08 WestinghouseCentrifugal Packaged Chiller

installation, operation and maintenance INSTRUCTIONS for

PEO95WPE105WPE115WPE125WPE130WPE135W

Figure 1.

GENERALThis manual contains complete detail for thecorrect installation, operation and maintenanceof the most modern and unique self-containedcentrifugal package water chiller available. Some

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of1.

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the outstanding features are listed below:The unit is completely assembled and tested;;,“,he factory and requires no field assembly,

reducingcon&actor.

installation costs to the5.

The unit is shipped with a full operatingrefrigerant charge.The use of enclosed plug-in relays in thecontrol center provides greater reliabilityand ease of service or replacement. Onlytwo types of relays are used, keeping replace-ment parts cost to a minimum. Replacement

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is s imple and quick since there are noelectrical connections to change.The control center is completely prewiredand tested, and all controls are set. Thecontrol center requires no field connectionother than normal interlocks, i.e. pumps.The use o f re f r igerant -12 and a d i rec texpansion chiller reduce the size and weightof the package; and using R-12 also eliminatesthe need for a purge system.The design and use of the movable diffuserblock have virtually eliminated the rotatingstall or surging, present in all conventionalcentrifugal compressors.Unit is completely serviceable without removingrefrigerant charge.

NEW INFORMATIONSUPERSEDES PE-Gl DATED DECEMBER. 1964-R-1 EFFECTIVE JULY, 1970

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I N S T A L L A T I O N

RECE IV ING & H A N D L I N G WATER CONNECT IONSThe unit should be inspected immediately afterreceipt for possible shipping damage. The PEwater chillers are shipped f.o.b. factory, and allclaims for handling and shipping damage are theresponsibility of the consignee.

Leave the shipping skid in place until the unit isin its final position. This will aid in handlingthe equipment.

Extreme care should be used when rigging theequipment to prevent damage to the control center ,refrigerant piping or water chiller enclosure.

The unit can be lifted after fastening the rigginghooks to the 4 corners at the base of the equipmentwhere the mounting openings are located. Spreaderbars should be used between the rigging lines toprevent damage to the control center and thechiller enclosure.

Chilled Water Connections-The PE units comeequipped with flanged-type water connections. Theinstalling contractor must provide a matchingcompanion flange and gasket for the inlet andoutlet when making up these connections. Theconnection sizes are given in Table I page 14. Thewater inlet is the upper connection while the outletis at the bottom. With the warmest water enteringat the top, less refrigerant circuit area is requiredfor superheating. The inlet and outlet connectionpoints are shown in Fig. 2.

L O C A T I O N & M O U N T I N G

The chilled water piping should include sufficientshutoff valves to permit draining the water fromthe chiller without draining the complete system.The piping should also include thermometers atthe inlet and outlet connections and air vents atthe high points. The piping should be located andsupported so that excessive weight is not borneby the chiller connections. The piping should alsobe adequately insulated.

The PE unit should be mounted on a concrete orsteel base and should be located so as to provideservice clearances of 12 feet at the connection endof the water chillers for possible removal of tubebundle and condenser tubes and 3 feet at all otherpoints. (Condenser tubes are rolled into tubesheets to permit replacement if necessary).

In cases where the chilled water pump noise maybe objectionable, it is recommended that rubberisolation sections be used at both the inlet andoutlet of the pump.

Make certain that the floor or structural supportis adequate to support the full operating weightof the complete unit. Operating weights are shownin Table I.

Small water pressure test valves are provided atboth the inlet and outlet to the chiller. Thispermits checking of the water pressure dropthrough the chiller. The pressure drop through thevarious chillers is shown in Table III. Refer tochiller nameplate for identification.

The unit weight is equally divided between thetwo bottom horizontal base members. 30 squareinches of rubber Shearflex pads or “Isomode” sup-plied with unit under each corner is sufficient forproper isolation.

A cleanable-type water strainer with a mesh ofapproximately 20 is recommended at the inlet tothe chiller pump, particularly on installationswhere the chilled water piping is made up of steelpipe with welded joints or where the water orpiping is subject to foreign matter.

It will not be necessary to bolt the entire unit tothe mounting slab or framework; but should thisbe desirable, 1% inch mounting holes are providedat the base of the 4 corners.

The chiller is built with a removable U type tubebundle to permit easy removal of complete bundle(if repair or replacement necessary) without dis-turbing chilled water piping.

1. Scavenger Line 13. l iquid Line Strainer

2. Suction Line 14. Liquid Line Solenoid

3. External Eq. Lines 15. Oil Supply Line Vane Operation

4. Suction Line Motor Cooling 16. Oil Fi lter

5. Suction Service Valve 17. Chilled Water In

6. Expansion Valve Motor Cooling 18. Chilled Water Out

7. Liquid Line Motor Cooling 19. Discharge Coupling

8. Bearing Oil Supply 20. Suction Coupling

9. Discharge Check Valve 21. Oil Pump Assembly

10. Oil Cooler Water Conn. 22. Check Valve

11. Oil Cooler 23. Thermostat Wells

12. Liquid Line Shut Off Valve

Note: When common piping is used in connectionwith a heating system, care should be taken thatwater flowing through chiller cannot exceed 120°F.Condenser Water Piping-The condensers used onall standard units are 2-pass with the inlet at thebottom and the outlet at the top.Connection sizes are given in Table I.The condenser water heads can be interchanged(end for end) so that the water connections canbe made at either end of the unit. If this is done,new condenser end head gaskets should be used.Water piping should comply with local codes andshould always include:

1. Sufficient shutoff valves to permit draining thewater from the condenser without draining thecomplete system, thermometers at the inletand outlet connections and tappings for cir-culating a chemical cleaner if cleaning of con-denser becomes necessary (Tapping to belocated between shutoff valves and con-denser.)

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A cleanable-type strainer in the supply line.Provision for draining the condenser andpiping. Note: The condenser is not self-drainingand must be blown out. Refer to the section inthis manual under Seasonal Servicing foradditional information on draining.Insulation on the supply line, depending onwater temperature and ambient dew pointtemperature.Flow balancing valve on a cooling towerinstallation.Pipe hangers properly located so as to takethe weight and strain off the piping accessoriesand fittings.

