INSTALLATION GUIDE
TruClimate 300
R-454B
60Hz

R-454B 60Hz TruClimate 300

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.
WARNING: All WaterFurnace products are designed, tested, and manufactured to comply with the latest publicly released and available edition of UL 60335-240 for electrical safety certification. All field electrical connections must follow the National Electrical Code (NEC) guide standards and / or any local codes that may be applicable for the installation.
WARNING: Only factory authorized personnel are approved for startup, check test and commissioning of this unit.
INSTALLER: Please take the time to read and understand these instructions prior to any installation. Installer must give a copy of this manual to the owner.
Definition of Warnings and Symbols
WARNING
Indicates a situation that results in death or serious injury.
DANGER Indicates a situation that could result in death or serious injury.
CAUTION Indicates a situation that could result in minor or moderate injury.
NOTICE Indicates a situation that could result in equipment or property damage.
Conforms To UL STDS 60335-1 & 60335-2-40 Certified To CSA STDS C22.2 # 60335-1 & 60335-2-40
For the User
WARNING
This appliance is not intended for use by persons (including children) with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.
Keep this manual in a safe place in order to provide your serviceman with necessary information.
NOTICE
NOTICE: 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.
WaterFurnace’s TruClimate 300 & 500 products are certified by AHRI Standard 550/590 for Water-Cooled Water Chilling and Heat Pump Water-Heating Packages.

General Installation Information

NOTICE: Do not store or install units in corrosive environments or in locations subject to temperature or humidity extremes.
Corrosive conditions and high temperature or humidity can significantly reduce performance, reliability, and service life. NOTICE: A minimum of 24 in. clearance should be allowed for access to front access panel.
NOTICE: To avoid equipment damage, DO NOT use these units as a source of heating or cooling during the construction process. The mechanical components and filters can quickly become clogged with construction dirt and debris, which may cause system damage and void product warranty.
For the Installer
If you are NOT sure how to install or operate the unit, contact your dealer.
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 ating 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.
This manual contains specific information about the required qualification of the working personnel for maintenance, service and repair operations.
Every working procedure that affects safety means shall only be carried out by competent persons.
Examples for such working procedures are:

• breaking into the refrigerating circuit;
• opening of sealed components or ventilated enclosures.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available for all brazing operations. Follow all procedures to remain in compliance with national gas regulations.
Prior to beginning work on systems containing FLAMMABLE REFRIGERANTS, safety checks are necessary to ensure that the risk of ignition is minimized. Work shall be undertaken under a controlled procedure so as to minimise the risk of a flammable gas or vapor being present while the work is being performed. All maintenance staff and others working in the local area shall be instructed on the nature of work being carried out. Work in confined spaces shall be avoided.
The area shall be checked with an appropriate refrigerant detector prior to and during work, to ensure the technician is aware of potentially toxic or flammable atmospheres. Ensure that the leak  etection equipment being used is suitable for use with all applicable refrigerants, i.e. non-sparking, adequately sealed or intrinsically safe.
If any hot work is to be conducted on the refrigerating equipment or any associated parts, appropriate fire extinguishing equipment shall be available to hand. Have a dry powder or CO2 fire extinguisher adjacent to the charging area.
No person carrying out work in relation to a REFRIGERATING SYSTEM which involves exposing any pipe work shall use any sources of ignition in such a manner that it may lead to the risk of fire or explosion. All possible ignition sources, including cigarette smoking, should be kept sufficiently far away from the site of installation, repairing, removing and disposal, during which refrigerant can possibly be released to the surrounding space. Prior to work taking place, the area around the equipment is to be surveyed to make sure that there are no flammable hazards or ignition risks. “No Smoking” signs shall be displayed. Where electrical components are being changed, they shall be fit for the purpose and to the correct specification. At all times the manufacturer’s maintenance and service guidelines shall be followed. If in doubt, consult the manufacturer’s technical depart- ment for assistance.
The following checks shall be applied to installations using FLAM- MABLE REFRIGERANTS:

• the actual REFRIGERANT CHARGE is in accordance with the room size within which the refrigerant containing parts are installed;
• the ventilation machinery and outlets are operating adequately and are not obstructed;
• if an indirect refrigerating circuit is being used, the secondary circuit shall be checked for the presence of refrigerant;
• marking to the equipment continues to be visible and legible. Markings and signs that are illegible shall be corrected;
• refrigerating pipe or components are installed in a position where they are unlikely to be exposed to any substance which may corrode refrigerant containing components, unless the components are constructed of materials which are inherently resistant to  being corroded or are suitably protected against being so corroded.

