Jetson FWCD Series Installation Operation & Maintenance Download

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FWCD Series Chillers

Installation, Operation,

& Maintenance

Summary of Contents for FWCD Series

Page 1: ...FWCD Series Chillers Installation Operation Maintenance...

Page 2: ...Jetson www JetsonHVAC com 2...

Page 3: ...aid to the following statements NOTE Notes are intended to clarify the unit installation operation and maintenance CAUTION Indicates a potentially hazardous situation which if not avoided could result...

Page 4: ...erify proper operation after servicing Secure all doors with key lock or nut and bolt WARNING QUALIFIED INSTALLER Improper installation adjustment alteration service or maintenance can cause property...

Page 5: ...fication and Labeling of Chemicals guidelines for information on allowable personal exposure levels proper respiratory protection and handling instructions If there is a risk of energized electrical c...

Page 6: ...tor Temperature Range 14 Digit 19 Evaporator Control Valves 14 Digit 20 Condenser Heat Exchanger Type 14 Digit 21 Condenser Fluid Type 14 Digit 22 Condenser Heat Recovery 15 Digit 23 Condenser Corrosi...

Page 7: ...52 Avoidance of Short Water Loops 52 Minimum Water Volume for a Process Application 53 Unit Piping 53 Exchanger Water Pressures 53 Flow Sensing Devices 53 Water Piping Recommendations 53 Water Flow R...

Page 8: ...9 Software Installation and Setup 69 Downloading and Installing Unit Controller MCS Connect Software 69 Connecting to the Chiller 70 Setpoint Changes 70 Viewing and Troubleshooting ALARMS 70 Downloadi...

Page 9: ...aintenance 79 When to Clean a Brazed Plate Heat Exchanger BPHE 79 How to Clean a Brazed Plate Heat Exchanger BPHE 79 Cleaning in Place CIP Procedure 79 CIP Fluids 80 Bio Gen Active Scale 132 Copper 80...

Page 10: ...Glycol 3 Propylene Glycol 9 Not Applicable Compressor Chiller Digit 22 Condenser Heat Recovery 0 No Heat Recovery 1 Heat Recovery Digit 23 Condenser Corrosion Resistance 0 Standard 1 Cupro Nickel Avai...

Page 11: ...r Wye Strainer with Installation Kit Digit 39 Water Accessories 0 Chilled Water Flow Switch A Condenser Water Flow Switch B Analog Water Temperature Gauge C Analog Water Pressure Gauge D Chilled Water...

Page 12: ...lugs and 12V control circuits A 208 V 60 Hz 3 Phase B 230 V 60 Hz 3 Phase F 460 V 60 Hz 3 Phase G 575 V 60 Hz 3 Phase Digit 9 Unit Application A Water Cooled Chiller Standard water cooled chiller with...

Page 13: ...are a common header is limited to approximately 300 total tons or 900 gpm Digit 15 Evaporator Heat Exchanger Type 0 Brazed Plate Brazed plate heat exchangers are one of the most efficient ways to tran...

Page 14: ...s that all of the water inside the ice storage tanks has been frozen An external signal can be sent to the chiller to reset the chilled water setpoint back to conventional chilled water leaving fluid...

Page 15: ...stalled in array headers These valves can also be used to isolate a module in an array for service or cleaning 2 Motorized Head Pressure Control Valve The integral condenser water regulating valve opt...

Page 16: ...ncludes field provided power and an additional factory installed phase power monitor designed to protect the chiller from premature failure and damage due to common voltage faults such as voltage unba...

Page 17: ...where a single larger chiller with one controller is replaced by modular chillers controlled with one controller A Supervisory Array Controller w Controller per Module This option allows up to ten 10...

Page 18: ...otection Active Freeze Protection is standard on all FWCD Series chillers The chiller s unit controller continually monitors the saturated suction pressure and will open energize the Active Freeze Pro...

Page 19: ...or replacement since closing these valves isolates the compressor B Moisture Indicating Sight Glass Replaceable Core Filter Driers In addition to the Moisture Indicating Sight Glass Replaceable Core...

Page 20: ...er Water Wye Strainer with Installation Kit Digit 39 Water Accessories 0 Chilled Water Flow Switch An evaporator flow proving device is required for all FWCD Series chiller applications A paddle style...

Page 21: ...ions that are sensitive to noise and vibration optional neoprene isolator pads can be provided for load bearing points on a FWCD Series modular chiller B Leveling Kit A height adjustment mechanism loc...

Page 22: ...it 45 Warranty 0 Standard Warranty Warranty period is a period of twelve 12 months from date of start up or eighteen 18 months from date of original shipment whichever may occur first Digit 46 Special...

