CATALOG Centrifugal Compressor Water Chillers THE DISTINCTION SERIES ¥ Model WSC, Single Compressor, Cooling Model WDC, Dual Compressor, Cooling Model HSC, Single Compressor Heat Recovery Model TSC, Single Compressor, Templifier™ Water Heater R-134a, The Global Refrigerant of Choice Engineered for flexibility and performance.
Cutaway view of McQuay Model CE 063 Compressor, Nominal 250 Tons MicroTech II™ Controller, 12-inch VGA Operator Interface, Home Screen Table of Contents Introduction..............................................................3 Customer Benefits Summary....................................5 Heat Recovery Models ...........................................12 Control Features.....................................................15 Building Automation Systems................................
Introduction There is an excellent reason for naming McQuay’s centrifugal chiller products as “THE DISTINCTION SERIES”. Our chillers offer customers an unbeatable combination of performance, reliability, unique construction features, a long-term refrigerant, and advanced control technology, all adding up to a superior value. After reviewing our features and benefits, choose the superior value of McQuay centrifugal chillers for your next project.
Wide Choice of Capacities and Efficiencies The range of capacities and chiller types shown in the following chart gives the plant designer the ability to pick and chose the exact capacity, optimum chiller type and efficiency for either a single or multiple unit chiller plant. This flexibility is also a tremendous asset for replacement chiller applications.
Customer Benefits Summary All McQuay Distinction Series units offer the following benefits. See the additional referenced pages for details. Excellent Performance It is important to choose a performance philosophy consistent with your application. McQuay has a solution for your specific application. Contact your local McQuay sales office for computer selections of chillers to match your requirements. The following chart provides recommendations for the model choice for your application.
No Vessel Heating Blankets When negative pressure chillers are expected to be inoperative for a long period of time, during winter shutdown for example, it is common to apply an electric heating blanket to the evaporator in order to raise the refrigerant pressure above atmospheric. In other words, try to force it to behave like a McQuay R-134a unit! The initial and operating costs of these blankets are not necessary with a McQuay chiller.
Unmatched Unloading McQuay’s Distinction Series chillers offer unloading to 10% of full load for a WSC single compressor chiller and 5% for a WDC dual compressor units, without using inefficient hot gas bypass. This unloading capability, unique in the industry, provides improved stability of the chilled water temperature and less harmful cycling of compressors.
Quieter as Chiller Unloads Many centrifugal compressors become louder as they unload. McQuay’s design results in a reduction in sound levels at lower loads, where most chillers spend most of their operating hours. Power Loss Damage Protection Unfortunately, loss of electric power without allowing chillers to proceed through their normal shutdown sequence is becoming common in many areas. When this occurs, most compressors must coast to a stop without benefit of their lubricant pump running.
WDC, Dual Compressor Chillers One WDC Dual Compressor Chiller = Two Single Compressor Chillers Lower equipment costs than two separate chillers Lower installation cost than two separate chillers Lower annual operating cost than either one large or two small chillers Less equipment room space required than for two separate chillers Capacity reduction to 5% of design cooling tons Standby redundancy for most of the cooling season Greatly reduced starting load for emergency standby power plants Industry Leadi
Why a Compressor Motor Failure Will Not Contaminate the Common Refrigerant Circuit The compressor motor is isolated from the main refrigerant flow circuit so that any contaminants generated by a motor failure will not pass into the main refrigerant circuit. Moisture, acid and/or carbon particles will be automatically trapped within the compressor’s dedicated coolant feed and exit lines. Internally, the compressor motor compartment is separated and sealed from the main refrigerant compression chamber.
Part Load Efficiency Chillers usually spend 99% of their operating hours under part load conditions, and most of this time at less that 60% of design capacity. One compressor of a dual chiller operates with the full heat transfer surface of the entire unit. For example, one 500-ton (1,750 kW) compressor on a 1,000 ton (3,500 kW) dual chiller utilizes 1,000 tons (3500 kW) of evaporator and condenser surface. This increases the compressor’s capacity and also results in very high efficiency.
Heat Recovery Models For decades, McQuay International has pioneered the use of heat recovery chillers and the unique McQuay Templifier™ Heat Pump Water Heater to reduce energy costs. These products have become more important than ever with the current emphasis on total building efficiency. ASHRAE Efficiency Standard 90.1 mandates the use of heat recovery equipment of this type in a wide range of buildings.
Templifier™ Heat Pump Water Heaters Model TSC, 3,000 to 24,000 MBH (880 to 7,000 kW) Heating Capacity The Model TSC Templifier was developed in the 1970s, after the 1973 oil embargo, as a device to replace fossil-fired COOLING TOWER SUPPLEHEATING water heaters with electric MENTAL LOAD HEATER heaters.
