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Operating Manual

OM WGS-5

Group:

Chiller

Part Number: 331373701

Effective: November 2008

Supersedes: OM WGS-4

Water-Cooled Screw Compressor Chillers

WGS 130AW to WGS 190AW, Packaged Water-Cooled Chiller

WGS 130AA to WGS 190AA, Chiller with Remote Condenser

120 to 200 Tons, 420 to 700 kW

R-134a, 60 Hz

Software Version WGSD30101H

Содержание WGS130AA: WGS140AW

Страница 1: ...Effective November 2008 Supersedes OM WGS 4 Water Cooled Screw Compressor Chillers WGS 130AW to WGS 190AW Packaged Water Cooled Chiller WGS 130AA to WGS 190AA Chiller with Remote Condenser 120 to 200...

Страница 2: ...mp and Tower Control 48 Cooling Tower Control 49 Evaporative Condenser Control 51 Circuit Controller Functions 54 Refrigerant Calculations 54 Compressor Control 55 Internal Capacity Overrides 58 Slide...

Страница 3: ...charge valves are included Each circuit s liquid line components are manual liquid line shutoff valve charging valve filter drier liquid line solenoid valve sight glass moisture indicator and electron...

Страница 4: ...ue is then limited to a range defined by the Condenser Saturated Temperature Target minimum and maximum setpoints These setpoints simply cut off the value to a working range and this range can be limi...

Страница 5: ...thin 3 degrees of the maximum discharge pressure The purpose is to keep the compressor online during periods of possibly temporary elevated pressures High Superheat Error The degrees of temperature di...

Страница 6: ...such as temperature or pressure and the reading shown on the microprocessor as a result of the sensor signal See notes on page 33 for explanation of sensor off set pLAN Peco Local Area Network is the...

Страница 7: ...st compressor or fan The Delta T is the dead band on either side the setpoint in which no action is taken Stage Up Delay The time delay from the start of the first compressor to the start of the secon...

Страница 8: ...MANUAL REMOTE STOP SWITCH BY OTHERS ICE MODE SWITCH BY OTHERS TIME CLOCK 71 4 20MA FOR EVAP WATER RESET BY OTHERS 4 20MA FOR DEMAND LIMIT BY OTHERS GND FU4 FU5 FU7 CHWR ABR 85 2 EVAP PUMP RELAY 2 BY O...

Страница 9: ...Y SUPPLIED ALARM FIELD WIRED ALARM BELL OPTION ABR NO1 2 N 120 VAC NO2 2 N 120 VAC NO3 2 N 120 VAC NO4 2 N 120 VAC M14 NO5 2 N NO6 2 N M11 M12 M13 120 VAC 120 VAC M15 M16 LOCATED ON CIRCUIT CONTROLLER...

Страница 10: ...tches Open at 310 psi Close at 250 psi T2 Unit Controller T13 Circ 1 Controller T14 Circ 1 Load Solenoid T15 Circ 1 EXV Power T25 Circ 2 EXV Power T24 Circ 2 Load Solenoid T23 Circ 2 Controller Unit C...

Страница 11: ...wn Circ 1 Solid State Starter Circ 2 Solid State Starter SSS1 Bypass Contactor SSS2 Bypass Contactor Secondary Fuses Circ 1 Circuit Breaker Circ 2 Circuit Breaker Unit Disconnect Switch W External Han...

Страница 12: ...ERM ISTOR CARD CT3 CT2 CT1 BYPASS CONTACTOR D3 CONTR BRD THERM ISTOR CARD CT3 CT2 CT1 F U 6 T1 C B 1 C B 2 DS1 G N D F U 4 F U 5 SINGLE POINT OR CIR 1 DS HANDLE MULTI POINT CIR 2 DS HANDLE MULTI POINT...

Страница 13: ...s normal design envelope If an alarm condition develops the controller will shut down the compressor or entire unit and activate an alarm output Important operating conditions at the time an alarm con...