Instructions for Equipment Using R-454B Refrigerant
WARNING

• Do NOT pierce or burn
• Do NOT use means to accelerate the defrosting process or to clean the equipment, other than those recommended by the manufacturer
• Be aware that refrigerants may not contain an odor

WARNING

• The Appliance should be stored so as to prevent mechanical damage and in a room without continuously operating ignition sources (example: open flames, an operating gas appliance or an operating electric heater)

WARNING
Ventilated Area: ensure that the area is in the open or that it is adequately ventilated before breaking into the system of conducting any hot work. A degree of ventilation should continue during the period that the work is carried out. The ventilation should safely disperse any released refrigerant and preferably expel it. Keep ventilation area clear of obstructions!
WARNING
Do NOT use potential sources of ignition in searching for or detection of refrigerant leaks. A halide torch (or any other detector using a naked flame) shall not be used.
The following leak detection methods are deemed acceptable for all refrigerant systems. Electronic leak detectors may be used to detect refrigerant leaks but, in the case of FLAMMABLE REFRIGERANTS, the sensitivity may not be adequate, or may need re-calibration. (Detection equipment shall be calibrated in a refrigerant-free area.) Ensure that the detector is not a potential source of ignition and is suitable for the refrigerant used. Leak detection equipment shall be set at a percentage of the LFL. of the refrigerant and shall be calibrated to the refrigerant employed, and the appropriate percentage of gas (25 % maximum) is confirmed. Leak detection fluids are also suitable for use with most refrigerants but the use of detergents containing chlorine shall be avoided as the chlorine may react with the refrigerant and corrode the copper pipe-work. NOTE Examples of leak detection fluids are bubble method, fluorescent method agents If a leak is suspected, all naked flames shall be removed/extinguished. If a leakage of refrigerant is found which requires brazing, all of the refrigerant shall be recovered from the system, or isolated (by means of shut off valves) in a part of the system remote from the leak. Removal of refrigerant shall follow the procedure outlined in this manual.
Installation Site
Maximum altitude for this equipment shall not exceed 2000 m. (6561 ft.) For installation only in locations not accessible to the general public.
WARNING
For appliances using A2L refrigerants connected via an air duct system to one or more rooms, only auxiliary devices approved by the appliance manufacturer or declared suitable with the refrigerant shall be installed in connecting ductwork. The manufacturer shall list in the instructions all approved auxiliary devices by manufacturer and model number for use with the specific appliance, if those devices have a potential to become an ignition source.
Installation Space Requirements
NOTE: Equipment with refrigerant charge less than 64 oz does not require have a minimum floor area requirement and does not require a refrigerant leak detection sensor. The sensor might be added as a feature.
WARNING
Equipment containing R-454B refrigerant shall be installed, operated, and stored in a room with floor area larger than the area defined in the “Minimum Floor Area” chart based on the total refrigerant charge in the system. This requirement applies to indoor equipment with or without a factory refrigerant leakage sensor.
CAUTION
This equipment requires connections to a water supply. See the “Water Quality Guidelines” section of this manual for more information on the quality of water required for this operation. If a potable water source is used for this equipment’s water supply, the source water supply shall be protected against back siphonage by the equipment.
WARNING
This equipment comes with a factory installed Refrigerant Detection Device which is capable of determining it’s specified end-of-life and replacement instructions. Refrigerant sensors for refrigerant detection systems shall only be replaced with sensors specified by the appliance manufacture.
WARNING
Take sufficient precautions in case of refrigerant leakage. If refrigerant gas leaks, ventilate the area immediately.
POSSIBLE RISKS: Excessive refrigerant concentrations in a closed room can lead to oxygen deficiency
WARNING
ALWAYS recover the refrigerant. Do NOT release them directly into the environment. Follow handling instructions carefully in compliance with national regulations.
General Installation Information: Refrigerant Detection and Mitigation
WARNING
Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges or any other adverse environmental effects. The check shall also take into account the effects of aging or continual vibration from sources such as compressors or fans. Refrigerant Leak Detection and Mitigation Each chiller unit is provided with A2L leak detection sensors and alarm output from the Aurora Control. This allows the leak detection strategy to occur at the chiller unit level and the
leak mitigation strategy to occur at either the room level or the chiller unit/bank level depending on the application.
Room Ventilation Method

