McQuay MicroTech 100 Installation Manual

Installation, Operating and Maintenance Manual

Field Installation Procedure for MicroTech II Centrifugal Chiller Control Panel Retrofit Kit

Description Kit Part Number

WSC 50/60 Hz, All Models with Touch Screen Panel 300042762 WSC 50/60 Hz, All Models without Touch Screen Panel 300042763 WDC 50/60 Hz, All Models with Touch Screen Panel 300042764 WDC 50/60 Hz, All Models without Touch Screen Panel 300042765 Operator Interface Upgrade kit 50/60 Hz 300040547

IM 786

Group: Aftermarket Products Part Number: 331357301 Effective: October 2005

Supersedes: January 2004

 2004 McQuay International

2 Field Installation Procedure IM 786

Table of Contents

Introduction...................................................................................................... 5

Building Automation Systems (BAS) Interface .....................................................................5

Disassembly....................................................................................................... 6

Important Note on Downloading Settings..............................................................................6

Existing MicroTech Control Panel.......................................................................................10

Lube Box (MT 100 with PSC oil pump motor shown)........................................................11

Installing the MT II Control Elements......................................................... 13

Install New Panels...............................................................................................................13

Enhanced Surge Protection..................................................................................................18

Install New Components......................................................................................................20

Sensor Locations..................................................................................................................22

Control Panel Connections..................................................................................................26

Check Out and Startup.................................................................................. 31

Table of Figures

Figure 1, MicroTech 200 Panel .............................................................................................6

Figure 2, Existing Data Record: MicroTech 200...................................................................7

Figure 3, Existing Data Record: MicroTech 100...................................................................9

Figure 4, Unit Control Panel, brackets and optional Touch Screen Panel ...........................15

Figure 5, Unit Control Panel, brackets and optional Touch Screen Panel ...........................16

Figure 6, Unit Control Panel and optional Touch Screen Panel mounting locations ...........17

Figure 7, Suction temperature sensor location.....................................................................18

Figure 8, Sensor Locations on unit (Models WSC/WDC)...................................................22

Figure 9, Partial front view of unit.......................................................................................23

Figure 10, Detail of sensor locations...................................................................................23

Figure 11, Sensor locations (Models PEH/PFH) .................................................................25

Figure 12, Unit Control Panel detail....................................................................................26

Figure 13, Unit Control Panel connections..........................................................................27

Figure 14, Compressor Control Panel detail........................................................................28

Figure 15, Compressor Control Panel connections..............................................................29

Manufactured in an ISO Certified Facility



Illustrations and information cover McQuay International products at the time of publication and we reserve the right

to make changes in design and construction at anytime without notice.

IM 786 Field Installation Procedure 3

2003 McQuay International

4 Field Installation Procedure IM 786

Introduction

These procedures must be performed only by technicians with training and experience on Westinghouse/McQuay centrifugal water chillers including, but not limited to, MicroTech Series 100 and 200 controllers and MicroTech II (MT II) controllers.

Before commencing any actual replacement work, review the entire procedure, step by step, for the unit being considered. Also, study the unit to pinpoint the location of the new control components. This should help prevent difficulties during the procedure.

The procedure consists of:

1. Disassembling of the old control components

2. Installing the MT II control panels

3. Installing new sensors and rewiring.

4. Installing and configuring new software and checking unit operation.

Building Automation Systems (BAS) Interface

Determine if the new chiller controls will be required to tie into the building’s BAS. If so, verify that the communication protocol is BACnet, L for these protocols can be obtained separately and field installed on the controller. MicroTech II cannot talk to an existing BAS through McQuay Open Protocol Master Panels (OPM, CVPC, CSC, and direct connections) that may be on the job. Communication module part numbers are:

ONTALK, or Modbus. Communication modules

ONMARK: 350147401

BACnet: 350147404 Modbus: 350147402

IMPORTANT: Because the new MicroTech II controllers utilizes open, standard protocols listed above, they are not compatible with legacy MicroTech system controls which utilize legacy, proprietary McQuay Open Protocol. Therefore, the new MicroTech II chiller unit control panel is not compatible with the existing MicroTech Chiller System Controller (CSC), Chiller Plant Controller (CPC), MicroTech Monitor software, MicroTech Network Master Panels (NMP), or MicroTech Remote Monitoring and Sequencing (RMS) panels. Your McQuay Representative can help you plan the efficient management of your MicroTech and MicroTech II chiller equipment with your building’s chiller plant or overall building automation system as your building needs change.

IM 786 Field Installation Procedure 5

Disassembly

Important Note on Transferring Settings

Record all settings from the existing MicroTech 100 or 200 controller before de-energizing the panel and removing it. Many of the settings will have to be changed from default later in the MT II controller to configure the unit correctly. Forms are included on pages 6 and 7 to record settings.