Страница 14: ...ch II controller menu structure is separated into three distinct categories which provide the operator or service technician with a full description of the following 1 Current unit status 2 Control pa...

Страница 15: ...LEFT RIGHT have three modes of use 1 Scroll between data screens as indicated by the arrows default mode 2 Select a specific data screen in a hierarchical fashion using dynamic labels on the right sid...

Страница 16: ...ater temperature leaving the evaporator is less than the Active Leaving Water Temperature Setpoint minus Stage Delta T The last remaining circuit will shut down when the water temperature leaving the...

Страница 17: ...an alarm Remote Condenser EXV Operation For units configured for remote condensers there is pre open logic that allows the electronic expansion valve to open prior to starting the compressor This all...

Страница 18: ...t status will be Off BAS Disable When the remote switch is open the unit status will be Off Remote Switch When a unit alarm is active the unit status will be Off Unit Alarm In cases where no circuits...

Страница 19: ...load when it reaches 75 slide target it reaches the max slide target setting or it encounters a problem and is running in an inhibited state If a single circuit is not enough to satisfy the load the s...

Страница 20: ...s will be added removed as needed to control condenser pressure The EXV will begin controlling at this point as well The compressor cannot start loading until it has at least 22o discharge superheat f...

Страница 21: ...e next one on If there is a need for more cooling capacity the compressor designated as next on can start When the circuit is in the Off state the EXV is closed compressor is off and all fans are off...

Страница 22: ...ndenser pressure is controlled to a target that is based on evaporator pressure with the target getting higher as the evaporator pressure gets higher If this compressor has the most run hours or the o...

Страница 23: ...and cooling tower Check all piping for leaks Vent the air from the evaporator and condenser water circuit as well as from the entire water system The cooler circuit should contain clean treated non co...

Страница 24: ...With the unit in this condition it will not restart until these switches are turned back on Leave on the power to the unit disconnect closed so that the sump heaters will remain energized Start up af...

Страница 25: ...sump heaters to operate for at least 12 hours prior to start up 9 Start the chilled water pump and purge the water piping as well as the evaporator in the unit 10 Start the system auxiliary equipment...

Страница 26: ...ate Pressure Drop Flow Rate Pressure Drop Flow Rate Pressure Drop WGS Model gpm L s Ft kPa gpm L s Ft kPa gpm L s Ft kPa 130AW AA 195 12 3 5 8 17 4 312 19 7 13 5 40 4 520 32 9 33 9 101 1 140AW AA 211...

Страница 27: ...kPa 130AW 304 19 2 4 1 12 2 390 24 7 6 5 19 3 650 41 1 16 0 47 9 140AW 304 19 2 4 1 12 2 422 26 7 7 4 22 2 704 44 5 18 5 55 1 160AW 304 19 2 4 1 12 2 470 29 8 9 0 26 9 784 49 6 22 4 66 8 170AW 372 23...

Страница 28: ...No Flow 24 VAC Flow 6 Open 7 Open 8 Open Table 4 Digital Outputs Description Load Output OFF Output ON 1 Evaporator Water Pump 1 Pump Contactor Pump OFF Pump ON 2 Evaporator Water Pump 2 Pump Contact...

Страница 29: ...N M Cond Pump Select water cooled only 1 Only 1 Only 2 Only Auto N M LWT Reset Type NONE NONE RETURN 4 20mA OAT N M Max Reset 0 F 0 to 20 F N M Start Reset Delta T 10 F 0 to 20 F N M Soft Load Off Of...

Страница 30: ...1 On 70 F 40 to 120 F N M Stage 2 On 75 F 40 to 120 F N M Stage Differential 3 0 F 1 0 to 10 0 F N M Stage Up Time 2 min 1 to 60 min N M Stage Down Time 5 min 1 to 60 min N M Stage Fan Down 20 0 to 10...

