WaterFurnace TruClimate 900 Executives Give Update on Geothermal Industry Trends Installation Guide

TruClimate 900 Executives Give Update on Geothermal Industry Trends

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Specifications

• Model: TruClimate 900
• Refrigerants: R-410A and R-454B
• Frequency: 60Hz
• Model Number: IG9001AW

Product Information

General Installation Information

TruClimate 900 air conditioning and heating equipment should
only be installed in locations not accessible to the general
public. Installation and servicing should be done by trained and
qualified service personnel due to potential hazards from system
pressure and electrical components. Safety precautions including
wearing safety glasses, work gloves, and having a fire extinguisher
available for brazing operations should be observed.

Dimensional Data

– Minimum 24-inch clearance required for access to front access
panel.
– Do not store or install units in corrosive environments or
extreme temperature/humidity conditions as it can reduce
performance and service life.

Physical Data

– Do not use the units for heating or cooling during
construction to prevent clogging of mechanical components and
filters with dirt and debris, which can lead to system damage.

Product Usage Instructions

Installation

1. Ensure the installation location is not accessible to the
   general public.

2. Only allow trained and qualified service personnel to install
   the equipment.

3. Observe all safety precautions including wearing safety
   glasses, work gloves, and having a fire extinguisher available for
   brazing operations.

Maintenance

1. Regularly check for any signs of corrosion or extreme
   environmental conditions that may affect performance.

2. Maintain a minimum 24-inch clearance for access to the front
   panel.

3. Avoid using the unit for heating or cooling during construction
   to prevent damage from dirt and debris.

FAQ

Q: Can the TruClimate 900 units be used in corrosive

environments?

A: No, it is advised not to store or install the units in
corrosive environments as it can significantly reduce performance
and service life.

Q: What precautions should be taken during installation?

A: Only trained and qualified service personnel should install
the equipment. Safety precautions like wearing safety glasses and
work gloves should be followed.

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INSTALLATION GUIDE
TruClimate 900
R-410A and R-454B 60Hz

IG9001AW

General Installation Information…………………………………………………………………………………… 2 Dimensional Data……………………………………………………………………………………………………………. 6 Physical Data …………………………………………………………………………………………………………………… 12
Installation ……………………………………………………………………………………………………………………….. 13 Water Connections & Water Quality …………………………………………………………………………… 19 Electrical Connections …………………………………………………………………………………………………… 20 Refrigerant Removal and Evacuation …………………………………………………………………………. 22 Refrigeration Cycle Analysis…………………………………………………………………………………………. 24 Revision Guide ………………………………………………………………………………………………………………… 26

WARNING
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

CAUTION
Maximum altitude for this equipment shall not exceed 2000 m. For installation only in locations not accessible to the general public.
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 heating 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.
Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available for all brazing operations.
NOTE: Before installing, check voltage of unit(s) to ensure proper voltage.
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.

DANGER WARNING CAUTION NOTICE

Indicates a situation that results in death or serious injury.
Indicates a situation that could result in death or serious injury.
Indicates a situation that could result in minor or moderate injury.
Indicates a situation that could result in equipment or property damage.

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.

All TruClimate 900 30 Ton product is Safety listed under UL60335-2-40 thru ETL UL-60335-1 / CAN/CSA- C22.2 No. 60335-1 / UL-60335-2-40 / CAN/CSA- C22.2 No. 60335-2-40

TRUCLIMATE 900 INSTALLATION GUIDE

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 WaterFurnace representative.
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 heating 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 detection 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 department for assistance.
The following checks shall be applied to installations using FLAMMABLE 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)

2

General Installation Information

TRUCLIMATE 900 INSTALLATION GUIDE

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!

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
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.

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.
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.

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.

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.

3

TRUCLIMATE 900 INSTALLATION GUIDE

General Installation Information:

1. Unpack and inspect unit. Note and photograph any external and internal damage that is visible. Check for:

Panel damage

Damage during transportation

Loose victaulic connections (that will not be removed during installation)
Tight compressor bolts Tight frame bolts Secure headers Wiring or component movement in control box

Oil inside the unit Verify Serial Plate matches unit Verify voltage of unit Axial Fan assemblies Air Coils and fin pack

