WaterFurnace TruClimate 300 Installation Manual Download Page 1

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IM1910WW 01/22

Installation Information

Water Piping Connections

Electrical Data

Microprocessor Control

Startup Procedures

Preventive Maintenance

ruClimat

e 300 W

ter-C

ooled Chiller with HybrEx T

echnology Ins

tallation Manual

Formerly WC HybrEx Chiller
Commercial 60 Hz
Water-Cooled Chiller with HybrEx Technology

•

R-410A

Refrigerant

•

30-50

Tons

Summary of Contents for TruClimate 300

Page 1: ...l Data Microprocessor Control Startup Procedures Preventive Maintenance TruClimate 300 Water Cooled Chiller with HybrEx Technology Installation Manual ll l Formerly WC HybrEx Chiller Commercial 60 Hz...

Page 2: ......

Page 3: ...mperature Operational Maps 26 HPC and MOP Entering Water Temperature Limits 27 Chiller Components 28 Detailed Component Callouts 29 Electrical System and Controls 31 Aurora HydroLink2 Chiller Control...

Page 4: ...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 length...

Page 5: ...ntroller and Left Single Point Disconnect Panel W Primary Unit Master Controller and Right Single Point Disconnect Panel Sound Kit Option A None B Compressor Sound Blanket Cabinet Option S Standard No...

Page 6: ...7 Seven Variable Speed 8 Eight Variable Speed 9 Nine Variable Speed A Ten Variable Speed 1 L Configuration L Left Configuration R Right Configuration 0 Number of Units Fixed 0 None 1 Single Fixed Spee...

Page 7: ...enclature NOTES 1 Bypass assemblies are equipped with inlet and outlet temperature sensors B 6 H K G 3 4 5 Model B Bypass Header T Temperature Header Pipe Diameter 6 6 8 8 Configuration H Standard Acc...

Page 8: ...and Accessory Nameplates Model S N Job Unit Volts Frequency Phase FLA Compressor ea RLA Max Fuse Time Delay LRA Max HACR BRKR USA Qty Max BRKR Canada Short Curcuit Current High kA Symmetrical Type Lo...

Page 9: ...enclosure with superb sound attenuation Excellent accessibility to all refrigerant circuit components for ease of trouble shooting and serviceability Standard Aurora HydroLink 2 microprocessor contro...

Page 10: ...r for efficiency and compact size Electronic expansion valve for precise superheat control Forklife pallet jack pockets for maneuverability Dual scrol mpressors efficiency reliability Removable high v...

Page 11: ...ced or removed Waterfurnace HybrEx modular chillers feature several industry rsts to provide a true modular chiller 1 Majority of servicing can be accomplished from front control box of unit Zero serv...

Page 12: ...LOGY INSTALLATION MANUAL Formerly the WC Hybrex Chiller The WC HybrEx Chiller Features cont Header Rack Optional Factory Installed 0 045perf Condenser Strainer Optional Factory Installed 40 Mesh Evapo...

Page 13: ...g each 158 71 5 158 71 5 134 61 245 111 245 111 245 111 Oil Charge oz 122 3 6 122 3 6 122 3 6 228 6 7 228 6 7 Evaporator Quantity 1 1 1 1 Weight lbs kg 127 57 127 57 197 89 3 197 89 3 Water Volume gal...

Page 14: ...9 5 55 7 80 30Ton VS Speed 208 230 60 3 187 253 75 110 48 08 88 0 351 20 136 1 158 0 250 460 60 3 414 506 38 6 55 24 7 44 0 197 20 68 7 79 7 125 50Ton Fixed Speed 208 230 60 3 187 253 128 0 82 1 560 0...

Page 15: ...INSTALLATION MANUAL Formerly the WC Hybrex Chiller Dimensional Data 30 Ton Single Module 54 62 72 28 5 STRAINER OPTION 35 10 50 10 50 11 FRONT END BACK TOP CHILLED WATER INLET CHILLED WATER OUTLET CON...

Page 16: ...merly the WC Hybrex Chiller Dimensional Data 30 Ton Bank of Units 28 711 56 1422 55 1406 60 WITH STRAINER OPTION NUMBER OF MODULES X 28 8 205 7 178 4 90 POWER FEED 9 234 OPTIONAL SINGLE POINT PANEL RI...

