McQuay WMC-B 145D Installation Manual

Installation Manua l

Supersedes: February 2012

STARTER

COMPRESSOR

OIL PUMP

UNIT

CONTROLLER

EVAPORATOR

CONDENSER

SUPPORT

IM 1128-1

WSC, WME and WMC-B Centrifugal Chillers Reassembly of Knockdown Shi pm e nts

Group: Chiller Part Number: 331375601 Effective: April 2012

REV: 01

DANGER

WARNING

CAUTION

Table of Contents

WSC Chiller Introduction ............................................................................... 3

Type I Reassembly ............................................................................................ 5

Type II Reassembly ........................................................................................ 14

Unit Photographs ................................................................................................................. 26

Type III Reassembly ....................................................................................... 28

Field Insulation Guide ................................................................................... 29

Dimensions and Weights ................................................................................ 31

Type I ................................................................................................................................... 31

Type II ................................................................................................................................. 33

Shipping Lists ................................................................................................. 38

WMC-B Introduction ..................................................................................... 42

Type IV Disassembly-Reassembly....................................................................................... 43

Ty pe V Disassembly-Reassembly ........................................................................................ 43

WME Introduction ......................................................................................... 51

Type I Reassembly .......................................................................................... 52

Type II Reassembly ........................................................................................ 53

Type III Reassembly ....................................................................................... 56

Knockdown Dimensions ...................................................................................................... 57

Piping Removal ................................................................................................................... 58

Compressor Removal and Re-Attachment ........................................................................... 63

Compressor Removal and Re-Attachment ........................................................................... 64

Recognize Safety Symbols, Words, and Labels

The following label is used in this manual to indicate immediate or potential hazards. It is the responsibility of the owner and i nst all er t o read a nd comply with all safet y information and inst ruct ions accompanying these symbols. Improper installation, operation and maintenance can void the warranty.

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.

Cautions indicate potentially hazardous situations, which can result in personal injury or equipment damage if not avoided.

©2012 McQuay International. Illustrations and data cover the McQuay International product at the time of publication and we reserve the right to make changes in design and construction at anytime without notice.

™® The following are trademarks or registered trademarks of their respective companies: Magnitude, MicroTech E, from McQuay Internation al, Victaulic from Victaulic Company

2 Field Installation Procedure IM 1128-1

WSC Chiller Introduction

It is estimated that fifty percent of retrofit applications require partial or complete disassembly of the chiller. Daikin McQuay offers three solutions to the disassembly and reassembly effort on Model WSC, single compressor centrifugal chillers.

TYPE I: The compressor is removed and put on a skid. All associated wiring and piping possible will remain on the vessel stack. The remaining loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5-psi helium holding charge.

3. The compressor will not be insulated at the factory. An insulation kit will be shipped with the unit.

4. The starter will ship loose. Bracket and cable kit to be included for unit-mounted starters and/or

cableway for mini-cabinet starters.

5. The evaporator will be insulated at the factory.

6. Refrigerant will not be shipped with the unit and must be secured locally and furnished and

installed by the installer.

7. Lubricant will be shipped in containers from the factory for field installation.

8. All field piping connections will be Victaulic, O-ring face seal or copper brazing.

9. All free piping ends will be capped.

10. Touch-up paint will be included.

11. The unit will undergo the rigorous, full Daikin McQuay test program at the factory.

12. Contact local McQuay Factory Service for pricing and scheduling of required installation

supervision.

TYPE II: The compressor with its terminal box is removed and placed on a skid. The condenser, evaporator, oil pump, oil cooler and tube sheet supports will remain connected only by their attachment bolts, ready for field disassembly and reassembly in the building. All wiring and piping that interconnects the components will be removed. The loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels have a 5-psi helium holding charge.

3. The compressor will not be insulated at the factory. An insulation kit will be shipped with the unit

and will also include a container of adhesive.

4. Only the evaporator shell will be factory insulated. Loose insulation will be shipped for the

suction line and remaining surface areas.

5. The starter will ship loose.

6. Refrigerant will not be shipped with the unit and must be secured locally and furnished and

installed by the installer.

7. Lubricant will be shipped in containers from the factory for field installation.

8. All field piping connections will be Victaulic, flanged, O-ring face seal or copper brazing.

9. Bracket and cable kit will be included for all unit-mounted starters and/or cableway for mini-

cabinet starters.

