WaterFurnace CLW Chiller User Manual

CLW Quad Series 60 to 140 Tons

Commercial Chiller - 60 Hz

Installation Information

Water Piping Connections

Electrical Data

Microprocessor Control

Startup Procedures

Preventive Maintenance

CLW Quad Series Chiller Installation Manual

IM1900WW 11/13

Table of Contents

Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

Physical Data

Field Connected Water Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

System Cleaning and Flushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13

Field Wiring and Control Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Control Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-16

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Reference Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Unit Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Heat of Extraction/Rejection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Heating and Cooling Cycle Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Startup and Troubleshooting Form. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Revision Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

CLW

1-3 4 5-7 8 9 10

11 12 13

C 060 V Q 4 S S 1 1N

14-15SD15-16

Model Nomenclature

Model Type

CLW – Quad R-410A Series

Operation

C – Chiller
R – Heat Recovery
H – Heat Pump

Unit Capacity (Tons)

060, 080, 100, 120, 140

Compressor Series

V – Standard Series

Compressor Quantity

Q – Quad

Voltage

2 – 208-230/60/3
3 – 380/60/3
4 – 460/60/3
5 – 575/60/3

Chassis

S – Standard

Water

SD – Standard
NC – Non-Modular with Isolation Valves
NH – Non-Modular with Isolation Valves
and Head Pressure Control

Refrigeration

0N – EEV Optimized
1N – TEV
0H – EEV with Hot Gas Bypass
1H – TEV with Hot Gas Bypass

Electrical

0 – No Disconnect
1 – Non-Fused Disconnect
3 – Breaker
4 – Separate 120VAC Connection

Controls

S – Standard
N – No Local Interface
P – Primary
E – Enhanced Interface
W – Local Workstation Present

Rev.: 23 July 2013D

4

General Installation Information

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

Safety Considerations

Installing 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 other
safety precautions that may apply.

Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloth for brazing operations. Have
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.

Application

Units 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 Storage

Move 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.

WARNING: 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 Location

Provide 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.

Unpacking the Unit

Remove the stretch warp and protective cardboard from
the unit. Where applicable, remove any additional crating or
bracketing and discard.

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.

5

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

Physical Dimensions With Enclosure

Electrical
Connection

B

High Voltage
Elec Panel

CWR

(Inlet)

17.00

12.00

CWS

(Outlet)

Dimensional Data and Physical Data

A

Length

060

080

100

120

140

Model

in. 96 36 76 2976 22

cm. 243.8 91.4 193.0 1349.9 10.0

in. 96 36 76 3174 24

cm. 243.8 91.4 193.0 1439.7 10.9

in. 96 36 76 3352 24

cm. 243.8 91.4 193.0 1520.4 10.9

in. 100 36 76 3540 26

cm. 254.0 91.4 193.0 1605.7 11.8

in. 100 36 76 3642 28

cm. 254.0 91.4 193.0 1652.0 12.7

All dimensions in inches, [mm]
All water connections are 4 in. Victaulic

?

A

B

Width

C

Height

Low Voltage
Elec Panel

HWS

(Outlet)

4'' Victaulic

(standard)

HWR

(Inlet)

Weight

lbs [kg]

C

Charge

(per Circuit)

lbs [kg]

6

Field Connected Water Piping

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

General

System piping should be kept as simple as possible to
minimize the pressure drop, but hand valves should be field
installed to facilitate unit servicing. The piping installation
should provide service personnel with the ability to measure
and/or monitor water temperatures and pressures.

Source and load fluid connections are provided with 4-inch
[10.2cm] Victaulic grooved nipples. Each nipple will also
have a PT port installed for test and balance purposes.
It will be the installing contractor’s responsibility to
adequately support incoming piping to avoid damage to the
unit’s piping or heat exchangers. The water lines should be
routed so as not to interfere with access to the unit.

For any installation where the transmission of vibration
through the piping connections could cause unacceptable
noise levels in occupied spaces it is important to provide
adequate vibration damping. One method is to use the
optional Adapter Hose Kit (kit number TKC16S-4). This Kit
consists of four pieces of a braided stainless steel flexible
hose with a 4” Victaulic connection on one end and a 4”
MPT connection with pipe union on the other. Overall length
of each piece is 18”.

NOTE: Units are factory run-tested using propylene
glycol. Prior to connecting piping to unit, thoroughly flush
heat exchangers.

7

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

Field Connected Water Piping cont.

Before final connection to the unit, the supply and return
hose kits must be connected to each other, bypassing
the unit, and the system flushed to remove dirt, piping
chips and other foreign material. Normally, a combination
balancing and close-off (ball) valve is installed at the return,
and a rated gate or ball valve is installed at the supply. The
return valve can be adjusted to obtain the proper water
flow. The valves allow the unit to be removed for servicing.

The proper water flow must be delivered to each unit
whenever the unit heats or cools. The proper flow rate
cannot be accurately set without measuring the water
pressure drop through the refrigerant-to-water heat
exchanger. A 3 GPM flow rate per ton [0.054 LPS per kW]

of cooling capacity (2.25 GPM per ton [0.0404 LPS per
kW] minimum) is required.

NOTE: The placement and connection of the water

circulating pump(s) must be taken into consideration prior
to designing the final water piping systems.

Closed Loop Tower/Boiler Systems

The water loop is usually maintained between 60°F [15.5°C]
and 90°F [32.2°C] for proper heating and cooling operation.
This is accomplished with a cooling tower and a boiler.

Earth Coupled Systems

All supply and return water piping should be insulated to
prevent excess condensation from forming on the water
lines. Ensure pumping system is capable of providing
adequate flow rate at the system pressure drop, 3.0 GPM
per ton [0.054 LPS per kW] (source side) is recommended.
Antifreeze in the loop is strongly recommended.

To reject excess heat from the condenser water loop, the
use of a closed-circuit evaporative cooler or an open type
cooling tower with a secondary heat exchanger between
the tower and the condenser water loop is recommended.
If an open type cooling tower is used without a secondary
heat exchanger, continuous chemical treatment and filtering
of the water must be performed to ensure the water is free
from damaging materials.

CAUTION: Water piping exposed to outside
temperature may be subject to freezing.

Open Loop Well Water Systems

Installation of an open loop system is not recommended
without using a secondary heat exchanger unless water
quality guidelines are met.

8

Water Quality

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

General

Commercial 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.

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 qualified
water treatment specialist should be engaged to determine
what treatment, if any, is required. The product warranty
specifically 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 confirm it does not have a detrimental effect
on the materials in the system.

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.

Strainers

These units must have properly sized strainers upstream of
both brazed plate heat exchangers to protect them against
particles in the fluid. 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.

Field supplied strainers with 20-40 mesh (530-1060 microns)
are recommended, with 30 mesh (800 microns) being the
optimum choice. The strainers selected should have a mesh
open area of at least 6 square inches (39 square centimeters)
for each unit being serviced by the strainer. Using strainers
with a smaller amount of open area will result in the need for
more frequent cleaning.

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 flow rate
of the units; low enough to be within the pumping capacity of
the pump being used.

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

Water Quality Guidelines

Material Copper 90/10 Cupronickel 316 Stainless Steel

pH Acidity/Alkalinity

Scaling

Corrosion

Iron Fouling

(Biological Growth)

Erosion

NOTES: Grains = ppm divided by 17

mg/L is equivalent to ppm

Calcium and

Magnesium Carbonate

Hydrogen Sulfide

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, FE

Bacterial Iron Potential

Iron Oxide

Suspended Solids

Threshold Velocity

(Fresh Water)

Less than 0.5 ppm (rotten egg

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

2

+ (Ferrous)

smell appears at 0.5 ppm)

Less than 1 ppm, above this

level deposition will occur

Less than 10 ppm and filtered

for max. of 600 micron size

7 - 9 7 - 9 7 - 9

(Total Hardness)

less than 350 ppm

< 0.2 ppm < 0.2 ppm < 0.2 ppm

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

(Total Hardness)

less than 350 ppm

10 - 50 ppm Less than 1 ppm

Less than 1 ppm, above this

level deposition will occur

Less than 10 ppm and filtered

for max. of 600 micron size

(Total Hardness)

less than 350 ppm

Less than 1 ppm, above this

level deposition will occur

Less than 10 ppm and filtered

for max. of 600 micron size

9

2/22/12

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

System Cleaning and Flushing

Cleaning and Flushing

Prior to start up of any heat pump, the water circulating
system must be cleaned and flushed of all dirt and debris.