4

TRUCLIMATE 900 INSTALLATION GUIDE

General Installation Information

Application
Units are not intended for heating domestic (potable water) by direct coupling. If used for this type of application, a secondary heat exchanger must be used.
Moving and Storage
Move units in the normal “Up” orientation as indicated by the labels on the unit packaging. When the equipment is received, all items should be carefully checked against the bill of lading to ensure that all crates and cartons have been received in good condition. Examine units for shipping damage, removing unit packaging if 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.
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 lengths. Note unit labels and markings for safe picking points. Do not pick the unit up from points not specified and keep the unit level during transport and handling. Using improper equipment handling methods can result in damage and/or void the warranty.
Unit Location
The unit or bank of units can be installed in a suitable location at ground level or on the building rooftop. Both locations must be able to support the weight of the unit(s) and be located away from any source of discharge gas that could affect the performance of, or prematurely deteriorate metal components in the unit. Examples of discharge gases include boiler flue gases and vents discharging corrosive airborne chemicals. In either location the unit must be installed on a level surface where all four sides of the unit are supported and the front and rear of the unit can be anchored. A concrete slab with footers or mounted on steel channel is favored. It is also recommended that vibration dampening measures be taken in every installation. In addition to supporting the unit, care must be taken in selecting a location with ample clearance for airflow and service personnel as well as consideration for unit noise.
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).

Halt
meter
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200

ft
0 656 1312 1969 2625 3281 3937 4593 5249 5906 6562

AF
1.00 1.00 1.00 1.00 1.02 1.05 1.07 1.10 1.12 1.15 1.18

Not recommended

In cases where the minimum room area cannot be met, ventilation must be provided from either the equipment enclosure, natural ventilation to the adjacent space, or provide mechanical ventilation in the room.

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.
NOTICE: Do not store 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: To avoid equipment damage and possible voiding of warranty, be sure that properly sized strainers are installed upstream of both brazed plate heat exchangers to protect them against particles in the fluid.

5

TRUCLIMATE 900 INSTALLATION GUIDE
Dimensional Data:
15.58″ 396mm BRAZE PLATE CLEARANCE
42.44″ 1078mm

94.38″ 2397mm

34.12″ 867mm
5.47″ 139mm

14.96″ 380mm

SUPERVISORY COMMUNICATION ENTRANCE TYPICAL BOTH SIDES 2″ KNOCKOUT

80.15″ 2036mm

O

6″ 154mm

TYP

HOT WATER OUT

HOT WATER IN

27.00″ 686mm
TYP.

40.26″ 1023mm

27.00″ 686mm
TYP.

POWER INLET 2″ KNOCKOUT

CHILLED WATER IN

15.36″ 390mm
TYP.

CHILLED WATER OUT

10.61″ 269mm
TYP.

6

TRUCLIMATE 900 INSTALLATION GUIDE
Dimensional Data: Service Clearance (TruClimate 900)

24.00″ 610mm

Minimum

Both Sides

0.0″ CLEARANCE UNIT TO UNIT

36.00″ 914mm

Recommended

24.00″ 610mm

Minimum

36.00″ 914mm

Recommended

72.00″ 1829mm

Minimum

CONSULT FACTORY FOR DUCTED APPLICATIONS

34.12″ 867mm

Minimum

CONSULT LOCAL CODE FOR CONTROL BOX CLEARANCES

7

TRUCLIMATE 900 INSTALLATION GUIDE
Dimensional Data: Service Clearance (banked units) RIGHT HAND CONFIGURATION
95.1″ 2416mm

127.4″ 3235mm

(42.1 X 3)

42.1″ 1070mm

Note: See single unit service clearances for banked clearances.

5.1″ 131mm
41.3″ 1048mm

8

Dimensional Data: Concrete Pad Requirements

TRUCLIMATE 900 INSTALLATION GUIDE

21.72

24.39

94.00

26.56

9

A
21.53
2.00
2.00 0.19
DETAIL A
Note: Embed 2″ x 2″ x 0.19″ angle iron in concrete house keeping pad to ensure pipe alignment is consistent.

