Quantech QWC4 Owner's manual

MODEL QWC4
SINGLE COMPRESSOR
60 HZ
120 TONS TO 200 TONS
WATER-COOLED SCREW
LIQUID CHILLERS
INSTALLATION, OPERATION, MAINTENANCE New Release Form QWC4-NM1 (221)
Issue Date:
February 28, 2021
035-28391-000
R-134a

QUANTECH
2
FORM QWC4-NM1 (221)
ISSUE DATE: 02/28/2021
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 accordance with Quantech’ published specications and must be performed only by a qualied
electrician. Quantech will NOT be responsible for damage/problems resulting from improper con-
nections to the controls or application of improper control signals. Failure to follow this warning
will void the manufacturer’s warranty and cause serious damage to property or personal injury.

QUANTECH 3
FORM QWC4-NM1 (221)
ISSUE DATE: 02/28/2021
MANUAL DESCRIPTION FORM NUMBER
QWC4 Chiller Installation Checklist QWC4-CL1
QWC4 Chiller Start-up Checklist and Request for Authorized Start-up Technician QWC4-CL3
QWC4 Renewal Parts QWC4-RP1
Limited Warranty QTC-NM2
ASSOCIATED LITERATURE
CHANGEABILITY OF THIS DOCUMENT
In complying with Quantech’s policy for continu-
ous product improvement, the information contained
in this document is subject to change without notice.
Quantech 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 Quantech Service
office or accessing the Johnson 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.

QUANTECH
4
FORM QWC4-NM1 (221)
ISSUE DATE: 02/28/2021
QWC4
MOD
LEVEL
EVAP
TUBES*
BB
BC
BD
CB
CC
CD
DB
DC
DD
MB
MC
MD
ME
NB
NC
ND
NE
M2
M3
M4
M5
N2
N3
N4
N5
UNIT TYPE
Quantech Variable Speed
Screw Water-Cooled Chiller
Design Series
MB
COND
TUBES*
BB
BC
BD
CB
CC
CD
DB
DC
DD
MB
MC
MD
ME
NB
NC
ND
NE
M2
M3
M4
M5
N2
N3
N4
N5
MB
APPLICATION
S=Std Water Chiller
D=Dry Tower/Radiator
P=Process Brine
T=Ice Thermal Storage
A=Heat Pump
S
X=NO SELECTION
Q=SPECIAL
QUOTE
XA
CMPR
FX=(1) 145 mm
GX=(1) 151 mm
EE=(2) 136/136 mm
FE=(2) 145/136 mm
FF=(2) 145/145 mm
EE
PASS
A=Evap: 1-pass; Cond: 1 pass
B=Evap: 2-pass; Cond: 1 pass
C=Evap: 3-pass; Cond: 1 pass
D=Evap: 1-pass; Cond: 2 pass
E=Evap: 2-pass; Cond: 2 pass
F=Evap: 3-pass; Cond: 2 pass
G=Evap: 1-pass; Cond: 3 pass
H=Evap: 2-pass; Cond: 3 pass
I =Evap: 3-pass; Cond: 3 pass
B
STARTER
A=2 CMPR VSD Frame A
B=2 CMPR VSD Frame B
C=2 CMPR VSD Frame C
D=2 CMPR VSD Frame D
J=1 CMPR VSD Frame B
L=1 CMPR VSD Frame D
R=1 CMPR Air Cooled Frame A
S=1 CMPR Air Cooled Frame B
T=1 CMPR Air Cooled Frame C
U=1 CMPR Air Cooled Frame D
A
NOMINAL
CAP
0150
*First letter represents tube size. The second
letter designates the number of tubes.
Nomenclature