Unventilated Room
Determine the total refrigerant charge in the system. In packaged systems, the factory charge should be the total charge for the system and there should not be a reason for adding charge in the field. The equipment serial plate and unit Physical Data table should serve as reference for the total charge.
Use Table 1 to determine the minimum floor area, Amin. The equipment must be installed with a minimum floor area equal or larger than the area listed in the chart based on the total refrigerant charge of that system. If the area is not large enough, you must move to next step for additional installation requirements.
When the location of the installation is above 1969 ft (600m), the Altitude Adjustment Factor in the table is needed to calculate the minimum room size”.
Example: For instance, if your elevation is 5249Ft (1500mm) your area factor would be 1.12.  If your charge weight is 80oz (2.268 kg) at a floor height installation.  The Amin would be 516 square Ft (48.0 square meters).  Take 516 square ft x 1.12 for a new Amin of 577.92 square feet (53.76 square meters).

2400
2600
2800
3000
3200

In cases where the minimum room area cannot be met, ventilation must be provided rom either the equipment enclosure, natural ventilation to the adjacent space, or provide mechanical ventilation in the room.
Machine Room
Equipment containing R-454B refrigerant may be installed, operated, and stored in a machinery room and shall comply with applicable sections of ANSI/ASHRAE 15 (USA) or CSA B52 (Canada). To intergrate the mitigation control at the room level into the unit leak detection control, see Figure C for require field wiring instructions.
Ventilated Room
Equipment containing R-454B refrigerant shall be installed, operated, and stored in a room with floor area larger than the area defined in the “Minimum Floor Area” chart based on the total refrigerant charge in the system per UL60335-2-40. This requirement applies to indoor equipment with or without a factory refrigerant leakage sensor. If a permanent vent is used to exhaust air from A1 to EAmin, Qmin, the minimum volumet- ric fl ow of air is provided in Table 1. General Installation Information: Refrigerant Detection and Mitigation

Model| Charge| Amin| Area (A1)| Exhaust Area (EAmin)| Ventilation (Qmin)
---|---|---|---|---|---
lbm| oz| kg| ft2| m2| ft2| m2| ft2| m2| ft^3/min| m^3/hr
T3HS030SN2| 13.3| 212| 6.01| 604| 56.1| 121| 11.2| 235.9| 21.9| 213| 362
T3HS050SN2| 22.3| 356| 10.09| 1703| 158.2| 341| 31.6| 366.8| 34.1| 331| 562
T3HS030LN2| 12.5| 200| 5.67| 537| 49.9| 107| 10.0| 231.2| 21.5| 208| 354
T3HS050LN2| 21.5| 344| 9.75| 1590| 147.7| 318| 29.5| 356.4| 33.1| 321| 546

General Installation Information: Refrigerant Detection and Mitigation

Natural Ventilation to the Outdoors or Adjacent Indoor Space
Nature ventilation can be achieved by ensuring that there is a connected space to the room housing the equipment.

1. There must be a permanent opening between the spaces.
2.  The area housing the equipment cannot be less than 20% of the minimum floor area.
3. Permanent openings such as louvers must meet the fol- lowing requirements and have a free area greater than Anv as shown in the chart.

Mechanical Ventilation of the Equipment Room
One option for mitigation is to provide mechanical ventilation to another area or room. The ventilation rate must be equal to or greater than the airflow rate established in the Mechanical Ventilation Rate chart. The area requirement for the room size where the ventilation is directed must be equal or larger to the area in established in the Minimum Room Area – Exhaust Ventilation chart. For modular chillers, the ventilation rate is only necessary for the largest refrigerant charge in the bank. All chillers must have the ability to trigger the mechanical ventilation system if a leak is detected.
Additional measures that can be taken to reduce the minimum floor area for a given refrigerant charge is to elevate the equipment installation. The ventilation and room area calculated above are based on equipment mounted to the floor. If the installation height exceeds 2 ft up to a max of 6.6 ft, the minimum room area requirement reduces.

