McQuay THR-060D Installation Manual

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TABLE OF CONTENTS

INTRODUCTION

General Description . . . . . . . . . . . . . . . . . . . . . . . . . ...3

Nomenclature . . . . . . . . . . . . . . . . ., . ., . . . . . . . . . ...3

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3

INSTALLATION

Handling . ., ., . . . . . . . . . . . . . . ., . . . . . . . . . . . . . ...3

Moving The Unit, ., . .,,..,... . . . . . . . . . . . . . . . ...4

Location .,.....,........,.. ., . ., ., ., . . . . . . . ...4

Clearance Requirements ...,. . . . . . . . . . . . . . . . . ...4

Placing the Unit . ., ..,.,.... , . . . . . . . . . . . . . . . ...4

Vibration isolators,.,...,.,.. . . . . . . . . . . . . . . ...5.6

WATER PIPING

General . . . . . . . . . . . . . . . . . . . . . . ., . . . . . . . . . . . ...6

Evaporator Piping . ., ..,.,.... . .,.,......,....,.6

Evaporator Temperature Limits . ., . . . . . . . . . . . . . ...6

Flow Rate Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7

Evaporator Pressure Drop Corrections . . . . . . . . . . ...7

Evaporator Pressure Drop Curve.... . ., . . . . . . . . ...7

CONDENSER WATER PIPING . . . . . . . . . . . . . . . . . . ...8

Condenser Temperature Limits . . . . . . . . . . . . . . . . ...8

Condenser Temperature Rise . . . . . . . . . . . . . . . . . ...8

Condenser Flow Rate Limits... . . . . . . . . . . . . . . . ...8

Condenser Water Arrangements . . . . . . . . . . . . . . . ...9

Condenser Pressure Drop Correction ., .,........,.9

Condenser Pressure Drop Curves . ., . . . . . . . . ...9. 10

TYPICAL PIPING DIAGRAMS., . . . . . . . . . . . . . . . . ...11

Water Quality . . . . . . . . . . . . . . . , . ., ., . ., . . . . . ...12

Condenser Water Thermostat .,, . . . . . . . . . . . . . ...12

Flow Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...12

Relief Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . ...13

DIMENSIONAL DATA . . . . . . . . . . . . . . . . . . . . .14.15.16

STARTUP&SHUTDOWN

Pre Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...45

Startup . . . . . . . . . . . . . . . . . . . . . . . . .,.,.....,.,.,45

Temporary Shutdown .,,.,... . . . . . . . . . . . . . . . ...45

Extended Shutdown .,,.,.... , . . . . . . . . . . . . . . ...46

Startup After Extended Shutdown ,, ., . . . . . . . . . ...46

SYSTEM MAINTENANCE

General ..,.,..,..,....,.,.. . . . . . . . . . . . . . . ...47

Control Center Service, .,..... . . . . . . . . . . . . . . ...47

Electrical Terminals.,....,.. ., ., . . . . . . . . . . . ...47

Compressor Oil Level, .,....,. . ., ., . . . . . . . . . ...47

Refrigerant Sightglass .,.,.... ., . . . . . . . . . . . . ...48

Lead-Lag . . . . . . . . . . . . . . . . . . . . . ., ., . . . . . . . . ...48

Crankcase Heaters .,, ..,..... . ., . ., ., . ., ..,...48

SYSTEM SERVICE

Filter-driers ., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...49

Liquid Line Solenoid Valve.... , . . . . . . . . . . . . . . ...49

Thermostatic Expansion Valve, ...,.,.,. . .,.....,49

Evaporator, . . . . . . . . . . . . . . . . . .,,...,.,,..,.,.,50

Watercooled Condenser,..,.. ., ., ., . . . . . . . . ...50

IN-WARRANTY RETURN MATERIAL PROCEDURE

Compressor . ., .,, . . . . . . . . . . . . . . . . . . . . . . . . . ...50

Components Other Than Compressor . . . . . . . . . . ...51

APPENDIX

STANDARD CONTROLS:

Thermostat, . . . . . . . . . . . . . . . . . ., ..,.,.......,51

Oil Pressure Safety Control ., . ., . ., ., . ., ..,.,.51

Compressor Lockout ., . . . . . . . . . ., . . . . . . . . . ...52

High Pressure Control. .,...... . . . . . . . . . . . . ...52

Low Pressure Control .,.....,. . . . . . . . . . . . . ...52

Freezestat . . . . . . . . . . . . . . . . . . , ., . ., . . . . . . ...52

Compressor Motor Protector . . . . . . . . . . . . . . . ...53

PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . ...17.18

Compresor Locations . . . . . . . . . , . . . . . . . . . . . . . ...19

Contactor Designation . . . . . . . . . . . . . . . . . . . . . . ...19

Major Components . . . . . . . . . . . . . . . . . . . . . . . . . ...19

WIRING

Field Wiring, Power...,..,.. . . . . . . . . . . . . . . . ...20

Field Wiring, Control, . . . . . . . . . . . . . . . . . . . . . . . . ..2o

Interlock Wiring . . . . . . . . . . . . . . , . . . . . . . . . . ...20.21

Sequence of Operation . . . . . . . . ., . . . . . . . . ...22.23

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...24

Control Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...25

Electrical Legend . . . . . . . . . . . . . . . . . . . . . . . . . . ...26

Power Schematics . . . . . . . . . . . ,. ... . . . . . ..27—33

Control & Safety Schematics . . . . . . . . . . . . . . ...34.35

Thermostat Schematics . . . . . . . . . . . . . . . . . ..36—41

Electrical Schematic Drawing Decision Tables.42—44

Page2/lM377

OPTIONAL CONTROLS:

Part Winding Start, . . . . . . . . . . , . ., . ., ., ..,....53

Phase/VoltageMonitor., . . . . . . . . . . . . . . . . . . ...53

Alarm Bell . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . ...53

Low Source Water, . . . . . . . . . . , . . . . . . . . . . . . ...54

Hot Gas Bypass . . . . . . . . . . . . . . . . . . . . . . . . . ...54

CONTROLS, SETTINGS, & FUNCTIONS. ., . . . . . . ...55

TROUBLESHOOTING CHART,. . . . . . . . . . . . . . . . ...56

PRESSURE TEMPERATURE TABLE . . . . . . . . . . . ...57

—

INTRODUCTION

GENERAL

McQuay Type THR Templifier heat pump water heaters are designed for indoor installations. Each unit is completely assembled and factory wired before evacuation, charging and testing. Each unit consists of multiple accessible hermetic compressors, replaceable tube dual circuit shell-and-tube evaporator, water cooled condenser, and complete refrigerant piping.

Liquid line components that are included are manual liquid line shutoff valves, charging valves, filter-driers, liquid line solenoid valves, sightglass/moisture indicators, and diaphragm element thermal expansion valves. Other features

NOMENCLATURE

THR-040 D-1

D;::+J

(Accessible Hermetic)

Nominal Capacity (Tons)

DESCRIPTION

include compressor discharge check valves, crankcase heaters, recycling pumpdown during “on” or “off” seasons, compressor lead-lag switch to alternate the compressor starting sequence, and sequenced starting of compressors.

The electrical control center includes all safety and operating controls necessary for dependable automatic operation.

Compressors are not fused, but may be protected by op-

tional circuit breakers, or may rely on the field installed fused disconnect for protection.

Basic Unit With Single Water Cooled Condenser Per Refrigerant Circuit

‘1

1 = R-22 Refrigerant, 130” F Max. Leaving Water Temp.

INSPECTION

When the equipment is received, all items should be careful- be checked before unloading the unit to be sure that it agrees Iy checked against the bill of lading to insure a complete shipment. All units should be carefully inspected for damage upon arrival. All shipping damage should be reported to the carrier and a claim should be filed. The unit serial plate should

with the power supply available. Physical damage to unit after acceptance is not the responsibility of McQuay International.

Note: Unit shipping and operating weights are available in

the physical data table (pages 17 and 18).

INSTALLATION

Note: Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations, and experienced with this type of equipment. Caution: Sharp edges are a potential injury hazard. Avoid contact.

HANDLING

Every model THR Templifier heat pump is supplied with a full area since the refrigerant will displace the air. Avoid exposrefrigerant charge. For shipment the charge is contained in ing an open flame to refrigerant when moving the unit. Care the condenser and is isolated by the manual condenser li- should be taken to avoid rough handling or shock due to dropquid valve and the compressor discharge service valve. ping the unit.

Should the unit be damaged, allowing the refrigerant to other than the unit base, unit skid, or rigging holes in the escape, there may be danger of suffocation in the equipment, area since the refrigerant will displace the air. Avoid exposure

evaporator or condenser vessels.

Never lift, push or pull unit from anything

IM 377 I Page 3

MOVING THE UNIT

The McQuay Templifier heat pump is mounted on heavy wooden skids to protect the unit from accidental damage and to permit easy handling and moving.

It is recommended that all moving and handling be performed with the skids under the unit when possible and that the skids not be removed until the unit is in the final location.

When moving the unit, dollies or simple rollers can be

used under the skids.

Never put the weight of the unit against the control box.

In moving, always apply pressure to the base on skids only and not to the piping or shells, A long bar helps move the unit easily. Avoid dropping the unit at the end of the roll.

If the unit must be hoisted, it is necessary to lift the unit by attaching cables or chains at the lifting holes in the

evaporator tube sheets. Spreader bars must be used to protect the control cabinet and other areas of the chiller (see

Figure 1).

Do not attach slings to piping or equipment. Move unit in the upright horizontal position at all times. Set unit down gently when lowering from the trucks or rollers.

Note: On unit sizes 120 through 170D, ordered with the op-

tional acoustical enclosure, there will be extension brackets attached to the evaporator tube sheets. These brackets will be used for hoisting the unit and should be removed when unit is in place.

Figure 1.

Unit is designed for indoor application and must be located in an area where the surrounding ambient temperatures are 40F or above,

Because of the electrical control devices, the units should not be exposed to the weather. A plastic cover over the control box is supplied as temporary ’protection during transfer.

SPACE REQUIREMENTS FOR CONNECTIONS AND SERVICING

The chilled water piping for all units enters and leaves the evaporator from the rear, with the control box side being the front side of the unit. (A clearance of 3 to 4 feet should be provided for this piping and for replacing the filter-driers, for servicing the solenoid valves, or for changing the compressors, should it ever become necessary). Recommended service

clearances are shown in Figure 2.

The condenser water piping enters and leaves the shell from the ends. Work space must be provided in case water regulating valves are being used and for general servicing.

Clearance should be provided for cleaning condenser tubes or for removing evaporator tubes on one end of the unit as specified in Table 1. It is also necessary to leave a work area on the end opposite that used for replacement of a cooler tube.

Table 1. Minimum recommended clearance requirements

961<

41“

I Minimum clearance required for removal and replacement of cooler tubes

(either end).

flJ 36,,

I 96” 0! 46 “

A B

120” @ 36 “ 120“ (u

LOCATION

A reasonably level and sufficiently strong floor is all that is required for the Templifier heat pump. If necessary, additional structural members should be provided to transfer the

weight of the unit to the nearest beams.

Note: Unit shippinq and operating weights are available in

the physical data’ table, pages 17 and I8

Figure 2. Clearance requirements

FRONT

cONTROL BOX

The small amount of vibration normally encountered with the Templifier makes this unit particularly desirable for basement or ground floor installations where the unit can be bolted directly to the floor. The floor construction should be such that the unit will not affect the building structure, or transmit noise and vibration into the structure, See vibration isolator

Page 4 I IM 337

PLACING

THE UNIT

section for additional mountina information.

Note: On the THR 120D thru 170D, shipping bolts are used

to secure the compressor rails to the evaporator brackets. Remove these and discard after unit is mounted and before unit is started.

VIBRATION ISOLATORS

Rubber-in-shear or spring isolators can be furnished and field placed under each corner of the package, It is recommended that a rubber-in-shear pad be used as the minimum isolation on all upper level installations or areas in which vibra-

tion transmission is a consideration.

Transfer the unit as indicated under “Moving the Unit.” In all cases, set the unit in place and level with a spirit level. When spring type isolators are required, install springs running under the main unit supports. Adjust spring type mountings so that upper housing clears lower housing by at least 1/4” and not more than 1/2”.A rubber anti-skid pad should be used under isolators if hold-down bolts are not used.

Vibration eliminators in all water piping connected to the Templifier are recommended to avoid straining the piping and transmitting vibration and noise.

Table 2.

-----

Figure 3. Isolator Locations

REAR

= o Q

K 0

FRONT

CONTROL BOX

Table 3. Spring Flex Isolators

CP-1-25 Gray WI 1 Red Stripe CP-1-26 Gray WI 2 White Stripes CP-1-27 Gray WI 1 Orange Stripe CP-1-28 Gray WI 1 Green Stripe CP-1-31 Gray WI 2 Yellow Stripes 1100 0.63 7% CP-2-26 Gray WI 2 White Stripes

CP-2-27 Gray WI 1 Orange Stripe 1500 1.06 1 CP-2-28 Gray WI 1 Green Stripe CP-2-31 I Gray w/ 2 Yellow Stripes I 2200 I 0.83 IIOV. I 9Vz I 6 CP-4-27 I Gray w/ 1 orange Stripe I 3000 I 1.06 II ol/4 [ 9’/2 I 7’/2 I 5 ] 6% ] 886-58051 3A-27

450 1.22 71/z 600 1.17 ?kJ 750 1.06 71/2

900 1.02 i’~/2

1200 1,17 I ol/4

1800 1.02 1ol/4

6V2 5 6VZ 5 6VZ 5 6VZ 5 6V2 5 9Vi 6

ov4

9v4 8 91/2 8

23h 5y8 886-477927A-25 23h 57/s 886-477927A-26 23h 5778 886-477927A-27 23,4 57/8 886-477927A-28 23h 578 886-477927A-31 23h 5y~

23h 5778 866-477929A-27 23h 5778 886-477929A-28

] 23A I 578 I 866-477929A-31

888-477929A-26

Figure 4. Spring Flex Mountings

wc/2y

ADJUST MOUNTING S0 UPPER

HOUSING CLEARS LOWER HOUSING

BY AT LEAST I 16’ AND NOT MORE THAN I 2

ACOUSTICAL NON. SKID NEOPRENE PAD

I 2 DIA

POSITIONING PIN

r–

ivJ_

IM 377 I Page 5

Table 4. Rubber-in-Shear Isolators

Figure 5. Single Rubber-in-Shear

Mounting

-D DIA

,-0- DIA.

‘Os’’’O”’”’ w--A--

WATER PIPING

Since regional piping practices vary considerably, local ordinances and practices will govern the selection and installation of piping. In all cases local building and safety codes and ordinances should be studied and complied with.

All piping should be installed and supported to prevent the unit connections from bearing any strain or weight of the system piping.

Vibration eliminators in all water piping connected to the unit are recommended to avoid straining the piping and transmitting pump noise and vibration to the building structure.

It is recommended that temperature and pressure indicators be installed within 3 feet of the inlet and outlet of the shells

to aid in the normal checking and servicing of the unit.

A strainer or some means of removing foreign matter from

EVAPORATOR PIPING

The water flow entering the evaporator must always be on the

end nearest the expansion valves and evaporator refrigerant piping connections to assure proper expansion valve opera-

tion and unit capacity (see pages 14 thru 16).

Design the piping so that it has a minimum number of changes in elevation. Include manual or automatic vent valves at the high points of the chilled water piping, so that air can be vented from the water circuit, System pressures can be

GENERAL

the water before it enters the unit or the pump is recom-

mended. It should be placed far enough upstream to prevent

cavitation at the pump inlet (consult pump manufacturer for

recommendations). The use of a strainer will prolong pump

and unit life and thus keep system performance up.

A preliminary leak check of the water piping should be

made before filling the system.

Shutoff valves should be provided at the unit so that normal servicing can be accomplished without draining the system.

A water flow switch or pressure differential switch must be mounted in the water lines to the evaporator and the condenser to verify water flow before unit is permitted to start.

maintained by using an expansion tank or a combination pressure relief and reducing valve.

All chilled water piping should be insulated to prevent con-

densation on the lines. If insulation is not of the self-contained

vapor barrier type, it should be covered with a vapor seal.

Piping should not be insulated until completely leak tested.

Vent and drain connections must extend beyond pro-

posed insulation thickness

for accessibility.