Page 17: ...y the WC Hybrex Chiller Dimensional Data 50 Ton Single Module 33 00 FRONT 64 00 72 07 WCXDM050 TON DIMENSIONAL DATA 5 01 STRAINER OPTION 35 19 10 50 10 50 10 50 END TOP 7 00 3 54 Power Inlet O 2 00 BA...

Page 18: ...UCLIMATE 300 WATER COOLED CHILLER WITH HYBREX TECHNOLOGY INSTALLATION MANUAL Formerly the WC Hybrex Chiller 30 00 15 57 SERVICE CLEARANCE 40 00 20 00 Dimensional Data 50 Ton Single Module Service Clea...

Page 19: ...N MANUAL Formerly the WC Hybrex Chiller 33 838 66 1676 NUMBER OF MODULES X 33 7 178 4 90 OPTIONAL SINGLE POINT PANEL RIGHT INSTALLATION SHOWN 9 223 64 1626 5 130 OPTIONAL STRAINER REQUIRED TEMPERATURE...

Page 20: ...40 CARBON STEEL PIPE 1 2 NPT BUNG CUT GROOVE PER VIC 25 01 REV J CUT GROOVE PER VIC 25 01 REV J WATER PRESSURE SENSOR OPTIONAL WATER TEMP SENSOR TYPE II 2 75 5 25 C B Configuration A in B in C in 8 i...

Page 21: ...0F CLASS 125 FLANGES CLASS 125 FLANGES Screen 0 045 perf 304SS ASTM A 167 Screen 40MESH 304SS ASTM A 167 Hardware Zinc Plated Bolts Hardware Zinc Plated Bolts Groove Adapters Ductile iron ASTM A395 Gr...

Page 22: ...l Data Service Requirements 30 762 MIN REQUIRED FOR REMOVING SERVICING CONDENSER TEMPERATURE HEADER LEFT INSTALLATION SHOWN 16 406 MIN REQUIRED FOR SERVICING EVAPORATOR 24 610 RECOMENDED OPTIONAL SING...

Page 23: ...23 TRUCLIMATE 300 WATER COOLED CHILLER WITH HYBREX TECHNOLOGY INSTALLATION MANUAL Formerly the WC Hybrex Chiller Pressure Drop Unit...

Page 24: ...24 TRUCLIMATE 300 WATER COOLED CHILLER WITH HYBREX TECHNOLOGY INSTALLATION MANUAL Formerly the WC Hybrex Chiller Strainer Pressure Drop New Basket...

Page 25: ...on under head pressure control and maximum evaporator pressure control For more details on Head Pressure Control and Maximum Evaporator control see HPC and MOP Entering Water Temperature Limits Operat...

Page 26: ...26 TRUCLIMATE 300 WATER COOLED CHILLER WITH HYBREX TECHNOLOGY INSTALLATION MANUAL Formerly the WC Hybrex Chiller Leaving Water Temperature Operational Maps...

Page 27: ...Minimum Flow During Head Pressure Control HPC and Maximum Evaporator Pressure Control MOP During HPC and MOP operation the valves are modulated to keep the compressor running within the operation limi...

Page 28: ...chillers shall have a eld installed by others or factory installed optional Y strainer The optional strainer for the condenser consist of 0 045perf screen and the brazed plate evaporator strainer cons...

Page 29: ...TALLATION MANUAL Formerly the WC Hybrex Chiller Detailed Component Callouts Cabinet Removed Coax Condenser Compressor Brazed Plate Evaporator Filter Drier Electronic Expansion Valve Motorized Isolatio...

Page 30: ...TECHNOLOGY INSTALLATION MANUAL Formerly the WC Hybrex Chiller Detailed Component Callouts Full Assembly Unit Serial Plate Warning Label Removable High Volt Panel VFD VENT OPENING 6IN Grooved Headers E...

Page 31: ...tocol Drive faults are communicated and stored in the Aurora HydroLink2 controls system and can be accessed through the BAS or primary unit controller and interface Unit Power Blocks optional Fused an...

Page 32: ...DRIVE VARIABLE SPEED DRIVE FUSES OPTIONAL INTERFACE PRIMARY UNIT ONLY HIGH VOLT PANEL COOLING FANS TRANSFORMERS UNIT GROUND TRANSFORMER FUSES LOW TO HIGH VOLT HARNESS QUICK CONNECTOR POWER BLOCKS OPT...

Page 33: ...BC A for compressor A and to ABC B for compressor B via Modbus protocol The HydroLink2 controls all higher functions as a master control managing lead lag other functions of each ABC AXB combination b...

