Westinghouse PD06OD Installation and operation manual

Page 2
Inspection And Handling
When unit is received, it should be checked for
visible or concealed damage. If damage has oc-
curred it should be reported to the carrier im-
mediately and claim filed.
Units are factory mounted on two permanent
angle beam, carbon steel skids. Four
2-7/8” lif-
ting eyes are provided in the skids to allow rig-
ging. Spreader bars must be used between rig-
ging lines to prevent damage to the unit.
Rollers may be used under the skids to
facilitate moving the unit a short distance.
Physical damage to the unit, after accep-
tance, is not the responsibility of
Westinghouse.
Location And Mounting
Westinghouse Model PD060 135 Air Cooled
Packaged Water Chillers are designed for out-
door application and may be mounted on roof
or at ground level. Air flow through the con-
denser is vertical and the unit may be located
adjacent to outside of building or on roof
without regard for prevailing wind direction.
Since these units are air cooled, the flow of air
to and from the condenser coil must not be im-
peded. There must be no obstruction above
the unit that would tend to deflect discharge
air downward where it could be recirculated
back to the inlet of the unit. The required
overhead air space should be a minimum of 8
feet. Duct work must not be applied to the fan
outlets.
The unit must be installed with sufficient
clearance for air entrance to the condenser coil
and for servicing access. The unit should be
located not closer than four feet from any wall
or other obstruction. Clearance must be provid-
ed at either end of the unit to permit removal
of tubes from the chiller.
Unit must be set on a solid and level founda-
tion.
On roof installations the unit should be
mounted on subbeams which span load- bear-
ing walls to prevent excessive vibration.
On ground level installations the unit should be
mounted on a substantial base that will not
settle. A one piece concrete slab with footings
extended below the frost line is recommended.
A space should be left between the slab and
the building to prevent the transmission of
sound and vibration.
Vibration mounts may be used for roof
mounted units or other locations where noise
might be objectionable.
Wiring
A unit wiring diagram showing the required
power supply characteristics and all factory
supplied wiring details is provided with unit.
Separate, field supplied, disconnects must be
installed in the power supply and should be
within the sight of the unit.
Separate 110 volt power source must be field
supplied to provide power for control and
heater circuits.
Chiller Piping
The chiller inlet water pipe should be con-
nected to the expansion valve end of the liquid
chiller barrel and the outlet water pipe con-
nected to the opposite end of the chiller barrel.
A flow switch must be installed in a straight
horizontal section of the chilled water piping.
Chiller water pressure drop data for the PD
units are shown in Table 2. Gauges should be
installed in the piping to and from the chiller to
measure the pressure drop and to insure the
proper (GPM) flow rate.
A strainer should be installed in the piping on
the inlet side of the chiller and vibration
eliminators should be employed on both the in-
let and outlet pipes. Air vents should be
located at all high points in the piping system.
Vents should be located to be accessible to
servicing. Drain connections should be
provid-
ed at all low points to permit complete
drainage of chiller and piping system.
The chiller water piping should be insulated to
reduce heat pickup and to prevent condensa-
tion. If the system is for year round operation
or it it will not be drained in the winter, the
chilled water piping should be protected
against freezing by electric heating cable or
other suitable means.
Upon completion of chiller piping, start the
system water pump and purge air from the
system. Air purging should be done from the
high points in the water circuit. Purging of the
chiller barrel may be accomplished through the
vent pipe located on the top of the chiller com-
partment. Failure to purge air from the water
circuit will result in inadequate water flow and
may cause the unit to cut out on low water
flow freeze protection.
Start-Up
Refer to start, test, and check list included
with this manual
Check all electrical and mechanical connections
for shipping looseness and tighten all screws
on electrical terminals.
Activate the 120 volt chiller and crankcase
heater circuit 24 hours prior to unit start-up.
Rotate each fan prior to start-up. Fans should
turn freely. On belt drive units check belt ten
sion and pulley alignment. After two weeks of
operation, readjust belt tension to ac-
commodate for belt stretching.
Check all control settings as specified in Table
1.
Check the compressor oil level through
crankcase sight glass. The oil level should be
1/3 to 2/3 of the way up on the sight glass. If
oil is low, add oil in accordance with the direc-
tions in “Maintenance” instructions below.
Caution: The compressor suction and
discharge service valves must be open or
backseated before starting the compressor.
Close the valves no more than two turns to
give the pressure taps access to the system for
pressure readings, charging, etc. All receiver
valves must also be open for sustained opera-
tion.
All compressors are solid mounted on isopads,
therefore, compressor hold down bolts must
not be loosened. Loosening these bolts will
cause excessive vibration of the compressor
and may result in refrigerant line breakage.
Prior to start- up check all compressor hold
down bolts for tightness.
To start unit, throw main disconnects into
“ON” position and place system “OFF-ON”
switch
(S1) in “ON” position. (Note: If unit is
equipped with optional lock-out timer, unit will
not start until timer has completed its cycle.)
Once the main disconnect switches and system
“ON-OFF” switch (S1) have been energized
and providing chiller water flow has been
established, the unit will operate automatically
in response to the chiller water thermostat.
Maintenance
Condenser
Units equipped with direct drive fans have in-
herently protected motors and permanently
lubricated bearings, which do not require
lubrication.
Units equipped with belt drive fans have in-
herently protected motors. Fan belts, fan bear-
ings and motor bearings require periodic
maintenance as follows:
Fan Belts After two weeks operation, the
belts will have nearly reached their perma-
nent stretch, therefore, each belt should be
checked again and proper adjustments
made. To maintain good fan and motor
operation, the belt tension should be check-
ed at three month intervals.
Fan Bearings Each fan shaft is provided
with ball bearings of the relubricable type.
Each bearing is provided with grease fit-
tings, accessible through the individual
motor access panels. It is recommended the
bearings be greased by adding 4 to 5 shots

Installation Bulletin
PDG4
Page 3
with a hand gun. The suggested greasing
interval is indicated on a sticker attached to
the unit.
3. Motor Bearings Each motor is equipped
with ball bearings. Ball bearings consume a
very small amount of lubricant, but enough
must be present at all times to prevent
motor injury. The length of time a bearing
can run without having grease added or
replaced will depend upon the operating
conditions. Under normal operating condi-
tions the motor bearings should be
lubricated at 2000 hour operating intervals,
The lubricant should be from a clean closed
container and should be anti-friction type
bearing grease free from solid fillers or
other harmful ingredients. Lubricant should
have a safe operating temperature of
2OOO’=F.
The air inlet of the condenser coil should be
kept clean through a regular preventative
maintenance program.
Compressor
The oil level of the compressor(s) should be
checked periodically, with the unit shut off. If
oil is needed, allow unit to
pumpdown and
then place system “OFF-ON” switch
(S1) in
the off position. Close the suction and
discharge valves at the compressor. Partially
screw the pipe plug out of the filler hole (the
filler hole is located just above and left of the
crankcase sight glass on most compressors)
and allow pressure to bleed from crankcase
completely before removing plug.
Add oil through the filler hole, using only
Suniso G3 Refrigerant oil that has not been ex-
posed to air or other contaminates.
(Do not
overfill).
Replace and tighten filler hold pipe plug.
Reopen compressor suction and discharge
valves. (CAUTION: Do not run compressor
when discharge valve is closed).
On systems equipped with the AC&R method
of oil equalization, the oil may be added
through the
1/4 SAE flare gage port of the up-
per valve on the oil reservoir when the stem is
in the front seated position. (The valve stem
must be backseated when the unit is
operating).
The oil level should be between the two sight
ports. Check oil level after 2 hours of operation
and again after 2 days of operation.
Winter Control Data
Due to the wide range of applications, it is
sometimes necessary to operate the Chillers at
ambients below summer conditions. Without
proper control, when ambients drop below 60F
the pressure differential between the condenser
and the evaporator is below the level to insure
proper thermal expansion valve operation. As a
result, the unit may cycle on low pressure con
trol with the possibility of evaporator freezing.
Westinghouse offers two types of system con-
trol allowing the units to operate at the winter
ambients indicated:
Fan Cycling
Medium Ambient Control To 30°F
(STANDARD EQUIPMENT - FACTORY
INSTALLED)
A fan cycling control is standard on all
Westinghouse Air Cooled Packaged Water
Chillers to provide proper operating head
pressures, in ambient conditions
to 30°F.
This is an automatic operation and is ac-
complished by cycling one fan on two fan
units; two fans, in sequence, on three fan
units; and three fans, in sequence, on four fan
units. The last fan on each unit is connected
directly to the load side of the fan contactor,
which in turn is controlled by the operation of
the fan cycling pressure control(s) and the
compressor contactor auxiliary
contact. This
arrangement provides positive start-up control
down to + 30F by delaying the condenser fan
operation until a predetermined head pressure
is obtained.
