Johnson Controls RW Series User manual

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1

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5

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s Engineering Guide

R

W

S

erie

s

iGid

RW Series

Commercial Reversible Chiller - 60 Hz

• 10-50 Tons

9LQWDJH'

Design Features

Factory Options

Accessories

Dimensional Data

Physical Data

Performance Data

En

g

ineerin

g

G

uide

S

peci

ﬁ

cations

Form: 146.00-EG6A (0614)

Supersedes: 146.00-EG6A (0314)

R

W

S

ERIE

S

REVER

S

IBLE

C

HILLER

S

PE

C

IFI

C

ATI

O

N

C

ATAL

OG

T

able of Contents

N

o

m

e

n

c

l

a

t

u

r

e

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4

AHRI D

a

t

a

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5

-

6

The RW

S

eries

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7-

8

Inside the RW

S

eries

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9

-1

1

C

ontrols

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12-1

5

R

W

S

eries Application Notes

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1

6

-1

7

Water

Q

ualit

y

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1

7

S

election Process

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1

8

T

y

pical Pipin

g

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1

8

-1

9

Ph

y

sical Dimensions

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2

0

-2

1

V

i

b

r

a

ti

o

n I

so

l

a

t

o

r

s

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2

2

Ph

y

sical Data

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2

3

El

ec

tri

ca

l D

a

t

a

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24

Anti

f

reeze

C

orrection

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2

5

R

e

f

erence

C

alculations

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2

6

Le

g

end and Notes

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2

6

Pressure Dro

p

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2

7

P

e

r

fo

rm

a

n

ce

D

a

t

a

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2

8

-

37

Wirin

g

S

chematics

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38

-

39

En

g

ineerin

g

G

uide

S

peci

f

ications

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4

0

-4

3

R

evision

G

uid

e

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4

5

4

R

W

S

ERIE

S

REVER

S

IBLE

C

HILLER

S

PE

C

IFI

C

ATI

O

N

C

ATAL

OG

M

odel Nomenclatur

e

All RW

S

eries product is

S

a

f

et

y

listed under UL1995 thru ETL and per

f

ormance tested in accordanc

e

with standard AHRI

/

I

SO

1

3

2

56

-2.

V

olta

g

e Availabilit

y

V

olta

ge

Mode

l

12

0

1

80

24

0

360

600

2

08

-2

30/60/3

•

•

•

•

N

/

A

4

60/60/3

••

••

••

•

•

5

7

5/60/3

•

•

•

•

•

380/60/3

••

N

/

A N

/

A

•

•

03/05/

14

Le

g

end

:

NA = N

o

t Av

a

il

ab

l

e

•

= Volta

g

e available in this siz

e

••

= Volta

g

e and so

f

t start available in this siz

e

RWXW 120 R 3 A E 8 N N

1-4 5-7 8 9 12 13 14

Model

RWXW –RW Series

Reversible Chiller

Unit Capacity (MBTUH)

120, 180, 240, 360, 600

Operation

R - Reversible

Voltage

3–208-230/60/3

4–460/60/3

5–575/60/3

8–380/60/3

Phase Protection

A–Non-Fused Disconnect, Phase Guard

B–Non-Fused Disconnect, IntelliStart®

C–Fused Disconnect, Phase Guard

D–Fused Disconnect, IntelliStart

Chassis

E–Enclosed

P–Enclosed with Pressure Gauges

Vintage

Non-Standard Options

SS - Standard

Future Option

N–Future Use

Future Option

N–Future Use

Controls

8–FX10 without Communication,

with User Interface

9–FX10 with Open N2 Communication

Card with User Interface

0–FX10 with Lonworks Communication

Card with User Interface

3–FX10 with BacNet Communication

Card with User Interface

Rev.: 14 February 2014D

SS

15-16

'

17

10 11

Notes:

See electrical availability table for detailed offering by voltage

5

R

W

S

ERIE

S

REVER

S

IBLE

C

HILLER

S

PE

C

IFI

C

ATI

O

N

C

ATAL

OG

AHRI/ASHRAE/ISO 13256-2 Water-to-Water Ratings

g

E

n

g

lish

(

IP

)

Units

M

ode

l

Capacit

y

M

odulation

Flow Rat

e

Water Loo

p

Heat Pum

p

G

round Water Heat Pum

p

G

round Loo

p

Heat Pum

p

Coolin

g

E

ST 86°F

E

LT 53.