Страница 31: ...10k 25 C 58 to 212 F 6 Open 7 Slide Load Indicator 4 to 20 mA 0 to 100 8 Condenser LWT circuit 1 water cooled only NTC Thermister 10k 25 C 58 to 212 F Table 11 Analog Outputs Description Output Signal...

Страница 32: ...be active in order to change the setpoint Codes are as follows O Operator 100 M Manager Table 14 Circuit Setpoints Description Default Range PW Compressor Circuit Mode enable Disable enable test M Sli...

Страница 33: ...0 20 0 o F M Stage 3 On Deadband 11 0 1 0 20 0 o F M Stage 4 On Deadband 12 0 1 0 20 0 o F M Stage 2 Off Deadband 20 0 1 0 25 0 o F M Stage 3 Off Deadband 16 0 1 0 25 0 o F M Stage 4 Off Deadband 11...

Страница 34: ...ondition 1 When the alarm occurs due to this trigger it can auto reset the first two times each day with the third occurrence being manual reset For the auto reset occurrences the alarm will reset aut...

Страница 35: ...rator Water Temperature Sensor Fault Alarm description as shown on screen Evap LWT Sens Fault Trigger Sensor shorted or open Action Taken Rapid stop all circuits Reset This alarm can be cleared manual...

Страница 36: ...energized while alarms are active Alarm descriptions apply to both circuits the circuit number is represented by N in the description Low Evaporator Pressure Alarm description as shown on screen Evap...

Страница 37: ...vel Switch input is open for time greater than Low Oil Level Delay while compressor is in the Run state AND the Low Oil Level Event has occurred in the past hour Action Taken Rapid stop circuit Reset...

Страница 38: ...e events are not enabled until the compressor has started and the evaporator pressure has risen above the Low Evaporator Pressure Hold set point The unit mode must also be Cool Then while running if e...

Страница 39: ...equal to the Start Start timer set point Reset N A Condenser Freeze Protect Event description as shown on screen Cond Frz Protect Cir N Trigger Cond Sat Refr Temp Condenser Freeze SP AND Cond Pump Sta...

Страница 40: ...th the Manager password Clearing Alarms Alarms may be cleared at the unit controller and no password is required The BAS can clear evaporator flow loss evaporator water freeze and pLAN failure regardl...

Страница 41: ...PAD x ON x ON ON NETWORK x x OFF OFF ON NETWORK OFF x x OFF ON NETWORK ON x ON ON Example 1 If the Control Source is set to Switches enabling is controlled by the field installed remote stop switch If...

Страница 42: ...setup and determines the operational modes available at any time with options of COOL cooling only operation with setpoints available for normal chilled water temperatures COOL w Glycol cooling only o...

Страница 43: ...Unit Test Mode The unit test mode allows manual testing of controller outputs Entering this mode shall require the following conditions Unit OFF input OFF i e entire chiller is shut down Technician p...

Страница 44: ...mer starts when the first compressor starts while the unit is in ice mode While this timer is active the chiller cannot restart in Ice mode The time delay is user adjustable The ice delay timer may be...

Страница 45: ...primary pump will shut off and the standby pump will start When the evaporator is in the run state if flow is lost for more than half of the flow proof set point the primary pump will shut off and th...

Страница 46: ...eset would be at the maximum value 10 degrees when the Evap Delta T is zero and at the minimum value when the Evap Delta T is at the Start Reset Delta T value and is proportional in between The Start...

Страница 47: ...max reset at 60 F At ambient temperatures less than 60 F reset is equal to the Max Reset setpoint 75 Cool LWT Max Reset 54 Cool LWT Set Point 44 OAT Reset 60 Max Reset 10 OAT oF Active LWT o F Planned...

Страница 48: ...t control source is set to network The signal will be received through the BAS interface on the unit controller As the signal varies from 0 up to 100 the maximum unit capacity changes linearly from 0...

