WC Series Variable Speed Dual Screw Chiller WC Series ...

IM1903WC 07/19

Installation Information

Water Piping Connections

Electrical Data

Microprocessor Control

Startup Procedures

Preventive Maintenance

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WC Series Variable Speed Dual Screw Chiller 175-275 Ton60Hz

60 Hz

WC SERIES VARIABLE SPEED DUAL SCREW CHILLER INSTALLATION MANUAL

Table of Contents

General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Electrical Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

WC Series Variable Speed Screw Chiller Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Rigging Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Water Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Electrical System and Controls Safety Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Start-Up Service Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Refrigeration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Reference Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Unit Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Startup and Troubleshooting Form. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Chiller Startup Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Revision Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4


Safety ConsiderationsInstalling and servicing air conditioning and heating

equipment can be hazardous due to system pressure and

electrical components. Only trained and qualified service

personnel should install, repair or service heating and air

conditioning equipment. When working on heating and

air conditioning equipment observe precautions in the

literature, tags and labels attached to the unit and follow

other safety precautions that may apply.

Follow all safety codes. Wear safety glasses and work

gloves. Use quenching cloth for brazing operations. Have a

fire extinguisher available for all brazing operations.

NOTE: Before installing, check voltage of unit(s) to ensure

proper voltage.

WARNING: Before performing service or maintenance operations on the system, turn off main power switches to the unit. Electrical shock could cause serious personal injury.

ApplicationUnits are not intended for heating domestic potable water

by direct coupling. If used for this type of application, a

secondary heat exchanger must be used.

Moving and StorageMove units in the normal “Up” orientation as indicated by

the labels on the unit packaging. When the equipment

is received, all items should be carefully checked against

the bill of lading to ensure that all crates and cartons

have been received in good condition. Examine units for

shipping damage, removing unit packaging if necessary

to properly inspect unit. Units in question should also

be internally inspected. If any damage is observed, the

carrier should make the proper notation on delivery receipt

acknowledging the damage. Units are to be stored in a

location that provides adequate protection from dirt, debris

and moisture.

Units are setup to be side picked using a fork lift. Some

units include pick bars allowing for picking from the end

with required fork lengths. Note unit labels and markings

for safe picking points. Do not pick the unit up from points

not specified and keep the unit level during transport and

handling. Using improper equipment handling methods can

result in damage and/or void the warranty.

General Installation InformationWARNING: To avoid equipment damage, do not leave the system filled in a building without heat during cold weather, unless adequate freeze protection levels of antifreeze are used. Heat exchangers do not fully drain and will freeze unless protected, causing permanent damage.

Unit LocationProvide sufficient room to make water and electrical

connections. If the unit is located in a confined space,

provisions must be made for unit servicing. Locate the

unit in an indoor area that allows easy removal of the

access panels and has enough space for service personnel

to perform maintenance or repair. These units are not

approved for outdoor installation and, therefore, must be

installed inside the structure being conditioned. Do not

locate units in areas subject to freezing conditions.

WARNING: Do not store or install units in corrosive environments or in locations subject to temperature or humidity extremes (e.g. attics, garages, rooftops, etc.). Corrosive conditions and high temperature or humidity can significantly reduce performance, reliability, and service life. WARNING: To avoid equipment damage and possible voiding of warranty, be sure that properly sized strainers are installed upstream of both brazed plate heat exchangers to protect them against particles in the fluid.

5


Model Nomenclature

All WC Series product is Safety listed under UL1995 thru ETL

Electrical Availability

Voltage Dual Variable Speed

208-230/60/3460/60/3 ● ● ●575/60/3

7/21/2019● - “CH” only models

W CH V E 275 * 4 A2-3 5 6-8 10 11 12

Brand W - WaterFurnace

Model Type CH – Heat Recovery Chiller

Compressor Type V – Variable Speed

Cabinet Configuration E – Enclosed

Unit Capacity (Nominal Tons) 175,225,275

Vintage * – Factory Use Only

Voltage 4 – 460/60/3

Electrical Option A – Standard, Fused Disconnect Control Option B – Stand-Alone / BACnet