Page 6 I IM 377

EVAPORATOR TEMPERATURE LIMITS

EVAPORATOR FLOW RATE LIMITS–GPM*

Table 6.

THR

UNIT

SIZE

040D

0500 0600 0700 080D

0900 1000

1100

1200 t30D 1400

1500

1600 1700

‘ Water flows are basedon 10 FPS for max. flow and3 FPS formin, flow.

CHILLER WATER FLOW *

MAX.

230 244 316 312 352 352 370 460 403 463 463 439 579

579

MIN.

31 34 45 47 44 44 54 68 50 67 67 41 93 93

EVAPORATOR

MODEL

NUMBER

E-1008-2 E-1OO8-1 E-1208-3 E-1208-2 E-1208-1 E-1208-1 E-1408-2 E-1408-1 E-141 O-2 E-141 O-1 E-141 O-1 E-161 O-3 E-161 O-1 E-161 O-1

EVAPORATOR PRESSURE DROP CORRECTION

EVAPORATOR PRESSURE DROP CURVE

NOTE: Maximum allowable evaporator water pressure is 175 psig

WATER FLOW –GPM

lM3771Page7

CONDENSER WATER PIPING

THR condensers have factory manifolds for single inlet and outlet connections. Water flow may be 2-pass parallel, 4-pass

parallel or 8-pass series/parallel to suit the application, Refer to Figure 6 to determine condenser water circuiting arrangement. For proper performance, the condenser water must enter the bottom connection of the condenser on all circuiting arrangements.

Condenser water pressure drop for the unit should be

measured at the common inlet and outlet pipe, through a port

provided by the installing contractor. All pressure drop measurements should be made with the same gauge to insure an accurate reading, Before the pressure drop curves can be read, the pressure drop values on the curve must be corrected based on the average hot condenser water temperature. The

correction factor can be obtained from page 9, and then

multiplied by the values on the pressure drop curves to adjust them according to the average water temperature in the system.

CONDENSER TEMPERATURE LIMITS

Table 7. Condenser temperature limits, operating and maximum ( 0F)

UNIT SERIES

REFRIGERANT

TW%

OPERATING MAX. ALLOWABLE

MAX. LEAVING

WATERTEMP.

WATERTEMP, IN CONDENSER

(“F) (“F)

Note: Water flowlng through the condenser should never exceed the maximum allowable

temperature in the table above even when the urmt IS not operating.

R-22

130

145

CONDENSER TEMPERATURE RISE

Table 8. Allowable condenser temperature rise applicable to refrige

!rant 22

Note: Temperature rise for various water circuit arrangements may for a given

load be limited by the maximum or minimum flow hsted in the unit condenser and evaporator flow Iimlt tables. The flow Iimlts for a given unit should be used to calculate the temperature rise limit before a water circuiting arrangement and temperature rise are established.

CONDENSER FLOW RATE LIMITS

Table 9. Unit Condenser Water Flow Limits (GPM)*

060D

070D 080D 090D

100D

I1OD 508 1200 440 56

130D 506 64 260 32

140D 506 64 260 32 150D 610 80

1600 610 170D 610

‘Values shown are total unit flow AdJust flow per condenser to meet flow requirement for flow arrangement being used

252 32 126 16 63 8 316

360 444 56

444

40 44

56 62

158 180 22 90

222 222

254 224

305 305

305

20 79 10

28 111 14 28 111 14

31 130 28 112 14

40 150 40 150 20

40 150

130 16 130 16

Page 8 I IM 377

Figure 6. Condenser Water Arrangements.

2-Pass Parallel

OUT

NOTE: When parallel circuiting is used, design leaving condenser water temperature may not be obtainable unless both condenser circuits

are in operation.

4-Pass Parallel

OUT

8-Pass Series/Parallel

OUT

CONDENSER PRESSURE DROP CORRECTION

2E W;

:: O*

~$ m

z% o, gg

0 u

CONDENSER PRESSURE DROP CURVES

NOTE: Maximum allowable condenser water pressure is 250 psig.

2-Pass Parallel Flow (Standard Arrangement).

k t

K n

m u K n.

a w 1-

110 130 lwl

AVERAGECONDENSERWATERTEMPERATURE

170 193 210

230 253

WATER FLOW – GPM

IM 3771 Page 9

4-Pass Parallel Flow (Alternate Arrangement).

8-Pass Series/Parallel Flow (Alternate Arrangement).

WATERFLOW– GPM

Page 10 / IM 377

WATERFLOW— GPM

TYPICAL PIPING DIAGRAMS

HEAT RECOVERY

FROM WASTE FLUlO

WASTE

HEAT

SOURCE

up ORAIN1

HEAT LOAD

FROM WATER TO AIR HEAT PUMP SOURCE

SUPPLEMENTARY CLOSEOCIRCUIT COOLER

HEAT RECOVERY

--------

USEFUL

HEAT LOAO

------ -. TEMPLIFIER

SUPPLEMENTARY

HEATER

SOLAR HEAT SOURCE

COLLECTOR

ARRAY

TANK

i i

I_/

USEFUI

HEAT LOAD

WITH INTERMITTENT WATER FLOW

HEAT OUTPUT

(SERVICEHOT WATERI

OUTPUT

140° F

TEMPLIFIER

STORAGE

TANK

<140”C

t- STANOBY

AUXILIARY

I I

140°F

I 1(T

I L--------J

HEAT

SOURCE

TEMPLIFIER

CIRCULATOR

,r HEAT

HEAT RECOVERY

FROM GAS OR AIR SOURCE

------ _ r I

i 1

- ----.- .I

EXHAUSTAIR

NOTES: Valves, drains, vents, expansion tanks and instrumentation must be added in accordance with good piping practice.

Temperatures, where shown, are for illustration only. These are typical Templifier application possibilities shown in schematic way. Each specific application will vary in the use of storage, supplemental heat, etc., to suit the job characteristics

WASTE HEATCONVERSIONUNIT

# I

150°F

170”F *

L------ ----

-------. ~

TEMPLIFIER

FROM PARTIAL SOURCE FLUIO FLOW

HEAT RECOVERY

-------

!~~

—EVAPORATOR-

I I

CONDENSER!

--..-.-

1+=

TEMPLIFIER

USEFUL

TOWEROR CLOSEO

CIRCUITCOOLER

IM 377 I Page 11

WATER QUALITY

The water flowing through the condenser and evaporator must

be of suitable quality for use with standard materials of construction:

Condenser: Steel heads and tube sheets,

rubber gaskets, copper tubes.

Evaporator: Steel shell, copper tubes,

polypropylene baffles

Any additives that may be harmful should not be used.

quality may deteriorate later, an intermediate heat exchanger is recommended, Plate type exchangers should be considered for minimum temperature approach at economical cost.

Note: If cooling”tower or other source water containing dirt, sediment or other foreign matter is used, assure that take-offs to the Templifier are at the top of horizontal pipelines to minimize foreign matter getting into the evaporator. Depending on water conditions, dual strainers and/or a settling drum should be considered.

Where water or other fluids of unsuitable quality, or where

CONDENSER WATER THERMOSTAT

On units THR-040D thru 170D units, the condenser water thermostat (CP1) is mounted inside the control console. The con-

ever be removed from the well for servicing, care should be

taken as not to wipe off the heat conducting compound suptrol sensor is mounted in a well, located in the condenser plied in the well. water inlet manifold. Care should be taken not to damage the sensor cable or leadwires when working around the unit. It

is also advisable to check the leadwire before running the unit to be sure that it is firmly anchored and not rubbing on

the frame or any other component, Should the sensor

Figure 7. Thermostat Well Installation

Note: See page 51 for additional thermostat information.

Caution: The thermostat bulb should not be exposed to

water temperatures above those listed in the condenser water temperature limit Table 7.

EVA

INLET

The water flow switches must be mounted in either the entering or leaving water lines to insure that there will

INSTALLED

FLOW SWITCHES

be adequate water flow and load to the evaporator and condenser before the unit can start. This will safeguard against liquid

refrigerant entering the compressors on startup. 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 ordering number 175033 B-00. It is a “paddle” type switch and adaptable to any pipe size from 1“ to 6“ nominal. Certain minimum flow rates are required to close the switch and are listed in Table 10. Installation should be as shown in Figure 8. Electrical connections in the unit control center should be made at terminals 5 and 6. The normally open contacts of the flow switch should be wired between these two terminals. There is also a set of normally closed contacts on the switch that could be used for an indicator light or an alarm to indicate when a “no flow” condition exists.

1. Apply pipe sealing compound to only the threads of the

switch and screw unit into D“x D“x1” reducing tee (see

Figure 8). The flow arrow must be pointed in the correct

direction.

2. Piping should provide a straight length before and after

the flow switch of at least five times the pipe diameter.

3. Trim flow switch paddle if needed to fit the pipe diameter. Make sure paddle does not hang up in pipe.

Caution: Make sure the arrow on the side of the switch is pointed in the proper direction of flow.

The flow switch is designed to handle the control voltage and should be connected according to the wiring diagram (see wiring diagram inside control box door).

Table 10. Flow Switch Minimum Flow Rates

NOMINAL PIPE SIZE MINIMUM REQUIRED FLOW TO

(INCHES) ACTIVATESWITCH (GPM)

1 6.00 11A

I 1/2 2 18.80

21/2

5 6

9.80

12.70

24.30

30.00

39.7C

-. .

58.70 79,20

Page 12 I IM 377

Figure 8.

FLOW SWITCH

PADDLE

FLOW SWITCH

1“2,,

VIEW FROM END OF EVAPORATOR/CONDENSER

PIPE

-EF;?’ )

~ FLOW3

STRAIGHT PIPE FOR AT LEAST 5D”

The ANSI/ASHRAE Standard 15-1978 specifies that pressure relief valves on vessels containing Group 1 refrigerants (R-22) “shall discharge to the atmosphere at a location not less than 15 feet above the adjoining ground level and not less than 20 feet from any window, ventilation opening or exit in any building.” The piping must be provided with a rain cap at the outside terminating point and a drain at the low point on the vent piping to prevent water buildup on the atmospheric side

of the relief valve. In addition, a flexible pipe section should

be installed in the line to eliminate any piping stress on the relief valve(s).

Figure 9. Relief Valve Piping

f“’”

‘EI %%’:,w%’on

I ;~;~ble to relief

‘;

3“

Wall

Rain Cap

“eeve&Vent

Pitch !O Outside OUTSIDE

WALL

15 Ft. Min. Clearance To Ground

Level (See

Adjacent

Information)

RELIEF VALVE PIPING

The size of the discharge pipe from the pressure relief valve shall not be less than the size of the pressure relief outlet. When two or more vessels are piped together, the common header and piping to the atmosphere shall not be less than

the sum of the area of the relief valve outlets connected to the header. Fittings should be provided to permit vent piping to be easily disconnected for inspection or replacement of the

relief valve.

Note: Provide adequate fittings in piping to permit repair or

replacement of relief valve.

Refrigerant Condenser

3/8” N.P.T

Inlet

RELIEF VALVE (SET AT 450 PSI)

Outlet

IM 377 / Page 13

Figure 10. THR-040D thru 11 OD, 2-pass parallel.

‘i- I ‘-w:’”’

29 ~

DIMENSIONAL DATA

— L—

I %4 MOUI{TIIIG HOLES -1 k7vz

7,,8 DIA

b IEVLP03LTOR

w,i TER !PILET)

~ fl:~CTATOR

. . .

—90 7/8

– POWER

I 1

k“

A [EVAPORATOR

--F

wIRING CONNECTION

I?; OUIRED FOR TUBE REMO$IAL EITHER END

WATER OUTLET)

Table 11. THR-040D thru 11 OD, 2-pass parallel.

THR

MODEL

0500

060D 070D 0s00 OSOD 100D

11OD

Ficrure 11. THR-120D thru 170D, 2-pass parallel.

Recommended

t-36”–

lFOr ‘“W’””’

“D” Evaporator _

Water Corm

MAX. OVERALL

DIMENSIONS

125% 34

125%

125?4 34 125% 34 125% 34 127 127

127

— 34” ~46°

34 65?4 34 34

EVAP. WATER CONN.

621/4 23h 621/4 633~ 633A 633A

661/4 661/4

IClearance” ‘

—

23A 31/2 31/2 31/2

31/2

51/2 51/2

(VIcTAULtC)

23% 23~8 24V8 24T/o 24VB

261/2

271~ 271~

1] Door SwIna

‘f

P“ Victaul,c

Top Outlet

Bottom Inlet

---E

CONDENSER WATER

CONNECTIONS (VICTAULlc) ~

4 4

E “F

65/8 65A 65/8

65/8

71/2

Q&31fl,.--j

11~* 11~8 lly~ llye lly* 131A 131/s 13%

x-Ae

11~/2

17%

111/2

171h

I I 1/2

171~

111/2

171/E

I I 1/2

171/E 161/4

12y8

161/4

12y8

161/4

123/8

~ Ind(cator L,ghts

. . . . . . . . .

~ u:

283/3 561/k

28% 58%

28% 59% 43

26~8 59% 43

28% 59% 43

293A 61 1/>

29% 62%

1517A ~’’””l

Power Wlrlng ConnectIons

CENTER, OFWWWTY

‘

“x

4278 23 42~8 23

431/2

4378 28 433~

y ‘ “z

251/3 251A 25% 27V8 13

13 13

123A 123~ 123A

I 25h 125/8

Requ,red For

ube Removal

E,ther End

L..

27A -

Tabie 12. THR-120D thru 170D, 2-pass parallel.

34 77 34 34 34 77

77 77

160D

160D 170D

Page 14 I IM 377

1517* 1517~ 151y~ 151T/~

EVAP. WATER CONN.

3131A

51/2

51/2 51/2

51/2

3131/4 3131/4

301/4

6 6

Evaporator

‘AL

Water Inlet

CONDENSER WATER

131/Is

77A 6

131/16

7~16

13~h6

7~16

131/Is

7YIS

109A6

109/16

10%6

167/,s 4 167/,6 4 167/,6 4 167/,,3 4

~ A fi::~:;e,

163/4

l-/-

CENTER OF

@liWITY .’

P x y z

293~ 293A 293~ 293A

561/3 56%

561/2

561/4

32V8 32%

331/4

337/2

131/2 131/2

13ye

13y8

Figure 12. THR-040D thru 110D, 4-paas parallel.

36RECOMMENDED FOR SERVICING

EVAPORATOR WATER CONNECTION

SI 1111/ II (iTls”s’DE1

&3’1

L–

-1

2 3/4 -

MAX. OVERALL

DIMENSIONS

124% I 34 124% I 34 124% ] 34

124%4 124% 34 125% 34 125% 34 125% 34

MO UN T:NG HOLES

Table 13. THR-040D thru 110D, 4-pass parallel.

,THR

. . .

T- l\L

29+

?49

621A 621/4

633A 31/2

&j3~

633A 65%

661/4

661/4 51/2

BOTTOM

‘.

...-

EVAP. WATER CONN.

(WCTAULIC)

23A 23~

31/2 31/2 31/2 51/2

c D

23Y8 4 23% 24~B

24~a 24Y8

261/2 271~

271~

TO. Ou

‘LET

INLET

4 7%

5 72/~ 5 5 8 6 6 8

irD=r

E F

73/4

73/3

778 11~~

. . .

=lnrz

IIL‘i%

CONDENSER WATER

CONNECTIONS (VICTAULIC)

111/s

111A

111/s

111A

I 21/2 gl~ 121/2

121/2 914

— 4 UOUNT’NG HOLLS J~

7/8 31A

1-1

r---

—Y<e

81/4 61A 61/4

al~

81/4

91/4

—90 7/8

1578 157/, 157/8 157/8

157/8 1478 3 14y8 3

14T/~ 3

EVLDORb TOP 4-’

CO I:DF!SEP

I I

21/2

271/2

21/2

271/2

21/2

271/2

21/2 271/2

21/2

271/, 281/2 281/2 281/2

T-l n r

LJ[. ”-

<oUT.

--ill

--/

CENTER OF

2514 251k 251~ 27Ye 13

581~

42S~ 23

581~

425~ 23 59y* 43 595A 43 59y* 43

61 1/2 431/2 621A

437/, 28

433A

621A

-P OWFI? WIRING c01it4Fc Tlotl

c’

GRAV!W.

,..’;J;:F

13 13

lz3~ 123A

123~

123/8 125h

,’::

Figure 13. THR-120Dthru 170 D,4-passparalleI.