Page 34: ...pressor is started after the control exits the emergency shutdown mode there will be an anti short cycle delay followed by a random start delay Input must be tied to common to activate Load Shed The L...

Page 35: ...gration and a myriad of information available to the BAS from the heat pump control Plus it also allows individual unit con guration such as freeze protection setting directly over the BAS without the...

Page 36: ...Used 9 Yes Hard or Soft Not used 10 Fault Compressor Monitor 10 Yes Hard or Soft Open Crkt Run Start or welded cont 11 Not Used 11 Yes Hard or Soft Not used ABC AXB Advanced Faults 12 Not Used 12 Not...

Page 37: ...the compressor s is operating if either ow switch opens for 5 continuous seconds the compressor s will be immediately shut down until ow returns If ow does not return within 60 seconds the controller...

Page 38: ...System cont Modbus Primary Unit Secondary HL2 Controller Primary HL2 Controller ABC Controller AXB Controller Ethernet Switch Modbus Secondary Unit Secondary HL2 Controller ABC Controller AXB Controll...

Page 39: ...ller Aurora HydroLink2 Chiller Control System cont Control Panel Overview ABC A ABC B AXB A AXB B STO Relay Power Supply Borad EEV board Unit HydroLink2 Controller Primary HydroLink2 Controller Quick...

Page 40: ...21 High Volt Panel CPC Harness Connector to low vol t panel GR YL H24 G Chiller Interface 24VDC G LAN Chiller Interface 24VDC G LAN Optional HMI Primary Unit Only Red H19 PB2 1 2 3 24Vac Black H20 Bla...

Page 41: ...H29 Bl Wh H13 Red Wh H16 Bl Wh H14 Red Wh H15 Comp CT B T2 Comp CT B T1 Comp CT B T2 Comp CT B T1 Blue H17 White H18 Blk H23 Red H22 Gr Yl H21 Gla nd Fi tting To Compressor Compartment To Low Volt Pa...

Page 42: ...Black H20 Black H28 Green H27 Red H25 Black H26 High Volt Panel Door Comp CT B T2 Comp CT B T1 Comp CT A T2 Comp CT A T1 T3 T1 T2 COMP A CC A T1 L1 T2 L2 T3 L3 A1 A2 CC A T1 L1 T2 L2 T3 L3 A1 A2 Comp...

Page 43: ...h H15 Comp CT B T2 Comp CT B T1 Comp CT B T2 Comp CT B T1 Blue H17 White H18 Blk H23 Red H22 Gr Yl H21 Gland Fitting To Compressor Compartment To Low Volt Panel Plastic Bushing Panel COM Shielded Cabl...

Page 44: ...12 X1 12 X1 13 X1 13 X1 14 X1 14 Bl WH H14 Red Wh H15 Red Wh H16 Blue N13 Red N14 3 4 5 2 3 4 5 2 1 STO Relay Vi N09 Vl N08 X1 15 X1 16 Wh H1 8 Blue H17 Red N05 Black N06 X1 18 X1 17 Black H20 Red H19...

Page 45: ...s inputs inputs outputs USB PRI SEC RS 485 1 S S RS 485 2 24VAC DC niagara Framework outputs inputs inputs outputs Wh ite 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 To ABC A P8 Or an ge Blac k Re d 1 2 3 4 5 6 7...

Page 46: ...0 3 2 5 711 623 601 230 3 3 6 807 719 697 230 3 4 7 903 815 793 460 2 3 5 341 297 286 460 2 4 6 390 346 335 460 2 5 7 440 396 385 460 2 6 8 489 445 434 460 2 7 9 539 495 484 460 2 8 10 588 544 533 460...

Page 47: ...d 460 3 248 288 238 460 2 6 8 728 688 678 50Fixed 460 4 328 368 318 460 2 7 9 808 768 758 50Fixed 460 5 407 447 397 460 2 8 10 887 847 837 50Fixed 460 6 487 527 477 460 3 2 5 511 471 461 50Fixed 460 7...

Page 48: ...2 T2 L3 T3 BREAKER CHILLER 1 L1 T1 L2 T2 L3 T3 BREAKER CHILLER 2 L1 T1 L2 T2 L3 T3 BREAKER CHILLER 2 L1 T1 L2 T2 L3 T3 BREAKER CHILLER 3 L1 T1 L2 T2 L3 T3 BREAKER CHILLER 3 Chiller 1 L2 L1 L3 Type NM...

