Quantech QTC3040T Owner's manual

QTC3040T to QTC3225T
With Brazed Plate Heat Exchanger
Style B (60 Hz) 4-12 Fan
40 ton to 230 ton
140 kW to 800 kW
R-410A
Issue Date:
August 3, 2022
Air-Cooled Scroll Chiller
Installation, Operation, Maintenance Supersedes: QTC3-NM1 (1021) Form QTC3-NM1 (822)
Products are produced at a
f a c i l i t y w h o s e q u a l i t y -
management systems are
ISO9001 certified.
LD18971a
035-24487-000

QUANTECH
2
FORM QTC3-NM1
ISSUE DATE 08/03/2022
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.

3
QUANTECH
FORM QTC3-NM1
ISSUE DATE 08/03/2022
MANUAL DESCRIPTION FORM NUMBER
Equipment Standard Limited Warranty QTC-NM2
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 equip-
ment.
ASSOCIATED LITERATURE
AFFECTED PAGES DESCRIPTION
19 Flow switch section updated
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.

QUANTECH
4
FORM QTC3-NM1
ISSUE DATE 08/03/2022
LD23522
UNIT NOMENCLATURE
Base Product Type
Nominal Capacity
QTC H 46 X
Starter
X = Across the line starter
T = Soft Start
Voltage Code
17 = 200-3-60
28 = 230-3-60
40 = 380-3-60
46 = 460-3-60
58 = 575-3-60
3110T BE
Q = Quantech
T = Variable
Speed Scroll
QTC3055T
QTC3060T
QTC3070T
QTC3075T
QTC3080T
QTC3085T
QTC3090T
QTC3095T
QTC3100T
Unit Designator
S = Standard Efficiency
H = High Efficiency
Design Series
B = Design Series
B
Development Level
(Engineering Change
or PIN)
QTC3110T
QTC3120T
QTC3125T
QTC3130T
QTC3140T
QTC3150T
QTC3160T
QTC3170T
QTC3205T
QTC3225T
Refrigerant
E=R-410A

5
QUANTECH
FORM QTC3-NM1
ISSUE DATE 08/03/2022
TABLE OF CONTENTS
SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY ................................................................ 11
Introduction..................................................................................................................................................... 11
Warranty ......................................................................................................................................................... 11
Handling ......................................................................................................................................................... 11
Safety and Quality .......................................................................................................................................... 11
About this Manual...........................................................................................................................................12
Misuse of Equipment......................................................................................................................................12
SECTION 2 – PRODUCT DESCRIPTION...........................................................................................................15
Introduction.....................................................................................................................................................15
General System Description........................................................................................................................... 15
Communications.............................................................................................................................................18
Building Automation System Interface............................................................................................................ 18
Power Panel ...................................................................................................................................................18
Accessories and Options................................................................................................................................18
SECTION 3 – RIGGING, HANDLING AND STORAGE ..................................................................................... 31
Lifting Weights................................................................................................................................................31
Delivery and Storage......................................................................................................................................31
Inspection .......................................................................................................................................................31
Moving the Chiller...........................................................................................................................................32
Unit Removal from Shipping Container ..........................................................................................................32
Lifting Using Lugs...........................................................................................................................................32
Lifting Using Shackles ....................................................................................................................................32
SECTION 4 – INSTALLATION .............................................................................................................................35
Installation Checklist.......................................................................................................................................35
Startup/Commissioning ..................................................................................................................................35
Location and Clearances................................................................................................................................35
Spring Isolators (Optional).............................................................................................................................. 36
Compressor Mounting ....................................................................................................................................36
Chilled Liquid Piping.......................................................................................................................................36
Pipework Arrangement ...................................................................................................................................37
Wiring .............................................................................................................................................................37
Relief Valves...................................................................................................................................................38
High Pressure Cutout .....................................................................................................................................38
Single-Point Supply Connection – Terminal Block, Non-Fused
Disconnect Switch or Circuit Breaker .............................................................................................................39
SECTION 5 – TECHNICAL DATA........................................................................................................................45
Operational Limitations (English) ...................................................................................................................45
Physical Data QTC3040T – QTC3225T 60 Hz............................................................................................... 47
Electrical Data ................................................................................................................................................50
Compressor Heaters ......................................................................................................................................50
Electrical Notes ..............................................................................................................................................60
Dimensions.....................................................................................................................................................84
Weight Distribution and Isolator Mounting Positions ......................................................................................91
Clearances .....................................................................................................................................................92
Isolator Locations ...........................................................................................................................................93
Isolator Information.........................................................................................................................................96