— 46,,

Door SW,ng

Clearance

D,, Evaporamr

walercm”

Control Con. % Knockout ,7

lanleter

Holes

l-z+

Table 14. THR-120D thru 170D, 4-pass parallel,

THR

MODEL

NO. 1201J 15u12 1300

140D

wor 160D

170D

MAXIMUM OVERALL

DIMENSIONS

L w H A c o

# .. -.,.

150Yz I

1501/2]~

1501/z I 34

i501/z I

1501/2 34

EVAP. WATER CONN.

1 I

51/2

51/2 3131,4

51/2

51/2 301~

5 1/,

----- ,.w

P Vlcla”l,c ToDOu!lel Bottom Inlet

(VICTAULIC)

30 1/4

3r31A

3(31/4

q(l

1/”

150%

Ind,cator L,ghls

. . . . . .

I +1 4“-—.-~

I- T+... __

‘AL

Evaporator Wz!er Inlet

11413/,, –-

CONDENSER WATER

CONNECTIONS (WCTAULIC

F F n .1

1 I !

127A6

8 12fi6

127A6

8 127/4~

8 127/, ~

8I127/,6

71/2

151/& I

71/2

151/s

71/2

151~

71/2

151A

77/2

151/s

71/2

151/s

I I

$ 1

I I

h!:.m

203/,

205A

3 203/~

203/8

2os~

557/*

561A 32VB 56~B

561/2

561/4 331/2

I R

6 6

–~ 120 -

Req., red For

“be Remov:

.p.aporatm

--4

325h

32V8

331~

Erlher End

waler

131/2 131/2

133h

133/4

I I

(

k16,4-–

CENTER OF ..+ “]

35,%

outlet

31/2

IM 377 I Page 15

Figure 14. THR-040Dthru 11OD, 8-pass series/parallel.

L7/yiiR$’:LEs,o,/

‘“”NT’NGH”LESJ++] ‘-,,,,:

Lz4e

Table 15. THR-040Dthru 11OD, 8-pass series/parallel.

.-rrn

7 !/2

A (EVAPORATOR

—T

WATER OUTLETI

Fiaure15. THR-120Dthru 170 D,8-pass series/parallel.

l==

Q~,-

Door Sw,ng Clearance

- 3%

Control Con. ~%,,Knockout

p,, V,claullc

Too Outlet

BotlomInlet

*36+ _. 3-- Recommended

For Sermng

,,D ~

Waler

Lz -/

T Ind!calor L,ahts

I V’”””””:, I

3 D

Power W,r(ng Connections ~

Evaporator

‘AL

Waler Inlet

‘1

~o,A+ --

L——- x –– ---J

114>%-

L6:~fi~r~fi”

120--+

Mequired For

Tube Flemoval

E(lher End

Page 16 / IM 377

PHYSICAL DATA

Table 17. THR-040D thru 11 OD

~ UNIT SIZE

Nominal Horsepower Number Speed RPM (60 Hz/50 No. of Cylindera Oil Charge (Oz.) Discharge Line Size (In.)

Number 2 2 2 Diameter (In,) Tube Length (In.) 96 I 96 Design W.P, (PSIG):

Refrigerant Side Water Side

I Rc,l,.nfl=, ore

Purge Valve Flare Liquid Subcooler

No. Water Passes Pump-Out Capacity 0

Connections:

Water inlet&Outlet (Victaulic)l 2V2

No. Water Passes

Pump-Out Capacity @

Connections:

Water Inlet & Outlet (Victaulic)

Water Passes@

No.

Pump-Out Capacity 0 130

Hz) _

20 ] 25

1],

040D

0500

25 I 25 30 35 35 35

1 1

1750/1 450 1750/1 450 1750/ 1450

I 4

136 136 136 I 1:

11A 11/2

8Y8 85/8 8%

4 4 4 6 6

11A 1ye 1yo

11A

85/8 878

96 I 96 96 [ 96 96 I 96

450 450

250

1/,

Y4 & ~/2

250

1/..

1/4 & J/2

Integral Integral Integral Integral Integral

2 I 2 I 2 12 I 2 / 2 I 2 I 2 I 2 I 2 I 2 I 2 I 2 12 I 2 I .2

130 130

I I

41414 41414/4 4 14 I 4 14 14 I 4 I 4 14 I 4

130

2V2

4 4

130

130 125

21/2 21/2 21/2 21/2 21/2

130 130

21/2 27/2

130

21/2

4 4 14 14 14 I 4 I 4 14 I 4 I 4 14 I 4

130 130

130

060D

070D

080D

G60D

1OOD

cOMPRESSORS

40 40 50 50 50

1 1 1

152 160

1750/ 1450

160 160

1% 1ye

1 1 1 1

1750 II 450

6 6 6 8 8 8

242

1ye

1750/ 1450 1750/

242

260

260 260

1% 1yeI1ye 1ye 1yeI1ye

CONDENSERS

2 2

85~ 6Y8 85/, 85/3 85A

96 ] 96 96 ] 96 96 I 96

450 450 450 450 450 450 250 250 250

1/,

J14 & V2

I v?

~/4 & ~/2

I v, I v? I

Y4 & J/2

2.PASS ARRANGEMENT

125 116 116

21/2 21/2

109 199 199

109

21/21 3 I 3 I 3 I 3

21/2

4-PASSARRANGEMENT

125 125 116 116 109

21/2 21/2 21/2

21/2

109 199

21/2 21/2 I 3 I 3

2 2 2

103A 103/4

103A

250

250 I 250

Y4 & ~/2

Integral

7/4 & 3/2

Integral

188

199 166

313/3 3

8-PASSARRANGEMENT

125 125 116 116 109 109

199 199 166 188 166 188

1100

60 60 I 60

1 1 1

1750/1 450

1450

8 618

260 260

lf33~

v, I v? I

166 168

186

103A 103~

96 ! 96

J/a & 7/2

Integral

3 3

188 188

260

15h

186

Water inlet&Outlet (Victaulic) I 2 21212121212 121212

EVAPORATOR

Refrigerant Circuits

No.

Diameter (In.) Tube Length (In.) Water Volume (Gallons)

Refrigerant Side D.W.P. (PSIG) Water Side D.W.P. (PSIG) Water Connections:

Inlet & Outlet (NPT EXT.) Drain & Vent (NPT INT.)

2 2 2

103,4

lo3~

lz3~

96 96 96

20.6 17.9 26.0 225

225

175 175 175

=/8

5 5 5

DlMENSIONS– 2-PASS

Length (In,)

Width (In,)

Height (In.)

3/i

125

125%

34 34 34

&J1/4 &.1/4 ss3~

125?4

DlMENSiONS– 4-PASS

Length (In,) Width (In,) Height (In.)

124%

szl/4

124?4

Gzl/4

124%

Gs3~

DIMENSIONS– 6-PASS

Length (In.) Wdth (In,) Height (In,)

1167/s 116VS

34 34 34 621/4 621/4

1167/s 1167/s

Gs3~

WEIGHTS—2-& 4-PASS

Operating Weight (Lbs.) Shipping Weight (Lbs.) Operating Charge Lbs. R-22

Operating Weight (Lbs.)

Shipping Weight (Lbs.) Operating Charge Lbs. R-22

NOTES: @ 60Vo Full refrigerant at90° F. @ 8-Pass Series/Parallel Arrangement.

3655 3705

3655

40 I 50 I 50 I 50 150 160 I 60 I 60

3635 3665

3635 3695 3895

3735

40 I 50 I 50 ] 50 I 50 I 60 I 60 I 60

3995 4065 4240 3935

WEIGHTS-8-PASS

3955

21/2 21/2 21/2 21/2 21/2I21/2

2 2

1 z3~

lZ3~

2 2

1 z3~

96 96 96 96

25,6 24.3 24.3 30.5

225

175 175

225 225

175

5 6 6

3/8 % =/8 %

125% 125%

34 34

6? 3/4

633A

12434 124%

&,3~

34 34 34

Gs3~

1167/8

127 127

655A

125% 125%

65%

117% 1171~

34 34 34 34

Gs3~ ss3~

655/3

4675

4025 4185

4690

65 I 65 I 70 I 70 [ 60 I 60 I 60 I 60

4045

4200

3965 4045

4715 4630

5255 5115

65 I 65 70 I 70 60 I 80

175

~~l/d

sG1/4

GG1/4

5315 5175

27.6 225

175

127

fjfjlfi

125?4

&jl/4

117%

GG1/4

5465 5325

5405 5265

60 I 80

Table 18. WHR-120D thru 170D.

UNIT SIZE

120D

130D 140D

COMPRESSORS

Nominal Horsepower Number Speed RPM (60 Hz/50 Hz) No. of Cylinders Oil Charge (Oz.) Discharge Line Size (In.)

Number Diameter (In,)

Tube Length (In.)

Design W.P, (PSIG):

Refrigerant Side

Water Side Relief Flare Purge Valve Flare Liquid Subcooler Integral

No. Water Passes PumpOut Capacity 0 Connections:

Water Inlet & Outlet (Victaulic)

No. Water Passes Pump-Out Capacity @ I 250.0

Connections:

Water Inlet & Outlet (Victaulic)

160/1 36 160/136 160/1 36 160/1 60 160/1 60

35/25 35/25 35/25

2 2 2 2

1750/ 1450

6/4 6/4 614

1%111A 1y*ll 1/3 12/8/11A

2 2

103~ liJ3~ lrJ3~ 1133~

120 120 120

450 450 450 250 250 250

% 5/8

V4 & V2

2 2 2

250.0 250.0

4 4 4

3 3 3

2-PASS ARRAN QEMENT

238.6 238.6 238.6 236.6

4-PASS ARRANGEMENT

250,0 238,6

35135 35135 35/35 35/35 35/40

2 2

1750/1 450

6/6

1yJl 1A

CONDENSERS

120 120

V4 & V2 V4 & V2

Integral

2 2

4 4 4

4 4 4 4 4

238,6 236,6 236.

3 3 3 3 3 3

1750/ 1450 1750/ 1450

6/6 6/6 6/6 6/6 6/6

160/1 60 160/160 160/242

1%/1 ye

13/Jl Ya

1034 103~ f 03~ I03/4

1133~

120 120 120

5/8

Integral Integral Integral

2 2 2 2

6 219.2 219.2

S-PASS ARRANGEMENT

No. Water Passes@ PumpOut Capacity @ 250.0 250.0 Connections:

Water Inlet & Outlet (Victaulic)

No. Refrigerant Circuits Diameter (In,) Tube Length (In.) Water Volume (Gallons) 38.2 36.1 36.1 Refrigerant Side D.W.P. (PSIG) Water Side D.W.P. (PSIG) Water Connections:

Inlet & Outlet (NPT EXT.) 6 6 6 Drain & Vent (NPT INT.)

Length (In.) Width (In,) Height (In.) 77 77

t nla*EM@lnNe

Length (In.)

Width (In,)

Mainht (In 1 77 77 77 77 77 77

,,“, =,!. ,, !!.,

4 4 4

21/2

2 2 2

14 14 14

120 120 120

225 225 225

175 175 175

% %

1517/~ 1517/8

34 34 34

150% t501/2 150Vz

34 34 34

238.6 236.6 238.6 238.6 219.2

21/2 21/2

DIMENSIONS - 2-PASS

“,!wE,.e,”$.” — .rr””!

4 4 4

21/2 21/2

EVAPORATOR

21/2

3/8

151y~ 1517/8

A-CI&~s

DIMENSIONS - 8-PASS

Length (In.)

Width (In,) Height (In,)

142s%

34 34 34 77 77 77

14234

142% 142%

WEIGHTS -2 & 4 PASS

Operating Weight (Lbs.) Shipping Weight (Lbs.) 6160 6335

Operating Charge Lbs. R-22

6370 6525

100 100 105

110 110 110

6600 6940 7290

6410 6775 6990

WEIGHTS -6 PASS

Operating Weight (Lbs.) 6330 6485

Shipping Weight (Lbs.) 6140 6295

Operating Charge Lbs. R-22 100 100

NOTES: 0 60°/0 Full refrigerant at 90” F. @ 8 Pass Series/Parallel Arrangement.

105 110 110 110 115 115

6560 6900 7250 6380 6735 6950

150D 160D

35/40 35/40

2 2 2

1750/ 1450

160/242 160/242 242/242 242/242

1%11%

I %1~%

2 2

120 120

450 450 450

250 250 250

=% %

X4 & Y2

219.2 219.2

4 4 4

219,2

Y4 & V2

219.2 219.2 219.2 219.2

219.2

219,2 219.2 219.2 219.2

21/2 21/2 .21/2

2 2

120 120

53.7 225 225 175 175

34 34 77 77

15ol/z

34 34

. .

34 34 77 77

115

115 120 120

16 16

45.1

6 6

Y8 %’s

1517/8

1507/2

. .

142?4

120 120 125 125

2 2 2

6/6 6/6 6/6

1%11ye 13/”11Vi 12/!!11ye

103~ 103/4

2 2 2

4 4 4

219.2 219.2

3 3 3

4 4 4

21/2 21/2 21/2

170D .

40/40 40/40

1750/1 450

120 120

7/4& V2

Integral

120

45.1 225 175

1517/~

34 77

150%’

142%

34 77

7400

7100

125 125

7360 7060

103~

219.2

Page 18 I IM 377

Figure 16. Compressor Locations

UNITS 040D thru 11OD

cOMP.

.J–

SUCTION

PIPING

Table 19. Contactor Designation

CONTROL BOX

COOLER

‘–

COMP,

UNITS 120D thru 170D

SUCTION

PIPING

I I

CONTROL aOX

Two contractors are used per compressor on all 208 volts units. Two

NOTE:

contractors are also used on THR-090—I 10 all voltages, and on all 460 & 575 part winding start units.

IM 377 I Page 19

WIRING

FIELD WIRING, POWER

The THR TEMPLIFIERS are built standard with compressor contractors and power terminal block, designed for single

power supply to unit. Optional power connections include a non-fused disconnect switch mounted in the control box or multi-point power connection.

A factory installed control circuit transformer is available as an option with single power supply or disconnect switch; it is not available with multi-point option.

Optional circuit breakers are available for backup compressor short circuit protection on 040D thru 110D units and are standard on all four (4) compressor units 120D thru 170D.

Wiring and conduit selections must comply with the National Electrical Code and/or local requirements.

FIELD WIRING, CONTROL

Control circuits on all units are designed for 115 volt operation. A separate source of 20 amp, 115 volt AC power may be brought to terminals 1 and 14 (terminal 14 on the ground side) to power the control circuit. On 208 volt power, leads from any line and neutral of the 208 volt system may be brought to terminals 1 and 14 to provide 120 volts to the control circuit.

An optional factory mounted transformer is available to pro-

vide the correct control circuit voltage. All models include the

An open fuse indicates a short, ground, or overload. Before replacing a fuse or restarting a compressor or fan motor, the trouble must be found and corrected. Tables in the Electrical Data section give specific information on recommended wire sizes.

Unit power inlet wiring must enter the side of the control box (right side) through an inlet hole provided for field terminating conduit. (Refer to control panel layout drawings for

general location of power inlet and components.)

WARNING: Use only copper conductors in main terminal block. If the power input conductors are aluminum, use a compression splice to change to copper before terminating in block.

necessary factory wiring to power the transformer.

On models THR-040D thru 170D the transformer power

leads are connected to the power block PBI or disconnect

switch DS1.

Six 1/2° conduit knockout openings are provided for field

wired options and are located on the left side of the control

panel when facing the unit control panel doors.

NOTE: See page 51 for additional information on the con-

trol thermostat.

INTERLOCK WIRING

The control arrangement shown on the wiring diagram will permit continuous or cycling operation of the source water pump. Provision has been made to permit source water pump cycling by the addition of a field supplied relay “MA” and

wiring it between terminals 11 and 16. if relay “MA” is not

added the pump must be wired for continuous operation. When continuous source water circulation is used, the flow switch contacts should be tied into the control circuit as shown on the interlock schematic (see Figure 17).

The condenser water pump must be arranged for con-

tinuous water circulation, otherwise leaving condenser water

– PUMP STARTERS

temperatures will not be properly controlled.

Condenser water flow switches must be wired into the control circuit as shown on the interlock schematic and depending on the application it may be necessary to install a time delay relay with timed open contacts connected into the control circuit in parallel with the flow switch to prevent nuisance tripping.