Serial Plate

Dimensional Data: 30 Ton Single Module

Dimensional Data: 30 Ton Service Clearance Dimensional Data: 30 Ton Bank of Units Dimensional Data: 50 Ton Single Module

Dimensional Data: 50 Ton Single Module Service Clearance Dimensional Data: 50 Ton Bank of Units Dimensional Data: 50 Ton Bank Service Clearance Dimensional Data: Bypass and Temperature Headers Dimensional Data: Strainers Strainer Specifications 0.045perf

175PSIG, 250F
CLASS 125 FLANGES
Screen:| 0.045 perf 304SS ASTM A-167
Hardware:| Zinc Plated Bolts
Groove Adapters| Ductile iron, ASTM A395
175PSIG, 250F
CLASS 125 FLANGES

Strainer Specifications 40MESH

175PSIG, 250F
CLASS 125 FLANGES
Screen:| 40MESH 304SS ASTM A-167
Hardware:| Zinc Plated Bolts
Groove Adapters| Ductile iron, ASTM A395
175PSIG, 250F
CLASS 125 FLANGES

Physical Data

Model| Fixed Speed| VS Modular| Fixed Speed| VS Modular
---|---|---|---|---
030 Ton| 030 Ton| 050 Ton| 050 Ton
Refrigerant| R-454B| R-454B
Number of Circuits| 2| 2| 2| 2
Factory Charge, lbs [kg]*| 13.25 [6.01]| 12.50 [5.67]| 22.25 [10.09]| 21.50 [9.75]
Compressor| | |
Compressor Quantity [tons]| 2 [15]| 2[15]| 2 [15]| 2[15]
Compressor Weight, lbs [kg] (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 [L]| 3.6 [13.5]| 3.6 [13.5]| 5.6 [21.1]| 5.6 [21.1]
Configuration| BP Dual Circuit| BP Dual Circuit
Condenser| |
Quantity| 1| 1| 1| 1
Weight, lbs [kg]| 315 [142]| 315 [142]| 420 [190]| 420 [190]
Water Volume, gal [L]| 3.1 [11.8]| 3.1 [11.8]| 4.13 [15.6]| 4.13 [15.6]
Configuration| Dual Circuit| Coax Dual Circuit 4 Coils per circuit
Modular**| | |
Shipping Weight, lbs [kg]| 1750 [793]| 1828 [829.2]| 2456 [1114]| 2536 [1150]

*Charge per Circuit 11/6/23
– Variable Speed Compressor
Electrical Data**

Model| Rated Voltage| Voltage Min/Max| **Compressor*| Total Unit| Min Circ| Max Fuse/
---|---|---|---|---|---|---
MCC| RLA| LRA| FLA| Amp| HACR*
30Ton Fixed Speed| 208-230/60/3| 187/253| 75.0| 48.1| 351.0| 96.2| 108.2| 150
460/60/3| 414/506| 38.6| 24.7| 197.0| 49.5| 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| 164.1| 184.6| 250
460/60/3| 414/506| 62.0| 39.7| 260.0| 79.5| 89.4| 125
50Ton VS Speed| 208-230/60/3| 187/253| 128/143.8| 82.1/115.0| 560/143.8| 197.1| 225.8| 325
460/60/3| 414/506| 62/76.3| 39.7/61.0| 260/76.3*| 100.7| 115.9| 150

HACR circuit breaker in USA only  09/03/21
MCC, RLA, & LRA rating per Breaker & FLA sized for both compressors.