Non-Standard Options SSS – None

Future Option N – Not Applicable

Future Option 0 – Not Applicable

Future Option 0 – Not Applicable

Future Option N – Not Applicable

Water Control Option 6FA - 6" w/iso vlv

Water Coil Option B – Brazed-Plate

Refrigeration Option 3 – EEV

Cabinet Option S – Standard

Sound Kit Option B – Sound Kit

13 1514 16 17 - 19 20 21 22 23 24-2691 4B B S 3 B 6FA N 0 0 N SSS

Fused Disconnect

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6


The WC Series Variable Speed Screw Chiller FeaturesHydroLink2 Aurora controls

platform is a field proven

communicating compressor

management control

Low impedance line reactors

reduce harmonic noise and

improve power factor

Fused disconnects for

each compressor

Factory installed flow

switches and modulating

isolation valves

Variable speed drive

integrated with

compressor provides

envelope control for

improved reliability

HydroLink2

is a NiagraAX

based system

controller

Fused power supply for

high short circuit current

rating

2

7


The WC Series Variable Speed Screw Chiller Features

High efficiency compact

R134a screw compressors for

efficiency, reliability and

capacity control

Acoustical sound enclosure

for maximum sound reductionStructural Steel

frame to reduce

vibration

Flange style

water connections

for an easier and

faster connection

High efficiency

brazed plate

heat exchangers

for efficiency and

compact size

Electronic expansion valves

for enhanced efficiency and

control

Water headers for

integrated parallel flowServiceable core

filter driers

Large touch

screen tablet with

high quality HMI

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8


Operating Limits

Condenser Evaporator

Fluid Limit ˚F ˚C ˚F ˚C

Min Entering Water 40 4.4 45 7.2

Min Entering Brine 50 10.0 30 -1.1

Min Leaving Brine 70 21.1 25 -3.9

Min Leaving Water 70 21.1 40 4.4

Max Entering Water/Brine 133 56.1 80 26.7

Max Leaving Water/Brine 140 60.0 70 21.1

Min Differential Temperature 7 3.9 5 2.8

Max Differential Temperature 30 16.7 20 11.1

Flow Rate Limit gpm/ton L/min-kW gpm/ton L/s-kW

Minimum fl ow rate 1 3.8 1 3.8

Maximum fl ow rate 4.5 17.0 4.5 17.0

Ambient Temperature ˚F ˚C

Minimum Ambient 55 12.8

Maximum Ambient 95 35.0

7/22/19

9


Dimensional Data

DE

10


Dimensional Data cont.

ADETAIL A

11


Dimensional Data cont.

12


Rigging Data

USE SPREADER BARSTO PREVENT DAMAGEOF UNIT

13


Center of Gravity

C D

BA

F

E

G

1

MODEL SHIPPING WEIGHT NET WEIGHTWCHVE 175 13,000 13,000WCHVE 225 12,500 12,500WCHVE 275 12,000 12,000

14


Water Quality1.0. Minimum Fluid Volume

A. Water cooled chillers require a minimum amount of source and load side fl uid volume to ensure accurate and stable temperatures during system operation. For normal air conditioning type applications, it is recommended to use at least 7 gallons/ton.

B. Applications that require more precise temperature control or low loading will occur the minimum fl uid volume shall be no less than 10 gallons/ton. Installation of a buffer tank that will properly mix the fl uid is recommended.

1.1. Water Cooled Chiller Sizing

A. Chillers should be adequately sized for optimal system effi ciency and run time. Oversizing by more than 15% can diminish performance resulting in higher power consumption, short cycling of compressors, and unstable conditioning temperatures.

B. In applications where the minimum load is signifi cantly less than the design condition, it is better to install 2 smaller Chillers for load matching rather than a single large Chiller.

1.2. Chiller Piping

A. Multiple Chillers can be installed in series or parallel confi gurations. The preferred system design is to pipe the equipment in parallel due to its simplicity and fl exibility. In parallel systems, the Chiller equipment can vary in size as long as fl ow rate and system volume are accounted for.

B. Piping equipment in series is not desired; however, it can be done if proper guidelines are followed. Always observe proper temperature and fl ow rate requirements for each unit. Sometimes this method is desired to achieve larger temperature differences.

1.3. Strainers

A. All brazed-plate heat exchangers shall have a strainer within 8 ft of the water/brine inlet. It is highly recommended to use 30 mesh in order to provide maximum fi ltration. In any case, the strainers should never have a mesh size larger than 60 or less than 20.

B. Failure to install proper stainers and perform regular service can result in serious damage to the unit, and cause degraded performance, reduced operating life and failed compressors. Improper installation of the unit (which includes not having proper strainers to protect the heat exchangers) can also result in voiding the warranty.

C. Strainers should be selected on the basis of acceptable pressure drop, and not on pipe diameter. The strainers selected should have a pressure drop at the nominal fl ow rate of the units; low enough to be within the pumping capacity of the pump being used.

1.4. Flow Sensing Devices

A. A fl ow switch or equivalent must be installed on the evaporator for each unit to be installed. If the unit is to operate as both modes (heating/cooling), a fl ow switch is needed on both heat exchangers.

B. A differential pressure switch can be used in place of a fl ow switch. The differential switch must be capable of pressure range as indicated in the pressure drop tables.

1.5. Water Quality

A. General: Reversible chiller systems may be successfully applied in a wide range of commercial and industrial applications. It is the responsibility of the system designer and installing contractor to ensure that acceptable water quality is present and that all applicable codes have been met in these installations.