Whenever the application will permit, continuous water circulation in both the source water and condenser water circuits is preferred and the use of flow switches in both circuits is recommended.

Page 20 I IM 377

Figure 17. Typical Interlock Schematic

NOTE: FOR SINGLE STARTER APPLICATION, JUMPER TERMINAL 11 AND 12 AND WIRE STARTER BETWEEN 11 AND 16.

PHASE

POWER SUPPLY

UNIT DISCONNECT SWITCH(BY OTHERS)

—7

COMP.

@!&d

-2

M3 CB1

—

l——

S1 CONTROL

()

RELAY

1~-

IQ--U–––––-J

RIO

4 CONTACTS 11

r——x

——

--M~i=~

41 Al

120V

UNIT OPERATING

CONTROLS(CKT. 1)

I OPTIONAL CONTROL I CKT. TRANSFORMER

COMP

COMP.

.U4

LEGEND

—— . ——— —

TIMECLOCK CONTACTS

EVAPORATOR FLOW SWITCH

NOTE: For single starter application, jumper terminal 11 and 12 and wire starter between 11 and 16.

FIELD CONNECTION TERMINAL

FACTORY WIRING FIELD WIRING

OPTIONAL FACTORY WIRING

Ml—MB COMPRESSOR CONTRACTORS CB1—CB4 PB1 MA, MB

UNITOPERATING

CONTROLS(CKT.2)

TEMPLIFIERUNIT

CAPACITYCONTROLS

COMPRESSOR CIRCUIT BREAKERS UNIT POWER TERMINAL BLOCK CONDENSER PUMP STARTERS (MAX. 20VA EA.)

IM 377 I Page 21

SEQUENCE OF OPERATION – THR-040D thru 110D

The following sequence of operation is typical for THR TEMPLIFIER HEAT PUMP, models THR-040D thru THR-110D. The sequence varies somewhat depending upon options.

HEAT ONLY OPERATION Compressor Heaters

and the control stop switch S1 open, 115V power is applied through the control circuit fuse F1 to the compressor crankcase heaters HTR1 and HTR2.

Startup —

power is applied to the compressor motor protectors MPI and MP2 and the primary of the 24V control circuit transformer. The 24V transformer provides power to the central processor thermostat CPI and to the optional alarm bell.

When the remote time clock or manual shutdown switch turns on the water pump, the flow switch closes and 115V power is applied to the relay contacts on the central processor CP1. The unit will automatically operate in response to the central processor CP1 provided the manual pumpdown switches PSI and PS2 are closed (in the auto position), the compressor lockout time delays TD1 and TD2 have closed, energizing the safety relays R5 and R6, and the freezestats FS1 and FS2, high pressure controls HPI and HP2, and compressor motor protectors MPI and MP2 do not sense failure conditions.

On a call for heating, the central processor CP1 energizes the liquid line solenoid SV1 for refrigerant circuit #1, opening the valve and allowing refrigerant to flow through the expansion valve and into the evaporator. As the evaporator refrigerant pressure increases, the low pressure control LPI closes. This energizes the compressor contractors M1 and M5, starting the compressor. Also, R9 relay is energized. R9 relay is wired to terminals providing a means for interlocking

the pump starter, MA with the compressor operation. See page 21 for pump control.

As additional stages of heating capacity are required, the

central processor CPI energizes the liquid line solenoid valve SV2 of refrigerant circuit #2. After the compressor sequencing time delay TD11 has closed, the same starting sequence is initiated in refrigerant circuit #2.

If additional heating is still required, the central processor

will de-energize the unloader solenoids of each compressor, respectively.

HEATING/COOLING OPERATION Heat/cool units are designed to supply hot water for heating

needs and to allow switching to cooling operation when it is needed.

The sequence of operation for combination heating/cooling units is similar to heating only, the difference is in the thermostat arrangement. On heat/cool models the heating thermostat “CPI” is still used, but in conjunction with a changeover switch and the addition of a separate cooling thermostat “CP2”. Changeover from heating to cooling operation or cooling to heating is accomplished by setting the changeover switch for the desired mode to activate the desired heat or cool thermostat. The thermostat relay con-

tacts then activate the control circuit whenever compressor operation and/or loading or unloading is required to satisfy the thermostat setting for the mode selected.

The heating thermostat controls the leaving hot water

temperature leaving the condenser through a sensor located in the return water to the condenser.

Conversely the cooling thermostat controls the water

temperature leaving the evaporator through a sensor located

in the return water, to the evaporator temperature selection

With the control stop switch S1 closed, 115V

— With the control circuit power on

dials inside the thermostats, are used to set the desired leav-

ing water temperatures for either heating or cooling. Seethe

thermostat bulletin packed with the unit for additional

information.

Check the applicable 4 or 6 stage heat/cool wiring diagrams

starting on page 39 for specific wiring details. Pumpdown Cycle System Shutdown — As the central pro-

cessor is satisfied, it will unload the compressors and then de-energize the liquid line solenoid valves SV1 and SV2, causing the valves to close, starting the pumpdown cycle. When the compressor has pumped most of the refrigerant out of the evaporator and into the condenser, the low pressure controls LPI or LP2 will open, shutting down the compressors. During the off cycle, if a closed solenoid valve allows refrigerant to leak into the evaporator, the increase in pressure will cause the low pressure control LPI or LP2 to close. This will energize the compressor contractors Ml and M2 and start the compressor, which will quickly pump the refrigerant out of the evaporator and into the condenser (recycling pumpdown).

A compressor which repeats recycling pumpdown every 5 minutes indicates a malfunction due to the temperature control or a system cause. A buildup of heat in the compressor without proper cooling of suction gas could cause a mechanical failure in the compressor. McQuay recommends corrective measures be taken if the compressor recycles repeatedly within 15-minute intervals.

Safety Relay Operation —

be energized to permit normal operation. If the freezestats FSI and FS2, high pressure controls HP1 and HP2, oil pressure controls OP1 and 0P2 or compressor motor pro-

tectors MP1 and MP2 sense a fault condition and open, the safety relay R5 or R6 will be de-energized. The relay contacts open and de-energize the compressor contactor and the liquid line solenoid valve.

Compressor Anti-Short Cycle Time Delay — The unit is equipped with 5-minute time delay relays TD1 and TD2 which provide anti-short cycling protection. When low pressure control LP1 closes and energizes Ml compressor contactor, LP1 also energizes R9 which provides power to auxiliary relay MA for control of a starter for a remote evaporator pump. A second contact on R9 shunts out TD1 opening up TDI. When LPI opens, cutting power to R9, then compressor #1 cannot be started until TD1 times out and energizes safety relay R5.

Operation of LP2, TD2, M2, R1O and R6 is similar for opera-

tion of the second compressor.

Note: The motor protector in the compressor terminal box

has a 2-minute time delay. When power is interrupted to terminals 3 and 4 of any motor protector, the MP contacts between MP terminals 1 and 2 open and will not close for two minutes.

Indicator Lights —

with indicator lights to show the status of electrical control operation.

ON-STOP Switch — Has an inherent light which glows when the control circuit is energized.

Lights SV1 and SV2 — Glow when the safety relays are energized indicating compressor circuit safety contacts are closed, and compressor will operate in response to CP1

thermostat.

Lights RLI and RL2 — Glow when the compressor con-

3. tractors are energized and cooling circuit is in operation.

Heating Stage Indicator Lights — Red lights next to the relays on the main central processor thermostat indicate

which heating stages are energized.

The safety relays R5 and R6 must

The THR unit control box is equipped

Page 22 I IM 337

SEQUENCE OF OPERATION – THR-120D thru 170D

The following sequence of operation is typical for THR

TEMPLIFIER, models THR-120D thru THR-170D. The se-

quence varies somewhat depending upon options. Compressor Heaters

— With the control circuit power on

and the control stop switch S1 open, 115V power is applied

through the control circuit fuse FI to the compressor

crankcase heaters HTRI, HTR2, HTR3, and HTR4. Startup — With the control stop switch S1 closed, 115V

power is applied to the compressor motor protectors MP1, MP2, MP3, and MP4 and the primary of the 24V control circuit transformer. The 24V transformer provides power to the

central processor thermostat CP1 and to the optional alarm

bell.

When the remote time clock or manual shutdown switch

turns on the water pump, the flow switch closes and 115V

power is applied to the relay contacts on the central processor CP1. The unit will automatically operate in response to the central processor CP1 provided the manual pumpdown switches PS1 and PS2 are closed (in the auto position), the compressor lockout time delays TD1 and TD2 have closed, energizing the safety relays R5 and R6, and the freezestats

FSI and FS2, high pressure controls HPI and HP2, and compressor motor protectors MP1, MP2, MP3, and MP4 do not sense failure conditions.

On a call for heating, the central processor CP1 energizes the liquid line solenoid SVI for refrigerant circuit #1, opening the valve and allowing refrigerant to flow through the expansion valve and into the evaporator refrigerant pressure increases, the low pressure control LPI closes. This energizes the compressor contractors Ml and M5, starting the compressor. Also, R9 relay is energized. R9 relay is wired to terminals providing a means for interlocking the pump starter MA with the compressor operation.

As additional stages of capacity are required, the central processor CP1 energizes the liquid line solenoid valve SV2 of refrigerant circuit #2. After the compressor sequencing time delay TDI 1 has closed, the same starting sequence is initiated in refrigerant circuit #2.

If additional heating is still required, the central processor

will activate additional cylinders on the lead compressor of

each system or activate compressors #3 and #4, depending

on the load requirements and the capacity control stops

available on the unit. Pumpdown Cycle System Shutdown — As the central pro-

cessor is satisfied, it will cut off compressor #4 and #3, then

unload compressors #2 and #1, and finally de-energize the liquid line solenoid valves SV1 and SV2, causing the valves

to close. When the compressor has pumped most of the

refrigerant out of the evaporator and into the con-

denser, the low pressure controls LP1 or LP2 will open, shutting down the compressors. In the event a closed solenoid valve allows refrigerant to leak into the evaporator, the increase in pressure will cause the low pressure control LPI

or LP2 to close. This will energize the compressor contractorsMl and M2 and start the compressor, which will quickly pump the refrigerant out of the evaporator and into the condenser (recycling pumpdown).

Safety Relay Operation —

The safety relays R5 and R6 must be energized to permit normal operation. If the freezestats FSI and FS2, high pressure controls HPI and HP2, oil pressure controls OP1 and 0P2 or compressor motor protectors MP1 and MP2 sense a fault condition and open, the safety relay R5 or R6 will be de-energized. The relay contacts open and de-energize the compressor contactor and the liquid line solenoid valve. Safety relays

R7 and R8 pro-

vide a similar function for compressors #3 and #4. Compressor Anti-Short Cycle Time Delay — The unit is

equipped with 5-minute time delay relays TD1, TD2, TD3 and TD4 which provide anti-short cycling protection. When low pressure control LPI closes and energizes Ml compressor contactor, LPI also energizes R9 which provides power to auxiliary relay MA for control of a starter for a remote pump. A second contact on R9 shunts out TD1 opening up TD1. When LP1 opens, cutting power to R9, then compressor #1 cannot be started until TDI times out and energizes safety relay R5.

Operation of LP2, TD2, M2, RIO, R6 and Ml is similar for

operation of the second compressor.

Note: The motor protector in the compressor terminal box has a 2-minute time delay. When power is interrupted to terminals 3 and 4 of any motor protector, the MP contacts between MP terminals 1 and 2 open and will not close for two minutes.

Indicator Lights —

The THR unit control box is equipped with indicator lights to show the status of electrical control operation.

ON-STOP Switch — Has an inherent light which glows when the control circuit is energized.

Lights SW, SV2, SV3, and SV4 — Glow when the safety relays are energized indicating compressor circuit safety contacts are closed, and compressor will operate in response to CP1 thermostat.

Lights RL1, RL2, RL3, and RL4 — Glow when the compressor contractors are energized and cooling circuit is in operation.

Heating Stage Indicator Lights — Red lights next to the

relays on the main central processor thermostat indicate which heating stages are energized. Note: Located inside control box.

377 / Page 23

Table 13. Compressor motor amp draw

--.,

,Uqw

4 . . .

‘.

---- ,: 230 162 202 1070

‘,

.:. .,.

11OD

J6VV

. .

“:14.90

.,.I?ww

:..,-,

..:.

.. z,-- 230 113.129 113.129 565.594

:9700: ,,

..-

230 460 Q

I 4600 I 53 I 61 I 235

575

208

208 230 202 202 1070 460 Q 101 101

1 460 Q I 61, 42 I 61, 421283,214

208 230 113, 113 113, 113 565,565 460 D 61, 61 61, 61 283.283

4600 I 61, 61 I 61, 651283,263

206

230 129, 129 129, 129 594, 594 460 ~ 65, 65 65, 65 297, 297 575 52, 52 52, 52 235, 235

77 42 42

113, 113 113, 113 565, 565

113, 153 113, 153 565, 660

45 45

153

162

202

153

202

428 214 172

428 428 214

172

565 565 283 230

660 594 297 235

1070 1070

535 405

1070 1070

535 405

1070 1070

535

405

orAfly9 ,

:&%$i;,:#)

~&&it:

186

84 61

250

-a--4-E

250

117 103

292 292

141 130

340 340 156 138

400

340

170 135

654 654 330 262

654 654 330

262

654

654 330 262

340, 250 340, 250 156, 117 136 103

340, 250 340, 250

156, 117 138 103

340, 340 340, 340

156, 156

138 138

340, 340 340, 340 156, 156 138 138

340, 400 340, 340

156, 170 138, 135

400, 400 340, 340 170, 170 135, 135

140, 340

156.156

ERiT

38, 135

100, 400 i40, 340 548

70, 170 I 276 35, 135 I

250

117 95

170 135

654 654 365

330 262 135

654 654

330 208

146

117 65 365

165

415 415

460 259

207 650 344

221 117

173

96 53 39

96 96 53

203 203

103

203 203 103

254 137

110

290 146

141 141

191 161

81 65

203 203 103

253 253

126

253 253

126

218 218 118

254 254 137

101

254 254 137

101

304 274

142 110

304 274

142

110 344

290

146 117

T5?i(

&i,?!!,:

circuit3

428 214

230 660

1070

535

i65, 426 i65, 426 ?83, 214 ?30, 172

j65, 428 i65, 426 ?83, 214 ?30 172

;65, 565 ;65, 565

!83, 283 !30, 230

;65, 660 i65, 660 !83, 297 !30, 235

i65, 660 i65, 594 !63, 297 !30, 235

;60, 660 ’94, 594 ’97, 297 ’35, 235

NOTES:

@ ALLOWABLE VOLTAGE LIMITS:

Unit Nameplate 208V/60Hz/3Ph: 187V to 253V (except THR-080D: 180V to 220V). Unit Nameplate 230V/60Hz13Ph: 187V to 253V (except THR-080D: 207V to 253V). Unit Nameplate 460V/60Hz/3Ph: 414V to 506V. Unit Nameplate 575V/60Hz/3Ph: 517V to 633V. Unit Nameplate 380V/50Hz/3Ph: 342V to 418V. Compressor RLA values are for wire sizing purposes only and do not reflect normal operating current draw

Compressor LRA for Dart windina starl are for the first windina,

Unit tire size amm a;e eaual to 725V0 of the Iaraest comoress~r-motor RLA DIUS100VO of RLA of all other loads in the circuit includina control transformer. Wire size amps ;or separate 115V control circu~ power (s 10 amps. Single point power supply requires a single fused disconnect to supply electrical power to the unit.

Multiple point power supply requires three independent power circuits with separate fused disconnects (two compressor circuits, one control circuit).

Data also applies to 380V/50Hz/3Ph units.

page 24 I IM 377

CONTROL CENTER

All electrical controls are enclosed in a control center with

Iocking, hinged access door(s). A partition separates the adjustable safetv controls from the starting and operating con- justable controls are covered and can be adjusted without

trols. A “deadfront” panel covers all starting and operating

CONTROL CENTER LAYOUT, THR-040D thru 11OD

Figure 18. Left Side, 115V Control Section

controls so that no electrical contacts or terminals are exposed. The deadfront panel is hinged for servicing. The ad-

fear of contacting line voltage.

