Quantech QTC40160 Owner's manual

Air-Cooled Screw Liquid Chillers
Installation, Operation, Maintenance New Release Form QTC4-NM2 (523)
R-134a or R-513A
525 kW to 1,934 kW
2 Compressor
50 Hz and 60 Hz
Model QTC4 Style B
Air-Cooled Screw Liquid Chillers with Variable Speed Drive
Frame Sizes 016 to 026
150 ton to 550 ton
035-29078-000
Issue Date:
May 12, 2023

Quantech
2
Form QTC4-NM2
Issue date: 05/12/2023
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.

Quantech 3
Form QTC4-NM2
Issue date: 05/12/2023
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 operat-
ing or service personnel to verify the applicability of
these documents to the equipment. If there is any ques-
tion regarding the applicability of these documents,
rigging, 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.
Changeability of this document

Quantech
4
Form QTC4-NM2
Issue date: 05/12/2023
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.
Working with chiller vessels which are designed to contain contents under pressure must only be
conducted under fully qualied technicians that 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. Refrigerant must be handled in accordance with all
governing regulations. Failure to meet this requirement may 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.
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 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 5
Form QTC4-NM2
Issue date: 05/12/2023
ASHRAE 90.1 Compliant
Products are produced at a
facility whose quality-
management systems are
ISO9001 certified.
LD23520a
UNIT NOMENCLATURE
Base Product Type
Q = Quantech
TC = Variable Speed Screw
4 = Air Cooled Design Series
Model Number
Configuration
S = Condenser Code
X = Evaporator Code
X = Compressor Code
X = Condenser Fan
& Sound Kit Code
QTC4 SXXX 46 AA
-
Level / Refrigerant
A = Refrigerant R-134a
B = Refrigerant R-513A
Voltage
17 = 200 / 3 / 60
28 = 230 / 3 / 60
40 = 380 / 3 / 60
42 = 400 / 3 / 60
46 = 460 / 3 / 60
50 = 380-415 / 3 / 50
58 = 575 / 3 / 60
210
The Control/VSD Cabinet contains lethal
high AC and DC voltages. Before per-
forming service inside the cabinet, remove
the AC supply feeding the chiller and
verify using a non-contact voltage sensor.
The DC voltage on the VSD DC Bus will
take 5 min to bleed o, after AC power
is removed. Always check the DC Bus
Voltage with a Voltmeter to ensure the
capacitor charge has bled o before work-
ing on the system.
NEVER short out the DC Bus to dis-
charge the lter capacitors.
NEVER place loose tools, debris, or any
objects inside the Control Panel/VSD
Cabinet.
NEVER allow the Control Panel VSD
Cabinet doors to remain open if there is a
potential for rain to enter the panel. Keep
doors closed and ensure that all latches
are engaged on each door unless the unit
is being serviced.
ALWAYS lockout the disconnect supply-
ing AC to the chiller.
The 1L Line Inductor will reach operating
temperatures of over 300°F (150°C). DO
NOT open panel doors during operation.
Ensure that the inductor is cool whenever
working near the inductor with power
OFF.
Unit nonmenclature

Quantech
6
Form QTC4-NM2
Issue date: 05/12/2023
Table of contents
Section 1 - General chiller information and safety............................................................................................. 11
Introduction..................................................................................................................................................... 11
Warranty ......................................................................................................................................................... 11
Quality assurance and safety .........................................................................................................................12
Fluorinated greenhouse gases.......................................................................................................................12
Responsibility for safety ................................................................................................................................. 12
About this manual...........................................................................................................................................12
Misuse of equipment ......................................................................................................................................12
Section 2 - Product description ...........................................................................................................................15
General system description............................................................................................................................15
Semi-hermetic Quantech twin-screw compressors ........................................................................................17
Evaporator......................................................................................................................................................17
Condenser......................................................................................................................................................17
Refrigerant circuit ...........................................................................................................................................17
Electrical.........................................................................................................................................................17
Building automation system capabilities.........................................................................................................18
Microcomputer control center.........................................................................................................................18
Accessories and options ................................................................................................................................19
Fan options.....................................................................................................................................................19
Condenser coils..............................................................................................................................................19
Section 3 - Rigging, handling, and storage.........................................................................................................23
Lifting weights.................................................................................................................................................23
Delivery and storage ......................................................................................................................................23
Inspecting the delivery....................................................................................................................................24
Moving the chiller ........................................................................................................................................... 24
Section 4 - Installation .........................................................................................................................................29
Location requirements....................................................................................................................................29
Outdoor installations.......................................................................................................................................29
Location clearances .......................................................................................................................................29
Vibration isolators...........................................................................................................................................31
Shipping braces..............................................................................................................................................31
Chilled liquid piping ........................................................................................................................................31
Evaporator pressure drop...............................................................................................................................32
Water treatment..............................................................................................................................................33
Pipework arrangement ...................................................................................................................................33
Minimum water volume .................................................................................................................................. 33
Leaving water temperature out of range ........................................................................................................33
Thermal storage .............................................................................................................................................34
Variable primary flow .....................................................................................................................................34
Connection types and sizes ...........................................................................................................................34
Evaporator connections..................................................................................................................................34
Refrigerant relief valve piping.........................................................................................................................36
Electrical connection ......................................................................................................................................36
Power wiring...................................................................................................................................................37
Power supply wiring ....................................................................................................................................... 37