Typical Templifier Applications Service Hot Water Piping OUTPUT 140°F (60°C) Intermediate Heat Exchanger Ground Water Heat Source RETURN / MAKEUP STORAGE TANK 140°F (60°C) STANDBY / AUXILIARY HEAT 140°F (60°C) T-C CONDENSER EVAPORATOR TEMPLIFIER HEAT SOURCE 14 Catalog WSC/WDC-4
Control Features ® Chillers Feature MicroTech II Controls McQuay has incorporated the latest microprocessor technology into the MicroTech II control system to give you the ultimate in chiller control. The control includes many energy-saving features to keep your chiller running efficiently . . . day in, day out, for years to come. Figure 3, Unit Controller and Operator Interface Touch Screen The unit controller and operator interface touchscreen mounted on a chiller unit are shown to the right.
MicroTech II Features and Benefits FEATURE BENEFIT Easy integration into a building management system via McQuay’s exclusive Protocol Selectability™ feature. Designer can to select any BAS supplier using industry standard protocols and know the MicroTech II control will easily interface directly with it.
Alarm History for Easy Troubleshooting The MicroTech II controller's memory retains a record of faults and a time/date stamp. The controller's memory (no batteries required) can retain and display the cause of the current fault and the last twenty-five fault conditions. This method for retaining the fault is extremely useful for troubleshooting and maintaining an accurate record of unit performance and history.
Trend Logging Ever wonder how your chiller performed last week? Were you holding the correct chilled water temperature? What kind of cooling load did the chiller have? The McQuay MicroTech II controller can provide the answers, thanks to its huge memory, and plot water temperatures, refrigerant pressures, and motor load data. These values can also be downloaded through a convenient USB port, located in the unit control panel, and pasted into a spreadsheet for archiving or further detailed evaluation.
Starter Data Displayed As standard, the percent of rated load amps (RLA) is displayed on the interface screen as a bar chart. In addition, there are two options available to display additional starter data on screen. The options are: • Ammeter Display, which displays phase amps and average amps • Full Metering Display, which displays phase and average amps, phase and average volts, compressor kilowatts, power factor and unit kilowatt-hours.
Multiple Chiller Control McQuay’s standard MicroTech II control system, as shipped on all units, will control up to three chillers, either single or dual compressor type. A simple RS 485 interconnection and minor set point adjustments are all that is required. When a chiller system will have more than three chillers, McQuay has a flexible and reliable chiller manager available.
Building Automation Systems All MicroTech II controllers are capable of communications, providing seamless integration and comprehensive monitoring, control, and two-way data exchange with industry standard protocols such as LONMARK®, Modbus® or BACnet®.
Table 1, Typical Data Point Availability Typical Data Points1 (W = Write, R = Read) Active Setpoint Actual Capacity Capacity Limit Output Capacity Limit Setpoint Chiller Enable Chiller Limited Chiller Local/Remote Chiller Mode Output Chiller Mode Setpoint Chiller On/Off Chiller Status Compressor Discharge Temp Compressor Percent RLA Compressor Run Hours Compressor Select Compressor Starts Compressor Suction Line Temp R R R W W R R R W R R R R R W R R Cond EWT Cond Flow Switch Status Cond LWT Cond Pump Ru
Unit Design Features Compressor Design Gear-Drive Offers Greater Operating Efficiency Than Direct Drive Centrifugal compressor efficiency is a function of impeller design and application to the refrigeration system. The increased heat transfer surface and efficiency of modern heat exchangers have changed compressor head and impeller tip speed requirements. Direct-drive designs limit the manufacturer’s ability, within a single compressor size, to select impellers at or near peak impeller efficiency.
Systems with refrigerants that operate at a positive pressure, such as R-134a, have smaller impellers and gas lines since these refrigerants require lower gas flow rates. R-123 requires approximately six times the gas flow rate in cfm per ton than R-134a. At ARI standard conditions, 18.1 cfm (8.54 l/sec) of R-123 is required per ton of refrigeration. Contrast this to R-134a that requires only 3.2 cfm (1.5 l/sec) per ton.
Figure 8, HFC 134a Impeller Compared to R-123 Impeller Left: Impeller from a McQuay single stage 300 ton (1050 kW) compressor; diameter = 6.3 in. (16 cm), weight = 3.0 lb (1.4 kg) Right: One of three impellers from a 300 ton negative pressure compressor; diameter = 26 in. (66 cm), weight = 27 lb. 12.2 kg) Single Stage Simplicity = Savings Compressor efficiency is not a function of multiple impellers.
Figure 9, McQuay’s million-dollar compressor test stand with advanced data acquisition provides comprehensive information on new compressor designs. Bearings Since the impeller shaft must be sized to support the static, rotational and torsional loads applied by the impeller, as impellers become larger, shafts must also become proportionally larger. These factors also come into play in the design or selection of a bearing. The primary criteria used in bearing design are: 1.
Bearing design, and consequently bearing life, is determined largely by the above criteria. Rpm, by itself as an absolute, is only one half of the equation in the design process. One can also see that higher rpm and smaller, lighter parts actually reduce the load and wear on bearings. It is the surface velocity in conjunction with the load to be supported that determines bearing life and therefore bearing selection.
