McQuay WMC-B 145D Installation Manual Download Page 1 | Manualshive

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Installation Manual

IM 1128-2

Group:

Chiller

Part Number:

331375601

REV: 02

Effective:

July 2015

Supersedes:

June 2013

WSC and WMC-B Centrifugal Chillers
Reassembly of Knockdown Shipments

STARTER

COMPRESSOR

OIL PUMP

UNIT

CONTROLLER

EVAPORATOR

CONDENSER

SUPPORT

1
2
3
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Summary of Contents for WMC-B 145D

Page 1: ... 2 Group Chiller Part Number 331375601 REV 02 Effective July 2015 Supersedes June 2013 WSC and WMC B Centrifugal Chillers Reassembly of Knockdown Shipments STARTER COMPRESSOR OIL PUMP UNIT CONTROLLER EVAPORATOR CONDENSER SUPPORT ...

Page 2: ...allation operation and maintenance can void the warranty DANGER Dangers indicate a hazardous situation which will result in death or serious injury if not avoided WARNING Warnings indicate potentially hazardous situations which can result in property damage severe personal injury or death if not avoided CAUTION Cautions indicate potentially hazardous situations which can result in personal injury ...

Page 3: ...stallation 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 ...

Page 4: ...anges 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 ...

Page 5: ... 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 ...

Page 6: ...ng 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 ...

Page 7: ...s 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 ...

Page 8: ... COOLING REFRIGERANT FROM COND BTM OIL LINE VENT FROM TOP FRONT OF OIL PUMP ATTACH 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 OIL PRESSURE TRANSDUCER MOTOR DRAIN TO EVAP BOTTOM MOTOR COOLING FROM COND BTM OIL SUP...

Page 9: ...CHARGE BLOCKOFF REF DRAIN REF DRAIN REF DRAIN MOTOR COOLING MOTOR DRAIN 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 OU...

Page 10: ...g R331311308C0100 BOLT ON BLOCKOFF PLATE TYPE II UNITS RECEIVE SLIP ON ASME FLANGES TYPES II III TYPES I II TYPES I II VICTAULIC BLOCKOFF PLATE INSTALL SUCTION PIPING EVAPORATOR AND CONDENSER ARE EVACUATED AND CHARGED WITH 30 PSI OF HELIUM TYPES I II ...

Page 11: ...ser The lines and the compressor each have block off plates resulting in extra bolts Figure 5 Motor Cooling Lines R331311303C0100 MECHANICAL BREAK POINT MECHANICAL BREAK POINT LIQUID INJECTION LINES NOT ALL VARIATIONS SHOWN TYPE I BLOCKOFF TYPE I BLOCKOFF TORQUE TO 58 FT LBS R331311304C0100 MECHANICAL BREAK POINT MECHANICAL BREAK POINT MOTOR COOLING LINES NOT ALL VARIATIONS SHOWN TYPE I BLOCKOFF T...

Page 12: ...2 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 ...

Page 13: ...W FLOW FLOW NOTE THIS LINE IS NOT ALWAYS PRESENT SOME UNITS HAVE ELECTRONIC VALVES 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 TYPES I II INSTALL TOP PORTION ...

Page 14: ... 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 CLOSE SWITCH 146 145 VANE OPEN SWITCH 103 104 VFD SPEED SIGNAL 102 101 ON VFD ONLY LI HG VO VC SA SB OC VFD LEAVING EVAP WATER TEMP OIL FEED TEMP COMPR DISCHARGE TEMP COMPR SUCTION TEMP OIL SUMP TEMP COND PRESS SENSOR EVAP PRESS SENSOR O...

Page 15: ...ouch 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 comp...

Page 16: ...ion line see Figure 4 Note that any given injection line may be configured somewhat differently than shown on the drawing If the oil cooler and oil sump have been removed on the job site reinstall them using the fasteners that came on the unit See Figure 12 for piping between the cooler and sump and the cooling water piping See 6 Figure 8 for the balance of the four oil lines connected to the comp...

Page 17: ...IM 1128 2 17 Figure 18 Unit panel wiring and connections Figure 15 Unit panel detail ...

Page 18: ...ion Guide on page 29 This completes the reassembly procedure Figure 11 Liquid Line Installation 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 SHOWN IS E36 C36 STACK WITH 20 INCH MOTOR R331311306C0100 VIEW B SEE VIEW B TOP OF EVAPORATOR FROM PILOT TX VALVE EVAPORATOR CONNECTION CO...