6

o

F

Heatin

g

E

ST 68°F

E

LT 10

4

o

F

Coolin

g

E

ST 59°F

E

LT 53.

6

o

F

Heatin

g

E

ST 50°F

E

LT 10

4

o

F

Coolin

g

Full EST 77°F

P

art EST 6

8

o

F

E

LT 53.

6

o

F

Heatin

g

Full EST 32°F

P

art ELT 4

1

o

F

E

LT 10

4

o

F

S

g

pm

Lg

p

m

Capacit

y

Btuh

E

ER

Btuh

/W

Capacit

y

Btuh CO

P

Capacit

y

Btuh

E

ER

Btuh

/W

Capacit

y

Btuh CO

P

Capacit

y

Btuh

E

ER

Btuh

/W

Capacit

y

Btuh CO

P

120 Full 4

0

4

0

145,400 1

6

.

0

189,000 4.

5

161,400 22.

5

157,200

3

.

8

147,700 17.

3

118,800

3

.

0

P

ar

t

4

0

4

0

79,300 17.4 101,500

5

.

1

84,400 24.

1

84,600 4.4 82,900 22.

2

69,800

3

.

3

180 Full

60

60

201,300 1

5

.

9

263,700 4.

6

225,100 21.

5

217,000

3

.

9

208,300 17.

2

173,400

3

.

2

P

ar

t

60

60

105,500 17.

0

138,700

5

.

0

177,700 2

3

.

0

112,600 4.

2

115,400 2

0

.

5

100,900

3

.

5

2

40 Full

80

80

265,700 1

6

.

0

347,500 4.

7

306,900 2

3

.4 280,600

3

.

9

275,300 17.

9

219,400

3

.

3

P

ar

t

80

80

140,100 1

6

.

7

182,100

5

.

0

163,600 24.

6

141,400 4.

2

150,000 21.

6

115,800

3

.

5

3

60 Full 12

0

12

0

394,700 1

6

.

0

487,600 4.

3

452,300 22.

1

420,300 4.

0

410,200 17.

5

339,300

3

.

3

P

ar

t

12

0

12

0

206,000 1

6

.

9

256,000 4.

6

241,100 2

3

.

2

214,400 4.

3

223,200 21.

2

183,500

3

.

7

600 Full 2

00

2

00

602,000 1

5

.

2

798,000 4.

3

756,000 1

9

.

9

622,000 4.

0

633,000 1

6

.

5

533,100

3

.4

P

ar

t

2

00

2

00

313,300 1

6

.

1

419,000 4.

6

407,000 2

0

.

9

318,000 4.

3

376,000 1

9

.

6

303,900

3

.

7

3/5/

14

6

R

W

S

ERIE

S

REVER

S

IBLE

C

HILLER

S

PE

C

IFI

C

ATI

O

N

C

ATAL

OG

The per

f

ormance standard AHRI

/

A

S

HRAE

/

I

SO

13256-2 became e

ff

ective Januar

y

1, 2000. This new standard has three ma

j

or cate

g

ories:

Water Loop,

G

round Water, and

G

round Loop.

U

nit o

f

Measure: The

C

ooling

CO

P

The coolin

g

e

ff

icienc

y

is measured in EER

(

U

S

version measured in Btuh per Watt. The Metric version is measured in a coolin

g

CO

P

(

Watt per Watt

)

similar to the traditional

CO

P measurement.

P

ump Power

C

orrection

C

alculation

Within each model, onl

y

one water

f

low rate is speci

f

ied

f

or all three

g

roups and pumpin

g

Watts are calculated usin

g

the

f

ollowin

g

f

ormula. This additional power is added onto the existin

g

power consumption.

• Pump power correction =

(g

pm x 0.0631

)

x

(

Press Drop x 2990

)

/

30

0

Where

‘g

pm’ is water

f

low in

g

pm and

‘

Press Drop’ is the pressure drop throu

g

h the unit heat exchan

g

er at rated water

f

low in

f

eet o

f

head

.

ISO

C

apacit

y

and E

ff

icienc

y

C

alculation

s

The

f

ollowin

g

equations illustrate coolin

g

calculations

:

• I

SO

C

oolin

g

C

apacit

y

=

C

oolin

g

C

apacit

y

(

Btuh

)

x 3.41

2

• I

SO

EER E

ff

icienc

y

(

W

/

W

)

= I

SO

C

oolin

g

C

apacit

y

(

Btuh

)

x 3.412

/

[Power Input

(

Watts

)

+ Pump Power

C

orrection

(

Watt

)

]

The

f

ollowin

g

equations illustrate heatin

g

calculations

:

• I

SO

Heatin

g

C

apacit

y

= Heatin

g

C

apacit

y

(

Btuh

)

x 3.41

2

• I

SO

CO

P E

ff

icienc

y

(

W

/

W

)

= I

SO

Heatin

g

C

apacit

y

(

Btuh

)

x 3.412

/

[Power Input

(

Watts

)

+ Pump Power

C

orrection

(

Watt

)

]

T

est Conditions

Performance Standard (AHRI/ISO/ASHRAE 13256-2)

()

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Conversions

Water Flow

(

lps

)

=

G

PM x 0.0631

Press Drop

(

Pascals

)

= Press Drop

(f

t hd

)

x 299

0

R

W

S

ERIE

S

REVER

S

IBLE

C

HILLER

S

PE

C

IFI

C

ATI

O

N

C

ATAL

OG

7

T

he R

W

Series

RWXW Features

D

ual scroll com

p

ressors

p

fo

r

eff

icienc

y

and reliabilit

y

H

H

ea

vy

gau

ge

i

nsulated sheet metal

c

abine

t

t

o

r

educe

no

i

se

Heav

y

g

au

g

e

ste

el

wel

ded

fra

me

to

re

duc

e

vi

b

r

a

ti

on

Small modular

desi

g

n

fo

r

app

lication

f

lexibili

ty

Hig

h efficie

ncy

b

razed

pl

ate heat

e

xchan

g

ers

fo

r

eff

icienc

y

and

c

ompact siz

e

Sta

inl

ess

st

eel

bi

-

dir

ect

ion

al

TXV

fo

r

p

recise superheat

con

tro

l

Full

y

insulated heat

e

xchan

ger

, r

efr

ige

rant

p

ipin

g

, and water lines

to

pre

vent condensation

at reduced

f

luid operatin

g

tem

per

atures

So

p

histicated

m

icro

p

rocessor

c

ontrol with r

obus

t

s

a

f

et

y

controls and

ad

v

a

n

ced

f

r

ee

z

e

de

t

ec

ti

o

n

Fork truck

p

ockets

fo

r

maneuverabilit

y

Factor

y

installed

f

used or non-fused

disconnec

t

t

o

i

so

l

a

t

e

e

lectrical suppl

y

Int

ern

al cla

ss

J

/

CC fusin

g

fo

r

p

rotection o

f

electrical

c

omponents

V

ibration absorbers

a

nd isolation loo

p

s

to miti

g

ate re

f

ri

g

erant

lea

k

s

due

t

o

vi

b

r

a

ti

on

Optional factor

y

i

nstalled

pr

essure

ga

u

ges

8

R

W

S

ERIE

S

REVER

S

IBLE

C

HILLER

S

PE

C

IFI

C

ATI

O

N

C

ATAL

OG

T

he RW Series cont

.

J

ohnson

C

ontrols is proud to announce the up

g

rade o

f

the RW

R

eversible

C

hiller

S

eries with premium e

fﬁ

cienc

y

, additional

s

a

f

et

y

f

eatures, improved serviceabilit

y

, in a compact

f

ootprint.

This product comes with new electrical

f

eatures such as a

l

ow volta

g

e emer

g

enc

y

stop button,

f

actor

y

mounted, internal

disconnect, and Intelli

S

tart. With internal,

ﬁ

n

g

er-touch

f

usin

g

the RW

S

eries Reversible

C

hiller

S

eries is protected a

g

ainst

l

ar

g

e current

f

aults that ma

y

occur. The control panel was

desi

g

ned with the technician in mind b

y

dividin

g

hi

g

h and low

volta

g

e, a removable, hin

g

ed lockable service door, and plent

y

o

f

space

f

or installation and dia

g

nostics. Additional

f

eatures and

improvements are listed below

:

RW Series Reversible Chiller Hi

g

hli

g

hts

•

C

apacities ran

g

in

g

f

rom 120-600 MBtu

/

h outpu

t

•

C

omplete commercial volta

g

e selection o

f

208-230V

/

60Hz

/

3ph, 460

/

60

/

3, 575

/

60

/

3

•

O

versized brazed plate heat exchan

g

ers o

ff

er hi

g

h e

fﬁ

cienc

y

with industr

y

low waterside pressure dro

p

• True-dual brazed plate heat exchan

g

ers provide better part

l

oad e

fﬁ

ciencies compared to two sin

g

le-circuit evaporators

•

C

ompressor suction

/

dischar

g

e tubes come with braided

s

tainless steel vibration absorbers to dampen compressor

vibration on s

y

stem pipin

g

•

H

eav

y

g

au

g

e,

g

alvanized steel enclosure with hin

g

ed access

p

anels that can easil

y

be removed

f

or ease o

f

servic

e

• Fork pockets and li

f

tin

g

points in the

f

rame enable

maneuverabilit

y

f

or installation and shipmen

t

• Factor

y

installed pressure

/

temperature port externall

y

accessible

f

or improved serviceabilit

y

• Low-volta

g

e emer

g

enc

y

stop button disabl

e

c

ompressor operation

• Fin

g

er-touch sa

f

e power

f

uses provide circuit protection

• Primar

y

f

usin

g

to control trans

f

ormer to protect low volta

g

e

c

omponents

f

rom spikes in current

f

aul

t

•

R

u

gg

ed plu

g

assembl

y

wirin

g

harness provides a solid

y

et

s

erviceable connection

f

or control wirin

g

to the control panel.

•

S

hort circuit current ratin

g

up to 100kA with

f

used disconnect

and phase

g

uard optio

n

• Temperature setpoint control

Wide arra

y

o

f

standard

f

actor

y

installed options includin

g:

• Factor

y

mounted, internall

y

wired, rotar

y

-st

y

le,

no

n-

fused

d

i

sco

nn

ect

• 2 1

/

2” dial-t

y

pe re

f

ri

g

erant pressure

g

au

g

es

f

actor

y

mounted below the control panel aid the technician in

sy

stem dia

g

nostics

• FX10

C

ontrols with N2, LonWorks, BA

C

net,

or non-communicatin

g

• Intelli

S

tart reduces compressor in-rush current b

y

40

%

meanwhile reducin

g

mechanical shock on re

f

ri

g

erant

tubin

g

due to hi

g

h motor start-up torque

• Phase

g

uard monitor provides phase reversal, phase

imbalance, and loss o

f

phase protectio

n

9

R

W

S

ERIE

S

REVER

S

IBLE

C

HILLER

S

PE

C

IFI

C

ATI

O

N

C

ATAL

OG

Cabine

t

All unit

f

rames are constructed o

f

heav

y

g

au

g

e steel channel and

p

ainted with a corrosion resistant black, pol

y

ester, powder coat

p

aint. The optional sheet metal cabinets are constructed o

f

heav

y

g

au

g

e

g

alvanized sheet steel painted with white, pol

y

ester, powder

c

oat paint rated at more than a 1,000 hours salt spra

y

ratin

g

. The

f

rame includes

f

ork truck access pockets in two dimensions and

l

i

f

tin

g

points

f

or eas

y

maneuverin

g

durin

g

installation and servicin

g

.

Com

p

ressors

R

eversible chillers use hi

g

h e

ff

icienc

y

R-410A, hermeticall

y

s

ealed, scroll compressors that are mounted on rubber

g

rommets

f

or vibration isolation.

S

croll compressors provide hi

g

h e

ff

icienc

y

while providin

g

g

reater tolerance to liquid re

f

ri

g

erant enterin

g

the

s

uction port.

V

ibration Absorbers

Vibration absorbers are

f

actor

y

installed

on ever

y

compressor suction and

dischar

g

e tube to dampen the vibrations

introduced b

y

compressor on the

r

e

f

ri

g

erant pipin

g

. These absorbers are

c

onstructed

f

rom corru

g

ated copper

tubin

g

wrapped with stainless steel wire

braid to provide stren

g

th and

f

lexibilit

y

.

E

lectrical Bo

x

U

nit controls

f

eature quick connect

wirin

g

harnesses

f

or eas

y

servicin

g

.

S

eparate knockouts

f

or low volta

g

e,

and two

f

or power on two sides

allow eas

y

access to the control

box. A lar

g

e 75VA trans

f

ormer

assures adequate control's power

f

or accessories. Flexible

J

ohnson

C

ontrols FX10 microprocessor

c

ontrol is included,

f

eaturin

g

several

innovations.

S

ee

C

ontrols section

fo

r m

o

r

e

in

fo

rm

a

ti

o

n.

Water Connections

All water line connections are Victaulic

g

rooved nipples

f

or ease

o

f

installation with optional connection kits. Factor

y

installed

thermistors are used on all water lines and can be viewed throu

g

h

the microprocessor inter

f

ace tool. Pressure ports are also added at

the

f

actor

y

f

or eas

y

service access.

Inside the RW Series

T

hermostatic Ex

p

ansion Valv

e

All r

e

v

e

r

s

i

b

l

e

c

hill

e

r

s

u

tiliz

e

ba

l

a

n

ced

p

ort, bi-directional, thermostatic

e

xpansion valves

(

TXV

)

f

or re

f

ri

g

erant

meterin

g

. These valves have

s

tainless steel capillar

y

tube and

bulb

f

or improved robustness over

c

onventional copper sensin

g

capillar

y

l

in

es

. Th

e

v

a

lv

e

co

n

s

i

s

t

s

of

a

l

ase

r-

welded power-head,

f

or

g

ed brass

valve bod

y

and diaphra

g

m optimized

f

or R-410A applications.

This valve desi

g

n allows precise re

f

ri

g

erant

f

low in a wide ran

g

e o

f

e

nterin

g

water variation

g

eothermal s

y

stems.

Water-to-Refri

g

erant Heat Exchan

g

er

Lar

g

e oversized stainless steel

interlaced copper-brazed plate

water-to-re

f

ri

g

erant heat exchan

g

ers

p

rovide unparalleled e

ff

icienc

y

. The

h

eat exchan

g

ers have common

water circuits with isolated re

f

ri

g

erant

c

ircuits so that in part load operation,

the

f

ull mass o

f

the heat exchan

g

er

is utilized. All heat exchan

g

ers are

p

ressure rated to 450 psi water

s

ide and 650 psi re

f

ri

g

erant side. All

h

eat exchan

g

ers, water lines, and

s

uction lines are insulated to prevent

c

ondensation durin

g

low temperature

inlet water operation.

Strainers

All r

e

v

e

r

s

i

b

l

e

c

hill

e

r

s

s

h

a

ll h

a

v

e

a

f

i

e

l

d

-in

s

t

a

ll

ed

s

trainer either Y-t

y

pe or basket t

y

pe.

S

trainers

s

hould be made o

f

a suitable bod

y

such as brass

with

3

1

6

stainless steel screens with a minimum

o

f

60

mesh.

WARNING: Warrant

y

is void if

strainers are not used on the

e

nterin

g

side of the load and source

.

Service Connections and Serviceabilit

y

Two

S

chrader service ports are provided

f

or

e

ach circuit on ever

y

unit. The suction side

and dischar

g

e side ports are

f

or

f

ield char

g

in

g

and servicin

g

access. All valves are 7

/

16”

S

AE connections.

1

0

R

W

S

ERIE

S

REVER

S

IBLE

C

HILLER

S

PE

C

IFI

C

ATI

O

N

C

ATAL

OG

Flow Switch

A

f

low switch or equivalent must be installed on the evaporator

f

or

e

ach unit to be installed. I

f

the unit is to operate as both modes

(

heatin

g/

coolin

g)

, a

f

low switch is needed on both heat exchan

g

ers.

D

ifferential Pressure Switch

A di

ff

erential pressure switch can be used in place o

f

a

f

low switch.

The di

ff

erential switch must be capable o

f

pressure ran

g

e as

indicated in the pressure drop tables.

