SERVICE MANUAL

MODEL ACWC-SC I & 0 6500A

Screw Type
AIR COOLED
PACKAGED CHILLERS

INSTALLATION, OPERATION
&
MAINTENANCE INSTRUCTIONS
TABLE OF CONTENTS
DESCRIPTION PAGE NO.

Inspection & Handling ........................................................................................... 2

Location & Mounting . ....... ... ...... ............................................... ................... . ..... .... 2
Wiring .............................................................................................................. 2
Chiller Piping ..................................................................................................... 2
Start-Up ........................................................................................................ 2 & 3
Maintenance .... . .... . ....... ..... ........... . ........ . ............. ... .... .... ........ .. ......................... 3
Slide Valve Unloading System .................................................................................. 4
Low Ambient Operation ......................................................................................... 5
Control Settings .................................................................................................. 5
Unit Operating Limitations ...................................................................................... 5
Sequence of Operation ...................................................................................... 6 & 7
Models ACWC-160SC Thru 200SC
Sequence of Operation ...................................................................................... 8 & 9
Model ACWC-215SC
Control Wiring Diagram .................................................................................. 10 & 11
Models ACWC-160SC Thru 200SC
Control Wiring Diagram .................................................................................... 12-15
Model ACWC-215SC
Power Wiring Diagram ............. .... . . .. ... . . ... .... .. ..... . ... .. .... .. ....... ...................... . ........ 16
Across-The-Line Start
Power Wiring Diagram .......................................................................................... 17
Star-Delta
Electrical Data ................................................................................................... 18
Cooler Pressure Drops .......................................................................................... 18
Unit Loading/Suspension Points .............................................................................. 18
Troubleshooting Guide .... .. ........... .... ........... ... .......... . ........... ..... ..... .. .... ... ............ . 19
Causes & Prevention of Freeze-Up ............................................................................ 19
Start-Up Check List ..................................... . ..... .. .. ... . .......................................... 20
Operating Data ... ..... ........... .... . ... .... ..... .. ................ . ...... ........................... ... ...... .. 20

BOHN HEAT TRANSFER

A Gulf+Western Company
Danville, Illinois 61832{217)446-371 0
I
.!
 INSPECTION & HANDLING
When unit is received, it should be checked for visible or concealed
damage . If damage has occurred it should be reported to the carrier
imm e diately .o.nd clo.im filed .
Models ACWC 160SC thru 215SC are factory mounted on two (2)
permanent angle beam, carbon steel skids. Eight (8) 2W' lifting eyes
are provided in the skids to allow rigging. Spreader bars must be
used between rigging lines to prevent damage to the unit. Rollers
may be used under the skids to facilitate moving the unit a short
distance. Physical damage to the unit, after acceptance, Is not the
responsibility of the factory.
LOCATION & MOUNTING
Model ACWC Air Cooled Packaged Water Chillers are designed for
outdoor application and may be mounted on roof or at ground level.
Air flow through the condenser is vertical and the unit may be
located adjacent to outside of building or on roof without regard for
prevailing wind direction.
Since these units are air cooled, the flow of air to and from the
condenser coil must not be impeded. There must be no obstruction
above the unit that would tend to deflect discharge air downward
where it could be recirculated back to the inlet of the unit. The
required overhead air space should be a minimum of eight (8) feet.
Ductwork must not be applied to the fan outlets.
The unit must be installed with sufficient clearance for air entrance
to the condenser coil and for servicing access . The unit should be
located no closer than four (4) feet from any wall or other obstruction .
Clearance must be provided at either end of the unit to permit
removal of tubes from the chiller.
Unit must be set on a solid and level foundation .
On roof installations the unit should be mounted on support beams
which span load-bearing walls to prevent excessive vibration .
On ground level installations, the unit should be mounted on a
substantial base that will not settle . A one-piece concrete slab with
footings extended below the frost line is recommended. A space
should be left between the slab and the building to prevent the
transmission of sound and vibration .
Vibration mounts may be used for roof mounted units or other
locations where noise might be objectionable.
WIRING
A unit wiring diagram showing the required power supply character-
istics and all factory supplied wiring details is provided with unit.
Separate, field supplied, disconnects must be installed in the power
supply and should be within the sight of the unit.
Separate 115 volt power source must be field supplied to provide
power for control and heater circuits.
2
CHILLER PIPING
The chiller inlet (return) water pipe should be connected to the water
connection closest to the control panel end of the unit and the outlet
(:.upply) vvdte 1-'ifJt:: <..v""""'t"'u tv u,., wat.,r <,;urrrr.,<,;llun on the
opposite end of the cooler(s) .
A flow switch must be installed in a straight horizontal section of the
chilled water piping .
Gauges should be installed in the piping to and from the chiller to
measure the pressure drop and to insure the proper (GPM) flow rate
in accordance with submittal data . A strainer should be installed in
the piping on the inlet side of the chiller and vibration eliminators
should be employed on both the inlet and outlet pipes . Air vents
should be located at all high points in the piping system . Vents
should be located to be accessible to servicing . Drain connections
should be provided at all low points to permit complete drainage of
chiller and piping system .
The chilled water piping should be insulated to reduce heat pickup
and to prevent condensation . If the system is for year-round
operation or if it will not be drained in the winter, the chilled water
piping should be protected against freezing by electric heating cable
or other suitable means.
Upon completion of chiller piping, start the system water pump and
purge air from the system . Air purging should be done from the high
points in the water circuit. Purging of the chiller barrel may be
accomplished through the vent pipe located on the top of the chiller
compartment. Failure to purge air from the water circuit will result in
inadequate waterflow and may cause the unit to cutout on low water
flow freeze protection.
..
START-UP ~
Refer to start, test, and check list included with this manual.
Check all electrical and mechanical connections for shipping
looseness and tighten all screws on electrical terminals.
Activate the 115 volt chiller and crankcase heater circuit 24 hours
prior to unit start-up .
Rotate each fan prior to start-up. Fans should turn freely. Check belt
tension and pulley alignment. After two (2) weeks of operation,
readjust belt tension to accommodate for belt stretching.
Check all control settings as specified in Table 1.
Check the compressor oil level through the crankcase sight glass.
The oil level should be to the top of the glass. If the level is low, add
oil in accordance with the directions in the maintenance instruction
(page 3) .
.--..,_
. CAUTION:
The discharge line valve must be open before starting the compres-
sor. Liquid line valves must also be open for sustained operation .
All compressors are soli a mountea on 1sopads, therefore, compressor
hold-down bolts must not be loosened . Loosening these bolts will
cause excessive vibration of the compressor and may result in
refrigerant line breakage. Prior to start-up check all compressor
hold-down bolts for tightness .
MAINTENANCE
CONDENSER
Units equipped with belt drive fans have inherently protected
motors. Fan belts , fan bearings and motor bearings require periodic
maintenance as follows:
1. Fan Belts -After two (2) weeks operation , the belts w ill have
nearly reached their permanent stretch , therefore, each belt
should be checked again and proper adjustments made. To
maintain good fan and motor operation , the belt tension should be
checked at three (3) month intervals.
2. Fan Bearings- Each fan shaft is provided with ball bearings of
the relubricatable type. Each bearing is provided with grease
fittings, accessible through the individual motor access panels . It
is recommended the bearings be greased by adding 4 to 5 shots
with a hand gun . The suggested greasing interval is indicated on a
sticker attached to the unit.
3. Motor Bearings- Each motor is equipped with ball bearings. Ball
bearings consume a very small amount of lubricant, but enough
must be present at all time to prevent motor injury. The length of
time a bearing can run without having grease added or replaced
will depend upon the operating conditions . Under normal
operating conditions, the motor bearings should be lubricated at
2000 hour operating intervals . The lubricant should be from a
clean closed container and should be an anti-friction type bearing
grease-free from solid fillers or other harmful ingredients .
Lubricant should have a safe operating temperature of 2000 F.
The air inlet of the condenser coil should be kept clean through a
regular preventative maintenance program .
COMPRESSOR
1. OIL LEVEL - The oil level in the compressor(s) should be
checked periodically, with the compressor either running or
stopped . If the oil level is below one-half ( '12 ) the sight glass , oil
must be added .
Oil should be added only with the compressor shut off. To do so,
turn the return water thermostat (T1) to a higher temperature
setting , and wait for the unit to pumpdown and shutoff. Place the
system " ON-OFF" switch in the " OFF" position . Close the line
valve in the discharge line between compressor and condenser.
Refrigerant pressure inside of the compressor will now be
approximately 80 to 90 PSI G. The low pressure cut-out setting is
35 PSIG , but the residual discharge pressure (upstream of the
discharge check valve) will equalize back into the suction side
after the compressor stops.
3
Locate the discharge pressure port adjacent to solenoid valve
UL-3 (see drawing below) ; remove the cap and release the
residual pressure by pushing in on the pressure port fitting itself.
u,.,
Pump oil into this flU' t u11til uil level Is to the tOP Of the sight
glass .
Replace the discharge port cap. Re-open the discharge line valve.
Do not allow compressor to run with discharge valve closed.
Place the system "ON-OFF" switch in the " ON " position . Using a
jumper wire, make a "short" for five (5) seconds between terminal
#4 on terminal block TER5 and the switched terminal of a solenoid
valve feeding the circuit you have just "blown " (e .g . terminal #121
on TER4 to energize SOL 1). Reset return water thermostat (~1) to
the operational temperature setting and allow unit to return to
normal operation .
2. RECOMMENDED OIL- The unit is factory-charged with BOHN
SR-30 refrigeration oil.
Do not add any other type of oil to this factory charge.
Do not operate compressor If oil level is below one-half ('h) sight
glass.
If the oil level is below the minimum specified above, and BOHN
SR-30 is not on hand , you may drain the entire factory oil charge,
then refill with SUN ISO 4GS refrigeration oil. The factory (BOHN)
oil is of the synthetic type and will not mix with SUN ISO 4GS. Do
not attempt to operate the screw compressor with any oil other
than these two specified above .
It is suggested that a gallon or more of BOHN SR-30 oil be
obtained and kept on hand at the job site. The substitution of
SUNISO 4GS oil, as outlined above, will result in a 2% to 4%
capacity loss, and no reduction in input K.W.
3. COMPRESSOR REPAIRS (Internal) - Contact factory or an
authorized BOHN Service Agency if a compressor malfunction is
suspected .
4. COMPRESSOR REPAIRS (External) - Proper operation of
unloaded start , loading , and unloading is controlled by solenoid
valves UL-1 , UL-2 and UL-3. Any of these three (3) solenoid valves
may be repaired or replaced in the field , as required .
HIGH PRESSURE
PORT
 SLIDE VALVE
UNLOADING SYSTEM
1 ne tlonn screw compressor capacity control system for infinite
modulation consists of a slide valve and hydraulic piston/ cylinder
operator internal to the compressor; plus three hydraulic solenoid
valves (UL-1, UL-2 & UL-3) piped externally.
The slide valve forms a portion of the chamber wall in which the
rotors turn; thus, its position with respect to the rotors determines
the effective rotor length and thereby the percent of full load
capacity.
Upon compressor start-up, UL-3 is opened. This allows oil pressure
to act upon the hydraulic piston, holding it in the fully unloaded
position . After 30 seconds, during which time full oil flow is
established to all bearings surfaces, UL-3 is closed . At this point, the
temperature controller is free to open and close UL-1 or UL-2 in
response to the supply water temperature.
The slide valve will move to the left (loading) by force of discharge
pressure, whenever UL-1 opens to permit flow to the oil return (low
pressure) line. The slide valve will move to the right (unloading)
whenever UL-2 opens the oil supply (high pressure) line, since the
force of the oil exceeds that of the discharge gas.
The temperature controller sends a series of power (energizing)
" pulses " to the appropriate solenoid to adjust to load conditions.
The further the supply water temperature is from the controller set
point, the longer is the duration of the pulses. The series of pulses
will continue until the controller is satisfied. As the water temperature
approaches the set point, the pulses become quite brief to prevent
overshooting the set point.
This method of compressor unloading in conjunction with supply
water sensing minimizes action / reaction lag time and overshoot
resulting in an exceptionally precise and stable control of supply
r
water temperature.