10. All free piping ends will be capped.

11. Touch-up paint and stick-on wire ties will be included.

12. A bolted bracket instead of a weld will mount the oil pump.

13. The discharge piping assembly will have a bolted flange connection (instead of welded) at the

condenser. This assembly will ship loose.

14. Piping that remains attached to a component will be supported if it is not rigid.

15. The chiller will not be run-tested at the factory but the compressor, oil pump assembly and heat

exchangers will be tested as sub-assemblies.

IM 1128-1 Field Installation Procedure 3

16. The control panels are shipped separately but have all sensors wired in, labeled and tied up.

Matching labels will exist at the sensor connection on the unit.

17. Contact local McQuay Factory Service for pricing and scheduling of required installation

supervision.

TYPE III: The uni t ships fully assembled and is field ready to knockdown. Included are the vessel bolt-on connection brackets, the discharge stack bolt-on flanges at the condenser and the bolt-on oil pump assembly.

1. The unit is shipped fully charged with refrigerant and lubricant.

2. The unit will be factory insulated and painted.

3. All electrical and sensor wiring will be fastened as usual.

4. The starter will ship per order instructions.

5. Touch up paint and stick-on wire ties will be included.

6. This unit will be fully tested at the factory.

7. Labels will be provided with the instructions to mark piping, electrical wiring and sensor wiring.

NOTE: If disassembly involves breaking any refrigerant connection, the refrigerant charge must be pumped down and isolated in the condenser.

Typical WSC Centrifugal Chiller

4 Field Installation Procedure IM 1128-1

Type I Reassembly

WARNING

Description

TYPE I: The compressor with its terminal box is removed and placed on a skid as a separate package. The suction piping is removed and shipped loose. All other piping will be disconnected from the compressor and remain attached to the vessel stack, where possible. Wiring and sensors to the compressor will be disconnect ed, rolled up and tied to the control pane ls. The remaining loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5-psi helium holding charge.

3. The compressor will not be insulated at the factory. An insulation kit will be shipped with the unit

and will also include a container of adhesive.

4. The unit vessel stack will be insulated at the factory.

5. This unit will be tested with a full refrigerant charge at the factory and the charge will be removed

after testing.

6. Refrigerant will not be shipped with the unit and must be secured locally and furnished and

installed by the installer.

7. Bracket and cable kit will be included for all unit-mounted starters and/or cableway for mini-

cabinet starters.

8. All free piping ends will be capped.

9. Touch-up paint and stick-on wire ties will be included.

10. Lubricant will be shipped in containers from the factory.

11. The starter will ship loose.

12. All field piping connections will be Victaulic, flanged, O-ring face seal or copper brazing.

13. The unit control panel and compressor control panel will be attached to the unit with loose sensor

wires tied up behind the panel.

Reassembly Steps

NOTE: Additional instructions may be shown on the assembly drawings.

1. Mount the compressor on the stack. Be careful to avoid damaging lines already mounted on the unit.

Mounting bolts, washers and nuts are shipped loose. Leave the mounting bolts loose until the suction and discharge lines are installed and aligned.

During assembly, bolts holding block-off plates (motor cooling connection, for example), are used for reassembly of the component. See Figure 1 or Figure 2 for the location and description of the blockoffs.

2. Do not remove block-offs until ready to install piping. The compressor and vessels have a Schrader

valve on their block-off plates to be used for relieving the helium holding charge.

Remove compressor and vessel holding charge through the Schrader valve in the block-off plates before attempting to loosen any fittings on them. Failure to do so can cause severe bodily injury.

3. Install the suction and discharge piping (see Figure 3). Before tightening the Victaulic couplings,

position the suction and discharge piping so that the compressor can be aligned to give the best fit-up. When this is achieved, secure the compressor mounting bolts and proceed with installing the Victaulic couplings using a light coating of Victaulic lubrication.

IM 1128-1 Field Installation Procedure 5

4. Install the liquid injection line (see Figure 4). The liquid injection line is attached to the condenser

and has shipping straps securing it to the evaporator and condenser. It, and the compressor, each have a block-off. Note that any given injection line may be configured somewhat differently than shown on the drawing.