Chiller Installation

Unit Storage and Environmental Requirements
NOTE: The chiller must be stored in dry location. Failure to protect the chiller from water ingress can result in extensive electrical component damage and potentially void warranty.
If the unit needs to be stored outdoors, it is recommended that a professionally installed shrink wrap cover is applied by third party.
Each heat exchanger has residual Propylene Glycol mixture which protects the unit heat exchangers from freezing during transportation and storage. Replacing the PG mixture from the heat exchangers with straight water and storing the unit at low ambient temperatures can cause freeze damage and void the warranty.
Moving and Rigging
The chiller can be moved using a pallet jack or a fort lift from left or right side. Machine moving casters can be used in the front and back for 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.
General Recommendations:

• It is recommended to install the chiller plant on a set of mounting rails for assemblies consisting of more than 3 units. Recommended mounting rails to have 4 in top flange.
• Always secure the chiller to the rails or slab using the provided holes in the chiller frame.
• Do not install spring vibration absorbers under each individual chiller. Installation of rubber isolation pads is possible.
• If vibration absorbers are required, install the vibration absorbers under the chiller plant mounting rails.
• Always bypass the chillers during initial building pipe flushing. Install flexible piping connections to chiller plant inlet and outlet pipes.
• Care must be taken to install chiller modules in correct order to ensure factory controller addressing is properly maintained. Failure to do so may result in system not operating properly.

Installation Procedure
Chiller Plants with Single Point Disconnect Panel:

1. Installation of banks with single point disconnect panel requires the units to be installed in sequence order based on the label provided in the high volt panel.
   NOTICE
   Each unit is supplied with power feed wires. Failure to install the unit in sequential order can cause issues with the supplied power wires not reaching the single point panel and require transferring 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 starting the installation with “Primary Unit”, start with the installation with a secondary chiller and ensure that the chillers are installed in sequential order based on the chiller number identify caution label or nomenclature identification (digit 21 See unit nomenclature). There are three different installation scenarios for chiller plants with single point power panel:
   A. Left Single Point C. Right and Left Single Point Panel
   When installing a chiller plant with two single point panels, one will be attached to the primary unit (always labelled as chiller 1), and the second panel will be attached to a secondary unit. The example below shows a primary chiller with right single point panel and left secondary panel attached to Chiller 7.![Water Furnace R-454B 60Hz TruClimate 300 - Room Ventilation Method

• Point Panel](https://manuals.plus/wp-content/uploads/2024/02/Water-Furnace-R -454B-60Hz-TruClimate-300-Room-Ventilation-Method-Point-Panel.jpg)

  3. Place all other consecutive secondary chillers to the bank ensuring that the large headers are aligned. Install the grooved header fittings. Do not over torque the bolts of the groove pipe fittings. Recommended tightening torque: 73 ft-lb.
  4.  After all units have been connected, proceed with installing the bolts which secure the chillers to the railing or slab. The provided holes are for a 3/8” bolt.

Installation Information: Bypass and Temperature Headers
Water Connections
Water Piping must be installed in accordance with application codes and per necessary standards. Supply and return connections should be connected per units’ directions. Strainers are required on supply to machine per engineer specification to prevent heat exchanger fouling from occurring. Strainers can be installed on each chiller, one per loop or both.
Before start-up can occur, water must be CLEAN and proper procedures and care should be implemented in order to ensure and maintain a clean system. Water should be treated and clean per necessary standards before startup is scheduled. Each water header is equipped standard with a temperature well sensor for supply and return water temperatures of the units’ performance. Also included is a flow switch located on the exit side of the heat exchanger to ensure flow through the heat exchangers, which is integrated into the controls and is adjusted in pre-shipping testing procedures.
The two available flow configurations are Reverse Return and Direct Flow. The Reverse Return configuration provides better flow balance between the chillers compared to the Direct Flow Configuration. This flow imbalance shortcoming of the Direct Flow configuration can be overcome by utilizing the Delta T control provided in the HydroLink2 controls platform. Installation Information: Bypass and Temperature Headers
Temperature Header Installation
The chiller plant requires global temperature reading to properly control the staging of the chillers. The global temperature sensors are placed in a temperature header in the inlet and outlet of each loop between the chiller plant and the building. The temperature header is provided as a separate line item and is a field installed item. The temperature sensors and optional differential sensors need to be field wired to the primary HydroLink2 controller.
The default configuration of the temperature header consists of factory installed temperature sensor and P/T port. Optional differential pressure sensors are field installed in place of the P/T port.
Installation Recommendations:

1. Do not over torque the bolts of the groove pipe fittings. Recommended tightening torque: 73 ft-lb.
2.  Always rotate the temp header so full access is provided to the sensors and P/T port.
3. Insulate Header with min CCF insulation with minimum thickness of 0.75in.

