Installation, Operation and Maintenance Manual: Date: October 2005 Supersedes
Installation, Operation and Maintenance Manual: Date: October 2005 Supersedes
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Inspection
When the equipment is received, all items on the bill of lading should be carefully checked to insure a complete
shipment. All units should be carefully checked and all shipping damage should be reported to the carrier. The unit
serial plate should be checked before unloading the unit to be sure that it agrees with the power supply available.
Physical damage to unit after acceptance is not McQuay’s responsibility.
Responsibilities
McQuay Italia declines all present and future responsabilities referred to injuries to people and damage to things
and unit, coming from operators negligence, the unrespected installation/maintenance data carrier in this manual,
the lacking of the current regulations respect referred to the safety of the equipment and the qualified personnel.
Characteristics
General description
McQuay International introduces their newest water cooled screw chillers equipped with new single screw
compressors.
McQuay water cooled WHS XE chillers equipped with 1, 2, 3 and 4 McQuay screw compressors are a new range
of the unit using the StarGateTM Frame 4 single screw compressors. They are manufactured by McQuay to satisfy
the requirements of the consultants and the end user. McQuay WHS XE units are designed to minimise energy
costs while maximising the refrigeration capacities. Once again McQuay has developed a line of chillers
unsurpassed in performance and quality that will meet the most stringent requirements of comfort cooling, ice
storage and process applications.
McQuay’s chiller design experience, combined with outstanding features makes the WHS XE chiller unmatched in
the industry.
Safety measures
The unit must be suitably clamped to the ground.
It is necessary to follow these cautions and warnings:
- The unit must be lifted only by using the proper tools able to support the weight of the unit.
- No admittance to unauthorized or unqualified personnel should be allowed.
- No operation on electrical components is allowed without having switched off electricity supply.
- No operation on electrical components is allowed without using insulated platforms; no water or moisture should
be present.
- All the operation on refrigerant circuit and pressurised components are to be performed by qualified personnel
only.
- Compressor substitution or oil addition must be performed by qualified personnel only.
- Avoid contamination of unrelated bodies into the water piping during the unit connection to the water system.
- It is necessary that a mechanical filter is fitted to the piping connected to the exchangers entry.
Warning
Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and
regulations, and who are experienced with this type of equipment. Must be avoided the installation of the unit in
places that could be considered dangerous for maintenance operations.
Location
A levelled and sufficiently strong floor is required. If necessary, additional structural members should be provided
to transfer the weight of the unit to the nearest beams.
Rubber-in-shear isolators can be furnished and field placed under each corner of the package. A rubber anti–skid
pad should be used under isolators if hold-down bolts are not used.
Vibration isolator in all water piping connected to the chiller are recommended to avoid straining the piping and
transmitting vibration and noise.
Compressor Condensation
Condensation occurs on the compressor surface when the temperature of the compressor surface is lower than
the ambient dew point temperature. Drain pans with drain connections are provided underneath each compressor
to collect the condensate. The compressor motor housing extends past the drain pans. Install a floor drain close to
the unit to collect condensate from motor housing and condensate pans.
Water treatment
If unit is operating with a cooling tower, clean and flush cooling tower. Make sure tower "blowdown" or bleedoff is
operating. Atmospheric air contains many contaminants which increases the need for water treatment. The use of
untreated water may result in corrosion, erosion, sliming, scaling, or algae formation. A water treatment service is
recommended. McQuay International is not responsible for damage or faulty operation from untreated or
improperly treated water.
Note: Freeze damage is not considered a warranty failure and is not the responsibility of McQuay International.
Water piping
Due to the variety of piping practices, it is advisable to follow the recommendations of local authorities. They can
supply the installer with the proper building and safety codes required for a safe and proper installation.
Basically, the piping should be designed with a minimum number of bends and changes in elevation to keep
system cost down and performance up. It should contain:
1. Vibration eliminators to reduce vibration and noise transmission to the building.
2. Shutoff valves to isolate the unit from the piping system during unit servicing.
3. Manual or automatic air vent valves at the high points of the system. Drains at the low parts in the system. The
evaporator should not be the highest point in the piping system.
4. Some means of maintaining adequate system water pressure (e.g., expansion tank or regulating valve).
5. Water temperature and pressure indicators located at the unit to aid in unit servicing.
Prior to insulating the piping and filling the system, a preliminary leak check should be made.