Страница 49: ...e first two selections will use a single pump output all the time The auto selection will start the pump with the least run hours The selected output will be ON if the Evap State is set to START or RU...

Страница 50: ...is output shall be set to 0 Otherwise it shall be controlled as described below Initial Valve Position When the condenser pump is not in the RUN state the valve output shall be set as a function of en...

Страница 51: ...A chillers less condenser with evaporative condensers It is the installer s responsibility to provide the evaporative condenser control because this condenser type is not available from McQuay The WG...

Страница 52: ...quence for the shut down procedure 6 Provide the maximum number of condenser staging steps as possible to provide as stable operation as possible 7 Recognize that condenser pressure will change drasti...

Страница 53: ...supporting LONWORKS BACnet or Modbus Refer to the other McQuay brochures listed in this manual for a complete description of capabilities As a general statement the McQuay communication cards do NOT s...

Страница 54: ...0 246 5 145 0 320 0 165 0 428 5 188 1 Table 19 Condenser Pressure Conversion Pressure PSI Temperature o F 0 0 6 17 5 18 5 31 5 35 9 50 0 53 7 76 0 73 4 115 0 95 6 161 5 116 2 185 0 125 2 260 0 149 2...

Страница 55: ...if starts are equal and stop on run hours The above two modes can be combined so that there are two or more groups where all compressors in the first group are started based on number of starts hours...

Страница 56: ...acity Control section Starting A compressor will start stage up IF LWT is above the Active LWT Setpoint plus the Startup Delta T SP AND no compressors are running OR all running compressors are at ful...

Страница 57: ...get adjustment LWT Error LWT Slope x 4 Load Balance Offset Compressors Running Ice Mode In ICE mode the compressor capacity is increased at the maximum rate continuously until reaching the maximum sli...

Страница 58: ...ure Hold setpoint the High Lift Pressure Inhibit event is triggered When this happens the compressor will not be allowed to increase capacity This event is active until the condenser pressure drops 10...

Страница 59: ...Position is a relative capacity adjustment from 0 0 Min load to 100 0 Max Load There are two MicroTech readings that apply to the indicator Slide Target and Slide Position It is important to understan...

Страница 60: ...ressure and other unit readings are OK Always keep discharge superheat above 22 F When the slide target is at 100 verify that the load coil is energized Press the calibrate button The red LED will com...

Страница 61: ...air cooled condenser operation the liquid line solenoid shall remain closed until the compressor starts During pre open the EXV signal is held at 3000 steps For remote condenser configuration units t...

Страница 62: ...return to its closed position This logic has been added to help prevent hydraulic lock between the liquid line solenoid and the electronic expansion valve EXV State Transitions The following state dia...

Страница 63: ...EXV post open timer non field adjustable at 30 seconds has expired Compressor State not Run T6 T7 Transition from any state to Closed state Requires the following Compressor State not Run EXV State T...

Страница 64: ...control range for every change in slide position Compressor Size EXV Slide 167 179 197 Min 0 250 250 250 Max 0 3000 3000 3000 Min 100 870 1080 1300 Max 100 3400 4200 5000 Based on the values in the a...

Страница 65: ...t R Amps 1028 L2 Current R Amps 1029 L3 Current R Amps 1032 Avg Voltage R Volts 1033 L1 L2 Voltage R Volts 1034 L2 L3 Voltage R Volts 1035 L3 L1 Voltage R Volts 1037 PF R 99 to 100 in 16 bit two s com...

Страница 66: ...R Starter Fault 47 Stack Protection Fault Starter Fault 48 Bypass Contactor Fault on Stop Input No Starter Transition 50 Control Power Low Starter Fault 51 Current Sensor Offset Error Starter Fault 52...

Страница 67: ...if the temperature is rising slowly The Stage Up Error Step is added to Stage Up Accumulator once every Stage Up Error Delay seconds When the Stage Up Error Accumulator is greater than the Stage Up Er...