If the system is equipped with water shutoff valves, the
supply and return runouts must be connected together
at each unit location (This will prevent the introduction of
dirt into the unit, see Flushing with Water Shutoff Valve
Equipped Systems illustration). The system should be filled
at the water make-up connection with all air vents open.
After filling, vents should be closed.

Flushing with Water Shutoff Valve Equipped Systems

Return Runout

Supply Runout

Mains

Rubber Hose

Runouts Initially
Connected Together

The contractor should start the main circulator with the
pressure reducing valve makeup open. Vents should be
checked in sequence to bleed off any trapped air and to
verify circulation through all components of the system.

As water circulates through the system, the contractor
should check and repair any leaks found in the piping
system. Drain(s) at the lowest point(s) in the system should
be opened for initial flush and blowdown, making sure
water fill valves are set at the same rate. Check the pressure
gauge at the pump suction and manually adjust the make­up water valve to hold the same positive pressure both
before and after opening the drain valves. Flushing should
continue for at least two hours, or longer if required, until
drain water is clean and clear.

The supplemental heater and/or circulator pump, if used,
should be shut off. All drains and vents should be opened
to completely drain the system. Short-circuited supply and
return runouts should now be connected to the unit supply
and return connections.

Refill the system with clean water. Test the system water
for acidity and treat as required to leave the water slightly
alkaline (pH 7.5 to 8.5). The specified percentage of
antifreeze may also be added at this time. Use commercial
grade antifreeze designed for HVAC systems only.
Environol™ brand antifreeze is recommended.

Once the system has been filled with clean water and
antifreeze (if used), precautions should be taken to protect
the system from dirty water conditions. Dirty water will
result in system-wide degradation of performance, and
solids may clog valves, strainers, flow regulators, etc.
Additionally, the heat exchanger may become clogged
which reduces compressor service life and can cause
premature unit failure.

In boiler/tower application, set the loop control panel
set points to desired temperatures. Supply power to all
motors and start the circulating pumps. After full flow has
been established through all components including the
heat rejector (regardless of season), air vented and loop
temperatures stabilized, each of the units will be ready for
check, test and start up and for air and water balancing.

Ground Source Loop System Checkout

Once piping is completed between the unit pumping
system and ground loop, final purging and charging of
the loop is needed. A high pressure pump is needed to
achieve adequate flow velocity in the loop to purge air
and dirt particles from the loop itself. Antifreeze solution
is used in most areas to prevent freezing. Flush the
system adequately to remove as much air as possible;
then pressurize the loop to a static pressure of 40-50
PSI (summer) or 50-75 PSI (winter). This is normally
adequate for good system operation. Loop static pressure
may decrease soon after initial installation, due to pipe
expansion and loop temperature change. Running the
unit for at least 30 minutes after the system has been
completely purged of air will allow for the “break-in”
period. It may be necessary to adjust static loop pressure
(by adding water) after the unit has run for the first time.
Loop static pressure will also fluctuate with the seasons.
Pressures will be higher in the winter months than during
the cooling season. This fluctuation is normal and should be
considered when charging the system initially.

Ensure the pump provides adequate flow through the unit
by checking pressure drop across the heat exchanger.
Usually 2.25-3.0 GPM of flow per ton of cooling capacity is
recommended in earth loop applications.

10

Electrical Data

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

Model

060

080

100

120

140

Notes:

1. Where RLA1 is equal to the largest compressor in the system and the others RLA's are all subsequent
motors present in the system.

2. Total unit MCA shall not exceed 500A or a second connection will be required.

Rated

Voltage

208-230/60/3 187/253

460/60/3 414/506 43.0 27.6 35.0 117.3 144.9

575/60/3 517/633 34.4 22.0 28.0 93.5 115.5

208-230/60/3 187/253

460/60/3 414/506 54.1 34.7 48.8 147.5 182.2

575/60/3 517/633 43.3 27.8 39.1 118.2 146.0

208-230/60/3 187/253

460/60/3 414/506 63.5 40.7 53.2 173.0 213.7

575/60/3 517/633 50.8 32.6 42.6 138.6 171.2

208-230/60/3 187/253

460/60/3 414/506 82.8 53.1 65.6 225.7 278.8

575/60/3 517/633 66.3 42.5 52.5 180.6 223.1

208-230/60/3 187/253

460/60/3 414/506 80.2 51.4 75.0 218.5 269.9

575/60/3 517/633 64.2 41.1 60.0 174.7 215.8

Voltage

Min/Max

HP

15

20

25

30

35

MCC RLA1 MOA MCA HP MOCP

89.9 57.6 77.3 244.8

110.7 70.9 108.0 301.3

132.8 85.1 117.7 361.7

165.6 106.2 145.1 451.4

160.4 102.8 165.8 436.9

Compressor Unit

302.4

60

372.2

80

446.8

100

557.6

120

539.7

140

11/05/13

MCA (Maximum Current Rating) is a calculation based off the RLA of the compressor on the electrical connection
and is used to properly size the wire. Please refer to NEC for additional information.

MOCP (Maximum Over Current Protection) is a calculation based off the RLA of the compressor on the electrical
connection and is used to fuses and breakers. Please refer to NEC for additional information.

11

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

WIRE LEGEND

(TB-P7): 120VAC Power (Comp 3&4)

(TB-P12): 24 VAC Power (Circuit 1 & 2)

(TB-P5): 120 VAC switch power

(TB-P11): 24 VAC switch power

(TB-P16):24VDC switch power

(TB-P13): 24 VAC Power (Circuit 3 & 4)

(TB-P8): 120 VAC Neutral (Comp 1&2)

(TB-P9): 120VAC Neutral (Comp 3&4)

(TB-P14): 24 VAC Neutral (Circuit 1 & 2)

(TB-P15): 24 VAC Neutral (Circuit 3 & 4)

(TB-P17): 24 VDC Power (Circuit 1 & 2)

(TB-P20): 24 VDC Neutral (Circuit 3 & 4)

(TB-P10): 120VAC Ground

(TB-P2): 120 VAC Power (Outlets & Heaters)

(TB-P1): 120 VAC switch power

(TB-P3): 120 VAC Neutral (Outlets & Heaters)

(TB-P4): 120 VAC Ground

(Outlets)

(

TB

-

P

6

)

(TB-P6): 120 VAC Power (Comp 1&2)

(TB-P19): 24 VDC Neutral (Circuit 1 & 2)

(Outlets)

(TB-P2)

(RIB-2.1 & Outlets)

(

R

-

3

.

13

,

TB-

B

22

)

(

RIB-

7

.1

)

(

RIB

-

1

.

1

)

INPUT/OUTPUT SIGNAL

INPUT/OUTPUT COMMON

120VAC, 24VAC

120VAC (+)/ 24VDC (-)

GROUND

24VAC &24VDC (+)

BLACK
WHITE

GREEN

RED

BLUE

GRAY

(

R

-

9

.

13

,

TB

-

Y

22

)

(

KMC

-

U

1

,

2

,

3

)

(

K

MC

-

U

4

,

5

,

6

&

TB-

O

1

9

)

(

KMC

-

U

1

,

2

,3

)

(KMC

-

U

4

,

5,

6

& TB

-

B

20

)

(

U2

-

C

-

5

,

U

3

-

C

-

5

)

(U5

-C

-

5,

U6-

C

-5

)

(

TB

-

O

4

)

ETHERNET WIRE

(TB-P18): 24 VDC Power (Circuit 3 & 4)

10A

10A

5A

1A

120 VAC POWER 24 VAC POWER 24 VDC POWER COMPRESSOR 2 SENSORSWATER TEMP SENSORS & CONTROL VALVES

(

120

VAC

Transformer

)

(24 VACTransformer)

(24 VDCTransformer)

(120 VAC

Transformer)

120VAC 15A Duplex

Receptacle

(

T

B

-

G

4

)

COMPRESSOR 1 SENSORS

(

TB

-

P12

)

(

TB

-

P

1

7

)

LOW VOLTAGE PANEL LAYOUT

UNIT TYPE:
UNIT MODEL:
SERIAL NUMBER:

Touch Screen IP: ________________________ (Assigned)
Master Controller IP: _____________________ (Assigned)
Chipkin Field Server IP:___________________ (Assigned)

START-UP DATE:
START-UP TECHNICIAN:

CHILLIT CHILLERS LLC PH: [phone]

Rev: E 08/01/13 CPM

© CHILLIT CHILLERS 2013

(TB-B19):Isolation Valves (24VAC)

