WaterFurnace TRUCLIMATE 300 Operation & Maintenance Manual
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WaterFurnace TRUCLIMATE 300 Operation & Maintenance Manual

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OPERATION & MAINTENANCE
TRUCLIMATE 300, 500, AND 700
60HZ CHILLERS
OM1904WW

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Summary of Contents for WaterFurnace TRUCLIMATE 300

  • Page 1 OPERATION & MAINTENANCE TRUCLIMATE 300, 500, AND 700 60HZ CHILLERS OM1904WW...
  • Page 2 Heat exchangers do not fully drain and will freeze unless protected, causing permanent damage. WaterFurnace’s TruClimate 300 & 500 products are certified by AHRI Conforms To UL STDS 60335-1 & 60335-2-40 Standard 550/590 for Water-Cooled Water Chilling and Heat Certified To CSA STDS C22.2 # 60335-1 &...

  • Page 3: Table Of Contents

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Table of Contents UNIT OVERVIEW General Installation Information............4 Nomenclatures .

  • Page 4: General Installation Information

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL General Installation Information NOTICE: Do not store or install units in corrosive environments No person carrying out work in relation to a REFRIGERATING SYSTEM which involves exposing any pipe work shall use any or in locations subject to temperature or humidity extremes. sources of ignition in such a manner that it may lead to the risk of Corrosive conditions and high temperature or humidity can fire or explosion.
  • Page 5 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL General Installation Information Installation Space Requirements WARNING NOTE: Equipment with refrigerant charge less than 64 oz does Ventilated Area: ensure that the area is in the open or that it is adequately ventilated before breaking into the system of not require have a minimum floor area requirement and does not conducting any hot work.

  • Page 6: Nomenclatures

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Nomenclatures TruClimate 300 T3HS030SN23**AA1N6GCSSNSSS 18-20 24-26 Brand T – TruClimate Non-Standard Options Model SSS – None 3 – 300 Series Future Option Type N – None H – Heat Recovery Chiller Condenser Strainer Option Cabinet Configuration N –...
  • Page 7 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Nomenclatures cont. TruClimate 500 T5HS020SN23**CHNN1FCNNNSSS 18-20 24-26 Brand T – TruClimate Non-Standard Options SSS – None Model 5 – 500 Series Future Option N – None Type H – Heat Recovery Chiller Future Option R –...
  • Page 8 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Nomenclatures cont. TruClimate 700 T7HS090WN14**CHNN8GCNNNSSS 18-20 24-26 Brand T – TruClimate Non-Standard Options SSS – None Model 7 – 700 Series Future Option N – None Type H – Heat Recovery Chiller Future Option N –...

  • Page 9: Physical Data

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Physical Data - TruClimate 300 Physical Data Fixed Speed VS Modular Fixed Speed VS Modular Model 050 Ton 050 Ton 030 Ton 030 Ton Refrigerant R-454B R-454B Number of Circuits Factory Charge, lbs [kg]* 13.25 [6.01]...
  • Page 10 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Physical Data - TruClimate 500 Modular Physical Data Dual Scroll Modular VS Modular Model Refrigerant R-454B R-454B Number of Circuits Factory Charge Heat Recovery, lbs [kg]* 8.00 [3.63] 10.00 [4.54] 13.75 [6.24] 16.00 [7.26] 17.25 [7.82] 18.50 [8.39] 18.50 [8.39] 10.50 [4.76] 16.00 [7.62] Factory Charge Reversible, lbs [kg]*...
  • Page 11 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Physical Data - TruClimate 700 Dual Variable Speed Screw Model R-513A Refrigerant Number of Circuits Factory Charge, lbs [kg] 109 [49] 140 [64] 170 [77] Compressor Variable Speed Screw Compressor Quantity [tons] 1 [87] 1 [112] 1 [137] Compressor Weight, lbs [kg]...

  • Page 12: Dimensional Data

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: 30 Ton (TruClimate 300) Power Inlet 2" 7" 4" 28" 11" CHILLED WATER OUTLET CHILLED WATER 10.50" INLET 10.50" CONDENSER WATER OUTLET 72" CONDENSER WATER INLET 35" 54.62" 5" STRAINER OPTION FRONT...
  • Page 13 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: 30 Ton Bank (TruClimate 300) REQUIRED TEMPERATURE HEADER LEFT OR RIGHT CONFIGURATION 9" 8" OPTIONAL SINGLE POINT PANEL RIGHT INSTALLATION SHOWN 55" 1406 33" 60" WITH STRAINER OPTION 28" 7" 4" 56"...
  • Page 14 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: 50 Ton (TruClimate 300) Power Inlet 2.00 7.00 3.54 33.00 10.50 CHILLED WATER OUTLET CHILLED WATER 10.50 INLET 10.50 CONDENSER WATER OUTLET 72.07 CONDENSER WATER INLET 35.19 5.01 64.00 STRAINER OPTION FRONT...
  • Page 15 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: 50 Ton Service Clearance (TruClimate 300) SERVICE CLEARANCE 30.00 15.57 40.00 20.00...
  • Page 16 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: 50 Ton Bank (TruClimate 300) 5" OPTIONAL STRAINER REQUIRED TEMPERATURE HEADER LEFT OR RIGHT CONFIGURATION 9" 64" OPTIONAL 1626 SINGLE POINT PANEL (RIGHT INSTALLATION SHOWN 4" 33" 7" 66" 1676 (NUMBER OF MODULES X 33")
  • Page 17 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: Service Clearance (TruClimate 300)
  • Page 18 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: Modular Units Service Clearance (TruClimate 500) 24.00 RECOMMENDED 15.41 34.00 68.00 30.00 REQUIRED NUMBER OF UNIT X 34 INCH 24.00 RECOMMENDED SERVICE CLEARANCE 24.00 53.25 INCH REQUIRED FOR RECOMMENDED REMOVING THE MODULE SERVICE CLEARANCE AVOID INSTALLING PIPING ABOVE 24.00...
  • Page 19 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: Modular Units with Header Rack (TruClimate 500) SCH 40 GROOVE PIPE 6IN AND 8IN 73.29 61.1 45.2 32.2 16.4 20.3 TYP 77.31 27.69 79.11 34.00 Header Index Configuration 4 Pipe Standard (with Reversible Chiller) Load Outlet Load Inlet Source Inlet...
  • Page 20 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: Modular Units with Header Rack (TruClimate 500) HEADER INDEX 6 PIPE AND 4 PIPE REVERSING DIMENSIONS SCH 40 GROOVE PIPE 6IN AND 8IN 73.29 27.70 27.50 33.00 47.1 34.00 Dimensional Information (Inch) Configuration Header Size 8 inch...
  • Page 21 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: Modular Units - No Header Rack (TruClimate 500) DUAL SCROLL MODULE - STANDALONE DIMENSIONS ANSI 150 FLANGE SOURCE LOAD OUTLET INLET SOURCE INLET LOAD OUTLET 24.6 23.3 28.8 12.5 46.3 53.5 55.50 with Isolation Valve MAIN POWER 18.0 73.5...
  • Page 22 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: (TruClimate 700) 34" 866MM LOW VOLT CONTROL BOX 78" 1982MM HIGH VOLT CONTROL BOX 20" 516MM 16" 406MM 16" 406MM 16" 406MM 19" 475MM 74" 1884MM 105" 2665MM...
  • Page 23 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: Center of Gravity (TruClimate 700) CENTER OF GRAVITY 17.45" 43.95" MODEL WCHSM SINGLE CENTER OF GRAVITY 43.26"...
  • Page 24 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: Concrete Pad Requirements (TruClimate 700) 24" 37" 37" 31" 24" 610MM 942MM 942MM 781MM 610MM Note: Embed 2” x 2” x 0.19” angle iron in concrete house keeping pad as shown in red above. DETAIL A...
  • Page 25 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: Service Clearance Banked Units (TruClimate 700) 24" 610MM RECOMMENDED 76" 1941MM 24" 24" 610MM 610MM RECOMMENDED 80 INCH REQUIRED FOR RECOMMENDED 30" SERVICE CLEARANCE REMOVING THE MODULE SERVICE CLEARANCE 762MM REQUIRED AVOID INSTALLING PIPING ABOVE 24"...
  • Page 26 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: Service Clearance (TruClimate 700) POWER INLET 29" 737MM SERVICE CLEARANCE 0" Ø SOURCE OUT SOURCE IN LOAD OUT LOAD IN...

  • Page 27: Hydrolink2 Aurora Controls

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL HydroLink2 Aurora Controls - Overview Overview HydroLink2 Control The HydroLink2 Control is a Niagara control that functions as The HydroLink2 Aurora Control is the ultimate chiller control a master control communicating to ABC “A” for compressor system that accurately controls fluid temperatures while A and to ABC “B”...
  • Page 28 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL HydroLink2 Aurora Controls - Overview cont. Control Features Software ABC Standard Version 3.0 Control Hardware Features • Setpoint, aquastat or network control methods with adjustable PID parameters. • 3D color graphics for easier diagnostics •...

  • Page 29: Header Rack Configuration Availability

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Header Rack Configuration Availability Unit Capacity Nomen Pipe Description Digit Diameter ●● ●● ●● ●● ●● ●● ●● 2-1/2” Standard No Isolation ●● ●● ●● ●● ●● ●● ●● 2-1/2” Standard w/ Isolation ●● ●●...

  • Page 30: Bypass And Temperature Header Dimensional Data

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: Bypass (Temp + Valve) 6 PIPE BYPASS ASSEMBLIES SCH 40 CARBON STEEL PIPE 15.27 D (TYP) 4.00 6.50 15.00 Configuration A (in) B (in) C (in) D (in) E (IN) 8 inch 19.0 28.9 33.2...
  • Page 31 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: Temperature Header TEMPERATURE WEATHER SCH 40 CARBON STEEL PIPE WATER TEMP SENSOR TYPE II WATER PRESSURE CUT GROOVE SENSOR (OPTIONAL) PER VIC 25.01 REV J 1/2" NPT BUNG 2.75 5.25 8.00 CUT GROOVE PER VIC 25.01 REV J Configuration A (in) B (in)
  • Page 32 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: Bypass and Temperature Headers (TruClimate 700) 16.00 25.86 30.17 ORIGINAL ISSUE 15.00 5/9/23 EC-0006348 4.31 (TYP) 4.00 6.50 15.00...

  • Page 33: Strainer Dimensional Data

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Dimensional Data: Strainer (TruClimate 300) PLUGGED ACCESSORY PORTS 16.0 ANSI 125 FLANGE 2.5" GROOVE PIPE FITTING 2.5" GROOVE PIPE FITTING 6.5 INCH CLEARANCE REQUIRED FOR BASKET REMOVAL DRAIN/BLOW-OFF PLUG Strainer Specifications 0.045perf Strainer Specifications 40MESH...

  • Page 34: Hydrolink Supervisory Control Nomenclature

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Nomenclatures cont. HydroLInk Supervisory Control (Accessory) 9-10 Family Vintage HSC – HydroLink Supervisory Control * – Factory Use Only Chiller Module N – NXW/T1 – Compact Scroll Non-Standard Option Details D – WC/T5 – Dual Scroll Modular Chiller SS –...

  • Page 35: Hydrolink Supervisory Control Overview

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Optional Accessories - Supervisory Control - Overview The HydroLink2 Supervisory Control is a Niagara AX based control, designed to consolidate all chiller mechanical room chillers and hydronic components into one supervisory control. By consolidating all components into one control complete plant room management can be obtained to ensure proper operation and easier servicing with a turn-key solution.
  • Page 36 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL HydroLink 2 Supervisory Control (optional accessory) • HydroLink2 Control uses powerful 15 Amp convenience outlet Color NIAGARA AX software Platform. touchscreen • HydroLink2 Control with standard I/O 34 ard I/O 34 tablet and up to two optional I/O 16 modules modules can be added for fl...

  • Page 37: Electrical Data

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Electrical Data TruClimate 300 Total Compressor* Rated Voltage Unit Circ Fuse/ Model Voltage Min/Max HACR 208-230/60/3 187/253 75.0 48.1 351.0 96.2 108.2 30Ton Fixed Speed 460/60/3 414/506 38.6 24.7 197.0 49.5 55.7 208-230/60/3 187/253 75/110* 48.08/88.0*...

  • Page 38: Thermistor And Compressor Resistance

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Thermistor and Compressor Resistance TruClimate 300 Compressor Resistance Compressor Resistance Chart (ohms) Model 208-230 30Ton Fixed Speed 0.220 0.830 30Ton Variable Speed 0.220/ 0.02 0.830 / 0.05 50Ton Fixed Speed 0.130 0.520 50Ton Variable Speed 0.13/0.01*...

  • Page 39: Water Quality

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Water Quality 1.0. Minimum Fluid Volume 1.4. Flow Sensing Devices Water-to-water heat pumps require a minimum amount A fl ow switch or equivalent must be installed on the of source and load side fl uid volume to ensure accurate evaporator for each unit to be installed.
  • Page 40 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Water Quality cont. 1.6. Insulation 1.8. Heat Exchangers The Condenser and Evaporator heat exchangers utilize Chillers are built with factory installed insulation on any a single wall design. Do not install use for potable water surface that may be subject to temperatures below the applications without intermediate heat exchanger.

  • Page 41: Antifreeze Corrections

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Antifreeze Corrections Catalog performance can be corrected for antifreeze use. Please use the following table and note the example given. Heating Cooling Antifreeze % Pressure Antifreeze Type by wt Drop Load Source Load Source EWT - °F [°C] 90 [32.2] 30 [-1.1]...

  • Page 42: Operating Limits

    Note that certain portions of the map will require operation under head pressure control and maximum evaporator pressure control. For more details on Head Pressure Control and Maximum Evaporator control see HPC and MOP Entering Water Temperature Limits Operational Maps. TruClimate 300 Condenser Evaporator...

  • Page 43: Hpc And Mop Entering Water Temperature Limits

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL HPC and MOP Entering Water Temperature Limits Minimum Flow During Head Pressure Control (HPC) and Maximum Evaporator Pressure Control (MOP). During HPC and MOP operation, the valves are modulated to keep the compressor running within the operation limits. During the modulation, the valve can close to 40%.

  • Page 44: Leaving Water Temperature Operational Maps

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Leaving Water Temperature Operational Maps Recommended Pressure Drop and Water Velocity Diameter ft/100 ft ft/sec 4.14 6.93 8.46 10.08 4” 18.51 15.12 4.03 8.89 6” 5.33 10.27 1300 10.27 14.44 Velocity should never exceed 15 ft/s. Noise, erosion, and water hammer will be more significant at higher velocities...

  • Page 45: Pressure Drop

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Pressure Drop TruClimate 300 Unit Pressure Drop TruClimate 300 Strainer Pressure Drop (New Basket)
  • Page 46 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Pressure Drop cont. TruClimate 500 Modular Pressure Drop TruClimate 500 - Header Rack...
  • Page 47 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Pressure Drop cont. TruClimate 700 Evaporator Pressure Drop TruClimate 700 Condenser Pressure Drop...