QUANTECH 5
FORM QWC4-NM1 (221)
ISSUE DATE: 02/28/2021
TABLE OF CONTENTS
SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY ................................................................. 11
Introduction..................................................................................................................................................... 11
About this Manual........................................................................................................................................... 11
Warranty ......................................................................................................................................................... 11
Quality Assurance .......................................................................................................................................... 11
Fluorinated Greenhouse Gases .....................................................................................................................12
Responsibility for Safety.................................................................................................................................12
Misuse of Equipment......................................................................................................................................12
SECTION 2 - PRODUCT DESCRIPTION............................................................................................................15
Components ...................................................................................................................................................15
Semi-Hermetic Quantech Screw Compressors .............................................................................................19
Evaporator .....................................................................................................................................................19
Condenser .....................................................................................................................................................19
Refrigerant Circuit .........................................................................................................................................19
Complete Factory Package ...........................................................................................................................19
Electrical ........................................................................................................................................................19
Building Automation System Capabilities ......................................................................................................19
Microcomputer Control Center ....................................................................................................................... 20
Options ...........................................................................................................................................................20
SECTION 3 - HANDLING, STORAGE, INSTALLATION, AND REASSEMBLY...............................................23
Shipment and Storage.................................................................................................................................... 23
Inspection, Damage, and Shortage................................................................................................................25
Lifting Weights................................................................................................................................................26
Moving the Chiller for Forms 1 and 2 ............................................................................................................. 27
Foundation .....................................................................................................................................................28
Clearance for Service ....................................................................................................................................28
Installing Elastomeric Vibration Isolator Pads ................................................................................................ 29
Installing Optional Spring Isolators.................................................................................................................30
Form 7 Reassembly ....................................................................................................................................... 31
Piping Joint Assembly ....................................................................................................................................46
Pipe Thread Joints..........................................................................................................................................46
Gasket Joints.................................................................................................................................................. 47
Torque Values................................................................................................................................................. 48
Refrigerant Tubing Reassembly .....................................................................................................................48
Brazed Joints .................................................................................................................................................50
Piping Connections ........................................................................................................................................52
Check for Piping Alignment ............................................................................................................................ 52
Condenser and Chilled Liquid Piping ............................................................................................................52
General Requirements ...................................................................................................................................52
Water Treatment.............................................................................................................................................53
Pipework Arrangement ...................................................................................................................................54
Minimum Water Volume .................................................................................................................................54
Leaving Water Temperature Out of Range.....................................................................................................54
Nozzle Connections .......................................................................................................................................55
Options for Flanges ........................................................................................................................................55
Refrigerant Relief Piping ...............................................................................................................................55

QUANTECH
6
FORM QWC4-NM1 (221)
ISSUE DATE: 02/28/2021
TABLE OF CONTENTS (CONT'D)
Unit Piping ......................................................................................................................................................57
Electrical Connection...................................................................................................................................... 57
Power Wiring ..................................................................................................................................................57
Power Supply Wiring ......................................................................................................................................57
115 VAC Control Supply Transformer.............................................................................................................57
Control Wiring................................................................................................................................................. 57
System Inputs................................................................................................................................................. 58
Analog Inputs .................................................................................................................................................58
SECTION 4 - TECHNICAL DATA.........................................................................................................................65
Single Compressor Unit Dimensions.............................................................................................................. 72
Dimensions of Evaporator Nozzle Arrangements...........................................................................................74
Dimensions of Condenser Nozzle Arrangements...........................................................................................75
SECTION 5 - COMMISSIONING..........................................................................................................................77
Preparation.....................................................................................................................................................77
First Time Start-up..........................................................................................................................................77
SECTION 6 - OPERATION ...................................................................................................................................83
Operating Controls .........................................................................................................................................83
Basic Operating Sequence............................................................................................................................. 84
User Interface.................................................................................................................................................88
Fault Messages ..............................................................................................................................................91
Microboard (331-03478-xxx) ..........................................................................................................................91
Program Update .............................................................................................................................................93
Data Logging ..................................................................................................................................................94
Acceptable Printers ......................................................................................................................................123
Printer Connections......................................................................................................................................123
Printer Setup ................................................................................................................................................123
Printing a Report ..........................................................................................................................................124
BAS Communications ..................................................................................................................................128
SECTION 7 - MAINTENANCE ...........................................................................................................................131
General Requirements .................................................................................................................................131
Daily Operating Inspections .........................................................................................................................132
Compressor Oil ............................................................................................................................................132
Oil Filter Replacement..................................................................................................................................135
Refrigerant Charging ....................................................................................................................................137
Handling Refrigerant for Dismantling and Repairs .......................................................................................137
Checking System for Leaks.......................................................................................................................... 138
Refrigerant Leak Checking...........................................................................................................................138
Pressure Connections ..................................................................................................................................138
Testing for Evaporator and Condenser Tube Leaks .....................................................................................139
Evacuation and Dehydration of Unit.............................................................................................................140
Condensers and Evaporators Maintenance .................................................................................................142
Cleaning Evaporator and Condenser Tubes ................................................................................................142
Compressor Maintenance ............................................................................................................................144
Electrical Controls ........................................................................................................................................144

QUANTECH 7
FORM QWC4-NM1 (221)
ISSUE DATE: 02/28/2021
TABLE OF CONTENTS (CONT'D)
SECTION 8 - TROUBLESHOOTING.................................................................................................................147
Abnormal Operation, Analysis and Correction ............................................................................................. 147
Troubleshooting the Compressor and Oil Separation System ..................................................................... 147
SECTION 9 - DECOMMISSIONING, DISMANTLING, AND DISPOSAL........................................................153

