McQuay WMC-145DBS Installation Manual
Installation Manua l
331374611
00
April 2012
IM 1029-2
Group: Chiller
Part Number:
Effective:
Supersedes: February 2011
Magnitude™ Magnetic Bearing Centrifugal Chillers
Model WMC-145SBS to 400DBS
HFC-134a
50/60 Hertz
Manufactured in an ISO Certified Facility
*
Applies to 60 Hz Units Applies to 60 Hz Units
Table of Contents
Introduction ........................................... 3
Nomenclature ................................................. 3
Installation ............................................. 4
Receiving and Handling ................................. 4
Location and Mounting ........................ 5
Wa te r Piping ................................................... 5
Field Insulation ............................................... 8
Physical Data and Weights ................... 9
Chiller Dimensions .............................. 11
Harmonic Filter Dimensions ........................ 17
Relief V alves ......................................... 21
Electrical Data ..................................... 23
Power Wiring ............................................... 23
VFD Line Harmonics ................................... 40
Fuses ............................................................ 42
System Pumps ..................................... 42
Multiple Chiller Setup ........................ 43
Prestart System Checklist .................. 45
Long Term Storage ............................. 46
Operation ............................................. 47
Operator Responsibilities ............................. 47
Compressor Operation ................................. 47
MicroTech II Control ................................... 48
Use with On-Site Generators ....................... 48
Building Automation Systems ...................... 49
*Unit Controllers are LonMark certified with an optional LonWorks communication module.
©2012 McQuay International. Il lustrations and data cover the McQuay Int ernational product at the ti me of publication and we reserve
the right to make changes in design and construction at anyt i me without notice.
™® The following are trademarks or regist ered trademarks of their res pective companies: BACnet from ASHRAE;
L
ONWORKS, and the LONMARK logo are managed, granted and us ed by LONMARK Int ernational under a license granted by Echelon
Corporation; Modbus from Schnei der E l ectric; MicroTech II, and Open Choices from McQuay International .
2 Magnitude™ Frictionless Centrifugal Chillers – Model WMC IM 1029-2
LONMARK, LonTalk,
!
DANGER
!
WARNING
!
CAUTION
Water-cooled
Magnetic Bearings
Centrifugal Compressor
D=Dual Compressors
Nominal Tons
Vintage/Single Circuit.
Introduction
General Description
The Daikin McQuay Magnitude™ Frictionless Centrifugal Chillers are complete, self-contained,
automatically controlled, fluid-chilling units featuring oil-free, magnetic bearing compressors. Each unit is
completely assembled and factory tested before shipment.
They are designed for indoor, non-freezing installation only.
Magnitude chillers are equipped with two compressors operating in parallel with a single evaporator and
single condenser. The model WMC 145S has a single compressor.
The chillers use refrigerant R-134a that operates at a positive pressure over the entire operation range, so no
purge system is required.
The controls are pre-wired, adjusted and tested. Only normal field connections such as water piping, relief
valve piping, electric power and control interlocks are required, thereby simplifying installation and
increasing reliability. Necessary equipment protection and operating controls are included.
All Daikin McQuay centrifugal chillers are factory-tested prior to shipment and must be commissioned by a
factory-trained McQuay service technician. Failure to follow this startup procedure can affect the equipment
warranty.
The standard limited warranty on this equipment covers parts that prove defective in material or
workmanship. Specific details of this warranty can be found in the warranty statement furnished with the
equipment.
Nomenclature
W M C 290 D BS
HAZARD IDENTIFICATION INFORMATION
Dangers indicate a hazardous situation which will result in death or serious injury if not
avoided.
Warnings indicate potentially hazardous situations, which can result in property damage,
severe personal injury, or death if not avoided.
S=Single Compressor
IM 1029-2 Magnitude™ Frictionless Centrifugal Chillers – Model WMC 3
Cautions indicate potentially hazardous situations, which can result in personal injury or
equipment damage if not avoided.
Compressor #2
Control Panel
Operator Interface
Rigging Holes
Evaporator
Condenser
Evap. Relief Valve
Power Panel
Inlet
Outlet
Compressor #1
Electronic Expansion Valve
Suction Shutoff Valve
Installation
Receiving and Handling
The unit should be inspected immediately after receipt for possible damage.
All Daikin McQuay centrifugal water chillers are shipped FOB factory and all claims for handling and
shipping damage are the responsibility of the consignee.
On units with factory-installed insulation, the insulation is removed from the vessel lifting hole (also used for
transportation tie-downs) locations and are shipped loose. They should be secured in place after the unit is
finally placed. Neoprene vibration pads are also shipped loose in a control panel.