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Figure 3.

1. Scavenger Line 6. Condenser Water In2. Suction Line 7. Oil Level Sight Glass3. Solenoid Assembly - 8. Expans ion Valve #l

Vane Control - Oil Safety 9. Sight Glass (Rotation)4. Oil Heater Well 10. Oil Pump Assembly5. Condenser Water Out

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Note: In most cases, it will not be necessary toprovide vibration eliminator sections in the inletand outlet water lines; but where noise and vibra-tion is critical (an example would be where a pipechase goes through walls adjoining living quartersin an apartment building), they must be used.

OIL COOLER P IP ING

The oil cooler is sized to maintain proper oiltemperature when supplied with 4 G.P.M. of waterat 85F or lower. If it is desired to conservewater when the water temperature is below 85F.flow can be adjusted to maintain maximum dis-charge oil temperature of 110F. Temperaturesmust be measured with a Simpson thermometer orequal.

If the oil cooler water supply does not stop withmachine, a normally-closed solenoid valve willhave to be installed and wired as recommended onthe diagram furnished with unit.

If the oil cooler is piped to city water, a normally-closed solenoid valve and balancing cock must beinstalled. The oil cooler water inlet connection isat the bottom. Water off the oil cooler should bepiped to an open sight drain, and trapped toprevent the cooler from draining on the off cycle.This leaving water can also be used for towermake-up water. See Figure 4 for piping.

When the oil cooler is piped to chilled water,it should be connected across full pump pressure.This method is preferred since full pump pressuredifferential is maintained across the cooler at alltimes the compressor is running. See pipingsketch, Figure 4.

VENT P IP ING

As a safety precaution, each system is equippedwith two pressure relief valves located on the con-denser, for the purpose of relieving excessive re-frigerant pressure to the atmosphere. Many localcodes require that relief valves be vented to theoutside, and this is a desirable installationpractice for all installations. Wherever ventpiping is installed the lines should be run inaccordance with local code requirements or wherelocal codes do not apply ASME code recommenda-tions should be followed.

ELECTRICAL

IMPORTANT: The voltage to these units shouldbe within the limitation of plus or minus 10%(except on 208/220 volt units where the voltagelimitation is plus 10% on 220 volts and minus 5%on 208 volts), and the voltage unbalance betweenphases must not exceed 3%. Since a 3 1/2 % voltageunbalance will cause an approximate 25% increasein motor temperature, it is most important thatunbalance between phases be at a minimum.

POWER WIRING

Wiring, fuse and wire size must be in accordancewith information in Electrical Data section.

Standard NEMA motor starters require modifi-cation to meet Westinghouse specifications. Referto the Electrical Data section for details.

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Power wiring to compressor must be in properphase sequence. Motor rotation-is set up for clock-wise rotation facing lead end with phase sequenceof l-2-3. Care should be taken that proper phasesequence is carried through starter to compressor.With the phase sequence of l-2-3 and Llconnected to Tl and T6 - L2 connected to T2 andT4-L3 connected to T3 and T5-Rotation isproper.

Note: Do not make final connections to motorterminals until wiring has been checked and ap-proved by Westinghouse representative.

Under no circumstances is compressor to be startedunless proper phase sequence and rotation hasbeen established. Serious damage mav result ifcompressor starts in wrong rotation. JOG machineonly to check rotation using sight glass on gearcover to observe. Phase sequence can be deter-mined by using GE No. 546703265 phase sequencemeter or equal.

Care should be taken when attaching leads to com-pressor terminals. Make sure terminals do notturn. Slots are provided on terminals for screw-cr,, to hold against rotation when tightening

CONTROL WIR ING

The control circuit on the PE packagedchiller is designed for 115 volts. It should be sup-plied from a separate circuit and fused at 18 amps.The disconnect switch should be tagged to preventcurrent interruption. Switch is to remain on atall times in order to keep oil heater operative, andprevent refrigerant from accumulating in oil.

The control center hand-off-auto switch should beturned to the “off” position any time compressoroperation is not desired.

In the event control voltage is supplied by a trans-former, the transformer should be rated at 2 KVA,with an inrush rating of 12 KVA. Again disconnectswitch should be marked to prevent control circuitfrom being de-energized. Pump interlock terminalsare provided on the control center terminal strip.See field connection diagram in electrical datasection or in cover of control center for proper con-nections. The purpose of the pump interlocks isto prevent compressor operation until such a timethat both the chilled water and condenser waterpumps are running.

With this arrangement the chilled water pumpmust be started manually and will run continuous-ly. The cooling tower pump will cycle with themachine. The holding coil of the cooling towerpump motor starter must be rated at 115 voltswith a maximum volt-ampere rating of 100. If thisvolt-ampere rating is exceeded, a control relay isrequired.

C O N T R O L C E N T E R

The control center contains all of the necessaryprotective and operating controls. These includethe cycling thermostat, the Guardistor protec-tive circuit controls, low water temperature cutout,low refrigerant temperature cutout, high and low

pressure cutouts, oil pressure protector, dischargetemperature cutout, oil temperature cutout, lowpressure override, compressor time delay, oil pumptime delay, oil pump contactor, overloads, capa-citor, recycling timer, indicator lights and relays.The function of operating controls is as follows:

(For complete control summary see table II onpage 14.)

Oil Pump Time Delay (OTD) -Set at 30 seconds tokeep oil pump running 30 seconds after machinehas shut down.Compressor Time Delay (CTD)-Set for 5 seconds.Delays compressor start to allow oil pressure tobuild up and lubricate bearings before start.

Recycling Timer (TDR) - Set 40 minutes. Limitsstarts to 3 in 2 hours maximum.The control center is wired so that an indicatinglight will be energized upon the action of anyof the safety controls. The light will remainon until such a time that the control circuit isreset, even though the cause of compressor shut-down has been corrected, or has corrected itself.See Table IV for light and switch identification.

Repeated trippings of any safety control shouldbe investigated by a qualified refrigerationmechanic or service engineer.

The control reset button is located on the outsideof the control center door. Discharge, suction andoil pressure gauges are provided on the controlcenter.