Hydraulic Piston

Load Unload

::J c::> Oil Pressure Vent to

Suction
Slide Valve

Oil Pressure Lines

Screw Rotor
UL-1

Oil Oil
Return Supply

The following table lists solenoid valve position for all three
operating modes.

UL-1 UL-2 UL-3

Starting Close Close Open
Loading Open Close Close
Unloading Close Open Close

'-...../'

4
 LOW AMBIENT OPERATION
Due to the wide range of applications, it is sometimes necessary to
operate the Air Cooled Packaged Water Chillers at ambients below
summer conditions. Without proper control, when ambients drop
below 60 F. the pressure differential between the condenser and
the evaporator is below the level to insure proper thermal expansion
valve operation . As a result, the unit may cycle on low pressure
control with the possibility of evaporator freezing. Three types of
system control are available allowing the units to operate at the
ambients indicated:
FAN CYCLING
MEDIUM AMBIENT CONTROL TO 30 F.
(STANDARD EQUIPMENT -FACTORY INSTALLED)
A fan cycling control is standard on all Air Cooled Packaged Water
Chillers to prov1de prop er operating head pressures, in ambient
conditions to 30 F.
This is an automatic operation in which the condenser fans are
cycled on and off, as required, in response to head pressure. With
two compressors running , three fans are cycled (in sequence) on
five-fan units; four fans on six-fan units; and five fans on seven-fan
units. With one compressor running, all but the lead fan are cycled in
sequence, in response to head pressure.
This arrangement provides positive start-up control down to +30 F.
by delaying the condenser fan operation until a predetermined head
pressure is obtained.
GRAVITY (Discharge) DAMPERS
LOW AMBIENT CONTROL TO oo F.
(OPTIONAL EQUIPMENT- FACTORY INSTALLED)
All condenser fans are equipped with gravity dampers mounted on
the fan discharge to minimize the effect of prevailing winds; and to
prevent convection drafts up through the condenser coil in still air.
All compressors are enclosed in individual insulated housings. An
auxiliary heater is included to supplement the standard crankcase
heater; the temperature within the compressor compartment is
thermostatically controlled .
The standard condenser fan cycling package, operating in con-
junction with the discharge dampers , will maintain suitable head
pressure down to oo F. ambient. A 90-second time delay relay
provides an electrical by pass around the low pressure freezestat to
prevent nuisance tnp-out during cold start-up.

ACWC-SC
CONTROL SETTINGS
PRESSURE ACTUATED LEGEND FACTORY SETTING
High Pressure Control HP-1 Cut-In 300 PISG
(Manual Reset) HP2 & HP3 Cut-Out 365 PSIG
Pumpdown Control PD1 Cut-In 55 PSIG
(Auto Reset) PD2 & PD3 Cut-Out 35 PSIG
Fan Cycling Pressure Control 2 Fan Cell Cut-In (PSIG) Cut-Out
(Adjustable) FCP 1 280 170
FCP 2 295 180
3 Fan Cell
FCP 1 260 160
FCP 2 275 175
FCP 3 290 215
4 Fan Cell
FCP 1 260 160
FCP 2 275 175
FCP3 285 210
FCP4 295 235
Low Pressure Freeze Control LPF 1 Cut-Out 54 PSIG
(Manual Reset) --
LPF 2 & LPF-3

TEMPERATURE ACTUATED LEGEND FACTORY SETTING

Chiller Low Water Temperature Thermostat T2 Cut-Out 37 F.
Chiller Water Cycling Thermostat (Adjustable) T1 Dial Set At 55 F.
Chiller Heater Thermostat Included With Cut- In 40 F.
(Non-Adjustable CBH1 Heater Cut-Out 45 F.
Oil Temperature Safety Control OTS 1
(Adjustable) OTS 2 Cut-Out 240 F.
Manual Reset OTS3
Capacity Control Thermostat (Adj.) Mode Control Position T3 Dial Set At 44 F.

UNIT OPERATING LIMITATIONS

1. Maximum ambient air to condenser is 115 F. (60 Hertz operation).
2. Maximum allowable cooler water pressure is 150 PSI G.

-
(."'-._./
3.
4.
5.
Maximum allowable water temperature to cooler is 75 F.
Units must not have leaving water temperatures of 42 F. or lower unless used with a glycol solution.
Unit must be allowed to pumpdown at the end of each operating cycle (except on safety control shutdown).