5. Install the motor cooling line (see Figure 5) using the same procedure as the liquid injection line.

6. Install the motor drain line (see Figure 6) using the same procedure as the liquid injection line.

7. Piping for the optional hot gas bypass is shipped mounted on the unit except for models WSC100,

WSC113 and WSC126 with vessel stacks sizes E36C30, E36C36, E42C36, E42C42, E48C42 and E48C48. These units have the piping assembly shipped loose for field mounting. See Figure 7.

8. Install the compressor lubrication lines. There are four lines as shown in Figure 8: a. Thrust pump return, injects lubricant from the compressor thrust pump (thrust bearing) into

the lubricant supply line.

b. Oil drain, drains lubricant from the compressor to the sump. c. Vent line, vents refrigerant from the sump back to the compressor suction. d. Oil supply, supplies lubricant from the pump in the sump to the compressor.

There is a variety of fitting types employed on the oil lines. Reconnect the compression fittings, bolt on the flanges using new gaskets furnished, and re-sweat the sweat connections.

9. Install the four-way solenoid on the compressor suction housing.

10. Install compressor wiring using Figure 9 (including notes) as a guide. Figure 9 shows connections for

both Type I and Type II arrangements. Only the connections listed below are required to be made for Type I. The wire end that has been disconnected, and its attachment point on the compressor, will each have a label attached (VC for the vane close switch, for example) for matching purposes.

a. Guardistor, G1 (and G2 on some units), terminal box located on side of motor housing. b. Compressor heaters, CP1 (and CP2 on some units), located on the bottom of the compressor. c. Vane load/unload solenoids, SA and SB, located on the four-way solenoid assembly. d. Vane close switch, VC, located on compressor next to the discharge housing. e. Vane open switch, VO, located on suction end of compressor. f. High pressure switch, HPS, located on compressor discharge nozzle.

11. If the unit has been ordered with a starter or VFD as unit mounted, brackets for mounting it and

interconnection cables to the compressor motor will be included as ship loose items. Control wiring as shown in Figure 9 and Figure 13 (field wiring diagram), will also be required. The field wiring diagram located on the control panel door should also be consulted as it will be current. If the unit has a free standing starter, use normal field procedures for mounting and wiring.

Normal procedure of leak testing, triple evacuation, and charging with refrigerant and lubricant must be followed prior to the start up procedure.

12. Insulate the compressor motor, suction line, and other miscellaneous areas with the included insulation

and adhesive after leak testing. See Field Insulation Guide on page 29.

This completes the reassembly procedure.

6 Field Installation Procedure IM 1128-1

Figure 1, WSC 063 - 087 Compressor Connections

RIGHT VIEW

R331311301C0100

15" MTR. HSG.

LEFT VIEW

(20" MTR.HSG.)

MOTOR COOLING

REFRIGERANT

FROM COND. BTM

OIL LINE VENT

FROM TOP FRONT

OF OIL PUMP

ATT ACH TAG TO ONE

TERMINAL INSIDE BOX

4-WAY SOLENOID VALVE

LIQUID

INJECTION

FROM COND. BTM.

OIL THRUST RETURN

TO OIL LINE TEE

OIL DRAIN TO TOP BACK OF OIL PUMP

MOTOR DRAIN

TO EVAP BOTTOM

MOTOR DRAIN

OIL OUT TO SA AND SB

SOLENOID VALVES AND

MOTOR DRAIN

TO EVAP BOTTOM

MOTOR COOLING FROM COND. BTM.

OIL SUPPLY

FROM OIL COOLER

Notes:

1. New O-rings and gaskets are in a plastic bag.

2. Compressor is charged with 5-psi of helium.

IM 1128-1 Field Installation Procedure 7

Figure 2, WSC 100-126 Compressor Connections

LEFT VIEW

(22" MTR. HSG.)

20" MTR. HSG.

RIGHT VIEW

BOTTOM VIEW

OIL VENT

OIL SUPPLY

MOTOR COOLING

OIL DRAIN

DISCHARGE

BLOCKOFF

REF. DRAIN

REF.DRAIN

REF. DRAIN

MOTOR COOLING

MOTOR DRAIN

LIQUID INJECTION

UNSWEAT LINE AND

SHUT VALVE

FROM TOP FRT.

OF OIL PUMP

FROM CONDENSER

BOTTOM

TO TOP BACK OF OIL PUMP

TO EVAP.

BOTTOM

TO EVAP.

BOTTOM

TO EVAP. BOTTOM

TO EVAP.

BOTTOM

TO EVAP.

BOTTOM

FROM COND.

