Johnson Controls RW Series, Installation Operation & Maintenance

Page 1: ...MODEL RW 10 TON 50 TON 60 HZ VINTAGE D Issue Date December 3 2019 COMMERCIAL REVERSIBLE CHILLER RW SERIES INSTALLATION OPERATION MAINTENANCE Supersedes 146 06 NOM1 614 Form 146 06 NOM1 1219 ...

Page 2: ...enced materials This in dividual shall also be familiar with and comply with all applicable industry and governmental standards and regulations pertaining to the task in question SAFETY SYMBOLS The following symbols are used in this document to alert the reader to specific situations Indicates a possible hazardous situation which will result in death or serious injury if proper care is not taken I...

Page 3: ...ield Wiring and Control Setup 19 20 Control Features 21 22 Sequence of Operation 23 Inputs and Outputs Configuration 24 Networking Protocol 24 Unit Display and Interface 25 26 Reference Calculations 27 Legend 27 Unit Startup 27 Operating Parameters 28 Pressure Drop 30 Compressor Thermistor Resistance 31 Operating Limits 31 Troubleshooting 32 Heating and Cooling Cycle Analysis 33 Troubleshooting Fo...

Page 4: ... 8 380 60 3 Phase Protection A Non Fused Disconnect Phase Guard B Non Fused Disconnect IntelliStart C Fused Disconnect Phase Guard D Fused Disconnect IntelliStart Chassis E Enclosed P Enclosed with Pressure Gauges Vintage D Factory Use Only Non Standard Options SS Standard Future Option N Future Use Future Option N Future Use Controls 8 FX10 without Communication with User Interface 9 FX10 with Op...

Page 5: ...f 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 d...

Page 6: ... compressor shipping brackets located at the base of each compressor To do so lift up the bottom of the compressor sound jacket and remove the two bolts that hold the bracket General Installation Information cont Rubber Isolators RD2 RD3 Part Number Type Color Code Max Load lbs Deflection in Qty 99S502 01 RD2 Green 380 0 50 4 Compatible with RW120 180 Part Number Type Color Code Max Load lbs Defle...

Page 7: ... OUT CONTROL BOX COVER MAIN POWER CONNECTION VIBRATION PADS ACCESS DOOR DISCONNECT SWITCH EMERGENCY STOP SWITCH FX 10 CONTROLLER DISPLAY NOTES 1 DO NOT SCALE DRAWING SIDE ACCESS PANEL DOORS SERVICE PORTS Model A B C D E F G H J 120 180 57 3 1455 24 1 612 42 5 1080 5 0 127 17 0 432 8 8 224 17 0 432 11 9 302 4 6 117 240 360 64 2 1631 24 1 612 50 5 1283 6 9 175 17 0 432 13 9 353 17 0 432 12 1 307 3 6...

Page 8: ...IPMENT T T Physical Dimensions cont Model K L M N P R S T 120 180 57 0 1448 42 0 1067 63 1 1603 15 9 404 19 5 495 9 7 246 1 3 33 2 0 50 8 240 360 65 0 1651 42 0 1067 69 9 1775 19 9 505 19 5 495 9 7 246 1 8 46 2 0 50 8 600 70 0 1778 42 0 1067 76 8 1951 22 0 559 19 5 495 12 7 323 1 8 46 2 5 63 5 All dimensions in inches mm T Units shipped with groove pipe connection 5 12 14 ...

Page 9: ...360 Scroll 2 17 9 1320 1388 8 1 600 631 600 Scroll 2 27 3 1748 1850 12 4 795 841 Weights shown in Pounds kg 1 30 2014 Refrigerant per circuit in Pounds kg Add 32 lbs 15 kg for fluid weight when full 120 Add 48 lbs 22 kg for fluid weight when full 180 Add 64 lbs 29 kg for fluid weight when full 240 Add 110 lbs 50 kg for fluid weight when full 360 Add 144 lbs 65 kg for fluid weight when full 600 NOT...

Page 10: ...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 Field Connected Water Pipin...

Page 11: ...solation Valves Isolation Valve Strainer Pump From Load To Load Water Temperature Sensors Field Supplied and Installed Factory Installed 1 4 NPT Pressure Temperature Port Standard Piping Pressure Regulated Piping Note System piping should have drain ports to enable flushing and cleaning of heat exchangers On systems utilizing pumps with VFDs an automatic flow control valve must be installed Note S...

Page 12: ...ed 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 1 4 Flow Sensing Devices A A flow 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 cooli...

Page 13: ...rt Room Ambient Condition Surface 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 316 Stainless Steel pH Acidity Alkalinity 7 9 Scaling Calcium and Magnesium Carbonate Total Hardness less than 350 ppm Corrosion Hydrogen Sulfide Less than 1 ppm Sulfates Less than 200 ppm Chlorine Less than 0 5 ppm Chlorides Less than 3...

Page 14: ...ronol 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 ...

Page 15: ...87 253 75 0 48 1 351 0 96 2 108 2 110 0 150 460 60 3 414 506 38 6 24 7 197 0 49 4 55 6 60 0 80 575 60 3 517 633 35 0 22 4 135 0 44 8 50 4 60 0 70 380 60 3 342 418 51 0 32 7 239 0 65 4 73 6 80 0 100 600 460 60 3 414 506 62 0 39 7 260 0 79 4 89 3 100 0 125 575 60 3 517 633 45 0 28 8 210 0 57 6 64 8 70 0 90 380 60 3 342 418 72 0 46 2 310 0 92 4 104 0 110 0 150 HACR circuit breaker in USA only 1 MCC R...

Page 16: ...trol Box Transformer Fused Non Fused Disconnect Power Supply Field line voltage connection Class CC Fusing for Transformer Compressor Contactor Lower Compressor Contactor Upper Compressor Current Sensors Field Low Voltage Connections FX10 Control Board FX10 Expansion Board Class J Fuses ...

Page 17: ...the jumpers 5 A field installed flow switch is required for the source side and must be connected to R for the unit to operate 7 Reversing Valve will be energized for heating mode 9 M1 and M2 are located on the compressor protection modules CPM1 and CPM2 inside of the compressor junction boxes Only used on the 600 model 8 In Emergency Shutdown line voltage is still present in control box Emergency...

Page 18: ...t it must be removed to check the jumpers 5 A field installed flow switch is required for the source side and must be connected to R for the unit to operate 7 Reversing Valve will be energized for heating mode 9 M1 and M2 are located on the compressor protection modules CPM1 and CPM2 inside of the compressor junction boxes Only used on the 600 model 8 In Emergency Shutdown line voltage is still pr...

Page 19: ...nnections 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 t...

Page 20: ...s Celsius can be selected using the following procedure To Change Unit of Measure On FX10 control using up and down keys scroll to SETTINGS Using up and down keys scroll to UNIT OF MEASURE hit ENTER and UNIT OF MEASURE begins flashing Using up and down keys select F for degrees Fahrenheit or C for degrees Celsius Other Field Options Other field selectable options are available as shown in the main...

Page 21: ...ompressor will not restart until the short cycle time delay has been satisfied If the high pressure fault occurs in one circuit the other compressor will continue to operate based on the heating or cooling demand Advanced Freeze Detection System The source and load heat exchangers are protected by a multi sourced temperature logic strategy The temperature logic is based upon the refrigerant temper...

Page 22: ...on applications that have more than two water to water heat pumps installed Unique temperature setting should be set for each unit on a common load To operate in setpoint mode consider the following The selected mode must be changed from Aquastat to Setpoint The Y1 input must be activated This may be done by connecting R to Y1 on the terminal board or by commanding Y1 to ON in the Maint menu of th...

Page 23: ...ation is as follows If only a single Y call is introduced either Y1 or Y2 then one compressor will start and it will be the compressor that has been Off the longest When that call is removed the compressor will stop if the compressor minimum run time has been satisfied If the single Y call is re introduced then the other compressor will start In this manner if single compressor operation is used t...

Page 24: ...hortened to 5 seconds Compressor Minimum On Delay The compressor minimum on delay will ensure that the compressor output is enabled for a minimum of five 5 minutes each time the compressor output is enabled This will apply in every instance except in the event the high pressure switch is tripped freeze protection or emergency shutdown then the compressor output will be disable immediately Compress...

Page 25: ...11 Stage 2 High Pressure DI12 XP10 Expansion Card Input Name Input Output Name Output Entering Source Water Temperature AI 1 Unused DO 1 Leaving Source Water Temperature 1 AI 2 Unused DO 2 Current Switch 1 Compressor 1 AI 3 Unused DO 3 Current Switch 2 Compressor 2 AI 4 Unused DO 4 Unit Display and Interface The Unit Display allows the user to view entering and leaving water temperatures freeze de...

Page 26: ...ive XX X Integ r Ena PID Y1 Off PID Y2 Off D_Neg Off D_Pos Off O 2 Off O 4 Enum_0 Pos Err Off PID Out XXX X Maintenance Y1 Input Off Y2 Input Off B Input Off Emerg SD Normal Acc 1 Sel On Comp Lead Lag Select On Low Frz Setpt XX X F Hi Frz Setpt XX X F Acc I Dly XXXX S LagCompDly XXX S Alarm Events PreFrz1 0 Lo Press 1 0 Src Freeze 1 0 Ld Freeze 1 0 Bad Ld Sensor 0 Lo Press 2 0 Src Freeze 2 0 PreFr...

Page 27: ...its setpoint LD FP 1 Sensor Bad The sensor for load freeze detection on compressor circuit 1 is unreliable or is not reading Source Flow Source Flow Switch is Not Closed The source flow switch must be closed prior to either compressor starting and must remain closed for the entire run time of the compressor s Unit Display and Interface cont High Pressure 1 Compressor Circuit 1 High Pressure Switch...

Page 28: ...ed 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 Unit Startup Startup Steps Set aquastat control above cooling setpoint Set aquastat control in...

Page 29: ...165 330 345 25 30 8 12 100 30 85 110 365 380 10 12 7 11 50 110 135 385 400 12 14 7 11 70 135 165 400 415 14 18 3 7 120 50 110 135 485 500 12 14 7 11 70 135 165 500 515 14 18 3 7 1 30 14 Cooling Mode Entering Load Temp o F Entering Source Temp o F Suction Pressure psig Discharge Pressure psig Superheat o F Subcooling o F 50 30 80 90 140 175 15 20 3 6 50 90 100 200 235 11 15 6 9 70 100 110 250 285 1...

Page 30: ...odel 180 Model 240 Model 360 Model 600 Note Pressure drop is the same for load and source heat exchangers at 30 F fluid temperature Model GPM Pressure Drop psi 30 F 50 F 70 F 90 F 110 F 120 20 0 8 0 7 0 6 0 6 0 5 30 2 1 1 9 1 8 1 7 1 5 40 3 3 3 1 2 9 2 8 2 5 180 30 0 9 0 8 0 7 0 7 0 6 45 2 3 2 2 2 0 2 0 1 8 60 3 7 3 5 3 3 3 2 2 9 240 40 1 3 1 2 1 1 1 1 1 0 60 3 2 3 0 2 9 2 8 2 6 80 5 0 4 7 4 6 4 4...

Page 31: ...7 140 1305 1341 149 1350 1386 1 30 14 Operating Limits Operating Limits Cooling Heating F C F C Source Side Water Limits Min Entering Water 30 1 1 30 1 1 Normal Entering Water 85 29 4 60 15 6 Max Entering Water 110 43 3 90 32 2 Load Side Water Limits Min Entering Water 50 10 0 60 15 6 Normal Entering Water 60 15 6 100 37 8 Max Entering Water 90 32 2 120 48 9 Notes Minimum maximum limits are only f...

Page 32: ...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 com...

Page 33: ..._____PSI ______SAT F ______ F ______PSI ______SAT F ______ F ______ F Liquid Line NOTE Do not attach refrigerant gauges unless a problem is suspected Suction Discharge Compressor RV Braze Plate Braze Plate FD ______PSI ______SAT F ______ F ______PSI ______SAT F ______ F ______ F Liquid Line Unit Amp Draw ____________ Line Voltage _________ Loop ______ Open ______ Closed Subcooling _______ Superhea...

Page 34: ..._ AMPS n ______ AMPS n ______ AMPS Watts m x n x 0 85 o _____ WATTS o ______ WATTS o ______ WATTS 6 CAPACITY Cooling Capacity HR o x 3 413 p _____ btu hr Heating Capacity HE o x 3 413 p _____ btu hr 7 EFFICIENCY Cooling EER p o q _____ EER Heating COP p o x 3 413 q _____ COP 8 SUPERHEAT S H SUBCOOLING S C COOLING HEATING HYDRONIC Suction Pressure r ______ PSI r ______ PSI r ______ PSI Suction Satu...

Page 35: ...t and record Thermistor Checks prior to energizing the compressors or water flow 4 Start Pumps and verify flow through the heat exchangers by recording the pressure drop in the Evaporator Condenser Flow Analysis section 5 Locate the maintenance menu in the MUI and enable Y1 compressor 1 If lead lag is enabled compressor 1 might not always be the first compressor to start 6 Allow the unit to run fo...

Page 36: ...ng Source Water Temperature with no Compressors running Leaving Source Water Temperature with no Compressors running Freeze Protection Setpoint in The MUI Source Freeze Temperature Water Flowing thru unit only No compressors on LOAD SOURCE Load Freeze Temperature Water Flowing thru unit only No compressors on 33 15 33 15 Compressors Energized Entering Load Water Temperature Fluid Samples Taken Lea...

Page 37: ...rized warranty personnel Contact your local distributor for warranty return authorization and assistance Replacement Fuse Chart Model Size Line Voltage Frequency Phase Disconnect Fuse if applicable Branch Circuit Fuse Transformer Primary Fuse Size A Type Part Size A Type Part Size A Type Part 120 208 230 60 3 60 Class J Round 19P605 06 30 Cube 19P602 04 1 3 Class CC 19P600 07 380 60 3 30 Class J R...

Page 38: ...41 RW SERIES REVERSIBLE CHILLER INSTALLATION MANUAL Pages Description Date By 6 8 Updated Dimensional Data Added Detail 25 Jun 2014 DS All First Published 31 Mar 2014 DS Revision Guide ...

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Page 40: ...ut notice Printed in USA www johnsoncontrols com ALL RIGHTS RESERVED P O Box 1592 York Pennsylvania USA 17405 1592 Copyright by Johnson Controls 2019 Form 146 06 NOM1 1219 Issue Date December 3 2019 Supersedes 146 06 NOM1 614 ...