The right side drawing shows the unique McQuay movable discharge geometry. As the capacity reduces, the movable unloader piston travels inward, reducing the discharge cross section area and maintaining the refrigerant velocity. This mechanism allows capacity reduction to 10%. Discharge Line Sound Packages For extremely sensitive projects, an optional discharge line sound package is offered consisting of sound insulation installed on the unit’s discharge line.
For these abnormal conditions, McQuay compressor designers have developed a protective control system that senses the potential for a surge, looks at the entire chiller system operation and takes corrective action if possible; or stops the compressor, to help prevent any damage from occurring. This protection, called “ESP” is provided as standard on all McQuay centrifugal compressors.
• True System Efficiency (KW/ton or COP); deals with the total annual power consumption of a chiller system including auxiliaries such as pumps, purge units, Pre-Vac heaters and fans-of great importance in determining facility energy cost and power plant CO2 emissions.
Retrofit Disassembly It is estimated that fifty percent of retrofit applications require partial or complete disassembly of the chiller. On WSC chillers, McQuay offers two solutions to this problem to best fit job conditions. On-site disassembly-The major components; evaporator, condenser, and compressor, are shipped fully assembled and can be taken apart at the site to facilitate difficult rigging work.
TYPE I ... McQuay provides ease of installation without requiring construction alterations of entryways to your building. The compressor and compressor control box are removed and put on a skid. All associated wiring and piping will remain attached if possible. The remaining loose parts will be packaged in a separate crate. A. B. C. D. E. F. G. H. I. J. K. Blockoffs will cover all openings on the compressor and vessels. The compressor and vessels will receive a nitrogen holding charge.
Table 2, Type I Knockdown Dimensions & Weights UNIT SIZE VESSEL CODE UNIT WIDTH UNIT HEIGHT COMPRESSOR WIDTH HEIGHT COMPRESSOR WEIGHT 050 E1809 / C1609 44.1 (1118.9) 64.6 (1640.3) 20.0 (508.0) 20.8 (528.6) 050 E2009 / C1609 44.1 (1118.9) 64.6 (1640.3) 20.0 (508.0) 20.8 (528.6) 050 E2009 / C1809 44.1 (1118.9) 64.6 (1640.3) 20.0 (508.0) 20.8 (528.6) 050 E2209 / C2009 44.4 (1128.3) 64.6 (1640.3) 20.0 (508.0) 20.8 (528.6) 050 E1812 / C1612 44.1 (1118.9) 64.6 (1640.3) 20.0 (508.0) 20.8 (528.
Table 3, Type II Knockdown Dimensions & Weights UNIT SIZE VESSEL CODE CONDENSER HEIGHT 35.3 (895.6) 35.3 (895.6) 35.3 (895.6) 37.4 (948.9) 35.3 (895.6) 35.3 (895.6) 35.3 (895.6) 37.4 (948.9) 36.8 (933.5) 36.8 (933.5) 36.8 (933.5) 36.8 (933.5) 42.3 (1073.2) 42.3 (1073.2) 36.8 (933.5) 36.8 (933.5) 36.8 (933.5) 36.8 (933.5) 42.3 (1073.2) 42.3 (1073.2) 33.1 (841.0) 35.9 (911.4) 39.3 (997.0) 39.3 (997.0) 45.8 (1162.1) 45.8 (1162.1) 33.1 (841.0) 35.9 (911.4) 39.3 (997.0) 39.3 (997.0) 45.8 (1162.1) 45.8 (1162.
Type II Table Continued UNIT SIZE OIL PUMP VESSEL CODE WIDTH HEIGHT CONDENSER WEIGHT EVAPORATOR WEIGHT COMPRESSOR WEIGHT UNIT SHIPPING WEIGHT 6972 (3162) 7330 (3326) 7595 (3445) 8238 (3737) 7704 (3495) 8133 (3689) 8467 (3841) 9277 (4208) 9612 (4360) 10319 (4681) 10616 (4815) 11448 (5193) 12184 (5527) 14092 (6392) 10484 (4756) 11382 (5163) 11757 (5333) 12777 (5796) 13694 (6203) 15103 (6851) 11340 (5144) 12180 (5525) 12916 (5859) 14092 (6392) 15276 (6929) 17113 (7762) 12481 (5661) 13509 (6128) 14426 (6
Pumpdown Pumpout systems provide a means to collect and contain the refrigerant charge without loss, when the access to internal chiller components is required for service. McQuay condensers are sized to hold the entire unit refrigerant charge when not more than 90% full at 90°F (32°C) ambient temperature. They are equipped with a tight-seating check valve at the hot gas inlet and a manual shutoff valve in the liquid outlet.
Options and Accessories Vessels Marine water boxes Provides tube access for inspection, cleaning, and removal without dismantling water piping. Flanges (Victaulic® connections are standard) ANSI raised face flanges on either the evaporator or condenser. Mating flanges are by others. 0.028 or 0.035 in. tube wall thickness For applications with aggressive water conditions requiring thicker tube walls.
NEMA 4 watertight enclosure For use where there is a possibility of water intrusion into the control panel. NEMA 12 Dust tight enclosure For use in dusty areas. Controls English or Metric Display Either English or metric units for operator ease of use. BAS interface module for the applicable protocol being used. Factory-installed on the unit controller (can also be retrofitted). See page 21 for details. Unit Export packaging Can be either slat or full crate for additional protection during shipment.