Refrigerant Charge
All units are designed for use with HFC-134a and are shipped with a full operating charge. The operating charge
for each unit is shown in the Physical Data Table.
Flow Switch
A water flow switch must be mounted in either the entering or leaving water line to insure that there will be
adequate water flow to the evaporator before the unit can start. This will safeguard against slugging the
compressors on start-up. It also serves to shut down the unit in the event that water flow is interrupted to guard
against evaporator freeze-up. A flow switch is available from McQuay and it is a "paddle" type switch and
adaptable to any pipe size from 1" (25mm) to 8" (203mm) nominal.
Certain minimum flow rates are required to close the switch and are listed in Table 1.
Tee
MINIMUM REQUIRED FLOW
NOMINAL PIPE
TO ACTIVATE SWITCH –
SIZE INCHES (MM)
LITERS PER SECONDS
5 (127) 3.7
6 (152) 5.0
8 (203) 8.8
Figure 3 – Flow Switch
Table 1
60
Leaving condenser water temp. (°C)
55
50
45
40
35
30
25
20
15
-10 -5 0 5 10 15 20
Leaving evaporator water temp. °C
Note: (1) Nominal cooling capacity and power input are based on: 12/7 °C entering/leaving evaporator water temperature;
30/35 °C entering/leaving condenser water temperature. The power input is for compressor only.
Note: (1) Allowed voltage tolerance ± 10%. Voltage unbalance between phases must be within ± 3%.
(2) Absorbed current referred to nominal condition: 12/7 °C entering/leaving evaporator water temperature; 30/35 °C
entering/leaving condenser water temperature.
(3) Absorbed current referred to the following conditions: 14/9 °C entering/leaving evaporator water temperature;
50/55°C entering/leaving condenser water temperature.
(4) StarDelta inrush current for the unique compressor (units 098.1÷138.1); absorbed current of compressor n°1 at 75%
+ inrush current of second compressor (units 196.2÷272.2).
(5) Compressor FLA (Full Load Ampere)
Note: in case of pressure drop higher than 100 kPa, it is necessary to contact the factory.
Note: in case of pressure drop higher than 100 kPa, it is necessary to contact the factory.
Note: in case of pressure drop less than 10 kPa it is necessary install a 4 passes
condenser
Note: in case of pressure drop higher than 100 kPa, it is necessary to contact the factory.
Standard controls
High pressure control
The high pressure switch will shut-down the compressor when the discharge pressure exceeds the setting point
value.
Warning: during testing, stand by the emergency stop switch on control panel, to shut the unit down should the
safety control malfunction. Be sure that the installed gauge is accurately adjusted.
Phase/voltage monitor
The phase/voltage monitor is a device which provides protection against three-phase electrical motor loss due to
power failure conditions, phase loss, and phase reversal. Whenever any of these conditions occur, a contact
opens to the microprocessor which then de-energizes all inputs. When proper power is restored, contacts close
and microprocessor enables compressors for operation. When three-phase power has been applied, the output
relay should close and the "run light" should come on. If the output relay does not close, perform the following
tests:
1. Check the voltages between L1-L2, L1-L3 and L2-L3 (L1, L2, L3 are the three phases). These voltages should
be approximately equal and within + 10% of the rated three-phase line-to-line voltage.
2. If these voltages are extremely low or widely unbalanced check the power system to determine the cause of the
problem.
3. If the voltages are good, using a phase tester, verify that phases are in A, B, C sequence for L1, L2 and L3.
Correct rotation is required for compressor operation. If required to do so by phase sequence, turn off the power
and interchange any two of the supply power leads at the disconnect. This may be necessary as the phase voltage
monitor is sensitive to phase reversal. Turn on the power. The output relay should now close after the appropriate
delay.
System Maintenance
General
To ensure proper operation at peak capacity and to avoid damage to package components, a program of periodic
inspections should be set up and followed. The following items are intended as a guide and are to be used during
inspection and must be combined with sound refrigeration and electrical practicies to ensure trouble-free
performance. The liquid line sightglass indicator on all circuits must be checked to be sure the glass is full and
clear. If the indicator shows that a wet condition exists or if bubbles show in the glass, even with a full refrigerant
charge, the filter-drier element must be changed.
Caution: It is necessary to de-energize the complete panel, including crankase heater, before doing any servicing
inside.
Prior to attempting any service on the control centre it is advisable to study the wiring diagram so that you
understand the operation of the water chiller. Electrical components do not require particular maintenance other
than a monthly tightening of cables.