5
 KEY TO WIRING DIAGRAM INDEXING SYSTEM
The wiring diagrams and sequence instructions on the following pages have been devised to simplify the understanding and tracing of circuit
theory. The following key shows how the indexing system can be used.
12 Line number on wiring diagram
[12] Line number in text
(RS) Component identification symbol in text (Relay #5)
~ Normally open contact- line number location
~ Normally closed contact- line number location
@ Holding coil - line number location
& Note number
EXAMPLE
30
~ ] ]
SEQUENCE OF OPERATION
MODELS ACWC 160 To 200 SC
The following sequence of operation is typical for the ACWC 160 to
200 SC (see Pages 10 and 11 for typical wiring diagram). Refer to the
wiring diagram furnished with unit for specific information.
Control Identification Symbol
Circuit Line Number
Important Notel
The compressor crankcase heater must be energized and remain
active for a minimum fa 24 hours prior to unit start-up.
PRELIMINARY SEQUENCE
Place control circuit "ON-OFF" switches (SW1 thru SW4) in the
"OFF" position, and set the staging thermostat (T1) to its highest
temperature.
Activate the 115 volt electrical service to terminals #2 and #4 [1 and
3] on terminal board (TEAS) to distribute power to the control circuit
up to the control circuit switches. Crankcase heater relay contacts
(R19) (3]. (R20) [5]. and (R21) [7] are closed and are supplying
power to the compressor crankcase heaters. Power is also supplied
to the chiller barrel heater (CBH1) (11]. the receiver heaters (RH1, 2,
3) (8, 9, 10] (optional), and the low ambient crankcase heaters
(SCH1, 2, 3) [3, 5, 7] (optional).
Close the main power disconnect switch. Check to see that the red
indicating light on the phase loss monitor (PLM1) is lit (NOTE: There
will be two phase loss monitors, (PLM1) and (PLM2), on 208-230 volt
models). This light must be on to indicate proper phase rotation for
the compressor(s) . If the light is not on, the main control circuit to
the compressors will not be energized. Reverse any two phase legs
at the Main Incoming Power Terminal Block. DO NOT reverse the
leads on the phase loss monitor, for this will allow the compressor to
run backwards, causing severe damage, and WILL VOID THE
COMPRESSOR WARRANTEE!
Start-up the chilled water pump. The water flow is confirmed when
the water flow switch completes an electrical circuit across terminals
#12 (58] and #13 [60] of terminal board (TEAS). Terminals #14 [61]
6
@@&
~ See Note Number 3
The holding coil for the first contact shown on this
line (reading from left to right) can be found on line
#44; the holding coil for the second contact can be
found on line #74.
The contacts for the holding coil shown on this line can be found on
lines 66, 23, and 54. The contact on line 23 is normally closed .
This is the number which identifies the line of wiring shown at the left.
and #15 [63] provide an interlock for the water pump starter(s);
either contact (R14). (R16), or (R18) [62] will close any time a
compressor is running.
Set the staging thermostat (T1) to the design range of operation (e.g .
54 F. return water) . Set the capacity control thermostat (T3) to the
design range of operation (e.g. 44 F. supply water) .
Place the four (4) control circuit switches (SW1-SW4) in the "ON"
position , thus energizing the balance of the control circuit. The
system will be In the "Time-In" mode for five minutes before any
compressor will start.
STAGE 1 LOADING
Upon demand for cooling, the first step of the staging thermostat
(T1) will close, energizing relay (TD10) (63] and staging relay (R1)
[62]. closing (R1) contacts 7-4 [22]. 8-5 [25]. and 9-6 (16] . If the
safety controls and switches are closed, the control circuit [16] for
compressor No.1 and liquid line solenoid (SOL 1) (25] will energize,
allowing the compressor to start. Fan contactor (C13) (21] will also , -~
close, bringing power to the line side of fan cycling pressure
controls (FCP1) and (FCP2) (see Power Wiring Diagram- Pages 16
and 17). Fan motor #1 will start as soon as the head pressure reaches
the "cut-in" setting of (FCP1 ).
NOTE: ALL FAN MOTORS ARE CONTROLELD BY THEIR OWN
FAN CYCLING CONTROL AND WILL CUT IN AT
DIFFERENT HEAD PRESSURES.
Relay (R19) [20] contact 7-1 [3] opens, de-energizing compressor#1
crankcase heater(s). Relay (R14) (19] contact 8-5 (24] closes,
energizing (TD7) [23]. This will force compressor #1 to run for five
minutes. COMPRESSOR #2 CANNOT BE STARTED UNTIL (TD7)
TIMES OUT.
Time delay relay (TD1 0) [63] contact C-NC (26] holds the compressor
in an unloaded condition for 30 seconds. When relay (TD10) times
out, it will energize relay (R4) [27]. closing contacts 9-6 [71] and 7-4 \....__./
[74] . This allows the capacity control thermostat (T3) to energize
solenoid valve (UL 1-1) [71]. loading the compressor; or to energize
solenoid valve (UL2-1) [74]. unloading the compressor.
 Relay (R14) (19] contact 7-4 [62] closes, which completes the
interlock circuit for the water circulating pump.
~TAGE! Z LOADINu
Upon a further increase in return water temperature, the second step
of the staging thermostat (T1) will close. If the lock-out timer (TD5)
and the lock-in timer (TD7) [64] have timed out, relays (R2) [64] and
(TD11) [65] will be energized, closing (R2) contacts 9-6 [32]. 8-5
[40]. and 7-4 [37]. If the safety controls and switches are closed, the
control circuit [32] for compressor #2 and liquid line solenoid
(SOL2) [ 40] will energize, allowing the compressor to start.
Relay (R20) [36] contact 7-1 [5] opens, de-energizing crankcase
heater(s). Contact 9-6 [44] closes, energizing fan contactor (C14)
(44]. bringing power to the line side of the balance of the fan cycling
pressure controls (see power wiring diagrams) . Fan motor #3 will
start as soon as the head pressure reaches the "cut-in" setting of
(FCP3) .
Relay (R16) [35] contact 8-5 [39] closes , energizing (TD8) (38]. This
will force compressor #2 to run for five minutes. Compressor #3
cannot be started until (TDS) times out.
Time delay relay (TD11) [65] contact C-NC (41] holds compressor#2
in an unloaded condition for 30 seconds. When (TD11) times out, it
will energize (R5) (42]. closing contacts 9-6 (72] and 7-4 (75] . This
allows the capacity control thermostat (T3) to energize solenoid
valve (UL 1-2) [72]. loading the compressor; or to energize solenoid
valve (UL2-2) [75]. unloading the compressor.
STAGE 3 LOADING
Upon a further increase in return water temperature, the third step of
the staging thermostat (T1) will close. If the lock-out timer (TD6) and
the lock-in timer (TD8) (66] have timed out , relays (R3) (66]. (R7)
(68]. and (TD12) [67] will be energized . Relay (R3) contacts 9-6 [48].
7-4 [53]. and 8-5 [56] close. If the safety controls and switches are
closed, the control circuit [ 48] for compressor #3 and liquid line
solenoid (SOL3) [56] will energize, allowing the compressor to start.
Relay (R21) [52] energizes , opening contact 7-1 [7], de-energizing
compressor #3 crankcase heater(s). Relay (R18) (51] contact 8-5
[55] closes, energizing (TD9) [54] . This will force compressor #3 to
run for five minutes.
Relay (R7) contact 9-6 [70] closes, energizing solenoid valve (UL 1-
1). thus locking compressor #1 in the fully loaded position. Relay
(R7) contacts 8-2 [71] and 7- 1 [74] open to disconnect the capacity
control thermostat (T3) from compressor #1 capacity control
solenoid valves.
Time delay relay (TD12) [67] contact C-NC [57] holds compressor
#3 in an unloaded condition for 30 seconds. When (TD12) times out,
it will energize relay (R6) [58]. closing contacts 9-6 [73] and 7-4 [76].
This allows the capacity control thermostat (T3) to energize solenoid
valve (UL 1-3) [73]. loading the compressor; or to energize solenoid
valve (UL2-3) [76]. unloading the compressor.
Compressor #1 is fully loaded.
Compressors #2 and #3 are being capacity-modulated.
,.-......__/
7
PUMPDOWN SEQUENCE
STAGE 3 PUMPDOWN
A dccrca:>e in return water temperature will t;iiU>Se the third step or
the staging thermostat (T1) to open, thereby de-energizing staging
relay (R3) , opening contacts 8-5, 9-6, and 7-4. Liquid line solenoid
(SOL3) will de-energize, stopping the flow of refrigerant to chiller
circuit #3. The compressor will continue to run until the chiller
circuit has been cleared of refrigerant and the suction pressure is
approximately 35 PSIG . Low pressure control (LP3) contact will
then open, de-energizing compressor contactors (C5) (49] and (C6)
[50]. stopping compressor #3; and de-energizing relays (R18) and
(R21 ). Relay (R18) N.C. (normally closed) contact 2-8 (54] energizes
lock-out timer (TD6). preventing compressor #3 re-start for . five
minutes. Relay (R21) energizes the compressor crankcase heater(s).
Staging thermostat (T1) also de-energizes relay (R7). opening
contact 9-6, releasing compressor #1 from continuous full-load
operation. Relay (R7) contacts 8-2 and 7-1 close, allowing the
capacity control thermostat (T3) to operate capacity control solenoid
valves (UL1-1) and (UL2-1) as required .
STAGE 2 PUMPDOWN
A further decrease in return water temperature will de-energize
staging relay (R2), closing liquid line solenoid (SOL2) . When chiller
circuit #2 has pumped out, low pressure control (LP2) opens,
stopping compressor #2; and de-energizing relays (R16) and (R20) .
Relay (R16) N.C. contact (8-2) [38] energizes lock-out timer (TD5),
preventing compressor #2 re-start for five minutes. Relay (R20) (36]
energizes compressor#2 crankcase heater(s); and also de-energizes
fan contactor (C14) (44]. stopping the fan motor(s) servicing the
two-circuit condenser slab.
STAGE 1 PUMPDOWN
Step 1 of the staging thermostat (T1) will open when the return water
temperature is reduced to the set point . This de-energizes staging
relay (R1 ), closing liquid line solenoid (SOL 1), stopping refrigerant
flow to chiller circuit #1. Compressor#1 continues to run until chiller
circuit #1 pressure is down to the low pressure control (LP1) set
point. The (LP1) contact opens, de-energizing compressor contac-
tors (C1) (17]. (C2) (18], and fan contactor (C13) [21]. stopping
compressor #1 and the remaining fan motor(s).
Relay (R14) N.C. contact 8-2 (23] energizes lock-out timer (TD4),
preventing compressor #1 re-start for five minutes ; relay (R14)
contact 7-4 (62] opens, removing the circulating pump starter
interlock . Relay (R19) de-energizes, closing contacts 7-1 [3].
energizing compressor #1 crankcase heater(s) .
SAFETY CONTROLS
Each refrigerant circuit is protected by seven standard safety
controls, and one optional safety control.
1. High Pressure (HP)
2. Low Pressure Freeze (LPF)
3. High Discharge Temperature (OTS)
4. Low Oil Temperature (LOT)
5. Compressor Solid State Module (CSTM)
6. Low Water Temperature (T2)
7. Low Pressure (LP)
8. Compressor Starter Overloads (OLH) (Optional)
If any of these devices should open due to abnormal conditions, the
compressor will automatically stop. All controls must be manually
reset , except Low Oil Temperature (LOT), Low Pressure (LP) and
Compressor Solid State Module (CSTM), which resets itself after a
two minute bleed-down period. The compressor motor windings are
also equipped with a thermal protector, automatic reset , which is not
shown on the wiring diagram .
 SEQUENCE OF OPERATION
MODEL ACWC 215 SC
The following sequence of operation is typica l for the ACWC 215 SC
(see pages 12 to 15 for typical w iring diagram ). Refer to the wiring
diagram furnished with un it for specific information.
( ) Control Identification Symbol
[ ] Circuit Line Number
Important Notel
The compressor crankcase heate r must be energized and remain
active a minimum of 24 hours prior to unit start.
PRELIMINARY SEQUENCE
Place control circuit " ON-OFF" switches (SW1 thru SW5) in the
" OFF" position , and set the staging thermostat (T1 ) to its highest
temperature.
Activate the 115 volt electrical service to terminals #2 and #4 [ 1 and
3] on terminal board (TER5) to distribute power to the control circu it
up to the control c ircuit switches. Crankcase heater relays (R20) [3],
(R21) (5], (R22) [8], and (R23) (10] are closed and are supp ly ing
power to the compressor crankcase heaters . Power is also supplied
to the chiller barrel heaters (CBH1) [17] and (CBH2) [20], the
receiver heaters (RH1 , 2, 3, 4) (12, 13, 15, 16] (optional) , and the low
ambient crankcase heaters (SCH1 , 2, 3, 4) [3, 5, 8, 10] (optional) .
Close the main power disconnect switch. Check to see that the red
indicating lights on the phase loss monitors (PLM1 ) and (PLM2) are
lit. These lights must be on to indicate proper phase rotation for the
compressor(s). If the lights are not on , the main control circuit to the
compressors will not be energized . Reverse any two phase legs at
the main Incoming power terminal block. DO NOT reverse the leads
of the phase loss monitor, fo r this w ill allow the compressor to run
backwards, causing seve re damage , and WILL VOID THE
COMPRESSOR WARRANTEE!
Start-up the chilled water pump. The water flow is confirmed when
the waterflow switch completes an electrical circuit across terminals
#12 [89] and #13 [91] of terminal board (TER5) . Terminals #14 [92]
and #15 (94] provide an interlock for the water pump starter(s) ;
either contact (R11 ), (R12) , (R13) , or (R14) [95] will close any time a
compressor is running .
Set the staging thermostat (T1) to the design range of operation (e.g.
54 F. return water). Set the capacity contro l thermostat (T3) to the
design range of operation (e.g . 44 F. supply water) .
Place the five control circuit switches (SW1 thru SW5) in the " ON "
position , thus energizing the balance of the control circuit. The
system will be in the "time-In" mode for five minutes before any
compressor will start.
STAGE 1 LOADING
Upon demand for cooling , the first step of the staging thermostat
(T1) will close, energizing relay (TD15) [94] and staging relay (R1)
(93], closing (R1) contacts 7-4 [32], 8-5 [35], and 9-6 [26] . If the
safety controls and switches are closed , the control circuit [26] for
compressor #1 and liquid line solenoid (SOL 1) (35] will energize,
allowing the compressor to start.
Relay (R20) (30] contact 9-6 (39] closes, energizing fan contactor
(C13) (39], bringing power to the line side of fan cycling pressure
controls (FCP1) thru (FCP6) (see Power Wiring Wiring Diagram on
Pages 16 and 17) . Fan motor #1 will start as soon as the head
pressure reaches the " cut-in " setting of (FCP1 ).
NOTE: ALL FAN MOTORS ARE CONTROLLED BY THEIR OWN
FAN CYCLING CONTROL AND WILL CUT IN AT
DIFFERENT HEAD PRESSURES.
Relay (R20) contact 7-1 (3] opens, de-energizing compressor #1
crankcase heater(s) . Relay (R11) [29] contact 8-5 [34] closes ,
energizing (TD9) [33]. This will force compressor #1 to run for five
minutes. COMPRESSOR #3 (Stage 2) CANNOT BE STARTED
UNTIL (TD9) TIMES OUT.
Time delay relay (TD15) ]94] contact C-NC [36] holds the compressor
in an unloaded condition for 30 seconds . When relay (TD15) times
out, it will energize relay (R5) (37], closing contacts 9-6 [1 06] and 7-4
(112]. This allows the capacity control thermostat (T3) to energize
solenoid valve (UL 1-1) [1 06], loading the compressor; or to energize
8
solenoid valve (UL2-1) [1 12], unloading the compressor.
Relay (R11 ) [29] contact 7-4 [95] closes , wh ich completes the
interlock circuit for the water c irculating pump.
STAGING 2 LOADING ~
Upon a further increase in return water temperature, the second step \
of the staging thermostat (T1) will close. If the lock-in timer (TD9)
[95] and lock- out timer (TD7) [95] have timed out , relays (R2) [95]
and (TD16) [96] will be energized , closing (R2) contacts 9-6 [62], 7-4
(67], and 8-5 [70] . If the safety controls and switches are closed , the
control circuit [ 62] for compressor #3 and liquid line solenoid
(SOL3) [70] will energize, allowing the compressorto start.
Relay (R22) [66] contact 7-1 [8] opens, de-energizing crankcase
heater(s). Contact 9-6 [74] closes , energizing fan contactor (C14)
[74], bringing power to the line side of fan cycling pressure controls
(FCP7) thru (FCP12) (see power w iring diagrams) . Fan motor#4 will
start as soon as the head pressure reaches the " cut-in " setting of
(FCP7) .
Relay (R13) [65] contact 8-5 [69] closes, energizing (TD11) [68] .
This will fo rce compressor #3 to run fo r five minutes . Compressor#2
cannot be started until TD11) times out.
Time delay relay (TD16) [96] contact C-NC [71] holds compressor
#3 in an unloaded condition for 30 seconds . When (TD16) times out,
it will energize (R7) [72], closing contacts 9-6 [1 08] and 7-4 [113] .
This allows the capacity control thermostat (T3) to energize solenoid
valve (UL 1-3) [108], loading the compressor; or to energize solenoid
valve (UL2-3) [113], unload ing the compressor.
STAGE 3 LOADING
Upon a further inc rease in return water temperature, the th ird step of
the staging thermostat (T1) will close. If lock-in timer (TD11) and
lock-out timer (TD6) [66] have timed out, relays (R3) [97], (R9) [99],
and (TD17) (98] wil l be energized . Relay (R3) contacts 9-6 [45], 8-5
and 7-4 [50] close . If the safety controls and switches are closed , the
control circuit [45] for compressor #2 and liquid line solenoid
(SOL2) [53] will energize, allowing the compressor to start.
Relay (R21) [49] energizes , opening contact 7-1 [5], de-energizing
\....__/
compressor #2 crankcase heater(s) . Relay (R12) [48] contact 8-5
[52] closes , energizing (TD1 0) [51] . This will force compressor#2 to
run for f ive minutes. Compressor #4 cannot be started until (TD10)
times out.
Relay (R9) contact 9-6 [1 05] closes, energizing solenoid valve (UL 1-
1), thus locking compressor #1 in the fully loaded position . Relay
(R9) contacts 8-2 [106] and 7-1 [112] open to disconnect the
capacity control thermostat (T3) from compressor #1 capacity
control solenoid valves.
Time delay relay (TD17) [98] contact [54] holds compressor#2 in an
unloaded condition for 30 seconds. When (TD17) times out, it will
energize relay (R6) [55], closing contacts 9-6 [109] and 7-4 [114] .
This allows the capacity control thermostat (T3) to energize solenoid
valve (UL 12) (1 09], load ing the compressor; or to energize solenoid
valve (UL2-2) (114], unloading the compressor.
Compressor #1 is full loaded .
Compressors #2 and #3 are being capacity-modulated .
STAGE 4 LOADING
Upon a further increase in return water temperature, the fourth step
of the staging thermostat (T1) will close. If the lock-in timer (TD1 0)
and the lock-out timer (TD8) [1 00] have timed out, relays (R4) [1 00],
(R1 0) (1 02], and (TD18) [1 01] will be energized . Relay (R4) contacts
9-6 [79], 7-4 (84], and 8-5 [87] close. If the safety controls and
switches are closed , the control circuit [79] for compressor #4 and
liquid line solenoid (SOL4) [87] will energize , allowing the com pres-
so r to start.
Relay (R23) [83] energizes, opening contact 7-1 (7], de-energizing
compressor #4 crankcase heater(s). Relay (R14) [82] contact 8-5
(86] closes, energizing (TD12). This will force compressor #4 to run
for five minutes. ~~
Relay (R1 0) contact 9-6 [1 07] closes, energizing solenoid valve
(UL1-3 , thus locking compressor #3 in the fully loaded position .
Relay (R1 0) contacts 8-2 (1 08] and 7-1 [113] open to disconnect the
capacity control thermostat (T3) from compressor #3 capacity
control solenoid valves.
 Time delay relay (TD18) (101] contact C-NC (88] holds compressor
#4 in an unloaded condition for30 seconds. When (TD18) times out,
it will energize relay (R8) [89]. closing contacts 9-6 [11 0) and 7: 4
(116]. Thio o.llowo tho capacity control thormootat (T'l) to .. norgi:zo
solenoid valve (UL 1-4) [11 OJ, loading the compressor; or to energize
solenoid (UL2-4) [115) , unloading the compressor.
'-.._/
Compressors #1 and #3 are fully loaded .
Compressors #2 and #4 are being capacity-modulated.
PUMPDOWN SEQUENCE
STAGE 4 PUMPDOWN
A decrease in return water temperature will cause the fourth step of
the staging thermostat (T1) to open , thereby de-energzing staging
relay (R4), opening contacts 8-5, 9-6, and 7-4. Liquid line solenoid
(SOL4) will de-energize, stopping the flow of refrigerant to chiller
circuit #4. The compressor will continue to run until the chiller
circuit has been cleared of refrigerant and the suction pressure is
approximately 35 PSIG. Low pressure control (LP4) contact will
then open, de-energizing compressorcontactors (C7) [80) and (C8)
[81), stopping compressor #4; and de-energizing relays (R14) and
(R23) . Relay (R14) N.C. (normally closed) contact 2-8 [85] energizes
lock-out timer (TD8), preventing compressor #4 re-start for five
minutes. Relay (R23) energizes compressor#4 crankcase heater(s) .
Staging thermostat (T1) also de-energizes relay (R10) , opening
contact 9-6, releasing compressor #3 from continuous full-load
operation. Relay (R1 0) contacts 8-2 and 7-1 close, allowing capacity
control thermostat (T3) to operate capacity control solenoid valves
(UL1-3) and (UL2-3) as required.
STAGE 3 PUMPDOWN
A further decrease in return water temperature will de-energize
staging relay (R3), closing liquid line solenoid (SOL2) . When chiller
circuit #2 low-side has pumped out, low pressure control (LP2)
opens, stopping compressor #2; and de-energizing relays (R12) and
(R21 ). Relay (R12) N.C. contact 2-9 [51) energizes lock-out timer
(TD6), preventing compressor #2 re-start for five minutes. Relay
r (R21) energizes compressor #2 crankcase heater(s) .
Staging thermostat (T1) also de-energizes relay (R9), opening
contact 9-6, releasing compressor #1 from continuous full-load
operation. Relay (R9) contacts 8-2 and 7-1 close, allowing the
capacity control thermostat (T3) to operate capacity control solenoid
valves (UL 1-1) and (UL2-1) as required .
STAGE 2 PUMPDOWN
A further decrease in return water temperature will de-energize
staging relay (R2), closing liquid line solenoid (SOL3) . When chiller
circuit #3 has pumped out, low pressure control (LP3) opens,
stopping compressor#3; and de-energizing relays (R13) and (R22).
Relay (R13) N.C. contact 2-8 [68) energizes lock-out timer (TD7),
STAR-DELTA STARTING
OPEN TRANSITION
The following starting sequence applies to the power wiring diagrams
on Page 17 as well as the control wiring on Pages 10 thru 15. Detail
"A" on Page 10 is typical of all screw compressor star-delta start, and
will be used as an example.
Staging relay (R1) contact 9-6 [16) closes, energizing star contactor
(S1) [168) and the 5 second transition timer (TD1) [16A) . The (S1)
power contacts close, tying the center legs of the motor windings
together into the "star" (wye) configuration. The (S1) N.C. (normally
closed) auxiliary contact [18] opens to prevent contactor (C2) from
~
energizing. The (S1) N.O. (normally open) auxiliary contact [17)
closes, energizing (C1) [17] . The (C1) power contacts close,
applying power to the motor. The (C1) N.O. auxiliary contact closes,
9
preventing compressor #3 re-start for five minutes. Relay (R22)
energizes compressor #3 crankcase heater(s); and also de-energizes
fan contactor (C14) [74). stopping the fan motor(s) on the "lag" half
nf thA condAn!':Ar !':lab.
STAGE 1 PUMPDOWN
Step 1 of the staging thermostat (T1) will open when the return water
temperature is reduced to the set point. This de-energizes staging
relay (R1 ), closing liquid line solenoid (SOL 1), stopping refrigerant
flow to chiller circuit #1 . Compressor#1 continues to run until chiller
circuit #1 pressure is down to the low pressure control (LP1) set
point. The (LP1) contact opens, de-energizing compressor contac-
tors (C1) (27) and (C2) [28), and relay (R20), stopping compressor
#1 . Relay (R20) de-energizes fan contactor (C13), stopping the
remaining fan motor(s); and also energizes compressor #1 crankcase
heater(s) . The (LP1) contact also de-energizes relay (R11 ). Relay
(R11) N.C. contact 2-8 [33) energizes lock-out timer (TDS), prevent-
ing compressor #1 re-start for five minutes. Relay (R11) contact 7-4
[95) opens, removing the circulating pump starter interlock.
SAFETY CONTROLS
Each refrigerant circuit is protected by seven standard safety
controls, and one optional safety control.
1. High Pressure (HPO)
2. Low Pressure Freeze (LPF)
3. High Discharge Temperature (OTS)
4. Low Oil Temperature (LOT)
5. Compressor Solid State Module (CSTM)
6. Low Water Temperature (T2)
7. Low Pressure (LP)
8. Compressor Starter Overloads (OLH) (optional)
If any of these devices should open due to abnormal
conditions, the compressor will automatically stop. All
controls must be manually reset , except Low Oil Temper-
ature (LOT) , Low Pressure (LP) and Compressor Solid
State Module (CSTM), which resets itself after a two
minute bleed-down period . The compressor motor wind-
ings are also equipped with a thermal protector, automatic
reset, which is not shown on the wiring diagram .
locking (C1) in the energized position .
The compressor operates in the star mode until (TD1) times out (5
seconds) at which time (TD1) contact (168) opens, de-energizing
(S1 ). The (S1) N.C. contact [18) closes, energizing contactor (C2)
[18), closing (C2) power contacts, thereby completing the Delta
wiring configuration. (C2) N.C. auxiliary contact [16A] opens,
preventing (S1) from energizing until the next starting sequence.
There is an instant of time (the "open transition " ) between the
opening of (S1) power contacts and the closing of (C2) power
contacts, in which power across the motor windings is interrupted .
 ~ .. ~
8
Rrt- OPTIOHAlr----
1~~ C8FI WHITE
2
DESIGNATIONS : POWER SUPPLY 1 ~ I: OPPrfiOfll
7 R.z2~ Ill PCHI zoow 142 WHITE
115V/60'\,/IIf L _ y_ ____j I ..::=--~oPT 12GA
4 4 BLACK ..--..... 108- RED 7 Rl9 t 112 ~~ !lOW I~ .
0 HOLDING COILS WITH LINE NO.
12GA CB2 I =I ~ @
0 NORMALLY CLOSED CONTACTS WITH LINE NO. ~222 ,I 113 PCH2 zoow

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6
NORIIIALL'f Of>EN

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CONTACTS WITH

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LINE NO. I

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YELLOW.~ 203 RHT3 206 RH 3 II
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8 Co _ _ r--r==e- : -------"l OPTIONAL 0
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TYPICAL. FOR UGHT OPTION ON ALARM CIRCUITS 1,2 8 3. z
: ' 1 ~:o 1J CST . LEir "cd
(NOT SUPPLIED WITH BELL OPTION.)
L :vuu A--
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NO 227 R4 } - - - - - - ' ETI!3 en

10-
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ALARM CIRCUIIIT - - ~OPTIONAL -1
STAR DELTA STARTING CIRCUIT 2 0 ~
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OPTiONAL 0LH4 OLH5 OLH6 [ Co::\'-----~ 0
228 229 230 ~ 13*91821
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DETAIL "B" - ~ ~'i!il~
5
8 1!3 8
COMPRESSOR CIRCUIT 2 rlJ"': :::E A T0 w;;:
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7
8 R2 5 5 N~NT R20 128 SOL 2 148

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STA NDARD
LEGEND &
&
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r
CONTACTOR - COioiPRESSOR 0
Cl3-14 CONTACTOR - CONDENSER FAN ol>ol<l
CBI CIRCUIT BREAKER- CONTROL CIRCUIT 0
CB l, 4 CIRCUIT BREAKER- HEATERS
CHILLER BARREL HEATER
L:.J..I~ z
CSTMI 3 ! COMPRESSOR SOLID STATE NODULE -t
~ @
HPI -3 I HIGH PRESSURE CONTROL ::D
LOT 1-3 LOW OIL TEMPERATURE
LPI - 3 LOW PRESSURE CONTROL
~ 0
LPF I 3 I LOW PRESSURE FREEZE
OTS I 3 I OIL TEMPERATURE SAFETY
00 r
PLM 1 I PHASE LOSS MONITOR
Rl -3 !RELAY-STAG ING
00 :e
RELAY - CAPACITY CONTROL
RELAY - LOCK IN
::D
SWITCH- MASTER NO ,., .. R6}-----_j 58@
Rl4, 16, IB I RELAY - TNTEIIILOCK
~
~ z
R 19 -21 I RELAY-CRANI<CASE REMOTE SWITCHES! ,.
SOLI 3 I SOLENOID-LIQUID LINE TO 8 WIRED IN C)
SERIES WHITE
SWl - 4 I SWITCH- COMPR. CIRCUITS 60 &/!::,.
THERMOSTAT - SEQUENCER
TZ ] THERMOSTAT- LOW TEMPERATURE
)>
THERMOSTAT- CAPACITY CONTROLLER " 0
TO PUMP MOTOR
INTERLOCK. \1s\22\z5l ~
TO 4-8 I TINE DELAY- CYCLING

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~~ ;o~~2 ~:=~ ~~~:~ ~ ~A~~~~~~c~~:TROL
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TERMINAL BOARD-CUSTOMER WIRING 0 \32137149 .> ~
TERMINAL BOARD-FACTORY WIRING Q
UNLOADERS-SOLENOIO COMPRESSOR @) 0)
0
~@>
-t
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OPTIONAL NOTES "5
AMBIENT HIGH TEMPERATURE THEA"'.
.. 1701~1~ ~ ::D
I T2 AND T3 TEMP. SENSORS LOCATED IN u
WATER OUTLET, Tl IN WATER INLET. c:
GF 1- 3 I GROUND FAULT PROTECTION 2. WHEN TO 13,14 a IS ARE SUPPLIED ,
HOT GAS SOLENOID WIRE S FROM 120,127 a 133 TO T2 N
BE CO JojE 218, 236 8 255 RESPECTIVELY. 70 @
LOW AMBIENT THERMOSTAT UL I-1 . 1 0
l. WHEN LATI IS NOT SUPPLIED, WIRE 265
OLH 1-9 OVERLOAD HEATERS - STARTERS 140
BECOMES 13. 0
PCH I 3 PR IMARY COMPRESSOR HEATER 4. WHEN GF!,GF2 8 GF3 ARE NOT SUPPLIED, 00 &
PL I 9 PILOT LIGHTS WIRES 213, 231 8 250 BECOME 117, 124 8
130 RESPECTIVELY. 72 @ en
R 22 RELAY- SECONDARY HEATERS 5 FOR CONTACTOR COILS Cl THRU C6, Cl3 8 ULI -3
RH 13 RECE IVER HEATER C 14, SEE MAIN POWER DIAGRAM FOR 0
RECEIVER HEATER PRESSURE CONTROL CONTACTS
UL2 1 "
6. ALARM LIGHT OPTION AND ALARM BELL
RECEIVER HEAT ER THERMOSTAT
CIRCUIT BREAI<[R- RtC. HEATER
OPTION ARE NOT SUPPLIED SIMULTANEOUSLY.
7. WHEN VLN I IS NOT SUPPLIED, WIRE 209
... WHITE
H @@
UL2 2
SCH I 3 SECONDARY CRA NI<CASE HEATER 8ECOio4ES 272 .
TC 1-3 TRANSITION CONTACTOR
'"
UL2-3 "
TO 1-3 TI N E DELAY - TRANSITION CONTACTOR
76
TO 13 - 15 I TINE DELAY- LOCI< OUT LPF
STARTER - COMPRESSOR 77
VOLT LOSS MONITOR

"
 @]
il
,---------.._~
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0 I-IOLDING COILS WIT H :..I NE NO. 2 -'"~ I I ~ "' I ~
30

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PO WER SUPPLY
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11 2 BLACK ::D
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209 BLACK )>
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STAR DELTA STARTIN G ALARM CIRCUIT ,. I T 23~
CIRCUIT I 1\)
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~~
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~2.0 ~
,., " ,-t<
@X)
NC
TOI!I ,."' ,." 0
30 SEC ... e )>
NO m 37~

181 BLUE
j r
BLUE 0
~~. "' 8 @ &
z~~t j" "
0
e z
-t
STAR DELTA STARTING ~~R~R0~ c~RCUITI I I I (o2i) I u@J lJ
&
@ &. 0
1 r
(..) 1 _TOZ 242 ~1 2 .. ~~ I I - IN r.c.z ,;;, ,.......,.. I I I I I I LPFZ , , . LOT 2 ,,Q OTS 2 I I I 129 R LP2 v Q R3 ... llOl l ~I"==" NTR 12ovl l1es I
~ ., ~ ~
"" e
.. @ &
"" lJ
I 237
4 47 ~
--
~ & z
411 [4e[~[tol~l
C)
BLUE )>
"9l.:J4o[s,[
DETAIL "B' I BLUE 0
so"] @ i
8
COMPRESSOR CIRCUIT 2 51~
~
[
I VLioll
I T 2
e
@
0
1\)
00 ......
,." (11
0 @
BLUE
:'-r: t en
0) 55~
250 I ,.
j 0
 STAR DELTA START I NG ..... ..., .... I I I I I I ~~-
c.:::..__l___ 1 59~
&
e &

" @
e &
l
..~
;:;
-i
.,-<
z
&
..
s' js3jse \95 \ 0
5 SEC - YELLOW
)>
s~ u ~rOIH ! ~
DETA I L "C" I I I t I c ~~ ~ I r
0
8 @ 0
68 ~
0 0
e .
e z
70
EX3 -i
138 :lJ
0 71
T DI6 ~30 ; ~
SEC
,.. YELLOW
e 0
NO 7Z ~ r
~

-1>- I I18ll
e 73
j =e
BR OW N g R22 6 BROW N ,., Cl4 14 @
:t23 6 :lJ
" e z
STAR DELTA STARTING ~~~Ru~Tc~currl 76 EJ &
I I nPTinN.I.I
C)
@
6l
& )>
.&.: 0
9 ~
;:; =e
e & z
.. 0
& I\)
leo\e5 \951 ......
5SEC
~ U1
I BROWN
c 139 t~J r5 j er \ 0

DETAIL " D"

~~~- I I I 7
~ R<t c ... ...., ..... ~ en
84 @>
. I e: El 0
85 ~ @
@
SWI 07
~ 00
NC 144
- T O 18
!0 SEC BROWN " @)
NO "' u ffi J
 (

LEGEND
TO FLOW SWITCH.

STANDA RD REMOTE SWITCHES 90

TO BE WIRED IN
... v~~wown v-- "~~vw" SERIES.
13 t BLACK BLACK 14!5 BLACK
Cll-14 CONTACTOA - CONDENSER FAN
CBI- 2 CIRCUIT MEAkER - CONTROL CIRCUIT
~I
~
C83-4,7 CIRCUIT BREAKER- HEATERS
CB H 1-2 CHILLER BARREL HEATER
CSTMI-4 COMPRESSOR SOLID STATE MOOULE
HPI-4 HIGH PRESSURE CONTROL
lu/32/3sJ@
.,-<
LOT 14 LOW OIL TEN PERATURE 94 8
L.PI-4 LOW PRESSURE CONTROL
0
TO PUMF MOTOR
LPF 1-4 LOW PRESSURE FREEZE 95~ l>
IHTEALOCK
OTS 1-4 OIL TEMPERATURE SAFETY r
PL.M 1-2 PHASE LOSS MONITOR 96 ~
R 1-4 RELAY - STAGING
R!S - 8 RELAY - CAPACITY CONTROL TER5 97 ~lso/ss/ @) 0
R 910 RELAY- LOCK IN 0
SW I SWITCH WASTER
Rll-14 RELAY- INTERLOCK ~ z
R 20-23 REU.Y- CRANkCASE
~
SOL 1-4 SOLENOID- LIQUID LINE ~
sw 2-5 SWITCH- COMPRESSOR CIRCUITS 100 179/84/871 <E:) ::D
THE tOSTAT - SEQUENCER !5 MIN
T2
" THERMOSTAT- LOW TEMPERATURE NOTES 101 ~ - 0
T3 THERMOSTAT- CAPACITY CONTROLLER ! r
TO 58 TIME DELAY CYCLING I. T2 AND TJ TEMP SENSORS LOCATED IN 102!1oij~
~
TO -12 TIME DELAY- 5 MIN, LOCK IN WATER OUTLET, Tl IN WATER IHLET. i~
(}1 ~
TO 15-18 TIME DELAY- CAPACITY CONTROL Z . WHEN TO 2023 ARE SUPPLIED, WIRES ,
TER 5 TERWINAL 80AROCUSTONER WIRING 0 FROt.t 124,131,137 6 143 TO T2 BECOME
~
223,241,259 & 279 RESPECTIVELY. 10< ::D
TERWINAL BOARD- FACTORY WIRING 0
Ul I THRU4 llhll . 040FR~- ~01 FhiOIO COt.IPti~~!IOR 3. WHEH LATI IS NOT SUPPLIED, WIRE 289 ~i
BECOWES 13 .
100 -~
--
4. WHEH Gfl-4 ARE NOT SUPPLIED, WIRES
176 1
e z
218,237,254 ll 274 r.ECOME 121,128, C)
106
134 6 140 RESPECTIVELY. 00
6. FOR CONTACTOR COILS C 1- 8, 13 8 14,
SEE WAIN POWER DIAGRAM FOR CONTACTS. @ 8 l>
OPTIONAL
6 ALARM LIGHT OPTION AND ALARM BELL 108 0
AHT 1-2 AMBIENT HIGH TEWPERATURE THERN.
OPTION ARE NOT SUPPLIED SIWULTANEOUSL't". 3
CBF 1-2 CONTROL BOX FANS
7 WHEN VLM 1-2 ARE NOT SUPPLIED, WIRES
GROUND FAULT PROTECTION 109 @ ~
213 a 270 8ECOWE 214 8 12 RESPECTIVELY.
HGS I I HOT GAS SOLENOID
LOAD 0
LOW ANBIENT THERWOSTAT 110
OLH 1-12 I OVERLOAD HE4TERS - STARTERS
e N
PCHI-4 IPRIWARY COloiPRESSOR HEATER ....
PL 1-12 PILOT LIGHTS c.n
R 30 31 RELAY- SECONDARY HEATERS
RH 1-4 RECEIVER HEATER UL2-3 I
'" ~
AHPC 1- 4 RECEIVER HU.TER PRESSURE CONTROL ~
en
RHT 1-4 RECEIVER HEATEA THUMOSTAT "' I 0
CB 5-6 I CIRCUIT BREAKER- REC . HEATER @
SECONDAI!:Y CRANKCASE HEATER
'"
TC 1-4 ITRAHSITION COHTACTOR @
TlloiE DELAY- TRANSITION CONTACTOR "'
TO 20-23 I TINE DELAY - LOCK OUT LPF ...
STAI!:TE"- COMPRESSOR
\ILt.tt-2 IVOLT LOSS NONITOR
 TYPICAL POWER WIRING
ACROSS-THE-LINE START
USE COPPR COHOUCTORS OHLT
ACWC 160-200 SC
r-,
'A
Dl.SI

L lti_jOf'fiOIU.L

.. '
PC 8 7

.. ' o,,.,
~~;,;L"m
11 9 l puu t
I9 9
1 -rDI'TIDNAL )

TOCONTIIOLCI II CUrt

,..m
fCPI
lU$
r--~
LEGE ND
I ~ j - I
OV11l.OolOIIUTU-SUIIT11
CQNTACTOOI-CO'IPIIESSOII

~~~~~~) ~~:::~::"~C:~:S11 UN
FCPIIO FA~ CYClfi'IG PRESSURE COOITIIOL
GilD GIIOUNOINGlltG

~ W.i~ III I I loi:Ov.JIII-COHDNSRFAN

I'CII J CIRCUIT i!IIIAK(III C00.1"111ESSOII

'::t I'C871 CIJICUITIIII[AK11-FAII MOTOOI

Pfll ll POWEll FUS T IIANSf OII MUI
"'-MIl PHASE lOSS IIIONI!Ofl
l[llll l(II III IN .. LIIOARO MAIN POWf~

HIU. HRVI".I.l iiOAIIOCONO[NSlll U~

DETAil FOR ONE TER'-IINAl BLOCK TAOOHS Hll~ TUI011NALI04110 CUSTOiol11 ""IIHG

sni'<OTt-
, ,----
NOT ES
I I I 6FCP9 1 10 All(~fii0U111(00NIIOSC

I 2 fOil Cl-14 S~l CONTROl CIRCUIT tiii "'G OIAG~A III

~" -
-
-
-
- flllO WilliNG
F tTOIIT WIIIING

ACWC 215 SC US COPP[R

CONDUCTORS ON LY

REFER TO UNIT SPEC PLATE FOR VOLTAGE

for~ Fo~;l
'A A I
LY.J L_l,,_j

'
19
.. ' , t PLiol l/
\' lvc
I 1
19
.. '
g I PLM2/
? lvcwz --..;

m.
~-TOPTIONAL 1 - r O PTION.I.L

I TOCONTI!OI.CIIICUIT

'

II I II e.-l!t.
l t:l t:l t::i l

Cl$14 CONT.I.tTOIIICONDNSEIIFAN
CMI'I-4 tO WI'RESSOIIIIIPQTQII
CIUI-2 00011 LATCHING $0\,_(N()IQ
ftl'lll fA N tTCLINGI'RUSUIIECONTIIOL
GilD GIIOUHDI NG LUG
IIII -I flfOTORCONDNSIII,AN
~114 CIIICUIT PEAK(II-COioii'IIUSOII

I'CI71 CIRCUIT I II!AKEII- n.JI WOTC)III

Pf'!IU I'O'IIIEIIFUSE-TIIAN!'OII IIIEII
"-1111-2 .... ASI:LDSS IIIOJIITOIII
T1111-2 TERIII IN.U.IOAIIID-IIIAHoii'O'IIIU
TEII! - 4 Tl:lllolllt.I.LIOAIIOCONDENS11F"""
,
fEllS TEIIMINAliOAIID-CUSJOM[IIWIIIING

NOTES
1. .. 4, WII.'CI'7,1,1S,IIlMNOTIIEQUIIIIEDD N 215SC.
t.I'OR Cl-1 4 lEE CONTIIOl CIIICUIT WIII IIIO DIAGIIAIII
- - - ,.IL O WIII INI
- - ,ACTOIIITWI II INI

16
 TYPICAL POWER WIRING
STAR-DELTA START

ACWC 160-200 SC
N;t~t;"'
r:-. : ..... N~:E"
I
1 1
1 1"1.1111/ ,n I
I _ I ~LIII/
(YUI:I:
~~fiOtlll
A I t ( YLIII o;
OI'T IOIIAL) OI'TIOIIAl}

11t
1 111111111 '

NOTES
1. 11 1 I ' t , I ,IO Ut lOOT U IIIII III:D 011 1 1 01 ~ .

l,OII CIC IOIII tOU IOOI.C tuiT I IM!Ho\&UII

\....../

UKCOfi'NII
ACWC215 SC COtiOUCTOM OtiLT

lltEF11 TO U"IT PlC 'LJ.Tt 'ClR VOLTAGE TO CI:*TIIQ. CMeurT

r+-h
I A I C !1'\.11111/
...i
: mull I
rr.I n
~
if t
l
n i ...
1
wu 1 rt-h
I A I C !PLII2:/

""' ""'

&
r.;~-j J''
S3 u S4

:fW ; ;~: I :trtl ~~~ f

I

II V Y
e J ~U4
1 111111 1

~ NOTES
l iiA,.II'a' T,I , IS ,II4111MI'tiiiOUIIICIOIINK
1.- CI CMKl~ el !tCUITWIR I . . _IIAII

17
 ELECTRICAL DATA 60HZ.
TOTAL UNIT CHARACTERISTICS COMPRESSORS CONDENSER FANS
VOLTAC:E Min. Clroult Max. Fuoo &uggoatod Rated Locked Full Locked
Amps' Size 3 Wire Size Load Rotor Load Rotor
Model Name Circuit Circuit Circuit Circuit Circuit Circuit Qty. Type Amps Amps Amps Amps
ACWC Plate Range 1' 2' 1' 2' 1' 2' H.P. Start Each Each Phase Each Each
208-230 187-253 322 460 450 600 400 700 205 1228 13.2 92.0
(3)60 ATL" 3
160SC 460 414-506 326 - 400 - 400 - 90 491 6.6 46.0

208-230 187-253 335 468 450 600 400 750 IJ.!.@_ 205 1228
13.2 92 .0
(2)75 208 1415
185SC ATL"
460 414-506 350 - 400 - 500 - IJ.!.@_ 90 491
3 6.6 46.0
(2)75 98 562
208-230 187-253 339 468 500 600 500 750 208 1415 13.2 92.0
200SC (3)75 ATL " 3
460 414-506 358 - 450 - 500 - 98 562 6.6 46.0
208-230 187-253 501 501 700 700 900 v 900/ 205 1228 13.2 92.0
215SC 460 414-506 222 222 300 300 0000 0000 (4)60 ATL" 90 491 3 6.6 46.0
460 5 414-506 420 - 500 - 600 - 90 491 6.6 46.0
"ATL- Across The Line
'208-230 voltage requires two field wiring supplies (circuits).
' Minimum circuit ampacity is per N.E.C. Section 430-24.
3
Use time delay (dual element) fuses only. Suggested fuse sizes based on N.E.C. Section 440-22.
Wire size based on copper conductors with 75 C. insulation per N.E.C . Table #31 0.16.
5 Single point power terminals '
NOTE:
Maximum inrush amps is L.R .A. of lag compressor+ R.L.A. of all other compressors+ F.L.A. of all fans.
Lag Compressor: 75 H.P. on 185SC.

COOLER WATER PRESSURE DROP

(Feet of Water)

Model GALLONS PER MINUTE

ACWC 320 340 360 380 400 420 440 460 480 500 520 540 560 580
160SC 12.0 13.7 15.4 17.1 18.8 20.6 - - - - - - - -

185SC - - 10.6 11.9 13.1 14.3 15.7 17.1 18.6 20.2 - - - -

200SC - - - - 13.1 14.3 15.7 17.1 18.6 20.2 - - - -
215SC ---
- - - - 11.1 12.2 13.3 14.4 15.5 16..Z_ _1_7 . ~ 19.4 20.8

01 Q3 Qs 7L51

()2 1}4 Qs slJl

6~~~- 138Y,
~ 8
+ 107Y,
~
LOADING (LBS.)
Model LOCATION POINT NUMBER Dim.
ACWC 1 2 3 4 5 6 7 8 8
160SC 2120 2120 2120 2120 1830 1830 1510 1510 74
185SC 2280 2280 2280 2280 1960 1960 1630 1630 129
200SC 2340 2340 2340 2340 2010 2010 1670 1670 129
215SC 2330 2330 2330 2330 2150 2150 2150 2150 129

18
 START-UP CHECK LIST

YES NO
Equipment Inspection: a. Unit damaged on arrival
~
b. Material received agrees with sh ipping papers
I
Setting Unit: a. Vibration isolator used
"" b. Spring isolator adjusted for equal height
c . If rubber-in-shear isolators are used, is unit leveled by shimming

Wiring: a. Power wiring complete i

b. Control wiring complete

c. Electric service adequate for load
d . Power source voltage correct for motor(s) used
e. Motor circuit has proper size fusetrons
f. System wired per diagram
g. All lead connections tight I'

h. Wiring complies with local codes

Piping: a. Piping complies with applicable codes .

b. External piping independently supported
c. Chilled water lines insulated

Alignment: a. All belts adjusted and checked for tension

b . All pulleys checked and adjusted for proper pitch , tightness and
alignment

Before Start-Up: a. Open compressor discharge service valve

b. Open liquid valve(s)
c . Open suction , and discharge valves to pressure gauges (if supplied)
d . Check rotation of all fan motors
e. All motors and bearings lubricated
g. Start auxiliary equipment (pumps, fans , etc.)
h. Is crankcase heater operating?

After Start-Up: a. Check high pressure control

b. Check oil temperature safety switch

-
c. Check and adjust low pressure or temperature freeze control
d. Check and adjust operating thermostat
e. Check and adjust low pressure operating control
f. Check and adjust expansion valve superheat
g. Check and adjust capacity control thermostat

OPERATING DATA
CHILLER
Voltage: L-1 L-2 L-3 _ _ __

Pressure Gauge Readings:

a. Suction psig b. Discharge psig
High pressure switch setting: (Cut-In) psig - - - - psig (Out)
Checked Setting Yes No
Low Pressure Switch Setting: (Cut-In) psig - - - - psig (Out)
Checked Setting Yes No
Low Pressure Freeze Control Cut In Cut Out
Oil Temperature Safety Switch Cut Out
If Star-Delta start, time delay is seconds.
Temperature of air entering condenser oF.
Temperature of air leaving condenser oF.
Temperature of chilled water entering chiller oF.
Temperature of water (chilled) leaving chiller oF.
Chilled water pressure entering chiller psig
Chilled water pressure leaving chiller psig

..,._._..