Motor Controllers Motor Starters McQuay has a wide variety of starter types and options to fit virtually all applications. The specifics of the final selection of size, enclosure, and options are covered in the catalog PM Starters. Please consult the local McQuay sales office or the starter catalog for starter details. This section contains a general overview only. Mounting Options, Low Voltage, 200 to 600 Volts Factory-mounted; starters furnished, mounted and wired in the factory.
Variable Frequency Drives Impact of Variable Frequency Drives The chart below illustrates the relative IPLV efficiencies of various McQuay options for a typical 500-ton selection. The chiller cost increases as the efficiency improves. Comparative Efficiencies (kW/Ton) .6 .505 IPLV .5 .403 .4 .365 .337 .
Standard Components 1) 2) 3) 4) 5) 6) 7) 8) 9) Incoming and outgoing power terminals. Transformer to supply power to the control circuit, oil heaters and oil pump. Redundant motor control relays with coils in series. The VFD is current rated at 2 kHz carrier frequency for all 200–1000 HP drives. The drive is capable of running at 110% of nameplate current continuously and provides a minimum of 150% of this rated current for 5 seconds.
g) Standard input/output (I/O) Expansion Interface Card with the following features: − − − − − − − 10) Proportional/integral (PI) regulator for setpoint control Four isolated 24 VDC programmable digital inputs An additional analog input for speed feedback to PI regulator One frequency input (0 to 200 Hz) for digital control of current limit Four programmable isolated digital outputs (24 VDC rated) One form A output relay rated at 250 VAC or 24 VDC Two NO/NC programmable output relays rated at 250 VAC or 24
VFD Line Harmonics Care must be taken when applying VFDs due to the effect of line harmonics on the electric system. VFDs cause distortion of the AC line because they are nonlinear loads; that is, they don't draw sinusoidal current from the line. They draw their current from only the peaks of the AC line, thereby flattening the top of the voltage waveform. Some other nonlinear loads are electronic ballasts and uninterruptible power supplies.
Figure 12, VFD (047 and Larger) Cooling Water Piping for Free-Standing VFD * STOP CHILLED WATER PUMP VALVE * BALANCING * STOP VALVE VALVE CHILLER WATER REGULATING VALVE (Factory Mounted) VFD HEAT EXCHANGER SOLENOID VALVE (Factory Mounted) * STOP VALVE * STRAINER * Field Supplied Piping Components * STOP * DRAIN VALVE MAX.
Refrigerant Recovery Units Although McQuay chillers can pump the entire refrigerant charge into the condenser and valve it off, there are occasions when pumpout units are required, due purely to specification requirements or unusual job considerations. McQuay offers two sizes of refrigerant recovery units (Model RRU) and one recovery unit that is factory mounted on a storage vessel (Model PRU). Recovery units are ETL listed. Capacities for R-22 are ARI certified.
MODEL RRU570 Recovers at R-134a at 300 lb/min liquid and 5.7 lb/min vapor, ideal for the medium size chiller job. Rugged 3 hp open-drive compressor provides years of reliable service, even on refrigerants heavily contaminated with oil, air, moisture, or acids. Purging and switching from liquid to vapor recovery only involves turning 3-way valves-no switching of hoses is necessary. Suitable for most high pressure refrigerants and blends. Equipped with air-cooled condenser.
Refrigerant Monitors Detects all halogen based refrigerants Optional analog output for remote monitoring Visual alarm indication Fresh air inlet for automatic re-zeroing ETL listed Continuous digital display of system status System malfunction detection and indication Can sample up to 250 feet (76 meters) away Multi-unit capability in a single monitor UL STD 3101-1 and CAN/CSA 1010.
Unit Selection Many combinations of compressor configuration and condensers and evaporators are available for a given capacity. The units range from low first cost and relatively high kW per ton (COP) to high first cost and low kW per ton (COP). A graphic display of the optional performance available is shown at the right. The COP curve would be mirrored and is not shown for clarity. Optimum unit selection for maximum operating return on the invested first cost is in the area identified by the X.
ARI Standard 550/590-98 for Centrifugal or Screw Water-Chilling Packages and associated manuals define certification and testing procedures and performance tolerances of all units that fall within the application rating conditions. Leaving chilled water temperature ......................... 40°F to 48°F (4.4°C to 8.9°C) Entering condenser water temperature ................... 60°F to 95°F (15.
Application Considerations Optimum Water Temperatures and Flow Rates A key to improving energy efficiency for any chiller is minimizing the lift, or pressure difference, between the compressor suction and discharge pressures. Reducing the lift reduces the compressor work, and hence its energy consumption per unit of output. The chiller typically has the largest motor of any component in a chilled water system.
