1. Manuals
  2. Brands
  3. Water Furnace Manuals
  4. Chiller
  5. TRUCLIMATE 900
  6. Operation & maintenance manual

Water Furnace TRUCLIMATE 900 Operation & Maintenance Manual

60hz chillers
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
OPERATION & MAINTENANCE
TRUCLIMATE 900
60HZ CHILLERS
OMT9-0004W

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the TRUCLIMATE 900 and is the answer not in the manual?

Questions and answers

Related Manuals for Water Furnace TRUCLIMATE 900

Summary of Contents for Water Furnace TRUCLIMATE 900

  • Page 1 OPERATION & MAINTENANCE TRUCLIMATE 900 60HZ CHILLERS OMT9-0004W...

  • Page 2: For The User

    Indicates a situation that could result in NOTICE causing permanent damage. equipment or property 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...

  • Page 3: Table Of Contents

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Table of Contents UNIT OVERVIEW General Installation Information............4 Nomenclatures .

  • Page 4: General Installation Information

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL General Installation Information No person carrying out work in relation to a REFRIGERATING NOTICE: Do not store or install units in corrosive environments or in locations subject to temperature or humidity extremes. SYSTEM which involves exposing any pipe work shall use any...

  • Page 5: Installation Site

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL General Installation Information WARNING WARNING Ventilated Area: ensure that the area is in the open or that it Take sufficient precautions in case of refrigerant leakage. If refrigerant is adequately ventilated before breaking into the system of gas leaks, ventilate the area immediately.

  • Page 6: Nomenclatures

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Nomenclatures T9RS030VV23**CH1N6GCSSNSSS 18-20 24-26 Brand Non-Standard Options T – TruClimate SSS – None Model Future Option 9 – 900 Series N – None Type Condenser Strainer R – Heat Pump Chiller Option N – No strainer Cabinet Configuration S –...

  • Page 7: Physical Data

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Physical Data Model R454B/208-230V R454B/460V Refrigerant Number of Circuits Factory Charge Per Circuit, lbs [kg] 23.4 [10.6] 23.4 [10.6] Compressor Compressor Quantity Compressor Weight, lbs [kg] Each 91.9 [41.7] 88.8 [40.3] Oil Charge, oz [L] Per Circuit 77.8 [2.3]...

  • Page 8: Dimensional Data

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Dimensional Data: 2-Pipe Application 15.58" 34.35" 396mm 872mm BRAZE PLATE CLEARANCE 42.625" 1083mm END OF HEADER 94.38" 5.47" 2397mm 139mm SUPERVISORY COMMUNICATION ENTRANCE 14.96" 380mm TYPICAL BOTH SIDES 2" KNOCKOUT 80.15" 2036mm 6"...
  • Page 9 TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Dimensional Data: 4-Pipe Application 15.58" 34.35" 396mm 872mm BRAZE PLATE CLEARANCE 42.625" 1083mm END OF HEADER 94.38" 5.47" 2397mm 139mm SUPERVISORY COMMUNICATION ENTRANCE 14.96" 380mm TYPICAL BOTH SIDES 2" KNOCKOUT 80.15" 2036mm 6"...
  • Page 10 TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Dimensional Data: Service Clearance (All Variants) 77D005 04 36.00" Recommended 24.00" 914mm Minimum 610mm Both Sides Both Sides 0.0" CLEARANCE UNIT TO UNIT 24.00" 610mm Minumum 34.35" Minimum 872mm 36.00" 914mm Recommended CONSULT LOCAL CODE FOR CONTROL BOX CLEARANCES 72.00"...
  • Page 11 TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Dimensional Data: Banked Units Service Clearance (All Variants) 95.11 0.51 42.625 36.00 DISTANCE BETWEEN UNITS HEADER LENGTH DOES NOT INCLUDE AT BASE RAIL BOLTS/GFCI 213.12 ZERO CLEARANCE BETWEEN UNIT HEADERS. END OF HEADER UNIT 1 TO END OF HEADER UNIT 5 253.94...
  • Page 12 TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Dimensional Data: Concrete Pad Requirements (All Variants) 21.72 24.39 26.56 21.53 94.00 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.
  • Page 13 TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Dimensional Data: Frame Rail Bolt Hole Locations 6.68" 170mm 0.62" 4 PLCS 16mm 28.75" 730mm 0.82" 92.35" 21mm 2346mm...
  • Page 14 TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Dimensional Data: Center of Gravity (4-Pipe) 533 LBS 665 LBS 22.37" 568mm CENTER OF GRAVITY 55.85" 1419mm 395 LBS 680 LBS CENTER OF GRAVITY 37.32" 948mm CENTER OF GRAVITY...
  • Page 15 TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Scuttle Clearance: 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.

  • Page 16: Hydrolink2 Aurora Controls

    TRUCLIMATE 900 CHILLER 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 17 TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Controls - Overview Before applying power ensure the DIP switch settings on the Aurora controls are correct. See table below for DIP switch factory settings. ABC-A ABC-B Factory Setting Factory Setting Freeze Protection-...
  • Page 18 TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Controls - Overview The Hydrolink and Aurora controls validates specific criteria is met before allowing the unit to start. This prevents the unit from running when required system conditions are not met. When the unit is in stand-by mode the following conditions are true.
  • Page 19 TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Controls - Overview • After the 3-minute start-up and conditional is met, depending on load requirements, the compressor will ramp up or down to desired speed. • The fans will ramp to desired speed based on ambient temperature •...