If so equipped, leave the shipping skid in place until the unit is in its final position. This will aid in handling
the equipment.
Extreme care must be used when rigging the unit to prevent damage to the control panels and refrigerant
piping. See the certified dimension drawings included in the job submittal for the center of gravity of the unit.
If the drawings are not available, consult the local Daikin McQuay sales office for assistance.
The unit can be lifted by fastening the rigging hooks to the four corners of the unit where the rigging eyes are
located (see Figure 1). A spreader bar must be used between the rigging lines to prevent damage to the
control panels, piping and electrical panels. The spreader-bar length should be equal to, or no more then 1foot shorter than the distance between the lifting holes located at opposite ends of the chiller. The unit will
require a single spreader-bar of this length capable of supporting 1.5 times the shipping weight of the unit.
Separately, all cables and hooks by themselves must also be capable of supporting 1.5 times the shipping
weight of the unit.
Figure 1, WMC, Major Component Locat ions
Combined Discharge
Check and Shutoff Valve
(Behind Panel)
Relief Valves
Behind Panel
Each Corner
Condenser
4 Magnitude™ Frictionless Centrifugal Chillers – Model WMC IM 1029-2
Touch Screen, OITS
Location and Mounting
Location
WMC chillers are intended only for installation in an indoor or weather protected area consistent with the
NEMA 1 rating on the chiller, controls, and electrical panels. Equipment room temperature for operating and
standby conditions is 40°F to 104°F (4.4°C to 40°C).
Clearance
The unit must be mounted on a level concrete or steel base and must be located to provide service clearance at
one end of the unit for possible removal of evaporator and/or condenser tubes. Evaporator and condenser
tubes are rolled into the tube sheets to permit replacement if necessary. The length of the vessel should be
allowed at one end. Doors or removable wall sections can be utilized. Clearance at all sides, including the
top, is 3 feet (1 meter). The U.S. National Electric Code (NEC) or local codes can require more clearance in
and around electrical components (4-feet in front of electrical panels) and must be checked for compliance.
They are designed for indoor, non-freezing installation suitable for NEMA 1 enclosures.
Vibration Pads
The shipped-loose neoprene vibration pads (shipped in the power panels) should be located under the corners
of the unit (unless the job specifications state otherwise). They are installed to be flush with the sides and
outside edge of the feet.
Insulation Corners
Insulation corners that cover the rigging holes on the upper corners of the vessel end plates are shipped loose
(in the power panels) and should be installed with adhesive after the init is set in place.
Mounting
Make sure that the floor or structural support is adequate to support the full operating weight of the complete
unit.
It is not necessary to bolt the unit to the mounting slab or framework; but should this be desirable, 1-1/8"
(28.5 mm) mounting holes are provided in the unit support at the four corners.
Note: Units are shipped with refrigerant valves closed to isolate the r efrigerant in the unit
condenser. Valves must remain closed until start-up by the f act ory service technician.
Nameplates
There are several identification nameplates on the chiller:
• The unit nameplate is located on the Unit Control Panel. It has a Model No. XXXX and Serial No.
XXXX. Both are unique to the unit and will identify it. These numbers should be used to identify the unit
for service, parts, or warranty questions. This plate also has the unit refrigerant charge.
• Vessel nameplates are located on the evaporator and condenser. They have a National Board Number
(NB) and a serial number, either of which identify the vessel (but not the entire unit).
Water Piping
Vessel Drains at Start-up
The unit is tilted and drained of water in the factory and shipped with open drain valves in each head of the
evaporator and condenser. Be sure to close the valves prior to filling the vessel with fluid.
Evaporator and Condenser Water Piping
All vessels come standard with groove-type nozzles for Victaulic couplings (also suitable for welding), or
optional flange connections. The installing contractor must provide matching mechanical connections of the
size and type required. Victaulic connections are AWWA C-606 on 14-inch and larger sizes. Field supply
transitions if Victaulic brand AGS® (Advanced Groove System) type grooves are used on the field piping.
IM 1029-2 Magnitude™ Frictionless Centrifugal Chillers – Model WMC 5
!
CAUTION
!
CAUTION
Freeze Notice: Neither the evaporator nor the condenser is self-draining;
both must be blown out to help avoid damage from freezing temperatures.
The piping should include thermometers at the inlet and outlet connections and air vents at the high points.
The water heads can be interchanged (end for end) so that the water connections can be made at either end of
the unit. If this is done, use new head gaskets and relocate the control sensors.