B. Water Treatment: Do not use untreated or improperly treated water. Equipment damage may occur. The use of improperly treated or untreated water in this equipment may result in scaling, erosion, corrosion, algae or slime. The services of a qualifi ed water treatment specialist should be engaged to determine what treatment, if any, is required. The product warranty specifi cally excludes liability for corrosion, erosion or deterioration of equipment.

The heat exchangers in the units are 316 stainless steel plates with copper brazing. The water piping in the heat exchanger is steel. There may be other materials in the building’s piping system that the designer may need to take into consideration when deciding the parameters of the water quality.

If an antifreeze or water treatment solution is to be used, the designer should confi rm it does not have a detrimental effect on the materials in the system.

C. Contaminated Water: In applications where the water quality cannot be held to prescribed limits, the use of a secondary or intermediate heat exchanger is recommended to separate the unit from the contaminated water.

The following table outlines the water quality guidelines for unit heat exchangers. If these conditions are exceeded, a secondary heat exchanger is required. Failure to supply a secondary heat exchanger where needed will result in a warranty exclusion for primary heat exchanger corrosion or failure.

WARNING: Must have intermediate heat exchanger when used in pool applications.

15


Water ConnectionsWater Piping must be installed in accordance with application codes and per necessary standards. Supply and return connections should be connected per units’ directions. Strainers are required on supply to machine per engineer specification to prevent heat exchanger fouling from occurring.

Before start-up can occur, water must be CLEAN and proper procedures and care should be implemented in order to ensure and maintain a clean system. Water should be treated and clean per necessary standards before start-up is scheduled. Each water header is equipped standard with a temperature well sensor for supply and return water temperatures of the units’

performance. Also included is a flow switch located on the exit side of the heat exchanger to ensure flow through the heat exchangers, which is integrated into the controls and is adjusted in pre-shipping testing procedures.

Furthermore, it is recommended to provide water isolation valves for proper isolation and maintenance of the unit, pumps, and strainers.

Water Quality Cont.1.6. Insulation

A. Chillers are built with factory installed insulation on any surface that may be subject to temperatures below the room dew point.

1.7. Brine Applications

A. Applications where the leaving fl uid temperature goes below 40°F a suitable brine solution must be used. Failure to do so can cause immediate damage to the system. The brine must be approved for use with heat exchangers. Automotive antifreeze solutions are not suitable for use in brazed plate heat exchangers.

B. The freeze detection must be adjusted appropriately for brine applications. The brine solution concentration should be at least 15°F below the lowest leaving fl uid temperature.

Surface Condensation Chart

Room Ambient ConditionSurface Temperature

50°F 35°F 0°F

Normal (Max 85°F, 70% RH) 1/2" 3/4" 1"

Mild (Max 80°F, 50% RH) 1/8" 1/4" 1/2"

Severe (Max 90°F, 80% RH) 3/4" 1" 2"

Material Copper 90/10 Cupronickel 316 Stainless SteelpH Acidity/Alkalinity 7 - 9 7 - 9 7 - 9

ScalingCalcium and

Magnesium Carbonate(Total Hardness)

less than 350 ppm(Total Hardness)

less than 350 ppm(Total Hardness)

less than 350 ppm

Corrosion

Hydrogen SulfideLess than 0.5 ppm (rotten egg

smell appears at 0.5 ppm)10 - 50 ppm Less than 1 ppm

Sulfates Less than 125 ppm Less than 125 ppm Less than 200 ppm

Chlorine Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Chlorides Less than 20 ppm Less than 125 ppm Less than 300 ppm

Carbon Dioxide Less than 50 ppm 10 - 50 ppm 10 - 50 ppm

Ammonia Less than 2 ppm Less than 2 ppm Less than 20 ppm

Ammonia Chloride Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Ammonia Nitrate Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Ammonia Hydroxide Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Ammonia Sulfate Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Total Dissolved Solids (TDS) Less than 1000 ppm 1000 - 1500 ppm 1000 - 1500 ppm

LSI Index +0.5 to -0.5 +0.5 to -0.5 +0.5 to -0.5

Iron Fouling(Biological Growth)

Iron, FE2+ (Ferrous)Bacterial Iron Potential

< 0.2 ppm < 0.2 ppm < 0.2 ppm

Iron OxideLess than 1 ppm, above this level deposition will occur

Less than 1 ppm, above this level deposition will occur

Less than 1 ppm, above this level deposition will occur

ErosionSuspended Solids

Less than 10 ppm and filtered for max. of 600 micron size



Threshold Velocity(Fresh Water)

