Unit Electrical Data (5 compr) R-454B, single point............................................... 51
Table 18 - Standard Efficiency Unit Electrical Data (6 compr) R-454B, single point............................................... 51
Table 19 - High Efficiency Unit Electrical Data (5 compr) R-454B, single point ......................................................53
Table 20 - High Efficiency Unit Electrical Data (6 compr) R-454B, single point ......................................................53
Table 21 - Standard Efficiency Unit Electrical Data (4 compr) R-410A, dual point .................................................54
Table 22 - Standard Efficiency Unit Electrical Data (5 compr) R-410A, dual point .................................................54
Table 23 - Standard Efficiency Unit Electrical Data (6 compr) R-410A, dual point .................................................57
Table 24 - High Efficiency Unit Electrical Data (4 compr) R-410A, dual point.........................................................57
Table 25 - High Efficiency Unit Electrical Data (5 compr) R-410, dual point ...........................................................57
Table 26 - Standard Efficiency Unit Electrical Data (4 compr) R-454B, dual point .................................................58
Table 27 - Standard efficiency unit electrical data (5 compr) R-454B, dual point ...................................................58
Table 28 - Standard Efficiency Unit Electrical Data (6 compr) R-454B, dual point .................................................59
Table 29 - High Efficiency Unit Electrical Data (5 compr) R-454B, dual point.........................................................61
Table 30 - High Efficiency Unit Electrical Data (6 compr) R-454B, dual point.........................................................61
Table 31 - Lug Sizing ..............................................................................................................................................62
Table 32 - Cooling Setpoints Programmable Limits and Defaults......................................................................... 131
Table 33 - Program and Defaults ..........................................................................................................................131
Table 34 - Discharge Air Temperature Control For 5 and 6 Compressors (7 and 8 Steps)...................................140
Table 35 - Discharge Air Temperature Control For 4 Compressors (6 Steps).......................................................140
Table 36 - QCC3080C – QCC3090C Condenser Fan Control Using Outdoor Ambient Temperature
and Discharge Pressure.......................................................................................................................143
Table 37 - QCC3080C –QCC3090C Condenser Fan Control Using Discharge Pressure Only ........................... 143
Table 38 - QCC3080C – QCC3090C Low Ambient Condenser Fan Control –
Discharge Pressure Control .................................................................................................................144
Table 39 - QCC3100C – QCC3130C Condenser Fan Control..............................................................................145
Table 40 - QCC3145C – QCC3160C Condenser Fan Control..............................................................................146
Table 41 - Compressor Operation – Load Limiting ...............................................................................................147
Table 42 - I/O Digital Inputs...................................................................................................................................151
Table 43 - I/O Digital Outputs................................................................................................................................151
Table 44 - I/O Analog Inputs..................................................................................................................................151
Table 45 - I/O Analog Outputs...............................................................................................................................151
Table 46 - Outdoor Air Sensor Temperature/Voltage/Correlation..........................................................................153
Table 47 - Discharge Air Temperature Sensor Temperature/Voltage/Resistance Correlation...............................154
Table 48 - Pressure Transducers ..........................................................................................................................155
Table 49 - Troubleshooting....................................................................................................................................158
Table 50 - BAS Received Data .............................................................................................................................166
Table 51 - BAS Transmitted Data..........................................................................................................................166
Table 52 - BAS Operational and Fault Codes .......................................................................................................168

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FORM QCC3-NM1
ISSUE DATE: 12/19/2023
Table 53 - Minimum, Maximum and Default Values..............................................................................................170
Table 54 - Real Time Error Numbers ....................................................................................................................170
Table 55 - Serial Communication Analog Value Data ...........................................................................................171
Table 56 - Serial Communication Binary Value Data ............................................................................................171
Table 57 - Serial Communication Analog Input Data ............................................................................................171
Table 58 - Serial Communication Binary Input Data .............................................................................................173
Table 59 - Temperature Conversion Chart - Actual Temperature ..........................................................................174
Table 60 - Temperature Conversion Chart Differential Temperatures................................................................... 174
Table 61 - Pressure Conversion Chart - Gauge Or Differential.............................................................................175
Table 62 - R-410A Pressure-Temperature Chart...................................................................................................175
Table 63 - R-454B pressure-temperature chart ....................................................................................................176
List of tables