Page 19: ...ockdown units 3 Type III knockdown units are shipped with oil R331311302C0100 WATER SUPPLY WATER RETURN THRUST RETURN OIL LINE OIL SUPPLY WATER RETURN WATER SUPPLY OIL SUPPLY TO VALVE ON COMP OIL DRAIN LINE OIL VENT LINE DUE TO DIFFERENT PIPE ROUTINGS SOME OR ALL PIPING SHOWN MAY BE SHIPPED LOOSE FLOW FLOW FLOW FLOW FLOW F L O W FLOW FLOW PRESSURE EQ UALIZATIO N PLUG PLUG OIL COOLER ...

Page 20: ...OOLING 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...

Page 21: ...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 CLOSE SWITCH 146 145 VANE OPEN SWITCH 103 104 VFD SPEED SIGNAL 102 101 ON VFD ONLY LI HG VO VC SA SB OC VFD LEAVING EVAP WATER TEMP OIL FEED TEMP COMPR DISCHARGE TEMP COMPR SUCTION TEMP OIL SUMP TEMP COND PRESS SENSOR EVAP PRESS SENSOR OI...

Page 22: ...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 J3 J4 J5 J6 UTB1 CONTROLLER pCO2 152 C N O 151 N O C 149 150 EF CF 149 151 150 152 249 251 250 252 T3S1 T3S2 EF1 CF1 EF2 CF2 EF BLACK CF...

Page 23: ...URE TRANSDUCER STANDARD TEMPERATURE SENSOR OPTIONAL TEMPERATURE SENSOR SEE DETAIL A SEE DETAIL C SEE DETAIL E SEE DETAIL D SEE DETAIL D 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 ...

Page 24: ... TEMP EVAP ENTERING WATER TEMP CS01 CS02 COND ENTERING WATER TEMP US09 COND LEAVING WATER TEMP US10 EVAP REFRIGERANT PRESSURE COND REFRIGERANT PRESSURE LIQUID LINE TEMPERATURE CS03 CS06 CS04 COMP DISCHARGE TEMP OIL FEED TEMPERATURE OIL SUMP TEMPERATURE OIL SUMP PRESSURE OIL FEED GAUGE PRESSURE COMPRESSOR AMPS STARTER ENT HEAT RECOVERY TEMP LVG HEAT RECOVERY TEMP SENSOR NUMBER DESCRIPTION CS05 CS07...

Page 25: ...IM 1128 2 25 Figure 18 Compressor Control Box ...

Page 26: ...26 IM 1128 2 Figure 19 Unit Control Box ...

Page 27: ...IM 1128 2 27 Figure 20 Flow Switch Wiring ...

Page 28: ...28 IM 1128 2 Unit Photographs Figure 21 WSC 087 Photo Figure 22 WSC 100 Photo ...

Page 29: ...IM 1128 2 29 Figure 23 WSC 126 Photo ...

Page 30: ...h 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 Reassembly Steps Type III units offer a variety of disassembly opportunities In some cases the condenser and tube support plate are removed to meet narrow entrance requirements Sometimes the compressor ...

Page 31: ...IM 1128 2 31 Field Insulation Guide Figure 24 Insulation Requirements ...

Page 32: ...32 IM 1128 2 ...

Page 33: ...1624 8 6982 3170 44 0 1118 6 25 1 638 3 2000 908 063 E2212 C2212 57 1 1450 6 64 0 1624 8 7357 3340 44 0 1118 6 25 1 638 3 2000 908 063 E2612 C2212 57 1 1450 6 67 5 1715 0 8377 3803 44 0 1118 6 25 1 638 3 2000 908 063 E2612 C2612 57 1 1450 6 73 1 1857 8 9294 4219 44 0 1118 6 25 1 638 3 2000 908 063 E3012 C2612 56 8 1441 7 75 7 1922 0 10703 4859 44 0 1118 6 25 1 638 3 2000 908 079 E2209 C2209 50 2 1...

Page 34: ...2 92 2 2342 9 86 7 2202 7 23298 10577 44 0 1117 9 31 5 800 1 6000 2724 100 E4812 C4212 98 2 2495 3 90 6 2300 2 26024 11815 44 0 1117 9 31 5 800 1 6000 2724 113 E3012 C3012 67 4 1712 2 76 5 1943 1 13397 6082 44 0 1117 9 31 5 800 1 6000 2724 113 E3612 C3012 77 2 1961 6 77 6 1971 5 15578 7072 44 0 1117 9 31 5 800 1 6000 2724 113 E3612 C3612 83 2 2114 0 77 6 1971 5 17826 8093 44 0 1117 9 31 5 800 1 60...