QUANTECH
8
FORM QWC4-NM1 (221)
ISSUE DATE: 02/28/2021
LIST OF FIGURES
FIGURE 1 - Emergency Shutdown Handle ............................................................................................................13
FIGURE 2 - QWC4 Chiller Major Components (Front View) ..................................................................................16
FIGURE 3 - QWC4 Chiller Major Components (Rear View)...................................................................................17
FIGURE 4 - Basic System Control and VSD System Architecture .........................................................................18
FIGURE 5 - Control Center User Interface .............................................................................................................20
FIGURE 6 - Head Pressure Control System ..........................................................................................................22
FIGURE 7 - Unit Rigging for Forms 1 and 2 ...........................................................................................................27
FIGURE 8 - Service Clearance Requirements .......................................................................................................28
FIGURE 9 - Elastomeric Vibration Isolator Pad Mounts (Standard) - Inches (mm)................................................29
FIGURE 10 - Spring Isolators, in. (mm)..................................................................................................................30
FIGURE 11 - Rigging the Evaporator .....................................................................................................................33
FIGURE 12 - Condenser Rigging ...........................................................................................................................34
FIGURE 13 - Isolator Installation............................................................................................................................35
FIGURE 14 - Heat Exchanger Shipping Brackets ..................................................................................................37
FIGURE 15 - Heat Exchanger Pipes ......................................................................................................................37
FIGURE 16 - Liquid Injection Piping.......................................................................................................................38
FIGURE 17 - Filter Drier and Piping .......................................................................................................................38
FIGURE 18 - Driveline (Compressor/Motor) Assembly ..........................................................................................39
FIGURE 19 - Oil Separator Discharge Piping on Single Compressor Units...........................................................41
FIGURE 20 - Transducer, Eductor and Oil Return Piping ......................................................................................42
FIGURE 21 - Oil Supply Piping...............................................................................................................................42
FIGURE 22 - Variable Speed Drive (VSD) .............................................................................................................44
FIGURE 23 - Control Panel ....................................................................................................................................45
FIGURE 24 - VSD Cooling Hoses ..........................................................................................................................45
FIGURE 25 - Alternate Piping for VSD ...................................................................................................................46
FIGURE 26 - Torque Pattern ..................................................................................................................................47
FIGURE 27 - Adjustable End Fitting .......................................................................................................................48
FIGURE 28 - Back O󰀨 Locknut...............................................................................................................................49
FIGURE 29 - Screw Fitting Into Port.......................................................................................................................49
FIGURE 30 - Torque Fitting ....................................................................................................................................49
FIGURE 31 - SAE or ISO 6149 Straight Thread O-ring Port ..................................................................................49
FIGURE 32 - Brazed Joints ....................................................................................................................................51
FIGURE 33 - Schematic of a Typical Piping Arrangement .....................................................................................54
FIGURE 34 - Leaving Water Temperature Out-of-Range Suggested Layout ........................................................55
FIGURE 35 - Grooved Nozzle ................................................................................................................................55
FIGURE 36 - Flange Attachment ............................................................................................................................55
FIGURE 37 - Typical Components of Relief Piping ................................................................................................56
FIGURE 38 - Power Connections...........................................................................................................................62
FIGURE 39 - Single Compressor Unit Dimensions ................................................................................................72
FIGURE 40 - Evaporators - Compact Waterboxes (2-Pass) ..................................................................................74
FIGURE 41 - Evaporators - Compact Waterboxes (3-Pass) ..................................................................................74
FIGURE 42 - Condensers - Compact Waterboxes (1-Pass) ..................................................................................75
FIGURE 43 - Condensers - Compact Waterboxes (2-Pass) ..................................................................................75
FIGURE 44 - Condensers - Compact Waterboxes (3-Pass) ..................................................................................75
FIGURE 45 - Keypad and Display..........................................................................................................................83
FIGURE 46 - Control Operation..............................................................................................................................85
FIGURE 47 - Status Key.........................................................................................................................................89
FIGURE 48 - New 331-03478-xxx Microboard.......................................................................................................92
FIGURE 49 - Unit Data Key..................................................................................................................................104
FIGURE 50 - System Data Key ............................................................................................................................105
FIGURE 51 - VSD Data and Operating Hours/Start Counter Keys ......................................................................107
FIGURE 52 - History Key......................................................................................................................................108
FIGURE 53 - Setpoints Key.................................................................................................................................. 110
FIGURE 54 - Setpoint High and Low Limits Dened By Control Range (CR)...................................................... 111