Warning: The warranty becomes void if the wiring is not in accordance with the specification. A blown fuse or
tripped protector indicates a short ground or overload.
Before replacing the fuse or restarting the compressor, the problem must be found and corrected. It is important to
have a qualified control panel electrician service this panel. Unqualified tampering with the controls can cause
serious damage to equipment and void the warranty.
Refrigerant sightglass
The refrigerant sightglasses should be observed periodicaly (a weekly observation should be adequate). A clear
glass of liquid indicates that there is adequate refrigerant charge in the system to insure proper feed through the
expansion valve. Bubbling refrigerant in the sightglass, during stable run conditions, indicates that the system may
be short of refrigerant charge. Refrigerant gas flashing in the sightglass could also indicate an excessive pressure
drop in the liquid line, possibly due to a clogged filter-drier or a restriction eisewhere in the liquid line. If subcooling
is low add charge to clear the sightglass. If subcooling is normal and flashing is visible in the sightglass check the
pressure drop across the filter-drier. An element inside the sightglass indicates the moisture condition
corresponding to a given element color. If the sightglass does not indicate a dry condition after about 3 hours of
operation, the unit should be pumped down and the filter-driers changed.
The following table is a guide to determinate the dry or wet condition of the system:
COLOUR MEANS
Green (Sky Blue) Dry
Yellow (Pink) Wet
Filter-driers
A replacement of the filter-drier is recommended during scheduled service maintenance of the unit, any time
excessive pressure drop is read across the filter-drier and/or when bubbles occur in the sightglass with normal
subcooling. The maximum recommended pressure drop across the filter-drier at 75% to 100% circuit loading is 70
kPa. The maximum recommended pressure drop across the filter-drier at 25% to 50% circuit loading is 35 kPa.
The filter-drier should also be changed if the moisture indicating liquid line sightglass indicates excess moisture by
the wet system color indicators. During the first few months of operation the filter-drier replacement may be
necessary if the pressure drop across the filter-drier exceeds the values listed in the paragraph above. Any
residual particles from the unit heat transfer tubing, compressor and miscellaneous components are swept by the
refrigerant into the liquid line and are caught by the filter-drier.
To change the filter drier, pump the unit down by moving the ON/OFF compressors switches in “off” position.
Move the ON/OFF switch unit Q0 to the “off” position. Turn off all power to the unit and install jumpers across the
terminals.
This jumps out the low pressure control. Close the manual liquid line shutoff valve.
Turn the power of the unit back on and restart the unit by moving the ON/OFF switch unit Q0. The unitwill start
pumping down past the low pressure setting.
Evaporator
The evaporator is a direct expansion type with refrigerant inside the copper tubes and water on the outside. The
evaporators are manufactured with carbon steel shells, high efficiency copper tubes and polypropylene baffles.
The copper tubes are roll expanded into carbon steel tube plates.
Condensers
Condensers are shell and cleanable, through-tube type (1 pass). The unit has indenpendent condensers, one per
circuit. Each condenser has a carbon steel and seamless, integrally finned high efficiency copper tubes, roll
expanded into heavy carbon steel tube sheets. Water heads are removable and include vent and drain plugs.
Condensers come complete with liquid shut-off valve, spring loaded relief valve.
Note: The units are furnished with 1 pass condensers as standard (water entering a side and water leaving the
opposide side of the heat exchanger). On request the chillers will be equipped with 2 passes condensers (entering
and leaving water on the same side of the heat exchanger); two different options are available:
o condensers two passes standard water ∆T (∆T between 4 and 8 °C)
o condensers two passes high water ∆T (∆T between 8 and 15 °C). In this case total heat recovery is not
available.
Lubrificating oils
Besides lubrificating the bearing and other moving parts, the oil has the equally important task of sealing the
clearances between the rotors and other potential leakage paths thereby improving pumping efficiency; the oil also
assists in dissipating the heat of compression. The amount of oil injected is therefore well in excess of that
required for lubrification alone.
Lubricating oil approved for use with McQuay Screw compressor is POE Emkarate RL220H.
The oil differential pressure switch monitors the pressure differential between oil injection pressure and
compressor suction pressure.
After the compressor has started and been in operation for a short time, allowing sufficient time for the system
pressure differential to become established, the oil differential pressure switch is brought into the safety trip circuit.
Oil is now being supplied to the compressor under the action of the system pressure differential, monitored by the
switch. If the pressure differential falls below the switch contacts ‘ break ’ setting and the oil differential pressure
switch trips and stops the compressor.