TRUCLIMATE 900 INSTALLATION GUIDE
Dimensional Data: Center of Gravity
665 LBS
FL

533 LBS
RL

22.37″ 568mm CENTER OF GRAVITY
FR
680 LBS

55.85″ 1419mm
CENTER OF GRAVITY

RR
395 LBS

37.32″ 948mm CENTER OF GRAVITY
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TRUCLIMATE 900 INSTALLATION GUIDE
Dimensional Data: Rigging
1. When lifting the chiller all lifting brackets must be used. 2. Always use spreader bars. The enclosure of the chiller may be damaged if spreader bars are not used.
USE SPREADER BARS TO PREVENT DAMAGE OF UNIT
TOL EXCEP
MAT. PAINT MAT. PAINT SPEC. INSULATED
Note: All bottom attachment points must be used for lifting (4 total). Upper attachment for tie down only. Not to be used as lift point.
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TRUCLIMATE 900 INSTALLATION GUIDE
Dimensional Data: Bypass (Temp and Valve)
LTR
A

1/2″ NPT BUNG
1/2″ N WATER PRESSURE SENSOWR ATE
SENSO

CUT GROOVE PER VIC 25.01 REV J
4.00″ 6.50″

4 3
2

15.00″

1

15.36″ CENTER LINE

1/2″ NPT BUNG
WATER TEMP SENSOR TYPE II
7 6 5 8

12

Physical Data

TRUCLIMATE 900 INSTALLATION GUIDE

Model R410A/460V

030

Model R454B/460V

030

Model R454B/208-230V

030

Refrigerant Number of Circuits Factory Charge, lbs [kg]*

2 26 [11.8]

Refrigerant Number of Circuits Factory Charge, lbs [kg]*

Refrigerant

2

Number of Circuits

23.4 [10.6] Factory Charge, lbs [kg]*

2 23.4 [10.6]

Compressor

Compressor Quantity [tons]

2 [15]

Compressor Weight, lbs [kg] (ea.) 89.3 [40.5]

Oil Charge, oz [L]

44 [1.8]

Compressor

Compressor

Compressor Quantity [tons]

2 [15]

Compressor Quantity [tons]

Compressor Weight, lbs [kg] (ea.) 88.8 [40.3] Compressor Weight, lbs [kg] (ea.)

Oil Charge, oz [L]

44 [1.8]

Oil Charge, oz [L]

2 [15] 91.9 [41.7] 44 [1.8]

Fans Quantity Weight, lbs [kg] Max RPM

2 100.3 [45.3] 1100

Fans Quantity Weight, lbs [kg] Max RPM

Fans

2

Quantity

100.3 [45.3] Weight, lbs [kg]

1100

Max RPM

2 100.3 [45.3] 1100

Evaporator Quantity Weight, lbs [kg] Water Volume, gal [L] Condenser Quantity Weight, lbs [kg] Water Volume, gal [L] Unit

1 127 [57] 3.6 [13.5] 1 127 [57] 3.6 [13.5]

Evaporator Quantity Weight, lbs [kg] Water Volume, gal [L] Condenser Quantity Weight, lbs [kg] Water Volume, gal [L] Unit

1 127 [57] 3.6 [13.5] 1 127 [57] 3.6 [13.5]

Evaporator Quantity Weight, lbs [kg] Water Volume, gal [L] Condenser Quantity Weight, lbs [kg] Water Volume, gal [L] Unit

1 127 [57] 3.6 [13.5] 1 127 [57] 3.6 [13.5]

Shipping Weight, lbs [kg]

2273 [1031] Shipping Weight, lbs [kg]

2273 [1031] Shipping Weight, lbs [kg]

2273 [1031]

• – Charge per Circuit

2/22/24

13

TRUCLIMATE 900 INSTALLATION GUIDE
Chiller Installation: Single Unit with Supervisory
Place unit on pad and or rails. Reference Detail A of drawing on page 9.
Align Supervisory box to the unit and attach with field supplied screws/bolts. Note: Bracket ships with supervisory panel. If single point panel is to be installed, see “Single Point Power Kit” instruction manual before installing the supervisory panel. Note: Supervisory box may be mounted remotely, but will require additional field wiring and supplies.
14

TRUCLIMATE 900 INSTALLATION GUIDE
Chiller Installation: Single Unit with Supervisory
2″ knockouts are provided on both the supervisory and the sides of the unit. Communication connections are routed through conduit (field installed). NOTE: Connections must be weatherproof and rated for outdoor installation.
15

TRUCLIMATE 900 INSTALLATION GUIDE
Chiller Installation: Multiple Units with Supervisory
If units are being installed in a bank, only the primary unit (Unit A in figure below) will ship with all side panels assembled. Once the primary unit A is placed, remove side panels 1-9 and relocate them to the side of the end unit C. Panels can be removed in any order, but must be reassembled in the same location on the end unit C.

C

B

C

B

A
1 1 2 3 74
5 6 7 89 A

16

TRUCLIMATE 900 INSTALLATION GUIDE
Chiller Installation: Multiple Units Victualic Connections
Interior victaulic connections can be accessed through the center lower side panel (shown below). Once this panel is removed, a 21″ opening allows a technician to enter a bank of units and establish secure victaulic connections throughout multiple units.
17

TRUCLIMATE 900 INSTALLATION GUIDE
Chiller Installation: Multiple Units Victualic Connections
Additional access for victaulic connections can be accessed through the front of the cabinet. All louvered panels are removable on the unit. See example below.
18

TRUCLIMATE 900 INSTALLATION GUIDE
Installation Information: Bypass and Temperature Headers
1. Install header bypass header pipes with grooved couplings to the header rack as shown below. Tighten the large grooved fittings just enough so the headers are supported and can still be moved side-to-side. This freedom of movement is necessary when installation the second floating flange. Do not fully tighten
Headers should be able to move from side to side
19

TRUCLIMATE 900 INSTALLATION GUIDE
Installation Information: Bypass and Temperature Headers
2. Install both floating flange gaskets on the small pipes. The gasket must be installed as shown. DO NOT LUBRICATE THE FRONT FACE OF THE GASKET. Failing to install the gasket in the correct orientation will cause a leak. Section view of the flange is shown in Figure 3.

Do not lubricate this surface
Figure 2: Floating flange gasket

Figure 2a: View of proper gasket installation with flange

Figure 3 : Section view of floating flange
20

TRUCLIMATE 900 INSTALLATION GUIDE
Installation Information: Bypass and Temperature Headers
3. Place the floating flange and hand thread one bolt in the valve body. Place the flange sandwich plate between the valve seal and the flange seal. Add the rest of the bolts and only hand tighten. Center the sandwich plate using a ruler or a tool with marking of the correct distance between the ring and outer diameter of the flange (SEE Figure 4). Failure to center the ring correctly can cause a leak.
4. Rotate the valve assembly to a desired angle or to the suggested orientation in the assembly drawing shown in Figure 5. Once the ring is centered tighten all bolt to 40ft-lb following the pattern shown in Figure 5.
Flange ring
Figure 4: Valve and floating flange adapter installation
5. Add the second floating flange to the assembly. Thread one bolt to the valve body and hand tighten. Add the floating flange sandwich plate while pushing the header assemblies apart. Add the rest of the bolts and hand tighten. Center the flange in the same way as shown in step 4. Tighten all bolts.
6. Tighten the large header grooved clamps.
Figure 5: Flange torque pattern
21

TRUCLIMATE 900 INSTALLATION GUIDE
Chiller Installation: Bank with Single Point Power

6

15

2

1

16 27

3 2
18 33

7 1
9 2

11 4
13 8

Item Number P/N

1

79D665-03

2

19P086-05

3

47P921-02

4

47P921-01

5

19P086-07

6

19P086-04

7

19P086-06

8

19P086-09

9

2″ Liquid Tight 90

10

19P086-08

11

47P818-60N

12

1/4-20X1″ Machine Screw

13

91P015A82

14

GASKET

15

GASKET

16

19P086-04

17

19P086-04

18

19P086-04

Quantity 1 2 2 2 6 2 1 1 2 1 4 4 8 7 1 27 6 33

17 6
12 4

14

7

8

1

10 1

1 1

2 2
5 6
4 2

22

TRUCLIMATE 900 INSTALLATION GUIDE

Water Connections

Water Piping
Water Piping must be installed in accordance with application codes and standards. Supply and return connections are to be installed per installation instructions. Strainers are required on the water supply, per engineering specification, to prevent heat exchanger fouling.

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.

It is recommended to provide water isolation valves for proper isolation and maintenance of the unit, pumps, and strainers. Proper procedure and care must be taken to ensure a clean system.

Bypass Headers
Bypass headers will need to be installed between the chiller outlet and the building connection.

BEFORE START-UP IS SCHEDULED, Piping system must be cleaned, flushed, and filled with water that is clean and treated in accordance with the necessary standards and specifications.

Each water header is equipped with standard supply and return water temperature sensors.

Software ingratiated flow switches are installed on the headers to insure water flow is present before the unit will start.

Units must be powered with all control wiring connected in accordance with the wiring schematic.

Complete chiller pre-startup form and submit to startup technician prior to scheduling startup services.

Water Quality Guidelines

Material pH
Scaling

Acidity/Alkalinity Calcium and
Magnesium Carbonate

Hydrogen Sulfide

Corrosion
Iron Fouling (Biological Growth)

Sulfates Chlorine Chlorides Carbon Dioxide Ammonia Ammonia Chloride Ammonia Nitrate Ammonia Hydroxide Ammonia Sulfate Total Dissolved Solids (TDS) LSI Index Iron, FE2+ (Ferrous) Bacterial Iron Potential
Iron Oxide

Suspended Solids

Erosion

Threshold Velocity (Fresh Water)

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

Copper 7 – 9
(Total Hardness) less than 350 ppm Less than 0.5 ppm (rotten egg smell appears at 0.5 ppm) Less than 125 ppm Less than 0.5 ppm Less than 20 ppm Less than 50 ppm Less than 2 ppm Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm Less than 1000 ppm
+0.5 to -0.5

90/10 Cupronickel 7 – 9
(Total Hardness) less than 350 ppm
10 – 50 ppm
Less than 125 ppm Less than 0.5 ppm Less than 125 ppm
10 – 50 ppm Less than 2 ppm Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm 1000 – 1500 ppm
+0.5 to -0.5

< 0.2 ppm

< 0.2 ppm

Less than 1 ppm, above this level deposition will occur
Less than 10 ppm and filtered for max. of 600 micron size

Less than 1 ppm, above this level deposition will occur
Less than 10 ppm and filtered for max. of 600 micron size

< 6 ft/sec

< 6 ft/sec

316 Stainless Steel 7 – 9
(Total Hardness) less than 350 ppm
Less than 1 ppm
Less than 200 ppm Less than 0.5 ppm Less than 300 ppm
10 – 50 ppm Less than 20 ppm Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm 1000 – 1500 ppm
+0.5 to -0.5
< 0.2 ppm
Less than 1 ppm, above this level deposition will occur Less than 10 ppm and filtered for max. of 600 micron size
< 6 ft/sec
2/22/12

23

TRUCLIMATE 900 INSTALLATION GUIDE
Electrical Connections
HydroLink IB-G BOARD-A IB-G BOARD-B
ABC-A FAN FUSING DISCONNECT

Compressor Drive Circuit A

Power Supply Board

AXB-A-2

Compressor Drive Circuit B

AXB-B-2
AXB-A-1 AXB-B-1
ABC-B LOW VOLT TERMINAL BLOCKS COMPRESSOR CONTACTOR A COMPRESSOR CONTACTOR B CONTROL TRANSFORMERS

COMPRESSOR FUSING
NOTE: · Pressure screw torque 275 lb.in (31.1 Nm) · Lug bolt torque 70.8 lb.in (8 Nm)

TRANSFORMER FUSING

24

Electrical Data

TRUCLIMATE 900 INSTALLATION GUIDE

Model

Rated Voltage

Voltage Min/Max

208-230/60/3 030 R454B
460/60/3

187/253 414/506

Compressor*

MCC 87.7 71.4

MRC 60.8 49.5

FAN
FLA 7.2 4.2

Total Unit FLA
136.0 107.4

Min Circ Amp
151.2 119.8

Max Fuse/ HACR
175 150

030 R410A

460/60/3

414/506

71.4 49.5 4.2

107.4

119.9

150

HACR circuit breaker in USA only

10/17/23

• – MCC, MRC & LRA rating per compressor / fan.FLA, MCA and Max Fuse sized for both compressors & fans.

25

TRUCLIMATE 900 INSTALLATION GUIDE

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 REFRIGERATING 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.
26

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.

TRUCLIMATE 900 INSTALLATION GUIDE

27

TRUCLIMATE 900 INSTALLATION GUIDE
Refrigeration Cycle Analysis

M

VI EEV
V
S
SYSTEM EEV

HEATING BPHX

COOLING BPHX

AIR COIL

FD M

28

Notes

TRUCLIMATE 900 INSTALLATION GUIDE

29

Revision Guide

Pages: Description:

All

Document Creation

Date: 04 March 2024

By: SW/MA

IG9001AW
IG9001AW 03/24

Product: Type: Size: Document:

Manufactured at 9000 Conservation Way Fort Wayne, IN 46809
TruClimate 900 Water-Cooled Chiller – 60 Hz 30 Ton Installation Manual

©2024 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 specifications without notice.

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