Quantech 7
Form QTC4-NM2
Issue date: 05/12/2023
Table of contents, cont'd
115 VAC control supply transformer ...............................................................................................................37
Control wiring .................................................................................................................................................37
Volts free contacts ..........................................................................................................................................38
System inputs.................................................................................................................................................38
Power supply wiring ....................................................................................................................................... 39
Customer control wiring..................................................................................................................................41
Thermal dispersion flow switch connections ..................................................................................................42
Section 5 - Technical data.....................................................................................................................................65
Elastomeric isolator installation ......................................................................................................................88
Elastomeric isolator specifications ................................................................................................................. 89
One inch deflection isolator installation ..........................................................................................................90
One inch deflection spring isolator specifications...........................................................................................91
Two inch deflection, isolator installation and adjustment................................................................................92
Two inch deflection, restrained spring isolator specifications.........................................................................93
Section 6 - Commissioning ..................................................................................................................................95
Preparation.....................................................................................................................................................95
First time startup.............................................................................................................................................98
General operation...........................................................................................................................................98
Freeze damage protection .............................................................................................................................98
Section 7 - Operation ..........................................................................................................................................101
Operating controls ........................................................................................................................................101
Basic operating sequence ............................................................................................................................104
Microboard (331-03478-xxx) ........................................................................................................................104
SC-EQ communications card .......................................................................................................................107
Updating the program...................................................................................................................................107
Data logging .................................................................................................................................................108
Unit warning .................................................................................................................................................109
Unit safeties.................................................................................................................................................. 110
System safeties, faults ................................................................................................................................. 111
Section 8 - Micropanel ........................................................................................................................................ 117
Unit data key ................................................................................................................................................120
System data keys 1 through 4......................................................................................................................122
VSD data key ...............................................................................................................................................125
Operating hours/start counter key ................................................................................................................127
History key....................................................................................................................................................128
Setpoints key................................................................................................................................................135
Program key .................................................................................................................................................137
Unit setup mode ...........................................................................................................................................140
Options key ..................................................................................................................................................147
Date/time and schedule keys .......................................................................................................................150
Manual override key .....................................................................................................................................153
Print key .......................................................................................................................................................154
System switches key ....................................................................................................................................157

Quantech
8
Form QTC4-NM2
Issue date: 05/12/2023
Table of contents, cont'd
Section 9 - Maintenance......................................................................................................................................159
General requirements...................................................................................................................................159
Checking the system for leaks .....................................................................................................................160
Leak testing ..................................................................................................................................................160
Leak testing during operation .......................................................................................................................160
Vapor connection locations...........................................................................................................................160
System pressure test....................................................................................................................................161
Conducting the gas pressure hold test.........................................................................................................161
What to do next ............................................................................................................................................161
Conducting the soap visual gas leak test .....................................................................................................161
Conducting the optional trace gas leak test .................................................................................................162
System evacuation .......................................................................................................................................163
Vacuum dehydration.....................................................................................................................................163
Dehydration ..................................................................................................................................................164
Conducting the dehydration process............................................................................................................165
Conducting the final evacuation ...................................................................................................................166
Refrigerant charging.....................................................................................................................................166
Removing the refrigerant charge for service ................................................................................................169
Checking and trimming the refrigerant charge .............................................................................................170
Definitions.....................................................................................................................................................170
Checking the refrigerant charge during unit shutdown.................................................................................170
Microchannel coil cleaning ...........................................................................................................................171
Cleaning procedure required for standard and environment guard microchannel coils ...............................171
Cleaning procedure for environment guard premium microchannel coils ....................................................172
Steps to touch-up small sections of the finned coil surface:.........................................................................172
Steps to touch-up end, dead tubes or condenser coil headers: ...................................................................173
Materials required:........................................................................................................................................173
Chilled liquid system maintenance ...............................................................................................................173
Maintenance requirements for QTC4 chillers...............................................................................................175
R-134a conversion table ..............................................................................................................................179
R-513A conversion table, temperature to pressure......................................................................................180
Chilled liquid and suction temperature sensor input voltage .......................................................................181
Section 10 - Decommissioning, dismantling, and disposal ............................................................................ 185
General.........................................................................................................................................................185
Temperature .................................................................................................................................................186