< 6 ft/sec < 6 ft/sec < 6 ft/sec

NOTES: Grains = ppm divided by 17 mg/L is equivalent to ppm

2/22/12

Water Quality Guidelines

16


Electrical Data

ModelRated

VoltageVoltage Min/Max

Compressor1 TotalUnitFLA

MinCircAmp

MinFuse/HACR

MaxFuse/HACRMOA RLA LRA2

175 460/60/3 414/506 190.0 156.0 20.0 312.0 351.0 400 500

225 460/60/3 414/506 225.0 185.0 20.0 370.0 416.0 450 600

275 460/60/3 414/506 290.0 240.0 20.0 480.0 540.0 600 800

HACR circuit breaker in USA only 7/22/191 - MCC, RLA, & LRA rating per compressor. Breaker & FLA sized for both compressors.2 - LRA is compressor motor starting current

Electrical Connections

Compressor Bfused disconnect

Class J Protective Fuse for incoming

power

High Voltage

line reactors

Cooling Fans

Low Voltage

control transformer

Transformer to

VFD power

Ground Block

Compressor A fused disconnect

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2LPS

LPSH

PSHP

S

K1-RV Relay

K2-CC Relay

K3-CC2 Relay

K4-Fan Relay

K5-A

larm

Relay K6

-Acc

Re

lay

CC

R

ES LS

P2EH

1

YG

G

G

C-

+R

CFM P1

3

P4

SW1

P5

JW2

P9

LO O/B

Y2 W DH

P8P7

RS48

5 NET

RS48

5 NET

P6

RS48

5 EXP

P3

SW2On

Futu

re U

se

L Ou

tput T

ype

CC –

Dual/

Sing

leAc

c – D

ip 5

Acc –

Dip

4RV

– B/

OFP

2 – 15

°F/3

0°F

FP1 –

15°F

/30°

F

Com1

LED5

Com2

LED5

Test

Mod

e

F1-3A

P1

CPWM 1 2 3 4 5 6 7 8

ALM

ALG

ACC

COM

ACC

NOAC

C NC

R C G Y1

EH2

CEH

1C

COC

R-

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R-

+

Off

Faul

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D1 R

Stat

usLE

D3

Conf

igLE

D2

CC2

CCF

CR

FFG

CCCC

GCC2

HICC

2LO

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REVR

EVFP

1FP

1FP

2FP

2LPS

LPSH

PSHP

S

Auro

ra B

ase C

ontro

l(A

BC-C

OMPR

ESSO

R B)

K1-RV Relay

K2-CC Relay

K3-CC2 Relay

K4-Fan Relay

K5-A

larm

Relay K6

-Acc

Re

lay

CC

R

ES LS

P2EH

1

YG

G

G

Yello

w (0

13)

2223 24

21

10 9T

12 11T

15 13

Brow

n

RED

Blue

Blac

k

14

COM

P B

DIS

CH T

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T1T2

T3

COM

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+

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Mod

bus

L N

Red

(128

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d(1

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COM

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EMP

X02-

213

4

5 2ST

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w (0

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(012

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22 21

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te (S

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Blac

k (S

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Yello

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(SA2

)

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(SA1

)

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te (S

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k (S

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ATER

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Modbus Add. IDFuture Use

Acc 2 – Dip 1Acc 2 – Dip 2

ON

Gre

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(002

)

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Blac

k (S

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(SB2

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(SB1

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te (S

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k (S

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Yello

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(SA1

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USB

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(225

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4

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in

Dra

in

Dra

in

Dra

in

Dra

in

HMI

POW

ER

SEC

18

WC SERIES VARIABLE SPEED DUAL SCREW CHILLER INSTALLATION MANUALW

irin

g S

ch

em

ati

cs

co

nt.

DU

AL S

CREW

WCH

VE 2

75/2

25/1

7597

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B 7

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NO

TES:

1. B

ACne

t ADD

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TTER

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cces

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cle

wit

h Co

mpr

esso

rO

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ater

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ve S

low

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N

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4SW

1-5

DES

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N

ON

ON

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d

OFF

ON

Cycl

es w

ith

CC (N

orm

al)

ON

OFF

Not

Use

d

OFF

OFF

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Use

d

AXB

Acc

esso

ry 2

DIP

Set

ting

s

SW1

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bus A

dd.

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ture

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1 2 3 4 5

ONOF

F

Futu

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seAc

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1Ac

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2

SW2On

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re U

se

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put T

ype

CC –

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l/Sin

gle

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5Ac

c – D

ip 4

RV –

B/O

FP2

– 15

°F/3

0°F

FP1

– 15

°F/3

0°F

1 2 3 4 5 6 7 8

Off

PB2

21 3

Whi

te (3

04) W

hite

(308

)

Whi

te (3

12)

Whi

te (3

16)

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nge

(307

)

Ora

nge

(303

)

Ora

nge

(311

) Ora

nge

(315

)

Blac

k (3

01)

Blac

k (3

01)

Blac

k (3

05)

Red

(314

)Bl

ack

(313

)