BOTTOM

FROM COND. BOTTOM

4 WAY SOLENOID VALVE

OIL THRUST RETURN TO

OIL LINE TEE

TO OIL COOLER

R331311301D0200

OIL OUT TO SA AND SB

SOLENOID VAL VES AND

OIL PRESSURE TRANSDUCER

Notes:

1. New O-rings and gaskets are in a plastic bag.

2. Compressor is charged with 5-psi of helium.

8 Field Installation Procedure IM 1128-1

Figure 3, Suction and Discharge Piping

R331311308C0100

BOLT-ON

BLOCKOFF PLATE

TYPE II

UNITS RECEIVE

SLIP-ON ASME

FLANGES

TYPES II & III

TYPES I & II

VICTAULIC

BLOCKOFF PLATE

INSTALL SUCTION

PIPING

EVAPORATOR AND CONDENSER ARE EVACUATED

AND CHARGED WITH 30 PSI OF HELIUM.

TYPES I & II

IM 1128-1 Field Installation Procedure 9

Figure 4, Liquid Injecti on Li nes

MECHANICAL

TORQUE TO 58 FT/LBS

R331311304C0100

MECHANICAL

BREAK POINT

MECHANICAL BREAK POINT

MOTOR COOLING LINES (NOT ALL VARIA TIONS SHOWN)

TYPE I

BLOCKOFF

TYPE I

BLOCKOFF

BREAK POINT

TYPE I BLOCKOFF

R331311303C0100

MECHANICAL

BREAK POINT

TYPE I BLOCKOFF

LIQUID INJECTION LINES (NOT ALL VARIATIONS SHOWN)

NOTE: The liquid injection line (above) and the motor c ooling line (below) are attached to the condenser and have shipping straps securing them to the evaporator and condenser. The lines and the compressor, each have blockoff plates, resulting in extra bolts.

Figure 5, Motor Cooling Lines

10 Field Installation Procedure IM 1128-1

Figure 6, Motor Drain Line

R331311305C0100

20" MOTOR REF. DRAIN

CONNECTION

(REAR VIEW)

15" MOTOR REF. DRAIN

CONNECTION

(REAR VIEW)

MOTOR HOUSING DRAIN LINE

MOTOR DRAIN LINE (NOT ALL VARIATIONS SHOWN)

MECHANICAL BREAK POINT

IM 1128-1 Field Installation Procedure 11

Figure 7, Optional Hot Gas Bypass Piping

R331311307C0100

HOT GAS

BYPASS

LINE

HOT GAS

BYPASS

PILOT

LINE

SHUT OFF

VALVE

EXPANSION

VALVE

CONNECTION TO

DISCHARGE NOZZLE

MECHANICAL

BREAK POINTS

MECHANICAL

BREAK POINT

MECHANICAL

BREAK POINT

MECHANICAL

BREAK POINT

FLOW

NOTE: THIS LINE IS NOT ALWAYS PRESENT. SOME UNITS HAVE ELECTRONIC VAL V ES.

BLOCKOFF

TYPE II UNITS

INSTALL HOT GAS PIPING

TYPE I UNITS

INSTALL HOT GAS PIPING ON WSC MODELS

100, 113, & 126 WITH STACK SIZES

E36C30, E36C36, E42C36, E42C42,

E48C42, E48C48

R331311302C0200

OIL VENT

OF THRUST RETURN LINE

OIL SUPPLY

RESWEAT LINE

ABOVE REDUCER

RESWEAT LINE

ABOVE TEE

TYPES I & II

INSTALL T OP PORTION

TYPES I AND II

INSTALL

INSTALL WATER LINES

TYPE II

INSTALL TOP PORTION

OF LINE

TYPES I & II

TYPES I AND II

INSTALL

OIL DRAIN

Figure 8, Oil and Water Lines

12 Field Installation Procedure IM 1128-1

Figure 9, Electrical and Sensors, Compr essor Contr ol Box and Connections

R331311501C0100

155

155 155

154

GUARDISTOR

CONNECT LEAD 155 TO TERMINAL IF 2nd

BOX IS NOT USED.

2nd TERMINAL BOX USED ON SELECTED MOTORS.

HIGH

PRESSURE

SWITCH

NUMBER OF HEATERS MAY VARY DUE TO COMPRESSOR SIZE. JUNCTION BOX NOT ON ALL UNITS.