An interior view of the control center is shown inFigure 5.

T E S T I N G C O N T R O L C I R C U I T

Upon completion of power and control wiring, thecircuit should be tested functionally; but in doingthis, the compressor must not be started.

The first few minutes of compressor operation arecritical and require experienced observation of alloperating characteristics.

The circuits can be completely tested withoutenergizing the compressor.

In cases where a separate control voltage source isfurnished (as required), it is only necessary toenergize the control circuit. Have compressor dis-connect switch open.

Correct operation of time delays, safety and inter-locks can be determined by observing operation ofrelay “MCR” (motor control relay) located instarter. (Furnished by starter manufacturer.)

On systems using a transformer to obtain controlvoltage, it will be necessary to remove load leadsfrom the starter to compressor and observe starteroperation.

All field interlock connections should be checkedfor proper operation by stopping each pump inorder. Motor control relay should de-energize atthe same time interlock is opened.

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GUARDISTOR PROTECTIVE CIRCUITPositive protection against motor overheating isprovided with this unique Westinghouse motordevelopment. The heart of the Guardistor pro-tective circuit is the thermistor embedded in themotor winding, which senses motor temperature.

When the motor temperatures are normal. thethermistor has low resistance which remains nearlyconstant up to predetermined critical temperature.At this temperature, a sharp increase in resistanceoccurs for a small increase in temperature. Thissharp increase in resistance causes the Guardistorrelay to drop out. When the guardistor relay con-tacts open, the compressor starter holding coil be-comes de-energized stopping the compressor.

A thermistor-equipped motor which utilizes theGuardistor protective circuit integrates all heat-causing factors of load, ambient and power supplyright in the motor wmdings to give you greatlyincreased protection against motor burnout.

Figure 5.

The Guardistor protection is not intended toreplace the standard overload motor protection butto supplement it. Should the Guardistor protec-tive circuit become inoperative and cease tofunction properly, it can be removed from the con-trol circuit by placing a jumper across terminalsNos. 1 and 2 on the GR Guardistor relay. Thefact that the Guardistor circuit relay becomes de-energized does not mean that the protective circuithas become permanently inoperative but couldindicate a high motor temperature or faulty controlcomponents. For example, a defective capacitorwould cause the relay to become de-energized. Thedefective items should then be replaced.The Guardistor control is a manual reset protectivedevice. The reset button is provided on the controlcenter. THE CONTROL CIRCUIT MUST BER E S E T I N T H E E V E N T O F A P O W E RFAILURE O R W H EN EV E R T H E C O N T R O LVOLTAGE SOURCE IS INTERRUPTED.

STARTING SEQUENCEPlacing the hand-off-auto switch in the automaticposition will allow the unit to start, assumingelectric power is available to all controls andstarters and that all pilot lights are out. (The latterindicates all safety control contacts are closed.)

The oil pump will start immediately, build uppressure and close the oil pressure protector switch,and at the same time energize the compressor timedelay relay. The oil pump will run for approxi-mately 5 seconds before the compressor time delayrelay contacts close, which in turn allows thecompressor to start.

During the time the oil pump is running beforethe machine starts, the vanes will move to a closedposition. On a normal shut down, the vanes willmove to a closed position during the 30 secondsthe pump operates.

When and if the load drops below the minimumthe unit can handle, (approximately 1 0 % of fullload) the cycling thermostat will open and stop themachine. A recycling timer limits the number ofstarts to 3 in 2 hours; therefore, if the previous“on” cycle was less than 40 minutes in duration,the balance of the 40 minutes must expire beforethe machine can restart.

1. Electronic Motor ControlModule

2. Electronic TemperatureControl Module

3. Oil Pump Time Delay4. Recycling Timer5. Thermostat Chilled Water6. Thermostat Refrigerant7. Thermostat - Cycling

9. High Oil Temp. Thermostat10. Discharge Temp. Thermostat11. Oil Pressure Switch12. Low Pressure Switch13. High Pressure Switch14 Low Pressure Override Switch15. Fuse Oil Heater16. Oil Pump Motor Contactor17. 24 Volt Vane Control Relays

8. Compressor Time Delay Relay 1 8 . 115-Volt Control Relays19. O.P.T. Timer (Not in photo)

SHUTDOWNA manual shutdown can be accomplished byplacing the hand-off-auto switch in the “off”position. The compressor will stop immediately,but the oil pump will continue to run for 1 minuteand supply oil pressure to the compressor bearingswhile the compressor is coasting to a stop. Duringthis minute also, the vanes will move to a closedposition.

On an interruption due to a power failure or oilpump overload tripping, a normally-open solenoidvalve “SD” located in the vane control box, is de-energized. With this valve open, condenser gaspressure forces the oil in the oil supply line, theoil filter and the oil cooler, to the bearings. A checkvalve in the oil supply line prevents oil from beingforced back into the oil pump. A check valve inthe condenser gas line prevents oil from beingforced into the condenser. Fig. 6.

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This permits the operator to limit the power drawnby the unit, and allowing operating economy bylimiting demand charges.Example-With the demand limit switch in the50% position, the motor load control will preventthe motor load current from exceeding 50% ofrated amps.Incorporated in the motor load control circuit is afast - close solenoid “SC”. When either the lowpressure override switch or motor load control ex-ceed their set points, the solenoid is energized, by-passing the metering valve allowing the vanes toclose in approximately 15 seconds.The electronic controls are adjusted and calibratedat the factory and need no field adjustments; butin the event of damage or change of calibration dueto shipping, then and only then should the follow-ing steps be taken.

ELECTRONIC CONTROL OPERATIONThe electronic control system regulates the chilled-water temperature and prevents motor overloadby hydraulically positioning the inlet guide vanesto control unit capacity and motor current.Under normal operating conditions the chillerleaving-water temperature is controlled by atemperature module. A temperature element(electrically connected to module) is insertedin the chiller leaving-water. The temperatureelement is a resistance element which is part ofa bridge circuit from which signals are amplifiedby the electronic amplifier which in turn actuatesthe open and close relays.The relays operate solenoid valves “SA” and “SB”which allow oil to be fed to or bled from thehydraulic piston, which controls the position of theinlet guide vanes. An increase in chiller leaving-water temperature will cause the inlet guide vanesto move towards the open position, while a decreasein water temperature will move the vanes towarda closed position.The temperature module also contains a switchthat can manually position the inlet guide vanes.This switch is normally in the “Automatic”position. The vane position can be changedmanually by turning the switch to “Increase”to close vanes and increase water temperature,‘(Decrease” to open vanes and decrease watertemperature, or “Stop.” When switch is turnedto "Stop,"” the vanes will remain in the existingposition. The function of this switch is notdependent upon tubes or electronic components;therefore, it can be used as a service expedientto control the vanes.

Set the current limit knob to 100%

C h e c k f o r p r o p e r motor l o a d s i g n a l ( v o l t a g e ) at f u l l m o t o rc u r r e n t . V o l t a g e b e t w e e n t e r m i n a l s “ A ” a n d “ C ” s h o u l d b eb e t w e e n .45 and .55 volts. T h i s c o n b e c h e c k e d w i t h a volt-ohmeter. Fu l l load motor current can be determined by us inga c lamp-on ammeter on the motor leads. The vanes c a n b eoperated manually by placing the vane switch in the “Decrease”(open) position. If the compressor will not load at 100% it maybe n e c e s s a r y t o t u r n C R 1 a n d C R 2 a d j u s t i n g s c r e w s f u l l yc lockwise . Th is w i l l a l low the machine to load wi thout themotor load control.

The motor load control can override the operationof the vanes at any time. This operation is in-dependent of the vane selector switch, whether itis in the manual or automatic position.The motor load control also contains a demandlimit positioner, with a range from 40% to 100%.

4,

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CR1 re lay adjustment must be made f i rs t . Load t h e m a c h i n ewi th the manual swi tch, when the load reaches 105% of themotor load current (read on ammeter ) s lowly adjust the CR1screw counter -c lockwise unt i l CR1 re lay energizes ( re lays CR1and CR2 con be observed by removing cover)

Again, load machine to 100% wi th the manual s w i t c h . A d j u s tscrew CR2 unt i l re lay energizes just a s 1 0 0 % load is reached(Note ampere r e a d i n g )

Recheck settings by repeating steps 3 and 4. To load machineto 10556, i t w i l l b e n e c e s s a r y t o p l a c e a j u m p e r b e t w e e nterminals “D” and “E” ( I f jumper is not used vanes wi l l s topat 100%)

MOTOR LOAD CONTROL CHECKIf the signal to the motor load control is notbetween .45 and .55 volts, adjust as follows:

V A N E SOLENOID OPERATION

SA- ENERGIZEDOPENING SB - ENERGIZED

CLOSING SA- DE ENERGIZEDSB. DE ENERGIZED

ENERGIZED DE ENERGIZED

ENERGIZED DE ENERGIZED

CONDENSER

ENERGIZED DE-ENERGIZED

Figure 6.

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6. At times, i t w i l l not be poss ib le to fu l ly load the machine ,s o f u l l load c u r r e n t w i l l n o t b e a v a i l a b l e f o r a d j u s t m e n tpurposes. In th is case set the % current l imi t d ia l to a l o w e rsetting to calibrate.

T h e dial set t ing and the loads a t which CR1 and CR2 re laysshould be calibrated to operate can be calculated as follows:

Assume full load 400 amps but you can only load to 320 amps.

% Load setting =Max. load avail. - 5% of full load x 1 0 0

Full Load

3 2 0 - (5% of 400) x 1 0 0

4 0 0

3 2 0 - 20 = 7 5 %

4 0 0

CR2 Cal ibrat ion = 75% of full load.75 x 400 = 3 0 0 a m p s .

C R 1 C a l i b r a t i o n = CR2 + 5% of full load300 + 20 = 3 2 0 a m p s .

CR1 must be adjusted first.

N o t e - When amperage readings are token on the load s ide ofo f a s tar de l ta s tar ter the readings are in phase amps.To convert to line amps multiply by 1.732.

VANE CONTROL

The hydraulic system consists of__ one 3-wayone 3-waynormally-open solenoid valve “SB”,

normally-closed solenoid valve “SA”, one 2-waynormally-closed solenoid valve “SC” and onemanual metering valve. The action of thesesolenoids control the movements of the hydraulicpiston which operates the vanes. Oil underpressure is supplied to either or both sides ofthe piston depending upon the signal supplied bythe electronic control. Fig. 6.

To Open the vanes, “SA” and “SB” are energized.“SC” is de-energized. The flow through “SA” isfrom “B” to “A”. This puts pressure on thecylinder in the opening direction, solenoid “SB”is open from “A” to “B”, which allows oil to drainfrom cylinder and vanes open.

T o c l o s e t h e v a n e s , “SA” a n d “ S B ”de-energized.

are(“SC” can be energized or

de-energized depending on what signal is closingthe vanes. If low pressure or motor overload iscausing vanes to close, “SC” is energized.)

The flow through “SB” is from “C” to “A” put-ting pressure on piston in the “close” direction.Pressure on cylinder is relieved and allowed todrain through “SA” from “A” to “C”, closingvanes.

When the vanes are in the “hold” position, pressureis applied to both sides of the piston. “SA” isenergized; “SB” and “SC” are de-energized. Flowthrough “SA” is from “B” to “A” and from “C” to“A” through “SB”.

METERING VALVE

The needle type metering valve in the oil supplyline is used to control the speed of vanetravel while under temperature control. The valveis factory-set so that from a full close to full openposition of the vanes requires a minimum of 3minutes. Maximum rate of travel will be dictated

by load requirements. To decrease speed of travelclose the valve slightly. Speed should be slowenough to prevent over-controlling. At this rate oftravel, the temperature can be sensed and vanesstopped before a hunting situation occurs.However, the slow travel is undesirable undercertain circumstances. When low suction pressureor motor load control call for the vanes to close,a fast response is desired. This is accomplishedk;cby-passing the metering valve with solenoid

“. When “SC” is energized, vanes close inapproximately 15 seconds.