Red

(310

)

Blac

k (3

09)

Red

(302

)

Red

(306

)

Blac

k (3

05)

Blac

k (3

09)

Blac

k (3

13)

Red

(302

)

Red

(306

)

Red

(310

)

Red

(314

)

HR3

USB

PRISEC

RS-485-1

S - + S - +

RS-485-2

A1

A2

A3 A4 A5

A6

A7

A8C CC C

U1

U2

U3

U4

U5

U6

U7C CC C U8

U9

U12

U13

U14

U15C CC C

U16

U10

U11

D1

D4

D5

D6

D7C CC C

D8

D2

D3

D9 C

D1024VAC/DC

~ -~ +

SHL

D

LxH

LxL

A B C D

outputsinputs

inputsoutputs

D1 D2 D3 D4 D5

Whi

te (3

04)

Ora

nge

(307

)

Whi

te (3

08)

Ora

nge

(311

)

Whi

te (3

12)

Ora

nge

(315

)

Whi

te (3

16)

Ora

nge

(303

)

Blue

(95)

Gre

en (9

9)

D6 D7 D8 D9 D10

BAC

net C

onne

ctio

ns

NET

+

NET

-

COM

NOT

E 1

PB3

21 3

Yello

w (9

0)

Blue

(89)

To A

BC-A

P8

To A

BC-B

P8

Blac

kO

ran

geRe

d

Whi

te

Yello

w

Blue

HMI

POW

ER

Yello

w (9

6)

19


Wir

ing

Sch

em

ati

cs

co

nt.

DU

AL S

CREW

WCH

VE 2

75/2

25/1

7597

P920

-03 /

B 7

/08/19

Blac

k (4

13)

Blac

k (4

12)

FIEL

D IN

STA

LLED

GR

OU

ND

FUSE

BO

X

GR

OU

ND

Tran

sfor

mer

1

115V

21

F1F2

NO

TE 3

Blac

k (4

05)

Blac

k (4

06)

PB1

460V

Blac

k (4

07)

Whi

te (4

08)

NO

TE 4

F3

NO

TE 2

F4

UN

IT P

OW

ER S

UPP

LYM

AIN

FU

SES

800A

GR

OU

ND

BLO

CK CHA

SSIS

G

RO

UN

D

LIN

E RE

ACT

OR

A

LIN

E RE

ACT

OR

B

L1L2

L3

L1L2

L3

L1

T1

L2

T2

L3

T3

FUSE

D

DIS

CON

NEC

T SW

ITCH

B

FUSE

D

DIS

CON

NEC

T SW

ITCH

A

L1

T1

L2

T2

L3

T3

F1N

OTE

3

T1T2

T3

COM

P A

CO

NTR

OL

BOA

RD

STO

+

STO

-

DI2

+

DI2

- + - GND

LN XO5

X02-

1

X02-

2

T1T2

T3ST

O +

STO

-

DI2

+

DI2

- + - GND

LN XO5

X02-

1

X02-

2

COM

P B

CON

TRO

L BO

ARD

REA

CTO

R G

RO

UN

D

Tran

sfor

mer

2

24 V

PB3

21

3

Tran

sfor

mer

3

24 V

NO

TE 1

460

V46

0 V

Purp

lePu

rple

Blac

kBl

ack

Blac

k/W

hite

Yello

wBl

ack/

Whi

teYe

llow

Blue

(320

)Ye

llow

(322

)

Blue

(319

)

Yello

w (3

21)

NO

TE 5

S1S2

S3

Blac

k (4

19)

Blac

k (4

20)

Blac

k (4

03)

Blac

k (4

04)

Blac

k (4

01)Blac

k (4

02)

F2

Cont

rol P

ower

Dis

conn

ect

Whi

te (4

16)

Whi

te (4

15)

Blac

k (4

09)

Blac

k (4

10)

FACT

ORY

LOW

VOL

TAGE

LIN

E

FACO

RY L

INE

VOLT

AGE

460V

GRO

UND

FUSE

SCRE

W

CONN

ECTO

R

FACO

RY L

INE

VOLT

AGE

115V

NO

TES:

1. C

lass 2

tran

sfor

mer

s 2.

Inst

alle

d fu

ses F

1 an

d F2

- 7A

3.

Inst

alle

d fu

se- F

3 an

d F4

– 4

A4.

Loca

ted

Insid

e Hi

gh V

olt B

ox5.

Loca

ted

Insid

e Lo

w V

olt B

oxTRAN

SFOR

MER

LINE

REA

CTOR

L1 T1

L2 T2

L3 T3

FUSE

D DI

SCO

NNEC

T

Lege

nd

20


Evaporator Pressure Drop

Condenser Pressure Drop

21


Electrical System and Controls - Safety Circuit

--------------- IInnnstantaneous Lock-Out

--------------- IInnnstantaneous Lock-Out

---------------- Lock-Out after 30 sec

Chiller Safety Circuit• Safe Torque Off (STO)

• “motor-off” function.