SECOND HEATER CABLE FROM COMPR. ON WSC063-087 ONLY.

}

0708

OIL PUMP HEATERS

{TO STARTER

COMPRESSOR

HEATERS

CS04

CS05

CS07

CS09

CS10

CS06

CS03

CS02

CS01

HOT GAS

SOLENOID

LIQ. INJ.

SOLENOID

OPTION

135

136

133

134

141

142

139

140

132 131

137

138

OIL COOLER

SOLENOID

VANE CONTROL

SOLENOIDS

VANE

SWITCH

146 145

VANE OPEN

SWITCH

103

104

VFD SPEED

SIGNAL

102

101

(ON VFD ONLY)

VFD

LEAVING EVAP WATER TEMP.

OIL FEED TEMP.

COMPR. DISCHARGE TEMP.

COMPR. SUCTION TEMP.

OIL SUMP TEMP.

COND. PRESS. SENSOR

EVAP. PRESS. SENSOR

OIL FEED PRESS. SENSOR

OIL SUMP PRESS. SENSOR

VANE LOAD

VANE

UNLOAD

JUNCTION BOX ON COMPRESSOR MOUNTING BRACKET NEAR THE SUCTION PIPE.

OPH

CP1

CP2

HPS

COMPRESSOR CONTROL BOX

CCB POWER

10 LEADS 4 LEADS

(ON COMPRESSOR)

(ON VFD)

(ON SUPPLY

WATER LINE)

(ON COMPR.

FRONT)

(ON COMPR. NEXT

TO DISCHARGE)

(ON COMPR.

FRONT)

(ON HOT

GAS LINE)

(ON LIQUID INJ. LINE)

(ON DISCHARGE

NOZZLE)

Note:

1. Reference compressor controller schematic for detailed wiring connections.

IM 1128-1 Field Installation Procedure 13

EVAPORATOR

TUBE SHEET

SUPPORT

PLATE

CONDENSER

TUBE SHEET

BOLTED

WELDED

TWO ANGLE PLATES, ONE WELDED TO EVAP. ONE WELDED TO COND. THEN BOLTED TOGETHER.

Type II Reassembly

Description

TYPE II: The compressor with its terminal box is removed and shipped on a skid. The condenser, evaporator, oil sump, oil cooler and tube sheet support plates will remain connected only by their attachment bolts, ready for field disassembly on site and subsequent r eassembly in the building. All wiring and piping that interconnects the components will have been removed and will require reinstallation. The loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5-psi helium holding charge.

3. The compressor will not be insulated at the factory. An insulation kit will be shipped with the unit

and will also include a container of adhesive.

4. Only the evaporator shell will be factory insulated. Loose insulation will be shipped for the

remaining surface areas.

5. The starter will ship loose.

6. The refrigerant will be field supplied.

7. All field piping connections will be Victaulic, flanged, O-ring face seal or copper brazing.

8. Bracket and cable kit will be included for all unit-mounted starters and/or cableway for mini-cabs.

9. All free piping ends will be capped.

10. Touch-up paint and stick-on wire ties will be included.

11. A bolted bracket instead of a weld will mount the oil pump.

12. The discharge piping assembly will have a bolted flange connection (instead of welded) at the

condenser. This assembly will ship loose.

13. Piping that remains attached to a component will be supported if it is not rigid.

14. The chiller will not be run-tested at the factory but the compressor, oil pump assembly and heat

exchangers will be tested as sub-assemblies.

15. The control panels are shipped separately but have all sensors wired in, labeled and tied up.

Matching labels will exist at the sensor connection to the unit.

Reassembly Steps

NOTE: Additional instructions may be shown on the assembly drawings. The Type II arrangement is shipped with the evaporator, condenser, tube sheet support plate, oil cooler

and oil sump bolted together. This provides structural support during transit and also allows several options for disassembly.

Figure 10, Component Disassembly

In most cases for narrow entry, the condenser will be separated by unbolting it from the evaporator angle bracket and from the tube sheet support plate. This leaves the evaporator and the support plate that has the mounting foot extended under where the condenser used to be. Therefore, the evaporator is usually unbolted from the two support plates, which can then be easily handled by themselves.

14 Field Installation Procedure IM 1128-1

WARNING

Remove compressor and vessel holding charge through the Schrader valve in the block-off plates before attempting to loosen any fittings on them. Failure to do so can cause severe bodily injury.