(TB-B20):Isolation Valve (common)

(TB-B10) +24 VAC

(

T

B

-

B11

, U

1

-

G

-

16

)

(TB-B1): Evaporator Inlet C1&C2

(TB-B2): Common TBG1 & 3

(TB-B3): Evaporator Outlet Temp C1&C2

(U1-IN1-1)

(U1-C-2)

(U1-IN2-3)

(TB-B9): Evaporator Outlet Temp C3&C4

(TB-B8): Common TBG8&10

(TB-B21):C1&2 Isolation Valves Signal

(TB-B22): C3&4 Isolation Valve Signal

(TB-B18): Condenser Header Outlet Temp

(TB-B17): Common TBG20

(TB-O1): C1-Condenser Liquid Temp

(TB-O2): Common TBG1 & 3

(TB-O3): C1-Evaporator Gas Temp

(TB-O4): C1-Discharge Pressure

(TB-O5): C1-Discharge Pressure

(TB-O10): C1- Motor Protect Alarm

(TB-O12): C1-High Pressure Alarm

(TB-O13): C1-Low Pressure ALarm

(TB-O6): C1-Suction Pressure

(TB-O8): C1-Current Transducer

(TB-O9): C1-Current Transducer

(TB-O7): C1-Suction Pressure

(R-1.14)

(R-3.14)

(R-4.14)

(U2-IN1-1)

(U2-IN2-3)

(U1-IN3-4)

(U2-IN4-6)

(TB-P17) +24vDc

(TB-O4) +24vDc

(TB-Y1): C2-Condenser Liquid Temp

(TB-Y2): Common TBG1 & 3

(TB-Y3): C2-Evaporator Gas Temp

(TB-Y4): C2-Discharge Pressure

(TB-Y5): C2-Discharge Pressure

(TB-Y10): C2-Motor Protect

(TB-Y12): C2-High Pressure Alarm

(TB-Y13): C2-Low Pressure Alarm

(TB-Y6): C2-Suction Pressure

(TB-Y8): C2-Current Transducer

(TB-Y9): C2-Current Transducer

(TB-Y7): C2-Suction Pressure

(R-5.14)

(R-7.14)

(R-8.14)

(U3-IN1-1)

(U3-C-2)

(U3-IN2-3)

(U3-IN3-4)

(U3-IN4-6)

(TB-O8) +24vDc

(TB-Y4) +24vDc

(U2-IN5-7)

(

TB

-

O

6

) +

24

v

Dc

(U3-IN5-7)

(TB-Y6) +24vDc

(TB-Y11): C2-Thermal Overload Alarm

(TB-O11): C1- Thermal Overload Alarm

(R-2.14)

(R-6.14)

COMPRESSOR 4 SENSORSCOMPRESSOR 3 SENSORS

(TB-G1): C3-Condenser Liquid Temp

(TB-G2): Common TBG1 & 3

(TB-G3): C3-Evaporator Gas Temp

(TB-G4): C3-Discharge Pressure

(TB-G3): C3-Discharge Pressure

(TB-G10): C3- Motor Protect Alarm

(TB-G12): C3-High Pressure Alarm

(TB-G13): C3-Low Pressure ALarm

(TB-G6): C3-Suction Pressure

(TB-G8): C3-Current Transducer

(TB-G9): C3-Current Transducer

(TB-G7): C3-Suction Pressure

(R-9.14)

(R-11.14)

(R-12.14)

(U5-IN1-1)

(U5-C-2)

(U5-IN2-3)

(U5-IN3-4)

(U5-IN4-6)

(TB-P18) +24vDc

(TB-G4) +24vDc

(TB-N1): C4-Condenser Liquid Temp

(TB-N2): Common TBG1 & 3

(TB-N3): C4-Evaporator Gas Temp

(TB-N4): C4-Discharge Pressure

(TB-N5): C4-Discharge Pressure

(TB-N10): C4-Motor Protect

(TB-N12): C4-High Pressure Alarm

(TB-N13): C4-Low Pressure Alarm

(TB-N6): C4-Suction Pressure

(TB-N8): C4-Current Transducer

(TB-N9): C4-Current Transducer

(TB-N7): C4-Suction Pressure

(R-13.14)

(R-15.14)

(R-16.14)

(U6-IN1-1)

(U6-C-2)

(U6-IN2-3)

(U6-IN3-4)

(U6-IN4-6)

(TB-G8) +24vDc

(TB-N4) +24vDc

(U5-IN5-7)

(

TB

-

G6

)

+24

v

Dc

(U6-IN5-7)

(TB-N6) +24vDc

(TB-N11): C4-Thermal Overload Alarm

(TB-G11): C3- Thermal Overload Alarm

(R-10.14)

(R-14.14)

(TB-Z1): Enable Compressor 1

(TB-Z3): 120 VAC Neutral

(TB-Z5): Enable Compressor 2

(RIB-1.2)

(RIB-2.2)

(TB-Z2): Enable Heat Comp1

(TB-Z6): 120 VAC Neutral

(TB-Z7): Enable Heat Comp2

(RIB-3.2)

(RIB-4.2)

(TB-Z4): Reset Compressor 1

(TB-Z9): 120 VAC Neutral

(TB-Z8): Reset Compressor 2

(RIB-5.2)

(RIB-6.2)

(TB-P9)

(TB-Z3)

(TB-Z6)

(TB-Z19): Ground

(TB-Z10): Enable Compressor 3

(TB-Z12): 120 VAC Neutral

(TB-Z14): Enable Compressor 4

(TB-Z11): Enable Heat Comp3

(TB-Z15): 120 VAC Neutral

(TB-Z16): Enable Heat Comp4

(TB-Z13): Reset Compressor 3

(TB-Z18): 120 VAC Neutral

(TB-Z17): Reset Compressor 4

ENABLE COMPRESSORS & RESET

RIB-2

Heater C1

RIB-5

Heater C2

RIB-3

Reset C1

RIB-6

Reset C2

(TB-P2_120V+)

(RIB-2.1_120V+)

(TB-Z8)

(TB-Z4)

(TB-Z7)

(TB-Z2)

RIB-1

Enable C1

RIB-4

Enable C2

(

TB

-

P

6

)

(TB-Z5)

(TB-Z1)

(RIB-4.1_120V+)

(RIB-1.1_120V+)

(RIB-3.1_120V+)

(U2-G-4 & RIB-2.5)

(U2-OUT1-1)

(U3-G-4)

(U3-OUT1-1)

(RIB-1.5)

(U2-OUT2-3)

(U3-G-4)

(

U

3

-

OUT

2

-

3

)

(

U

2

-

G

-

8

)

(

U

2-

O

U

T

4-

7

)

(U3-G-8)

(U3-OUT4-7)

RIB-8

Heater C3

RIB-11

Heater C4

RIB-9

Reset C3

RIB-12

Reset C4

(R

I

B-5

.

1

_

1

2

0

V

+)

(RIB-8.1_120V+)

(TB-Z8)

(TB-Z4)

(TB-Z7)

(TB-Z2)

RIB-7

Enable C3

RIB-10

Enable C4

(TB-P7)

(TB-Z5)

(TB-Z1)

(RIB-10.1_120V+)

(RIB-7.1_120V+)

(

R

I

B

-

9

.

1_

120

V

+

)

(U5-G-4)

(U5-OUT1-1)

(U6-G-4)

(U6-OUT1-1)

(U5-G-4)

(U5-OUT2-3)

(U6-G-4)

(U6-OUT2-3)

(U5-G-8)

(U5-OUT4-7)

(U6-G-8)

(U6-OUT4-7)

1

(TB-Y10)

(R-4.13)

(TB-Y12)

(R-6.13)

(TB-Y13)

(R-7.13)

R-5

[120VAC]

Comp-2

MotorProtect

Alarm

R-7

[120VAC]

Comp-2

HighPressure

Alarm

R-8

[120VAC]

Comp-2

LowPressure

Alarm

(TB-O10)

(TB-P11)

(TB-O12)

(R-2.13)

(U2-IN6-9)

(U2-IN7-10)

(TB-O13)

(R-3.13)

(U2-IN8-12)

5(NO)

13(-)

9

1(NC)

14(+)

R-1

[120VAC]

Comp-1

MotorProtect

Alarm

R-3

[120VAC]

Comp-1

HighPressure

Alarm

R-4

[120VAC]

Comp-1

LowPressure

Alarm

(U2-C-11)

(R-2.5)

(R-3.5)

(U3-IN6-9)

(U3-IN7-10)

(U3-IN8-12)

(U3-C-11)

(R-6.5)

(R-7.5)

R-6

[120VAC]

Comp-2

Thermal

Overload

Alarm

(TB-O11)

(R-1.13)

(U2-IN6-9)

R-2

[120VAC]

Comp-1

Thermal

Overload

Alarm

(R-1.5)

(TB-Y11)

(R-5.13)

(U3-IN6-9)

(TB-B1)

(TB-B2)

(eSC-1)
(eSC-3)

(eSC-2)

(TB-B3)

(TB-B4)

(TB-B5)

(TB-B6)

(TB-B13)

(TB-B14)

NOTE: Pressuresensors &CT’s require resistors and DIP switches

(TB-P14)

(TB-P12)

(TB-P19)

(U1-IN1-1)

(U1-C-2)

(U1-IN2-3)

(U1-IN3-4)

(U1-C-5)

(U1-IN4-6)

(U1-IN5-7)

(U1-C-8)

(U1-IN6-9)

(U1-IN7-10)

(U1-C-11)

(U1-IN8-12)

Evap Inlet (Return) Temp C1 C2

Common IN1 & IN2

Evap Outlet (Supply) Temp C1 C2

Cond Inlet (Return) Temp C1 C2

Common IN3 & IN4

Cond Outlet (Supply) Temp C1 C2

Evap/Cond Flow Switch C1 C2

Common IN5 & IN6

[A]

[A]

Common IN7 & IN8

[A]

Input ID

U1 -A
U1 +B
U1 ϛ

U1 24Vac c
U1 24Vac ­U1 24Vac +

[A]

[A]

Common Out1 & Out2

[A]

[A]

Common Out3 & Out4

Output ID

[A]

Evap/Cond Iso 2-Way C1 C2

Common Out5 & Out6

[A]

[A]

U1-OUT1-1

U1-OUT2-3

U1-G-4

U1-OUT3-5

U1-OUT4-7

U1-G-8

U1-OUT5-9

U1-OUT6-11

U1-G-12

U1-OUT7-13

U1-OUT8-15

Common Out5 & Out6

U1-G-16

U1 – MASTER TEMPS C1 & C2

(U2-IN1-1)

(U2-C-2)

(U2-IN2-3)

(U2-IN3-4)

(U2-C-5)

(U2-IN4-6)

C1-Condenser Liquid Temp

Common IN1 & IN2

C1-Evaporator Gas Temp

C1- Discharge Pressure

Common IN3 & IN4

Input ID

C1-Suction Pressure

(U2-IN5-7)

(U2-C-8)

(U2-IN6-9)

(U2-IN7-10)

(U2-C-11)

(U2-IN8-12)

C1-Current Transducer (CT)

Common IN5 & IN6

C1-Motor+ Thermal Alarm

C1-High Pressure Alarm

Common IN7 & IN8

C1- Low Pressure Alarm

C1 – Enable Compressor

C1 – Crank Heater

Common Out1 & Out2

Not Used

C1 – Momentary Reset

Common Out3 & Out4

Output ID

Not Used

Not Used

Common Out5 & Out6

Not Used

Not Used

U2-OUT1-1

U2-OUT2-3

U2-G-4

U2-OUT3-5

U2-OUT4-7

U2-G-8

U2-OUT5-9

U2-OUT6-11

U2-G-12

U2-OUT7-13

U2-OUT8-15

Common Out5 & Out6

U2-G-16

U2 - COMPRESSOR 1

(

T

B

-

P

14

)

(

T

B

-

P1

2

)

(TB-Z19)

U2 24Vac c
U2 24Vac ­U2 24Vac +

(

U1

+

B

)

(

U

1

ϛ

)

(

U

1

-

A

)

U2 -A
U2 +B
U2 ϛ

(U3-IN1-1)

(U3-C-2)

(U3-IN2-3)

(U3-IN3-4)

(U3-C-5)

(U3-IN4-6)

C2-Condenser Liquid Temp

Common IN1 & IN2

C2-Evaporator Gas Temp

C2-Discharge Pressure

Common IN3 & IN4

Input ID

C2-Suction Pressure

(U3-IN5-7)

(U3-C-8)

(U3-IN6-9)

(U3-IN7-10)

(U3-C-11)

(U3-IN8-12)

C2-Current Transducer (CT)

Common IN5 & IN6

C2- Motor + Thermal Alarm

C2-High Pressure Alarm

Common IN7 & IN8

C2-Low Pressure Alarm

C2 – Enable Compressor

C2- Crank Heater

Common Out1 & Out2

Not Used

C2 – Momentary Reset

Common Out3 & Out4

Output ID

Not Used

Not Used

Common Out5 & Out6

Not Used

Not Used

U3-OUT1-1

U3-OUT2-3

U3-G-4

U3-OUT3-5

U3-OUT4-7

U3-G-8

U3-OUT5-9

U3-OUT6-11

U3-G-12

U3-OUT7-13

U3-OUT8-15

Common Out5 & Out6

U3-G-16

U3 - COMPRESSOR 2

(

T

B

-

P

1

4

)

(

T

B

-

P

1

2

)

(

T

B

-

Z

1

9

)

U3 24Vac c
U3 24Vac ­U3 24Vac +

U3 -A
U3 +B
U3 ϛ

250Ω
250Ω

250Ω

250Ω
250Ω

250Ω

(

U

2

+

B

)

(

U

2

ϛ

)

(

U

2

-

A

)

NOTE: Pressuresensors &CT’s require resistors and DIP switches

(U4-IN1-1)

(U4-C-2)

(U4-IN2-3)

(U4-IN3-4)

(U4-C-5)

(U4-IN4-6)

(U4-IN5-7)

(U4-C-8)

(U4-IN6-9)

(U4-IN7-10)

(U4-C-11)

(U4-IN8-12)

Evap Inlet (Return) Temp C3 C4

Common IN1 & IN2

EvapOutlet (Supply)TempC3 C4
CondInlet (Return)Temp C3C4

Common IN3 & IN4

CondOutlet (Supply)Temp C3C4

Evap/Cond Flow Switch C3 C4

Common IN5 & IN6

[A]

Evap Header Outlet Temp

Common IN7 & IN8

Cond Header Outlet Temp

Input ID

U4 -A
U4 +B
U4 ϛ

U4 24Vac c
U4 24Vac ­U4 24Vac +

[A]

[A]

Common Out1 & Out2

[A]

[A]

Common Out3 & Out4

Output ID

[A]

Evaporator Iso 2-Way C3 C4

Common Out5 & Out6

Condenser Iso 2-way C3 C4

[A]

U4-OUT1-1

U4-OUT2-3

U4-G-4

U1-2-OUT3-5

U4-OUT4-7

U4-G-8

U4-OUT5-9

U4-OUT6-11

U4-G-12

U4-OUT7-13

U4-OUT8-15

Common Out5 & Out6

U4-G-16

U4 – MASTER TEMPS C3 & C4

(U5-IN1-1)

(U5-C-2)

(U5-IN2-3)

(U5-IN3-4)

(U5-C-5)

(U5-IN4-6)

C3-Condenser Liquid Temp

Common IN1 & IN2

C3-Evaporator Gas Temp

C3- Discharge Pressure

Common IN3 & IN4

Input ID

C3-Suction Pressure

(U5-IN5-7)

(U5-C-8)

(U5-IN6-9)

(U5-IN7-10)

(U5-C-11)

(U5-IN8-12)

C3-Current Transducer (CT)

Common IN5 & IN6

C3-Motor+ Thermal Alarm

C3-High Pressure Alarm

Common IN7 & IN8

C3- Low Pressure Alarm

C3 – Enable Compressor

C3 – Crank Heater

Common Out1 & Out2

Not Used

C3 – Momentary Reset

Common Out3 & Out4

Output ID

Not Used

Not Used

Common Out5 & Out6

Not Used

Not Used

U5-OUT1-1

U5-OUT2-3

U5-G-4

U5-OUT3-5

U5-OUT4-7

U5-G-8

U5-OUT5-9

U5-OUT6-11

U5-G-12

U5-OUT7-13

U5-OUT8-15

Common Out5 & Out6

U5-G-16

U5 - COMPRESSOR 3

U5 24Vac c
U5 24Vac ­U5 24Vac +

U5 -A
U5 +B
U5 ϛ

(U6-IN1-1)

(U6-C-2)

(U6-IN2-3)