Страница 68: ...m speed and maximum speed set points are available An input for fan VFD fault was added at digital input 4 on each circuit controller VFD faults are logged in the event log and notification sent on BA...

Страница 69: ...ion using dynamic labels on the right side of the display this mode is entered by pressing the MENU key 3 Change field values in edit mode according to the following table LEFT Default D RIGHT Cancel...

Страница 70: ...y Pressing the ENTER key changes the function of the ARROW keys to the editing function as shown below LEFT key Default changes a value to the factory set default value RIGHT key Cancel cancels any ch...

Страница 71: ...after the enter key is pressed The operator password is 100 Once the correct password has been entered the ENTER PASSWORD screen indicates which password is active none operator technician or manager...

Страница 72: ...through the menus The keys are also used to change numerical setpoint values contained in certain menus As an alternate to selecting screens with the menu function it is possible to scroll through all...

Страница 73: ...1 SET UNIT SPs 1 SET COMP SPs 1 SET ALARM LMTS 1 SET TOWER SPs 1 TEST UNIT SET COMP SPs 2 SET ALARM LMTS 2 SET COMP SPs 3 SET ALARM LMTS 3 CONTINUATION FROM ABOVE ALARM LOG 25 ALARM ACTIVE n SET UNIT...

Страница 74: ...EMP VIEW CIRCUIT STATUS menu VIEW CIR CIR 1 STATUS CIR 2 VIEW REFRIGERANT menu VIEW REFR CIR 1 CIR 2 SET menu Water cooled Air cooled SET ALARM LIMITS SET ALARM LIMITS UNIT SPs UNIT SPs COMPRESSOR SPs...

Страница 75: ...X Demand Limit XXX X Network Limit XXX X VIEW UNIT STATUS 3 Unit Capacity XXX X Ice Delay XXh XXm Ice Delay will be visible only when unit mode is ice It prevents the unit from undesirable starts befo...

Страница 76: ...AT Lock Off Keypad Disable Off Pumpdown Switch Off Alarm Off Test Mode EXV Preopen Run Pumpdown Run Normal Run LWT PullDn Limit Run Unit Cap Limit Run High LWT Limit Run Evap Press Low Run Lift Press...

Страница 77: ...IEW REFRG CIR N 5 Evap Approach XX X F Cond Approach XX X F EXV position XXXX View Fans This screen is only viewable when unit is configured for air cooled VIEW FANS Fans On Cir 1 X Fans On Cir 2 X Vi...

Страница 78: ...ll through the list Parameters include Unit State Evap LWT Evap EWT Cond EWT OAT Circuit State Evaporator Pressure Condenser Pressure Suction Temperature Discharge Temperature Discharge Superheat EXV...

Страница 79: ...communication ports Unit Mode settings can be 1 COOL normal setting used with chilled water air condition applications 2 COOL w GLYCOL used with low temperature glycol applications It allows a lower L...

Страница 80: ...X sec Cond Pump 1 Only SET UNIT SPs 7 Reset Type none Max Reset XX X F StrtResetDT XX X F SET UNIT SPs 8 Soft Load Off Begin Capacity XXX SoftLoadRamp XXmin Water cooled Air cooled SET UNIT SPs 9 SET...

Страница 81: ...ocol Ident Number Baud Rate SET UNIT SPs 16 Enter Password 0000 Active Password Level none Compressor Set Points SET COMP SPs 1 Seq Comp 1 X Seq Comp 2 X SET COMP SPs 2 Max Comps On x Start Start XX m...

Страница 82: ...s prevented from starting thereby holding the unit capacity The last action to take place is the shutoff of all compressors running when the LowEvPrStop setting is reached default is 58 psi Reducing t...

Страница 83: ...tpoints Tower Control Tower Stages Stage Up Time Stage Down Time Stage Differential Stage 1 ON Stage 2 ON Stage Down Stage Up When the condenser pump starts the stage up timer shall start The first st...