OIL SAFETY SOLENOID

“SD” is a normally-open solenoid valve (2-way).The purpose of this valve is to provide oil to thebearings in case of a power failure or oil pumpoverload tripping. When “SD” is de-energized,the valve is open and condenser gas forces the oilin the oil filter, oil cooler and oil supply line tothe bearings. (See Figure 6.)

Check valves 1 and 2 are installed to preventoil from flowing back to the oil pump or oilflowing to the condenser. The condensing pressureshut-off valve (located on top of the condenser)must be opened, but only after the control circuithas been energized in order to prevent migration.

OIL SYSTEM

The oil pump is completely self-contained in itsown reservoir. The assembly includes the pump,pump motor, oil heater and separator. The oil ispumped through the oil discharge line, through aservice valve to the oil filter (filters foreign partsto 10 microns) and then to the shell-and-tube oilcooler. The cooler serves a dual purpose. It lowersthe temperature of oil on start to prevent refrig-erant flashing and maintains proper oil temp-erature under normal operating conditions.

Bearings are supplied with oil through internally-drilled passages. Oil drains from bearings intogear housing and returns to oil pump throughthe scavenger line.

The oil pump also supplies the oil to the hydraulicpiston for positive positioning of the inlet guidevanes. Proper operation of the hydraulic systemand bearing lube system can be maintained onlyif Westinghouse oil No. 350A353G0l is used.

Also as an additional safety, solenoid valve “SC”is installed in the oil supply line, to bypass themetering valve and close vanes rapidly in the caseof low suction pressure or motor overload. (Ex-cessive current draw.)

The oil heater must remain on at all times. Inthe event of a power loss to heater, allowing oilto cool, the oil heater should be energized aminimum of 24 hours prior to the time compressoris started. If compressor has to be started immed-iately, oil should be drained and recharged withfresh oil, which would be free of refrigerant.

The oil filter should be changed when the oilpressure differential (difference between suctionand oil pressure) drops to approximately 50 lbs.

PRESSURE TESTING (If Repair Necessary)No pressure testing is necessary unless some dam-age was incurred during shipment. After repairsare made, pressure test the system at a pressurethat does not exceed the standby pressure in thecondenser. (A test pressure higher than condenserpressure would open the discharge check valve andallow flow of test pressure into condenser). Incases where the entire refrigerant charge is lostfollow the recommendations in the following para-graphs. The evacuation procedure can be followedin both cases.

LEAK TESTING (If Repair Necessary)In the case of loss of the entire refrigerant charge,the unit should be checked for leaks prior to charg-ing the complete system. This can be done bycharging only enough refrigerant into the system tobuild the pressure up to approximately 10 PSIGand adding sufficient dry nitrogen to bring thepressure up to a maximum of 150 PSIG and thenleak test with a Halide or electronic leak detector.CAUTION: Do not use oxygen to build up pres-sure as a serious explosion can result. A pressure-regulating valve should always be used on the drumbeing used to build up the system pressure. Also,do not exceed the test pressures given above.When the test pressure is reached, disconnect thegas cylinder.If any leaks are found in welded or silver solderedjoints or if it is necessary to replace a gasket,relieve the test pressure in the system before pro-ceeding. For copper joints, Easy-Flo silver solderis recommended.

After making any necessary repair, the systemshould be evacuated as described below.

EVACUATION (If Repair Necessary)After it has been determined that there are norefrigerant leaks, the system should be evacuatedusing a vacuum pump with a capacity of approxi-mately 3 cu. ft./min. and that will reduce thevacuum to at least 1 millimeter (1000 microns).A mercury manometer, electronic or other type ofmicron gauge should be connected at the farthestpoint from the vacuum pump. For readings be-low 1 millimeter, the electronic or other microngauge should be used.The triple evacuation method is recommended andis particularly helpful if the vacuum pump isunable to obtain the desired 1 millimeter ofvacuum. The system is first evacuated to approxi-mately 29 inches of vacuum. Enough refrigerantvapor is then added to the system to bring thepressure up to zero pounds. About 1 hour shouldbe allowed for proper mixing before proceeding.Then the system is once again evacuated to ap-proximately 29 inches of vacuum. This is repeated3 times. The first pull down will remove about90% of the noncondensables, the second about90% of that remaining from the first pull down andafter the third only approximately 1/10 of 1%non-condensables will remain.

PREL IMINARY CHECKS BEFORE START INGIMPORTANT1. Open shut-off valve on condenser that provides

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refrigerant pressure to the oil system on apower failure.

2. Open all water valves to the condenser and

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5.

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9.

10.

11.

12.

13.

14.

see that water flow is possible when the waterpump (if used) is energized.Check that the actual line voltage is withinthe allowable plus or minus 10%.Make sure that all shipping protection hasbeen removed from control center components.With the main disconnect switch in the “off”position, control circuit energized, make sureall linestarter contacts meet with even pressureand that all moving parts move freely. Checkthat the Fusetrons are in the circuit, that thecycling thermostat is set below the chilledwater temperature and that the hand-off-autoswitch is in the “off” position.Check that the liquid shutoff valve and the 3gauge valves are open. NOTE: During normaloperation, it is recommended that the gaugeshutoff valves be kept in a closed positionexcept when taking a reading in order toprolong the life of the gauges.

See that the oil pump has a proper supply ofoil. The oil should be visible in the top r/4 ofthe sight glass.

Manually operate the condenser water-regulat-ing valve (used on city water installations) toclean the water lines of sediment that ac-cumulated during installation. This will pre-vent the sediment from damaging the seat ofthe water-regulating valve when operating inan automatic position. This can be done bylifting the spring mechanism.Check to make sure starter overloads are setat 105% F.L.A.Check all pumps visually for proper rotation.

Check compressor phase sequence-phase sequence to be l-2-3-. Refer to Page 5.Check all electrical connections to make surethey are tight. Even though they are checkedat the factory, they may have loosened duringshipment. Serious difficulty could result fromloose connections.

If all indicator lights are out and oil pump failsto start, check the following:

A.

B.

C.D.

