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1、Installation, Operating and Maintenance ManualIOMM WSCWDC Group: Chiller Part Number: 736015417 Effective: October 1999 Supersedes: IOMM PEHPFH 1997 McQuay International The McQuay DISTINCTION SERIES Single/Dual Compressor Centrifugal Chillers WSC/WDC 050, 063, 079, 087, 100, 126 2Centrifugal Chille
2、rsIOMM WSCWDC Table of Contents Introduction.3 General Description.3 Application.3 Installation.4 Receiving and Handling.4 Location and Mounting.5 Water Piping.6 Oil Cooler Piping.8 Refrigerant Vent Piping.9 Electrical.11 Power Wiring.11 Control Wiring.12 Prestart System Checklist.14 Operation.15 Op
3、erator Responsibilities .15 Nomenclature.15 MicroTech Control Panel.16 Capacity Control System.16 Lubrication System.19 Hot Gas Bypass.21 Maintenance.22 Pressure/Temperature Chart.22 Routine Maintenance.22 Annual Shutdown.25 Annual Startup.26 Repair of System.26 Maintenance Schedule.29 Service Progr
4、ams .32 McQuay is a registered trademark of McQuay International 1997 McQuay International Illustrations cover the general appearance of McQuay International products at the time of publication and we reserve the right to make changes in design and construction at anytime without notice IOMM WSCWDCC
5、entrifugal Chillers3 Introduction General Description The McQuay Centrifugal Water Chillers are complete, self-contained, automatically controlled fluid chilling units. Each unit is completely assembled and factory tested before shipment. In the WSC series, each unit contains one compressor connecte
6、d to a condenser and evaporator. The WDC series are equipped with two compressors operating in parallel on a single evaporator and condenser. The chillers use refrigerant R-134a to reduce the size and weight of the package compared to negative pressure refrigerants and since R-134a operates at a pos
7、itive pressure over the entire operation range, no purge system is required. The controls are pre-wired, adjusted and tested. Only normal field connections such as piping, electrical and pump interlocks, etc. are required thereby simplifying installation and increasing reliability. All necessary saf
8、ety and operating controls are factory installed in the control panel. The basic sizes of units are the WSC/WDC 050, 063, 076, 079, 087, 100 and 126. They provide a capacity range from 80 tons to 2500 tons. In this manual all references to the WSC models will equally apply to other models unless spe
9、cifically referenced otherwise. Application The operation and maintenance procedures presented in this manual apply to the standard WSC/WDC family of chillers. Reference to the Installation Manual, OM 125 for these units should be made for details pertaining to operation of the MicroTech control. Al
10、l McQuay centrifugal chillers are factory tested prior to shipment and must be initially started at the job site by a factory trained McQuay service technician. Failure to follow this startup procedure may affect the equipment warranty. The standard warranty on this equipment covers parts which prov
11、e defective in material or workmanship. Specific details of this warranty can be found in the warranty statement furnished with the equipment. Cooling towers used with McQuay centrifugal chillers are normally selected for maximum condenser inlet water temperatures between 75F and 90F (24C and 32C).
12、Lower entering water temperatures are desirable from the standpoint of energy reduction but a minimum does exist. For recommendations for optimum entering water temperature and cooling tower fan control, consult McQuay Product Manual PM WSC/WDC, Applications Section. 4Centrifugal ChillersIOMM WSCWDC
13、 Installation Receiving and Handling The unit should be inspected immediately after receipt for possible damage. All McQuay centrifugal water chillers are shipped FOB factory and all claims for handling and shipping damage are the responsibility of the consignee. Insulation corners from the evaporat
14、ors rigging hole locations is shipped loose and should be glued in place after the unit is finally placed. Neoprene vibration pads are also shipped loose. Check to be sure that these items are delivered with the unit. Leave the shipping skid in place until the unit is in its final position. This wil
15、l aid in handling the equipment. Extreme care should be used when rigging the equipment to prevent damage to the control center, or refrigerant piping. See certified dimension sheets for the center of gravity of the unit. The unit can be lifted by fastening the rigging hooks to the four corners of t
16、he unit where the rigging eyes are located (see Figure 1). Spreader bars should be used between the rigging lines to prevent damage to the control center and motor terminal boxes on WDC dual compressor units. Figure 1, Unit Components Control Panel Evaporator Relief Valve Evaporator Condenser Expans
17、ion Valve Liquid Line Shutoff Valve Condenser Dual Relief Valves IOMM WSCWDCCentrifugal Chillers5 Figure 2, Major Component Location Note The WDC126 Dual Compressor Chiller shown has the evaporator inlet in the bottom. Consult unit certified drawings for connection locations on specific units. Locat
18、ion and Mounting The unit should be mounted on a level concrete or steel base and should be located so as to provide service clearance at one end of the unit for possible removal of evaporator tubes and/or condenser tubes. Clearances required are 18 feet (5.5 meters) for units with 16 foot (4.9 mete