Figure 19. Right Side, High Voltage Control Section

——

-cmiP, ——— —————

TR HM

lx)

TB4(110–124,210-224)

CP2

!4604

IPS1 82 I

ElljallI

F1 PS2CTR HM

_ ~c)

❑

~————.

mmlmlma

TB6(70-93)

RACEWAY

TB2 (1—16) I TB3 (17-28) 1

Figure 20. Left Side, 115V Control Section

~~m

CONTROL CENTER LAYOUT, THR-120D thru 170D

PVM

EIEIEIEI

LOOKING AT THE BACK

NOTE CIRCUIT BREAKER SWITCH

POSJTP3N

“d

OFF

Figure 21. Right Side, High Voltage Power Section

OF THE CONTROL PANEL 1

!!$$

.7’

ALARM BELL

AB1

CTR HM

mi:l’:~

T84 1110–1240,210-2241

CTR HM I PSI S2

RACEWAY

‘---=iBT@’l@

❑ml-’l ❑ m+

RACEWAY

EIOGRD

PVM

‘mmmm-

NOTES:

PBI and PB2 are used with multiple point power wiring.

2. Circuit breaker8 are provided as an option, on THR-040D—110 units,

IM 337 I Page 25

ELECTRICAL LEGEND

DESIGNATION DESCRIPTION

AB Alarm Bell CB1–6 COMPR. 1—4 Compressorsl —4 CP1 CP2 CTR 1—4 DS1 F1 FB5

FS1 , 2 GFI GRD HM7–4 HP1 , 2 HTR1–4 LP1 , 2 Ml–8 FAA, MB MJ MP1–4 NB OL1–6 OP1–4 PB1, 2 Psi, 2 PVM RI, 2

R3, 4 R5–8

Circuit Breakers Compr, Motors

Central Processor Central Processor Satellite, CoollHeat Control Box Counter Compr. Total Hours Disconnect Switch Main Fuse Control Circuit Fuaeblock Control Power Freezestats, Pressure Control Ground Fault Interrupter Ground Hour Meter Compressors High Pressure Controls Heaters, Compressor Crankcase

Low Pressure Controls Contactorsr Compressor Pump Starter Coils Mechanical Jumpers Motor Protectors, Compressor Neutral Slock Overloads Oil Pressure Controls Power @lock, Main Pumpdown Switches Phaae Voltage Monitor Relays, Alarm

Relays, Starting Relays, Safety or Alarm

STANDARD LOCATION

Back or Side of Control Box Control Box Top of Evaporator Control Box

Control Box Control Box Control Box Control Box

Control Box Control Box Control Box Control Box Control ❑ox On Compressor Control Box Control Box Field Installed Control Box Compressor Junction Box Control Box Control Box Control Box Control Box Control Box Control Box

Control Box Control Box Control Box

DESIGNATION

R9–12 R13, 14 R17, 18 R21, 22

R23, 24 R25–30 RL1–4 RRM S1 S2 SD1 SL1–4

Svl, 2 SV5. 6 T1 T2 TB2 TB3 TB4–6 TC1 TC1O TC1l TC12 TD1–4 TD5–6 TD1l–13 TD20–24 Ul, 2

DESCRIPTION STANDARD LOCATION

Relays, Starting Relays, Low Ambient Start Relays, Capacity Control

Relays, High Return/Low Source Water Relays, Unloader Control Relays, Special Run Indicator Lights Remote Reset Module Switch, Control Stop Switch, Lead-Lag Solenoid Door Lock Safety Indicator Lights Solenoid Valves, Liquid Lines Solenoid Valves, Hot Gas Bypass

Transformer, Main Control Transformer, 23V Control

Terminal Block, 120V Field

Terminal Block, 24V Field Terminal Blocks, Controls Thermostat, Special Thermostat, Special Thermostat, Low Source Water Thermostat, Special

Time Delays, Compressor Lockout Time Delays, Compressor PW Start Time Delays, Compressor Sequencing Time Delays, Special

Unlosders

Control Box Control Box Control Box Control Box Control Box Control Box Front of Control Box Control Sox

Side of Control Box Control Box Control Box Front of Control Box On Liquid Piping On Hot Gas Piping Control Box Control Box

Control Box Control Box Control Box Control Sox Control Box or On Unit Control Box Control Box or On Unit Control Box Control Box Control Box Control Box On Compressors

1. ———— FIELD WIRING

2. —–-— 3, —. —-—

—200— WIRE NUMBER

WIRING IN REMOTE UNIT WIRING CONNECTING UNITS

5 ~ O’T’ON “OC”

6.—(— FACTORY WIRED TERMINAL

GENERAL NOTES

—o—

—@—

9 ~

10.—<+ PLUG CONNECTOR 11,

289 ‘

OPTIONAL LINEON TERMINAL BLOCK

FIELD WIRED TERMINAL REMOTE PANEL TERMINAL WIRE CONNECTOR

Page26/lM337

THR 040D THRU 080 D–SINGLE POINT 380/415/575V – AL, PW

11 :~~ 1,

[i-+-q ~~ ,

~“‘“3/ SET

~“ ;T:~

L --- - -.

GRLO:: D

‘1

—

TYPICAL POWER WIRING DIAGRAMS

‘- ‘ ‘cl

( )

,,o&---.–.7

5314:; ‘“M i 532-+.l_.i

PHA;:,J13~RAGE

-—.—. ~

—

CB2

101 102 [03

CBI

!d/A ON uINTS

380/415 /460 fi75V AL

104 105 106

107 108 109

110 !11 1[2

,.,

,2,

,, ~,, ,2JFS5

TO CO NT ROl-

TRANSFORM ER-TI

~380 V./5O-6O HZ. ]

[415 ‘/./50 HZ.

N/A (,N uINTS 380/4 i5j463fi75V AL

460 V./6O HZ.

113 H4 115

575 V./6O HZ.

IM 377 I Page 27

THR 040D THRU 080 D–SINGLE POINT 208/230 – AL, PW

-L. —

-H-

I ~–

53’ +---l

PHASE $OL:,16E MO PIITOA

101

102

103

IG4

!05 106

107 108 109

110

Ill

112

—.

TZ<,

—-

TO COtJTROL

TRANSFORMER-T1

113 114 1,5

Page 28 I IM 377

THR 090D THRU 11OD–SINGLE POINT 208/230 & 380/41 5/460/575 – AL, PW

_ i.

—

101 102 103

104

105

106

—

—,

107

(08

109

8 9

110 Ill

112

-W: OMPR,

●2

-B5

113

114 115

‘OcOTROL rgmTRANSFORM ER-TI

IM 377 I Page 29

THR-040D THRU 11OD—MULTIPLE POINT 380141514601575V — AL, PW

NO. I

I TI i, T3

PB2

GND LUG

PB I

TI T,

—

____ .—-=

530 +OLl

53 -+’ ‘v’” ~

532-b-L2—-_i

lJliS1:.&OL T AGE

—

CO~~R.

LlltE

No.

101

102

103

104 105 106

107 108

/’-’-

— N/A ON THR040D-080D UNITS

WITH 380/415 /’46O/’575V - AL

—

~. N/A ON 1HR040D-080D UNITS

NOTES :

PBI S PB2 ARE OMITTED ON 380/415 /460/575V

FOR UNIT SIZES WHR040-080D WHEN OVERLOAD OPTION 1S NOT USED.

FIELD CONNECT CIRCUIT NO. I DIRECTLY TO Ml CONTACTOR ANO CIRCUIT 2 TO M2 CONTACT OR.

- AL IACROSS LINE START I UNITS,

WITH 380/’4l5/46Ofi75V - AL

—’

10 II

115

Page 30 I IM 377

ELECTRIC E:;RCJ: +C

CIRCUIT

NO. 2

I I

—

NO.

THR-040D THRU 11OD– MULTIPLE POINT 208/230V – AL, PW

53o +Ll

53’ +’-2 ‘“MI

532 +-LI-J

~#f;EROL TAGE

101 102 103

_—_ —--

bq-

L-—-—. -.-J

I-—-—-___-i

104

105

106

[07 108 109

i10

Ill 112

113 114 !15

IM 377 I Page 31

THR-120D THRU 170D–SINGLE POINT 380/41514601575V – AL, PW

N/A ON THR 120D, 130D’

FROM D51 E PBI

— ,2

r, 12

—

“1 .3 “2 H4

!3J

—

~’”’ey<o

I ,,5

- N/A ON THR 120D.

—,20—

—,2(—;::

—122—

—130—

—,3, — —13*—

— ,33 —

Page 32 I IM 377

“. ., . .

THR-120D THRU 170D–SINGLE POINT 208/230V – AL, PW

. .

.,m!.

.. ,, ..—

,m..:~.

~~:.—

,,!

“..,,,,,, !..,

r..

“m,

.. ..

.,.,,, ,. ,., , . .. . .

<:~: ‘“‘=E:>

THR-120 THRU 170D–MULTIPLE POINT 2081230V & 380141514601575V – AL, PW

,(<.:,, . ,

!.. . .. . .

.,,. . ,. . .

. . . .

.,, #—

.,,

- ,,..

..,, -

.,,, —

,,.V.

r Ya-,,..

~“” +

l--’+

!,,,,

,-,,,.,

“WI T,.

:E:,

‘W ,

,.”., ,

,,’, ~

., ,,

‘k+ ..

%%,m.:.2L--

;$,,

,,,.

“W .,

co.,, .

..’

G”’

GE51

“i+ :.

./.. ......

s,.,, . .. . .. ..,,.

—,.,.

_,,..:*

–,-!1: .,, ,—

.,,..r.

.,,, .:::

IM 377 I Page 33

TYPICAL CONTROL & SAFETY WIRING DIAGRAMS

THR-040D THRU 11OD

L, 1~:’’:}:‘a-jJ

% 14

100

106

—-.

MJ45

$~’g:;”+–––+$––––+$-5’2–

2.;’~2.+

MI-NIX

l---#2~,~,

,37g13*:llo&lll~ 18y{l#~122&.J

COMPRESSOR

c! RcUIT

COMPRESSOR

CIRCUIT

[ SEE REFRIGERATION SCHEMATIC I

NOTE : FOR EVAPORATOR WATER PUUP CYCL lNO

WITH COUPSESSORS. +~~EL10WIW~lP$122, sTASTER BETWEEN

)lTR-1

UP1

I12 197

INqERm’

TIME CSLAY

●[

NIA ON 0400 THRU OeOD 380/415/4607575 v. u.

LP2

-++ 2,4 &5 77?l++#+317

‘“n’

●2

& 235 +X+:=

143

“,:$&kiJ:

++.

105~126–

153

j-m

FS2 ‘ ‘

———

54 ml

to ~

N/A ON 040D THRU 0000 380/415/460/575 V. AL

,my ,

/*’ \

c1 C2

3 106

———

~8 ,,0 C2 23C

152-

252

-2GG -

-201 -

-202

-203 -

-204 —202 —

— 206 -

-207 -

-209 -

—210 -

—211 — — 212 -

— 220 —

-221 -

- =2 — ::

— 223 - 204

— 224 -

— 225 - 222

-226 - 222

— 227 —

B- *** - ~

— 229 -

-230 -

— 231 - :2:

-232 — 108

-233 -

— 245 - 317

—243 - 321

-260 -

-261 —

— 262 — 266.314

, — 263 — 206

,—264 —

— 265 - 262

-266 — 262

-267 -

— 268 - ;:,

-269 — 270 —

— 2?1 - ::!

’272 - !14

-273 -

T32

5G2dG3

4 5C’6,5C4

3 240

lm,144 4 m2sG7

5 2GG 6 303510 7 510,522 B 324J70 9 10 II 142 !2 242 13 M 514 15 16 512

515 ~ 107,207

88 518

670 19 100,208

20 21 22 23 ?4 2s 26 27 516,671 ?. 519

785

40 187,160

100 41 137.186

42 l10,13e 43 44 113,114

4s 135

64CJ 63 146,150

129,154 +7 115,116

118 43 111,112

49 In

123,127 50 1=,~

128 51 12+,125

52 53 54 55 5s 57 S3 5s 60 61 62 63

7! 287280

200 71 237

72 210,22S 73

213,214

~ 235

6s0 76 266,320 229,2s4 77 215.216 218 78 211,212

222 79 223,337 @ X5~

228 81 224.235

?3 84 85 86 8? 36 09 m 91 92 93

0 :?:J;3

o /::152

O [&641

O 199,243

0 206,253

0 236,651 0 247,28S

o 0

182,196

0 282,2%

O 185,285

Page 34 I IM 377

THR-120D THRU 170D

—,40

-“’*.’’”~’’”+&-

COMPRESSOR CIRCUIT ●I

COMPRESSOR

CIRCUIT*3

FSl

,,,,

M1-AUX

,0;:., “2 ‘

-,;TTJ~”_,

HTR-I

qiy

—,20 ”/60,, —

?------’’k--g

. .

,>, ,—.

‘ ,20.

— *m-

—,., —

?++’--’

)

COMPRESSOR Cl RCUlT#2

cOMPRESSOR CIRCUIT*4

,,,

219

8s 4,

;4ZI

—--M

*7. —*O?

,,, —

27.—;;:

*T7 — ,,, —

,,, –;:;

,,, —,2

*, I —

—?7.

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.(.

:;;:.

H “iiv

y:~,.,.

.,,,,

4,, ,0 .,,

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92 93

IM 377 I Page 35

TYPICAL HEATING ONLY THERMOSTAT WIRING DIAGRAMS

4-STAGE HEATING ONLY THERMOSTAT—THR 040, 050, 060, 070, 080, 090, 100, 11 OD

J@?.sA

,,”0”,.,.,, .,0, m,

509 “510 10 t“S1.LL TIME

,,0,, ,$40 ,... SWITCH

m.,.crs.

L+.J

‘1

R,,.!