QUANTECH 9
FORM QWC4-NM1 (221)
ISSUE DATE: 02/28/2021
LIST OF FIGURES (CONT'D)
FIGURE 55 - Program Key................................................................................................................................... 112
FIGURE 56 - Options Key .................................................................................................................................... 118
FIGURE 57 - Date/Time and Schedule Key .........................................................................................................120
FIGURE 58 - Manual Override and Print Key.......................................................................................................122
FIGURE 59 - Printer Cable Connection from QWC4 Chiller to a Computer ........................................................122
FIGURE 60 - Printer Cable Connection from QWC4 Chiller to a Serial Printer....................................................123
FIGURE 61 - Sample Printout ..............................................................................................................................125
FIGURE 62 - System Switches and Service Keys................................................................................................127
FIGURE 63 - E-Link Gateway Option...................................................................................................................128
FIGURE 64 - Charging Oil ...................................................................................................................................134
FIGURE 65 - Oil Filter Assembly ..........................................................................................................................135
FIGURE 66 - Oil Eductor Assembly......................................................................................................................136
FIGURE 67 - Motor Windings Diagram ................................................................................................................138
FIGURE 68 - Saturation Curve.............................................................................................................................141

QUANTECH
10
FORM QWC4-NM1 (221)
ISSUE DATE: 02/28/2021
LIST OF TABLES
TABLE 1 - Unit Weight ...........................................................................................................................................26
TABLE 2 - Service Clearance Requirements .........................................................................................................28
TABLE 3 - Evaporator and Condenser Weight, lb (kg)...........................................................................................31
TABLE 4 - Torque Specification .............................................................................................................................32
TABLE 5 - Evaporator Dimensions, in. (mm) .........................................................................................................33
TABLE 6 - Condenser Dimensions, in. (mm) .........................................................................................................34
TABLE 7 - Compressor Weight and Dimensions ...................................................................................................39
TABLE 8 - Oil Separator Weight and Dimensions on Single Compressor Units ....................................................40
TABLE 9 - VSD Weight and Dimensions................................................................................................................43
TABLE 10 - Assembly Compounds ........................................................................................................................46
TABLE 11 - ANSI 150 lb Flange Torque Specifications..........................................................................................47
TABLE 12 - ANSI 300 lb Flange Torque Specifications..........................................................................................47
TABLE 13 - SAE J429 Gr 5 Bolts Torque Specifications........................................................................................48
TABLE 14 - Assembly Torque Metric for Metric Tube Fittings ................................................................................50
TABLE 15 - O-ring Assembly Torque Specifications ..............................................................................................51
TABLE 16 - Brazed Joints ......................................................................................................................................51
TABLE 17 - Water Volume for Applications ............................................................................................................54
TABLE 18 - Evaporator and Condenser Water Capacity (gal/l) ............................................................................ 54
TABLE 19 - Refrigerant Relief Characteristics (Per Valve) ....................................................................................56
TABLE 20 - System Input Connections..................................................................................................................58
TABLE 21 - Lug Data (UL/ASME/CE) - Pin 22/Power Field...................................................................................63
TABLE 22 - Lug Data (GB) - Pin 22/Power Field ...................................................................................................63
TABLE 23 - Voltage Variations ..............................................................................................................................63
TABLE 24 - Complete Pin Number Description......................................................................................................65
TABLE 25 - Evaporator Nozzle Dimensions, in. (mm) ........................................................................................... 74
TABLE 26 - Condenser Nozzle Dimensions, in. (mm) ........................................................................................... 75
TABLE 27 - Water Flow Rate Limits GPM (L/s) (Based Upon Standard Tubes at Design Full Load Conditions).. 76
TABLE 28 - Load Limiting Values...........................................................................................................................86
TABLE 29 - Flash Card Update Error XXXXX........................................................................................................93
TABLE 30 - Data Logging ......................................................................................................................................94
TABLE 31 - Unit Warnings......................................................................................................................................95
TABLE 32 - Unit Safeties (Faults) ..........................................................................................................................97
TABLE 33 - System Safeties (Faults).....................................................................................................................99
TABLE 34 - HPCO Mechanical Cutouts...............................................................................................................101
TABLE 35 - Timer Settings ...................................................................................................................................101
TABLE 36 - Sensor Minimum/Maximum Outputs.................................................................................................106
TABLE 37 - Setpoint Values ................................................................................................................................. 111
TABLE 38 - Program Limits.................................................................................................................................. 113
TABLE 39 - Setup Mode Programmable.............................................................................................................. 116
TABLE 40 - Okidata OKIPOS 441........................................................................................................................123
TABLE 41 - Printout Types ...................................................................................................................................124
TABLE 42 - Real Time Number Errors .................................................................................................................129
TABLE 43 - Operation/Inspection /Maintenance Requirements for QWC4 Chillers.............................................131
TABLE 44 - Compressor Oil Limits.......................................................................................................................133
TABLE 45 - System Pressures.............................................................................................................................140
TABLE 46 - Troubleshooting Guide......................................................................................................................148
TABLE 47 - 3K Temperature Sensor ....................................................................................................................150
TABLE 48 - 3K Temperature Sensor - Evaporator Refrigerant and Eductor Temperature Sensor ......................150
TABLE 49 - Pressure Transducer.........................................................................................................................151
TABLE 50 - SI Metric Conversion.........................................................................................................................154