Low Condenser Water Temperature Operation When ambient wet bulb temperature are lower than design, the condenser water temperature can be allowed to fall. Lower temperatures will improve chiller performance. Up to 300 Tons McQuay centrifugal chillers up to 300 tons are equipped with electronic expansion valves (EXV) and will start and run with entering condenser water temperatures as low as shown in Figure 13 or as calculated from the following equation on which the curves are based.
Figure 14, Minimum Entering Condenser Water Temperature (TXV) Minimum Entering Condenser Water Temperature - 10 F Range 65.0 44 LChWT 42 LChWT 46 LChWT 60.0 ECWT, F 55.0 50.0 45.0 40.0 35.0 30.0 0 10 20 30 40 50 60 70 80 90 100 110 Percent Load For example; at 44°F LWT, 10 degree F Delta-T, and 50% full load operation, the entering condenser water temperature could be as low as 50.5°F. This provides excellent operation with water-side economizer systems.
Mixing Single and Dual Compressor Chillers Dual compressor chillers excel at part load operation, while single compressor chillers usually have better full load efficiency. A good chiller plant strategy is to install one dual and one or more single compressor units. Run the dual until it is fully loaded, then switch to the single compressor unit and run it only at full load, using the dual to trim the load.
Oil Coolers McQuay centrifugal chillers, sizes 063 through 126, have a factory-mounted, water-cooled oil cooler with a temperature controlled water regulating valve and solenoid valve for each compressor. Cooling water connections are located at the rear of the unit, near the compressor and are shown on the specific unit certified drawings. Models WDC 063 through 087 have the cooling water connections in the lower portion of one tube sheet.
Cooling Water Connection Sizes: WDC 100/126 have 1 1/2 in. FPT connections, all other WDC and WSCs are 1 in. FPT. Figure 18, Oil Cooler Piping Across Chilled Water Pump PUMP CHILLER R S OIL COOLER STOP VALUE SOLENOID VALVE STOP VALVE STRAINER MAX. 40 MESH DRAIN VALVE OR PLUG Figure 19, Oil Cooler Piping With City Water R OIL COOLER S SOLENOID VALVE WATER SUPPLY COOLING TOWER STOP VALVE STRAINER MAX.
outlet of the pump. Vibration eliminator sections in the condenser inlet and outlet water lines are not normally required. Where noise and vibration are critical and the unit is mounted on spring isolators, flexible piping and conduit connections are necessary. If not factory installed, a flow switch or pressure differential switch must be installed in the leaving chilled water line in accordance with the flow switch manufacturer’s instructions.
operate during the day, when cooling tower water temperatures are high, a proper selection becomes more difficult because the two refrigerant pressure differentials are significantly different. A three-way condenser water control valve is always required. Variable Speed Pumping Variable speed pumping involves changing system water flow relative to cooling load changes. McQuay centrifugal chillers are designed for this duty with two limitations.
until the hot material is dipped into the water tank. Then, the load would increase drastically. Large storage capacity will usually be required for this type of application. System volume = {1000 gpm x 3 minutes} + {(5 increment of 10% increase) x (3 minutes) x 1000 gpm} = 18,000 gallons Since there are many other factors that can influence performance, systems can successfully operate below these suggestions.
d = inside diameter of pipe ln = natural logarithm P2 = absolute pressure at outlet of discharge piping, psi (kPa) Po = allowed back pressure (absolute) at the outlet of the relief valve. psi (kPa), 15% of set pressure, Po = (0.15P) + atmospheric pressure McQuay centrifugal chillers have the following relief valve settings and discharge capacity: WSC evaporator and condenser = 200 psi, 75.5 lb of air/min WDC evaporator = 180 psi, 68.5 lb of air/min WDC condenser = 225 psi, 84.
NOTES for Following Wiring Diagram 1. Compressor motor starters are either factory mounted and wired, or shipped separate for field mounting and wiring. If provided by others, starters must comply with McQuay specification 359AB99. All line and load side power conductors must be copper. 2. If starters are freestanding, then field wiring between the starter and the control panel is required. Minimum wire size for 115 Vac is 12 GA for a maximum length of 50 feet.
Figure 21, Typical Field Connection Diagram, WSC Unit MICROTECH CONTROL BOX TERMINALS (115V) GND (24V) PE 54 85 POWER * NOTE 7 86 NEUTRAL * NOTE 10 * COOLING TOWER FOURTH STAGE STARTER 55 O C4 74 H A O 86 * NOTE 10 O A EP2 86 C 79 H * COOLING TOWER THIRD STAGE STARTER 70 80 H C3 73 H A O EP1 78 A C 77 * NOTE 10 76 H * COOLING TOWER SECONDH STAGE STARTER O C2 75 A H O * NOTE 10 O A CP2 H * COOLING TOWER FIRST STAGE STARTER C T3-S C1 A EF CF 81 COMMON
Control Power The 115-volt control power can be supplied from the starter or a transformer (meeting the requirements of McQuay Specification 359A999) separate from the starter. Either source must be properly fused with 20-amp dual element fuses or with a circuit breaker selected for motor duty. If the control transformer or other power source for the control panel is remote from the unit, conductors must be sized for a maximum voltage drop of 3%. Required circuit ampacity is 20 amps at 115 volts.