Page 23: ...ts are shipped with an operating charge of refrigerant and oil General Data Table 2 General Unit Information Unit Size Nominal Tons 20 30 45 55 65 75 85 Compressors Compressor Quantity Nominal Size To...

Page 24: ...Plate Single Circuit Quantity 1 Connection Size Inch 2 Max GPM Single Refrigerant Circuit 90 135 180 225 273 273 273 Min GPM Single Refrigerant Circuit 30 45 60 75 90 105 120 Max Water Pressure psig 3...

Page 25: ...Condenser for Easy Cleaning Brazed Plate or Shell and Tube Condenser Locking Door OFF AUTO Switch RUN Light ALARM Light Touchscreen Single or Dual Refrigeration Circuit s Manual or Motorized Balancing...

Page 26: ...ery Notify the carrier s terminal of the damage immediately by phone and by mail Request an immediate joint inspection of the damage with the carrier and the consignee Notify the Jetson sales represen...

Page 27: ...9 32 69 74 100 80 575 3 60 41 41 175 175 26 28 26 28 59 80 70 55 200 230 3 60 128 128 560 560 82 05 82 05 185 250 225 460 3 60 62 62 260 260 39 74 39 74 89 125 100 575 3 60 45 45 210 210 28 85 28 85 6...

Page 28: ...fuse from this value b Standard Ampere Ratings for Fuses From NEC Handbook 240 6 The standard ratings for fuses shall be considered 15 20 25 30 35 40 45 50 60 70 80 90 100 110 125 150 175 200 225 250...

Page 29: ...Jetson www JetsonHVAC com 29 Dimensions Dimensions Figure 3 FWCD dimensions brazed plate condenser...

Page 30: ...Jetson www JetsonHVAC com 30 Figure 4 FWCD array dimensions brazed plate condenser...

Page 31: ...Jetson www JetsonHVAC com 31 Figure 5 FWCD dimensions shell and tube condenser...

Page 32: ...Jetson www JetsonHVAC com 32 Figure 6 FWCD array dimensions shell and tube condenser...

Page 33: ...Jetson www JetsonHVAC com 33 Figure 7 FWCD dimensions remote condenser...

Page 34: ...Jetson www JetsonHVAC com 34 Figure 8 FWCD array dimensions remote condenser...

Page 35: ...ly grounded parts Two units facing each other or other live parts require a clearance of 48 inches 36 inch clearance is recommended above the chiller See Figure 9 and Figure 10 p 18 for recommended cl...

Page 36: ...Jetson www JetsonHVAC com 36 Figure 10 Clearance FWCD array chiller application all condenser options...

Page 37: ...Jetson www JetsonHVAC com 37 Figure 11 Clearance needed to remove chiller from array FWCD array chiller application all condenser options...

Page 38: ...e Condenser Remote Condenser Brazed Plate Condenser Shell and Tube Condenser Remote Condenser Size lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg 20 1326 601 1467 665 1069 485 1525 692 1688 766 1168 530 30...

Page 39: ...enser entering water temperature range for the FWCD Series chiller is 65 F to 125 F The condenser leaving water temperature LWT maximum is 125 F for shell and tube condensers and 140 F for brazed plat...

Page 40: ...er Water circulated through the heat recovery heat exchanger condenser absorbs cooling load heat from the compressed refrigerant gas discharged by the compressors The heated water is then used to sati...

Page 41: ...Allowable F Swing Allowable F Swing is specified in the problem statement With a tolerance of 3 F the total allowable swing is 6 F We select the value of Min Volume Gal F Swing Ton from Table 5 Minim...

Page 42: ...a 45 F leaving water temperature the temperature will vary between 42 F to 48 F recall the variation tolerance 3 F with the cycling of the compressors at the water loop volume of 641 gallons The fina...

Page 43: ...make up water A strainer with a 20 mesh screen or screen with 0 5 mm sized openings or less is required to be installed at the individual compact chiller or compact chiller array inlet to protect the...

Page 44: ...a factor vibration isolators may be considered Rubber isolators are available as factory provided options Electrical Power Supply A disconnect switch that is accessible from the outside of the cabinet...

Page 45: ...mpressor chiller The filter drier should be changed whenever the system is opened for service FWCD Series compressor chillers do not include a filter drier as standard but one may be ordered if the in...

Page 46: ...nlet creating an inverted trap 5 Double risers are generally unnecessary The scroll compressors in FWCD Series chillers unload to the extent that a single properly sized riser can transport oil at any...