Page 35: ...2 6 44 0 1118 6 25 1 638 3 063 E2612 C2612 36 0 914 9 42 3 1073 2 8 0 203 2 27 7 704 6 39 2 996 7 35 9 912 6 44 0 1118 6 25 1 638 3 063 E3012 C2612 36 0 914 9 42 3 1073 2 8 0 203 2 27 0 685 5 42 6 1081 0 37 3 948 4 44 0 1118 6 25 1 638 3 079 E2209 C2209 30 5 775 2 33 1 841 0 8 0 203 2 20 6 522 0 32 8 834 1 31 5 799 8 43 6 1108 2 25 1 638 3 079 E2609 C2209 30 5 775 2 35 9 911 4 8 0 203 2 20 6 522 0...

Page 36: ... 7 43 6 1108 2 25 1 638 3 100 E3012 C3012 41 0 1041 9 46 2 1172 7 8 0 203 2 28 6 725 4 48 4 1229 6 38 4 974 6 44 0 1117 9 31 5 800 1 100 E3612 C3012 41 0 1041 9 46 2 1172 7 8 0 203 2 24 4 619 5 52 1 1324 1 44 1 1120 6 44 0 1117 9 31 5 800 1 100 E3612 C3612 45 3 1151 4 52 1 1322 3 8 0 203 2 24 4 619 5 52 1 1324 1 44 1 1120 6 44 0 1117 9 31 5 800 1 100 E4212 C3612 45 3 1151 4 52 1 1322 3 8 0 203 2 1...

Page 37: ...44 0 1117 9 31 5 800 1 126 E4212 C4212 49 6 1260 1 57 6 1462 0 8 0 203 2 21 4 543 3 54 4 1382 5 51 5 1307 6 44 0 1117 9 31 5 800 1 126 E4812 C4212 49 6 1260 1 57 6 1462 0 8 0 203 2 19 6 498 9 60 1 1527 0 57 1 1449 6 44 0 1117 9 31 5 800 1 126 E4812 C4812 53 9 1369 1 63 5 1612 9 8 0 203 2 19 6 498 9 60 1 1527 0 57 1 1449 6 44 0 1117 9 31 5 800 1 Notes 1 The overall vessel length can vary depending ...

Page 38: ... 5 29 1 739 6 3210 1454 4397 1992 3200 1440 14092 6392 079 E3009 C3009 18 8 476 5 29 1 739 6 4356 1973 4397 1992 3200 1440 15276 6929 079 E3609 C3009 19 8 501 9 26 7 678 9 4356 1973 5882 2665 3200 1440 17113 7762 079 E2212 C2212 18 8 476 5 29 1 739 6 3031 1373 3071 1391 3200 1440 12481 5661 079 E2612 C2212 18 8 476 5 29 1 739 6 3031 1373 3880 1758 3200 1440 13509 6128 079 E2612 C2612 18 8 476 5 29...

Page 39: ...00 30498 13834 113 E4812 C4212 19 8 501 9 34 8 884 4 10267 4651 11125 5040 6000 2700 33224 15070 113 E4812 C4812 19 8 501 9 34 8 884 4 13077 5924 11125 5040 6000 2700 36216 16427 126 E3612 C3012 19 8 501 9 34 8 884 4 5333 2416 6840 3099 6000 2700 22880 10378 126 E3612 C3612 19 8 501 9 34 8 884 4 7508 3401 6840 3099 6000 2700 25128 11398 126 E4212 C3612 19 8 501 9 34 8 884 4 7508 3401 8922 4042 600...

Page 40: ...IL VENT OIL PUMP VENT 1 COMP TO OIL PUMP R331311302 REMOVE AND CRATE OIL RETURN OIL RETURN TUBE THRUST 1 COMP TO OIL PUMP TEE NEAR COOLER R331311302 REMOVE PART OF LINE AND CRATE OIL SUPPLY OIL SUPPLY TUBE 1 COMP TO OIL COOLER BTM R331311302 REMOVE PART OF LINE AND CRATE STEEL PIPE ASSY S SUCTION LINE 1 COMP TO EVAP R331311308 REMOVE AND CRATE DISCHARGE NOZZLE AND CHECK VALVE 1 EA COMP TO DISCHARG...