• Inverter (VFD) is powered anytime the chiller power is on.

• STO is wired to the compressor contactor (CC) output of the Aurora control.

• Anytime Aurora senses a fault that would require compressor shutdown, it will trigger the STO input to turn

the motor off.

• High Pressure Switch • NC below 320 psig

• Low Pressure Switch • NC above 4 psig

• Emergency Stop Switch (E-stop)• Wired to both ABC – emergency shutdown (ES) inputs.• LED on E-stop will illuminate when tripped.• HydroLink will display that ABC has been put into emergency shutdown mode.

ABC Compressor Controller

Relay

CompressorSTO

VFD Power

Compressor VFD

22


Start-Up Data CollectionData Collection is to be schedule and implemented by a qualified representative.

Prior to Powering Up Machine

Suction Temperature Discharge Pressure

Super Heat Hx1 Gas Pressure

Subcooling Hx1 Sat

Capacity Hx2 Gas Pressure

Return Water from Geo Field Hx2 Sat

Hx2 Gas Temperature Supply Water to Building

Hx2 Liquid Temperature Hx1 Gas Temperature

Return water to Geo Field Hx1 Liquid Temperature

Return Water to Building

Notes

After Machine has been Running for 4 Minutes



Subcooling Hx1 Sat







Notes

After Machine has been Running for 60 Minutes



Subcooling Hx1 Sat







Notes

23


Screw Refrigeration Cycle Analysis

24


HE

GPM x 500*

Legend

Abbreviations and Definitions

Reference CalculationsHeating Calculations: Cooling Calculations:

LWT = EWT + HR

GPM x 500*LWT = EWT -

NOTE: * When using water.

HWR = Hot Water ReturnHWS = Hot Water SupplyCWR = Cold Water ReturnCWS = Cold Water SupplyHVR = Heat Recovery ReturnHVS = Heat Recovery SupplyHVP = High Voltage PanelLVP = Low Voltage PanelTC = Total Cooling Capacity in MBTUHMBTUH = Thousands of British Thermal Units per hour

LWT = Leaving Water TemperatureEWT = Entering Water TemperatureEER = Energy Efficiency Ratio (TC/kW)COP = Coefficient of Performance (HC/kW x 3.413)PSI = Pressure drop in pounds per square inchHC = Heating Capacity in MBTUHHE = Heat of Extraction in MBTUHkW = kilowattft hd = pressure drop in feet of headHR = Heat of Rejection

Verify the following:• High voltage is correct and matches nameplate

• Fuses, breakers and wire size are correct

• Low voltage wiring is complete

• Piping is complete and the water system has been

cleaned and flushed

• Air is purged from piping system

• Isolation valves are open and water control valves are

wired

• Service/access panels are in place

• Transformer has been switched to lower voltage tap if

needed (208/230 volt units only)

• Unit controls are in “off” position

• Flow switches are installed and ready

WARNING: Verify ALL water controls are open and allow water flow PRIOR to engaging the compressor. Failure to do so can result in freezing the heat exchanger or water lines causing permanent damage to the unit.

Unit Startup

25


Preventative Maintenance

Unit Heat Exchanger Maintenance1. Keep all air out of the water or antifreeze solution.2. Keep the system under pressure at all times. Closed

loop systems must have positive static pressure or air vents may draw air into the system.

NOTES: If the installation is in an area with a known highmineral content in the water, it is best to establish withthe owner a periodic maintenance schedule for checkingthe water-to-refrigerant heat exchanger on a regularbasis. Should periodic cleaning be necessary, use standard cleaning procedures. Generally, the more water flowing through the unit, the less chance there is for scaling. Low GPM flow rates produce higher temperatures through the heat exchanger. To avoid excessive pressure drop and the possibility of metal erosion, do not exceed GPM flow rate as shown on the specification sheets for each unit.

Quarterly Checks• Compressor oil levels• Test and check all manual safeties• Check strainers for debris• Check water flow rates and pressure drops across

evaporators and condensers• Verify graphical data and trending• Properly document all data

Annual Checks• Remove and clean all waterside strainers• Back washing of heat exchangers• Perform leak tests on all refrigerant circuits• Check all water flanged connections for wear or

leaks• Implement oil analysis if deemed necessary• Verify all electrical connections• Check and update all graphical interface items

along with main controller• Check and test all safeties both mechanical and

software• Verify sensor accuracy• Do a system check to get overall overview• Properly document all data

Replacement ProceduresWhen contacting the company for service or replacement parts, refer to the model number and serial number of the unit as stamped on the serial plate attached to the unit. If replacement parts are required, mention the date of installation of the unit and the date of failure, along with an explanation of the malfunctions and a description of the replacement parts required.