Because the oil pressure is generated by discharge pressure, a minimum discharge pressure must be maintained;
this minimum pressure increases as the suction pressure increases in order to maintain the pressure difference
required.
Warning: Verify the heaters have operated for at least 12 hours prior to start-up.
Refrigerant
Refrigerant charging
WHS XE water cooled screw chillers are shipped factory charged with a full operating charge of refrigerant but
there may be times that a unit must be recharged at the jobsite. Follow these recommendations when field
charging. WHS XE water cooled screw chillers are more sensitive to under-charging than to overcharging
therefore it is preferable to be slightly overcharged rather than undercharged on a circuit. The optimum charge is
the charge which allows the unit to run with a solid stream of liquid in the liquid line at all operating conditions.
When the liquid line temperature does not drop with the addition of 2,2-4,5 Kg of charge then the subcooler is
nearly full and proper charge has been reached. If the liquid line temperature does not drop and the discharge
pressure goes up 20,7-34,5 kPa as 2,2-4,5 Kg of refrigerant is added the correct maximum charge has been
reached. Unit charging can be done at any steady load condition, at any outdoor ambient temperature. Unit must
be allowed to run 5 minutes or longer so that the condenser fan staging is stabilized at normal operating discharge
pressure.
In case moisture is noticed in the system, through the moisture indicator, the system must be evacuated to
eliminate cause of trouble. After the evacuation, the system must be dried reducing it to an almost perfect vacuum.
For this purpose, a displacement vacuum pump should be used.
Any moisture and air left in the system will be absorbed by the dry nitrogen used to break the vacuum, and they
will be almost completely removed by the three evacuations.
If burnt oil or sludge are found in the refrigerant circuit (caused by the compressor motor burn-out), before the
vacuum operation it will be necessary to carefully clean the system using the filter dryer cleaneout method; which
basically involves the use of special filter dryers incorporating a suitable desiccant in both the liquid and suction
lines.
Excessive refrigerant losses can also leak oil from the system. Check the separator oil level during operation and
ensure that oil is visible in the top sightglass.
1. If the unit is slightly undercharged the unit will show bubbles in the sightglass. Recharge the unit.
2. If the unit is moderately undercharged the unit will most likely trip on freeze protection. Recharge the unit as
described in the charging procedure below.
If you do not know how much refrigerant has to be added, shut off the bottle valve every 5 minutes and continue to
charge the refrigerant until the sight glass is clear and free from bubbles.
Note: Do not discharge the refrigerant into the atmosphere. To recover it, use empty, clean and dry bottles. The
liquid refrigerant recovery can be made through the valve provided on the condenser coil subcooler outlet. To
facilitate the recovery of refrigerant, put the bottle inside a container full of ice; avoid excessive filling of the bottle
(70÷80% max).
Pre-Start-up
1. Open all electrical disconnects and check electrical connections are tight.
2. Verify water piping flow directions are correct and properly connected at the evaporator and condenser.
3. Using a phase tester, check that electrical phasing to each compressor circuit is A-B-C for phases L1, L2, & L3
respectively
4. Verify unit power supply is within 10% of nameplate rating.
5. Verify power supply wiring is the correct size and has a minimum temperature insulation rating of 75°C.
6. Verify all mechanical and electrical inspections have been completed according to local code.
7. Make certain all auxilliary control equipment is operative and an adequate cooling load is available.
8. Check all compressor valve connections for tightness.
9. Open compressor suction valve until backseated.
10. Open discharge shutoff valve until backseated.
11. Vent air from the evaporator and condenser water system piping.
12. Open all water flow valves and start chilled water pump.
13. Check all piping for leaks.
14. Flush the evaporator and condenser system piping.
Initial Start-up
Initial Start-up must be performed by McQuayService personnel.
1. Set up control as described in Initial Conditions.
2. Turn front panel switch to Auto position. (chilled water flow pump relay will energize.)
3. If the field installed flow indicator does not indicated chilled water flow after 30 seconds, then the alarm
output will be energized.
Note: The unit starts the compressor with the least starts and run hours while in auto lead lag setting
4. When the Active Setpoint is 3 °C lower than the actual leaving water temperature, the chiller starts.
5. When the chiller starts the following occurs:
• Crank case heaters de-energize
• Compressor starts
• Motor cooling solenoid is energized
6. Suction injection will turn off when the following conditions have been met: