Goodman WDC063 Installation Manual
Installation, Operating and Maintenance Manual IOMM WSCWDC
Group: Chiller
Part Number: 736015417
Effective: October 1999
Supersedes: IOMM PEHPFH
The McQuay DISTINCTION SERIES
Single/Dual Compressor Centrifugal Chillers
WSC/WDC 050, 063, 079, 087, 100, 126
© 1997 McQuay International
Table of Contents
Introduction.................................................................................................................3
General Description...........................................................................................................................................3
Application.........................................................................................................................................................3
Installation...................................................................................................................4
Receiving and Handling....................................................................................................................................4
Location and Mounting....................................................................................................................................5
Water Piping.......................................................................................................................................................6
Oil Cooler Piping................................................................................................................................................8
Refrigerant Vent Piping.....................................................................................................................................9
Electrical............................................................................................................................................................11
Power Wiring....................................................................................................................................................11
Control Wiring..................................................................................................................................................12
Prestart System Checklist...............................................................................................................................14
Operation...................................................................................................................15
Operator Responsibilities ...............................................................................................................................15
Nomenclature....................................................................................................................................................15
MicroTech Control Panel................................................................................................................................16
Capacity Control System................................................................................................................................16
Lubrication System..........................................................................................................................................19
Hot Gas Bypass................................................................................................................................................21
Maintenance..............................................................................................................22
Pressure/Temperature Chart...........................................................................................................................22
Routine Maintenance......................................................................................................................................22
Annual Shutdown............................................................................................................................................25
Annual Startup.................................................................................................................................................26
Repair of System..............................................................................................................................................26
Maintenance Schedule..............................................................................................29
Service Programs ......................................................................................................32
McQuay" is a registered trademark of McQuay International
"Illustrations cover the general appearance of McQuay International products at the time of publication and we reserve the right to make
changes in design and construction at anytime without notice"
1997 McQuay International
2 Centrifugal Chillers IOMM WSCWDC
Introduction
General Description
The McQuay Centrifugal Water Chillers are complete, self-contained, automatically controlled fluid
chilling units. Each unit is completely assembled and factory tested before shipment.
In the WSC series, each unit contains one compressor connected to a condenser and evaporator. The
WDC series are equipped with two compressors operating in parallel on a single evaporator and
condenser.
The chillers use refrigerant R-134a to reduce the size and weight of the package compared to negative
pressure refrigerants and since R-134a operates at a positive pressure over the entire operation range,
no purge system is required.
The controls are pre-wired, adjusted and tested. Only normal field connections such as piping,
electrical and pump interlocks, etc. are required thereby simplifying installation and increasing
reliability. All necessary safety and operating controls are factory installed in the control panel.
The basic sizes of units are the WSC/WDC 050, 063, 076, 079, 087, 100 and 126. They provide a
capacity range from 80 tons to 2500 tons. In this manual all references to the WSC models will equally
apply to other models unless specifically referenced otherwise.
Application
The operation and maintenance procedures presented in this manual apply to the standard
WSC/WDC family of chillers. Reference to the Installation Manual, OM 125 for these units should be
made for details pertaining to operation of the MicroTech control.
All McQuay centrifugal chillers are factory tested prior to shipment and must be initially started at the
job site by a factory trained McQuay service technician. Failure to follow this startup procedure may
affect the equipment warranty.
The standard warranty on this equipment covers parts which prove defective in material or
workmanship. Specific details of this warranty can be found in the warranty statement furnished with
the equipment.
Cooling towers used with McQuay centrifugal chillers are normally selected for maximum condenser
inlet water temperatures between 75°F and 90°F (24°C and 32°C). Lower entering water temperatures
are desirable from the standpoint of energy reduction but a minimum does exist. For recommendations
for optimum entering water temperature and cooling tower fan control, consult McQuay Product
Manual PM WSC/WDC, Applications Section.
IOMM WSCWDC Centrifugal Chillers 3
Installation
Condenser
Receiving and Handling
The unit should be inspected immediately after receipt for possible damage.
All McQuay centrifugal water chillers are shipped FOB factory and all claims for handling and
shipping damage are the responsibility of the consignee.
Insulation corners from the evaporator's rigging hole locations is shipped loose and should be glued
in place after the unit is finally placed. Neoprene vibration pads are also shipped loose. Check to be
sure that these items are delivered with the unit.
Leave the shipping skid in place until the unit is in its final position. This will aid in handling the
equipment.
Extreme care should be used when rigging the equipment to prevent damage to the control center, or
refrigerant piping. See certified dimension sheets for the center of gravity of the unit.
The unit can be lifted by fastening the rigging hooks to the four corners of the unit where the rigging
eyes are located (see Figure 1). Spreader bars should be used between the rigging lines to prevent
damage to the control center and motor terminal boxes on WDC dual compressor units.
Figure 1, Unit Components
Control Panel
Expansion Valve
Liquid Line
Shutoff Valve
Evaporator
Relief Valve
Evaporator
Condenser Dual
Relief Valves
4 Centrifugal Chillers IOMM WSCWDC
Figure 2, Major Component Location
Cooling Inlet
Eyes
Inlet (Note)
Pump, Heater
Oil Pressure Regulator
Shutoff Valve
(Duals Only)
Rigging
Eyes
Evaporator
Outlet
Evaporator
Condenser
Vent Line from Oil Sump
Suction
Outlet
Condenser
Inlet
Lubricant to Lub Control
Box for Unloader
Lubrication
Control Box
Lubricant Outlet
to Cooler
(2) Dual Relief
Values
Condenser
Oil Sump,
Discharge
Check Valve
Motor
Motor
Terminal Box
Rigging
Motor Cooling
Outlet Filter-Drier
Mounting Holes
(2) Each Corner
Note
The WDC126 Dual Compressor Chiller shown has the evaporator inlet in the bottom.
Consult unit certified drawings for connection locations on specific units.
Location and Mounting
The unit should be mounted on a level concrete or steel base and should be located so as to provide
service clearance at one end of the unit for possible removal of evaporator tubes and/or condenser
tubes. Clearances required are 18 feet (5.5 meters) for units with 16 foot (4.9 meters) long shells, 16
feet (4.9 meters) for units with 14-foot (4.3 meters) long shells, 14 feet (4.3 meters) for units with 12foot (3.7 meters) long shells, and 10 feet (3 meters) for units with 8-foot (2.4 meters) long shells.
Evaporator/condenser tubes are rolled into the tube sheets to permit replacement if necessary.
Clearance at all other points, including the top, is 3 feet (1 meter).
The shipped loose neoprene vibration pads should be located under the corners of the unit (unless
the job specifications state otherwise).
IOMM WSCWDC Centrifugal Chillers 5
Units are shipped with refrigerant and oil valves closed to isolate these fluids for
shipment. Valves must remain closed until start-up by McQuay technician.
Water Piping
Water Pumps
Make sure that the floor or structural support is adequate to support the full operating weight of the
complete unit.
Rubber Shearflex pads, or "Isomode," are supplied with the unit for use under each corner of the base
members. The unit must be level.
It will not be necessary to bolt the unit to the mounting slab or framework; but should this be
desirable, 1 1/8" (28.5 mm) mounting holes are provided in the unit support at the four corners and
under the compressor base on the side-mounted compressor units.
Note
Avoid the use of 3600/3000 rpm (two-pole motor) pump motors.
It is not uncommon to find these pumps operate with objectionable noise and vibration.
It is also possible to build up a frequency beat due to the slight difference in the operating rpm of the
pump motor and the McQuay centrifugal motor. McQuay encourages the use of 1750/1460 rpm or
four-pole pump motors whenever possible.
Evaporator and Condenser Water Piping
All WSC and WDC evaporators and condensers come equipped with groove-type nozzles for
Victaulic couplings (also suitable for welding) or optional flange connections. The installing
contractor must provide matching mechanical connections of the sizes given in the system dimension
and capacity tables.
Important Notes on Welding
1. If welding is to be performed on the mechanical or flange connections, the solid-state temperature
sensor and thermostat bulbs must be removed from the wells to prevent damage to those
components.
2. The unit must be properly grounded or severe damage to the MicroTech Controller may occur.
Small water pressure test valves or pipe plugs are provided at both the inlets and outlets of the vessel
heads. The test valves permit the water flow pressure drops to be checked. The pressure drops and
flow rates for the various evaporators and condensers are shown in McQuay Product Manual PM
WSC/WDC. Refer to the nameplate on the vessel shell for identification.
Evaporator inlet and outlet water connections have been reversed over time with design changes in
the vessel. Be sure that water inlet and outlet connections match certified drawings and stenciled
nozzle markings. The condenser is connected with the coolest water entering at the bottom to
maximize subcooling.
Note
When common piping is used in connection with a heating system, care should be
taken to insure that water flowing through the evaporator cannot exceed 110°F which
can cause the relief valve to discharge refrigerant or damage controls.
The piping should be supported to reduce the weight and strain on the fittings and connections.
Piping should also be adequately insulated. A cleanable 20-mesh water strainer should be installed
6 Centrifugal Chillers IOMM WSCWDC
at both inlets. Sufficient shutoff valves should be installed to permit draining the water from the
evaporator or condenser without draining the complete system.
Flow Switch
A water flow switch must be mounted in either the entering or leaving water line to insure that there
will be adequate water flow to the evaporator before the unit can start. This will safeguard against
slugging the compressors on start-up. It also serves to shut down the unit in the event that water
flow is interrupted to guard against evaporator freeze-up.
A flow switch is available from McQuay under Part Number 017503300. It is a "paddle" type switch
and adaptable to any pipe size from 1 inch to 8 inches.
Consult the manufacturer's data for the minimum flow rates required to close the switch. Installation
should be as shown in Figure 3.
Figure 3, Flow Switch Mounting
Flow direction marked
on switch
I in. (25mm) NPT flow
switch connection
Tee
Electrical connections in the unit control center should be made at terminals 62 and 63. The normally
open contacts of the flow switch should be wired between these two terminals. Flow switch contact
quality must be suitable for 24 VAC, low current (16ma). Flow switch wire must be in separate conduit
from any high voltage conductors (115 VAC and higher).
CAUTION
Freeze Notice: Neither the evaporator nor the condenser is self-draining;
both must be blown out.
The piping should also include thermometers at the inlet and outlet connections and air vents at the
high points.
The water heads can be interchanged (end for end) so that the water connections can be made at
either end of the unit. If this is done, new head gaskets must be used and control sensors relocated.
In cases where the water pump noise may be objectionable, rubber isolation sections are
recommended at both the inlet and outlet of the pump. In most cases, it will not be necessary to
provide vibration eliminator sections in the condenser inlet and outlet water lines; but where noise
and vibration are critical (for example, where a pipe chase goes through walls adjoining living quarters
in an apartment building), they may be required.
Where a cooling tower is used to supply condenser water, a flow balancing valve is required. Some
form of temperature control is required if tower water becomes too cold.
IOMM WSCWDC Centrifugal Chillers 7
Oil Cooler Piping
Figure 4, Oil Cooler Water Piping Across Chilled Water Pump
Figure 5, Oil Cooler with City Water or Other Supply
WSC-048/050 and WDC-048/050 units are equipped with internal self-contained refrigerant-cooled oil
coolers and require no field piping for the coolers.
WSC 063, 079, 087, 100 and 126 single compressor units have a factory mounted water-cooled oil
cooler, a solenoid valve, and a temperature controlled water regulating valve mounted inboard of the
compressor. Accessories must be installed as shown Figure 4 or 5.
WDC 063, 079, 087, and 126 dual compressor units are equipped as above but the solenoid valves and
temperature control valve are factory installed at each cooler as standard. The water piping for the
two oil coolers cooling is factory piped to a common connection at the tube sheet.
Field water piping to the inlet and outlet connections must be installed according to good piping
practices and should include stop valves to isolate the cooler for servicing. A 1" minimum cleanable
filter (40 mesh maximum), a solenoid stop valve wired in accordance with the field connection control
diagram (also available as a factory installed option,), and drain valve or plug should also be field
installed. The water supply for the oil cooler may be either from the chilled water circuit (preferred and
recommended) or from an independent source such as city water (see Figure 5).
8 Centrifugal Chillers IOMM WSCWDC
The use of condenser water for oil cooling is not recommended. When using chilled water it is
3-Way Valve
important that the water pressure drop through the oil cooler be less than the drop across the
evaporator or insufficient oil cooler flow will result. This is normally no problem except on single pass
evaporators in which case the oil cooler water should be piped across the chilled water pump to
provide the maximum possible head and flow.
The water flow through the oil cooler will be adjusted by the regulating valve so that the temperature
of oil supplied to the compressor bearings (leaving the oil cooler) is between 80°F (27°C) and 110°F
(43°C).
When supplied with city water, the oil piping should discharge through a trap into an open drain to
prevent draining the cooler by siphoning. The discharged city water may also be used for cooling
tower makeup by discharging it into the tower sump above the highest possible water level.
Refrigerant Vent Piping
As a safety precaution, each system is equipped with pressure relief valves located on the condenser,
evaporator, and oil sump vessel for the purpose of relieving excessive refrigerant pressure to the
atmosphere. Most codes require that relief valves be vented to the outside, and this is desirable
installation practice for all installations.
Note
Remove plastic shipping plugs (if installed) from the inside of the valves prior to
making pipe connections. Whenever vent piping is installed, the lines should be run
in accordance with local code requirements; where local codes do not apply,
ANSI/ASHRAE Standard 15-1994 code recommendations should be followed.
The condenser design incorporates two relief valves (one set) with a three-way shutoff valve
separating the two valves (see Figure 6). One valve remains/in the system at all times and the second
valve acts as a standby.
If one relief valve of the two-valve set fails, the shutoff valve may be used to isolate the faulty relief
valve, while the other valve provides pressure protection.
Figure 6, Condenser Relief Valve Set
Relief Valve # 1
Stem In: # 1 Open
Stem Out: # 2 Open
Always Front or Back Seat
Relief Valve # 2
When piping the vent line to a dual valve set, it may be sized for one relief valve and piped to both
valves. On large capacity condenser designs, two separate sets of dual relief valves are used. The
vent line must be sized to the total of two valves but piped to all four.
IOMM WSCWDC Centrifugal Chillers 9
Relief Valves
0
5
.
C4820 Thru C4824 1” FPT 4
Relief valve connection sizes and quantity
are shown to the right. Relief valves must
be piped to the outside of the building in
accordance with ANSI/ASHRAE 15. Twin
relief valves mounted on a transfer valve are
used on the condenser so that one relief
valve can be shut off and removed leaving
the other in operation. Where 4 valves are
Evaporator Code Connection Number
E1608 Thru E2616 1” FPT 1
E3016 Thru E4216 1” FPT 2
E4820 Thru E4824 1” FPT 2
Condenser Code
C1608 thru C3016 1” FPT 2
C3616 Thru C4216 1” FPT 4
shown, they consist of two valves mounted
on two transfer valves. Only two relief
valves of the four are active at any time.
Vent piping is sized for only one valve of the set since only one can be in operation at a time. In no
case would a combination of evaporator and condenser sizes require more refrigerant than the
pumpdown capacity of the condenser. Condenser pumpdown capacities are based upon
ANSI/ASHRAE Standard 15 recommendations of 90% full at 90°F (32°C).
Relief Valve
Relief Valve Pipe Sizing
Relief valve pipe sizing is based on the discharge capacity for the given evaporator or condenser and
the length of piping to be run. Discharge capacity for HFC-134a vessels is calculated as follows:
C xDxL= 0 133.
Where: C=Minimum discharge capacity, lbs of air/min
D=Vessel diameter, in.
L=Vessel length, ft.
Example: E3016 Evaporator, HFC-134a Refrigerant, 75 equivalent feet of piping
C x x Lbsof air= =0133 30 16 63 8. . / min
From the table below, 75 feet of piping for 63.8 lb. of air/min. at 180 psig valve setting requires a 2"
diameter pipe.
Discharge Capacity, lbs of Air/Min
EQUIVALENT DIAMETER STANDARD WALL IRON PIPE
LENGTH OF 1” (25mm) 1.25” (32mm) 1.5” (38mm) 2” (50mm) 2.5” (64mm) 3” (76mm)
DISCHARGE RELIEF VALVE PRESSURE SETTNG
PIPING, FT. (m) 180 225 180 225 180 225 180 225 180 225 180 225
50 (15.2) 21.4 26.8 42.8 53.6 62.7 78.4 117.0 146.3 182.2 227.7 315.4 393.7
75 (22.9) 17.5 21.9 35.0 43.8 51.5 64.4 95.4 119.3 150.5 188.1 257.4 321.8
100 (30.5) 15.2 19.1 30.2 27.8 44.3 55.4 82.6 103.3 129.6 162.0 222.5 278.1
150 (45.7) 12.4 15.6 24.7 30.9 36.0 45.0 67.3 84.2 105.1 131.9 182.2 227.7
200 (61.0) 10.6 13.6 21.4 26.8 31.4 39.3 58.4 73.1 91.1 113.9 157.7 197.1
300 (91.4) 8.8 11.1 17.5 21.9 25.5 32.0 47.6 59.6 75.6 94.5 128.5 160.7
Note: Standard relief valve settings; R-134a, evaporator=180 psig, condenser=225 psig
Note: Per ASHRAE Standard 15, the pipe size may not be less than the relief device, meaning a
minimum 1" diameter pipe is required. The discharge from more than one relief valve may be run into a
common header, the area of which shall not be less than the sum of the areas of the connected pipes.
For further details, refer to ASHRAE Standard 15. The common header can be calculated by the
formula:
10 Centrifugal Chillers IOMM WSCWDC
D
Common
222 2
D D D
= +
1
. ...
n
Electrical
Wiring, fuse and wire size must be in accordance with information located in the electrical data.
Standard NEMA motor starters require modification to meet McQuay specifications. Refer to electrical
data supplied with the unit or McQuay Product Manual PM WSC/WDC.
Important: The voltage to these units should be within the limitation of +10%, and the voltage
unbalance between phases must not exceed 3%. Since a 3 1/2% voltage unbalance will cause an
approximate 25% increase in motor temperature, it is most important that the unbalance between
phases be kept at a minimum.
Power Wiring
CAUTION
Qualified and licensed electricians must perform wiring. Shock hazard exists.
Power wiring to compressors must be in proper phase sequence. Motor rotation is set up for
clockwise rotation facing lead end with phase sequence of 1-2-3. Care should be taken that proper
phase sequence is carried through the starter to compressor. With the phase sequence of 1-2-3 and
L1 connected to T1 and T6, L2 connected to T2 and T4, and L3 connected to T3 and T5, rotation is
proper. See diagram in terminal box cover.
Proper phase sequence will be determined by the McQuay start-up technician.
CAUTION
Connections to terminals must be made with copper lugs and copper wire.
Care should be taken when attaching leads to compressor terminals.
Note
Do not make final connections to motor terminals until wiring has been checked and
approved by a McQuay technician.
Under no circumstances should a compressor be brought up to speed unless proper sequence and
rotation have been established. Serious damage may result if compressor starts in wrong direction.
It is the installing contractor's responsibility to insulate the compressor motor terminals when the unit
voltage is 600 volts or greater. This is to be done after the McQuay start-up technician has checked
for proper phase sequence and motor rotation.
Following this verification by the McQuay technician, the contractor should apply the following
furnished items.
Materials required:
1. Locktite brand safety solvent (12 oz. package available as McQuay part number 350A263H72)
2. 3M Co. Scotchfil brand electrical insulation putty (available in a 60-inch roll as McQuay part
number 350A263H81)
3. 3M Co. Scotchkote brand electrical coating (available in a 15 oz. can with brush as McQuay Part
Number 350A263H16)
4. Vinyl plastic electrical tape
The above items are also available at most electrical supply outlets.
IOMM WSCWDC Centrifugal Chillers 11
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