In-Warranty Material Return

Material may not be returned except by permissionof authorized warranty personnel. Contact your localdistributor for warranty return authorization and assistance.

26


Check One Start up/Check-out for new installation Troubleshooting Problem:___________________________________

1. FLOW RATE IN GPM (SOURCE/LOAD SIDE HEAT EXCHANGER)

Water In Pressure: a.______ PSIWater Out Pressure: b.______ PSIPressure Drop = a - b c.______ PSIConvert Pressure Drop to Flow Rate (refer to Pressure Drop table) d.______ GPM

a.______ PSIb.______ PSIc.______ PSI d.______ GPM

2. TEMPERATURE RISE OR DROP ACROSS SOURCE SIDE HEAT EXCHANGER

COOLING HEATINGWater In Temperature: e.______ °F e.______ °FWater Out Temperature: f. ______ °F f. ______ °FTemperature Difference: g.______ °F g.______ °F

3. TEMPERATURE RISE OR DROP ACROSS LOAD SIDE HEAT EXCHANGER

COOLING HEATINGWater In Temperature: h.______ °F h.______ °FWater Out Temperature: i. ______ °F i. ______ °FTemperature Difference: j. ______ °F j. ______ °F

4. HEAT OF REJECTION (HR) / HEAT OF EXTRACTION (HE) CALCULATION

HR or HE = Flow Rate x Temperature Difference x Brine Factor* d. (above) x g. (above) x 485 for Methanol or Environol, 500 for water*Heat of Extraction (Heating Mode) = btu/hrHeat of Rejection (Cooling Mode) = btu/hrCompare results to Capacity Data Tables

Note: Steps 5 through 8 need only be completed if a problem is suspected

5. WATTSCOOLING HEATING HYDRONIC

Volts: m._____ VOLTS m.______ VOLTS m. ______ VOLTSTotal Amps (Comp. + Fan): n. _____ AMPS n. ______ AMPS n. ______ AMPSWatts = m. x n. x 0.85 o. _____ WATTS o. ______ WATTS o. ______ WATTS

6. CAPACITYCooling Capacity = HR. - (o. x 3.413) p. _____ btu/hrHeating Capacity= HE. + (o. x 3.413) p. _____ btu/hr

7. EFFICIENCYCooling EER = p. / o. q. _____ EERHeating COP = p. / (o. x 3.413) q. _____ COP

8. SUPERHEAT (S.H.) / SUBCOOLING (S.C.) COOLING HEATING HYDRONICSuction Pressure: r. ______ PSI r. ______ PSI r. ______ PSISuction Saturation Temperature: s. ______ °F s. ______ °F s. ______ °FSuction Line Temperature: t. ______ °F t. ______ °F t. ______ °FSuperheat = t. - s. u. _____ °F u. ______ °F u. ______ °F

Head Pressure: v. ______ PSI v. ______ PSI v. ______ PSIHigh Pressure Saturation Temp.: w. _____ °F w. _____ °F w. _____ °FLiquid Line Temperature*: x. ______ °F x. ______ °F x. ______ °FSubcooling = w. - x. y. ______ °F y. ______ °F y. ______ °F

* Note: Liquid line is between the source heat exchanger and the expansion valve in the cooling mode; between the load heat exchanger and the expansion valve in the heating mode.

Company Name: _________________________________Technician Name: ________________________________Model No: ______________________________________Owner’s Name: __________________________________Installation Address: ______________________________

Company Phone No: ______________________________Date: __________________________________________Serial No:_______________________________________Open or Closed Loop: _____________________________Installation Date: _________________________________

COOLING

WC Commercial Screw Chiller Troubleshooting Form

27


Chiller Start-up Report

PRELIMINARY CHECKSINSPECTION ITEM RESULT INITIALS

INSPECT UNIT FOR SHIPPING OR INSTALLATION DAMAGE OK | NG

VERIFY UNIT IS LEVEL OK | NGINSPECT WATER PIPING FOR PROPER INSTALLATION,

AND THAT PIPING IS INSULATED ADEQUATELY OK | NGINSPECT INSIDE OF UNIT FOR POSSIBLE REFRIGERANT,

OIL, OR WATER LEAKS OK | NGVERIFY MOISTURE INDICATOR (IF PRESENT) IS GREEN

(INDICATING NO MOISTURE IN SYSTEM) OK | NG

VERIFY ALL REFRIGERANT VALVES ARE OPEN OK | NGVERIFY ELECTRICAL PANELS ARE FREE OF FOREIGN MATERIALS AND ALL WIRING IS TIGHT AND SECURE OK | NG

L1-L2 VOLTAGE (V)

L1-L3 VOLTAGE (V)

L2-L3 VOLTAGE (V)