274

c ,,

“4 *,6

Hot Gas Bypass and Phase/Volt Monitor Options

-304 -

—30. —

~~~’c’”~”

—,07—

-310—22,

-311—

—,,2—

-3,3—

—,!4 —

-3,5—

—,16-265

-,1, —

-,,.—

-,19 -

290

+.2,

2“e,,,.,—t,~.

-,20 -

-,2!—

-3a-

-,2, -

4-STAGE HEATING ONLY THERMOSTAT—THR 120, 130, 140, 150D

Hot Gas Bypass and PhaseNolt Monitor Options

TB4

I10

,7, ,,, 33!

,,2 y::

370 ,,3 !::

,,3. , ,4 ;:J ,,4. _

I ,5 1,6 ,,7

;j I ,8

,,9 357

,73

Im ::; (2, !22 !,3 ,24 2,0

,73 2,, 55.

2,2 :::

.70 2,3 ;EI

,93. ,,4 ;:J

284. _ 271

,,2 2!5

2)6 ,(7 ,,,

:;;

4,, 2,9 5.,

~ ::

221 222 223 224

Page 36 I IM 377

,,..”, .,.,, .,0, ..0

.,,0 ,. ,.,,.,, ,!., .,.,. ,., ,,..

,.”,,,,

6-STAGE HEATING ONLY THERMOSTAT–THR 070, 080, 090, 100, 11OD

Hot Gas Bypass and Phase/Volt Monitor Options

,.,,,.

.,..”

;;; =

‘

c “(

REM,

,77

c “(

,,,.”

“’-t%

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, ,,,.

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.,l. —

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.,,7 —

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320-

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322—

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3,5—

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212

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*,. ,,0 2!3 ;:L

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6-STAGE HEATING ONLY THERMOSTAT–THR 120, 130, 140, 150, 160, 170D

Hot Gas Bypass and Phase/Volt Monitor Options

,,,*—Y

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-,os —

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—,11—

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—,,, —

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–,,, —

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-323-

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-32,—269

6-STAGE HEATING ONLY THERMOSTAT—THR 120, 130, 140, 150, 160, 170D

.. .

Hot Gas Bypass and Phase/Volt Monitor Options

10‘z~.,[iG3&”~p

, , , W,,,* ,,”. .,”,,,

271+272

>:2’32“ “4 :: ‘ 5“%2’’=2”- 2“ 2’”:2”

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,,0

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2,0

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533~~534

PH/VOLT MONITOR

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Page 38 I IM 377

TYPICAL HEAT/COOL THERMOSTAT WIRING DIAGRAMS

4-STAGE HEATICOOL THERMOSTAT–THR 040, 050, 060, 070, 080, 090, 100, 11OD

Hot Gas Bypass and Phase/Volt Monitor Options

-3m--

-344-

-3n-

-97-

.m8--

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ns-

11 11 1 lZ 1 1 12 2!

SI n

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4-STAGE HEATICOOL THERMOSTAT—THR 120, 130, 140, 150D

Hot Gas Bypass and Phase/Volt Monitor Options

I 1

,,e~

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I I

Ill

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m —

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2 22 2?.

11 11

121 12 12 12 21

21 a

IM 377 I Page 39

6-STAGE HEAT/COOL THERMOSTAT–THR 070, 080,090, 100, 110D

Hot Gas Bypass and Phase/Volt Monitor Options

M.=

-w7-

k9-

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6-STAGE HEATICOOL THERMOSTAT—THR 120, 130, 140, 150, 160, 170D

Hot Gas Bypass and Phase/Volt Monitor Options

,274

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Page 40 I IM 377

-=+-m

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8-STAGE HEATICOOL THERMOSTAT—THR 120, 130, 140, 150, 160, 170D

Hot Gas Bypass and PhaseNolt Monitor Options

~85!-.&.- .95,4

129V. ,69 man Snmx

“77-+-%’’3+’7’-

AIR RESET DIAGRAM

810

i I

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274

277 r. w 27s—

1-l

216

l—

— ,,,

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w,. h,.

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LINE CONT.

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IM 377 I Page 41

Table 23. Drawing Reference Decision Table for Compressor Power Schematics.

NOTE: Each unit will have three electrical schematics: Power, Safety & Control, and Thermostat.

THR UNIT SIZE

040 THRU 080D

DRAWING

NUMaER

705192D-01

SINGLE

MULTIPLE

POINT

380141514601575V

2081230V

080, 100,1IOD

120 THRU 170D

040 THRU 11OD

120 THRU 11OD

040 THRU 11OD

120 THRU 170D

705191D-01

583403D-01

705190D.01

7051911-1-o1

583402D-01

705198D-01

583404D-01

705199D-01

583404D-01

Table 24. Drawing Reference Decision Table for Control and Safety Schematics.

Page 42 I IM 377

UNIT SIZE

040 THRU 110D

120 THRU 170D

DRAWING

NUMBER

706219D-01

583435D-01

Table 25. Drawing Reference Decision Table for Heating Only Thermostat Control Schematics.

DRAWINGNO.

WITHOUT

THR uNIT SIZE

OUTOOORAIR

OR LOW SOURCE

wATER RESET 583171C-02

WITH

1 CIRCUIT

583172C-02 58335L7C-02

+$=$=

583362C-02

563167C-02 583342C-02

563168C-02

563356C-02

‘H

ZERO OR 2 CIRCUITS

WITHOUT 6

120 – 170D

4 040 – 11OD

070- 11OD

120- 170D

D4O-11OD

120- 150D

O7O-11OD

120-1700

583360C-02

583169C-02

583170C-02 583357C-02

563361C-02

583165C-02 583341C-02 583166C-02

563355C-02

583359C-02

DRAWINGNO.

WITH

OUTOOORAIR

OR LOW SOURCE

WATER RESET

551515C-OIC

551519C-01

551525C-01

551529C-01

551513C-01 551521C-01

551517C-01 551523C-01

551527C-01 551514C-01

551516C.01

551524C-01

551528D-01

551512C-01 551520C-01 551516C-01

551522C-01

551526D-01

1 CIRCUIT

I I

ZERO OR

2 CIRCUITS

WITHOUT

wITH

040- 11OD

070 – 11OD

120- 170D

8 120- 170D

4 040-1100

070- 11OD

8 120–170D

040-1100

O7O-11OD

120– 170D

563163C-02

563164C-02 583346C-02

563350C.02

563159C-02 563340C-02

563160C-02

583344C-02

563348C-02

563161 C-02

583162C-02

583345C-02

583349C-02

563157C-02 563339C-02 563156C-02

563943C-02

563347C-02

IM 377 I Page 43

Table 26. Drawing Reference Decision Table for Heat/Cool Thermostat Control Schematics.

WITH

1 CIRCUIT

+=$==

DRAWINGNO. DRAWINGNO.

WITHOUT

OUTOOORAIR OUTOOORAIR

THR UNIT SIZE

OR LOW

SOURCE

wATER RESET WATER RESET

551533C-01

551537C-01 551543C-01

551531C-01 551539C-01

551535C.01

551541C-01

WITH

OR LOW SOURCE

‘e

551532C-01

551536C-01

551542C-01

120- 170D

551530C-01 55T538C-01 551534C-01

551540C-01

563163C-02

583164C-02 563346C-02

583350C-02

563159C-02 5~3340C-02

563160C-02

583344C-02

551544C-01

5515461=01

551545C-01

551547C-01

NOTES:

1. For units with reset diagrams not listed contact McQuay Service.

2. Diagrams for 8-stage heat/cool units are as follows:

● Unit application: 583455D-01

● Remote control panel with outdoor air/low source water reset: 551576D-01

● Remote control panel without reset: 551570D-01.

44 I IM 377

Page

563346C-02

563161 C-02

563162C-02

563345C-02

120- 170D

B 120- 170D

563349C-02

563157C-02 583339C-02 563156C-02

583943C-02

563347C-02

STARTUP AND SHUTDOWN

PRE STARTUP

1. With the main disconnect switch open, check allelec. trical connections in control panel and starter to be sure they are tight and provide good electrical contact. Although connections are tightened at the factory, they may have loosened enough in shipment to cause a malfunction.

2. Check and inspect all water piping. Make sure flow direction is correct and piping is made to correct connection on evaporator and condenser.

3. Open all water flow valves to the condenser and evaporator.

4. Flush the cooling tower (when used) and system piping. Start evaporator pump and manually start condenser pump and cooling tower. Check all piping for leaks. Vent

the air from the evaporator and condenser water circuit as well as from the entire water system. The evaporator circuits should contain clean, non-corrosive water.

5. If water regulating valves are provided, connect the control capillary to the manual valves provided on the condensers and open the manual valves.

6. Check to see that the water temperature thermostat sensor is installed in the entering water line to the condenser.

7. Making sure control stop switch S1 is open (off) and

STARTUP

1. Open the compressor suction and discharge shutoff valves until backseated. Always replace valve seal caps.

2. Open the manual liquid line shutoff valve.

3. Check to see that the unit circuit breakers are in the “off” position.

4. Check to see that the pumpdown switches PS1 and PS2 are in the “manual pumpdown” position and the con-

trol system switch S1 is in the “off” position.

5. Throw the main power and control circuit disconnects to the “on” position.

6. Verify crankcase heaters have operated for at least 12 hours prior to startup. Crankcase should be warm. in the refrigerant sightglass.

7. Adjust the dial on the temperature controller to the

pumpdown switches PSI and PS2 are on “manual pumpdown,” throw the main power and control discon-

nect switches to “on. ” This will energize crankcase heaters. Wait a minimum of 12 hours before starting up unit.

8. Check compressor oil level. Prior to startup, the oil level should cover at least one-third of the oil sightglass.

9. Check water pressure drop across evaporator and condenser, and see that water flow is correct per the pressure drop data on pages 7 and 10.

10. Check the actual line voltage to the unit to make sure it is the same as called for on the compressor nameplate

within + 10% and that phase voltage unbalance does not exceed 2%. Verify that adequate power supply and conductor size is available to handle load.

11. Make sure all wiring and fuses are of the proper size.

Also make sure all interlock wiring connections are com-

pleted per McQuay diagrams.

12. Verify that all mechanical and electrical inspections by code authorities have been completed.

13. Make sure all auxiliary load and control equipment is operative and that an adequate cooling load is available for initial startup.

desired hot and/or chilled water temperature.

8. Start the auxiliary equipment for the installation by turning on the time clock, ambient thermostat and/or remote

on/off switch and chilled water pump.

9. Check resets of all safety controls.

10. Switch the unit circuit breakers to on.

11. Throw pumpdown switches PSI and PS2 to “auto” for restart and normal operation.

12. Start the system by pushing the system switch S1 to on.

13. After running the unit for a short time, check the oil level in each compressor crankcase, and check for flashing

After system performance has stabilized, it is necessary that the ‘‘Compressorized Equipment Warranty Form” (Form No. 206036A) be completed to obtain full warranty benefits. This form is shipped with the unit and after

completion should be returned to McQuayService through your sales representative.

WEEKEND OR TEMPORARY SHUTDOWN

Move pumpdown switches PSI and PS2 to the “manual pumpdown” position. After the compressors have pumped down, turn off the evaporator water pump. NOTE: With the unit in this condition, it is capable of recycling pumpdown. To defeat this mode of operation, simply move control system

STARTUP AFTER TEMPORARY SHUTDOWN

1. Start the evaporator water pump.

2. With the control system switch S1 move the pumpdown switches PSI pumpdown” position.

in the “on” position, sounds or possible cycling of compressors. and PS2 to the “auto

switch S1 to the “off” position.

It is important that the compressors pump down before the water flow to the unit is interrupted to avoid freeze-up in the evaporator.

3. Observe the unit operation for a short time, noting unusual

4. Check compressor crankcase heaters.

IM 377 I Page 45

EXTENDED SHUTDOWN

1. Close the manual liquid line shutoff valves.

2, After the compressors have pumped down, turn off the

chilled water pump.

3. Turn off all power to the unit.

4. Move the control service switch S1 to the “off” position.

5. Close the suction and discharge shutoff valves on the compressor(s) and the liquid outlet valve(s) at the condenser(s)

STARTUP AFTER EXTENDED SHUTDOWN

1.’ Inspect all equipment to see that it is in satisfactory operating condition.

2. If cooling tower is used, make sure it is clean and filled with water.

3. Open the compressor suction and discharge valves until backseated. Always replace valve seal caps.

4. Open the manual liquid line shutoff valves.

5. Check circuit breakers. They must be in the “off” position.

6. Check to see that the pumpdown switches PSI and PS2 are in the “manual shutdown” position and the control system switch S1 is in the “off” position.

7. Throw the main power and control circuit disconnects

to the “on” position.

8. Allow the crankcase heaters to operate for at least 12 hours prior to startup.

9. Start the chilled water pump and purge the water piping

6. Tag all opened disconnect switches to warn against startup before opening the compressor suction and discharge

valves.

7. Drain all water from the unit evaporator and chilled water piping if the unit is to be shut down during the winter and exposed to below freezing temperatures.

as well as the evaporator in the unit.

10. Start the auxiliary equipment for the installation by turning on the time clock, ambient thermostat and/or remote on/off switch.

11. Adjust the dial on the temperature controller to the desired hot and/or chilled water temperature.

12. Check resets of all safety controls.

13. Switch the unit circuit breakers to “on,”

14. Start the system by pushing the system switch S1 to “on. ” CAUTION: Most relays and terminals in the con-

trol center are hot with S1 and the control circuit discon-

nect on.

15, Throw pumpdown switches PSI and PS2 to the “auto

pumpdown” position for restart and normal operation.

16. After running the unit for a short time, check the oil level

in each compressor crankcase and for flashing in the refrigerant sightglass (see Maintenance section).

Page 46 I IM 377

SYSTEM MAINTENANCE

To assure smooth operation at peak capacity and to avoid damage to package components, a program of periodic inspections should be set up and followed. The following items are intended as a guide to be used during inspection and

must be combined with sound refrigeration and electrical

practices to assure trouble-free performance.

The liquid line sightglasslmoisture indicator on all circuits must be checked to be sure the glass is full and clear and the moisture indicator indicates a dry condition. If the indicator shows that a wet condition exists or if bubbles show in the glass, even with a full refrigerant charge, the filter-drier element must be changed.

Water supplies in some areas may tend to foul the water cooled condenser to the point where cleaning is necessary. The fouled condenser will be indicated by an abnormally high condensing pressure and may result in nuisance tripouts. To clean the condenser, a chemical descaling solution should be used according to the manufacturer’s directions.

CONTROL CENTER ELECTRICAL SERVICE

The electrical control center is relatively easy to service since

indicator lights are provided to show unit status. Determine

that the problem is actually in the control panel before proceeding.

By referring to the schematic wiring diagrams, the trouble

can be isolated to a particular section of the panel.

WARNING: Warranty is voided if field wiring is not in accordance with specifications. A blown fuse or tripped protector indicates a short ground or overload. Before replacing a fuse or restarting a compressor, the trouble must be found and corrected. It is important to have a qualified control panel electrician service this panel. Unqualified tampering with the con-

trols can cause serious damage to equipment and void the warranty.

GENERAL

A lead-lag switch

models to permit even distribution of wear on the compressors. This switch should be turned on on an annual basis.

The compressor oil /eve/ must be checked periodically to be sure the level is at the center of the oil sightglass. Low oil level may cause inadequate lubrication and oil failure switch tripout. If the oil level is low and oil must be added, use oils referred to in “Compressor Oil Level” section below.

A pressure tap has been provided on the liquid line downstream of the filter-drier and solenoid valve but before the expansion valve. An accurate subcooled liquid pressure and temperature can be taken here. The pressure read here could also provide an indication of excessive pressure drop

through the filter-drier and solenoid valve due to a clogging filter-drier.

NOTE: A normal pressure drop through the solenoid valve is approximately 3 psig at full load conditions.

The following steps should be taken prior to attempting any

service on the control center:

1. Study the wiring diagram so that you understand the operation of the TEMPLIFIER.

2. Before investigating trouble in the control center, check for burned out pilot lights by testing across the appropriate

terminals.

CAUTION: The panel is always energized to ground even though the system switch is off. If it is necessary to de-energize the complete panel including crankcase

heaters, pull main disconnect.

If motor or compressor damage is suspected, do not restart

until a qualified serviceman has checked the unit.

is provided on all multiple compressor

ELECTRICAL TERMINALS CAUTION: Electric shock hazard. Turn off all power before continuing with following service. All power electrical terminals should be retightened every six months, as they tend to loosen

in service due to normal heating and cooling of the wire.

COMPRESSOR OIL LEVEL

The oil level should be watched carefully upon initial startup and for sometime thereafter.

At the present time, Suniso No. 3GS, Calumet RO15, and Texaco WF32 oils are approved by Copeland for use in these compressors. The oil level should be maintained at about onethird of the sightglass on the compressor body.

Oil may be added to the Copeland compressor through the oil fill hole in the crankcase. To add oil, isolate the crankcase and pour or pump in the necessary oil. If the system contains no refrigerant, no special precautions are necessary other

than keeping the oil clean and

dry.

If the system contains a refrigerant charge, close the suc-

“tion valve and reduce crankcase pressure to 1 to 2 psig. Stop

the compressor and close the discharge valve.

Add the required amount of oil. During the period the com-

pressor is exposed to the atmosphere, the refrigerant will generate a vapor pressure, retarding the entrance of contaminants. Before resealing the compressor, purge the crankcase by opening the suction valve slightly for 1 or 2 seconds. Close the oil port, open the compressor valves and restore the system to operation.

IM 377 I Page 47

REFRIGERANT SIGHTGLASS AND MOISTURE INDICATOR

The refrigerant sightglasses should be observed period- pressure drop in the line, possibly due to a clogged filter-drier