1. Disassemble the unit to the e xtent required by the site conditions. Rig the components to their final

location and reassemble them using the fasteners that came with the unit.

2. The compressor and its suction and discha rge piping should be installed on the stack before any other

lines are attached. Mount t he compressor on the stack. Mounting bolts, washers and nuts are shipped loose. Leave the mounting bolts loose until the suction and discharge lines are in place and aligned. Install the suction and discharge piping. Before tightening the Victaulic couplings, position the suction and discharge piping so that the compressor can be aligned to give the best fit-up. When this is achieved, secure the compressor mounting bolts and proceed with installing the Victaulics using a light coating of Victaulic lubricant. See Figure 3.

3. Install the liquid line using Figure 11 as a guide. Commonly used arrangements are illustrated. The

bottom two arrangements illustrate lines with electronic valves used on some size units. Due to the variety of vessel combinations available, variation on specific units will occur.

4. Install the motor cooling line using Figure 5 as a guide.

5. Install the liquid injection line (see Figure 4). Note that any given injection line may be configured

somewhat differently than shown on the drawing.

6. If the oil cool er and oi l sump have been removed on the job site, reinsta ll them using the fasteners tha t

came on the unit. See Figure 12 for piping between the cooler and sump and the cooling water pi ping. See Figure 8 for the balance of the four oil lines connected to the compressor. There are a variety of fitting types employed on the oil lines. Reconnect the compression fit tings, bolt on the flanges using new gaskets/O-rings furnished, and re-sweat the sweat connections.

Due to the wide variety of model arrangements, some or all of the oil piping may be shipped loose. When possible, the cooler and sump will be shipped mounted to their back plate with as much piping remaining as possible.

7. Install the four-way solenoid valve assembly on the compressor suction housing.

8. Install the two control panels; the compressor panel is mounted adjacent to the oil sump and the unit

panel is on top of the evaporator. Wire and sensor leads have been disconnected at their terminus and labeled. They remain connected at the panels and rolled up. Their destinations have matching labels, which simplifies the installation. Compressor panel sensor labels are prefixed with CS, unit panel labels with US. Use the following drawings as a guide for installing wiring and sensors:

Compressor panel detail ........................................Figure 18

Unit panel wiring and connections ........................Figure 15

Unit panel detail .....................................................Figure 19

Unit panel sensor locations ....................................Figure 16 and Figure 17

Flow switch wiring detail ......................................Figure 20

9. If the unit has been ordered with a starter or VFD as unit mounted, brackets for mounting it and

interconnection cables to the compressor motor will be i ncluded as shi p loose ite ms. Control wiring as shown in Figure 9 will also be required. If the unit has a free-standing starter, use normal field procedures for mounting and wiring.

Normal procedure of leak testing, triple evacuation, and charging with refrigerant and lubricant must be followed prior to the start up procedure.

IM 1128-1 Field Installation Procedure 15

10. Insulate the compressor, suction line, and other miscellaneous areas with the included insulation and

SHOWN IS E36/C36 STACK WITH 20-INCH MOTOR

R331311306C0100

VIEW B

SEE VIEW B

TOP OF

EVAPORATOR

FROM PILOT TX VALVE

EVAPORATOR

CONNECTION

CONDENSER SHUTOFF VALVE CONNECTION

TO TOP OF

EVAPORATOR

TO TOP OF EVAPORATOR

EVAPORATOR CONNECTION

CONDENSER SHUTOFF VALVE CONNECTION

FLOW

PLUG

EVAP. BLOCKOFF

LIQUID LINES (NOT ALL VARIATIONS SHOWN)

LIQUID LINES

FLOW

(VIEW 'B')

LIQUID LINE

PILOT LINE

RESWEAT PILOT LINE ABOVE THE SHUTOFF VALVE

PILOT LINE SHUT OFF VALVE

MECHANICAL BREAK POINT

CONDENSER SHUTOFF VALVE

TYPE II KNOCKDOWN ONLY

glue after leak testing. See Field Insulation Guide on page 29.

This completes the reassembly procedure.

Figure 11, Liquid Line Inst allation

NOTE: The bottom two liquid lines show the typical arrangement with electronic expansion valves. Liquid flow can be

in different directions depending on the valve size.