MicroTech 200

Figure 1, MicroTech 200 Panel

Perform the following steps to record setpoint data from the existing MicroTech 200 control. See manual OM 200 for detailed information.

Action View Record/Ignore

Press Water Setpoints Screen 12, Water Setpoints Record Press Next Menu Screen 13, Motor Setpoints Record Press Next Menu Screen 14, Time/Date Ignore* Press Next Menu Screen 15, Schedule Ignore* Press Next Menu Screen 16, Schedule Ignore* Press Next Menu Screen 17, Timers Setpoints Record Press Next Menu Screen 18-20, Tower Setpoints Record Press Next Menu Screen 21, Oil Setpoints Record Press Next Menu Screen 22, Alarms Setpoint Record Press Next Menu Screen 23, Lead/Lag, dual compressors Ignore

*The schedule function is not avaliable in the MTII

6 Field Installation Procedure IM 786

Figure 2, Existing Data Record: MicroTech 200

MicroTech 200

Setting Value Setting Value

Menu 12, Water Setpoints S creen 2 Screen 1 Stage 1 On Spt Source Stage 4 on Local Spt Stage 2 On Startup DT Stage 3 On Shutdn DT Menu 20 Tower Valve Control Screen 2 Screen1 Chw Reset Valve control Max lvg Spt Valve Spt Return Spt Valve Deadb No Reset at 70°F Reset Signal Max position Max reset

Screen 3 Pulldn Rate Sample Time

Amb Lockout Menu 13, Motor Setpoints PA Time Screen 1 Screen 3 Amp Reset Min Start Position Active Spt Max Start Position Reset Signal Min Amp Spt Max Pos At Network Spt Max Amp Spt Screen 1 Screen 2 Feed Spt Soft load No Start Diff Begin Amp Lim Htr On Diff Ramp Time Menu 22, Alarms Setpoint Menu 14, Time/Date Screen 1 Low Evap Press Shutdown Hh;mm;ss Day mm-dd-yy Menu 15, Schedule High Discharge Temp Shutdown Start-stop schedule Menu 16, Schedule High Condenser Press Shutdown Start-stop schedule Menu 17, Timers Setpoints Motor Current Thres hol d Screen 1 High Oil Feed Temp Start to Start Low Oil Delta Temp Evap recirc Screen 4 Stop to Start Low Net Oil Pressure Menu 18 Pump Setpoints Low Disch Superht at Min RLA Screen 1 High Disch Superht at Min RLA Evap Pmp Screen 5 Cond Pmp Low Disch Superht at Max RLA Menu 19 Cooling Tower Control High Disch Superht at Max RLA Screen 1 Surge-High Suct Superht-St artinf Tower Control Screen 6 Tower Stages Surge-High Suct Superht-Running Stageup Time Evap Water Freeze Stage Dn Time Cond Water Freeze Stage Differential

N/A on MTII

N/A on MTII N/A on MTII N/A on MTII

N/A on MTII

Min position

Screen 2 Valve Type Mod Limit

Max Change

Min Pos At

Menu 21, Oil Setpoints

Screen 1

Low Evap Press Unload Low Evap Press Hold Screen 2

High Discharge Temp Load

Screen 3

N/A on MTII N/A on MTII

N/A on MTII N/A on MTII N/A on MTII

N/A on MTII

IM 786 Field Installation Procedure 7

MicroTech 100

Setpoints reside in three locations on the MicroTech control. There are eight buttons under the “SETPOINT” heading, only three of which have information to be recorded as shown below. The buttons are pressed three times to access three different sets of data. Refer to manual IM 403.

Setpoint Menus

Set-up Options

Service Setpoint Menus

1. There are thirteen settings under the Service Setpoint button, accessed by repeatedly

pressing the button.

2. There are 18 settings under the Set-up Options button.

Action View Action

SETPOINTS

Press WATE R TEMPERATURE View LWT, Reset, Res et Record Data Press MAXIMUM AMP LIMIT View Amp Limit, Remote Limit, Si gnal Record Data Press SOFT LOAD View Soft Load, Beginning Amps , Ramp Time Record Data

SERVICE SETPOINTS

SET-UP O PTIONS

8 Field Installation Procedure IM 786

Figure 3, Existing Data Record: MicroTech 100

MicroTech 100

Setting Value

SETPOINTS, Password Required

Press WATER TEMPERATURE

LLVG EVAP SPT RESET LVG SIG This is a Read Only Value RMT RESET SIG This is a Read Only Value