Chiller Identification To provide a wide range of components to match job requirements of capacity, efficiency and competitive initial cost, McQuay WSC and WDC centrifugal chillers are selected by computer and identified by their components. The variations of compressor, impeller, gear ratio, evaporator and condenser tube surface and configuration provide over 1,000,000 combinations of standard components within the range of 80 to 2,500 tons. It is impractical to catalog all of these combinations.
Physical Data and Weights Evaporator The optional insulation of cold surfaces includes the evaporator and non-connection water head, suction piping, compressor inlet, motor housing, and motor coolant suction line. The insulation used is UL recognized (File # E55475). It is 3/4" thick ABS/PVC flexible foam with skin having a K factor of 0.28 at 75°F. The sheet insulation is fitted and cemented in place forming a vapor barrier, then painted with a resilient epoxy finish that resists cracking.
Condenser With positive pressure systems, the pressure variance with temperature is always predictable, and the vessel design and relief protection are based upon pure refrigerant characteristics. Negative pressure systems are not ASME designed, inspected and stamped. R-134a requires ASME vessel design, inspection and testing and uses spring-loaded pressure relief valves. Negative pressure units use rupture disks. When an over pressure condition occurs, the rupture disk is permanently destroyed.
Dimensions Notes: 1. Drawings included in this section are for rough layout purposes only. Detailed certified drawings, as pdf hard copies o dgm files, are available from the local McQuay sales office. Do not use for final construction drawings. 2. Obtain specific unit certified drawings for detailed dimensions of water, oil cooler, and relief valve connections. 3. Dimensions in inches (mm). 4. See Physical Data and Weights section for component and unit weights. 5.
Figure 24, WSC 063, 160 to 300 Tons (560 to 1050 kW) ADJUSTABLE OPERATOR INTERFACE PANEL UNIT CONTROL BOX 1” FPT VESSEL RELIEF VALVE CONNECTIONS FACTORY MOUNTED STARTER (OPTIONAL) B 0.75” FPT OIL COOLER CONNECTION EVAPORATOR CONDENSER Y X A D E OUT IN F G OUT IN Y Z C C +17” VESSEL CODE EVAP COND E2009 C1809 E2012 C1812 E2209 C2009 E2212 C2012 E2209 C2209 E2212 C2212 E2609 C2209 E2612 C2212 E2609 C2609 E2612 C2612 E3012 C2612 E3009 C2609 OVERALL LENGTH 1&3 PASS 2 PASS HEAD CONN.
Figure 25, WSC 079/087, 300 to 600 Tons (1050 to 2110 kW) ADJUSTABLE OPERATOR INTERFACE PANEL UNIT CONTROL BOX 1” FPT VESSEL RELIEF VALVE CONNECTIONS FACTORY MOUNTED STARTER (OPTIONAL) B EVAPORATOR 0.
Figure 26, WSC 100-113-126, 600 to 1300 Tons (2100 to 4550 kW) ADJUSTABLE OPERATOR INTERFACE PANEL UNIT CONTROL BOX 1” FPT VESSEL RELIEF VALVE CONNECTIONS FACTORY MOUNTED STARTER (OPTIONAL) B EVAPORATOR 1” FPT OIL COOLER CONNECTION CONDENSER Y X A D E IN F OUT G OUT IN Y Z C C +28” VESSEL CODE EVAP COND E3012 C3012 E3612 C3012 E3612 C3612 E4212 C3612 E4212 C4212 E4812 C4212 E4812 C4812 OVERALL LENGTH 1&3 PASS 2 PASS CONNECTIONS OVERALL OVERALL HEAD CONN HEIGHT WIDTH W/O
Figure 27, WDC 048/050, 180 to 320 tons (630 to 4620 kW) ADJUSTABLE OPERATOR INTERFACE PANEL UNIT CONTROL BOX 1” FPT VESSEL RELIEF VALVE CONNECTIONS B STARTER (OPTIONAL) EVAPORATOR STARTER (OPTIONAL) 1” FPT OIL COOLER CONNECTION Y CONDENSER X A D OUT IN FOOTPRINT OUT IN Y Z C C + 20” VESSEL CODE EVAP COND E2212 C2212 E2216 C2216 E2412 C2212 E2416 C2216 E2612 C2212 E2616 C2216 OVERALL LENGTH 1&3 2 PASS PASS OVERALL OVERALL HEAD CONN HEIGHT WIDTH W/O BOTH ENDS STARTER CONNE
Figure 28, WDC 063, 320 to 600 tons (1120 to 2100 kW) UNIT CONTROL BOX ADJUSTABLE OPERATOR INTERFACE PANEL 1” FPT VESSEL RELIEF VALVE CONNECTIONS B STARTER (OPTIONAL) EVAPORATOR STARTER (OPTIONAL) 1” FPT OIL COOLER CONNECTION Y CONDENSER X A D OUT IN FOOTPRINT OUT IN Y Z C C + 15” VESSEL CODE OVERALL LENGTH 1&3 EVAP COND E2416 C2416 E2416 C2616 E2616 C2416 E2616 C2616 E3016 C3016 E3616 C3016 E3616 C3616 PASS OVERALL OVERALL HEAD CONN HEIGHT WIDTH W/O STARTER PASS .