  • Page 48: Typical Piping

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Typical Piping: Modular Units (No Pipe Rack) Standard Piping Factory Installed Field Supplied and Installed Pump Isolation Valves From Load 1/4” NPT Strainer Brazed Plate Water Pressure/Temperature Heat Exchanger Port Temperature Sensors To Load Isolation Valve Note: System piping should have drain ports to enable flushing and cleaning of heat exchangers.
  • Page 49 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Typical Piping: Reverse Return Piping (Recommended) REVERSE RETURN 6 PIPE CONFIGURATION HEADER INLET PRESSURE (MOUNTED ON BYPASS ASSEMBLY) HEADER INLET TEMPERATURE (MOUNTED ON BYPASS ASSEMBLY) LOOP INLET HEADER BYPASS VALVE (REQUIRED ON 6 PIPE) LOOP OUTLET HEADER OUTLET TEMPERATURE (MOUNTED ON BYPASS ASSEMBLY)
  • Page 50 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Typical Piping: Direct (Non-Reverse Return) DIRECT PIPING (NON-REVERSE RETURN) CONFIGURATION - FOR LESS THAN 4 MODULES HEADER INLET PRESSURE (MOUNTED ON BYPASS ASSEMBLY) HEADER INLET TEMPERATURE (MOUNTED ON BYPASS ASSEMBLY) 30 MESH STRAINER REQUIRED ON EACH LOOP INLET LOOP INLET HEADER BYPASS VALVE...

  • Page 51: Application Notes

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Application Notes The following general application notes are intended to describe general common design practices for these chillers. More detailed explanation resides in the installation, operation and maintenance manual. Piping Considerations When Piping multiple units in a bank, reverse return piping is recommended to ensure adequate even water flow through each chiller circuit, however in banks of less than 4 chiller modules, Non-reverse return (direct return) piping can be used successfully.

  • Page 52: Header Rack Application

    Optional Header Pipe Rack Adding the patented WaterFurnace Header Pipe Rack allows several internal manifolded loop options. The header rack is factory mounted to the modular chiller or it can be shipped separately for ease of plumbing the mechanical room.
  • Page 53 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Optional Header Pipe Rack cont. 6 Pipe Standard 6 Pipe Standard allows a standard chiller to provide hot and chilled water simultaneously by controlling 3-way valves. There are seven different control modes of operation available with this configuration that are detailed on the next page. 6 Pipe Standard Cold Inlet Cold Inlet...

  • Page 54: Header Rack Operation Modes

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL 6 Pipe Header Rack: Operating Modes The HydroLink Aurora Control includes the Header Pipe Rack operating logic and operating modes for each chiller which are selectable through the chiller touchscreen tablet mounted on the high voltage door. The Header Pipe Rack operating modes are detailed as follows: 1 –...

  • Page 55: Hydrolink2 Aurora Controls

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL HydroLink2 Aurora Controls Field Selectable Options via Hardware Software Features DIP Switch (SW1) – Test/Configuration Button (See SW1 Safety Features Operation Table) The following safety features are provided to protect the compressor, heat exchangers, wiring and other components Test Mode from damage caused by operation outside of design The control is placed in the test mode by holding the push...
  • Page 56 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL HydroLink2 Aurora Controls cont. Freeze Detection - Refrigerant (Source – E5 or Load Operation Description HX E4) – Freeze detection can be triggered by either a Power Up - The unit will not operate until all the inputs and 30 sec.
  • Page 57 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL HydroLink2 Aurora Controls cont. Other Modes of Operation HydroLink2 Aurora in BAS Applications Emergency Shutdown - Four (4) seconds after a valid ES The HydroLink2 Aurora is designed to allow chillers to be input or communicated signal, P2-7 is present, all control integrated into Building Automation Systems (BAS) with outputs will be turned off and remain off until the emergency ease.
  • Page 58 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL HydroLink2 Aurora Controls cont. HydroLink2 Aurora Features HydroLink2 Aurora Touch Interface Utilizing a 10” color touch-screen interface, the HydroLink2 • Built-in surge transient protection circuitry provides a technician the ability to configure and diagnose •...
  • Page 59 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL HydroLink2 Aurora Controls cont. Fault, Configuration and Status Codes Fault Reset/ Fault Flash Lockout Fault Condition Summary Code Remove Code * Normal - No Faults Fault-Input Auto Tstat input error. Autoreset upon condition removal. Hard or Fault-High Pressure HP switch has tripped (>600 psi) [4.1 MPa]...
  • Page 60 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL HydroLink2 Aurora Controls cont. Field Relay 5 and 6 – This shows the state of the Field Relay 5 Other User Defined Field I/O and 6 on AXB A and B (labeled K5). When Field Relay is “ON” Field Temp 1 and 2 - Can display the temperature of a field the Field Relay 1 and 2 will be engaged.

  • Page 61: Controls And Bas Integration

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Controls and BAS Integration Operation and Connection Master Panel Connections With a DDC device the chiller may be controlled by a If a master panel is present, then the BAS will only connect building management system. The DDC device can work to the master panel and will need to run a single shielded over several different commination protocols (BACnet twisted pair cable (22 gauge) to the RS 485 card on the...

  • Page 62: Unit Startup

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Unit Startup Verify the following: • High voltage is correct and matches nameplate • Fuses, breakers and wire size are correct • Low voltage wiring and controls are complete • Piping is complete and the water system has been cleaned and flushed and no water leaks are present •...

  • Page 63: Electrical System And Controls - Safety Circuit

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Electrical System and Controls - Safety Circuit WARNING WARNING Do not apply any permanent inductive or capacitance During repairs to sealed components, all electrical loads to the circuit without ensuring that this will not supplies shall be disconnected from the equipment being exceed the permissible voltage and current permitted for worked upon prior to any removal of sealed covers, etc.

  • Page 64: Chiller Plant Controls Wiring

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Chiller Plant Controls Wiring Wiring Procedures • The differential pressure sensor pressure range need to match the DIP switch settings in the sensor controller. The adjustment can be made through the Primary Unit HMI. •...

  • Page 65: Chiller Plant Start-Up

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Chiller Plant Start-up...
  • Page 66 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Chiller Plant Start-up...

  • Page 67: Chiller Start-Up Report

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Chiller Start-up Report PRELIMINARY CHECKS INSPECTION ITEM RESULT INITIALS INSPECT UNIT FOR SHIPPING OR INSTALLATION DAMAGE VERIFY UNIT IS LEVEL INSPECT WATER PIPING FOR PROPER INSTALLATION, AND THAT PIPING IS INSULATED ADEQUATELY INSPECT INSIDE OF UNIT FOR POSSIBLE REFRIGERANT, OIL, OR WATER LEAKS VERIFY MOISTURE INDICATOR (IF PRESENT) IS GREEN (INDICATING NO MOISTURE IN SYSTEM)
  • Page 68 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Chiller Start-up Report cont. PRELIMINARY CHECKS CONT. INSPECTION ITEM RESULT INITIALS (GPM) SOURCE FLOW RATE GEO FLOW RATE (PSI) EVAPORATOR (LOAD) PRESSURE DROP EVAPORATOR PRESSURE DROP (PSI) CONDENSER PRESSURE DROP CONDENSER (SOURCE) PRESSURE DROP (PSI) SOURCE PRESSURE DROP GEO PRESSURE DROP...
  • Page 69 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Chiller Start-up Report cont. CONTROLS CHECKS INSPECTION ITEM RESULT INITIALS POWER ON INTERFACE AND ENSURE ALL PAGES AND DATA IS READING NORMALLY VERIFY USER MANAGEMENT IS SETUP PROPERLY (ENHANCED CONTROLS ONLY) VERIFY WATER TEMPERATURES CLOSELY MATCH REFRIGERANT SAT.
  • Page 70 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Chiller Start-up Report cont. RUN CHECKS INSPECTION ITEM RESULT INITIALS VERIFY COMPRESSOR OIL LEVEL (˚F) MODE (˚F) ENTERING HOT WATER TEMP (˚F) LEAVING HOT WATER TEMP (˚F) ENTERING COLD WATER TEMP (˚F) LEAVING COLD WATER TEMP COMPRESSOR 1 CAPACITY COMPRESSOR AMPERAGE SUCTION SAT...