Individual Unit Power Feed
The chiller has knockout provision for 1.5 in electrical conduit.

Water Connections

Water Piping Water Piping must be installed in accordance with application codes and per necessary standards. Supply and return connections should be connected per units’ directions. Strainers are required on supply to machine per engineer specification to prevent heat exchanger fouling from occurring.
Before start-up can occur, water must be CLEAN and proper procedures and care should be implemented in order to ensure and maintain a clean system. Water should be treated and clean per necessary standards before startup is scheduled. Each water header is equipped standard with a temperature well sensor for supply and return water temperatures of the units’ performance. Also included is a flow switch located on the exit side of the heat exchanger to ensure flow through the heat exchangers, which is integrated into the controls and is adjusted in pre-shipping testing procedures. Furthermore, it is recommended to provide water isolation valves for proper isolation and maintenance of the unit, pumps, and strainers.
Temperature Headers
Temperature headers will need to be installed between the building and chiller connections. DP transducers must be installed at the bank level to monitor water flow through the bank.
Bypass Headers
Bypass headers will need to be installed between the chiller outlet and the building connection with the temperature sensors on the building side of the bypass.
Water Quality Guidelines

Material| | Copper| 90/10 Cupronickel| 316 Stainless Steel
---|---|---|---|---
pH| Acidity/Alkalinity| 7 – 9| 7 – 9| 7 – 9
Scaling| Calcium and Magnesium Carbonate| (Total Hardness) less than 350 ppm| (Total Hardness) less than 350 ppm| (Total Hardness) less than 350 ppm
**Corrosion| Hydrogen Sulfide| Less than 0.5 ppm (rotten egg smell appears at 0.5 ppm)| 10 – 50 ppm| Less than 1 ppm
Sulfates| Less than 125 ppm| Less than 125 ppm| Less than 200 ppm
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 Fouling (Biological Growth)| Iron, FE2+ (Ferrous) Bacterial Iron Potential| < 0.2 ppm| < 0.2 ppm| < 0.2 ppm
Iron Oxide| Less than 1 ppm, above this level deposition will occur| Less than 1 ppm, above this level deposition will occur| Less than 1 ppm, above this level deposition will occur
****Erosion**| Suspended Solids| Less than 10 ppm and filtered for max. of 600 micron size| Less than 10 ppm and filtered for max. of 600 micron size| Less than 10 ppm and filtered for max. of 600 micron size
Threshold Velocity (Fresh Water)| < 6 ft/sec| < 6 ft/sec| < 6 ft/sec

NOTES: Grains = ppm divided by 17 mg/L is equivalent to ppm

Electrical Connections

High Voltage Panels Overview

Single Point Disconnect

The single point panel (SPP) is designed with the intent tobe mounted on the left or right side of the bank of units.
A single SPP can handle up to 10 units with limitations based on voltage ratings. Restrictions of the number of units is applied to 208-230/60/3 options. See Single Point Disconnect Panel nomenclature for availability and maximum number of units. In cases where a single SSP cannot service the bank of the units, a second single point disconnect panel can be installed. The single point panel is certified with accordance to UL508A. Single Point Disconnect
Single Point Disconnect Panel Electrical Connections – Chiller Plant with Single Point Wiring
Wiring Procedures
(Single Point Disconnect Options)

1. Remove top panels from each chiller to gain clear access to the high volt wiring path between each chiller and the single point panel.
2. Unfold all wire conduit runs and note the 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 and L3 terminals on the unit power block or disconnect switch.
4.  Make sure that each wire is properly seated in the lugs and the lugs are properly torqued. Recommended torque:

Breaker Lugs Tightening Torque

Wire| Nm| in-lb| ft-lb

14-#10| 5.6| 50.0| 4.2

8-2/0| 13.6| 120| 10

4/0| 25.5| 225| 18.75

9/7/2021

Electrical Connections – Chiller Plant with Single Point Wiring cont.
Wiring Procedures 

• The differential pressure sensor pressure range need to match the DIP switch settings in the sensor controller. The adjustment can be made through the Primary Unit HMI.
•  Use 20AWG wires size for wiring the temperature sensors and differential pressure sensors.
• The harness with all temperature inputs terminates in the back of the unit near the bottom header.
  Use crimp connectors to joint the temperature sensor wiring and the primary unit harness.