Страница 84: ...that must elapse between the condenser pump starting it starts with the unit and fan 1 starting or the time between fan 1 starting and fan 2 starting StageDown is the elapsed time between staging dow...

Страница 85: ...e Setpoint 1 Stage 1 ON 2 Stage 2 ON 3 Stage 3 ON 4 Stage 4 ON VFD Stage ValveSP VFDStage When the Valve VFD Control setpoint is set to None Valve Setpoint OR Valve Stage this output is set to 0 Other...

Страница 86: ...X Valve SP is the minimum tower water temperature acceptable default is 65 F Valve DB is the dead band in degrees default is 2 0 F SET TOWER SPs 6 Valve Start Position Min XXX XXX Max XXX XXX The Valv...

Страница 87: ...EW CIR STATUS 1 9 REFRIGERANT VIEW REFRIGERANT 1 7 VIEW FANS VIEW FANS 1 2 COMPRESSOR SPs SET COMP SPs 1 4 EXV SPs SET EXV SPs 1 2 FAN SPs SET FANS 1 6 SET SENSOR OFFSETS SET SENSOR OFFSET 1 3 Menu Ma...

Страница 88: ...Remote Switch Off BAS Disable Off Unit Switch Off Test Mode Auto Wait for load Auto Cond Recirc Auto Evap Recirc Auto Wait Cond Flow Auto Wait Evap Flow Auto Pumpdown Pump states include Off Start and...

Страница 89: ...VIEW CIR STATUS 4 Voltage L1 2 L2 3 L3 1 Avg XXX XXX XXX XXX VIEW CIR STATUS 5 PF 0 XX RLA XXX X KW XXX KVA XXX VIEW CIR STATUS 6 Digital Outputs 1 2 3 4 5 6 7 8 9 10 X X X X X X X X X X Status will b...

Страница 90: ...XX X F VIEW REFRIGERANT 6 MaxCondSatT XXX X F EXV Ctrl Superheat SH target XX X F VIEW REFRIGERANT 7 EXV Steps XXXX EXV ctrl range XXXX XXXX steps View Fans View Fans screens are only available when t...

Страница 91: ...When the Circuit control is powered up the starter set points MUST be adjusted from the Circuit control Ground Fault Enable Ground Fault Trip Level Rated RMS Voltage and CT Ratio set points are NOT ad...

Страница 92: ...X Stg4 XX X SET FAN SPs 3 Stg Off Deadband F Stg2 XX X Stg3 XX X Stg4 XX X Stg5 XX X SET FAN SPs 4 VFD Min Speed XX VFD Min Speed XXX SET FAN SPs 5 Cond Sat Temp Target Max XXX X F Min XXX X F SET FA...

Страница 93: ...rs the alarm type limit value if any date and time are stored in the active alarm buffer corresponding to that alarm viewed on the Alarm Active screens and also in the alarm history buffer viewed on t...

Страница 94: ...e Installation IM 743 Modbus Communication Module Installation ED 15062 0 MicroTech II Chiller Protocol Information BACnet and LONWORKS ED 15063 0 MicroTech II Chiller Unit Controller Protocol Informa...

Страница 95: ...ction or liquid line 3 Worn compressor 1 Check superheat setting of expansion valve 2 Relocate add or remove hangers 3 Replace High Discharge Pressure 1 Condenser water insufficient or temperature too...

Страница 96: ...erant 2 Velocity in risers too low A C only 3 Oil trapped in line 1 Check for leaks and repair Add refrigerant 2 Check riser sizes 3 Check pitch of lines and refrigerant velocities Motor Overload Rela...

Страница 97: ......

Страница 98: ...roduct Warranty Consult your local McQuay Representative for warranty details Refer to form 933 430285Y 00 A 09 08 To find your local representative go to www mcquay com This document contains the mos...

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