4

-Wa

y

Reversin

g

Valv

e

R

W units

f

eature a reliable all-brass pilot

operated re

f

ri

g

erant reversin

g

valve.

The reversin

g

valve operation is limited

to chan

g

e o

f

mode b

y

the control to

e

nhance reliabilit

y

.

V

ibration Isolation

U

nits are shipped with heav

y

dut

y

, durometer selected rubber

g

rommets to reduce sound that can be transmitted throu

g

h the

f

loor

via the

f

rame

(

see

g

rommets below

)

. For additional sound attenuation,

optional heav

y

dut

y

sprin

g

isolation can reduce sound levels b

y

3 dBA

(

see sprin

g

s below

)

can be purchased as an accessor

y

.

Cabine

t

All r

e

v

e

r

s

i

b

l

e

c

hill

e

r

f

r

a

m

es

a

r

e

co

n

s

tr

uc

t

ed

o

f

heav

y

g

au

g

e steel channel and painted

with corrosion resistant black, pol

y

ester,

p

ower coat paint. The

f

rame includes

f

ork

truck pockets and li

f

tin

g

points to assist

in maneuverabilit

y

o

f

the product durin

g

in

s

t

a

ll

a

ti

o

n. Th

e

r

e

v

e

r

s

i

b

l

e

c

hill

e

r

s

co

m

e

with

an enclosure that provides additional sound

attenuation, protection o

f

the electrical

and re

f

ri

g

eration s

y

stems, and makes the

p

roduct more aestheticall

y

pleasin

g

. The

e

nclosure is constructed o

f

heav

y

g

au

g

e

Inside the RW Series cont

.

G

rommets Standard

Heav

y

Dut

y

Mountin

g

Sprin

g

s Optional

I

S

-325-01

(

R120-360

)

I

S

-750-01

(

RW600

)

g

alvanized steel painted with

g

ra

y

textured, pol

y

ester, powder

c

oat paint rated at more than 1,000 hours salt spra

y

ratin

g

. The

e

nclosure includes heav

y

dut

y

hin

g

ed doors that can be easil

y

r

emoved

f

or improved serviceabilit

y

.

Control Panel

Re

v

e

r

s

i

b

l

e

c

hill

e

r

co

ntr

o

l

p

anel

f

eatures a heav

y

-

dut

y

, hin

g

ed service door

with

a

co

nv

e

ni

e

nt

use

r

inter

f

ace displa

y

f

or ease

of

se

rvi

ce

a

n

d

in

s

t

a

ll

a

ti

o

n.

The ke

y

ed service door

f

eatures a low volta

g

e

e

mer

g

enc

y

stop button

with an optional

f

actor

y

m

ou

nt

ed

d

i

sco

nn

ec

t

s

wit

c

h. Th

e

l

ef

t int

e

ri

o

r

of

the control panel

f

eatures

h

i

g

h volta

g

e components

suc

h

as

th

e

e

l

ec

tri

ca

l

disconnect,

f

uses, and

c

ompressor contactors.

The ri

g

ht interior o

f

the panel

f

eatures the FX10 main control

board, expansion board, control trans

f

ormer, and 24 VA

C

terminal

s

trip

f

or control wirin

g

. The control panel was desi

g

ned with the

technician in mind to provide convenient, clear wirin

g

with plent

y

o

f

workin

g

space.

E

lectrical Disconnec

t

A

f

actor

y

mounted, internall

y

wired, disconnect is available

to provide electrical isolation

f

rom hi

g

h volta

g

e suppl

y

at

the heat pump.

S

eparate

c

ircuit protection must be

f

ield

installed in the power wirin

g

and must compl

y

with National

Electric

C

ode

(

NE

C)

and

/

o

r l

oca

l

codes

. Di

sco

nn

ec

t

fea

t

u

r

es

in

c

l

ude

:

• Non-

f

used, rotar

y

d

i

sco

nn

ec

t wit

h

“

on

/

o

ff

” positio

n

• Door interlocked, external

p

istol handle keeps door

c

l

osed

wh

e

n

d

i

sco

nn

ect

i

s

“o

n

”

•

“

Lockout

/

Ta

g

out”

f

eature to

keep the unit

“

o

ff”

durin

g

servic

e

•

C

omplies with NE

C

Article 440-14