Quantech 9
Form QTC4-NM2
Issue date: 05/12/2023
List of figures
Figure 1 - QTC4 air-cooled screw liquid chiller with variable speed drive ..............................................................15
Figure 2 - Chiller control system.............................................................................................................................16
Figure 3 - View of Quantech control center user interface .....................................................................................19
Figure 4 - Lifting lugs ..............................................................................................................................................24
Figure 5 - Lifting using lugs.....................................................................................................................................24
Figure 6 - Power panel. 1 to 4 ................................................................................................................................25
Figure 7 - Power panel, 1 to 5 ................................................................................................................................26
Figure 8 - Power panel, 1 to 6 ................................................................................................................................27
Figure 9 - Power panel, 1 to 8 ................................................................................................................................28
Figure 10 - Acceptable minimum clearances around and between units ............................................................... 30
Figure 11 - Pipework arrangement .........................................................................................................................33
Figure 12 - Leaving water temperature out of range suggested layout .................................................................. 33
Figure 13 - Suggested layout for applications with a ow rate less than the evaporator minimum
allowable ow rate................................................................................................................................34
Figure 14 - Suggested layout for applications with a ow rate greater than the evaporator maximum
allowable ow rate................................................................................................................................34
Figure 15 - Grooved nozzle ....................................................................................................................................34
Figure 16 - Flange for GB vessels..........................................................................................................................36
Figure 17 - Flange attachment................................................................................................................................36
Figure 18 - Single point power wiring .....................................................................................................................39
Figure 19 - Dual point power wiring........................................................................................................................40
Figure 20 - Customer control connections .............................................................................................................41
Figure 21 - Thermal dispersion ow switch connections ........................................................................................42
Figure 22 - Reserved customer wiring entry ..........................................................................................................43
Figure 23 - Water box heater wiring box.................................................................................................................43
Figure 24 - Standard two-pass, right side inlet/outlet evaporator connections.......................................................70
Figure 25 - Optional two-pass left side inlet/outlet connections..............................................................................72
Figure 26 - Standard two-pass left side inlet/outlet connections ............................................................................74
Figure 27 - Optional three-pass inlet/outlet connections ........................................................................................75
Figure 28 - QTC4 dimensions.................................................................................................................................77
Figure 29 - Isolator selection and mounting locations ............................................................................................78
Figure 30 - Isolator selection and mounting locations ............................................................................................79
Figure 31 - Isolator selection and mounting locations ............................................................................................80
Figure 32 - Isolator selection and mounting locations ............................................................................................81
Figure 33 - Isolator selection and mounting locations ............................................................................................82
Figure 34 - Isolator selection and mounting locations ............................................................................................83
Figure 35 - Isolator selection and mounting locations ............................................................................................84
Figure 36 - Isolator selection and mounting locations ............................................................................................85
Figure 37 - Isolator selection and mounting locations ............................................................................................86
Figure 38 - Isolator selection and mounting locations ............................................................................................87
Figure 39 - Elastomeric isolator..............................................................................................................................88
Figure 40 - Elastomeric isolator specications .......................................................................................................89
Figure 41 - One inch deection isolator..................................................................................................................90
Figure 42 - One inch deection isolator specications ...........................................................................................91
Figure 43 - Two inch deection isolator ..................................................................................................................92
Figure 44 - Two inch deection isolator specications............................................................................................ 93
Figure 45 - LED indicator buttons...........................................................................................................................96
Figure 46 - Flow switch set.....................................................................................................................................97
Figure 47 - Flow below the representation range ................................................................................................... 97
Figure 48 - Flow exceeds the representation range ............................................................................................... 97
Figure 49 - Keyboard and display.........................................................................................................................101
Figure 50 - New 331-03478-xxx microboard ........................................................................................................106
Figure 51 - Micropanel.......................................................................................................................................... 117
Figure 52 - Unit data key ......................................................................................................................................120
Figure 53 - System data keys 1 through 4............................................................................................................122
Figure 54 - VSD data key .....................................................................................................................................125

Quantech
10
Form QTC4-NM2
Issue date: 05/12/2023
List of tables
Table 1 - Unit lifting point locations .........................................................................................................................25
Table 2 - Minimum evaporator tube removal clearance ..........................................................................................30
Table 3 - Evaporator connections dimensions ........................................................................................................ 35
Table 4 - Standard 2 hp condenser fans, single point electrical lug data................................................................45
Table 5 - Standard 2 hp condenser fans, dual point electrical lug data ..................................................................53
Table 6 - EBM condenser fans, single point electrical lug data............................................................................... 55
Table 7 - EBM condenser fans, dual point electrical lug data ................................................................................. 63
Table 8 - Physical data, microchannel coil ..............................................................................................................66
Table 9 - Standard two-pass, right side inlet/outlet evaporator connections...........................................................70
Table 10 - Optional two-pass left side inlet/outlet connections ...............................................................................72
Table 11 - Standard two-pass left side inlet/outlet connections ..............................................................................74
Table 12 - Optional three-pass inlet/outlet connections .......................................................................................... 75
Table 13 - Isolator selection and mounting locations .............................................................................................. 78
Table 14 - Elastomeric dimensions .........................................................................................................................89
Table 15 - Elastomeric weights ...............................................................................................................................89
Table 16 - One inch deflection isolator dimensions.................................................................................................91
Table 17 - One inch deflection isolator weights.......................................................................................................91
Table 18 - Two inch deflection isolator weights.......................................................................................................93
Table 19 - QTC4 freeze damage protection requirements......................................................................................99
Table 20 - Flash card update error XXXXX...........................................................................................................108
Table 21 - Low differential oil pressure cutout....................................................................................................... 113
Table 22 - Discharge pressure load limiting/unloading ......................................................................................... 114
Table 23 - Suction pressure load limiting/unloading.............................................................................................. 114
Table 24 - Start inhibit sensor thresholds.............................................................................................................. 115
Table 25 - System sensor minimum and maximum outputs .................................................................................124
Table 26 - Compressor overload settings .............................................................................................................126
Table 27 - Setpoint limits.......................................................................................................................................136
Table 28 - Programmable operating parameters ..................................................................................................139
Table 29 - Setup mode programmable values ...................................................................................................... 140
Table 30 - Printout types .......................................................................................................................................154
Table 31 - System pressures ................................................................................................................................164
Table 32 - R-134a pressure to saturated temperature conversion........................................................................ 167
Table 33 - R-513A pressure to saturated temperature conversion .......................................................................168
Table 34 - Part numbers........................................................................................................................................173
Table 35 - Troubleshooting guide..........................................................................................................................176
Table 36 - R-134a pressure to saturated temperature conversion........................................................................ 179
Table 37 - R-513A refrigerant temperature to pressure ........................................................................................180
Table 38 - Temperature input voltage sensor, measured signal to shield at the sensor .......................................181
Table 39 - Outside air temperature sensor input voltage, measured signal to shield at the sensor...................... 182
Table 40 - Pressure transducer output voltage, measured signal to return at the transducer ..............................183
Table 41 - Motor temperature sensor resistance ..................................................................................................184
Table 42 - SI metric conversion.............................................................................................................................186
Figure 55 - Operating hours/Start counter key .....................................................................................................127
Figure 56 - History key..........................................................................................................................................128
Figure 57 - Setpoints key......................................................................................................................................135
Figure 58 - Program key.......................................................................................................................................137
Figure 59 - Options key ........................................................................................................................................147
Figure 60 - Date/time and schedule key...............................................................................................................150
Figure 61 - Manual override key...........................................................................................................................153
Figure 62 - Print key .............................................................................................................................................154
Figure 63 - System switches key..........................................................................................................................157
Figure 64 - Service connections ...........................................................................................................................160
Figure 65 - Leak test hold times ...........................................................................................................................161
Figure 66 - Evacuation of the chiller operation .....................................................................................................163
Figure 67 - Saturation curve .................................................................................................................................165
List of Figures, cont'd