Page 49: ...hooting of setpoints In addition the variable speed compressor increases the part load ef ciency of the chiller Item Description HPS High Pressure Switch 600Psig Auto Reset LPS Low Pressure Switch 40P...

Page 50: ...o Sour ur ur ur ur ur ur ur urce ce ce ce ce ce ce ce ce O O O O O O O O Out ut ut ut ut ut ut ut utle le le le le le le le let t t t t t t t t He He He He He He He He Head ad ad ad ad ad ad ad ader e...

Page 51: ...10 gallons ton Installation of a buffer tank that will properly mix the uid is recommended Strainers All brazed plate heat exchangers shall have a strainer within 8 ft of the water brine inlet It is h...

Page 52: ...or moving the chiller through tight spaces Rigging the chiller must be done using a H Spreader Beam with recommended dimensions shown in below Always use rigging straps Figure 24 Moving the unit palle...

Page 53: ...ferring wires between different units 2 Always attempt to start the installation with the Primary Chiller and Single Point Disconnect Panel if equipped If the layout of the plant does not allow starti...

Page 54: ...e all other consecutive secondary chillers to the bank ensuring that the large headers are aligned Install the grooved header ttings Do not over torque the bolts of the groove pipe ttings Recommended...

Page 55: ...00 WATER COOLED CHILLER WITH HYBREX TECHNOLOGY INSTALLATION MANUAL Formerly the WC Hybrex Chiller 10 04 18 02 0 88 MOUNTING HOLE LOCATION FRONT 10 04 18 02 0 88 MOUNTING HOLE LOCATION REAR Chiller Ins...

Page 56: ...t up is scheduled Each water header is equipped standard with a temperature well sensor for supply and return water tem peratures of the units performance Also included is a ow switch located on the e...

Page 57: ...ink2 controller The default con guration of the temperature header consists of factory installed temperature sensor and P T port Optional differential pressure sensors are eld installed in place of th...

Page 58: ...label on each run 3 Install the conduit runs support brackets and start connecting each run to the corresponding breaker in the single point panel Each phase is color coded Match the colors to L1 L2 a...

Page 59: ...59 TRUCLIMATE 300 WATER COOLED CHILLER WITH HYBREX TECHNOLOGY INSTALLATION MANUAL Formerly the WC Hybrex Chiller Chiller Plant with Single Point Disconnect Panel cont...

Page 60: ...niagara Framework outputs inputs inputs outputs USB PRI SEC RS 485 1 S S RS 485 2 24VAC DC niagara Framework outputs inputs inputs outputs USB PRI SEC RS 485 1 S S RS 485 2 24VAC DC niagara Framework...

Page 61: ...are open and water control valves Pumping system is fully operable HE GPM x 500 Legend Abbreviations and Definitions Reference Calculations Heating Calculations Cooling Calculations LWT EWT HR GPM x 5...

Page 62: ...me Delay Restart 1 min Voltage across L1 L2 L1 Device ID MS TP Address BacNet IP 4 Inch 6 Inch Undervoltage Delay 0 02 sec Voltage across L2 L3 L2 Low Volt Amps 4 Pipe Standard 4 Pipe Reversing Underv...

Page 63: ...ote Do not attach refrigerant gauges unless a problem is suspected Unit Amp Draw Line Voltage Subcooling Superheat Evaporator Condenser Entering Hot Water o F Entering Water Pressure PSIG Leaving Hot...

Page 64: ...r is set to the highest position possible This ensures that no air pockets are created during the ushing procedure 5 Attach the circulation hoses Pump the descaling uid in the low side and return thro...

Page 65: ..._ VOLTS m ______ VOLTS Total Amps Comp Fan n _____ 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...

Page 66: ...HYBREX TECHNOLOGY INSTALLATION MANUAL Formerly the WC Hybrex Chiller Pages Description Date By Misc Implemented new product name 12 Jan 2022 MA Misc Added 50 Ton capacity 21 Sept 2021 MA All Document...

Page 67: ...67 TRUCLIMATE 300 WATER COOLED CHILLER WITH HYBREX TECHNOLOGY INSTALLATION MANUAL Formerly the WC Hybrex Chiller...

Page 68: ...d development and reserves the right to change design and speci cations without notice Product TruClimate 300 with HybrEx Technology Type Water Cooled Chiller 60 Hz Size 30 50 Ton Document Installatio...

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