Quantech QWC3050T-200T Owner's manual

QWC3050T-200T
WATER-COOLED LIQUID CHILLERS
STYLE A (60 HZ)
50 - 200 TONS
175KW THROUGH 700KW
INSTALLATION, OPERATION, MAINTENANCE
WATER-COOLED LIQUID CHILLERS
HERMETIC SCROLL
Supersedes: QWC3-NM1 (1118) Form: QWC3-NM1 (1120)
PART # 035-26707-000
R410A
Issue Date:
November 20, 2020
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.

FORM QWC3-NM1
ISSUE DATE: 11/20/2020
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This equipment is a relatively complicated apparatus.
During installation, operation maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: 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 respon-
sibility of 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
operating/service personnel. It is expected that these
individuals possess independent training that will en-
able 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 this document and any referenced mate-
rials. This individual shall also be familiar with and
comply with all applicable 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’s 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.

FORM QWC3-NM1
ISSUE DATE:11/20/2020
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MANUAL DESCRIPTION FORM NUMBER
Unit Replacement Parts QWC3--RP1
Unit Start-Up Checklist QWC3-CL1
All Products - Replacement Parts Electrical Connectors 50.20-RP1
All Products - Replacement Parts Fittings 50.20-RP2
ASSOCIATED LITERATURE
This manual contains installation, op-
eration and maintenance instructions for
both single and dual refrigerant circuit
models. If your unit is a single circuit
model (QTC2015T-030T), disregard refer-
ences to “System 2” which may appear in
this manual. Any references to Sys 2 are
applicable to QTC2015T-045T models.
SINGLE CIRCUIT AND DUAL CIRCUIT MODELS
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for con-
tinuous product improvement, the information con-
tained in this document is subject to change without
notice. Johnson Controls makes no commitment to
update or provide current information automatically
to the manual or product owner. Updated manuals, if
applicable, can be obtained by contacting the nearest
Johnson Controls Service office or accessing the John-
son Controls Knowledge Exchange website at https://
docs.johnsoncontrols.com/chillers/.
It is the responsibility of rigging, lifting, and operating/
service personnel to verify the applicability of these
documents to the equipment. If there is any question
regarding the applicability of these documents, rig-
ging, lifting, and operating/service personnel should
verify whether the equipment has been modified and
if current literature is available from the owner of the
equipment prior to performing any work on the chiller.
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.
AFFECTED PAGES DESCRIPTION
46,47 Physical Data table units updated
48-55 Electrical Data table units updated
171-181 Data maps updated

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TABLE OF CONTENTS
SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY ................................................................ 11
Introduction..................................................................................................................................................... 11
Warranty ......................................................................................................................................................... 11
Safety ............................................................................................................................................................. 11
Misuse Of Equipment .....................................................................................................................................12
SECTION 2 – PRODUCT DESCRIPTION...........................................................................................................13
Introduction..................................................................................................................................................... 13
Compressors ..................................................................................................................................................13
Refrigerant Circuits......................................................................................................................................... 13
Evaporator......................................................................................................................................................14
Condenser......................................................................................................................................................14
Refrigerant Circuit ..........................................................................................................................................14
Microprocessor Control Center ...................................................................................................................... 14
Power Panel ..................................................................................................................................................15
Accessories And Options ...............................................................................................................................16
Control / Power Panel Components ...............................................................................................................18
Unit Components............................................................................................................................................ 20
Product Identification Number (Pin) ...............................................................................................................22
Refrigerant Flow ............................................................................................................................................26
SECTION 3 – TRANSPORTATION, HANDLING AND STORAGE ...................................................................29
Delivery And Storage......................................................................................................................................29
Inspection .......................................................................................................................................................29
Moving The Unit .............................................................................................................................................29
Lifting Weights................................................................................................................................................30
SECTION 4 – INSTALLATION .............................................................................................................................31
Installation Checklist....................................................................................................................................... 31
Location Requirements ..................................................................................................................................31
Unit Isolation (Noise Sensitive Location)........................................................................................................31
Foundation .....................................................................................................................................................31
Installation Of Vibration Isolators ...................................................................................................................32
Pipework Connection .....................................................................................................................................32
Water Treatment.............................................................................................................................................34
Option Flanges ...............................................................................................................................................34
Refrigerant Relief Valve Piping.......................................................................................................................34
Condenser Cooling Liquid Systems ...............................................................................................................35
Pressure Tapping............................................................................................................................................36
Pipework Arrangement ...................................................................................................................................36
Connection Types And Sizes..........................................................................................................................36
Electrical Connection...................................................................................................................................... 37
Field Wiring ....................................................................................................................................................37
Control Panel Wiring ...................................................................................................................................... 37
Power Wiring ..................................................................................................................................................38
Compressor Heaters ......................................................................................................................................39
Relief Valves...................................................................................................................................................39
High Pressure Cutout .....................................................................................................................................39
Control Wiring................................................................................................................................................. 40

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TABLE OF CONTENTS (CONT’D)
SECTION 5 – TECHNICAL DATA........................................................................................................................41
Operational Limitations................................................................................................................................... 41
Condenser Pressure Drop Charts ..................................................................................................................44
Ethylene And Propolyne Glycol Correction Factors .......................................................................................45
Physical Data - Standard And High Efficiency................................................................................................46
Single Point Electrical Data ............................................................................................................................48
Dual Point Electrical Data............................................................................................................................... 56
Dual Point Electrical Data............................................................................................................................... 58
Single-Point Supply Connection – Terminal Block,
Non-Fused Disconnect Switch Or Circuit Breaker .........................................................................................60
Dual-Point Supply Connection – Terminal Block,
Non-Fused Disconnect Switch Or Circuit Breaker .........................................................................................61
Electrical Data ................................................................................................................................................62
Electrical Notes And Legend ..........................................................................................................................63
Ground Wire Sizing ........................................................................................................................................64
Elementary Wiring Diagram ........................................................................................................................... 66
Connection Wiring Diagram ........................................................................................................................... 74
Elementary Wiring Diagram Details ............................................................................................................... 82
Unit Dimensions - Four Compressor ..............................................................................................................87
Unit Dimensions - Five And Six Compressor .................................................................................................89
SECTION 6 – COMMISSIONING .......................................................................................................................107
Preparation – Power Off...............................................................................................................................107
Preparation – Power On...............................................................................................................................109
Unit Operating Sequence ............................................................................................................................. 113
SECTION 7 – UNIT CONTROLS........................................................................................................................ 115
Introduction................................................................................................................................................... 115
Status Key .................................................................................................................................................... 117
Status Key Messages................................................................................................................................... 122
Display/Print Keys ........................................................................................................................................123
Entry Keys ....................................................................................................................................................131
Setpoints Keys .............................................................................................................................................132
Unit Keys .....................................................................................................................................................139
SECTION 8 – UNIT OPERATION ......................................................................................................................147
Capacity Control...........................................................................................................................................147
Suction Pressure Limit Controls ...................................................................................................................147
Discharge Pressure Limit Controls...............................................................................................................147
Leaving Chilled Liquid Control...................................................................................................................... 147
Leaving Chilled Liquid Control Override To Reduce Cycling........................................................................148
Leaving Chilled Liquid System Lead/Lag And Compressor Sequencing .....................................................148
Return Chilled Liquid Control .......................................................................................................................149
Return Chilled Liquid System Lead/Lag And Compressor Sequencing .......................................................150
Anti-Recycle Timer ....................................................................................................................................... 151

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TABLE OF CONTENTS (CONT’D)
Anti-Coincidence Timer ................................................................................................................................ 151
Evaporator Pump Control And Hydro Kit Pump Control...............................................................................151
Evaporator Heater Control ...........................................................................................................................151
Pumpdown Control.......................................................................................................................................151
Load Limiting ................................................................................................................................................151
Compressor Run Status ...............................................................................................................................152
Alarm Status.................................................................................................................................................152
Ems-Pwm Remote Temperature Reset........................................................................................................152
Bas/Ems Temperature Reset Using A Voltage Or Current Signal ................................................................ 153
SECTION 9 – SERVICE AND TROUBLESHOOTING ..................................................................................... 155
Clearing History Buffers................................................................................................................................ 155
Service Mode ...............................................................................................................................................155
Service Mode – Outputs...............................................................................................................................155
Service Mode – Chiller Configuration...........................................................................................................156
Service Mode – Analog And Digital
Inputs............................................................................................................................................................ 156
Control Inputs/Outputs .................................................................................................................................157
Microboard Layout........................................................................................................................................ 158
Checking Inputs And Outputs.......................................................................................................................159
Optional Printer Installation ..........................................................................................................................163
Acceptable Printers ......................................................................................................................................163
Printer Connections......................................................................................................................................163
Printer Setup ................................................................................................................................................163
Printing A Report ..........................................................................................................................................164
Troubleshooting............................................................................................................................................165
SECTION 10 – MAINTENANCE.........................................................................................................................169
Important ......................................................................................................................................................169
Compressors ................................................................................................................................................169
Operating Parameters ..................................................................................................................................169
On-Board Battery Back-Up........................................................................................................................... 169
Overall Unit Inspection .................................................................................................................................169
BACnet And Modbus Data Communications................................................................................................170
Temperature Conversion Chart ....................................................................................................................184
R410-A
Pressure Temperature Chart ........................................................................................................................185
Temperature .................................................................................................................................................186

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LIST OF FIGURES
FIGURE 1 - QWC3 Water Cooled Liquid Chiller ....................................................................................................13
FIGURE 2 - Control / Panel Compowwnents..........................................................................................................18
FIGURE 3 - Control Power Panel Components......................................................................................................19
FIGURE 4 - Unit Components ................................................................................................................................20
FIGURE 5 - Control / Power Panel Components Dual System Units .....................................................................21
FIGURE 6 - Refrigerant Flow Diagram ...................................................................................................................26
FIGURE 7 - Process and Instrumentation Diagram................................................................................................27
FIGURE 8 - Chiller Rigging And Lifting Weights.....................................................................................................30
FIGURE 9 - ANSI/AWWA C-606 - Adapter Flanges........................................................................................................ 34
FIGURE 10 - Direct Pressure Control Diagram......................................................................................................35
FIGURE 11 - Inlet Temperature Control Diagram ...................................................................................................35
FIGURE 12 - Chilled Liquid System .......................................................................................................................36
FIGURE 13 - Condenser Cooling Liquid System....................................................................................................36
FIGURE 14 - Pipework Arrangements Legend.......................................................................................................36
FIGURE 15 - Cooler Connections ..........................................................................................................................36
FIGURE 16 - Control Wiring ...................................................................................................................................40
FIGURE 17 - Evaporator Water Pressure Drop Curves ........................................................................................43
FIGURE 18 - Condenser Water Pressure Drop Curves .........................................................................................44
FIGURE 19 - Glycol Solution Strengths..................................................................................................................45
FIGURE 20 - Single Point Power Supply Connection – Standard Unit ..................................................................60
FIGURE 21 - Dual Point Power Supply Connection – Standard Unit.....................................................................61
FIGURE 22 - Control Circuit, 4 Compressor...........................................................................................................66
FIGURE 23 - Control Circuit, 5 And 6 Compressor ................................................................................................68
FIGURE 24 - Power Circuit, 4 Compressor With Non Fused Disconnect Switch Or Circuit Breaker.....................70
FIGURE 25 - Power Circuit, 4 Compressor With Circuit Breaker...........................................................................71
FIGURE 26 - Power Circuit, 5 And 6 Compressor..................................................................................................72
FIGURE 27 - Power Circuit, 6 Compressor............................................................................................................73
FIGURE 28 - Connection Wiring Diagram, 4 Compressor .....................................................................................74
FIGURE 29 - Connection Wiring Diagram, 4 Compressor .....................................................................................76
FIGURE 30 - Connection Wiring Diagram, 5 And 6 Compressor ...........................................................................78
FIGURE 31 - Connection Wiring Diagram, 6 Compressor .....................................................................................80
FIGURE 32 - Elementary Wiring Diagram Details, 4 Compressor .........................................................................82
FIGURE 33 - Elementary Wiring Diagram Details, 5 And 6 Compressor ...............................................................84
FIGURE 34 - Elementary Wiring Diagram, EEV Controller, 4 And 6 Compressor..................................................86
FIGURE 35 - EEV IB-G Interface Board...............................................................................................................108
FIGURE 36 - Unit Keys Options Programming Quick Reference List .................................................................. 145
FIGURE 37 - Leaving Water Temperature Control Example ................................................................................148
FIGURE 38 - Setpoint Adjust ................................................................................................................................148
FIGURE 39 - Microboard Layout ..........................................................................................................................158
FIGURE 40 - I/O Board Relay Contact Architecture .............................................................................................162
FIGURE 41 - Micro Panel Connections................................................................................................................171

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LIST OF TABLES
TABLE 1 - Product Identification Number...............................................................................................................22
TABLE 2 - Condenser / Cooler Connections ...............................................................................................................36
TABLE 3 - Temperatures And Flows ......................................................................................................................41
TABLE 4 - Voltage Limitations................................................................................................................................42
TABLE 5 - Ethylene And Propolyne Glycol Correction Factors ..............................................................................45
TABLE 6 - Recommended Glycol Solution Strengths ............................................................................................45
TABLE 7 - Micro Panel Power Supply....................................................................................................................62
TABLE 8 - Voltage Range (Limitations)..................................................................................................................62
TABLE 9 - Status Key Messages Quick Reference List.......................................................................................122
TABLE 10 - Operation Data..................................................................................................................................126
TABLE 11 - Cooling Setpoints, Programmable Limits And Defaults.....................................................................134
TABLE 12 - Program Key Limits And Default .......................................................................................................137
TABLE 13 - Setpoints Quick Reference List.........................................................................................................138
TABLE 14 - Sample Compressor Staging For Return Water Control...................................................................149
TABLE 15 - Return Chilled Liquid Control For 4 Compressors (6 Steps).............................................................150
TABLE 16 - Return Chilled Liquid Control For 4 Compressors (6 Steps).............................................................150
TABLE 17 - Compressor Operation – Load Limiting ............................................................................................152
TABLE 18 - I/O Digital Inputs ...............................................................................................................................157
TABLE 19 - I/O Digital Outputs.............................................................................................................................157
TABLE 20 - I/O Analog Inputs ..............................................................................................................................157
TABLE 21 - I/O Analog Outputs............................................................................................................................157
TABLE 22 - Entering/Leaving Chilled Liquid Temp. Sensor, Temperature / Voltage Correlation .........................160
TABLE 23 - Pressure Transducers.......................................................................................................................161
TABLE 24 - OKIDATA OKIPOS 441 .....................................................................................................................163
TABLE 25 - Printout Types ...................................................................................................................................164
TABLE 26 - Troubleshooting ................................................................................................................................165
TABLE 27 - Values Required For Bas Communication ........................................................................................171
TABLE 28 - Real Time Error Numbers .................................................................................................................172
TABLE 29 - BACNET And Modbus Communications Data Map ..........................................................................173
TABLE 30 - Yorktalk 2 Communications Data Map ..............................................................................................178
TABLE 31 - SI Metric Conversion.........................................................................................................................186

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