QUANTECH
6
FORM QTC3-NM1
ISSUE DATE 08/03/2022
TABLE OF CONTENTS (CONT’D)
SECTION 6 – COMMISSIONING .......................................................................................................................103
Preparation – Power Off...............................................................................................................................103
Preparation – Power On...............................................................................................................................105
How to Commission the Pump VFD.............................................................................................................106
SECTION 7 – UNIT CONTROLS........................................................................................................................ 111
Introduction................................................................................................................................................... 111
IPU II and I/O Boards ................................................................................................................................... 111
Transformer ................................................................................................................................................. 112
Display.......................................................................................................................................................... 112
Keypad ......................................................................................................................................................... 112
Unit Switch ................................................................................................................................................... 112
Battery Back-Up ........................................................................................................................................... 112
Programming # of Compressors .................................................................................................................. 112
Status Key .................................................................................................................................................... 113
Display/Print Keys ........................................................................................................................................ 119
Entry Keys ....................................................................................................................................................127
Setpoints Keys .............................................................................................................................................128
Schedule/Advance Day Key.........................................................................................................................129
Program Key ................................................................................................................................................131
Unit Keys .....................................................................................................................................................137
Bacnet, Modbus, N2, and E-Link Communications......................................................................................143
SECTION 8 – UNIT OPERATION ......................................................................................................................155
Unit Operating Sequence .............................................................................................................................155
Capacity Control...........................................................................................................................................155
Suction Pressure Limit Controls ...................................................................................................................156
Discharge Pressure Limit Controls...............................................................................................................156
Leaving Chilled Liquid Control......................................................................................................................156
Leaving Chilled Liquid Control Override to Reduce Cycling.........................................................................157
Leaving Chilled Liquid System Lead/Lag and Compressor Sequencing...................................................... 158
Return Chilled Liquid Control .......................................................................................................................158
Return Chilled Liquid System Lead/Lag and Compressor Sequencing .......................................................159
Anti-Recycle Timer .......................................................................................................................................159
Anti-Coincidence Timer ................................................................................................................................159
Evaporator Pump Control and Hydro Kit Pump Control ...............................................................................159
Evaporator Heater Control ...........................................................................................................................160
Pumpdown Control.......................................................................................................................................160
Standard Condenser Fan Control ................................................................................................................160
VSD Fan.......................................................................................................................................................160
Changing the Switch Point of the Thermal Dispersion Flow Switch.............................................................160
Load Limiting ................................................................................................................................................164
Compressor Run Status ...............................................................................................................................164
Alarm Status.................................................................................................................................................164
Remote BAS/EMS Temperature Reset Using a Voltage or Current Signal ..................................................165

7
QUANTECH
FORM QTC3-NM1
ISSUE DATE 08/03/2022
TABLE OF CONTENTS (CONT’D)
SECTION 9 – SERVICE AND TROUBLESHOOTING ..................................................................................... 167
Clearing History Buffers................................................................................................................................167
Service Mode ...............................................................................................................................................167
Service Mode – Outputs...............................................................................................................................167
Service Mode – Chiller Configuration...........................................................................................................168
Service Mode – Analog and Digital Inputs.................................................................................................... 168
Control Inputs/Outputs .................................................................................................................................169
Checking Inputs and Outputs .......................................................................................................................171
Optional Printer Installation ..........................................................................................................................177
Troubleshooting............................................................................................................................................179
SECTION 10 – MAINTENANCE.........................................................................................................................183
Compressors ................................................................................................................................................183
Condenser Fan Motors.................................................................................................................................183
Condenser MCHX Cleaning .........................................................................................................................183
Operating Parameters ..................................................................................................................................183
On-Board Battery Back-Up...........................................................................................................................183
Thermal Dispersion Flow Switch ..................................................................................................................183
Overall Unit Inspection .................................................................................................................................183
Brazed Plate Heat Exchanger (Evaporator) Heater .....................................................................................184
Temperature .................................................................................................................................................187