Page 47: ...ge in 20 5 8 1 1 8 5 8 1 1 8 5 8 1 1 8 5 8 1 1 8 30 3 4 1 1 8 3 4 1 1 8 3 4 1 1 8 3 4 1 1 8 45 3 4 1 1 8 3 4 1 1 8 3 4 1 3 8 3 4 1 3 8 55 7 8 1 1 8 7 8 1 3 8 7 8 1 3 8 7 8 1 5 8 65 7 8 1 3 8 7 8 1 3 8...

Page 48: ...5 Array Piping shows examples of acceptable array piping configurations For help with determining the most effective array configuration for your application please contact the factory Figure 15 Array...

Page 49: ...e ordered with cleanable factory selected wye strainers to be installed in the field by others for protection of the brazed plate evaporators Supply and install suitable refrigerant pressure relief pi...

Page 50: ...codes will take precedence over these recommendations Ventilation Provisions must be made to remove heat generated by unit operation from the equipment room Ventilation must be adequate to maintain a...

Page 51: ...hich could result in death or serious injury and equipment or property only damage Ensure that all the lifting equipment used is properly rated for the weight of the unit being lifted Each of the cabl...

Page 52: ...Adjust to within 1 8 inch of level side to side Use shims as required to properly level the unit The serial number information is also on record at the factory Typical Water Piping All building water...

Page 53: ...ld result in equipment or property damage An external source EMS time clock or any other means should not be allowed to bring on a pump that would trigger the flow switch to start the chiller The flow...

Page 54: ...s Water Flow Rates Establish balanced water flow through both the evaporator and condenser Flow rates should fall between the minimum and maximum values given in General Data Table Flow rates above or...

Page 55: ...Pressure Drop 0 00 2 00 4 00 6 00 8 00 10 00 12 00 14 00 16 00 0 00 5 00 10 00 15 00 20 00 25 00 30 00 35 00 40 00 0 00 50 00 100 00 150 00 200 00 250 00 Pressure Drop psi Pressure Drop ft of water Fl...

Page 56: ...sure Drop 0 00 5 00 10 00 15 00 20 00 25 00 0 00 10 00 20 00 30 00 40 00 50 00 60 00 0 00 50 00 100 00 150 00 200 00 250 00 300 00 350 00 Pressure Drop psi Pressure Drop ft of water Flowrate gpm Braze...

Page 57: ...ure Drop 0 00 5 00 10 00 15 00 20 00 25 00 0 00 10 00 20 00 30 00 40 00 50 00 60 00 0 00 50 00 100 00 150 00 200 00 250 00 300 00 350 00 Pressure Drop psi Pressure Drop ft of water Flowrate gpm Shell...

Page 58: ...the warranty on the brazed plate evaporator and condenser FWCD chillers are equipped with brazed plate heat exchangers made of stamped stainless steel plates furnace brazed together with copper based...

Page 59: ...Measurement T2 Evaporator Inlet Temperature Sensor 7 c Strainer with 20 Mesh Screen T3 Evaporator Core Temperature Sensor 8 Evaporator Manual Air Vent Valve w Plug T4 Chiller Inlet Temperature Gauge...

Page 60: ...ottling water flow leaving the condenser in response to compressor discharge pressure Field supplied water regulating valves must be adjusted for proper operation during start up Under full load stand...

Page 61: ...inadvertently energized When necessary to work with live electrical components have a qualified licensed electrician or other individual who has been trained in handling live electrical components per...

Page 62: ...average without regard to sign divided by the average voltage EXAMPLE If the three voltages measured at the line voltage fused disconnect are 221 volts 230 volts and 227 volts the average would be 22...

Page 63: ...e Sequence indicator or equivalent and follow this procedure 1 Verify that all operating controls for the unit are in the Off position 2 Turn power to FWCD unit Off using supply power disconnect to th...

Page 64: ...flow within a fixed time relative to transition from enabled to run modes of the chiller or if the flow is lost while the chiller is in the running mode of operation the chiller will be prohibited fr...

Page 65: ...using remote run stop input remote demand limit reset and or remote chilled water reset functions As standard the unit controller Ethernet port is always ready to talk BACnet IP and Modbus TCP IP Mod...

Page 66: ...tion pressure rises safely above the upper set point level High and Low Discharge Pressure High and Low Superheat High and Low Compressor Amps The compressors will be locked out if any one of these co...

Page 67: ...ntrol The array controller option allows the FWCD Series chiller to be an ideal solution for facilities with growing occupancy and structural expansion plans because chillers can be added as capacity...

Page 68: ...considered an important factor The Master Secondary Array Controller is powered from the unit supply power and factory provided transformer The Master Secondary array control panel also contains a fi...