  • Page 20: Hydrolink Supervisory Control Nomenclature

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Accessory: Supervisory Control HydroLInk Supervisory Control Nomenclature 9-10 Family Vintage HSC – HydroLink Supervisory Control * – Factory Use Only Chiller Module N – NXW – Compact Scroll Non-Standard Option Detai D – WC/T5 – Dual Scroll Modular Chiller SS –...

  • Page 21: Single Point Power Nomenclature

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Accessory: Single Point Power Single Point Power Panel Nomenclature SPLC3030L410* Model SP – Single Point Disconnect Panel Vintage Fault Current Protection * – Factory Use Only L – Standard Fault Current - 5kA SCCR Future Use 0 –...

  • Page 22: Single Point Power Overview

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Accessory: Single Point Power cont. Item Number Quantity 79D665-03 19P086-05 47P921-02 47P921-01 19P086-07 19P086-04 19P086-06 19P086-09 2" Liquid Tight 90 19P086-08 47P818-60N 1/4-20X1" Machine Screw 91P015A82 GASKET GASKET 19P086-04 19P086-04 19P086-04...

  • Page 23: Electrical Data

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Electrical Data (All Variants) Electrical Table Compressor* Total Rated Voltage Model Unit Circ Fuse/ Voltage Min/Max HACR 208-230/60/3 187/253 87.7 60.8 136.0 151.2 030 R454B 460/60/3 414/506 46.1 32.0 72.4 80.4 11/15/24 HACR circuit breaker in USA only...

  • Page 24: Water Quality

    TRUCLIMATE 900 CHILLER 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 25: Heat Exchangers

    TRUCLIMATE 900 CHILLER 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 26: Antifreeze Corrections

    TRUCLIMATE 900 CHILLER 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]...

  • Page 27: Operating Limits

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Operating Limits The operational limits of the chiller are presented based on leaving water temperature for the condenser and evaporator (See Leaving Water Temperature Operational Maps). Note that certain portions of the map will require operation under head pressure control and maximum evaporator pressure control.

  • Page 28: Thermistor And Compressor Resistance

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Operating Limits cont. Thermistor and Compressor Resistance Compressor Resistance Chart R410A R454B Model 208-230 0.16 0.070 0.119 Resistance at 20°C 9/12/23...

  • Page 29: Recommended Pressure Drop And Water Velocity

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Recommended Pressure Drop and Water Velocity Optional unit level 20 mesh strainer is included with unit. Optional unit level strainer is available on brazed plate heat exchanger water inlet. Standard strainer is 20 mesh. If optional strainers are not installed, use Evaporator/Condenser Pressure Drop tables only.

  • Page 30: Unit Startup

    TRUCLIMATE 900 CHILLER 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 31: Startup Report

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Startup Report...
  • Page 32 TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Chiller Plant with Single Point Disconnect Panel cont. Unit Ground HSC Panel Fuse NEMA Enclosure Main Power Distribution Block Panel Ground...

  • Page 33: Chiller Plant With Single Point Disconnect Panel Wiring

    TRUCLIMATE 900 CHILLER 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 Supervisory Control Box HMI.

  • Page 34: Unit Level Strainer Cleaning

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Unit Level Strainer Cleaning 1. Turn off relevant pumps 2. Close heat exchanger inlet and outlet valves to isolate heat exchanges. 3. Remove end cap to access screen. 4. Remove screen taking note of orientation when removed.

  • Page 35: Braze Plate Heat Exchanger Cleaning Procedure

    TRUCLIMATE 900 CHILLER 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 36: Removing Scale

    TRUCLIMATE 900 CHILLER 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.

  • Page 37: Preventative Maintenance

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Preventative Maintenance Close Manual Isolation valves and verify that the Unit Heat Exchanger Maintenance Actuated valves are also in the close position. If Keep all air out of the water or antifreeze solution.

  • Page 38: Air Coil Cleaning Procedure

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Air Coil Cleaning Procedure Air Coil Maintenance and Cleaning NOTICE Periodic coil cleaning maintains the efficiency of the unit. Rinse the coil with water at low pressure to prevent damage, it is recommended to clean once every one to two months.

  • Page 39: Refrigerant Removal And Evacuation

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Refrigerant Removal and Evacuation When breaking into the refrigerant circuit to make repairs – or The refrigerant charge shall be recovered into the correct re- for any other purpose conventional procedures shall be used.

  • Page 40: Refrigerant Recovery

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL 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.

  • Page 41: Decommissioning

    TRUCLIMATE 900 CHILLER 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 42: Refrigeration Cycle Analysis

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Refrigeration Cycle Analysis: 4 Pipe M M M...
  • Page 43 TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Refrigeration Cycle Analysis: 2 Pipe M M M...

  • Page 44: Troubleshooting Guideline For Refrigerant Circuit

    TRUCLIMATE 900 CHILLER 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 45: Revision Guide

    TRUCLIMATE 900 CHILLER OPERATION & MAINTENANCE MANUAL Revision Guide Pages: Description: Date: Document Creation...
  • Page 46 Manufactured by WaterFurnace International, Inc. 9000 Conservation Way Fort Wayne, IN 46809 www.waterfurnace.com *OMT9-0004W* Product: TruClimate 900 Type: Water-Cooled Chillers - 60 Hz Size: 030 Tons Document: Operation & Maintenance Manual OMT9-0004W 04/25 ©2025 WaterFurnace International, Inc., 9000 Conservation Way, Fort Wayne, IN 46809-9794. WaterFurnace has a policy of continual product research and development and...

Table of Contents