16 Field Installation Procedure IM 1128-1

Figure 12, 16 Inch Oil Sump / O il Cooler Assembly

R331311302C0100

FLOW

PLUG

OIL

COOLER

OIL VENT LINE

OIL DRAIN LINE

THRUST RETURN OIL LINE

FLOW

OIL SUPPLY TO VALVE ON COMP.

FLOW

OIL

SUPPLY

WATER RETURN

WATER SUPPLY

DUE TO DIFFERENT PIPE ROUTINGS SOME OR ALL PIPING SHOWN MAY BE SHIPPED LOOSE

PPL

Notes:

1. Piping arrangements will vary according to specific model.

2. Oil sump is shipped without oil on Type I and Type II knockdown units.

3. Type III knockdown units are shipped with oil.

IM 1128-1 Field Installation Procedure 17

CP2

CP1

1 2

11 12 22

1 2

6 11 12 22

NOTE 2

(115V) (24V)

T3-S

CP2

CP1

23(5A)

24(5)

3 4

PE 85

82(NO) 83(NC)

POWER

EP2

EP1

L1 L2 L3

GND

T4 T5 T6

T1 T2 T3

T4 T5 T6T1 T2 T3

T1 T2 T3

T3T1 T2

U V W

T4 T3 T5T1 T6 T2

T1 T2 T3

T4 T3 T5T1 T6 T2

GND

LESS THAN 30V OR 24VA C

1-10 VDC

MICROTECH CONTROL

BOX TERMINALS

* COOLING

TOWER

FOURTH

STAGE

STARTER

* COOLING

TOWER

THIRD

STAGE

STARTER

* COOLING

TOWER

SECOND

STAGE

STARTER

* COOLING

TOWER

FIRST

STAGE

STARTER

COOLING TOWER

BYPASS VALVE

COOLING TOWER VFD

ALARM RELAY

(NOTE 4)

MICROTECH

COMPRESSOR CONTROL

BOX TERMINALS

CTB1

-LOAD-

COMPRESSOR

MOTOR

STARTER

(NOTE 1)

115 VAC

STARTER LOAD SIDE TERMINBALS

VFD

STARTER LOAD SIDE TERMINBALS

WYE -DELTA

STARTER LOAD SIDE TERMINBALS

SOLID STATE

STARTER LOAD SIDE TERMINBALS

MEDIUM AND HIGH VOLTAGE

COMPRESSOR TERMINALS

NOTE 12

- FOR DC VOLTAGE AND 4-20 MA CONNECTIONS (SEE NOTE 3)

- FOR DETAILS OF CONTROL REFER TO UNIT CONTROL SCHEMATIC 330342103

- COMPRESSOR CONTROL SCHEMATIC 330342203

- LEGEND: 330343003 * FIELD SUPPLIED ITEM

* NOTE 7

* NOTE 10

330387901-0A

COMMON

NEUTRAL

POWER

Figure 13, Typical Field Connection Diagram, WSC Unit

18 Field Installation Procedure IM 1128-1

Figure 14, Compressor Control Panel Elect rical and Sensor Connections

R331311501C0100

155

155 155

154

GUARDISTOR

CONNECT LEAD 155 TO TERMINAL IF 2nd

BOX IS NOT USED.

2nd TERMINAL BOX USED ON SELECTED MOTORS.

HIGH

PRESSURE

SWITCH

NUMBER OF HEATERS MAY VARY DUE TO COMPRESSOR SIZE. JUNCTION BOX NOT ON ALL UNITS.

SECOND HEATER CABLE FROM COMPR. ON WSC063-087 ONLY.

}

0708

OIL PUMP HEATERS

{TO STARTER

COMPRESSOR

HEATERS

CS04

CS05

CS07

CS09

CS10

CS06

CS03

CS02

CS01

HOT GAS

SOLENOID

LIQ. INJ.

SOLENOID

OPTION

135

136

133

134

141

142

139

140

132 131

137

138

OIL COOLER

SOLENOID

VANE CONTROL

SOLENOIDS

VANE

SWITCH

146 145

VANE OPEN

SWITCH

103

104

VFD SPEED

SIGNAL

102

101

(ON VFD ONLY)

VFD

LEAVING EVAP WATER TEMP.

OIL FEED TEMP.

COMPR. DISCHARGE TEMP.

COMPR. SUCTION TEMP.

OIL SUMP TEMP.