  • Page 71: Braze Plate Heat Exchanger Cleaning Procedure

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Brazed Plate Heat Exchanger Cleaning Procedure Signs of Fouling such as Scaling Temperature diff erence less than specifi ed indicates signs of scaling because of the decrease in heat transfer across the plates. Increase in pressure drop indicates scaling since it restricts the channel passage, increasing velocity.
  • Page 72 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Brazed Plate Heat Exchanger Cleaning Procedure Removing Scale Sequence of operations Using diff erential pressure (dP) sensors will enable you to monitor the cleaning process. Turn off relevant pumps Close heat exchanger inlet and outlet valves to isolate heat exchanges. Empty water from the heat exchangers by removing the relevant water piping.

  • Page 73: Preventative Maintenance

    GDS-C92 CIP machine available from Goodway®. Visit www. installation of the unit and the date of failure, along with goodway.com/waterfurnace-calculator for determining an explanation of the malfunctions and a description of the the correct amount ScaleBreak-MP descaler required for a replacement parts required.

  • Page 74: Refrigeration Cycle Analysis

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Refrigeration Cycle Analysis: TruClimate 300/500 PSIG = Condenser Discharge Filter Suction Drier Compressor Evaporator PSIG = Unit Amp Draw Entering Hot Water Line Voltage Entering Water Pressure PSIG Subcooling Leaving Hot Water Superheat Leaving Water Pressure...
  • Page 75 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Refrigeration Cycle Analysis: TruClimate 700...

  • Page 76: Troubleshooting Guideline For Refrigerant Circuit

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Troubleshooting Guideline for Refrigerant Circuit The chart below will assist in determining if measurements taken at the unit are within factory specifications and aid in accurate diagnosis (SYMPTOM) and repair. The chart is general in nature and represents whether a symptom would result in normal, high, or low readings from the typical operating range.

  • Page 77: Troubleshooting Form

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Troubleshooting Form Commercial Scroll Chiller Troubleshooting Form Company Name: _________________________________ Company Phone No: ______________________________ Technician Name: ________________________________ Date: __________________________________________ Model No: ______________________________________ Serial No:_______________________________________ Owner’s Name: __________________________________ Open or Closed Loop: _____________________________ Installation Address: ______________________________ Installation Date: _________________________________ Check One Start up/Check-out for new installation...
  • Page 78 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Decommissioning Before carrying out this procedure, it is essential that the technician is completely familiar with the equipment and all its detail. It is recommended good practice that all refriger- ants are recovered safely. Prior to the task being carried out, an oil and refrigerant sample shall be taken in case analysis is required prior to re-use of recovered refrigerant.
  • Page 79 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Refrigerant Recovery When removing refrigerant from a system, either for servicing The recovered refrigerant shall be processed according to or decommissioning, it is recommended good practice that all local legislation in the correct recovery cylinder, and the refrigerants are removed safely.
  • Page 80 TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL 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.

  • Page 81: Revision Guide

    TRUCLIMATE CHILLERS OPERATION & MAINTENANCE MANUAL Revision Guide Pages: Description: Date: Physical Data Table revision, updated refrigerant charge in 050, 060, 070, 080 Feb 23 2024 Feb 15 2024 Document Creation...
  • Page 82 Document: Operation & Maintenance Manual OM1904WW 02/24 ©2024 WaterFurnace International, Inc., 9000 Conservation Way, Fort Wayne, IN 46809-9794. WaterFurnace has a policy of continual product research and development and reserves the right to change design and specifi cations without notice.

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Truclimate 500Truclimate 700

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