Page 69: ...ting includes end user configuration A complete software support package is available for your PC allowing for system configuration dynamic on line display screens remote communication graphing and mo...

Page 70: ...10 second default intervals The controller stores 1008 packets of data replacing the oldest with the newest With the time interval set at 10 seconds graph data can be downloaded with a time span of 1...

Page 71: ...her folder by the same name on the computer s desktop Inside this folder will be the hex file It should be about 2300 KB In the MCS CONNECT software select TRANSMIT SW Locate the extracted hex file an...

Page 72: ...ions and under voltage conditions at the compressor motor check tightness of all connections in the compressor power circuit To prevent compressor damage do not operate the unit with discharge or liqu...

Page 73: ...t nameplate If operating conditions indicate an overcharge slowly to minimize oil loss remove refrigerant at the liquid line Schrader fitting Do not discharge refrigerant into the atmosphere Once prop...

Page 74: ...ass is clear Also consider superheat sub cooling and operating pressure Once oil level amp draw and operating pressures have stabilized measure system suction superheat Measure system liquid line sub...

Page 75: ...s for evaporator water pump Lock the disconnect in an open position 3 Open the unit main electrical disconnect and unit mounted disconnect and lock in open position Unit Restart Unit Restart After Ext...

Page 76: ...ter circuit if drained during shutdown Vent the system while filling it 4 Close the fused disconnect switches for the water pumps 5 Start the water pumps With water pumps running inspect all piping co...

Page 77: ...ecking oil level and check level every 30 minutes If oil is not at proper level after this period have a qualified service technician add or remove oil as required Check suction pressure and discharge...

Page 78: ...ence of a motor burnout If the oil is black and contains metal flakes a mechanical failure has occurred This symptom is often accompanied by a high amperage draw at the compressor motor Notes If a mot...

Page 79: ...r Hence the inlet and outlet temperatures of the BPHE should be measured continuously Pressure drops larger than specified indicate scaling since it restricts the channel passage and thus increases ve...

Page 80: ...between 1 and 5 volume percent Formic Acid Formic acid alone is unable to remove iron oxide when it s used as a mixture with citric acid or HCl Formic acid can be used on stainless steels it s relati...

Page 81: ...Jetson www JetsonHVAC com 81 the material It s used for reconditioning of waterborne systems The product is mild to user material and the environment...

Page 82: ...Jetson www JetsonHVAC com 82 Wiring Figure 26 FWCD wiring schematic...

Page 83: ...Jetson www JetsonHVAC com 83 Figure 27 FWCD wiring schematic continued...

Page 84: ...Jetson www JetsonHVAC com 84 Figure 28 FWCD dual circuit secondary wiring schematic...

Page 85: ...Jetson www JetsonHVAC com 85 Figure 29 FWCD dual circuit secondary wiring schematic continued...

Page 86: ...Jetson www JetsonHVAC com 86 Figure 30 Field wiring FWCD single unit single circuit...

Page 87: ...Jetson www JetsonHVAC com 87 Figure 31 Field wiring FWCD single unit dual circuit...

Page 88: ...Jetson www JetsonHVAC com 88 Figure 32 Field wiring FWCD array with master secondary controller single circuit modules...

Page 89: ...Jetson www JetsonHVAC com 89 Figure 33 Field wiring FWCD array with master secondary controller dual circuit modules...

Page 90: ...Jetson www JetsonHVAC com 90 Figure 34 Field wiring FWCD array with supervisory controller single circuit modules...

Page 91: ...Jetson www JetsonHVAC com 91 Figure 35 Field wiring FWCD array with supervisory controller single circuit modules...

Page 92: ...only Unit terminals are not designed to NOTES 1 All field provided control circuit wiring must have a minimum rating of 150V 2 All field wiring must be in accordance with NEC State Local requirements...

Page 93: ...m that is not supplied by NAPPS regardless of the cause of the failure of such portion or component Products on which the unit s identification tags or labels have been removed or defaced Products on...

Page 94: ...FOR ANY ANTICIPATED OR LOST PROFITS INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ANY OTHER LOSSES OR EXPENSES INCURRED BY REASON OF THE PURCHASE INSTALLATION REPAIR USE OR MISUSE BY BUYER OR THIRD PARTIES O...

Page 95: ...flushed out Prior to supplying water to the chiller the Water Treatment Specification shall be consulted for requirements regarding the water quality during chiller operation The appropriate chiller...

Page 96: ...Maintenance FWCD Series Revision 210204 It is the intent of Jetson to provide accurate up to date specification data However in the interest of ongoing product improvement Jetson Innovations reserves...

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