L1 TO GROUND VOLTAGE (V)VERIFY COMPRESSOR ROTATION BY BUMPING

COMPRESSOR AND VERIFYING NO ALARM WITHIN 5 SEC. OK | NGVERIFY ETHERNET CABLE W/INTERNET CONNECTION

HAS BEEN RUN TO UNIT (IF APPLICABLE) OK | NGVERIFY MS/TP COMMUNICATION WIRES HAVE BEEN

RUN FROM BAS TO UNIT (IF APPLICABLE) OK | NGVERIFY MS/TS COMMUNICATION WIRES HAVE BEEN

RUN BETWEEN UNITS (IF APPLICABLE) OK | NG

EVAPORATOR FLOW RATE (GPM)

CONDENSER FLOW RATE (GPM)

EVAPORATOR (LOAD) FLOW RATE

CONDENSER (SOURCE) FLOW RATE

28


Chiller Start-up Report cont.

PRELIMINARY CHECKS CONT.INSPECTION ITEM RESULT INITIALS

SOURCE FLOW RATE (GPM)

EVAPORATOR PRESSURE DROP (PSI)

CONDENSER PRESSURE DROP (PSI)

SOURCE PRESSURE DROP (PSI)EVAPORATOR (LOAD) SIDE ANTIFREEZE

CONCENTRATION % / TYPE

CONDENSER (LOAD) SIDE ANTIFREEZE CONCENTRATION % / TYPE

SOURCE (LOAD) SIDE ANTIFREEZE CONCENTRATION % / TYPE

APPROVAL OF ANTIFREEZE CONCENTRATION TO ADJUST FREEZE PROTECTION AND SET POINT SETTINGS

ADJUST LOW SAT SETTINGS BASED ON TABLE BELOW (˚F)

GEO FLOW RATE

GEO PRESSURE DROP

CONDENSER (SOURCE) SIDE ANTIFREEZE CONCENTRATION

GEO SIDE ANTIFREEZE CONCENTRATION

EVAPORATOR (LOAD) PRESSURE DROP

CONDENSER (SOURCE) PRESSURE DROP

29



CONTROLS CHECKSINSPECTION ITEM RESULT INITIALS

POWER ON INTERFACE AND ENSURE ALL PAGES AND DATA IS READING NORMALLY OK | NG

VERIFY USER MANAGEMENT IS SETUP PROPERLY (ENHANCED CONTROLS ONLY) OK | NG

VERIFY WATER TEMPERATURES CLOSELY MATCH REFRIGERANT SAT. TEMPERATURES OK | NG

VERIFY COMPRESSOR AND UNIT SETTINGS ARE CORRECT (SEE SHEET BELOW) OK | NG

COMPUTER STATIC IP ADDRESS (IF APPLICABLE) (FACTORY: 10.1.20.50)

VERIFY BAS IS COMMUNICATING WITH UNIT PROPERLY OK | NGVERIFY REMOTE ACCESS WORKS PROPERLY

(IF APPLICABLE) OK | NG

Notes:

COMPUTER STATIC IP ADDRESS (IF APPLICABLE) (FACTORY: 10.1.7.49)

VERIFY DDC IS COMMUNICATING WITH UNIT PROPERLY

30



RUN CHECKSINSPECTION ITEM RESULT INITIALS

VERIFY COMPRESSOR OIL LEVEL OK | NG

MODE (˚F)

ENTERING HOT WATER TEMP (˚F)

LEAVING HOT WATER TEMP (˚F)

ENTERING COLD WATER TEMP (˚F)

LEAVING COLD WATER TEMP (˚F)

COMPRESSOR 1 CAPACITY (%)

COMPRESSOR AMPERAGE (A)







SUBCOOLING ON ALL CIRCUITS BETWEEN 4˚F-15˚F OK | NG

SUPERHEAT ON ALL CIRCUITS BETWEEN 7˚F-19˚F OK | NG

SUCTION SAT

SUCTION SAT

DISCHARGE SAT

DISCHARGE SAT

(˚F)

(˚F)

(˚F)

(˚F)

COMPRESSOR 2 CAPACITY

31


Pages: Description: Date: By:

All Document Creation July 2019 MA

Revision Guide

©2019 WaterFurnace International, Inc., 9000 Conservation Way, Fort Wayne, IN 46809-9794. WaterFurnace has a policy of continual product research and development and

reserves the right to change design and specifi cations without notice.

Product: WC Series VS Dual Screw Chiller

Type: Water Cooled Chiller - 60 Hz

Size: 175-300 Tons

Document: Installation ManualIM1903WW 07/19

*IM1903WW*

Manufactured by

WaterFurnace International, Inc.

9000 Conservation Way

Fort Wayne, IN 46809

www.waterfurnace.com

Date post:	15-Feb-2022
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