Recycling timer (set at 40 minutes to limitstarts to 3 in 2 hours maximum.)Oil pump timer (O.T.D.) - There are in-stantaneous contacts on O.T.D. which mustclose immediately on energizing compressortime delay.Oil pump overload tripped.Defective contactor, holding coil orcontacts.

If all the indicator lights are out, the oil pumpstarts and the MCR,relay fails to energize,check:

A. Compressor time delay must be closed.(Timed to close after oil pump starts.)

Page 10

CHARGING THE SYSTEM (If Repair Necessary)PE water chillers are leak tested at the factory andshipped with the correct charge of refrigerant-12as indicated on Page 14. In the event the re-frigerant charge was lost due to shipping damage,the system should be charged as follows after firstrepairing any leaks and evacuating the system:

1.

2.

3.

4.

5.

6.

7.

Connect the refrigerant drum to the gaugeport on the liquid shutoff valve and purgethe charging line between the refrigerantcylinder and the charging valve. Then openthe valve to the mid position.Turn on both the cooling tower water pumpand chilled water pump and allow water tocirculate through the condenser and the chiller.(It will be necessary to manually close thecondenser pump starter.)If the system is under a vacuum, stand therefrigerant drum with the connection up andopen the drum and break the vacuum withrefrigerant gas.With a system gas pressure higher than theequivalent of a freezing temperature, invert thecharging cylinder and elevate the drum abovethe condenser. With the drum in this position,valves open, water pumps operating, liquidrefrigerant will flow into the condenser. Ap-proximately 75% of the total requirementestimated for the unit can be charged in thismanner.After 75% of the required charge has enteredthe condenser, reconnect the refrigerant drumand charging line to the service port on thecompressor suction line. Again, purge the con-necting line, stand the drum with the con-nection up and the suction service valve in theopen position.

1MPORTANT - At this point the chargingprocedure should be interrupted and all pre-start checks made before attempting to correctrefrigerant charge. Compressor must not bestarted at this time. (Preliminary check mustfirst be completed.) When all prestart checkshave been made, remaining steps in chargingprocedure can be made.

Make sure liquid refrigerant shutoff valve isopen and that water is still circulating throughthe chiller and condenser. Start the compres-ser by first closing the disconnect switch andthen place the control center selector switchin the “auto” position, checking that (a) oilpump starts immediately and all electricalcharacteristics are normal, (b) compressormotor starting characteristics are normal and(c) that suction pressure and leaving watertemperatures are above the freezing zone.To complete refrigerant charge, allow refrig-erant vapor to enter the system until the liquidline sight glass indicates a full flow of re-frigerant. The absence of any bubbles in thesight glass indicates a normal charge: but to beaccurate, this determination should be madewhen the system is operating under full load.Be careful not to overcharge; this may bechecked by the liquid line temperature which

should not have more than 10 to 15 degreesof sub-cooling at the condenser outlet.

STARTING AND OPERATIONAL CHECKSCheck the compressor and oil pump motoramperages to make sure they are not in excessof nameplate rating (normal.) The correctamperages are given on the nameplates and areincluded also in the Electrical Data.All accessories and controls should functionaccording to requirements. If the performanceof any accessories or any operational functionappear abnormal, stop compressor and investi-gate the malfunction.Check the operation of all the protective con-trols to make certain that each interrupts thecontrol circuit. The correct settings for thecontrols are given in Table II. Checkthe controls as follows:a. High pressure cutout-Throttle the con-denser water supply slowly until reaching thecutout point. Stop the compressor manuallyif the discharge pressure exceeds the correctcutout setting.b. Low pressure cutout-Throttle the liquidline shutoff valve slowly until reaching theCutout point.c. Oil pressure protector-Manually close thedifferential pressure switch by holding thespring toward the front of the control.d. High discharge temperature control-Oper-ate the switch manually by holding the springagainst the back of the control. This shouldstop the compressor by de-energizing the con-trol circuit.e. Low water temperature freeze control-If there is a thermometer in the outletwater of the chiller, the control can be checkedby slowly throttling the supply water to thechiller. This will cause the outlet watertemperature to drop. The reduction in waterflow must be done slowly enough for thethermometer to react to the temperaturechange. If a thermometer is not available inthe outlet water, the control can be checkedby placing the control bulb in a container ofwater; by slowly adding ice to the water,the operating point of the control can bereached. Observe temperature on thermo-meter.f. Follow same procedure as “e” above to checkcycling thermostat.g. Low refrigerant temperature control-Thebulb for this control is located on the No. 4expansion valve outlet. An electric-tempera-ture meter, such as a Simpson Thermometer,should be used in checking this control. Thecutout point can be checked by a thermo-couple, from the meter, in contact with thebulb. The refrigerant temperature can thenbe reduced by slowly throttling the liquidrefrigerant shutoff valve until the cutout pointis reached. If the compressor does not stopby the time the temperature drops to 28”F.,manually stop the unit and recalibrate thecutout.

h. High oil temperature control-Operateswitch manually holding the spring againstthe back of the control. This will stopcompressor.i. Low pressure override-Manually closeswitch and observe ammeter. Vanes shouldclose rapidly. Ammeter should drop tobetween 30 and 50% of nameplate rating(dependent upon suction and dischargepressures.)j. Check setting on recycling’timer. It is set at40 minutes to limit compressor to 3 starts in2 hours.k. Starter overloads at maximum of 105% ofnameplate rating, regardless of load or voltageconditions. (See attached tag-Do not adjust.)1. Oil pump timer (O.P.T.) The circuit iscompleted through the main starter. If thecompressor does not start the contacts onO.P.T. open and stop the oil pump.

4. See that the oil pressure protector is set toapproximately 50 PSIG differential.

5. Several causes for frequent complaints arelisted below:

6.

7.

Page 11

a. air in water circuit or water chillerb. inadequate quantity of water (check pres-sure drop through chiller and refer to TableIII for flow)c. water pump not functioning properlyd. plugged water strainere. lack of head pressure controlf. operation at lower than design watertemperatureg. inadequate air over cooling coilsh. lack of low side load-operating with onlya portion of air units installed or operating

Record complete set of operating data forfuture usage and preserve in your or the cus-tomer’s file.

Instruct the owner on proper operation andcare of the system. CAUTION: The dis-connect switch for control circuit (furnishedby contractors) must be left on at all timesin order to maintain operation of the oilheater. The control center selector switch canbe turned to the “off” position at such timesthat compressor operation is not desired.

ROUTINE MAINTENANCELubrication-After the system is once placed intooperation, no additional oil is required except inthe event that repair work becomes necessary tothe oil pump or unless a large amount of oil islost from the system due to a leak.The oil system can be isolated to service any oilpump component or I.G.V. (inlet guide vanes)solenoid system.To isolate I.G.V. system, it is only necessary tobackseat supply valves on filter outlet and oil pumpscavenger line. Relieve pressure slowly and I.G.V.system can then be serviced. When reassembling,purge air from lines and return valves to operatingposition (mid position). Failure to set valves willprevent I.G.V. from operating.To Change Oil Filter-Frontseat supply valve onoil pump cover. Frontseat valve on oil filteroutlet. Backseat valve on scavenger line on pumpcover.With all valves in proper positions, as described,bleed pressure from filter slowly. Remove cartridgeand install new cartridge. Assemble cover and ringbut do not tighten. Open supply valve slowly andallow suction pressure to force oil into oil filter andfill to the top, to displace all air possible. Tightencover. Return all service valves to their operatingpositions.Refrigerant Cycle-Maintenance of the refrigerantcycle consists mainly of keeping the system proper-ly charged with oil and refrigerant, and maintainingrunning check of operating conditions that willshow when trouble exists with some component.At every inspection, the oil, suction and dischargepressures should be noted and recorded, along withcondenser and chiller water temperatures. As-suming water flow is correct, this confirms correctrefrigerant charge. Correct suction pressure willbe indicated by reference to past suction readingson the same installation.

The suction line temperature at the compressorshould be taken at least once a year. Subtractingfrom this, the saturated temperature equivalentof the suction pressure will give the superheat.Changes in superheat over a period of time willindicate any deterioration of the expansion valves.Proper superheat setting is 6” - 7°F.The factory oil charge, supplied with the com-pressor, is adequate for the system. Normal oilcharge is indicated by an oil level visible in the oilreservoir sight glass. This level should be in thetop ‘/4 of glass during operation.Electrical-Maintenance of the electrical systeminvolves the general requirement of keepingcontacts clean and connections tight and checkingon specific items as follows:

A. The compressor current draw should bechecked and compared to nameplate value.Normally, the actual current will be lower, sincethe nameplate rating represents full loadoperation. Also check all pump and fan motoramperages and compare with nameplate ratings.B. Inspection should verify that the heater isoperative. The heater is an insert cartridge typeand can be checked by ammeter reading in thecontrol box. It should be energized wheneverpower is available to the control circuit. (When-ever compressor is inoperative.)C. At least once a year, all safety controls shouldbe made to operate and their operating pointmeasured. Any control may shift its operatingpoint as it ages, and this must be detected so thecontrol can be readjusted or replaced. Thecompressor overload relays are a satety control,but to force a compressor load to trip them maycause more trouble than it saves. They will notbe subject to age deterioration.

Page 12

D. The thermostat and control switches, theirassociated relays and contactors, plus any othersystem controls should be checked routinely onany operation inspection and their set point re-adjusted as necessary. The compressor startercontacts should be checked for wear.

Cleaning And Preserving - A common cause ofservice calls and equipment malfunction is dirt.This can be prevented with a little maintenance.The system components most subject to dirt are:

A. Permanent or cleanable filters must bewashed in accordance with the manufacturer’sinstructions; throwaway filters should be re-placed. The frequency of this service will varywith each installation.B . Remove and clean strainers in both chilledwater pump and condenser water pump at everyinspection.

SEASONAL SERVICINGPrior to seasonal shutdown periods and beforestarting again, the following service proceduresshould be completed.

SHUTDOWN1. Where freezing temperatures may be en-

countered, the condenser and chiller waterpipng should be disconnected from the supplyand drained of all water. Dry air blownthrough the condenser will aid in forcing allwater out. The condensers are not self-draining. Water permitted to remain in thepiping and condenser will rupture these partsif subjected to freezing temperatures. Forcedcirculation of antifreeze through the watercircuits is the only sure method of avoidingtrouble. Removal of condenser heads is alsorecommended.

2. Take measures to prevent the shutoff valve in

3.

4.

5.

the water supply line from being accidentallyturned on.If a cooling tower is used and if the waterpump will be exposed to freezing temperatures,be sure to remove the pump drain plug andleave it out so that any water which mayaccumulate will drain away.Open compressor disconnect switch and removeFusetrons. If transformer is used for controlvoltage, disconnect must remain on to providepower to oil heater. Set compressor switch to“off” position. To insure against the possibil-ity of an accidental start, remove relay R-4.Check for corrosion and clean and paint rustedsurfaces.

STARTUPA dangerous condition can exist if power is ap-plied to a compressor stator which has been burn-ed out. This condition can exist without the knowl-edge of the man starting the equipment, depend-ing on the previous history of the installation. Toeliminate this possibility and possible harm tothe operator, it is recommended that megger read-ings be taken on the motor windings. If the read-ings do not exceed 5 megohms do not start themachine. For readings above 5 megohms startthe machine and check again after approximately1 hour of operation. Resistance should increase toapproximately 20 megohms.

1.

2.3.

4.

5.

6.

7.

8.

9.

The control circuit should be energized at alltimes. If control circuit is off and oil is cool,Drain and replace with fresh Westinghouseoil, or allow 24 hours for heater to remove allFreon from oil before starting.Check and tighten all electrical connections.Replace the drain plug in evaporative con-denser or cooling tower pump if it was removedat shutdown time the previous season.Install Fusetrons in main disconnect switch.(If removed.)Reconnect water lines and turn on supplywater. Flush out condenser and check forleaks.Clean and flush water tower for all unitsoperating on a water tower. Make sure tower“blow-down” or bleed-off is operating. Set upand use a good maintenance program to pre-vent “liming up” of both tower and condensers.It should be recognized that atmospheric aircontains many contaminants which increasesthe need for proper water treatment. (Arrangefor local water analysis and treatment recom-mendations.)Clean all surfaces and remove all litter. Aclean unit is the sign of a good serviceman.Refer to the procedures of “PreliminaryChecks Before Starting” before energizing thecompressor circuit.Refer to procedures of “Starting and Ope-rational Checks” after starting the compressor.

PUMPING DOWNIf it becomes necessary to pump the system down,extreme care should be used to avoid damage tothe water chiller due to freezing. Always makesure that full water flow is maintained through thechiller while pumping down. With the liquid lineshutoff valve closed and water flowing throughchiller, start the compressor. In order to pumpsystem down as far as possible, it will be necessaryto by-pass the low pressure override switch andrefrigerant temperature switch.Operate machine until the suction pressurestabilizes at approximately 20-25 PSIG.Operate for approximately 2 minutes at thissuction pressure. Stop the machine.After the system has been pumped down the gaspressure remaining will have to be purged beforethe machine can be serviced. (Approximately 3 to4 pounds of refrigerant is lost)

OWNER INSTRUCTIONThe installation cannot be considered completeuntil the owner (or operator) has been instructedin the function of his system. The details of thisinstruction will vary with the system and theowner, but in general there are certain items thatmust be covered.Control Operation-Including-Reset-This is howto start and stop the system, reset it if it trips onsafeties (but not too often without calling for ser-vice) and how to handle power supplies inemergencies.Owner Maintenance-Impress with the importanceof maintenance, and detail what the owner can do.This may include filter changing or cleaning,

preservation of paint finish and equipment areamaintenance. Fan and pump motors, lubrication,and belt adjustment might also be handled by theowner or operator.Service Calls-Tell whom to call for service andwhen to call. Items like blown fuses and trippingsafety controls are often an indication of morecomplicated troubles to follow and should requireinvestigation by a serviceman.Warranty-Clarify the warranty coverage-what itapplies to, for how long, and what is provided bythe warranty.Owner instruction should always be done verbally,on the job, and then confirmed in writing. This isa good time to sell a maintenance contract tosupplement his warranty and safeguard the invest-ment.

MAINTENANCE RECOMMENDATIONS

,_.

It is necessary that an air conditioning system re-ceive adequate maintenance if the full equipmentlife and full system benefits are to be realized.Follow-Up Inspection-Maintenance should beginwith an inspection of the system after 3 to 4 weeksof normal operation on a new installation. Actual-ly, it is good insurance for the installer who has thesystem warranty responsibility since it enables himto catch and correct those little items that developin the first month of running (such as a loosewire). These little items left alone can cause majorfailure. This call presents another opportunity tocomplete owner education and sell a maintenancecontract and perhaps demonstrate the money-saving result of maintenance inspection. Also, if

Page 13

the system has been creating the desired results,this is the best time to tie down a living advertise-ment, a satisfied customer.Maintenance Contracts-A formal maintenancecontract between the installer and the owner is ahighly desirable thing for both parties. Second tothis is an informal arrangement where the installersuggests maintenance work at the appropriateseason by letter or phone to each of his customers.Contracts are a subject all by themselves thatcannot be covered here. Whether the contract isfull maintenance or inspection only, the generalrecommendations on inspection frequency are asfollows:Practical Minimum-For cooling systems, aseasonal startup inspect and adjust, covering thefunctions shown in the check-chart, plus onemidseason operating inspection. If the coolingseason exceeds 6 months, then an additionalinspection should be made for each additional 3months.The extent to which maintenance inspection is re-quired and can be justified depends on the yearlyhours of operation and the type of system. Aresidential cooling system down for several daysdue to lack of maintenance causes some discomfortbut little loss of income. On the other hand, anindustrial process system down for several dayscan cause a large loss of income. The amount ofmaintenance cost that an owner will pay, and bejustified in paying, is dependent on the dollarvalue to him of the system performance. This ex-tends directly to the amount and extent of main-tenance work that should be performed.

PRESTART SYSTEM CHECK LISTSYSTEM OPERATIONAL CHECKS CHILLER PACKAGE

0 All components’ locations and mounting adequate0 Accessories present and properly installed0 All piping completed-supports, insulations, etc.

q Suction, discharge and oil pressure normol0 Proper superheat on expansion valves0 Proper sub-cooling

CHILLER

0 All shipping protection removedq All service valves in operating positions0 Control circuit energized and oil heater operatingIJ Oil charge visible in top of sight glassq All safety switches interrupt compressor operation0 O i l c o o l e r b a l a n c e v a l v e adjusted t o a p p r o x i m a t e f l o w

Refer to Page 3

0 Cutout points at all safety controlsq Oil level0 Oil temperature

13 Proper flow through condenser and chiller

0 Vol tage w i th in 3110%0 Amperage proper for load cond i t ionsq Vane positioning thermostatic, manual and auto0 Motor control 50% _ 100%q Interlocks interrupt operation0 Recycling timer setting0 Cycling thermostat setting0 Check over loads to t r ip a t 105% of F .L .A. (nameplate ra t ing

ELECTRICAL only - do not adjust for line or voltage conditions)

0 Proper wire and breaker sizes0 All electrical work installed as per local c o d eIJ All wiring done in accordance q s per Westinghouse diagram0 All interlocks operating properly0 All pumps rotating in proper direction and lubricated[7 All electrical connections tight0 All starter ports move freely and contacts meet evenly0 All overloads set at approximately 105% of F.L.A.0 Al l load equipment opera t ive and lubr ica ted ( fan co i l un i ts ,

SYSTEM CHECKS

environmental equipment, process equipment)q Recycl ing t imer set to 40 minutes- tower fan and contro ls

operative

0 All pumps and fans checked-amps ond volts0 All pumps lubricated0 All strainers cleaned-condensing pump and chiller pump!J All filters on air handlers clean0 All condensate drains open0 All fan motors lubricated0 All fan belts adjusted q nd checked0 All electrical connections tight, starter contacts, starter movement

CUSTOMER’S APPROVAL

0 All valves in proper position and cops onIJ All panels in place0 All operating controls set properly0 All electrical junction boxes coveredq Owner instructed on operation of complete system