19、rs) long shells, 16 feet (4.9 meters) for units with 14-foot (4.3 meters) long shells, 14 feet (4.3 meters) for units with 12- foot (3.7 meters) long shells, and 10 feet (3 meters) for units with 8-foot (2.4 meters) long shells. Evaporator/condenser tubes are rolled into the tube sheets to permit re
20、placement if necessary. Clearance at all other points, including the top, is 3 feet (1 meter). The shipped loose neoprene vibration pads should be located under the corners of the unit (unless the job specifications state otherwise). Lubrication Control Box Discharge Check Valve Condenser Motor Cool
21、ing Outlet Filter-Drier Motor Cooling Inlet Rigging Eyes (2) Dual Relief Values Lubricant Outlet to Cooler Mounting Holes (2) Each Corner Condenser Inlet Condenser Outlet Evaporator Inlet (Note) Evaporator Outlet Rigging Eyes Suction Shutoff Valve (Duals Only) Oil Pressure Regulator Vent Line from O
22、il Sump Lubricant to Lub Control Box for Unloader Oil Sump, Pump, Heater Motor Terminal Box 6Centrifugal ChillersIOMM WSCWDC Units are shipped with refrigerant and oil valves closed to isolate these fluids for shipment. Valves must remain closed until start-up by McQuay technician. Water Piping Wate
23、r Pumps Make sure that the floor or structural support is adequate to support the full operating weight of the complete unit. Rubber Shearflex pads, or Isomode, are supplied with the unit for use under each corner of the base members. The unit must be level. It will not be necessary to bolt the unit
24、 to the mounting slab or framework; but should this be desirable, 1 1/8 (28.5 mm) mounting holes are provided in the unit support at the four corners and under the compressor base on the side-mounted compressor units. Note Avoid the use of 3600/3000 rpm (two-pole motor) pump motors. It is not uncomm
25、on to find these pumps operate with objectionable noise and vibration. It is also possible to build up a frequency beat due to the slight difference in the operating rpm of the pump motor and the McQuay centrifugal motor. McQuay encourages the use of 1750/1460 rpm or four-pole pump motors whenever p
26、ossible. Evaporator and Condenser Water Piping All WSC and WDC evaporators and condensers come equipped with groove-type nozzles for Victaulic couplings (also suitable for welding) or optional flange connections. The installing contractor must provide matching mechanical connections of the sizes giv
27、en in the system dimension and capacity tables. Important Notes on Welding 1. If welding is to be performed on the mechanical or flange connections, the solid-state temperature sensor and thermostat bulbs must be removed from the wells to prevent damage to those components. 2. The unit must be prope
28、rly grounded or severe damage to the MicroTech Controller may occur. Small water pressure test valves or pipe plugs are provided at both the inlets and outlets of the vessel heads. The test valves permit the water flow pressure drops to be checked. The pressure drops and flow rates for the various e
29、vaporators and condensers are shown in McQuay Product Manual PM WSC/WDC. Refer to the nameplate on the vessel shell for identification. Evaporator inlet and outlet water connections have been reversed over time with design changes in the vessel. Be sure that water inlet and outlet connections match
30、certified drawings and stenciled nozzle markings. The condenser is connected with the coolest water entering at the bottom to maximize subcooling. Note When common piping is used in connection with a heating system, care should be taken to insure that water flowing through the evaporator cannot exce
31、ed 110F which can cause the relief valve to discharge refrigerant or damage controls. The piping should be supported to reduce the weight and strain on the fittings and connections. Piping should also be adequately insulated. A cleanable 20-mesh water strainer should be installed IOMM WSCWDCCentrifu
32、gal Chillers7 at both inlets. Sufficient shutoff valves should be installed to permit draining the water from the evaporator or condenser without draining the complete system. Flow Switch A water flow switch must be mounted in either the entering or leaving water line to insure that there will be ad
33、equate 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 under Part N
34、umber 017503300. It is a paddle type switch and adaptable to any pipe size from 1 inch to 8 inches. Consult the manufacturers data for the minimum flow rates required to close the switch. Installation should be as shown in Figure 3. Figure 3, Flow Switch Mounting Electrical connections in the unit c
35、ontrol center should be made at terminals 62 and 63. The normally open contacts of the flow switch should be wired between these two terminals. Flow switch contact quality must be suitable for 24 VAC, low current (16ma). Flow switch wire must be in separate conduit from any high voltage conductors (
36、115 VAC and higher). CAUTION Freeze Notice: Neither the evaporator nor the condenser is self-draining; both must be blown out. The piping should also include thermometers at the inlet and outlet connections and air vents at the high points. The water heads can be interchanged (end for end) so that t
37、he water connections can be made at either end of the unit. If this is done, new head gaskets must be used and control sensors relocated. In cases where the water pump noise may be objectionable, rubber isolation sections are recommended at both the inlet and outlet of the pump. In most cases, it will not be necessary to provide vibration eliminator sections in the condenser inlet and outlet water lines; but where noise and vibration are critical (for example, where a pipe chase goes through walls adjoining