Figure 29, WDC 079 and WDC 087, 600 to 1200 tons (2100 to 4220 kW) ADJUSTABLE OPERATOR INTERFACE PANEL UNIT CONTROL BOX 1” FPT VESSEL RELIEF VALVE CONNECTIONS B STARTER (OPTIONAL) EVAPORATOR STARTER (OPTIONAL) 1” FPT OIL COOLER CONNECTION Y CONDENSER X A D OUT IN FOOTPRINT OUT IN Y Z C SEE NOTE 1 VESSEL CODE EVAP COND E3016 C3016 E3616 C3016 E3616 C3616 E4216 C4216 OVERALL LENGTH 1&3 2 PASS PASS OVERALL OVERALL WIDTH W/O HEIGHT CENTER OF GRAVITY BOTH ENDS STARTER CONNECTIONS HEAD CON
Figure 30, WDC 100, 1200 to 1700 tons, (4200 to 5950 kW), 16 foot shells WDC 113, 1400 to 1900 tons, (4900 to 6700 kW), 16 foot shells WDC 126, 1600 to 2700 tons, (5600 to 9450 kW), 16 foot shells ADJUSTABLE OPERATOR INTERFACE PANEL UNIT CONTROL BOX 1” FPT VESSEL RELIEF VALVE CONNECTIONS EVAPORATOR 1.
Figure 31, WDC 100, 1200 to 1700 tons, (4200 to 5950 kW), 20 foot shells WDC 113, 1400 to 1900 tons, (4900 to 6700 kW), 20 foot shells WDC 126, 1600 to 2700 tons, (5600 to 9450 kW), 20 foot shells ADJUSTABLE OPERATOR INTERFACE PANEL B UNIT CONTROL BOX EVAPORATOR 1.
Marine Water Boxes (WSC) Marine water boxes are an available option on all evaporator and condenser sizes. Epoxy coating of the water boxes and clad tube sheets are available for extreme duty applications. Caution: There is some nomenclature confusion in the industry. McQuay refers to our standard dished heads as “dished heads”. Some manufacturers refer to them, or similar devices as “water boxes”. They are not “marine water boxes” with removable end covers as illustrated below.
Marine Water Boxes (WDC) FIGURE 1 FIGURE 2 2 and 4 Pass Cond. (Except 18 in. 2 Pass) Evap. And Cond. 1 Pass Cover Thickness “C” Nozzle Flanges Are Optional .50 “D” “A” “B” “F” FIGURE 3 FIGURE 4 2 and 4 Pass Cond. (Except 18 in. 2 Pass) All 2 Pass Evap. - All 3 Pass Cond. 18 in. 2 Pass Cond. Nozzle Flanges Are Optional Nozzle Flanges Are Optional “E” “E” “E” “E” .50 .50 “D” “D” Notes: Shell Vessel O.D.
Table 13, Unit Weights, Single Compressor, WSC 1809 / 1609 1812 / 1612 2009 / 1609 2012 / 1612 2009 / 1809 2012 / 1812 2209 / 2009 2212 / 2012 Unit Refrig. Charge (1) Lbs. (kg) 341 (154) 447 (202) 395 (179) 519 (235) 410 (186) 539 (244) 479 (216) 631 (287) Max. Unit Weight Without Starter Shipping Operating lbs. (kg) lbs.
Table 14, Dual Compressor, WDC Max. Unit Weight Without Starter Shipping Operating lbs. (kg) lbs. (kg) Max. Unit Weight With Starter Shipping Operating lbs. (kg) lbs.
Supplemental Publications McQuay has a large number of publications and software applications relating to centrifugal chillers and to chilled water systems in general. The latest versions are available on www.mcquay.com or from the local McQuay sales office. Some of the available material is listed below: Catalogs/Manuals • PM Templifier, a catalog with detailed information on the capacities and application of Templifier™ Heat Pump Water Heaters.
Specifications SECTION 15XXX CENTRIFUGAL CHILLERS SINGLE COMPRESSOR PART 1 — GENERAL 1.1 SUMMARY Section includes design, performance criteria, refrigerants, controls, and installation requirements for water-cooled centrifugal chillers. 1.2 REFERENCES Comply with the following codes and standards ARI 550/590 NEC ANSI/ASHRAE 15 OSHA as adopted by the State ASME Section VIII 1.3 SUBMITTALS Submittals shall include the following: A.
PART 2 — PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. McQuay International B. (Approved Equal) 2.2 UNIT DESCRIPTION Provide and install as shown on the plans a factory-assembled, factory charged, and factory runtested water-cooled packaged chiller.
C. D. E. 82 Refrigerant Evaporator and Condenser: 1. Evaporator and condenser shall be of the shell-and-tube type, designed, constructed, tested and stamped according to the requirements of the ASME Code, Section VIII. Regardless of the operating pressure, the refrigerant side of each vessel will bear the ASME stamp indicating compliance with the code and indicating a test pressure of 1.1 times the working pressure, but not less than 100 psig.