Page 41: ... REMOVE AND CRATE MOTOR COOLING MOTOR COOLING 1 COND TO MOTOR R331311304 REMOVE PART OF LINE CRATE MOTOR DRAIN MOTOR DRAIN LARGE N A COMPRESSOR TO EVAP BOTTOM R331311305 BLOCK OFF AND SECURE MOTOR DRAIN MOTOR DRAIN SMALL N A COMP TO LARGE MOTOR DRAIN R331311305 BLOCK OFF AND SECURE OIL DRAIN OIL PUMP DRAIN 1 COMP TO OIL PUMP R331311302 REMOVE AND CRATE OIL VENT OIL PUMP VENT 1 COMP TO OIL PUMP R33...

Page 42: ...3501 WIRE TIE STICK ON MOUNTS 50 McQuay LONMARK LABEL BAG 1 LITERATURE AND SCHEMATIC IN MANILLA ENVELOPE 1 STARTER SHROUD 1 IF PRESENT STARTER BRACKETS 2 IF UNIT MOUNTED TERMINAL SHROUD 1 IF PRESENT ISOLATOR PADS 6 OPERATOR INTERFACE PANEL 1 LCD SUPPORT ARM 1 POWER CABLES 3 OR 6 IF UNIT MOUNTED CONTROL BOX WATER HOSES 2 COMPRESSOR 4 WAY VALVE ASSY 1 COMPRESSOR INSULATION KIT 1 SHEET INSULATION HEA...

Page 43: ...S PART NO 073244408 TOUCH UP SPRAY PAINT CANS 6 001358000 WIRE TIES 50 070183501 WIRE TIE STICK ON MOUNTS 25 McQuay LONMARK LABEL BAG 1 LITERATURE AND SCHEMATIC IN MANILLA ENVELOPE 1 STARTER BRACKETS 2 IF UNIT MOUNTED SHIPPED LOOSE ISOLATOR PADS 6 OPERATOR INTERFACE PANEL 1 LCD SUPPORT ARM 1 POWER CABLES 3 OR 6 IF UNIT MOUNTED CONTROL BOX WATER HOSES 2 IF UNIT MOUNTED KNOCKDOWN REFERENCE DWG PACKE...

Page 44: ... piping connections will be flanged or copper brazing 7 All free piping ends will be capped 8 Touch up paint will be included 9 The unit will undergo the rigorous full McQuay test program at the factory 10 Contact your service representative for McQuay International for pricing and scheduling of required installation supervision TYPE V Knockdown The unit ships fully assembled tested and is ready f...

Page 45: ...e line s See Figure 30 Tighten bolts after the entire line has been installed and aligned Insulate the suction line with the insulation and glue provided 5 Install the liquid line and motor cooling lines See Figure 31 and Figure 32 6 Install control panel and compressor power panels by bolting to the horizontal support members 7 If the unit has single point power connect the power leads from the t...

Page 46: ...es such as mounting brackets and disconnect handles WMC B Model Depth x Width x Height Length x Width x Height Compressor Power Panel Front End Box Control Panel Evaporator Condenser Stack Model Model 145S 32 x 22 x 18 17 x 40 x 67 9 x 19 x 33 2209 135 x 28 x 29 2009 128 x 36 x 33 135 x 36 x 60 145D 32 x 18 x 18 17 x 40 x 67 9 x 19 x 33 2209 135 x 28 x 29 2009 128 x 36 x 33 135 x 36 x 60 150D 32 x...

Page 47: ...IM 1128 2 47 Figure 25 Type IV Compressor Block Offs Figure 26 Type IV Parts in Crates WMC 145S Single Compressor ...

Page 48: ...48 IM 1128 2 Figure 27 Type IV Parts in Crates Dual Compressor NOTES 1 See previous page for WMC 145S crate 2 Crate 2 will have two sets of suction and discharge lines ...

Page 49: ...e Vessel Stack Figure 29 Part Load Bypass Valve PLBV The drawing shows the PLBV piping for one circuit Evaporator Liquid line connection Flange Connection This part stays on evaporator This part stays with discharge line PLBV Condenser ...

Page 50: ...50 IM 1128 2 Figure 30 Type IV Suction and Discharge Line Removal Figure 31 Type IV Motor Cooling Line Removal Suction Line 2 Discharge Line 2 ...

Page 51: ...IM 1128 2 51 Figure 32 Type IV Liquid Line Removal Figure 33 Type V Liquid line Removal ...

Page 52: ...52 IM 1128 2 Figure 34 Type V Vessel Separation ...

Page 53: ...ng Limited Product Warranty Consult your local McQuay International representative for warranty details To find your local McQuay International representative go to www DaikinApplied com Aftermarket Services To find your local parts office visit www DaikinApplied com or call 800 37PARTS 800 377 2787 To find your local service office visit www DaikinApplied com or call 800 432 1342 This document co...

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