In cases where the water pump noise can be objectionable, vibration isolation sections are recommended at
both the inlet and outlet of the pump. In most cases, it will not be necessary to provide vibration eliminator
sections in the condenser inlet and outlet water lines. But they can be required where noise and vibration are
critical.
Important Notes on Welding
If welding is to be performed on the mechanical or flange connections:
1. Remove the solid-state temperature sensor, thermostat bulbs and optional nozzle mounted flow switches (if
so equipped) from the wells to prevent damage to those components.
2. Properly ground the unit or severe damage to the MicroTech II® unit controller can occur.
Note: ASME certification will be revoked if welding is performed on a vessel shell or tube sheet.
Water pressure gauge connection taps and gauges must be provided in the field piping at the inlet and outlet
connections of both vessels for measuring the water pressure drop. The pressure drops and flow rates for the
various evaporators and condensers are job specific and the original job documentation can be consulted for
this information. Refer to the nameplate on the vessel shell for identification.
Connections
Be sure that water inlet and outlet connections match certified drawings and stenciled nozzle markings. The
condenser is connected with the coolest water entering at the bottom connection to maximize subcooling. The
evaporator outlet is on the right side of the head, regardless of which end the connections are on. Refer to
dimension drawings beginning on page 11.
When common piping is used for both building heating and cooling modes , care mus t be taken to
provide that water flowing through the evaporator cannot exceed 110°F. Water this hot can cause
the relief valve to discharge refrigerant or damage controls.
Piping must be supported to eliminate weight and strain on the fittings and connections . Chilled water piping
must be adequately insulated. Suffi cie nt shut off valves must be inst all ed t o permit draini ng the water f rom the
evaporator or condenser without draining the complete system and to allow vessel isolation.
Filtering and Treatment
Owners and operators must be aware that if the unit is operating with a cooling tower, cleaning and flushing
the cooling tower is required. Make sure tower blow-down or bleed-off is operating. Atmospheric air contains
many contaminants, which increases the need for water treatment. The use of untreated water will result in
corrosion, erosion, slime buildup, scaling, or algae formation. Water treatment service must be used. McQuay
International is not responsible for damage or faulty operation from untreated or improperly treated water.
Special care must be taken when utilizing open system water that is usually not treated (such as lakes, rivers,
and ponds). Special tube and water head material may be required to reduce damage from corrosion.
A cleanable 20-mesh water strainer must be installed in both vessels’ water inlet lines.
6 Magnitude™ Frictionless Centrifugal Chillers – Model WMC IM 1029-2
Flow Swi tc h
Note: Chiller units must have flow switches for the evaporator and
Figure 2, Unit-Mounted Flow Switch
condenser. McQuay International furnishes factory-installed and
wired, thermal-type flow switches as standard equipment on
Magnitude chillers. Field-installed and wired Delta-P switches can
be used instead.
They prevent the unit from starting without sufficient water flow
through the vessels. They also serve to shut down the unit in the
event that water flow is interrupted to guard against evaporator
freeze-up or excessive discharge pressure.
Additionally, for a higher margin of protection, normally open
auxiliary contacts in the pump starters can be wired in series with
the flow switches as shown in the Field Wiring Diagram on page 39.
Cooling Towers
The condenser water flow rate must be checked to be sure that it conforms to the system design. A tower
bypass valve, controlled by the unit controller, is required to control the minimum condenser entering
temperature. Unless the system and chiller unit are specifically designed for them, condenser bypass or
variable condenser flow is not recommended, since low condenser flow rates can cause unstable operation and
excessive tube fouling.
Cooling towers used with Daikin McQuay centrifugal chillers are normally selected for condenser water inlet
water temperatures between 75°F and 90°F (24°C and 32°C). Lower entering water temperatures are
desirable from the standpoint of energy reduction, but a minimum does exist.
Condenser Water Temperature
When the ambient wet bulb temperature is lower than design, the entering condenser water temperature can be
allowed to fall, improving chiller performance.
Daikin McQuay chillers will start with entering condenser water temperature as low as 55°F (12.8°C)
providing the chilled water temperature is below the condenser water temperature.
Depending on local climatic conditions, using the lowest possible entering condenser water temperature can
be more costly in total system power consumed than the expected savings in chiller power would suggest due
to the excessive fan power required.
To obtain lower than 55°F (12.8°C) entering condenser water temperature with a tower selected to produce
85°F (29.4°C) water temperature at design ambient air temperatures, cooling tower fans must continue to
operate at 100% capacity at low wet bulb temperatures. As chillers are selected for lower kW per ton, the
cooling tower fan motor power becomes a higher percentage of the peak load chiller power. The offsets of
compressor power and fan power must be examined. On the other hand, the low condenser water
temperatures can be easy and economical to achieve in mild climates with low wet bulb temperatures.
Even with tower fan control, some form of water flow control such as tower bypass must be used and
controlled by the chiller MicroTech II controller.
Figure 3 and Figure 4 illustrate two temperature-actuated tower bypass arrangements. The “Cold Weather”
scheme, Figure 4, provides better startup under cold ambient air temperature conditions since most of the
piping is indoors and not subjected to cold ambient air. The check valve may be required to prevent air at the
pump inlet.
IM 1029-2 Magnitude™ Frictionless Centrifugal Chillers – Model WMC 7
!
CAUTION
Insulation
sq. ft. (m2)
145S,
E2209
145D
E2209
250D
E2609
≈
≈
Weather Operation
≈
≈
Figure 3, Tower Bypass, Mild
Tower water treatment is essential for continued efficient and reliable unit operation. If
not available in-house, competent water treatment specialists should be contracted.
Figure 4, Tower Bypass, Cold
Weather Operation
Field Insulation
If the optional factory-installation of thermal insulation is not ordered, insulation should be field installed to
reduce heat loss and prevent condensation from forming. Insulation should cover
• The evaporator barrel, tube sheet, and water heads.
• The suction line from the top of the evaporator to the compressor inlet flange.
• The compressor support brackets welded to the evaporator.
• The liquid line from the expansion valve outlet to the evaporator inlet.
Insulation is UL recognized (File # E55475). It is 3/4" thick ABS/PVC flexible foam with a skin. The K
factor is 0.28 at 75°F. Sheet insulation is fitted and cemented in place forming a vapor barrier, then painted
with a resilient epoxy finish that resists cracking.
The insulation complies to or has been tested in accordance with the following:
ASTM-C-177 ASTM-C-534 T y pe 2 UL 94-5V
ASTM-D-1056-91-2C1 ASTM E 84 MEA 186-86-M Vol. N
CAN/ULC S102-M88
Approximate total square foot age of insulation surface required for individual packaged chillers is tabulated
by evaporator code and can be found below.
Table 1, Insulation Quantity
WMC Model
150D E2212
290D E2612
400D E3012
Evaporator
Code
Area
66 (6.1)
66 (6.1)
90 (8.3)
76 (7.1)
102 (9.4)
114 (11)
8 Magnitude™ Frictionless Centrifugal Chillers – Model WMC IM 1029-2
lb. (kg)
Volume, gal (L)
Valves
145S,
E2209
9 ft.
500 (227)
38 (145)
1
145D
E2209
250D
E2609
Capacity lb. (kg)
gal. (L)
145S, 145D
C2009
9 ft.
724 (328)
47 (147)
2
150D
C2012
250D
C2209
9 ft.
883 (401)
61 (231)
2
290D
C2212
12 ft.
1174 (533)
72 (273)
2
400D
C2612
12 ft.
1676 (760)
111 (419)
2
Physical Data and Weights
With positive pressure systems, the pressure variance with temperature is always predictable, and the vessel
design and pressure relief protection are based upon pure refrigerant characteristics. R-134a requires ASME
vessel design, inspection and testing and uses spring-loaded pressure relief valves. When an over-pressure
condition occurs, spring-loaded relief valves purge only that quantity of refrigerant required to reduce the
pressure to the valve’s set pressure and then close. See Relief Valves section for additional information.
Evaporator
Refrigerant-side design pressure is 200 psi (1380 kPa). Water-side is 150 psi (1034 kPa).
Table 2, Evaporator Physical Data
WMC Model
150D E2212
290D E2612
400D E3012
Notes:
1. Refrigerant charge is for the entire uni t and is approximate since the actual charge will depend on other variables. Actual charge will
be shown on the unit nameplate.
2. Water capacity is based on standard t ube configuration and standard dished heads.
Evaporator
Code
Tube
Length
9 ft. 600 (272) 38 (145) 1
12 ft. 800 (363) 45 (170) 1
9 ft. 600 (272) 61 (231) 1
12 ft. 1100 (500) 72 (273) 1
12 ft. 1240 (562) 88 (336) 1
Unit Refrigerant
Charge
Evaporator
Water
Condenser
Refrigerant-side design pressure is 200 psi (1380 kPa). Water-side design is 150 psi (1034 kPa).