ically. (A monthly observation should be adequate.) A clear or a restriction elsewhere in the system. An element inside

glass of liquid indicates that there is adequate refrigerant

the sightglass indicates what moisture condition corresponds charge in the system to insure proper feed through the ex- to a given element color. If the sightglass does not indicate pansion valve. Bubbling refrigerant in the sightglass indicates a dry condition after about 12 hours of operation, the unit that the system is short of refrigerant charge. Refrigerant gas

should be pumped down and the filter-driers changed. flashing in the sightglass could also indicate an excessive

LEAD-LAG

A standard feature on all McQuay TEMPLIFIERS is a system

for reversing the sequence in which the compressors start.

quence is compressor #2, then compressor #l. It is achieved electrically by multi-pole switching arrangement (see “Con-

For example, on a unit with the lead-lag switches in the “cir- trol Schematics” on pages 38 through 40). It is suggested

cuit 1 leads” position, the normal starting sequence is com- that the lead-lag switches in the unit control center be swit-

pressor #l, then compressor #2. With the lead-lag switches ched annually to provide even compressor life. in the “circuit 2 leads” position, the reversed starting se-

CRANKCASE HEATERS

The compressors are equipped with crankcase heaters. The When a system is to be started up initially in cold ambient, 20 hp and larger model compressors have heaters inserted the power to the heaters should be turned on for some time into the crankcase. The function of the heater is to keep the temperature in the crankcase high enough to prevent refrigerant from migrating to the crankcase and condensing in the oil during off-cycle.

(at least 12 hours) before the compressor is started. The crankcase should be up to about 80” F before the system is started up, to minimize lubrication problems or liquid slugging of compressor on startup.

Page 48 I IM 377

SYSTEM SERVICE

NOTE: Service on this equipment is to be performed by qualified refrigeration personnel. Causes for repeated tripping of safe-

ty controls must be investigated and corrected.

CAUTION: Disconnect all power before doing any service inside the unit.

FILTER-DRIERS

To change the filter-drier, pump the unit down by moving pumpdown switches PSI and PS2 to the “manual pumpdown” position.

UNITSIZE

040D THRU 170D

NOTE:Jumpersshouldbelongenoughtohangoutofthepanelandprevent the door from closing. This will insure jumper removal after unit is pumped-down.

Move the control switch S1 to the “off” position. Turn off all

power to the unit and install jumpers across the terminals shown in the table. This will jump out the low pressure control. Close the manual liquid line shutoff valve(s). Turn power

The liquid line solenoid valves, which are responsible for automatic pumpdown during normal unit operation, do not normally require any maintenance. However, in the event of failure they may require replacement of the solenoid coil or of the entire valve assembly.

The solenoid coil may be removed from the valve body without opening the refrigerant piping by moving pumpdown switches PSI and PS2 to the “manual pumpdown” position.

CIRCUITNO.

1 44 to 48 2 74 to 78

JUMPERACROSS

TERMINALS

LIQUID LINE SOLENOID VALVE

to the unit back on and restart the unit by moving the control switch S1 to the “on” position. The unit will start pumping down past the low pressure setting. When the evaporator pressure reaches Oto 5 psig, move control switch S1 to the “off” position. BE SURE TO REMOVE THE JUMPER.

Frontseat the suction line King valve(s). Remove and replace the filter-drier(s). Evacuate the lines through the liquid line manual shutoff valve(s) to remove non-condensables

that may have entered during filter replacement. A leak check

is recommended before returning the unit to operation.

THR UNIT SIZE

040 thru 1IOD

120 thru 170D 2 — Core Replaceable

NOTE: On Arrangement A units, the filter-drier cores are shipped in the unit control box and are to be installed prior to evacuating and charging the unit.

The coil can then be removed from the valve body by simply removing a nut or snap-ring located at the top of the coil. The coil can then be slipped off its mounting stud for replacement. Be sure to replace the coil on its mounting stud before returning pumpdown switches PSI and PS2 to the “auto pump-

down” position.

To replace the entire solenoid valve, follow the steps in-

volved when changing a filter-drier.

TYPE FILTER-DRIER

Sealed Core

THERMOSTATIC EXPANSION VALVE

The expansion valve is responsible for allowing the proper amount of refrigerant to enter the evaporator regardless of cooling load. It does this by maintaining a constant superheat. (Superheat is the difference between refrigerant temperature as it leaves the evaporator and the saturation temperature corresponding to the evaporator pressure.) All TEMPLIFIERS are factory set for between 80 F and 120 F superheat, at leaving source water temperatures near the maximum allowed, superheats can be expected to rise above this setting. If it is necessary to increase the superheat setting of the valve, remove the cap at the bottom of the valve to expose the ad-

justment screw. Turn the screw clockwise (when viewed from

the adjustment screw end) to increase the superheat and counterclockwise to reduce superheat. Allow time for system rebalance after each superheat adjustment.

Unit operation near the maximum leaving source water

temperature on a TEMPLIFIER unit can trigger the “Max-

imum Operating Pressure” (MOP) characteristic built into the units expansion valves. At higher leaving source water

temperatures and loads, the “MOP” will occur when the ex-

pansion valve and control bulb pressure reaches a predeter-

mined maximum value. Further increases in bulb temperature above the “MOP” point causes virtually no increase in bulb pressure. As a result adequate increases in refrigerant flow to the evaporator are no longer possible, and the ability of the unit to handle increases in load is limited. Once the

“MOP” for the expansion valve is reached. increases in suction superheat can be expected source water temperature.

near the maximum leaving

The expansion valve, like the solenoid valve, should not

normally require replacement, but if it does, the unit must be pumped down by following the steps involved when changing a filter-drier.

If the problem can be traced to the power element only, it can be unscrewed from the valve body without removing the valve, but only after pumping the unit down.

WARNING: Adjustment of expansion valve should only be

performed by a qualified service technician.

Figure 22.

Inlet

~, :..

li7r-

‘“ I,.,,,,. .._.(contains ‘iaphragm)

~.. ,

/ . . . ... ...

p(l-1

> ik

i!!li!z

Power Element

Outlet

Adjustment Screw Cap

IM 337 I Page 49

EVAPORATOR

The evaporator is of the direct expansion, shell-and-tube type with refrigerant flowing through the tubes and water flowing

through the shell over the tubes. The tubes are internally finned to provide extended surface as well as turbulent flow of refrigerant through the tubes. Normally no service work

is required on the evaporator. There may be instances where a tube will leak refrigerant into the water side of the system. In the cases where only one or two tubes leak, the problem can best be solved by plugging the tube at both ends. When

the tube must be replaced, the old tube can be removed and

replaced.

To remove a tube, the unit should be temporarily pumped down. Follow the steps involved when changing a filter-drier. These steps will insure a minimum amount of refrigerant loss when the evaporator is opened up. The tubes are mechan-

ically expanded into the tube sheets (see Figure 23) at each end of the cooler. In order to remove the tubes, it is necessary to break this bond by collapsing the tube. After doing this at both ends of the shell, the tube can be removed for replacement. The new tube can then be inserted and re-expanded into the tube sheet.

NOTE:

The bond produced by expansion must be refrigerant tight. This bond must be produced by applying Locktite (red) to the tube and rolling it into the tube sheet.

After re-assembling the evaporator, a small amount of refrigerant should be introduced by momentarily opening the manual liquid line valve. A leak check should then be performed on the evaporator.

Tube removal can only take place after the leaking tube

is located. One method that would work would be to subject

each tube to air pressure by plugging each end and, with a pressure gauge attached to one of the end plugs, observing if there is a loss of air pressure over a period of a minute or two.

Another method is to place a cork plug in each tube on both ends of the cooler and applying pressure to the shell of the cooler. After a period of time, the pressure will leak

from the shell into the leaking tube or tubes and pop out the

cork plug.

Figure 23.

Top View of Typical Dual Circuit Shell-and-Tube Evaporator

Liquid Connections

Suction Connections

k“ L

\\~

WATER COOLED CONDENSER

The condenser is of the shell-and-tube type with water flowing through the tubes and refrigerant in the shell. External

finned copper tubes are rolled into steel tube sheets. Integral

L–

I r-

& ~~’r.ozzles ~

Water Baffles

II II

—.

Refrigerant Tubes

Tube Sheets ~

11 11

1 I

‘T R

subcoolers are incorporated on 40 ton and larger units. All

condensers are equipped with 450 psig relief valves.

IN-WARRANTY RETURN MATERIAL PROCEDURE

COMPRESSOR

Copeland Refrigeration Corporation has stocking wholesalers who maintain a stock of replacement compressors and service parts to serve refrigeration contractors and service personnel.

When a compressor fails in warranty, contact your local sales representative, or the McQuay International Warranty Claims Department at the address on the back cover of this

bulletin. You will be authorized to exchange the defective compressor at a Copeland wholesaler, or an advance replacement can be obtained. A credit is issued you by the wholesaler for the returned compressor after Copeland factory inspection of the inoperative compressor. If that compressor is out

of Copeland’s warranty, a salvage credit only is allowed.

Page 50 I IM 377

Provide McQuay with full details; i.e., McQuay unit model and unit serial numbers. Include the invoice and the salvage value

credit memo copies and we will reimburse the difference. In this transaction, be certain that the compressor is definitely defective, If a compressor is received from the field that tests satisfactorily, a service charge plus a transportation charge will be charged against its original credit value.

On all out-of-warranty compressor failures, Copeland offers the same field facilities for service and/or replacement as described above. The credit issued by Copeland on the returned compressor will be determined by the repair charge established for that particular unit.

COMPONENTS OTHER THAN COMPRESSORS

Material may not be returned except by permission of authorized factory service personnel of McQuay International. A “return goods” tag will be sent to be included with the returned material. Enter the information as called for on the tag in order to expedite handling at our factories and prompt issuance of credits.

The return of the part does not constitute an order for replacement. Therefore, a purchase order must be entered through your nearest McQuay representative. The order

APPENDIX – STANDARD CONTROLS

NOTE: PERFORM AN OPERATIONAL CHECK ON ALL UNIT SAFETY CONTROLS ONCE PER YEAR.

THERMOSTAT—THR HEATING UNITS

should include part name, part number, model number and serial number of the unit involved.

Following our personal inspection of the returned part, and

if it is determined that the failure is due to faulty material or workmanship, and in warranty, credit will be issued on customer’s purchase order.

All parts shall be returned to the pre-designated McQuay

factory, transportation charges prepaid.

The thermostats supplied on all Templifiers are factory calibrated for use in the return water line to the condensers inlet. The thermostat bulb is installed in a well in the return water line in order to be more stable under temperature changes due to load conditions. The return water does not change temperature as rapidly as the outlet because of the “flywheel effect” of the total water system. This results in stable control of the outlet water temperature. Normally the

thermostat requires no adjustment in the field other than the dial setting for the required control point. The control will maintain an average leaving water temperature corresponding to dial setpoint (SPA) throughout the loading and unloading sequence of the unit. It should be realized, however, that there

cycles, unloads and loads.

The throttling range is adjustable from 1“F to 3° F per output relay via the TRA dial and is factory set at 3F. The control setpoint is adjustable from 120F to 150F via the SPA dial and is field set to meet application. The ambient operating temperature limits of the control is from 0F to 140” F.

Although the central processor CPI is calibrated at the factory, it may be necessary to re-calibrate the control should any changes in unit operation be made in the field. Refer to Installation and Maintenance Bulletin No. 348 for a more complete description of the control’s application, settings and ad-

justments, and checkout procedure. Note: See page 12 for

thermostat bulb installation.

will be fluctuation in the leaving water temperature as the unit

OIL PRESSURE SAFETY CONTROL

The oil pressure safety control is a manually resettable device

Figure 24.

which senses the differential between oil pressure at the discharge of the compressor oil pump and suction pressure inside the compressor crankcase. When the oil pressure reaches approximately 15 psi above the crankcase suction pressure, the pressure actuated contact of the control opens from its normally closed position. If this pressure differential cannot be developed, the contact will remain closed and energize a heater element within the control. The heater element warms a normally closed bimetallic contact and causes the contact to open, de-energizing a safety relay and breaking power to the compressor.

It takes about 120 seconds to warm the heater element

enough to open the bimetallic contact, thus allowing time for

Pressure Actuator

Contact

Line

Note 1

Line

Note 2

Bimetallic COntaCtS

NOTES: 1 Hot only when the un,t thermostat calls for compressor to run

2 Hot onlv when other safety control contacts are closed

Heater Element

Safety Relay

Neutral

the pressure differential to develop.

If during operation, the differential drops below 10 psi, the heater element will be energized and the compressor will stop. The control can be reset by pushing the reset button on the control. If the compressor does not restart, allow a few minutes for the heater elements and bimetallic contacts to

cool and reset the control again.

To check the control, pump down and shut off all power

to the unit. Open the circuit breakers or the fused discon-

nect for that compressor and install a voltmeter between ter-

minals L and M of the oil pressure control. Turn on power to the unit control circuit (separate disconnect or main unit disconnect depending on the type of installation). Check to

see that the control stop switch S1 is in the “on” position. The control circuit should not be energized, but with the absence of compressor power, no oil pressure differential can

develop and thus the pressure actuated contacts of the control will energize the heater element and open the bimetallic contacts of the control within 120 seconds. When this hap-

pens, the safety relay is de-energized, the voltmeter reading will rise to 115V, and the compressor contactor should open.

Repeated operations of the control will cause a slight heat

buildup in the bimetallic contacts resulting in a slightly longer time for reset with each successive operation.

IM 377 / Page 51

COMPRESSOR LOCKOUT

This feature locks out the compressor and prevents restart-

Figure 25. Compressor Lockout

ing for5 minutes after previous shutdown. The R9 relay is de-energized with Ml and the normally open contacts 4 and 6 open in parallel with TD1. After 5 minutes, TD1 contacts 1 and 2 time close, permitting the R5 safety relay to energize

and Ml to close on a demand for cooling. As soon as the com-

pressor starts, R9 is energized and normally open contacts 4 and 6 close, bypassing TD1 contact, permitting normal operation, The timer operation for the other compressor circuit is similar.

J-----qa---+--

NEUTRAL

LPI

—--%+’1

LINE

To check the control, the compressor must be running initially, Move the pumpdown switch PS1 or PS2 to the “manual pumpdown” position. Immediately after the compressor has stopped running, move the pumpdown switch back to the “auto pumpdown” position. The compressor should not restart for 5 minutes. Each refrigerant circuit can be checked the same way,

Notes:

Line is only hot when freeze control and high pressure control permit safe

operation

2. Line is only hot when oil pressure and compressor protection modules are closed.

HIGH PRESSURE CONTROL

The high pressure switch will shut down the compressor and The water cooled condensers are supplied with a 450 psig close the liquid line solenoid valve when the compressor discharge pressure reaches 380 psig. To check the control, slowly throttle the condenser inlet water or shut down the condenser fan. Observe the cutout point. During testing, stand

relief valve, After testing the high pressure control, check the

pressure relief device for leaks.

Caution: Although there isa pressure relief device in the

system set at 450 psig, it is highly recommended that the “con- by the system switch to shut down the unit should the safety trol stop” switch S1 be close at hand in case the high pressure device malfunction, Be sure the gauges used are accurate. control should malfunction.

LOW PRESSURE CONTROL

The low pressure control is a single pole pressure switch that closes on a pressure rise. The control senses evaporator pressure and must be set to suit unit application, refer to the nominal low pressure setting table for approximate control setting. To check the control (unit must be running), move the pumpdown switch(es) PSI and PS2 to the “manual pumpdown” position. As the compressor pumps down, the evaporator pressure will drop. The lowest evaporator pressure reached before cutout is the cutout setting of the control. Wait for the compressor lockout time delays TD1 and TD2 to time out, By moving the pumpdown switch(es) PS1 and PS2 to the