Fan Cycling And Heated
Receiver(s)
Low Ambient Control 0°F
(OPTIONAL EQUIPMENT FACTORY IN-
STALLED)
A heated receiver lone for each refrigerant cir-
cuit) to be used in conjunction with the fan
cycling control to assure compressor start in
ambient temperatures down to
O’F is offered
as an optional priced feature.
This, also, is an automatic operation and is ac-
complished by a pressure cycling control (set
to cut in at 180 PSI and set to cut out at 210
PSI), sensing the receiver pressure and con-
trolling a heater. A check valve, factory install-
ed, in the refrigerant circuit between the
receiver and the condenser prevents refrigerant
migration from receiver to condenser during
the off cycle. When the receiver pressure drops
below 180 PSI, as would be encounted on the
off cycle at low ambient conditions, the
pressure switch would close and the receiver
heater would be energized. With the refrigrant
flow blocked from receiver to condenser by the
check valve and prevented from flowing from
receiver to evaporator by the liquid line
solenoid valve receiver pressure would rise and
be maintained sufficiently to allow expansion
valve operation when the unit starts. If at any
time, the receiver pressure would rise to 210
PSI the pressure control would open and the
receiver heater would be de-energized. A back-
up safety thermostat is provided to shut off the
heater in the event the receiver temperature
reaches 130F
Once the unit has started, head pressure would
be maintained by the fan cycling controls as
explained under heading “Fan Cycling Medium
Ambient Control” above.

Page 4
PD060-135
Control Settings
Tskla ,
IrnYIW I
Pressure Actuated
Fan Cycling Pressure Control
(Adjustable)
High Pressure Control
(Manual Reset)
Low Pressure Control
(Auto Reset)
Oil Pressure Safety Control
(Non-Adjustable)
Manual Reset
Legend Factory Setting
FCP 1 Cut-In 280 PSIG
FCP2 cut-out 170 PSIG
HP 1 Cut-In 300 PSIG
HP2 cut-out 365 PSIG
LP 1
Cut-In 25 PSIG
LP2 cut-out 5 PSIG
OP1
OP2
Cut-Out Pressure
OP3
Differential 9 PSIG
OP4
Receiver Pressure Control
(Optional Heated Receiver)
Low Pressure Freeze Control
(Manual Reset)
P1
P2
LPF 1
LPF 2
Cut-In
cut-out
cut-out
180 PSIG
210 PSIG
48 Psig
Temperature Actuated
Chiller Low Water Temperature
Thermostat
Legend Factory Setting
T1
cut-out 37°F
Chiller Water Cycling
Thermostat (Adjustable) T2 Dial Set At
55’F
Fan Cycling Ambient
Thermostat (Adjustable)
FCT 1 FCT 1
Cut-In
75’F
cut-out 72’F
FCT 2 FCT 2
Cut-In
55’F
cut-out 52’F
FCT 3 FCT 3
Cut-In 38°F
cut-out
35’F
Chiller Heater Thermostat
(Non Adjustable)
Receiver Heater Thermostat
(Optional Heated Receiver)
(Optional Heated Receiver)
T3 Cut-In 40°F
cut-out 45’ F
T4 Cut-In
loOoF
T5 cut-out 13O“F
Unit Operating Limitations
1.
2.
3.
4.
5.
6.
Maximum ambient air to condenser is 1 loo.
For minimum ambient operation (see winter control data page 3).
Maximum allowable cooler water pressure is 150 PSIG.
Maximum allowable water temperature to cooler is
75O.
Units must not have leaving water temperatures of 42” or lower unless provided with capacity control or used with a glycol solution.
Unit must be allowed to pump down at the end of each operating cycle (except on safety control shut
down.) Where timeclock shut down, low
ambient lock out or remote manual shut down is required consult factory.

Sequence Of Operation
Starting Sequence
Move control switch
"S1" to the “On” posi-
tion. This will provide power for SSM
1-SSM4
(solid state motor protectors), through flow
switch T 1 (low water temp. safety), cycling
thermostat T2-Stage 1, through LLl (lead-lag
switch). to energize R1 (non-recycle relay) and
TD1 (stage start relay). Contacts 1 and 3 of R1
close providing power through HP1 (high
pressure safety), LPF1 (low pressure freeze
safety),
SSM1 and SSM2, OP1 (oil pressure
safety), contacts 4 and 6 of
R 1, to energize
SOL1 (liquid line solenoid).
When SOL 1 opens, low side pressure in-
creases to the cut-in setting of LP1 (low
pressure control), LP1 closes, energizing
com-
pressor
contactor Cl, which provides power to
compressor motor No.
1.
TD1 times out, closes contacts 2 and 4 of TD1
If T2 Stage 2 is calling for cooling, power is
provided through
LL1, contacts 2 and 4 of TDI
to energize R3 and TD2. Contacts 1 and 3 of
R3 close providing power through OP2 to
energize C3 which provides power to
com-
pressor
motor No. 2.
Compressor motors No. 3 and No. 4
(ref. cir-
cuit No. 2). start in same sequences as No. 1
and No 2 through T2 Stage 3 and 4. TD2 and
TD3, TD4 stages starting between compressor
motors No. 3 and No. 2 when LL1 is in op-
posite position.
The fan circuit is interlocked through auxiliary
contacts
C1A, C3A, C5A. C7A of contactors
Cl, C3, C5, C7 respectively, to energize fan
contactor
C9 when the high side pressure in-
creases to the cut-in setting of FCP1 or FCP2
(fan cycling pressure controll. Fan Motor M2
and M3 are energized through their respective
ambient thermostats
FCT1 and FCT2.
Pump-Down Sequence
T2 Stage 4 is satisfied and opens, R4
de-
energizes, contacts 1 and 3 of R4 opens de-
energizing C7. Compressor Motor No. 4 drops
off the line.
T2 Stage 3 is satisfied and opens, R2
de-
energizes, Contacts 1 and 3 and 4 and 6 of R2
open,
SOL1 de-energizes and closes. Contactor
C5 remains energized through
auxiliary contact
C5B until the low side pressure drops to the
cut-out setting of LP2. When LP2 opens, C5
de-energizes and compressor Motor No. 3
drops off the line.
Installation Bulletin
PD-G4
Page 7
Circuit No. 1 de-energizes in the same se-
quence as circuit No. 2 through T2 Stages 2
and 1, in response to return water temperature.
Optional Accessory Sequence
Part Winding Start (208/230 Volt Units
Only)
A time delay relay is wired in series with
compressor contractor C2 and delays
energizing of C2 for 1 second after Cl is
energized.
Unloading solenoids(s) mounted on
compressor head is energized in
response to return water temperature by
cycling thermostat T2.
Non-Short Cycling
Non-short cycling relay (TD5) is energiz-
ed through N. C contacts of R7 at start-
up and immediately following pump-
down. TD5 times out closing contacts 3
and 4 of TD5. This allows R1 to become
energized on cooling demand anytime
unit has been off for 5 minutes.

Installation Bulletin
PD-G4
Page 9
Sequence Of Operation
Starting Sequence
Move control switch
"S1" to the “On” posi-
tion. This will provide power for
SSM1-SSM4
(solid state motor protectors), through flow
switch
T1 (low water temp. safety), cycling
thermostat T2 Stage 1, through LL1 (lead-lag
switch), to energize R1 (non-recycle
relay) and
TD1 (stage start relay). Contacts 1 and 3 of R1
close providing power through HP1
(high
pressure safety), LPF1 (low pressure freeze
safety),
SSM1 and SSM2, OP1 (oil pressure
safety). contacts 4 and 6 of RR1, to energize
SOL1 (liquid line solenoid).
When SOL1 opens, low side pressure Increases
to the cut-in setting of LP1 flow pressure con-
trol). LP1 closes, energizing compressor con
tactor Cl, which provides power to compressor
motor No. 1.
TD1
times out, closes contacts 2 and 4 of TD1.
If T2 Stage 2 is calling for cooling, power is
provided through LL1, contacts 2 and 4 of TDI
to energize R3 and TD2. Contacts 1 and 3 of
R3 close providing power through OP2 to
energize C3 which provides power to
com-
pressor Motor No. 2.
Compressor motors No. 3 and No. 4 (ref. cir-
cuit No. 21, start in same sequence as No. 1
and No. 2 through T2 Stage 3 and 4, TD2 and
TD3 TD4 stages starting between compressor
motors No. 3 and No. 2 when LL1 is in
op-
posite position.
The fan circuit is interlocked through auxiliary
contacts CIA, C3A.
C5A, C7A of contactors
Cl, C3, C5, C7 respectively. to energize fan
contactor
C9 when the high side pressure in
creases to the cut-in setting of FCP1 or FCP2
(fan cycling pressure control). Fan Motor M2
and M3 are energized through their respective
ambient thermostats FCT1 and
FCT2.
Pump-Down Sequence
T2 Stage 4 is satisfied and opens, R4
de-
energizes, contacts 1 and 3 of R4 opens de-
energizing C7. Compressor Motor No 4 drops
off the line.
T2 Stage 3 is satisfied and opens, R2
de-
energizes, Contacts 1 and 3 and 4 and 6 of R2
open, SOL1 de-energizes and closes. Contactor
C5 remains energized through auxiliary contact
C5B until the low side pressure drops to the
cut-out setting of LP2. When LP2 opens, C5
de-energizes and compressor Motor No.3 drops
off the line.
Circuit No. 1 de-energizes in the same se-
quence as circuit No. 2 through T2 Stages 2
and 1. in response to return water temperature.
Optional Accessory Sequence
Part Winding Start (208/230 Volt Units
Only)
A time delay relay is wired in series with
compressor contractor C2 and delays
energizing of C2 for 1 second after Cl is
energized.
Unloading
solenoid(s) mounted on com-
pressor head is energized in response to
return water temperature, by cycling
thermostat T2.
Non-Short Cycling
Non-short cycling relay (TD5) is energiz-
ed through N. C. contacts of R7 at
start-up and immediately following
pump-down. TD5 times out closing con-
tacts 3 and 4 of TD5. This allows R1 to
become energized on cooling demand
anytime unit has been off for 5 minutes.

Packaged Air Cooled Water Chiller
Start Up
Procedure Check Points Yes No
Equipment Inspection: a. Unit damaged on arrival
b. Material received agrees with shipping
papers
Setting Unit:
Wiring:
Piping
Alignment:
(Belt Drive Units)
Before Start-up:
After start-up:
a. Vibration isolator used
b.Spring isolator adjusted for equal height
c. If rubber in sheer isolators are used, is
unit levelled by shimming
a. Power wiring complete
b. Control wiring complete
c.Electric service adequate for load
d. Power source voltage correct for
motor(s) used
e. Motor circuit has proper size fusetrons
f. System wired per diagram
g. All lead connections tight
h. Wiring complies with local codes
a. Piping complies with applicable codes
b. External piping independently supported
c. Chilled water lines insulated
a. All belts adjusted and checked for
tautness
b. All pulleys checked and adjusted for
proper pitch, tightness and alignment
a. Check compressor for proper oil level
b. Open compressor suction and discharge
service valves.
c. Open receiver liquid
valve(s)
d. Open suction, oil and discharge valves
to pressure gauges (if supplied)
e. Check rotation of all fan and blower
motors
f. All motors and bearings lubricated
(Belt
Drive Units)
g. Start auxiliary equipment (Pumps. fans,
etc.)
h. Is crankcase heater operating?
a. Check oil pressure. Is pressure at Mfg’s
recommendation?
b. Re-check oil level in crankcase
c. Check high pressure control

Start Up
Procedure Check Points Yes No
d. Check oil pressure safety switch
e. Check and adjust low pressure or
temperature freeze control
f. Check and adjust operating thermostat
g. Check and adjust low pressure operating
control
h. Check and adjust expansion valve
superheat
Operating Data
Chiller
Voltage: L-l _ L-2 _ L-3 _
Pressure gauge readings: a. Suction
b. Discharge
c. Oil
~
d. Net oil
Pressure
c-b =
High pressure switch setting: (cut in)
Checked setting Yes
Low pressure switch setting: (cut
in)
Checked setting
Yes
Low oil pressure switch checked
Yes
Low pressure freeze control
If part winding start, time delay is
Temperature of air entering condenser
Temperature of air leaving condenser
Temperature of Chilled Water entering chiller
~_
Temperature of Water (Chilled) leaving chiller
Chilled water pressure entering chiller
Chilled water pressure leaving chiller
psig
psig
psig
psig
psig _
psig (out)
No
psig
psig (out)
_ No
No
Cut in
~__~ _
cut out
seconds.
OF.
OF.
OF.
OF
psig
psig
0
e
Westinghouse 0 Commercial - Industrial Air Conditioning Division 0 Staunton, VA. 24401
In Canada: Westinghouse Canada Ltd. 492 Speers Road, Oakville, Ontario
World wide: Westinghouse Air Conditioning International
Westinghouse
Bld, Gateway Center, Pittsburgh, PA. 16222
V8/77/6M