Number of
Relief
Table 3, Condenser Physical Data
WMC Model
Notes:
1. Condenser pumpdown capacity based on 90% full at 90°F.
2. Water capacity based on standard confi gurat i on and standard heads and can be less with lower tube counts.
Condenser
Code
Tube
Length
12 ft. 971 (440) 62 (236) 2
Maximum
Pumpdown
Water
Volume
Number of
Relief Valves
IM 1029-2 Magnitude™ Frictionless Centrifugal Chillers – Model WMC 9
"LL"
"LW"
MFL
MFW
X
Z
RF
RB
LB
LF
OH
OW
OL
332834901
DRAWINGNUMBER
00
REV.
NONE
SCALE
Mounting/Lifting/Total Weights
Drawings are for reference only and are not indicative of all unit configurations.
10 Magnitude™ Frictionless Centrifugal Chillers – Model WMC IM 1029-2
6.2
157
14.7
375
112.1
2846
101.6
2579
128.3
3259
5.3
TYP.BOTH
ENDS
133
29.3
CONDENSER
RELIEF
VALVES
744
58.3
EVAPORATOR
RELIEFVALVE
1480
134.7
(UNITOVERALL)
3421
18.0
458
11.1
283
17.1
435
FRONT
END
BOX
UNIT
CTRL
BOX
EVAPORATOR
CONDENSER
COMPRESSOR
FRONTVIEW
X
Y
5,7,8
3
3
3
3
114.8
2916
57.5
1460
22.5
EVAPORATOR
RELIEFVALVE
571
22.6
SUCTION
RELIEF
VALVE
574
26.9
CONDENSER
RELIEF
VALVES
684
TOPVIEW
RB
RF
LF
LB
Z
X
4
3
3,4
3,4
5,13
5,13,14
5,7,8
4.0
102
26.5
673
34.5
876
10.0
254
32.7
8
31
37.8
960
44.3
(OVERALLWIDTH)
1126
16.8
425
44.8
1137
65.9
TOPUNIT
CTRLBOX
1675
74.3
TOPFRONT
ENDBOX
1887
81.0
TOP
COMPR.
2058
69.8
SUCTION
RELIEF
VALVE
1774
O.I.T.S.
IN
IN
OUT
OUT
RIGHTVIEW
Y
Z
5
5
5,10,12
5
4
5
5
5.6
INLET
142
5.6
OUTLET
142
8.0
NOM.
TYP.(2X)
203
EVAPORATORHEAD2-PASS
VICTAULIC150PSIWATERSIDE
C
L
C
L
OUT
IN
7,8
13.0
INLET
330
19.0
OUTLET
483
5.6
OUTLET
143
5.6
INLET
143
6.0
NOM.
TYP.(2X)
152
CONDENSERHEAD 2-PASS
VICTAULIC150PSIWATERSIDE
C
L
C
L
IN
OUT
7,8
13.0
INLET/
OUTLET
330
11.3
287
114.8
2916
34.5
876
1.13
MTG.HOLE
(TYP.)
29
6.3
160
8.9
225
16.0
407
31.9
809
34.0
864
9.0
230
14.0
357
13.8
352
8.0
203
8.0
203
MOUNTING
FOOT(TYP.)
ELECTRICAL
CONNECTIONS
FRONTENDBOX
UNITCTRLBOX
ALLDIMENSIONSAREINDECMAL
INCHESAND[MILLIMATERS]
SEEDRAWING332835001 FORNOTES
RB
LB
LF
RF
5,13,14
5,13
WMC145SBS
332834001 00 NONE
DRAWINGNUMBER REV. SCALE
Chiller Dimensions
Figure 5, WMC 145S, 2 Pass (See page 17 for notes.)
IM 1029-2 Magnitude™ Frictionless Centrifugal Chillers – Model WMC 11
Figure 6, WMC 145D, 2 Pass (See page 17 for notes.)
12 Magnitude™ Frictionless Centrifugal Chillers – Model WMC IM 1029-2
Figure 7, WMC 150D, 2-Pass (See page 17 for notes.)
IM 1029-2 Magnitude™ Frictionless Centrifugal Chillers – Model WMC 13
Figure 8, WMC 250D, 2-Pass (See page 17 for notes.)
14 Magnitude™ Frictionless Centrifugal Chillers – Model WMC IM 1029-2
Figure 9, WMC 290D, 2-Pass (See page 17 for notes.)
IM 1029-2 Magnitude™ Frictionless Centrifugal Chillers – Model WMC 15
Figure 10, WMC 400D, 2-Pass (See page 17 for notes.)
16 Magnitude™ Frictionless Centrifugal Chillers – Model WMC IM 1029-2
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