4
JOHNSON CONTROLS
FORM 201.21-NM4 (616)
TABLE OF CONTENTS
SECTION 1 - GENERAL CHILLER
INFORMATION & SAFETY
INTRODUCTION ......................................................9
WARRANTY ..............................................................9
SAFETY ......................................................................9
Standards for Safety................................................9
RESPONSIBILITY FOR SAFETY ..........................10
ABOUT THIS MANUAL .........................................10
MISUSE OF EQUIPMENT ......................................10
Suitability for Application ....................................10
Structural Support .................................................10
Mechanical Strength .............................................10
General Access .....................................................10
Pressure Systems ..................................................11
Electrical ...............................................................11
Rotating Parts .......................................................11
Sharp Edges ..........................................................11
Refrigerant & Oils ................................................11
High Temperature & Pressure Cleaning ...............11
Emergency Shutdown ...........................................11
SECTION 2 - PRODUCT DESCRIPTION
INTRODUCTION ....................................................12
General System Description .................................12
Compressor ...........................................................13
Evaporator ............................................................14
Condensor .............................................................14
Flash Tank Feed / Drain Valve ..............................15
Oil Separator / Oil System ....................................15
Relief Valves .........................................................15
Oil Cooling ...........................................................16
Capacity Controls .................................................16
Power and Control Panel ......................................16
Microprocessor & VSD Controls .........................16
Display ..................................................................17
Keypad ..................................................................17
Unit Switch ...........................................................17
Variable Speed Drive (VSD) ................................18
ACCESSORIES & OPTIONS ..................................19
Single Point Circuit Breaker .................................19
Building Automation System (BAS) Interface .....19
Condensor Coil Protection....................................19
DX COOLER OPTIONS ..........................................20
SERVICE VALVE OPTION .....................................20
UNIT ENCLOSURES ..............................................20
FANS .........................................................................20
SOUND REDUCTION OPTIONS ...........................20
VIBRATION ISOLATION .......................................20
UNIT NOMENCLATURE .......................................21
PRODUCT IDENTIFICATION NUMBER .............22
SECTION 3 -RIGGING, HANDLING AND
STORAGE
DELIVERY AND STORAGE ..................................26
INSPECTION ...........................................................26
MOVING THE CHILLER........................................26
Lifting Weights .....................................................26
UNIT RIGGING .......................................................27
SECTION 4 - INSTALLATION
LOCATION REQUIREMENTS ...............................29
OUTDOOR INSTALLATION ..................................29
INDOOR INSTALLATION ......................................29
LOCATION CLEARANCES ...................................30
VIBRATION ISOLATORS ......................................30
Installation ............................................................30
SHIPPING BRACES ................................................30
CHILLED LIQUID PIPING .....................................30
General Requirements ..........................................30
WATER TREATMENT .............................................32
PIPEWORK ARRANGEMENTS ............................32
CONNECTION TYPES & SIZES ............................32
COOLER CONNECTIONS .....................................32
Option Flanges ......................................................32
REFRIGERANT RELIEF VALVE PIPING .............33
DUCTWORK CONNECTION ................................33
General Requirements ..........................................33
ELECTRICAL CONNECTION ...............................33
POWER WIRING .....................................................34
POWER SUPPLY WIRING .....................................34
115 VAC CONTROL SUPPLY TRANSFORMER ..34
CONTROL PANEL WIRING ...................................34
VOLTS FREE CONTACTS .....................................35
Chilled Liquid Pump Starter .................................35
Run Contact ..........................................................35
Alarm Contact.......................................................35
SYSTEM INPUTS ....................................................35
Flow Switch ..........................................................35
Remote Run/Stop ..................................................35
Remote Print .........................................................35
Optional Remote Setpoint Offset Temp. ..............35
Optional Remote Setpoint Offset Current ............35
Optional Remote Setpoint Offset Sound Limit ....35