3. F. Catalog WSC/WDC-4 For open motor units, an oil reservoir shall collect any oil and refrigerant that leaks past the seal. A float device shall be provided to open when the reservoir is full, directing the refrigerant/oil mixture back into the compressor housing.
chiller control shall coordinate compressor speed and guide vane position to optimize chiller efficiency. 1. A digital regulator shall provide V/Hz control. 2. The VFD shall have 110% continuous overload of continuous amp rating with no time limit, PWM (pulse width modulated) output, IGBT (insulated gate bipolar transistors) power technology, full power rating at 2kHz, DC bus inductor (choke), and wireless construction. 3.
G. Catalog WSC/WDC-4 Main Control Relays Redundant motor control relays with coils in parallel and contacts in series to interlock the starter with the chiller. These two relays shall constitute the only means of energizing the motor contractors. No other devices (manual or automatic) with the capability of energizing the starter can be used. The starter is controlled by the unit microprocessor. Motor Protection and Overloads The starter shall include overload protection functions.
In addition to the trended items above, other real-time operating parameters are also shown on the touchscreen. These items can be displayed in two ways: by chiller graphic showing each component or from a color-coded, bar chart format.
For chillers communicating over a LONMARK network, the corresponding LONMARK eXternal Interface File (XIF) shall be provided with the chiller submittal data. All communication from the chiller unit controller as specified in the points list shall be via standard BACnet objects. Proprietary BACnet objects shall not be allowed. BACnet communications shall conform to the BACnet protocol (ANSI/ASHRAE1352001).
F. G. 3.2 START-UP A. B. 88 Coordinate controls with control contractor. Provide all materiel required to ensure a fully operational and functional chiller. Units shall be factory charged with the proper refrigerant and oil. Factory Start-Up Services: Provide for as long a time as is necessary to ensure proper operation of the unit, but in no case for less than two full working days.
SECTION 15XXX CENTRIFUGAL CHILLERS DUAL COMPRESSOR PART 1 — GENERAL 1.1 SUMMARY Section includes design, performance criteria, refrigerants, controls, and installation requirements for water-cooled centrifugal chillers. 1.02 REFERENCES Comply with the following codes and standards ARI 550/590 NEC ANSI/ASHRAE 15 OSHA as adopted by the State ASME Section VIII 1.3 SUBMITTALS Submittals shall include the following: A.
2.3 Provide and install as shown on the plans a factory assembled, charged, and run-tested water-cooled packaged chiller. Each unit shall be complete with two single-stage hermetic centrifugal compressors each having independent lubrication and control systems, factory mounted starters, and isolation valves. The evaporator, condenser, and refrigerant control device of each unit shall be common to the compressors.
2. D. E. Catalog WSC/WDC-4 Tubes shall be enhanced for maximum heat transfer, rolled into steel tube sheets and sealed with Locktite or equal sealer. The tubes shall be individually replaceable and secured to the intermediate supports without rolling. 3. Provide sufficient isolation valves and condenser volume to hold full refrigerant charge in the condenser during servicing or provide a separate pumpout system and storage tank sufficient to hold the charge of the largest unit being furnished. 4.
F. 92 Manufacturer shall warrant the shaft seal, reservoir, and float valve system against leakage of oil and refrigerant to the outside of the refrigerating unit for a period of 5 years from the initial start-up including parts and labor to replace a defective seal and any refrigerant required to trim the charge original specifications. 4. The starters must comply with Section 1.2 as required. Low Voltage (200 through 600 volts) controllers are to be continuous duty AC 5.
2. 3. A digital regulator shall provide V/Hz control. The VFD shall have 110% continuous overload of continuous amp rating with no time limit, PWM (pulse width modulated) output, IGBT (insulated gate bipolar transistors) power technology, full power rating at 2kHz, DC bus inductor (choke), and wireless construction. 4. Units 273 amps and below shall be air-cooled, units above 274 amps shall be water-cooled.
G. 94 Redundant motor control relays with coils in parallel and contacts in series to interlock the starter with the chiller. These two relays shall constitute the only means of energizing the motor contractors. No other devices (manual or automatic) with the capability of energizing the starter can be used. The starter is controlled by the unit microprocessor. Motor Protection and Overloads The starter shall include overload protection functions.
each component or from a color-coded, bar chart format.
2.5. MISCELLANEOUS ITEMS A. Pumpout System: The unit shall be equipped with a pumpout system complete with a transfer pump, condensing unit, and storage vessel constructed according to ASME Code for Unfired Pressure Vessels and shall bear the National Boards stamp. If the design of the unit allows the charge to be transferred to and isolated in the main condenser, then a pumpout system is not required.
Catalog WSC/WDC-4 97
Catalog WSC/WDC-4
This document contains the most current product information as of this printing. For the most up-todate product information, please go to www.mcquay.com. Post Office Box 2510, Staunton, Virginia 24402 • (800) 432-1342 • www.mcquay.