Press MA XI MU M AMP LIMIT

MAX AMP LIM REMOT AMP LIN This is a Read Only Value REMOT AMP SIG

Press SOFT LOAD SOFT LOAD AMP BEG AMP LIMIT RAMP UP TIME

SET-UP OPTIONS, Password Required

RESET OPTIONS MAX CHW RESET ENT EVAP SPT ENT EVAP TIMER START MODE START UP DELTA –T SHUTDOWN DELTA -T STARTTO START TIME STOP TO START TIME LOAD DELAY COND PUMP TMR TWR STG 1 ON TWR STG 1 OFF TWR STG 2 ON TWR STG 2 OFF ENABLE LAG DISABLE LAG DELAY TIMER

SERVICE SET-POINTS, Service Password Req’d

LOW MTR CURR HOT GAS SPT LOW OIL DELTA CALC OIL STP HIGH OIL FEED LOW EVAP PRESS LP OVERRIDE HI DISCHARGE HIGH SUCT RUN HIGH SUCT OFF HI COND PRESS

N/A on MTII N/A on MTII

N/A on MTII

N/A on MTII N/A on MTII

IM 786 Field Installation Procedure 9

WARNING

Electric shock hazard. Disconnect all power sources to the control box.

Existing MicroTech Control Panel

Chiller may need to be pumped down to allow installation of new pressure transducers and new mechanical high pressure switch before removal of old control panel. As in every case, make sure there is water flow during pumpdown.

CAUTION

1. Service on this equipment must be performed by trained, experienced refriger ation personnel familiar with equipment operat ion, maintenance, correct servicing preocdedures, and the safety hazards inherent in this work.

2. Anyone servicing this equipment must comply with EPA requirements reg arding

refrigerant r eclaim a t ion and venting.

1. De-energize power to existing MicroTech (MT) panel (lock and tag out).

2. Check with VOM for presence of voltage in the MT panel. Isolate and de-energize if present.

3. Check for and disconnect any BAS communication from motherboard or display board.

4. Identify all external wiring to and from the MT panel. Mark as necessary. Factory wiring

should be labeled with wire numbers.

5. Remove all external wiring and conduit.

6. Remove all temperature sensors and discard. MT II uses all new sensors, 10k versus 3k on the

older units.

7. Isolate refrigerant and oil lines connected to MT panel. Remove and cap to prevent loss of

refrigerant and oil. Isolate the oil sump while there is still some pressure in the system to prevent moisture from entering the tank. This is particularly important on R-134a systems.

8. Remove solenoid coil, wires, and conduit from oil cooler valve, liquid injection valve (if

present), and motor cooling valve (if present). Any valves that are not Sporlan brand will have to be replaced. Older controllers used 115V solenoids coils, MT II use 24V solenoids coils. Alternately, 115V to 24V interposing relays can be added to operate the existing valves.

9. Remove old control panel from chiller.

10. In most cases it is easier to leave the existing lube box on the unit and mount the new

compressor control panel adjacent to it. Two pieces of angle iron can be installed on the existing lube box supports, extending out to provide a mounting location for the new panel.

10 Field Installation Procedure IM 786

Lube Box (MT 100 with PSC oil pump motor shown)

There are two basic types of oil pump motors used on Westinghouse/McQuay centrifugal chillers. Many early design chillers with all size compressors, and all chillers (including current production) with compressor sizes CE050 and smaller use a Capacitor Start oil pump motor that has uses a voltage relay. Chillers from approximately 1981 onward with compressor size CE063 and larger use a Permanent Split Capacitor (PSC) oil pump motor which does not use the voltage relay. In addition to the presence or absence of the voltage relay the two style motors use different overload heaters and different capacitors. The same style oil pump motor will use slightly different value capacitors when used in a 50 Hz application as opposed to a 60 Hz application.

To account for these differences some changes to the factory assembled compressor control panel may be necessary as the kit is set up for a 60Hz PSC oil pump motor, and the chiller which the upgrade kit is being installed in may be different. Details on the necessary changes are documented in the following section.

1. Remove and discard oil pump contactor

(not shown). MT 200 has the pump contactor in lube box, . MT 100 has contactor in the control panel.

2. Remove Voltage Relay (not shown) if

present and discard. This is used only on Capacitor Start oil pump motors, and not on PSC oil pump motors. A new one is included in the kit for mounting in the compressor control panel.

3. Re-use Vane Close (VC) pressure switch.

4. Rewire terminal block as required and

document.

5. Remove and discard oil pump overload A

new overload is included in the

compressor control panel. This may need to have its heater replaced with the alternate. See following instructions.

6. Re-use SA/SB solenoid valve

7. Remove and discard oil pump capacitor(s) . A new capacitor is included in the compressor

control panel. This may need to be changed for one of the alternate capacitors, depending upon the oil pump motor type and Hz. See following instructions.

8. Existing Oil Pressure (OP) switch can be re-used if desired. Wire NO contacts in starter MCR

circuit. MT 200 does not have this switch, the microprocessor senses the pressures and performs this function.

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