QUANTECH
8
FORM QTC3-NM1
ISSUE DATE 08/03/2022
LIST OF FIGURES
FIGURE 1 - Compressor Enclosure for QTC3040HE.............................................................................................16
FIGURE 2 - Unit Components (Front) ....................................................................................................................20
FIGURE 3 - Unit Components (Side)......................................................................................................................21
FIGURE 4 - Power Panel Components ..................................................................................................................22
FIGURE 5 - Power Panel / Control Components....................................................................................................23
FIGURE 6 - Process and Instrumentation Diagram................................................................................................29
FIGURE 7 - Unit Rigging/Lifting Points...................................................................................................................33
FIGURE 8 - Chilled Liquid System ........................................................................................................................37
FIGURE 9 - Single-Point Supply Connection – Terminal Block, Non-Fused Disconnect Switch or
Circuit Breaker.....................................................................................................................................39
FIGURE 10 - Control Wiring Inputs ........................................................................................................................40
FIGURE 11 - Thermal Dispersion Flow Switch.......................................................................................................42
FIGURE 12 - (Combine Together) ..........................................................................................................................42
FIGURE 13 - Control Wiring Outputs......................................................................................................................44
FIGURE 14 - Elementary Wiring Diagram..............................................................................................................64
FIGURE 15 - Elementary Wiring Diagram..............................................................................................................66
FIGURE 16 - Fan Wiring, Standard Low Sound or Ultra Quiet, QTC3070T - QTC3225T......................................68
FIGURE 17 - Fan Wiring, High Air Flow .................................................................................................................70
FIGURE 18 - Single And Dual Point Wiring Options...............................................................................................72
FIGURE 19 - Compressor Wiring ...........................................................................................................................76
FIGURE 20 - Power Options Connection Diagram.................................................................................................78
FIGURE 21 - Power Panel......................................................................................................................................80
FIGURE 22 - Micro Panel Connections..................................................................................................................82
FIGURE 23 - Sample Printout Supplied in the Isolator Package and in the Chiller Panel Literature Packet ......... 91
FIGURE 24 - Unit Clearances – All Models ............................................................................................................92
FIGURE 25 - Status Key Messages Quick Reference List................................................................................... 118
FIGURE 26 - Operation Data................................................................................................................................122
FIGURE 27 - Setpoints Quick Reference List.......................................................................................................134
FIGURE 28 - Unit Keys Options Programming Quick Reference List ..................................................................142
FIGURE 29 - Micro Panel Connections................................................................................................................144
FIGURE 30 - Leaving Water Temperature Control Example ................................................................................156
FIGURE 31 - Setpoint Adjust ................................................................................................................................157
FIGURE 32 - Condenser Fan Locations...............................................................................................................161
FIGURE 33 - Microboard Layout ..........................................................................................................................170
FIGURE 34 - I/O Board Relay Contact Architecture .............................................................................................174
FIGURE 35 - Printer to Microboard Electrical Connections..................................................................................178

9
QUANTECH
FORM QTC3-NM1
ISSUE DATE 08/03/2022
LIST OF TABLES
TABLE 1 - Canadian Registration Numbers...........................................................................................................16
TABLE 2 - Complete Pin Number Description........................................................................................................24
TABLE 3 - Chemical Specification of Water ...........................................................................................................41
TABLE 4 - Temperatures and Flows.......................................................................................................................45
TABLE 5 - Ethylene And Propylene Glycol Correction Factors ..............................................................................46
TABLE 6 - Physical Data (English) 60 Hz .............................................................................................................. 47
TABLE 7 - Micropanel Power Supply .....................................................................................................................50
TABLE 8 - Voltage Range ......................................................................................................................................50
TABLE 9 - Pump Electrical Data (60 Hz)................................................................................................................51
TABLE 10 - Transformer Load................................................................................................................................51
TABLE 11 - Electrical Data Without Pumps............................................................................................................52
TABLE 12 - Wiring Lugs.........................................................................................................................................58
TABLE 13 - Cooling Setpoint, Programmable Limits and Defaults ......................................................................130
TABLE 14 - Program Key Limits and Default .......................................................................................................133
TABLE 15 - Program Key Limits and Default .......................................................................................................135
TABLE 16 - Minimum, Maximum and Default Values...........................................................................................144
TABLE 17 - Values Required for Bas Communication .........................................................................................145
TABLE 18 - Real Time Error Numbers .................................................................................................................146
TABLE 19 - Native Bacnet, Modbus, and N2 Communications Data Map...........................................................147
TABLE 20 - Yorktalk 2 Communications Data Map..............................................................................................151
TABLE 21 - Sample Compressor Staging for Return Water Control....................................................................157
TABLE 22 - Return Chilled Liquid Control for 4 Compressors (6 Steps)..............................................................157
TABLE 23 - Lead/Lag Return Chilled Liquid Control for 4 Compressors (6 Steps)..............................................158
TABLE 24 - QTC3 Standard Condenser Fan Control Using Discharge Pressure Only (2, 3, Or 4 Fans Per
System) .............................................................................................................................................162
TABLE 25 - QTC3 Standard Condenser Fan Control Using Discharge Pressure Only (5 Or 6 Fans Per
System) .............................................................................................................................................163
TABLE 26 - Compressor Operation Load Limiting ...............................................................................................164
TABLE 27 - I/O Digital Inputs ...............................................................................................................................169
TABLE 28 - I/O Digital Outputs.............................................................................................................................169
TABLE 29 - I/O Analog Inputs ..............................................................................................................................169
TABLE 30 - I/O Analog Outputs............................................................................................................................169
TABLE 31 - Outdoor Air Sensor Temperature/Voltage/Correlation....................................................................... 171
TABLE 32 - Entering/Leaving Chilled Liquid Temp. Sensor, Temperature/Voltage Correlation............................172
TABLE 33 - Pressure Transducers.......................................................................................................................173
TABLE 34 - Data Logging to Flash.......................................................................................................................175
TABLE 35 - Troubleshooting ................................................................................................................................181
TABLE 36 - SI Metric Conversion.........................................................................................................................189

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