COND. PRESS. SENSOR

EVAP. PRESS. SENSOR

OIL FEED PRESS. SENSOR

OIL SUMP PRESS. SENSOR

VANE LOAD

VANE

UNLOAD

JUNCTION BOX ON COMPRESSOR MOUNTING BRACKET NEAR THE SUCTION PIPE.

OPH

CP1

CP2

HPS

COMPRESSOR CONTROL BOX

CCB POWER

10 LEADS 4 LEADS

(ON COMPRESSOR)

(ON VFD)

(ON SUPPLY

WATER LINE)

(ON COMPR.

FRONT)

(ON COMPR. NEXT

TO DISCHARGE)

(ON COMPR.

FRONT)

(ON HOT

GAS LINE)

(ON LIQUID INJ. LINE)

(ON DISCHARGE

NOZZLE)

Note:

Refer to the compressor controller schematic for detailed wiring connections.

IM 1128-1 Field Installation Procedure 19

Figure 15, Unit Controller El ect r i cal and Sensor Connections

R331311502C0100

REFERENCE THE UNIT CONTROLLER SCHEMATIC

FOR DETAILED WIRING CONNECTIONS

US03 US04 US05 US09 US10

UNIT CONTROL BOX

US02

515253545556575859606162637070707171717273747576777879808182838485868686PE

MICROTECH II

AIR CONDITIONING

J11

J12

J13

J14

J15

B1B2B3

GND

+VDC

BC4B5BC5

J4 J5

J19

J20

Y5Y6B9

BC9

B10

BC10

ID17

ID18

IDC17

J16

J17 J18

J21 J22

J23

SERIAL CARDPRINTER CARD

EXPANSION MEMORY

J7 J8

UNIT COMP 1 COMP 2

CIRCUIT BKR. ON-(IN)

OFF-(OUT) PUMP/TOWER

OPERATOR

INTERFACE

PANEL

}

COND. GPM SENSOR (FIELD OPTION)

EVAP. GPM SENSOR (FIELD OPTION)

TOWER BYPASS/TOWER VFD (FIELD OPTION)

WATER RESET/REMOTE START-STOP/ MODE/DEMAND LIMIT (FIELD OPTION)

}

WATER PUMPS (FIELD INSTALLED)

TOWER STAGING (FIELD INSTALLED)

ALARMS (FIELD INSTALLED)

POWER (FIELD INSTALLED)

UTB1

CONTROLLER

pCO2

152

N.O.

151

N.O.

149

150

149,151

150

152

249,251

250

252

T3S1

T3S2

EF1

CF1

EF2

CF2

EF BLACK

CF BLACK

EF WHITE

CF WHITE

EF & CF BROWN

EF & CF BLUE

MASS FLOW SENSOR OPTION

EVAPORATOR

FLOW SWITCH

CONDENSER

FLOW SWITCH

7 LEADS

ENTERING EVAP. WATER TEMP. ENTERING COND. WATER TEMP.

LEAVING COND. WATER TEMP.

LIQUID LINE TEMP .

ENTERING HEAT RECOVERY

LEAVING HEAT RECOVERY

(OPTIONAL) (OPTIONAL)

OIP

UC POWER FS POWER

pLAN

UNIT CONTROLLER

FLOW SWITCH

CONNECT THESE LEADS

TO THE COMPRESSOR

CONTROL BOX

COMMUNICATION

TYPE II KNOCKDOWN ONLY

20 Field Installation Procedure IM 1128-1

Figure 16, Unit Electrical and Sensor Locat i ons

R3313115

CS10

US04

CS05

US05

CS04

CS09

CS02

CS03

EVAPORATOR

STANDARD PRESSURE TRANSDUCER

STANDARD TEMPE RATURE SENSOR

OPTIONAL TEMPERATURE SENSOR

SEE DETAIL A

SEE DETAIL C

SEE DETAIL E

SEE DETAIL D

SEE DETAIL F

CS01

US02

US10

US09

US03

CS07

CS06

CS08

FRONT VIEW AT COMPRESSOR

FIELD

OPTION

US05

SEE DETAIL E

EVAPORATOR

WITH ELECTRONIC EXPANSION VALVE

REAR VIEW SHOWN WITH PILOT OPERATED EXPANSION VALVE

LEGEND

SEE DETAIL B

SEE DETAIL D

Note: See Figure 17 for reference detail drawings.

IM 1128-1 Field Installation Procedure 21

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