(U6-IN3-4)

(U6-C-5)

(U6-IN4-6)

C4-Condenser Liquid Temp

Common IN1 & IN2

C4-Evaporator Gas Temp

C4-Discharge Pressure

Common IN3 & IN4

Input ID

C4-Suction Pressure

(U6-IN5-7)

(U6-C-8)

(U6-IN6-9)

(U6-IN7-10)

(U6-C-11)

(U6-IN8-12)

C4-Current Transducer (CT)

Common IN5 & IN6

C4- Motor + Thermal Alarm

C4-High Pressure Alarm

Common IN7 & IN8

C4-Low Pressure Alarm

C4 – Enable Compressor

C4- Crank Heater

Common Out1 & Out2

Not Used

C4 – Momentary Reset

Common Out3 & Out4

Output ID

Not Used

Not Used

Common Out5 & Out6

Not Used

Not Used

U6-OUT1-1

U6-OUT2-3

U6-G-4

U6-OUT3-5

U6-OUT4-7

U6-G-8

U6-OUT5-9

U6-OUT6-11

U6-G-12

U6-OUT7-13

U6-OUT8-15

Common Out5 & Out6

U6-G-16

U6 - COMPRESSOR 4

U6 24Vac c
U6 24Vac ­U6 24Vac +

U6 -A
U6 +B
U6 ϛ

250Ω
250Ω

250Ω

250Ω
250Ω

250Ω

(TB-N10)

(R-12.13)

(TB-N12)

(R-14.13)

(TB-N13)

(R-15.13)

R-13

[120VAC]

Comp-4

MotorProtect

Alarm

R-15

[120VAC]

Comp-4

HighPressure

Alarm

R-16

[120VAC]

Comp-4

LowPressure

Alarm

(TB-G10)

(R-8.13)

(TB-G12)

(R-10

.

13

)

(U5-IN6-9)

(U5-IN7-10)

(TB-G13)

(R-11.13)

(U5-IN8-12)

R-9

[120VAC]

Comp-3

MotorProtect

Alarm

R-11

[120VAC]

Comp-3

HighPressure

Alarm

R-12

[120VAC]

Comp-3

LowPressure

Alarm

(U

5

-C-11)

(R-10.5)

(R-11.5)

(U6-IN6-9)

(U6-IN7-10)

(U6-IN8-12)

(U6-C-11)

(R-14.5)

(R-15.5)

R-14

[120VAC]

Comp-4

Thermal

Overload

Alarm

(TB-G11)

(R-9.13)

(U5-IN6-9)

R-10

[120VAC]

Comp-3

Thermal

Overload

Alarm

(R-9.5)

(TB-N11)

(R-13.13)

(U6-IN6-9)

(TB-B10): Condenser Inlet (Return) C1&C2

(TB-B4): Condenser Inlet (Return) C1&C2

(TB-B5): Common TBG4,5 & 7

(TB-B6): Cond Outlet (Supply) Temp C1&C2

(U1-IN3-1)

(U1-C-5)

(U1-IN4-6)

(TB-B7): Evaporator Inlet C3&C4

(TB-B12): Cond Outlet (Supply) Temp C1&C2

(TB-B13): Evap & Cond Flow Switch C1&C2

(TB-B15): Evap & Cond Flow Switch C3&C4

(TB-B16): Evaporator Header Outlet Temp

(TB-B14): Common TBG11,12,14,15

BB2

2

(RIB-7.2)

(RIB-8.2)

(RIB-9.2)

(RIB-10.2)

(RIB-11.2)

(RIB-12.2)

(TB-Z9)

(TB-Z12)

(TB-Z15)

(TB-B11): Common TBG11,12,14,15

(U4-IN1-1)

(U4-C-2)

(U4-IN2-3)

(U4-IN3-1)

(U4-C-5)

(U4-IN4-6)

21 21 21 21 21 21 21 21 21 21 21 2

3 4 5 3 4 5 3 4 5 3 4 5 3 4 5 3 4 5 3 4 5 3 4 5 3 4 5 3 4 5 3 4 5 3 4 5

13(-)

9

14(+) 13(-)

9

14(+) 13(-)

9

14(+) 13(-)

9

14(+) 13(-)

9

14(+) 13(-)

9

14(+) 13(-)

9

14(+) 13(-)

9

14(+) 13(-)

9

14(+) 13(-)

9

14(+) 13(-)

9

14(+) 13(-)

9

14(+) 13(-)

9

14(+) 13(-)

9

14(+) 13(-)

9

14(+)

5(NO)1(NC) 5(NO)1(NC) 5(NO)1(NC) 5(NO)1(NC) 5(NO)1(NC) 5(NO)1(NC) 5(NO)1(NC) 5(NO)1(NC) 5(NO)1(NC) 5(NO)1(NC) 5(NO)1(NC) 5(NO)1(NC) 5(NO)1(NC) 5(NO)1(NC) 5(NO)1(NC)

(R-5.1)

(R-13.5)

(TB-O1)

(TB-O2)

(TB-O3)

(TB-O5)

TB-P19(24VDC-)

(TB-O7)

(TB-O9)

(U2-C-5)

(R-1 & 2.9)

(R-4.9)

(R-1.5)

(R-3.9)

(TB-Y1)

(TB-Y2)

(TB-Y3)

(TB-Y5)

TB-P19(24VDC-)

(TB-Y7)

(TB-Y9)

(U3-C-5)

(R-5 & 6.9)

(R-8.9)

(R-5.5)

(R-7.9)

(TB-B7)

(TB-B8)

(TB-B9)

(TB-B10)

(TB-B11)

(TB-B12)

(TB-B15)

(TB-B14)

(TB-B18)

(TB-B17)

(

U

4 +

B

)

(U4 ϛ)

(

U

4 -

A

)

(

U

5

+B

)

(

U

5

ϛ

)

(

U

5

-

A

)

(TB-B16)

(TB-G1)

(TB-G2)

(TB-G3)

(TB-G5)

TB-P20(24VDC-)

(TB-G7)

(TB-G9)

(U5-C-5)

(R-9 & 10.9)

(R-12.9)

(R-9.5)

(R-11.9)

(TB-N1)

(TB-N2)

(TB-N3)

(TB-N5)

TB-P20(24VDC-)

(TB-N7)

(TB-N9)

(U6-C-5)

(R-13 & 14.9)

(R-16.9)

(R-13.5)

(R-15.9)

EOL - ON

EOL – OFF

EOL – OFF

EOL – OFF

EOL – OFF

EOL – OFF

(U1-IN5-7)

(U1-C-8 & U4-C-8)

(U4-IN5-7)

(U4-IN7-10)

(U4-C-11)

(U4-IN8-12)

(RIB-1.4)

(RIB-1.5)

(RIB-2.4)

(RIB-3.5)

(RIB-3.4)

(TB-B21)

(TB-B20)

(RIB-4.4)

(RIB-4.5)

(RIB-5.4)

(RIB-6.5)

(RIB-6.4)

(TB-P15)

(TB-P13)

(TB-Z19)

(

T

B

-

P15

)

(

T

B

-P

13

)

(TB-Z19)

(RIB-7.4)

(RIB-7.5)

(RIB-8.4)

(RIB-9.5)

(RIB-9.4)

(TB-B22)

(U1-G-16)

(RIB-10.4)

(RIB-10.5)

(RIB-11.4)

(RIB-12.5)

(RIB-12.4)

(

T

B

-

P1

5

)

(

T

B

-P

13

)

(TB-Z19)

(

U

3

+B)

(

U

3

ϛ

)

(

U

3

-

A)

(U1-OUT7-13)

(U4-OUT7-13)

Low Voltage Wiring

12

Wiring Schematics

L1
L2
L3

1

2

L

11

N1214

L1
L2
L3

F1

F1 Main Fuse
F2 Compressor Fuse
K1 Motor Contactor
T/O Thermal Overload Relay
M Compressor Motor
F3 Control Circuit Fuse
RIB1 Enable Compressor Relay (HOA)
RIB2 Enable Crank Heater (HOA)
RIB3 Fault Reset (HOA)
BO1 Binary Controller Output (Enable Compressor)
BO2 Binary Controller Output (Crank Heater)
BO4 Binary Controller Output (Fault Reset)

LEGEND

Main

Switch

F2

K1

T/O

120V AC

M

1
2
3

F3

RIB3

N/C

RIB1

N/O

BO4
COM

BO1

COM

R1 Motor Protect Alarm Monitor Relay
R2 Thermal Overload Alarm Monitor Relay
R3 High Pressure Alarm Monitor Relay
R4 Low Pressure Alarm Monitor Relay
BI6 Binary Control Input 6 (Motor Protect & Thermal Overload)
BI7 Binary Control Input 7 (High Pressure Alarm)
BI8 Binary Control Input 8 (Low Pressure Alarm)
CK HTR Crankcase Heater

Note 1: Many different power connection configurations are available, refer to specifications.

RIB2

N/O

BO2

COM

R1

BI6

COM

Dual

Pressure

Switch

Low Pressure

High Pressure

R4

BI8

COM

R3

BI7

COM

CK HTR

R2

BI6

COM

120V

-

+

SE-E1

See Note 1

See Note 1

CHILLIT CHILLERS

(CLW SCROLL SERIES BASIC WIRING DIAGRAM)

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

13

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

Field Wiring and Control Setup

Line Voltage

High Voltage Connections

Connect power wiring as shown in the line voltage wiring
schematic on page 13.

Low Voltage Operation

Thermostat/Controller (Aquastat)

A two-stage 24 VAC thermostat or liquid controller (field
supplied) must be used to turn the commercial chiller on
or off, and to switch it from cooling to heating if
necessary. Multiple chillers in the same bank must be
controlled from one thermostat/controller (must be
isolation relays for multiple unit applications).

Low Voltage Connections

Connect low voltage thermostat wiring as shown in the low
voltage wiring schematic on page 12. Connections shown
are for typical thermostat. Actual connections may vary
with specific device used.

NOTE: If a separate transformer is used to supply a Y1, Y2, or
B signal to the unit controls, isolation relays must be used.

CAUTION: Use only copper conductors for field
installed wiring. Terminals in the unit are not
designed for other types of conductors.

WARNING: All wiring must comply with local and
state codes. Disconnect the power supply before
beginning to wire to prevent electrical shock or
equipment damage.

14

Control Features

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

The CLW’s microprocessor based control not only monitors

and controls the heat pump but also can communicate any
of this information back to the building automation system

(BAS) clearly putting the CLW Quad Series in a class of

its own. The control will enumerate all fault and warning
conditions which can be read over a BAS as well as display
on a local user interface. An enhanced local interface is
invaluable as a service tool for the building service team
and is used to aid in diagnosing issues and the initial setup,
startup, and commissioning.

The Control Provides:

• Operational sequencing

• High and low-pressure safety switch monitoring

• Monitoring motor rotation, oil temperature, and motor
windings overheating

• Monitors for electrical thermal overloading

• Lockouts and mode control

▶ The unit can be commanded to run from the local

display, BAS or HOA switches (manual hand-off-auto
switch) located in the low voltage panel.

▶ An alarm history can be viewed through the local

user interface.

▶ Trending of key inputs and variables are stored in the

controller and available to viewed and graphed.

▶ The Controller has unused analog and digital inputs and

outputs for field installed items such as additional water
temperature or status switches

Standard Features

• Operational sequencing and compressor and
unit staging

• High and low-pressure safety switch monitoring

• Monitoring motor rotation, oil temperature, and

motor overheating

• Monitors for electrical thermal overloading

• Monitors for high and low saturation temperatures

• Proves Flow prior to starting

• Short cycle warnings

• Lockout and mode control

DDC Operation & Connection

The controller is a native BACnet controller. Other optional

network protocols are supported via a protocol Gateway.

• Johnson Control N2

• LonWorks

• Modbus

• And many more

Control and Safety Feature Details

User Shutdown

• The shutdown mode can be activated by a command
from a facility management system or the local user
interface. When the unit is shut down any isolation
valves are close and any compressor heaters are
powered. Additionally the shutdown can be complete
and no outputs are active.

Alarm Shutdown

• Alarm Shutdown occurs when ever an alarm condition
is present from any physical safety: refrigerant system
high pressure, refrigerant system low pressure, motor
thermal overload, motor rotation direction incorrect,
electrical thermal overload, no flow, or freeze detection.

• Alarm Shutdown occurs when ever an alarm condition
is present from any software safety: High Sat, Low
Sat, trying to start a compressor too quickly. Other
software condition can trigger an alarm shut down
like approaching or exceeding the application range
of the compressor.

• When any valid fault signal remains continuously
active for the length of its recognition delay, the
controller will go into fault retry mode, which will
turn off compressors. If the safety is auto resetting,
after the compressor delay time for that alarm, the
compressors will attempt to operate once again. If
four consecutive faults occur in 2 hours, the unit will
go into lockout mode.

Alarm Lockout Mode

• Lockout mode is activated when a physical safety
requires a manual reset or a software safety with an
auto resetting safety is configured to lockout after
a number of repeated alarms in a period of time
described above.

• The lockout condition can be reset by powering down
the controller, by a commanding the unit off from the
local display or the BAS, or by the pushing the alarm
reset button on the local display.

Refrigerant System Low Pressure

• The low-pressure switch is a normally closed (NC)
switch that monitors the systems refrigerant pressure.

• This safety requires a manual reset.

Refrigerant System High Pressure

• The high-pressure switch is a normally closed (NC)
switch that monitors the systems refrigerant pressure.

• This safety requires a manual reset.

15

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

Control Features

Motor & Oil Thermal Overload

• The motor thermal overload switch is a normally
closed (NC) switch that monitors the temperature of
the motor.

• This safety can be configured to auto reset or manual
reset (factory default).

Motor Rotation Direction

• The motor rotation direction switch is a normally
closed (NC) switch that monitors the rotation direction
of the motor.

Electrical Thermal Overload

• The electrical thermal overload switch is a normally
closed (NC) switch that monitors the electrical thermal
conditions of the wires leaving the main contactor.

• This safety can be configured to auto reset or manual
reset (factor default).

Flow Switches

• The optional flow switches are normally closed (NC)
switch that monitors the flow in the pipes into the
evaporator and condenser.

• This safety clears when flow is present.

Alarm Outputs

• The control has 18-enumerated status variable for each
compressor and the unit.

• Compressor Lockout

• Any compressor can be locked out from the local
display or using the HOA switch.

Freeze Protection

• The optional freeze protection switch is a normally
closed (NC) switch that monitors the temperature of
the water in the pipe coming out of the evaporator for
freeze conditions.

• This safety can be configured to auto reset or
manual reset.

Low Refrigerant Saturation Temperatures

• The controller monitors the refrigerant saturation
temperatures for low saturation temperatures. Without
glycol, it is recommend to set the low saturation
temperature to 34°F and consider it an alarm condition
it the saturation temperature continuously remains
below that temperature for 90 seconds.

• The compressor will not restart until the low saturation
compressor delay time delay has been satisfied.

High Refrigerant Saturation Temperatures

• The controller monitors the refrigerant saturation
temperatures for high saturation temperatures. An
alarm condition occurs if the saturation temperature
exceeds the high limit.

• The compressor will not restart until the high saturation
compressor delay time delay has been satisfied.

16

Sequence of Operation

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

Power Fail Restart

• When the controller is first powered up, the outputs will
be disabled and delay timers reset to avoid a random

start or multiple compressors staring simultaneously.

Lead Compressor Start Delay Time

• The lead compressor Fixed-On-Delay-Time that will

ensure that the lead compressor output is not enabled
for 120 seconds after the control receives a call to start
the unit and the lead compressor.

• This delay is not adjustable.

Lag Compressor Start Delay Time

• The lag compressor Fixed-On-Delay-Time will ensure

that the lead compressor output is not enabled for 5

minutes after the control receives a call to start the
lead compressor.

• This delay is adjustable from 60 – 3600 seconds over a

BAS or a local display.

Compressor Minimum On Delay

• There is no compressor minimum on time safety but in

adjusting the on off dead band for any given site no
compressor should never be enabled for less than two
(2) minutes each time the compressor output is enabled.

Modes

• The flowing modes are supported. Optional dual 6-pipe
rack* or local valves are required to implement many of
the modes

• Heating Only Cycle

• Cooling Only Cycle

• Simultaneous Heating and Cooling*

• Fixed Building Heating and Cooling*

• Primary Heating Secondary Cooling*

• Primary Cooling Secondary Heating*

• Free Cooling*

Fault History

• If a fault occurs the fault will be recorded and
displayed on the local display and an enumerated
status is available for the BAS.

• Optional trending and archiving solutions are available.

• Control Accessories and Options

• Local 7” user display

• Local 7” user display and Web pages

• Local 17” touch Screen and SQL Database

Compressor Minimum Off Delay Time

• The compressor minimum time delay will ensure
that the compressor output will not be enabled for a

minimum of ten (10) minutes after it is disabled.

• This allows for the system refrigerant pressures to
equalize after the compressor is disabled.

• This delay is adjustable from 480 - 1200 over a BAS or
a local display.

Compressor Lead/Lag

• Compressor lead/lag is a standard part of the
system. The unit is shipped from the factory with lead/

lag disabled.

• Lead/lag can be activated through the unit from the
user interface.

17

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

Reference Calculations

Heating Calculations:

LWT = EWT -

NOTE: * When using water. Use 485 for 15% methanol/water or Environol solution.

HE

GPM x 500*

Cooling Calculations:

LWT = EWT +

GPM x 500*

HR

Legend

Abbreviations and Definitions

ELT = entering load fluid temperature to heat pump
LLT = leaving load fluid temperature from heat pump
LGPM = load flow in gallons per minute
LWPD = load heat exchanger water pressure drop
EST = entering source fluid temperature to heat pump
LST = leaving source fluid temperature from heat pump
SGPM = source flow in gallons per minute
SWPD = source heat exchanger water pressure drop
EER = cooling energy effciency (TC/KW)

PSI = pressure drop in pounds per square inch
FT HD = pressure drop in feet of head
KW = kilowatt
HR = heat rejected in MBTUH
TC = total cooling capacity in MBTUH

COP = coefficient of performance (HC/KW x 3.413)
HC = heating capacity in MBTUH
HE = heat of extraction in MBTUH

Unit Startup

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 closed loop system

• Isolation valves are open and water control valves or loop
pumps 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 or wires
are jumpered

• Freeze detection setpoints have been set in
the microprocessor

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.

Startup Steps

• Set thermostat control above cooling setpoint.

• Set thermostat control in cooling mode.

• Slowly reduce the control setting until both the
compressor and water control valve/loop pumps are
activated. Verify that the compressor is on and that
the water flow rate is correct by measuring pressure
drop through the heat exchanger and comparing to the
Pressure Drop table. Check for correct rotation of scroll
compressors. Switch any two power leads at the L1, L2,
and L3 line voltage termination block if incorrect.

• Perform a cooling capacity test by multiplying GPM x ΔT
x 485 (antifreeze/water). Use 500 for 100% water. Check
capacity against catalog data at same conditions.

• Set control to “OFF” position.

• Leave unit “OFF” for approximately five (5) minutes to
allow pressure to equalize.

• Adjust control below heating setpoint.

• Set control in “HEAT” position mode.

• Slowly increase the control setting until both compressor
and water control valve/loop pumps are activated. The
reversing valve should be heard changing over.

• Perform a heating capacity test by multiplying GPM x ΔT
x 485 (antifreeze/water). Use 500 for 100% water. Check
capacity against catalog data at same conditions.

• Check for vibrations, noise and water leaks.

• Set system to maintain desired setpoint.

• Instruct the owner/operator of correct control and
system operation.

18

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

Pressure Drop

Evaporator

CLW060 CLW080 CLW100 CLW120 CLW140

GPM PD GPM PD GPM PD GPM PD GPM PD

84.8 1.9 106.2 1.7 124.8 1.5 169.6 2.2 169.8 1.9

99.8 2.6 127.4 2.3 169.6 2.8 184.6 2.6 199.8 2.6

114.8 3.3 149.8 3.2 184.6 3.3 199.6 3.1 237.6 3.6

135.8 4.6 166.4 3.9 199.6 3.8 229.6 4.0 258.4 4.2

147.8 5.4 178.8 4.5 229.6 4.9 263.8 5.2 279.4 4.9

159.6 6.2 191.4 5.1 249.4 5.8 287.2 6.1 300.4 5.6

171.6 7.2 214.6 6.4 268.2 6.6 310.4 7.1 321.4 6.4

183.6 8.1 237.6 7.7 286.8 7.6 333.8 8.2 339.0 7.1

199.4 9.5 254.2 8.8 306.4 8.6 357.0 9.3 369.0 8.4

214.4 10.9 276.6 10.4 327.8 9.8 369.0 10.0 399.0 9.8

232.8 12.8 299.0 12.0 339.0 10.4 399.0 11.6 428.8 11.2

249.2 14.6 321.6 13.8 369.0 12.3 428.8 13.3 458.8 12.8

268.0 16.7 344.0 15.7 398.8 14.2 458.8 15.1 478.6 13.9

Condenser

CLW060 CLW080 CLW100 CLW120 CLW140

GPM PD GPM PD GPM PD GPM PD GPM PD

82.0 2.0 114.4 2.3 124.4 1.9 143.0 1.7 191.2 2.0

101.0 2.9 124.4 2.7 144.6 2.5 168.2 2.3 208.0 2.4

114.4 3.7 134.6 3.1 171.4 3.4 205.8 3.3 213.4 2.9

124.4 4.4 144.6 3.6 186.6 4.0 224.0 3.9 232.2 3.4

134.6 5.1 160.0 4.3 201.6 4.7 242.0 4.5 251.2 4.0

143.8 5.9 174.0 5.1 216.8 5.4 260.2 5.2 270.0 4.6

156.4 6.9 188.2 5.9 232.0 6.1 274.2 5.8 288.8 5.2

165.8 7.5 202.2 6.8 248.6 7.0 298.4 6.8 320.0 6.3

179.2 8.7 216.4 7.7 268.8 8.1 322.6 7.9 348.2 7.5

182.8 9.1 239.8 9.4 289.0 9.3 346.8 9.1 376.4 8.7

199.0 10.6 261.0 11.0 309.0 10.6 371.0 10.3 404.6 9.9

215.0 12.3 282.2 12.8 335.6 12.4 376.8 10.7 432.8 11.3

231.2 14.2 303.2 14.6 362.8 14.4 410.0 12.5

247.4 16.1 324.4 16.6 390.0 16.5 443.4 14.5 476.6 13.6

443.4 11.9

19

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

Heat of Extraction Data

Model

060

080

100

120

140

Source

GPM

180 180

240 240

300 300

360 360

420 420

Load
GPM

EST Heat Of Extraction (HE)

ºF 105°F 110°F 115°F 120°F 125°F

50 864.6 847.6 837.4 827.6 823.8

55 920.0 910.6 901.2 889.2 877.4

60 992.4 978.4 962.6 955.6 941.6

65 1062.0 1046.0 1035.8 1021.0 1003.2

50 1145.4 1129.0 1116.4 1111.4 1098.4

55 1226.4 1219.6 1201.6 1185.4 1169.8

60 1323.0 1304.2 1283.4 1276.2 1255.2

65 1426.8 1405.0 1380.8 1361.6 1337.6

50 1366.0 1360.6 1343.2 1329.0 1312.4

55 1462.6 1455.4 1436.8 1418.4 1398.2

60 1577.8 1556.4 1546.0 1524.8 1503.2

65 1701.0 1676.4 1664.0 1639.0 1613.8

50 1762.6 1743.6 1723.0 1700.8 1693.8

55 1892.0 1867.4 1857.4 1833.2 1807.2

60 2043.6 2014.8 1986.6 1973.6 1945.8

65 2189.2 2156.8 2140.8 2108.6 2076.8

50 1937.4 1910.0 1885.8 1876.0 1850.0

55 2077.2 2065.0 2033.2 2004.8 1974.2

60 2244.2 2211.6 2179.0 2159.2 2126.4

65 2405.0 2387.0 2349.6 2312.0 2287.6

07/24/13

20

Heat of Rejection Data

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

Model

060

080

100

120

140

Source

GPM

180 180

240 240

300 300

360 360

420 420

Load
GPM

EST Heat Of Extraction (HR)

ºF 65°F 70°F 75°F 80°F 85°F 90°F 95°F

42 934.0 923.0 915.6 905.0 897.0 888.8 878.8

44 960.0 953.8 946.0 934.4 922.8 910.2 905.8

46 990.6 980.0 968.4 963.8 951.6 939.4 934.4

48 1023.4 1011.8 1000.0 992.0 982.0 968.0 960.0

50 1048.0 1042.0 1030.0 1018.0 1004.0 998.0 986.0

42 1248.0 1234.6 1224.6 1210.4 1199.8 1188.8 1175.2

44 1290.0 1271.2 1261.0 1253.8 1234.4 1217.4 1209.4

46 1327.0 1308.4 1291.4 1285.0 1268.8 1253.2 1249.4

48 1371.2 1348.8 1332.8 1326.8 1312.6 1294.4 1284.4

50 1413.4 1392.0 1374.8 1357.0 1343.4 1329.4 1315.2

42 1493.2 1474.8 1464.8 1448.0 1435.4 1417.4 1409.0

44 1542.6 1525.0 1512.4 1494.6 1482.6 1465.0 1446.6

46 1591.0 1577.0 1559.6 1544.6 1524.8 1506.2 1493.6

48 1642.0 1625.2 1601.6 1591.2 1572.4 1552.2 1532.0

50 1692.6 1672.2 1651.6 1638.8 1620.0 1599.2 1581.6

42 1934.0 1907.0 1890.0 1868.0 1846.6 1828.4 1807.8

44 1955.2 1967.4 1948.4 1925.8 1903.0 1880.6 1861.6

46 2054.0 2033.0 2008.8 1985.0 1964.2 1937.4 1917.2

48 2122.0 2093.0 2071.2 2048.2 2024.0 1995.8 1971.0

50 2184.2 2160.0 2129.6 2108.0 2084.0 2057.6 2030.8

42 2112.0 2092.8 2072.8 2055.2 2028.6 2009.6 1986.4

44 2172.4 2160.0 2140.0 2114.4 2095.2 2067.8 2046.4

46 2244.0 2228.8 2206.0 2182.4 2154.4 2133.6 2111.0

48 2317.6 2293.8 2274.0 2249.4 2224.2 2194.4 2170.4

50 2386.0 2367.6 2344.2 2318.2 2294.6 2262.6 2242.2

07/24/13

21

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

Troubleshooting

Should a major problem develop, refer to the following information for possible causes and corrective steps.

If compressor won’t run:

1. The fuse may be open or the circuit breaker is tripped. Check electrical circuits and motor windings for shorts or
grounds. Investigate for possible overloading. Replace fuse or reset circuit breakers after fault is corrected.

2. Supply voltage may be too low. Check it with a volt meter.

3. Control system may be faulty. Check control for correct wiring of thermostat or aquastat and check the 24 volt
transformer for proper voltage.

4. Wires may be loose or broken. Replace or tighten.

5. The low pressure switch may have tripped due to one or more of the following:

a) Heating

1) Plugged heat exchanger on source side

2) Water flow source side -(Low)

3) Water too cold source side

4) Low refrigerant

b) Cooling

1) Plugged heat exchanger on load side

2) Water flow load side - (Low)

3) Water too cold load side

4) Low refrigerant

6. The high pressure switch may have tripped due to one or more of the following:

a) Heating

1) Plugged heat exchanger on load side

2) Low water flow load side

3) Water too warm load side

b) Cooling

1) Plugged heat exchanger on source side

2) Low water flow on source side

3) Water too warm source side

7. The compressor overload protection may be open. Disconnect power. Remove S1 & S2 wires from the compressor
protection module. Measure the resistance between the S1 & S2 wires. If the resistance measures > 2750 ohms, then
the internal compressor resistance has tripped the compressor protection module. The compressor protection module
will reset after a 30 minute delay and the resistance measures < 2250 ohms. Cycling the power off for a minimum of 3
seconds will manually reset the compressor module. The internal compressor resistance must measure < 2250 ohms for
the compressor module to reset.

8. The internal winding of the compressor motor may be grounded to the compressor shell. If so, replace the compressor.

9. The compressor winding may be open or shorted. Disconnect power. Check continuity with ohm meter. If the winding is
open, replace the compressor.

If sufficient cooling or heating is not obtained:

1. Check control for improper location or setting.

2. Check for restriction in water flow.

3. Check refrigerant subcooling and superheat for proper refrigerant charge and expansion valve operation.

4. The reversing valve may be defective and creating a bypass of refrigerant. If the unit will not heat, check the reversing
valve coil.

If the unit operation is noisy:

1. Check compressor for loosened mounting bolts. Make sure compressor is floating free on its isolator mounts. Check for
tubing contact with the compressor or other surfaces. Readjust it by bending slightly.

2. Check screws on all panels.

3. Check for chattering or humming in the contactor or relays due to low voltage or a defective holding coil. Replace
the component.

4. Check for proper installation of vibration absorbing material under the unit.

5. Check for abnormally high discharge pressures.

6. Compressor rotation incorrect

22

Heating Cycle Analysis

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

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MMMMMM 4

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:]OR

1]Of

MMMMMM 4:W_cW R:W\S

C\Wb/[^2`Oe

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CLW QUAD SERIES CHILLER INSTALLATION MANUAL

______

______

______

p

p

q

q

(

)

CLW Quad Startup and Troubleshooting Form

Company Name: _________________________________
Technician Name: ________________________________
Model No: ______________________________________
Owner’s Name: __________________________________
Installation Address: ______________________________

Company Phone No:______________________________
Date: __________________________________________
Serial No:_______________________________________
Open or Closed Loop: _____________________________
Installation Date: _________________________________

Check One

Start up/Check-out for new installation

1. FLOW RATE IN GPM (SOURCE SIDE HEAT EXCHANGER)
Water In Pressure: a.______ PSI

Water Out Pressure: b.______ PSI
Pressure Drop = a - b c.______ PSI
Convert Pressure Drop to Flow Rate

(refer to Pressure Drop table) d.______ GPM

2. TEMPERATURE RISE OR DROP ACROSS SOURCE SIDE HEAT EXCHANGER

Water In Temperature: e.______ °F e.______ °F
Water Out Temperature: f. ______ °F f. ______ °F
Temperature Difference: g.______ °F g.______ °F

3. TEMPERATURE RISE OR DROP ACROSS LOAD SIDE HEAT EXCHANGER

Water In Temperature: h.______ °F h.______ °F
Water Out Temperature: i. ______ °F i. ______ °F
Temperature Difference: j. ______ °F j. ______ °F

T Troubleshooting Problem:___________________________________T

COOLING HEATING

COOLING HEATING

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/hr
Heat of Rejection (Cooling Mode) = btu/hr
Compare results to Capacity Data Tables

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

5. WATTS
Volts: m._____

Total Amps (Comp. + Fan): n. _____ AMPS n. ______ AMPS n.
Watts = m. x n. x 0.85 o. _____ WATTS o. ______ WATTS o.

6. CAPACITY
Cooling Capacity = HR. - (o. x 3.413)
Heating Capacity= HE. + (o. x 3.413)

7. EFFICIENCY
Cooling EER = p. / o.
Heating COP = p. / (o. x 3.413)

8. SUPERHEAT
COOLING HEATING HYDRONIC
Suction Pressure: r. ______ PSI r. ______ PSI r. ______ PSI
Suction Saturation Temperature: s. ______ °F s. ______ °F s. ______ °F
Suction Line Temperature: t. ______ °F t. ______ °F t. ______ °F
Superheat = t. - s. u. _____ °F u. ______ °F u. ______ °F

Head Pressure: v. ______ PSI v. ______ PSI v. ______ PSI
High Pressure Saturation Temp.: w. _____ °F w. _____ °F w. _____ °F
Liquid Line Temperature*: x. ______ °F x. ______ °F x. ______ °F
Subcooling = 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.

S.H.) / SUBCOOLING (S.C.

COOLING HEATING HYDRONIC

VOLTS m.______ VOLTS m.

. _____ btu/hr
. _____ btu/hr

. _____ EER
. _____ COP

COOLING

VOLTS
AMPS
WATTS

24

Preventive Maintenance

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

Unit Heat Exchanger Maintenance

1. 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 high
mineral content in the water, it is best to establish with
the owner a periodic maintenance schedule for checking
the water-to-refrigerant heat exchanger on a regular
basis. 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

Replacement Procedures

When 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 permission
of authorized warranty personnel. Contact your local
distributor for warranty return authorization and assistance.

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

25

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

Service Parts List

Not available at time of publication. See selection software for a full part list.

26

CLW QUAD SERIES CHILLER INSTALLATION MANUAL

Revision Guide

Pages: Description: Date: By:

11 Updated Electrical Data 14 Nov 2013 DS

All First Published 06 Sept 2013 DS

27

Manufactured by
WaterFurnace International, Inc.
9000 Conservation Way
Fort Wayne, IN 46809
www.waterfurnace.com

Product: CLW Quad Series Chiller
Type: Commercial Chiller - 60 Hz
Size: 60-140 Tons

IM1900WW 11/13

©2013 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.

Document: Installation Manual