Refrigerant Removal and Evacuation

When breaking into the refrigerant circuit to make repairs – or for any other purpose conventional procedures shall be used.
However, for flammable refrigerants it is important that best practice be followed, since flammability is a consideration.
The following procedure shall be adhered to:

• safely remove refrigerant following local and national regulations;
• evacuate;
• purge the circuit with inert gas (optional for A2L);
•  evacuate (optional for A2L);
• continuously flush or purge with inert gas when using flame to open circuit; and
• open the circuit.

The refrigerant charge shall be recovered into the correct recovery cylinders if venting is not allowed by local and national codes. For appliances containing flammable refrigerants, the system shall be purged with oxygen-free nitrogen to render the appliance safe for flammable refrigerants.
This process might need to be repeated several times. Compressed air or oxygen shall not be used for purging refrigerant systems. For appliances containing flammable refrigerants, refrigerants purging shall be achieved by breaking the vacuum in the system with oxygen-free nitrogen and continuing to fill until the working pressure is achieved, then venting to atmosphere, and finally pulling down to a vacuum (optional for A2L). This process shall be repeated until no refrigerant is within the system (optional for A2L). When the final oxygenfree nitrogen charge is used, the system shall be vented down to atmospheric pressure to enable work to take place. The outlet for the vacuum pump shall not be close to any potential ignition sources, and ventilation shall be available.

Charging procedures

In addition to conventional charging procedures, the following requirements shall be followed.

• Ensure that contamination of different refrigerants does not occur when using charging equipment.
• Hoses or lines shall be as short as possible to minimise the amount of refrigerant contained in them.
• Cylinders shall be kept in an appropriate position according to the instructions.
• Ensure that the REFRIGERATING SYSTEM is earthed prior to charging the system with refrigerant.
• Label the system when charging is complete (if not already).
• Extreme care shall be taken not to overfill the REFRIG- ERATING SYSTEM.

Prior to recharging the system, it shall be pressure-tested with the appropriate purging gas. The system shall be leak-tested on completion of charging but prior to commissioning. A follow up leak test shall be carried out prior to leaving the site.

Refrigerant Recovery

When removing refrigerant from a system, either for servicing or decommissioning, it is recommended good practice that all refrigerants are removed safely.
When transferring refrigerant into cylinders, ensure that only appropriate refrigerant recovery cylinders are employed. Ensure that the correct number of cylinders for holding the total system charge is available. All cylinders to be used are designated for the recovered refrigerant and labelled for that refrigerant (i.e. special cylinders for the recovery of refrigerant). Cylinders shall be complete with pressure-relief valve and associated shut-off valves in good working order. Empty recovery cylinders are evacuated and, if possible, cooled before recovery occurs.
The recovery equipment shall be in good working order with a set of instructions concerning the equipment that is at hand and shall be suitable for the recovery of the flammable refrigerant. If in doubt, the manufacturer should be consulted.
In addition, a set of calibrated weighing scales shall be available and in good working order. Hoses shall be complete with leak-free disconnect couplings and in good condition.
The recovered refrigerant shall be processed according to local legislation in the correct recovery cylinder, and the relevant waste transfer note arranged. Do not mix refrigerants in recovery units and especially not in cylinders.
If compressors or compressor oils are to be removed, ensure that they have been evacuated to an acceptable level to make certain that flammable refrigerant does not remain within the lubricant. The compressor body shall not be heated by an open flame or other ignition sources to accelerate this process. When oil is drained from a system, it shall be carried out safely.
Refrigeration Cycle Analysis Unit Amp Draw………
Line Voltage…………..
Subcooling…………….
Superheat…………………..
Note: Do not attach refrigerant gauges unless a problem is suspected!

Revision Guide

Manufactured at
9000 Conservation Way
Fort Wayne, IN 46809

©2023 9000 Conservation Way, Fort Wayne, IN 46809-9794. Manufacturer has a policy of continual product research and development and reserves the right to change design and specifi cations without notice.

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