FREEZESTAT

The freezestat is a pressure type control connected to the low side of the system and is set to shut down the system when the pressure drops low enough to be dangerous as far as cooler freeze-up is concerned. The control must be set to suit unit application, refer to nominal freezestat setting table for approximate control setting. When dropping to this point, the normally open pressure actuated contacts of this control will

close, energizing a 115 volt heater. This causes the normally closed bimetallic relay switch of this control to open after a delay of approximately 60 seconds or less, stopping the com-

pressor and closing the liquid line solenoid valve. The time delay prevents nuisance trip-out on momentary low suction pressure and permits the operation of the system on a ‘pumpdown “cycle.”

The control must be checked while the system is operating.

To check the control, install a voltmeter or neon test light

Table 26. Nominal Low Pressure Cut-Out Settings

R-22 REFRIG.

Auto Reset

Note: Settings may vary from the nominal values shown to suit the particular

urmt application

LPI LP2

Cut-Out Press.

Reset Press. 60

35 psig

psig

“auto pumpdown” position, evaporator pressure will rise. The highest evaporator pressure reached before compressor restart is the cut-in setting of the control.

Table 27. Nominal Freezestat Pressure Settings

R-22 REFRIG.

Cut-Out Press

Reset Press.

Manual Reset

Note:

Settings may vary from the nominal values shown to suit the particular

unit application

FS1 , FS2

psig

57 psig

across terminal T1 and T2 of the low pressure freeze control. There should be a voltage indication or the test light will glow, indicating the contacts are opened. Throw the pumpdown switch to the manual position and check the pressure at which

the test light goes out or the voltmeter goes to zero. In actual operation, the compressor will shut down and the safety light will go out. The control can be manually reset in about 2

minutes.

Page 52 / IM 377

COMPRESSOR MOTOR PROTECTOR

The solid-state compressor motor protector module incor- Figure 26. porates a 2-minute “time off” relay utilizing the bleed down capacitor principle. Any time the protection system opens or power to the module is interrupted, the 2-minute “time off” delay is triggered, and the module will not reset for 2

rTIir7UteS. LINE ~~ “~

Once the 2-minute period is passed, the motor protector contacts 1 and 2 reset, provided the protection system is satisfied and power is applied to the module.

APPENDIX – OPTIONAL CONTROLS

PART WINDING START (OPTIONAL)

MP1

——

rj ~I

4L--&~~:+

—

,.,

$,,,.,.

Part winding start is available on all units and consists of a solid-state time delay wired in series with the contactor that energizes the second winding of each compressor motor. Its purpose is to limit current inrush to the compressors upon startup. As each compressor starts, the contactor of the first motor winding is delayed for 1 second.

Control checkout is best accomplished by observation as each contactor is pulled in to see that the 1 second delay occurs before the second contactor pulls in.

PHASE/VOLTAGE MONITOR (OPTIONAL)

The phase/voltage monitor is a device which provides pro-

tection against three-phase electrical motor loss due to power failure conditions, phase loss, and phase reversal, Whenever

any of these conditions occur, an output relay is deactivated,

disconnecting power to the thermostatic control circuit. The compressor will automatically pump down.

The output relay remains deactivated until power line con-

ditions return to an acceptable level. Trip and reset delays

have been provided to prevent nuisance tripping due to rapid

power fluctuations.

When three-phase power has been applied, the output relay

should close and the “run light” should come on. If the out-

ALARM BELL

Figure 27. Part Winding Start Option

Compr Contactor

Line

5---dk+-

Note: Line is only hot when the unit calls for compressor to run.

Pari W,nd,ng

Time Delay

[al Mol., W,nd, ”g,

(R2 Motor Wmd,.g)

put relay does not close, perform the following tests.

Check the voltages between LI—L2, L1—L3-and L2—L3.

These voltages should be approximately equal and within

+ 10% of the rated three-phase line-to-line voltage.

If these voltages are extremely low or widely unbalanced, check the power system to determine the cause

of the problem.

If the voltages are good, turn off the power and interchange

any two of the supply power leads at the disconnect.

This may be necessary as the phase/voltage monitor

is sensitive to phase reversal. Turn on the power. The out-

put relay should now close after the appropriate delay.

(OPTIONAL)

Neulral

This option is available and is factory installed with a 24 volt

alarm bell which can be remotely mounted. The bell is wired into the control circuit so that it will sound whenever there is a failure due to an abnormal low pressure condition in the

evaporator, excessive head pressure, motor overheating or

low oil pressure. Page 25 shows location of bell in back of

the control box.

Figure 36. Alarm Bell Option

LINE

R2 1

=+’

FS1

LINE

-l

120V

24V

ALARM BELL

HP1 OPT MP1 RELAY

1 lY

-fY

NEUTRAL

—

5AFETY

IM 377 / Page

LOW SOURCE WATER UNOLADING CONTROL (OPTIONAL)

The low source water unloading senses the temperature of evaorator return water and partially unloads one or both compressor circuits. The control has an adjustable OF to 100F

temperature range with 3° F switch differential.

The purpose of the control is to prevent overcooking the

source water, which will result in low suction pressure at the compressor. Low suction pressure with the compressor at full load could result in damage to the compressor. A setpoint

is recommended for the low source water thermostat of

HOT GAS BYPASS (OPTIONAL)

This option allows passage of discharge gas to the evaporator

permitting operation at lower loads than available with compressor unloading, It also keeps the velocity of refrigerant gas

high enough for proper oil return at light load conditions. A solenoid valve in the hot gas bypass line is wired in parallel with the compressor unloader U1. Thus, the hot gas solenoid cannot open unless the compressor is operating in an unloaded mode. If only one hot gas valve is specified for the unit, the hot gas bypass is wired in the first refrigerant circuit and the lead-lag switches are therefore eliminated. The hot gas bypass option is also available for the second refrigerant circuit whereby the lead-lag switches remain.

The pressure regulating valve is factory set to begin open-

ing at 58 psig (32”F for R-22). This setting can be changed

approximately 10° F to 15° F below the design return water temperature. The unit is shipped from the factory with the control sensor clamped to the side of the return water line

neat the cooler connection. (See Figure 7 page 12). To check the control, the system should be operating at full load conditions. By slowly turning the dial setting up, the control should partially unload one compressor circuit. By continuing to dial the setting up, the second compressor circuit should unload depending on what the interstage differential is set at.

by changing the pressure of the air charge in the adjustable bulb. To raise the pressure setting, remove the cap on the bulb and turn the adjustment screw clockwise. To lower the setting, turn the screw counterclockwise. Do not force the ad-

justment beyond the range it is designed for, as this will

damage the adjustment assembly.

The regulating valve opening point can be determined by slowly reducing the system load while observing the suction pressure, When the bypass valve starts to open, the refrigerant line on the evaporator side of the valve will begin to feel warm

to the touch.

Caution: The hot gas line may become hot enough to cause

injury in a very short time: care should be taken during valve checkout.

Figure 29. Hot Gas Bypass Piping Diagram

~Discharge Line

Hot Gas BypassValve

Table 28. Hot Gas Bypass Valve Selection

~REFRIGERANT

R-22

VALVECONN. EXT. EQUALIZER

ODF (INCHES) CONN.

11%

After ExpansionValve

SAE FLARE

Figure 30. Hot Gas Bypass Adjustment Range

R-22

rn : 40

a 2

g K

z i

w n

u >

-1 u >

30 40 50 60 70 80 90

VENDOR PART NO. ADJUSTABLERANGE

(SPORLAN)

DRHE-6-55/70AR 55–70

------- -,, , - .- .... . ... ... -. .,,..-

tltlWU I k 15ULU AIAJU> I MEN I tlAIN-C

TEMP. (0 F) AT BULB LOCATION

(PSIG) NO.

100

IWCQUAYPART

NO.

229735D-00

110

Page 54 I IM 377

. . .

=-3

Alarm Bell

Comi)reaaor Counter

Freeze Control

Compreaaor Hour Meter High Pressure Control

THR CONTROLS, SETTINGS AND FUNCTIONS

.. .........

Alarm will sound whenever there is a failure condition through a eafety control.

I Dkdawthe number oftimes eachcompressor slarts and

stops.

Protects the evaporator from water freezeup, Time delay prevents nuisance trips.

Displaystotal hours each compressor has been operating.

Stops compressorwhen discharge pressure istoo high,

fiJNcTloN-””: .:””->

CTRI–4

FSI 2

HM1–4 HP1, 2

N/A

NIA NIA NIA

Setting varies with refrigerant

used & unit operating conditions

Refer to pg. 52 for approximate

NIA Ooens at 360 Dsia.

Manual through a safety or when conditions return to an

acceptable level.

N/A

Manual thru HP1. 2

Back or side of control box

Control box

Pressure

sensor on suction

line, Control in control box.

Control box Control Box

NIA

3 psig. fixed

N/A 65

psig fixed.

Low Pressure Control

Compreaaor Motor Protector (Texaalnstrumenta)

Oil Preaaure Control

Pumpdown Switch

Phaae/Voltage Monitor

Control Stop Switch Lesd-Lsg Switch

Solenoid Valvea,

Liquid

Lfna

Solenoid Valves, Hot Gaa Bypaas

Unit Thermostat (Maater)

(Used for pumpdown.) Stops compressorwhen suction pressure is too low,

Protects motorfrom high temperature by sensing winding

temperature,

StoDscompressorif oil mesaure droos belowsetpoint for

120 seconds

Used to manually pump down compressor circuit. Protects motor from power failure, phase loss, phase

reversal and undervoltage, Shuts down entire control circuit, Reverses sequence that compressors start in,

Close off liquid line for pumpdown

Close off hot gas line for pumpdown,

Measures return condenser water temperature to control com

Unit Thermostat (Satellite)

Low Source Water Thermoatst

Compressor Lockout Time Delsy

Psrt Winding Start Time Delsy Compraaaor Sequencing

Time Oelay -

Comoreaaor Unlosders

The McQuay THR TEMPLIFIER heat pump provides not only lower operating costs,

but lower installation costs, low maintenance costs and areater desian flexibility, in both

comfort and process cooling applications.

(D m

In order for McQuay to better serve our customers, feedback of recurring service pro-

blems or complaints dealt with in the field would be appreciated. Problems or complaints

I Adds additional stages ofheating tounitthermostat CPl. NIA NIA

Unloads compressor circuits if return water temperature is too low.

Prevents short cycling of compressors,

Reduces inrush amp draw on startup. Staggers compressor starfina to reduce inrush amD draw,

Solenoid valves on compressor heada to load or unload

I compressors (energize ~ounload; de-energize toload).

LPI. 2

MP1–4

OP1–4 Control box

Psi, 2 PVM

S1 S2

Svl , 2

SV5, 6

CP1

CP2 TC1l, R21, R22

TD1–4

TD5–8 TD1l–13

U1,2

Setting varies with refrigerant used & unit operating conditions

Refer to pg. 52 for approximate

psig oil pressure. if pressure

closes, energizing a 120 second

Auto/manual I NIA

N/A

On/off Circuitl leads Circuit2

Circuit 2 leads Circuit 1

NIA

120° to 150”F

Should be set to desired

condenser leaving water temp.

Adjustable O to 100” F, Auto Recommended setpoint 10—15°F below design source water temp.

5 minutes, Auto

1 second

TDII: 20 seconds TD12, 1340 seconds

N/A

can be reported to McQuay International by filling out a Product Quality Report (Form

. .

No. 2S-636-784). These forms are available from McQuav and sales reDresentative

organizations and should be routed back through these &ganizations to McQuay’s

Engineering and Marketing departments.

Control Box

Compressorjuncfion box

Control box

When conditions return to an N/A

acceptable level.

NIA NIA

NIA

120” to150° F

NIA

Control box

Control box Control box

line after filler-drier and before TEV.

Condenser section NIA

Control box. Sensor in return waterline from building to condenser,

Control box Control box

Control box NIA

I NIA

NIA

NIA On compressor NIA

Control box Control box

25 psig fixed.

15,000ohms

5 psig

NIA

NIACondenser section on liquid

Adjustable from 1°Fto3°F per stage.I pressor staging.

Adjustable thru CP1, 3°F fixed

NIA

Compressor Noisy or Vibrating

High ~scharge Pressure

Low Oischarge Pressure

High Suction Pressure

Low Suction Pressure

Compressor Will

Not Unload or Load Up

Compressor Loading/Unloading Intervals Too Short

Little or No Oil Preaeure

>omDressor

.osek Oil

Iotor

circuit ;ircuit Breakers )pen

:ompressorThermal

kotector Switch Open

‘reeze Protection )pens

TROUBLESHOOTING CHART

~...:“;:.’:.,,...,,f“:,”..,,,==+,,L,,#.&

‘.;5E’-$,?’~”?mwi@**-”’:-;’??=’:?”!-?“

1. Main switch, circuit breakers open.

2. Fuse blown.

3, Defective conlactor or coil.

4. System shut down by safety devices.

5. No cooling required.

6. Liquid line solenoid will not open.

7. Motor electrical trouble.

6. Loose wiring.

1. Flooding of refrigerant into crankcase.

2. Improper piping support on suction or liquid line.

3. Worn compressor. 1, Condenser water insufficient or temperature too high.

2, Fouled condenser tubes

3. Noncondensables in system

4. System overcharged with refrigerant 5, Discharge shutoff valve paflially closed.

6. Discharge check valve not opening fully.

1. Fault condenser temperature regulation.

2. Suction shutoff valve partially closed.

3. Insufficient refrigerant in system.

4. Low suction pressure.

5. Compressor operating unloaded.

1. Excessive load–high return source water temp.

2. Expansion valve overfeeding.

3. Compressor unloaders open.

1. Lack of refrigerant.

2. Evaporator dirty.

3. Clogged liquid line filter-drier.

4. Clogged suction line or compressor suction gas strainers.

5. Expansion valve malfunctioning.

6. Gasket failure in evaporator head ring.

7. Condensing temperature too low. 8 Compressor will not unload.

9. Insuticient water flow.

1. Defective capacity control.

2. Unloader mechanism defective.

3. Faulty thermostat stage or brcken capillary tube.

4. Stages not set for application.

1. Erratic water thermostat

2. Insufficient water flow.

3. Throttling range set wrong thermostat.

1. Clogged suction oil strainer.

2. Excessive liquid in crankcase

3. Oil pressure gauge defective.

4. Low oil pressure safety switch defective.

5. Worn oil pump. & Oil pump reversing gear stuck in wrong position.

7. Low oil level.

9. Loose fitting on oil lines.

3. Pump housing gasket leaks.

2. Flooding of refrigerant into crankcase. 1, Lack of refrigerant.

2. Excessive compression ring blow-by.

1. Low voltage during high load conditions. 2, Defective or grounded wiring in motor or power circuits. 3, Loose power wiring. $, High condensing temperature.

5. Power line fault causing unbalanced voltage.

5. High ambient temperature around the overload relay.

7. Failure of second starter

atart system

t. Operating beyond design conditions. ?. Discharge valve partially shut.

1. Blown valve plate gasket

1. Evaporator water temp. too low. 2 Low water flow. 3 Low suction pressure.

to pull in on part winding

Close switch. Check electrical circuits and motor winding for shorts or grounds.

Investigate for possibleoverloading. Replace fuse or resel

breakers after fault is corrected. Repair or replace.

Determine type and cause of shutdown and correct it before reset-

4. ting safety switch.

None. Wait until unit calls for heating or cooling.

5. Repair or replace coil.

Check motor for opens, short circuit, or burnout. Check all wire junctions. Tighten all terminal screws.

Check superheat setting of expansion valve. Relocate, add or remove hangers.

1. Readjust temperature control or water regulating valve. Investigate ways to increase water supply.

2, Clean.

3. Purge the noncondensables.

4. Remove excess refrigerant.

5. Open valve

6. Repair or replace discharge check valve.

1. Check condenser control operation.

2, Open valve.

3. Check for Ieaka. Repair and add charge.

4, See corrective steps for low suction pressure below

5. See corrective steps for failure of compressor to load.

1. Reduce load or add additional equipment.

2. Check remote bulb, Requlate superheat.

3. See corrective steps fo;failure of compressor to load.

1. Check for leaks. Repair and add charge.

2, Clean chemically.

3. Replace cartridge(s).

4. Clean strainers.

5. Check and reset for proper superheat. Replace if necessary.

6. Check AP across evaporator.

7. Check means for regulating condensing temperature.

6. See corrective steps for failure of compressor to unload. 9, Adjust gpm.

1. Replace.

2. Replace 3, Replace.

4. Reset thermostat setting to fit application.

1. Rer)lace.

2. Adjust gpm.

3. Adjust thermostat settings.

1. Clean. 2, Check crankcase heater. Reset expansion valve for higher

auperheal. Check liquid line solenoid valve operation.

3. Repair or replace. Keep valve closed except when taking reading

4. Replace. 5, Replace. 6, Reverse direction of compressor rotation by swiiching compressor

leads.

7. Add oil. B. Check and tighten system.

9. ReDlace gasket.

0. Adjust th;rmal expansion valve.

1. Check for leaks and repair. Add refrigerant. 2, Replace compressor.

1. Check supply voltage for excessive line drop.

2. Replace compressor-motor.

3. Check all connections and tighten.

4. See corrective steps for high discharge pressure.

5. Check supply voltage. Notify power company. Do not start until fault is corrected,

5. Provide ventilation to reduce heat.

7. Repair or replace starter or time delay mechanism.

t. Add facilities so that conditions are within allowable limits. ?. Open valve.

3. Replace gasket.

1. Raise evaporator water temp.

2. Adjust gpm.

1. See “Low Suction Pressure.”

Page 56 I IM 377

PRESSURE TEMPERATURE TABLE

34 60.1 68 38 62.8 70

65.9 72

38 40 68.5 74

42 71,5 44 74.5 76

77.6 80 143.6

48 82.7 82 148.4

105.4 96 184.6 130

76 134.5 110 226.4

117.3 102 201.8

121.4

125.7 106 213.8

130.0 108 220.0

139.0 112 232.8

104 207.7 138 328.4

114 239.4 148 372.3 116 246.1 150 381.5

296.8 164

136 320.6

140 337.3 142 345.8

144 354.5 146

363.3

450.4

IM 377 I Page 57

McQuay THR-060D Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual