PFS Single Screw Water Cooled Chiller: Service Manual

Service Manual SM
Sort：Water Cooled Chiller
Effective Time：2010.04
PFS Single Screw Water Cooled Chiller

Ap pl i es t o f ol low ing mod el s and th ei r d er i v ativ e s or m odif i ed mod el s
PFS 110.1 PFS 135.1 PFS 150.1

PFS 170.1 PFS 200.2 PFS 240.2
PFS 265.2 PFS 280.2 PFS 300.2
PFS 325.2 PFS 350.2 PFS 370.3
PFS 390.3 PFS 410.3 PFS430.3
PFS 450.3 PFS 465.3 PFS 495.3
PFS 510.3
Thank you for purchasing McQuay chillers.
The manual expatiates on security cautions, as well as installation information.
Read these instructions thoroughly before installation and starting
i
Content
1. General Description .................................................................................................................................................................. 4
2. Chiller Design Features ........................................................................................................................................................... 4
2.1 Chiller Design Features.............................................................................................................................................................. 4
2.2 Control Features ......................................................................................................................................................................... 4
3. Chiller Introduction .................................................................................................................................................................... 5
3.1 Main parts of chiller ................................................................................................................................................................... 5
3.2 Pipes of Chiller Unit .................................................................................................................................................................. 6
3.3 Electrical parts ........................................................................................................................................................................... 8
3.3.1 Moulded Case Circuit Breaker: See Fig 3-7.................................................................................................................... 8
3.3.2 Phase Monitor: Refer to Fig 3-8 ........................................................................................................................................ 9
3.3.3 CPU ....................................................................................................................................................................................... 9
3.3.4 Pressure sensor: Refer to Fig 3-10 ................................................................................................................................ 10
3.3.5 Temperature sensor .......................................................................................................................................................... 10
3.3.6 Capacity sensor ................................................................................................................................................................. 10
3.4 System Flow Chart................................................................................................................................................................... 11
3.5 Electrical Wiring Diagram ....................................................................................................................................................... 12
3.6 Chiller Electrical Parameters ................................................................................................................................................... 32
3.7 Chiller Protection Set Point ..................................................................................................................................................... 32
4. PFS Chiller Performance Data ............................................................................................................................................. 34
5. Chiller Control Logic Flow Charge..................................................................................................................................... 36
6. Installation ................................................................................................................................................................................ 42
6.1 Receiving and handling............................................................................................................................................................ 42
6.2 Chiller lifting............................................................................................................................................................................ 42
6.3 Chiller mounting instruction .................................................................................................................................................... 43
6.3.1 Chiller mounting flat .......................................................................................................................................................... 43
6.3.2 Vibration absorption request............................................................................................................................................ 44
6.4 Condenser and evaporator water piping................................................................................................................................... 45
6.4.1 Water quality ...................................................................................................................................................................... 45
6.4.2 Measuring device .............................................................................................................................................................. 45
6.4.2.1 Pressure gauge ................................................................................................................................................................... 45
6.4.2.2 Thermometer ...................................................................................................................................................................... 45
6.4.3 Control Device ................................................................................................................................................................... 45
6.5 Salty device .............................................................................................................................................................................. 46
7. Operation ................................................................................................................................................................................. 46
7.1 Operator responsibilities .......................................................................................................................................................... 46
7.2 Unit running range ................................................................................................................................................................... 46
7.2.1 Cooling Tower Fans control ............................................................................................................................................. 46
7.2.2 Cooling tower By-pass valve control .............................................................................................................................. 47
7.2.3 Cooled water flow adjustment ......................................................................................................................................... 47
7.2.4 Lower Cooled water temperature regulation ................................................................................................................. 47
7.3 System star up pre-check ......................................................................................................................................................... 47
7.3.1 Waterside............................................................................................................................................................................ 47
1
7.3.2 Unit ...................................................................................................................................................................................... 48
7.3.3 Electrical and control system ........................................................................................................................................... 48
7.3.4 Oil temperature .................................................................................................................................................................. 48
7.4 Start-up and shut-off operation ................................................................................................................................................ 48
7.4.1 Chiller test/ start-up ........................................................................................................................................................... 48
7.4.2 Start-up/Shut-off ................................................................................................................................................................ 49
7.4.2.1 Start-up............................................................................................................................................................................... 49
7.4.2.2 Shut-off .............................................................................................................................................................................. 49
7.4.2.3 Emergency stop .................................................................................................................................................................. 49
7.5 Main components ..................................................................................................................................................................... 49
7.5.1 Compressor ........................................................................................................................................................................ 49
7.5.1.1 Compressor main components (Only used for HSS4200 series compressor) .................................................................... 50
7.5.1.2 Compression process ......................................................................................................................................................... 50
7.5.1.3 Compressor capacity control.............................................................................................................................................. 51
7.5.2 Evaporator .......................................................................................................................................................................... 52
7.5.3 Condenser .......................................................................................................................................................................... 52
7.5.4 Oil separator....................................................................................................................................................................... 52
7.5.5 Expansion valve system ................................................................................................................................................... 53
7.5.6 Refrigerant injection solenoid valve ................................................................................................................................ 53
7.5.7 Lubrication .......................................................................................................................................................................... 53
8. Maintenance ............................................................................................................................................................................ 53
8.1 Operator responsibilities .......................................................................................................................................................... 53
8.2 Daily Inspection ....................................................................................................................................................................... 54
8.3 Schedule maintenance.............................................................................................................................................................. 54
8.4 Seasonal servicing.................................................................................................................................................................... 55
8.4.1 Annually star-up ................................................................................................................................................................. 55
8.4.2 Annual shutdown ............................................................................................................................................................... 55
8.5 Vessel cleaning ......................................................................................................................................................................... 55
8.7 Lubricant oil ............................................................................................................................................................................. 56
8.7.1 Lubricant oil inspection ..................................................................................................................................................... 56
8.7.2 Lubrication renewing......................................................................................................................................................... 56
8.7.3 Oil filter change .................................................................................................................................................................. 57
8.7.3.1 Oil filter replacement periods ............................................................................................................................................ 57
8.7.3.2 Oil filter replacement process ............................................................................................................................................ 57
8.8 Safety Valve ............................................................................................................................................................................. 58
8.9 Electrical and control ............................................................................................................................................................... 58
9. Touch screen operate ............................................................................................................................................................. 59
9.1 K-TP178 Control panel Operating manual for PFS.1 .............................................................................................................. 59
9.1.1 Mode ................................................................................................................................................................................... 61
9.1.2 System ................................................................................................................................................................................ 65
9.1.3 Reset ................................................................................................................................................................................... 67
9.1.4 Data ..................................................................................................................................................................................... 67
9.1.5 Set ....................................................................................................................................................................................... 69
9.1.6 Alarm ................................................................................................................................................................................... 79
2
9.2 K-TP178 Control panel Operating manual for PFS.2 .............................................................................................................. 81
9.2.1 Mode ................................................................................................................................................................................... 83
9.2.2 System ................................................................................................................................................................................ 88
9.2.3 Reset ................................................................................................................................................................................... 89
9.2.4 Data ..................................................................................................................................................................................... 89
9.2.5 Set ....................................................................................................................................................................................... 92
9.2.6 Alarm ................................................................................................................................................................................. 103
9.3 K-TP178 Control panel Operating manual for PFS.3 ............................................................................................................ 106
9.3.1 Mode ................................................................................................................................................................................. 108
9.3.2 System .............................................................................................................................................................................. 112
9.3.3 Reset ................................................................................................................................................................................. 114
9.3.4 Data ................................................................................................................................................................................... 114
9.3.5 Set ..................................................................................................................................................................................... 116
9.3.6 Alarm ................................................................................................................................................................................. 128
10. Fault diagnosis .................................................................................................................................................................... 130
10.1 Fault diagnostic table ........................................................................................................................................................... 130
10.2 Oil lose analysis ................................................................................................................................................................... 132
11. Chiller maintenance parts packet ..................................................................................................................................... 139
11.1 Chiller maintenance parts ..................................................................................................................................................... 139
11.2 Wearing parts ....................................................................................................................................................................... 139
3
1. General Description
With unique single screw compressor design, McQuay has gained many reputations since 1970‟s. As
the first manufacturer who uses R134a in chiller in the world, McQuay launched high efficiency &
environmental friendly screw chiller PFS and WPS.C.
2. Chiller Design Features
2.1 Chiller Design Features
High efficiency and reliable compressors\Multiple compressor design\Stepless capacity

control\Precise water temperature control\ Environmental friendly refrigerant R134a and reliable
control system\ Low noise\ flexible application.
2.2 Control Features

Standard RS485 port and open protocol for free communication with BMS.
Pre-correct\Pre-alarm prevents chiller from emergency shut down caused by rapid load increasing
or reducing.
Integrated clock provides weekly scheduled chiller start\stop.
Touch screen is easily operated and can display all necessary parameters and alarm records;
Controller will output the signal of Y-Delta transition time to insure a stable startup.
Chilled & cooling water pump on\off control: start pump prior to chiller startup and stop pumps after
chiller shut down.
Cooling tower fan on/off control: CPU will send signal to start or stop cooling tower fan according
to cooling water inlet temperature.
Two units coordinated control: Connected by a shielded twisted pair (STP), the two CPU of each
unit will combine and work likes one package. When net mode is selected on control panel, the two
unit will start\stop based on building load; moreover, chiller lead-lag balance function will be
performed by master CPU.
Advanced capacity control ensure <±0.1℃ outlet chilled water temperature fluctuation.
4
3. Chiller Introduction
3.1 Main parts of chiller
PFS\ WPS.C can be categorized by compress quantity. Refer to Fig. 3-1
Operator
Control Cabinet
Touch Screen
1#Compressor 2#Compressor
Evaporator
Condenser
Float Valve EXV
Please refer catalogue or installation manual for the detail dimensions and parameters.
Oil Separator
Source Water
Inlet Pipe
Hot Water
Oultlet pipe
Source Water
Hot Water Inlet
Outlet Pipe
pipe
Figure 3-1
5
3.2 Pipes of Chiller Unit
Discharge pipe connect compressor and oil separator: Refer to Fig 3-2
Discharge pipes
Figure 3-2
Suction pipes of compressor: Refer to Fig 3-3 Suction pipes
Figure 3-3
6
Refrigerant feed line between condenser and evaporator Refer to Fig 3-4
Refrigerant Feed Line
Figure 3-4
Oil feed line between compressor & oil separator: Fig 3-5
Oil Feed Line
Figure 3-5
7
Oil return pipe connects middle of evaporator and suction pipe. See Fig 3-6.
Oil return pipe
Figure 3-6
3.3 Electrical parts
3.3.1 Moulded Case Circuit Breaker: See Fig 3-7
Figure 3-7
8
3.3.2 Phase Monitor: Refer to Fig 3-8
Fig 3-8
Input side protection： Dynamic phase loss\Static phase loss\Phase revised\Phase
unbalance\overvoltage\under voltage
Load side protection：Dynamic phase loss\Static phase loss\phase unbalance
Power supply: 380（±10%）VA
3.3.3 CPU
CPU226: Refer to Fig 3-9
Fig 3-9
9
Extension Module EM231
3.3.4 Pressure sensor: Refer to Fig 3-10
High pressure sensor: Working scope: 0~2500Kpa;

Low pressure sensor: Working scope: 0~1600Kpa;
Requested power supply: 10～30 VDC ,working current: < 15 mA; Signal output：1~5 VDC
Fig 3-10
3.3.5 Temperature sensor
Discharge temperature sensor parameters: Output signal 4~20 mA, temperature range 0~100℃
Water temperature sensor parameters: Output signal 4~20 mA, temperature range -20~80℃
3.3.6 Capacity sensor
Capacity sensor parameters: Output signal 4~20 mA, adjusted range : 6400~32000℃
10
3.4 System Flow Chart
11
3.5 Electrical Wiring Diagram
Below wiring diagram is for PFS.1:
12
13
14
15
16
17
Below drawing is PFS.2 wiring diagram
18
19
20
21
22
23
Below drawings are PFS.3 wiring diagram:
24
25
26
27
28
29
30
31
3.6 Chiller Electrical Parameters
Control parts feature and basic parameters

No. Item Part No. Parameter Working scope Test
Test its output signal,
calculate the pressure

1 PFS Pressure Sensor E8121019 1-5V 0-1600KPa
value by the linear
relation
38 2 Capacity Sensor M95822-413 4-20mA 6400-32000 Test the output current,
Discharge temperature calculate the value by

3 E8110209 4-20mA 0-100℃
Sensor(℃) the linear
relation.Capacity sensor
4 Water temperature sensor E8110219 4-20mA -20-80℃ upper\lower limit can be
adjusted in site
5 Motor overheat protector Energized @2700-3200Ω 25℃-100-200Ω Test the resistance value
Test the high pressure

6 PFS high pressure switch M74796302 1310KPa-off ; 931 KPa on
activated value
Test the low pressure

7 Low pressure switch (kPa) E8134013 130 KPa-off; 250 KPa on
activated value
Moulded case circuit

8 Io×Ir×In=RLA Isd MOCP
breaker
9 Anti-freezing protector (℃) E8133004 -20℃-35℃ Ex-factory set point 2℃
3.7 Chiller Protection Set Point
Suction Pressure: Set point scope is 180~500kPa; Pre-alarm will be energized when the pressure is
lower than it. Factory default value is 210kPa.
Discharge pressure: Set point scope is 800~2200kPa; Pre-alarm will be energized when the pressure
is higher than it. Factory default set point is 1600kPa.
Alarm: When alarm occurs, chiller will stop and alarm indicator light will be energized. Alarm can be
cleaned after settling the fault and pressing “alarm reset” bottom.
Discharge temperature: Set point scope is 50~100℃; Pre-alarm will be energized when the discharge
32
temperature is higher than it. For normal cooling mode, factory default setpoint is 70℃ and 90℃ for
heating mode.
Oil pressure differential: Setpoint scope is 100~800kPa; Pre-alarm will be energized when oil pressure
differential is lower than it. Factory default setpoint is 150 kPa.
Emergency stop temperature: In normal cooling mode, if chilled water outlet temperature is lower than
the emergency stop temperature set point, chiller will be tripped; setpoint scope is 1~5℃, factory
default setpoint is 3. In heating mode,
Chilled water flow switch time delay: When chilled water flow fluctuation time is longer than the
setpoint, alarm will be energized.Setpoint scope is 1~6 sec. Factory default is 2 sec.
Cooling water flow switch time delay: If cooling water flow fluctuates beyond the set point time during
chiller running, chiller will be tripped. Set point scope is 1~6 sec, default is 2 sec.
Discharge supper heat alarm time delay: If discharge superheat temperature doesn‟t go above
pre-alarm\alarm setpoint within certain time, chiller will be tripped. Set point is 300~1800 sec, default is
450 sec.
33
4. PFS Chiller Performance Data
Model PFS110.1 PFS135.1 PFS150.1 PFS220.2 PFS240.2 PFS265.2 PFS280.2 PFS300.2
U.S.RT 107.3 130.1 146.6 214.4 237.3 260.0 276.4 292.7
Cap. kW 377.5 457.7 515.5 754.0 834.4 914.3 972.0 1029.4
kCal/h 324,650 393,622 443,330 648,440 717,584 786,298 835,920 885,284
Power Input kW 63.2 75.9 82.9 129.2 141.8 156.2 163.3 170.4
COP 5.97 6.03 6.22 5.84 5.89 5.85 5.95 6.04
IPLV 6.82 6.88 7.09 7.50 6.93 7.52 7.60 7.75
Evap Water Flow l/s 18.0 21.9 24.6 36.0 39.9 43.7 46.4 49.2
Evap Pressure Drop 24.5 34.2 24.9 27.9 30.7 36.9 47.6 48.8
kPa
Cond Water Flow l/s 22.5 27.3 30.8 45.0 49.8 54.6 58.0 61.5
Cond Pressure Drop 36.8 29.7 30.5 35.7 36.8 44.4 51.7 58.6
kPa
Type Semi-hermetic Single Screw Compressor

Compressor
Qty 1 1 1 2 2 2 2 2
Starter Type Y-Δ
Capacity Control% 25%-100% Stepless 12.5%-100% Stepless
Type Shell & Tube Type

Condenser
Qty 1 1 1 1 1 1 1 1
Type Flooded Type

Evaporator
Qty 1 1 1 1 1 1 1 1
Type R134a
Refrigerant Charge 215 215 215 315 315 315 350 350
kg
Brand McQuay
Oil
Charge L 74 74 74 85 85 85 85 85
Temp Control Chilled water outlet temperature PID control
34
OD of Evap. Pipe (mm) φ168 φ168 φ168 φ219 φ219 φ219 φ219 φ219
OD of Cond.Pipe (mm) φ168 φ168 φ168 φ219 φ219 φ219 φ219 φ219
Insulation Material Closed Foam Polyethylene
Shipment Weight kg 3670 3701 3744 5512 5551 5576 5846 5883
Operation Weight kg 3924 3971 4032 5935 5990 6028 6323 6374
RLA A 120.5 137.5 147.5 244.6 261.6 281.3 291.4 301.5
Comp Inrush Current A 316.6 316.6 316.6 316.6 316.6 316.6 316.6 316.6
Chiller Inrush Current A 316.6 316.6 316.6 438.9. 456.2 457.2 467.5 467.3
L×W×H mm 3340×1443×1956 3462×1676×2235 3764×1676×2235
Model PFS330.3 PFS350.3 PFS370.3 PFS390.3 PFS410.3 PFS430.3 PFS450.3
U.S.RT 324.8 347.9 370.9 394.0 410.5 427.0 443.5
Cap. kW 1142.2 1223.5 1304.4 1385.7 1443.8 1501.8 1559.8
kCal/h 982,292 1,052,210 1,121,784 1,191,702 1,241,668 1,291,548 1,341,428
Power Input kW 193.4 205.8 218.9 231.7 238.8 246.9 253.9
COP 5.91 5.94 5.96 5.98 6.05 6.08 6.14
IPLV 7.44 7.54 7.58 7.51 7.56 7.65 7.72
Evap Water Flow l/s 54.6 58.5 62.3 66.2 69.0 71.8 74.5
Evap Pressure Drop kPa 80.1 75.6 82.0 86.2 86.1 81.0 85.6
Cond Water Flow l/s 68.2 73.1 77.9 82.8 86.2 89.7 93.2
Cond Pressure Drop kPa 79.0 78.1 81.5 79.7 75.4 79.2 83.9
Type Semi-hermetic Single Screw Compressor

Compressor
Qty. 3 3 3 3 3 3 3
Starter Y-Δ
Capacity Control% 8.3%-100%Stepless
Type Shell & tube type

Condenser
Qty. 1 1 1 1 1 1 1
Evaporator Type Flooded type
35
Qty. 1 1 1 1 1 1 1
Type R134a
Refrigerant
Charge kg 400 470 495 495 495 565 565
Brand McQuay
Oil
Charge L 145 145 145 145 174 174 174
Temp Control Chilled water outlet temperature PID control
OD of Evap. Pipe (mm) φ219 φ219 φ219 φ219 φ219 φ219 φ219
OD of Cond.Pipe (mm) φ219 φ219 φ219 φ219 φ219 φ219 φ219
Insulation Material Closed Foam Polyethylene
Shipment Weight kg 8030 8156 8236 8308 8546 8723 8723
Operation Weight kg 8600 8726 8823 8934 9172 9387 9387
RLA A 366.4 383.2 400.9 418.2 428.3 439.7 449.8
Comp Inrush Current A 316.6 316.6 316.6 316.6 316.6 316.6 316.6
Chiller Inrush Current A 560.9 577.9 595.6 595.4 605.5 616.7 616.5
L×W×H mm 4308×1980×2278
Note：
a Cooling capacities in above table are based on below condition:
b Chilled water outlet temp 7℃；chilled water flowrate 0.172 m3/(h·kW)；
c Cooling water inlet temp 30℃； Cooling water flowrate 0.215 m3/(h·kW);
d Evaporator side fouling factor 0.018m2·℃/kW, condenser side fouling factor 0.044m2·℃/kW;
e Power supply: 380V/3P/50Hz;
f Allowable power supply fluctuation (voltage): within ±10%；
g PFS110.1-PFS150.1 are not in AHRI550/590 certified scope.
5. Chiller Control Logic Flow Charge
Chiller startup
36
Start
Close the
main switch
Power light is on
If oil level switch

Close QF2
Control cabinet is closed,oil
is electrified heater is
electrified
Push the alarm

reset button
NO Alarm/error YES
ON
Eliminate
the alarm
ALARM
OFF
Error messages are displayed

1#、2#、3# low pressure switch alarm
1#、2#、3# high pressure switch alarm
1#、2#、3# motor overheat alarm
1#、2#、3# Y-△ transition alarm
1#、2#、3# discharge temp alarm
Phase order alarm
Oil level switch alarm
Freeze protect alarm
Alarm Enter the Alarm

confimed history chart
Push the alarm

clear button
NO Start time reached
Clear the
history alarm
The unit is
ready to start
37
Ready to start
BMS BMS
STOP
start singal Mode
Singal Screw
Remote Remote Chiller Control
Switch ON Start Mode
Schedule Cooling Mode Manual Mode

Mode
Cooling available Switch ON
NO Time to start up 3S/16S Test
Suction pressure pre-alarm

Chiller start Suction pressure alarm
indicate light on Discharge pressure alarm
Discharge pressure alarm
Chilled pump start Chiiled pump timing

30S
Chilled water
No chilled water flow alarm NO flow switch
closed or not
Waiting opreation If the alarm occur

turn to alarm/error status
60s time delay then chiller pump power off
NO Start Count Down
Chiller Start
Indicator Light On
Evap. Pump Start Evap. Pump Timing
YES 30s NO Evap. Flow

Evap.Water Flow Alarm
Count Down Switch On
YES
Press Compressor Switch SA1~SA3
Lead-lag Balance
1st Startup Comp is "1# Comp";
2nd Startup Comp is "2# Comp";
3ed Startup Comp is "3# Comp";
YES
Cond. Pump Start Cond. Pump Timing
Note: Flow switch connect to condenser

Evap.Water Flow Alarm
YES 30s NO Cond. Flow
Count Down Switch On during normal cooling and heating mode;
otherwise it connect to heat recovery
condenser when heat recovery mode is
chosen.
Evap.Temp>Startup
Waiting NO Delta T(2°) YES Wait for load
YES
Chiller Start & Run
Note:
Cooling mode:Startup Delta T= Evap. water temp - Evap water temp setpoint;
Heating mode:Startup Delta T= Cond. water temp - Cond water temp setpoint.
38
Lead compressor start-up
Ready
Press "SA1-SA3" button
The lead-comp is decided by the internal comparison time

The 1st running comp is marked 1#, 2nd running one is
marked 2#, and the last one is 3#
The running time of comp 1# is the shortest, and the
longest is comp 3#
wait NO TD-STD>2° YES wait for load
YES
Cond pump is on Start to time

30S
No flow alarm NO Water flow

switch is
ON?
30S
If
another comp
Only one runs NO is put in YES
running
YES ?
YES
YES NO 1# is faulty
The
capacity YES
Unload NO is unloaded under
30S 10%
2# starts up
YES
Wait for 30S
YES
Capacity
Unload alarm NO of lead-comp is YES
minimun
?
Lead-comp "Y" starts

Main contactor is closed
Start to time
Y contactor is closed.
Oil supply valve is energized Heaters are off
Oil drain valve is powered on
Liquid supply valve is ON

For 12S
when LP is lower than 250Kpa;
Liquid supply valve is OFF
when LP is higher than 330Kpa
Y-△ conversion
Y-contactor is OFF
△-contactor is ON
2S
△-conversion Receive △
failure alarm NO feedback signal
1.Tower fans are controlled by cond water temp:

Stage#1 is ON=29°,#2 ON=31°,#3 ON=33°
Stage#1 is OFF=27°,#2 OFF=29°,#3 OFF=31°
Another 2.Oil return valve is ON when dis SH is higher
Only one runs NO comp runs? YES Comp starts up/runs than 12° and OFF when dis SH is lower than
10°
3.After running for 90s, if oil DP is lower
than pre-alarm value and alarm value, an alarm
YES
will appear on the touch screen.
Dis temp pre-alarm
Dis temp alarm
Lead-comp: Dis SH pre-alarm
Comp#2 & #3 net oil pressure < suction pressure.
Dis SH alarm
wait NO forbid load. NO Lead-comp full load
YES YES
15S
lag-comp delay
NO
60s
YES
Next comp starts
39
Lag compressor start-up
Start
Start time
NO
is done
#2 / #3
Unload NO unload below
30S Min Capacity
YES
30S
If YES
the capacity
Unload failure NO of #2/3 unload YES
the minimum
#2/#3 Y start
Main contactor is closed
Time
Y contactor is closed
Heaters are OFF
Oil supply valve is ON
Oil drain valve is ON
Runnning for 8S Liquid supply valve is ON

when LP is lower than 250Kpa;
Liquid supply valve is OFF
when LP is higher than 330Kpa
Y-△ conversion
Y contactor is OFF
△ contactor is ON
2S
△conversion Receive △
alarm NO feedback signal
YES Oil return valve is ON when

dis SH is above 12° and OFF
when dis SH is below 10°
Comp starts/runs
After running 90s, if oil DP is
lower than pre-alarm and alarm
value, an alarm will occur
Dis T pre-alarm
Dis T alarm
Dis SH pre-alarm
Dis SH pre-alarm
40
Compressor stop
Capacity control mode
Remote stop YES Control mode YES Local stop

YES YES
Schedule opreating
Remote stop Turn off the switch SA4

switch off Time to stop
YES
YES
YES
Compressor unload
Compressor to less than
NO
unload for 30S Min Capacity
YES
Compressor unload
Unload failure alarm NO to less than YES
Min Capacity
Compressor stop If the level switch

Delta contactor is close is closed,the oil
Oil feed valve power off heater will power on
Upload/download valve power off
Oil drain valve power off
Refrigerant supply valve power off
Cooling water pump

stop after 1 minute
Chilled water pump

stop after 1 minute
Unit stop
Indicator light off
41
6. Installation
6.1 Receiving and handling
The unit (and any item that shipped with it) should be checked immediately upon receipt to check well
found or not. Confirm the unit and accessories are accord to the customer order and request, confirm
the model follow the nameplate. Check the damage of the unit especially parts and piping and fill out
the receiving report. Notify forwarder in case the unit sustains any damage, and submit formal claim
request in writing.
6.2 Chiller lifting
Wooden skid must be used during chiller lifting and moving into position to prevent damaging the
bottom part of the
f
chiller; wooden skid is not suggested to remove during moving and lifting. Cable or
chain with rigging hooks is recommended to lift chiller via marked lifting holes, also you can directly lift
by frapping lifting holes in evaporator and condenser with cable or chain. But cabinet and other
components should be protected during direct lifting.
Lifting Unit by lifting chain reference as below:
Model X（mm） Y（mm） L1(min)mm L2（min）mm

PFS110.1-PFS170.1 1459 400 1000 2700
PFS220.2-PFS265.2 1420 658 1200 2700
42
PFS280.2-PFS350.2 1573 658 1200 3000
PFS370.3-PFS510.3 2257 714 1200 3600
Note:
Only allowed to use the lifting hole marked on the unit
Unit must be installed on flat level
Please reference the gravity and lifting holes position
Make sure enough space for piping and maintenance;
Make sure an even and slow speed when lifting and translation
6.3 Chiller mounting instruction
6.3.1 Chiller mounting flat
Drain should be fully concerned of the base construction and around it. The base must be higher than
the floor, and waterproof treatment is need. Also illuminance must be fully concerned to convenient to
maintain and operate.
The unit mounting base construction and each model mounting diagram is as below:
M – M Section
Base Tube sheet

Base mounting bolt
Wash Anti-vibration pad
Nut Drain
W1 W2
W4 W3
Chiller electrical
panel direction
43
Model A B C D E
PFS110.1-170.1 2806 850 3206 1250 450
PFS 220.2-265.2 2840 1430 3240 1830 450
PFS 280.2-350.2 3145 1430 3545 1830 450
PFS 370.3-510.3 3762 1586 4162 1986 450
Model F G H J Bolts
PFS 110.1-170.1 350 200 500 200 4-M27  400

PFS 220.2-265.2 350 200 500 200 4-M27  400
PFS 280.2-350.2 350 200 500 200 4-M27  400
PFS 370.3-510.3 350 200 500 200 4-M27  400
Technical request:
Make sure to compact soil base with compaction coefficient of 95%, as well as 200mm thickness gravel layer.
Base should make use of concrete C25, thickness in accordance with the drawing, and pour twice for embedded bolts concrete
Earthwork excavation should get approval by related bureau before next procedure.
6.3.2 Vibration absorption request
A. Neoprene vibration pads should be located under the corners of the unit to prevent the vibration
pass to the base, the pads location as below:
● ●
● ●
Base
Bolts
Vibration Pad
B. Spring Insulation. McQuay can provide spring insulation as request. The location as below:
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Please install the spring insulation follow the letter on it.
6.4 Condenser and evaporator water piping
6.4.1 Water quality
● Unit circuit water quality (Evaporator and condenser inlet water) should accord with GB50050-95,
“Code for Design of Industrial Recirculating Cooling Water Treatment”
● Recirculating water in open system of the unit should keep the PH value in range of 7.0-9.0, and
the calcium ion content must lower than 200mg/L.
6.4.2 Measuring device
6.4.2.1 Pressure gauge
Recommend using 0.4-class & 200-dial pressure gauge, Specific reference to the water pressure of
the water system, it is recommended to use the same access to water pressure gauge.
6.4.2.2 Thermometer
Mercury thermometer is recommended. Precision: 0.1℃， range：-20℃～+80℃
6.4.3 Control Device
Water inspects device must be installed on both inlet and outlet piping of the unit, as water flow switch,
water DP switch, and wiring to the controller. The standard device is water flow switch and supplied by
user, McQuay can provide it in accessories under request.
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6.5 Salty device
Set a deflate valve on the peak point of the water system, the valve can be manual or automatically
controlled.
Water inspects device must be installed on both inlet and outlet piping of the unit, as water flow switch,
water DP switch, and wiring to the controller. The standard device is water flow switch.
Install check valve on the evaporator and condenser pipe between the unit and the pipe system; Install
flexible connectors or metal tubes to reduce vibration on the piping.
Impurity in the water system will block the heat exchange and cause deposit. Filter must install before
the pumps.
If the ambient may be below 0, increase in anti-freeze to protect the unit's operation is proposed
7. Operation
7.1 Operator responsibilities
Operator of PFS/WPS.C must be familiar with Water system, electrical and refrigeration knowable, If
necessary (The initial startup of the chiller), McQuay service personnel will advice the proper operating
procedures.
7.2 Unit running range
The optimize condenser water inlet for PFS is 24~35℃,High ECWT will course capacity reduce and
compressor power increase; Low ECWT will course low compressor oil feed pressure, compressor
has difficulty to load, and may not load to 100%. The compressor running life may be reduced under a
long period of low oil pressure
If customer needs running the unit at an low ambient temperature condition, raise the Condensation
Pressure is need by some key imperatives:
7.2.1 Cooling Tower Fans control
The most efficiency method is using VSD or multiple stages cooling tower fan control. The user can set
the on/off temperature setpoint at each stage.
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7.2.2 Cooling tower By-pass valve control
Use the by-pass valve to control the entry water flow of the cooling tower manually or automatically to
keep the temperature of the Mix-water.
7.2.3 Cooled water flow adjustment
Keep the CEWT constant; change the condenser entering water flow to control the condensation
temperature.
7.2.4 Lower Cooled water temperature regulation
If CEWT is lower than 20℃, below operation steps should be followed:

If is a two compressor chiller, the control mode must be “Auto”, then the two compressor can running
at the same time to increase the oil pressure difference. In this low CEWT condition, running a
compressor at high load for a long time will damage it and must to avoid, so load the compressor
manually is not recommended. At “Auto” mode, when the Oil DP can not meet the request, the
compressor load should be limited at around 80%, the actual cooling capacity should be around 94%
of nominal capacity.
If the CEWT is too low, (lower than 15℃), chiller must be failed to start up by oil DP alarm. A bypass
valve between the cooled water inlet and outlet piping is recommended for long time running at this
condition, if necessary, should reduce the cooled water flow to increase the condensation pressure.
7.3 System star up pre-check
The following steps should be carried out prior to starting of the chiller:
7.3.1 Waterside
Check all condenser/evaporator inlet/outlet water piping connections; ensure all connections are
connected according to the factory certified chiller drawing;
Check all the Evaporator/condenser inlet/outlet temperature sensor location and wiring ensure the
connection fastened and temp display correct. If temp display is not correct, use “System Setting”
page functions to calibrate;
Open all water valves, start up the water pump, and leak check all flanges connecting of water pipes.
Vent the air of both Evaporator and condenser;
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Check the pressure drop on both evaporator/condenser water sides, check the motion of water flow
switch or pressure differential switch is correct.
7.3.2 Unit
Open valves list below: Liquid line check valve, Oil line check valve, Evaporator oil return check valve,
Liquid level control check valve, and Liquid injection check valve.
7.3.3 Electrical and control system
Disconnect the chiller main breaker; check all wiring contractor to the chiller control cabinet
Check the power supply, the voltage fluctuate range should not exceed 10% of the rated voltage on
nameplate, and the voltage balance not exceed 2%.
Check the power capacity if it is enough to staring the chiller and running it at full load.
Ensure all cables and safety devices comply with the chiller‟s requirements. Check the chiller wiring
diagram for all wiring connections, such as the connections for remote on/off, condenser pump and
cooling tower fan.
Close all circuit to the main power supply and circuit breakers and turn the chiller emergency stop
button clockwise to power up the chiller control panel and electric heater.
7.3.4 Oil temperature
Ensure the oil temperature higher than 40℃， or 15℃ higher than ambient temperature
7.4 Start-up and shut-off operation
7.4.1 Chiller test/ start-up
The compressor test should be carried out of the first time of startup. Choose the “Test” mode, do 3
seconds and 16 seconds test.
3-second test: Check the rotation of each compressor through analyzing the difference between
discharge and suction pressure. If no PD increase means a wrong wiring, should check and re-wiring.
16-second test: Check the transition of the star-delta starter.
3, 16-second test: Check if there is any abnormal noise when compressor is operating.
Check and resolve all problems and re-energize the control panel. Check all the settings in the chiller
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“Setting” pages follow the actual requirement, choose the “Local” mode, set the LEWT, If the pumps
are not interlocking with the chiller controls, check if the condenser and chilled water pumps have been
turned on, Finally, turn the compressor on.
If the compressor cannot reach full load, check whether high pressure is two times of low pressure, if is,
check the compressor can be load to 100% by manual or not. If the compressor can not load to full
load, please adjust the compressor capacity upper/lower limit settings based on the real valve.
7.4.2 Start-up/Shut-off
Three running modes can be selected, they are “Use Local”, “Use Schedule” and “Use Remote”, user
can choose one mode in the control panel, once one mode selected, others are ignored.
7.4.2.1 Start-up
Choose chiller running mode.

Set chilled water outlet temperature.
If “Use Local”, press the start button on “Operate” page, once the starting temp difference meets, the
chiller will start up automatically. If “Use Schedule”, two conditions should be met, one is the preset
schedule, and the other one is the starting temp difference. If select “Remote”, the chiller start up
under the condition of meet the starting temp difference and receive a remote start-up signal.
7.4.2.2 Shut-off
If “Use Local”, press the stop button on “Operate” page, the compressor will unload automatically and
shut-off. If “Use Schedule”, the unit will stop follow the pre-set schedule. If “Use Remote”, the chiller
will shut-off once get a remote signal.
7.4.2.3 Emergency stop
A red button located on the control panel is emergency stop; press the button to stop the chiller when
chiller failure happens.
7.5 Main components
7.5.1 Compressor
WPS.C PFS unit use HSS series semi-hermetic single screw compressor.
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7.5.1.1 Compressor main components (Only used for HSS4200 series compressor)
7.5.1.2 Compression process
Suction:
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Compress:
Discharge:
7.5.1.3 Compressor capacity control
PFS/WPS.C compressor use capacity slide valve to control the exhaust volume, the capacity sensor
measure the displacement of the slide valve from 0-100%, respectively presented 25-100% exhaust
volume.
The compressor capacity is controlled by chilled water outlet temperature PID algorithm. When ELWT
is lower than setpoint, unload solenoid valve is energized, high pressure oil enters the piston chamber,
at this time the combined force of high oil pressure and spring sufficiently overcomes the differential
pressure to make slide valve move to unload, then spring force reduces, finally it achieves to balance
without energizing load/unload solenoid valve. Whereas, when CLWT is higher than setpoint, load
solenoid valve is energized, oil in piston chamber reduces, the combined force of high oil pressure and
spring is lower than differential pressure, the capacity slide valve moves to unload.
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Load/Unload principle scheme:
7.5.2 Evaporator
The evaporator of PFS is flood type, refrigerant in the shell circuit and water in tubes. The copper tube
outside dimension is 19mm with both sides enhanced treatment. 2-pass design, the refrigerant vapor
enters compressor from top of evaporator, PFS suction pipe is connected to compressor with Victaulic
while WPS.C using flange.
7.5.3 Condenser
The condenser is under the oil separator, refrigerant vapor is condensed here and sub-cooled, and the
copper tube OD is 19mm with both sides enhanced treatment, 2-pass design.
7.5.4 Oil separator
The mixture of refrigerant and oil discharged from the compressor flow through the discharge pipe,
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and enter the oil separator. The oil separated and the gas enters the condenser.
7.5.5 Expansion valve system
The expansion valve is directly controlled by a refrigerant level sensor placed on the condenser (a ball
type float valve). The system controls the refrigerant liquid level, to grant an adequate operation of the
expansion valve completely flooding the integrated sub-cooling section of the shell-and-tube
condenser. PFS/WPS.C unit uses SV type float valve and PMFH type servo-controlled valve
manufactured by Danfoss. When the liquid level in the float rises the float orifice opens. This brings
about a rise in the pressure across the servo and PMFH opens allowing more refrigerant flow, and vice
versa as the liquid level in the float drops. Manual override of PMFH is possible with the installation of
solenoid valve type EVM fitted in S ll. When EVM opens, it allows the servo pressure to control the
operation of the PMFH; when the chiller is under high evaporator pressure, EVM closes to override the
operation of the PMFH (PMFH closes) to prevent more refrigerant from flowing into the evaporator, to
lower the evaporator pressure.
7.5.6 Refrigerant injection solenoid valve
The low temperature refrigerant gas cools down the motor, control the motor temperature nearby an
optimized set point. Once system considers motor wirings need cool-down due to high discharge
temperature, controller will make liquid injection solenoid valve open, liquid refrigerant enters into
compressor to cool down.
7.5.7 Lubrication
PFS unit use McQuay Service Oil Brand B
8. Maintenance
8.1 Operator responsibilities
To ensure the unit is in good running condition, regular inspection should be done follow the list below.
If necessary, calibrate the pressure and temperature display in the system “Setting” page.
No. Item Content Method Standard

1 High pressure Check HP sensor Pressure guage 500-850KPa(depend on
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job conditions)
2 Low pressure Check LP sensor Pressure guage 230-350KPa
3 Oil pressure Check OP Pressure guage 10-50KPa lower than HP
4 LWT sensor Check LWT reading Thermometer Within 0.5℃

5 EWT sensor Check EWT reading Thermometer Within 1℃
6 Discharge T sensor Check discharge T Compare reading Within 0.5℃
reading with 50℃ water
7 Lubricant oil Check oil level of oil Eyeballing Above sight glass lower
separator limit
8 Refrigerant Check evaporator Eyeballing Higher than top tubes
liquid level layer while cond liquid
level is normal.
8.2 Daily Inspection

It is recommended that records of unit operation status and daily inspections to be kept for references
and analysis
Unit running log please refer to Appendix:
8.3 Schedule maintenance
Running time(H) Items
1000 2500 5000 20000 40000
Main Rotor bearing ○
Star-rotor bearing ○
Star rotor △ ○
motor △ △ △ △
solenoid valve △ △
Suction filter △ △ △ △ ○
Oil filter △ △ △ △ ○
Oil ○ ○
Noted：△Inspect ○change
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8.4 Seasonal servicing
8.4.1 Annually star-up
Megger test should be taken before start the chiller (380V voltage test the insulation for the unit, the
resistance must higher than 20MΩ ). Fasten all contactors, on power the unit at least 4 hours before
running to ensure the oil temperature can reach 40℃ or 15℃ higher than ambient.
8.4.2 Annual shutdown
Close the liquid supply valve, running the unit till low pressure alarm shut off.
Disconnect the main power supply; disconnect the circuit breaker in control panel. Prevent oil heater
energized or star up the unit suddenly.
Drain off the water in the heat exchanger to prevent the long term water flow to corrosion the heat
exchanger; meanwhile prevent the ice to rupture the tubes in winter when the ambient temperature
below 0.
8.5 Vessel cleaning
Because of the open loop water system, the heat exchange tubes are easy to deposit, and decrease
the heat exchange efficiency and cooling capacity, increase the compressor power consumption.
Demineralized water is recommended. Normally the tube cleaning works should be done annually, if
use polluted water, cleaning must be more frequently. The tubes are inner helix groove, and must use
circumrotate cleaning equipment to clean the tubes.
Based on checking result to confirm the cleaning period and water disposal is propriety. Check the
water temperature sensor on inlet/outlet piping, if corrosion, replace it, if deposit, clean it.
Noted:
● Before starting, preparing work should be done in advance, separate the piping system from
other equipment.
● After the cleaning by chemical agent, the tubes should be flushed by a mass of water to dilute
remaining chemical medicament, till the PH value around 6-8.
● Special brush should be used during the cleaning to avoid the damage of scratching or breaking
the tubes, liner brush is forbidden.
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8.7 Lubricant oil
8.7.1 Lubricant oil inspection
Inspection Items Description
Moisture Moisture in the oil
Acid number Acid number of the oil
Adhibit Oil kinematic viscosity under 40℃ and 100℃
Chroma The color of the oil
Educt content PET Oligomer content in oil
Anti-foaming property Test anti-foaming characteristic
Copper corrosion Corrosion to copper sheet
Open flash point Test open flash point of oil
Density Test density
Flocculation point Test refrigerant temperature when oil is leached
Low temperature leaching Test if refrigerant leaches at -40℃ for 4 hour
Insulating breakdown voltage Test insulating performance
8.7.2 Lubrication renewing
If the PFS unit repeating shut off by lower oil level alarm, it is likely to show an insufficient oil
charge; also maybe the system is in the process of oil reclaim:
1. Running the unit for one hour and a half, check the oil level is rising or not;
2. Re-start the unit and running at normal condition, if still low oil level alarm, means insufficient oil
charge, uses the oil charge valve at the bottom of the oil separator to charge.
3. Make sure the unit is shut off when charge oil to make the work easy. Even though the unit is
shut off but still under positive pressure, oil pump by manual or electrical is recommended.
4. Charge oil till the level reach the second scale line on eye sight glass on oil separator.
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Note:
 Oil can be pumped to the condenser with refrigerant. The oil should be separated and returned to the unit.
 Excessive oil charge will decrease the unit efficiency. Over volume charge will decrease the heat exchange efficiency.
8.7.3 Oil filter change
The HSS4200 single screw compressor is equipped with a high efficient filter for optimal filtration
(McQuay Wuhan, China Part No.M7348-188).A secondary filter is installed in the supply oil piping
8.7.3.1 Oil filter replacement periods
The main oil filter of the compressor should be inspected after the first 1000 hours of operation and
every 4000 hours thereafter. Should the compressor stops on „Load‟ alarm, check the oil filter pressure
drop.
Use a pressure gauge to check the discharge pressure P1 and filter outlet pressure P2 of the
compressor as shown in the Figure below. Should the pressure difference between P1 and P2 exceed
100 kPa, replace the oil filter
8.7.3.2 Oil filter replacement process
● Suction pressure adds 1000kPa based on original setting in “Sensor Calibration” page when
chiller is running;
● Shut-off the check valve at the bottom of the condenser, running till low pressure alarm to shut
down.
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● Remove the oil filter flange cover;
● Remove the old oil filter core under appreciably positive pressure;
● New O ring is recommended before fix the new oil filter core. Oil the O ring first and fix the filter,
make sure the system is under positive pressure otherwise should vent out the air with some
refrigerant.
Note:
Change the setting back after the replacement; open the check valve at the bottom of Condenser.
8.8 Safety Valve
The safety valve (NPT1) purges excessive refrigerant when over pressure condition occurs. Therefore,
the following maintenance must be carried out to ensure that it is working properly:
 Dismantle the gas discharge adaptor at the opening of the pressure relief valve, inspect the
valve carefully and check for corrosion, rust, dust built-up, fouling and leakage. Perform this
inspect at least once a year.
 In case of corrosion or any foreign substance built-up, remove all refrigerant and oil, and
replace the safety valve.
If the unit is installed in a corrosive environment or the safety valve discharges gas into a corrosive
environment, the inspection frequency should be increased.
8.9 Electrical and control

Note:
Disconnect power to the electric cabinet prior to carrying out maintenance and inspection.
Familiarity with the wiring diagram and the chiller system prior to carrying out maintenance on the
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electrical system. Maintenance of the electrical system involves the general requirement of keeping
contacts clean and connections tight and checking per month.
Control cabinet must be on power more than 1 hour during the long term shut off season, to
prevent the moisture.
Warning:
If the wiring is not follow the diagram, the quality guarantee will be lapse. Fuse disconnect or circuit breaker tripped means short circuit or
overload. Before re-start the compressor or change the fuse, should find out the fault and fix. The control panel must be maintained by
experienced electrical engineer.
9. Touch screen operate
9.1 K-TP178 Control panel Operating manual for PFS.1
Prolegomenon
PFS utilizes known K-TP 178 touch screen as the main human interface to offer operator easy
operation and maintenance. This manual will direct operator on how to view, set, and control PFS
chillers via K-TP178.
Figure 9.1.1 main interface
Note: The [Data] button will change to [Display] by pressing other buttons except [Set]
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Control Mode
Select
Manual Operation
Mode
Output Test
Compressor Test
Hardware
Information
System
Screen Setup
Reset alarm
Reset
Chiller Information
Data Compressor
Information
Capacity Slide
Calibration
System Setup
Chiller Capacity
PID Setup
Set
Alarm Setup
CDS WTR Flow

PID Setup
Schedule Setup
Page
Sensor Offsets
Active Alarm
Alarm
Alarm History
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9.1.1 Mode
Mode interface contains 4 sub-screens: control mode select, manual operation, output test and
compressor test.
9.1.1.1 Control mode settings
Four control modes available on McQuay PFS, see below detailed table:
Table 9.1.1 Control mode select
Mode Description
Remote To control chiller on/off by remote PC or other devices away from chiller plant room.
Local To control chiller on/off by chiller operating touch screen.
Schedule To control chiller on/off by pre-set time schedule, refer to section9.1. 5.6.
Pre-start testing, allow unit to check wiring and output prior start, refer to section
Test
9.1.1.3 and 9.1.1.4
The following interface will be displayed by pressing “Mode” button in the main interface.
Note 1: Only McQuay authorized operator has the rights to operate.
Note2: Program for Australia chillers will pop-out an input dialogue by pressing [Mode] button. It offers
two level user names and codes protection with different authorities. See below table:
Table 9.1.2 User identification
User Description
name
Admin Administrator has full rights to view, operate and change settings.
User Only allowed to view and operate, cannot change set points.
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Figure 9.1.2 Log on interface
After log on, interface will direct you into the mode selection screen.
Only one control mode could be selected each time, and a selection has to be made before start the
unit. Once one mode is pressed the button will reverse, for example press [Ignore local], then the
button will auto change to [Use local].
Figure 9.1.3 Control Mode Select interface
Ignore Local/Use local Press this button to disable/enable local control (on/off) of the chiller.
Ignore Remote/Use remote Press this button to disable/enable local control (on/off) of the chiller.
Ignore Schedule/Use Enable/disable chiller auto start according to preset time schedule.
Schedule
Ignore Test/Use test Enable/disable test mode of the chiller.
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9.1.1.2 Manual operation
The following interface will be displayed as follows by pressing [Operate] in the mode interface:
Figure 9.1.4 Start/Stop interface
Display the countdown time lag to allow chiller starts (from the moment of power
Wait time
bringing in to chiller starts).
Capacity Display the current running % load.
Start/ Stop Press [Start] for start of the unit and [Stop] for shutoff of the unit.
Load Press this button to increase compressor load.

Unload Press this button to decrease compressor load.
Press this button to interchange between Auto and Manual mode. During Auto
mode, chiller‟s control automatically adjusts its capacity according to field
Auto/Manual condition. During Manual mode, the chiller capacity can be adjusted manually by
pressing the [Load] and [Unload] buttons. When one mode is selected, chiller will
operate under the selected mode until a change is made by the operator.
Press “Mode” button to return to the [Control mode select] menu.
9.1.1.3 Output test
The following interface will be displayed as follows by pressing [Output Test] in the Operate interface.
This menu enables user to test chiller internal control wiring connection to the following parameters.
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Figure 9.1.5 Output Test interface
Evap Pump Chilled water pump.

Cond Pump Condenser water pump.
Tower Cooling tower fan.
Load Compressor loading solenoid valve.

Unload Compressor unloading solenoid valve.
Run Light Chiller run light.
Alarm Light Chiller alarm light.
Feed oil Oil feed solenoid valve.
Return oil Oil return solenoid valve.
To test for chiller internal control wiring, switch between the ON/OFF button (on the [Unit Output Test]
menu as shown in above figure) for the control parameter and check the corresponding LED on the
controller block inside the compressor control cabinet. Refer to the chiller wiring diagram for the
corresponding LED address.
Caution: The test of oil feed valve is not allowed when the high/low pressure is not built up to
prevent oil back to the oil separator from the compressor oil chamber
Press “Operate” button to return to [Manual operating] menu.
9.1.1.4 Compressor test
Press the [Compressor Test] button to the following compressor testing screen. Prior to bringing the
chiller into actual operation, the compressor testing function lets the operator to perform test on the
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compressor
Figure 9.1.6 Compressor Test interface
Press this button to perform a three-second running test on this chiller; the main
3S Test
purpose is to check compressor running rotation.
Press this button to perform a sixteen-second running test on this chiller, the main
16S Test
purpose is to check compressor abnormal noise, starter wye-delta transition, etc.
Displays the difference between discharge and suction pressure for compressor. A
Lift Press correct compressor rotation determined by a positive „Lift Press‟ value, otherwise a
negative value is displayed.
Press [operate] button or [output test] button to return to previous menu screen.
Note: compressor test can only be performed when control mode [use test] is selected.
9.1.2 System
System menu contains hardware information and screen setup.

9.1.2.1 Hardware information
It displays as follows by pressing “System” button in the main interface. Note this hardware means the
LCD system settings, not the chiller setup.
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Figure 9.1.7 Information of the touch screen
9.1.2.2 Screen setup

It displays as follows by pressing [Screen Setup] button in the system interface:
Figure 9.1.8 Screen Setup interface
Adjust Contrast Adjusts the LCD contrast.

Calibration Touch Calibrates the touch screen buttons.
Clear Screen Degauss the LCD touch screen from display error.
Transfers Initiates program download.
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9.1.3 Reset
9.1.4 Data
In this section will provide chiller information such as temps, pumps and compressor information to
view the operating condition of the chiller.
9.1.4.1 Chiller information
The following interface will be displayed as follows by pressing [Data] in the main interface:
Figure 9.1.9 Chiller information
Displays the active set point of leaving water temperature of the evaporator,
Active Set point
Active set point=Local spt + Remote CHW offset, refer to section 5.1.
Lvg Evap Displays the leaving water temperature of the evaporator.
Ent Evap Displays the entering water temperature of the evaporator.
Lvg Cond Displays the leaving water temperature of the condenser.
Ent Cond Displays the entering water temperature of the condenser.
Cooling Call When displays Call means the Remote switch is on, and No Call means it is
Received off.
Evap Pump Displays running hours and start times of the chilled water pump.
Hrs/Starts
Cond Pump Displays running hours and start times of the cooled water pump.
Hrs/Starts
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9.1.4.2 Compressor information
Press lower right [Comp] on above menu will switch the interface to compressor information to display
compressor temp and pressure in real time.
Figure 9.1.10 Compressor Information interface
Displays the value differential between the discharge temperature and the
Disch Superht
compressor‟s saturated discharge temperature.
Disch Temp Displays the real-time discharge temperature.
Saturated Cond T The corresponding saturation temperature of the discharge pressure.
Saturated Evap T The corresponding saturation temperature of the suction pressure.

Discharge Press Displays the real-time discharge pressure.
Suction Press Displays the real-time suction pressure.
Oil Press Displays the oil supplying pressure of the compressor.
Displays the value differential between oil supply pressure and the suction
Net Press
pressure.
Capacity Displays the operating capacity of the compressor.
Displays countdown waiting time of start, and the chiller will be allowed to
Wait Time
start only after the waiting-time is 0. Refer to section 1.2
Hours Displays the total operating time of the compressor.
Starts Displays the total starts of the compressor.
Press [Temp] button to return to previous chiller information menu.
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9.1.5 Set
Note: Only the [Set] button pressed doesn’t change [Data] to [Display]
9.1.5.1 System setting
Press the [Set] button on the main tool bar for system settings. A window will pop up prompting for
Username and Password. All system settings (except leaving chilled water set point) are password
protected.
Figure 9.1.11 System setup
Set leaving evaporator water temperature in the 3 to 15℃ range via human
Local Spt
interface touch screen. Factory default setting is 7℃.
Setting the offset value by remote analog signal(4-20mA) in the range of
Remote CHW
0-10℃.Factory default setting is 0℃.
offset
Active set point=Local spt+Remote CHW offset.
The temperature difference between the actual leaving chilled water
Start DT temperature and the user set point. Chiller starts when [Start DT] exceeds a
user preset value in the 1 to 5℃ range. Default factory setting is 2℃
temperature and the user setpoint. Chiller shuts down when [Shutdn DT]
Stop DT
falls below a user preset value in the -3 to -0.5℃ range. Default factory
setting is -2℃
Sat Cond Setpoint Corresponding saturated condenser temp of discharge pressure settings
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for the control of condenser water modulating valve or condenser water
VFD pumps. the arrange is 20-35℃.Default factory setting is 25℃.
The set point of the Pulldown Rate of chilled water with the range of
Pulldown Rate
0.1-2℃/minute, factory default setting is 0.2℃/minute.
Sets the minimum capacity that the chiller can unload to. Default factory
Min Capacity
setting is 10% but adjustable in 5%-50% range.
Modbus ID Sets machine Modbus address if multiple chiller control system applied.
Note：[Remote CHW offset] is used only for Australia chillers.
Active Set point＝Local Spt＋Remote CHW offset
9.1.5.2 Chiller capacity PID setup
To accurately control the capacity (related to chilled water temperature) and condenser water
temperature, PFS chiller temperature controller uses PID (Proportional, Integral, Differential) algorithm
in controlling the temperature. PID controller compares the actual temperature (feedback from sensor
reading) to the desired control temperature (setpoint); an error signal found by subtracting the
measured quantity from the setpoint is feedbacked to the PID controller. The PID controller computes
and sends a “corrective signal” (otherwise known as a “corrective value”) to the actuators based on:
the magnitude of the error (“P” = proportional), the sum of all previous errors (“I” = integral) and
anticipate future error from the rate of change of the error (“D” = differential). A “corrective action” is
performed by the actuator such that the error signal is reduced. The new output will be sent back to the
sensor again to find the new error signal (e). The looping of error feedback and corrective action
continues until the actual output is equal to the setpoint.
However, just simply by adding these three values (P, I and D) together would not compute the
“corrective value”, each of these 3 values needs to be multiplied by a constant, known as “gain”.
Corrective value (u) is equal to the proportional gain (KP) times the magnitude of the error (P), plus the
integral gain (KI) times the integral of the error (I), plus the differential gain (KD) times the differential of
the error (D). See the following equations:
u = KP(P) + KI(I) + KD(D)
Proportional gain, expressed in degree (oC), has the effect of reducing the rise time (response time)
and steady-state error when it is increased. (Note: steady-state error is the difference between the
70
actual temperature and the setpoint when the actual temperature has settled down to a constant
value).
Integral gain, expressed in seconds, has the effect of eliminating the steady-state error, however the
tradeoff is longer settling time which means more time is needed for the PID controller to adjust the
actual temperature back to the setpoint.
Differential gains, expressed in seconds, helps to improve the responsiveness and stability of the
temperature control by sensing the rate of rise or falls of system temperature and minimizes overshoot
or undershoot. Therefore, larger differential gain means that rate of error is evaluated longer so that
overshoot is minimized and PID controller will take lesser time to adjust the actual temperature back to
the setpoint (shorter settling time).
Effects of each of gains are summarized in the table shown below.
Table9.1.3 Effects on increasing PID gains
PID Gain Rise Time Overshoot Settling Time Steady State Error
Kp Decrease Increase Small Change Decrease
Ki Decrease Increase Increase Eliminate
Small
Kd Decrease Decrease Small Change
Change
The following are explanations for another two user adjustable parameters in PID settings.
Sample – Sampling period, the time taken to take a reading of the controlled parameter (in our case,
the output temperature)
Period – Output period, the time taken to feedback the error signal to the PID controller
NOTE: Correlations as shown in above Table 9.3.3 may not be exactly accurate, because Kp,
Ki, and Kd are dependent of each other. In fact, changing one of these variables can change the
effect of the other two. For this reason, the table should only be used as a reference and user
assumes all responsibility on changing the PID settings, and McQuay takes no responsibility
should the performance of the chiller be compromised.
71
Figure 9.1.12 PID interface
Sets the proportional gain of the controller in the 0.01 to 5 range. Default
Gain
factory setting is 0.8.
Sets the sampling rate of the controller in the 10 to 90 seconds range.
Sample
Default factory setting is 30 seconds.
Sets the integral time of the controller in the 200 to 9000 seconds range.
Integral
Sets the differential value of the controller in the 5 to 120 seconds range.
Differential
Sets the controller output period in the 2 to 60 seconds range. Default factory
Period
setting is 2 seconds.
Sets the time of load/unload solenoid valve energized in one output period,
Pulse Time
default factory setting for loading is 0.3S and unloading 0.4S.
9.1.5.3 Alarm setup

This menu will provide access of change alarm settings. McQuay PFS offers two kinds of alarms:
Pre-alarm: When pre-alarm occurs, machine will not necessarily automatically shut-off but alarm light
on control cabinet will flash and LCD displays the pre-alarm message.
Alarm: When alarm occurs, machine will auto shut off and alarm light on control cabinet will lit up
continuously, meanwhile LCD displays the alarm message.
Press [Alarm Setup] button to enter following screen.
72
Figure 9.1.13 Alarm Setup
A minimum temperature value can be preset to initiate chiller shutoff when

the evaporator leaving chilled water temperature goes below the preset
Ice Protect
value. Sets the refrigerant condensing temperature in the 2 to 7℃ range.
Default factory setting is 3.5℃.
Sets the compressor discharge temp alarm value in the 50 to 100℃ range.
Alarm light on the control cabinet lit up continuously, LCD displays alarm
Dis.T Alarm
message and machines shuts down when discharge temp goes higher than
the setpoint. Default factory setting is 70℃.
Sets the compressor suction pressure pre-alarm value in the 180 to 500 kPa
range. Alarm light on the control cabinet flashes, LCD displays alarm
Suct P Pre – Alarm
message and machine unloads when suction pressure falls below the
setpoint. Default factory setting is 210 kPa.
Sets the compressor suction pressure alarm value in the 180 to 500 kPa
range. Warning light on the control cabinet lit up, LCD displays alarm
Suct P Alarm
message and machine shuts down when suction pressure falls below the
Sets the compressor discharge pressure pre-alarm value in the 800 to 1200
Dis.P Pre-Alarm kPa range. Alarm light on the control cabinet flashes, LCD displays alarm
message and machine unloads when discharge pressure exceeds the
73
Sets the compressor discharge pressure alarm value in the 800 to 1200 kPa
range. Alarm light on the control cabinet lit up, LCD displays alarm message
Dis.P alarm
and machine shuts down when discharge pressure exceeds the setpoint.
Default factory setting is 1000 kPa.
Alarm will be given when the oil pressure differential is lower than this value,
Oil DP Alarm
the set value is 100-800 kPa, and that of the factory is 100 kPa
Timing delay of evaporator chilled water flow/PD switch alarm, setting

EDP Delay
ranges from 2S to 6S, factory default setting is 5S.
Timing delay of condenser cooling water flow/PD switch alarm, setting
CDP Delay
9.1.5.4 Cap. Offset

Below figure shows an enlarged view of spring piston of the capacity sensor. Imagine the piston move
horizontally along the dotted square (along point A and B) as the capacity modulation valve pushes the
tip of spring piston. Point A and B correspond to 100% and 0% compressor load, respectively.
Referring to Figure 14, a positional value is given to point A (upper limit) and B (lower limit). Factory
default setting for point A (100% load) and B (0% load) is 32000 and 6400, respectively. The capacity
sensor might need to be calibrated if point A shift to point A‟, which represents a new setting on the
position value for 0% compressor load (the same explanation goes for point B‟).
Capacity calibration menu (by pressing the [Cap. Offset] button) allows user to recalibrate the
positional value for point A and B. For example, when compressor stops, (which represents 0%
compressor load) the „Active‟ value shows the actual positional value of the transducer (point B‟, which
correspond to 0% load) which should be the same for the „Lower Limit‟ value (point B). Should the
„Lower Limit‟ value differ from the „Active‟ value, set the „Lower Limit‟ value according to the „Active‟
value.
74
Figure 9.1.14 Spring piston of the capacity sensor
Figure 9.1.15 Capacity Slide Calibration interface
Active Displays the current actual positional value of capacity sensor.

Sets the positional lower limit value of the transducer (Point A), factory
Lower Lim
default setting is 6400. Setting range 6400-32000.
Sets the positional upper limit value of the transducer (Point B), factory
Upper Lim
Demand limit control mode, can be shift from [local] to [remote] by press
Demand Reset
drop-down menu.
Sets the maximum cooling load the unit can produce. can be set at the
Demand Limit local and remote mode, ranges from 50% to 100％ with a factory default
setting 100％.
75
9.1.5.5 CDS WTR Flow PID Setup
Condenser water flow PID is to sense refrigerant saturated condenser temp corresponding to
discharge pressure (refer to section5.1 system setting-Sat. cond temp) and after PID calculation, send
the analogue output to modulate condenser water flow valve or VFD pumps.
Figure 9.1.16 CDS WTR Flow PID Setup interface
Gain
Sample
Integral
Differential
Period
Sets the lower limit of analog signal to control device of condenser
AO Low Level modulation valve or VFD pumps in range of 6400-32000, factory default
setting is 6400.
Sets the upper limit of analog signal to control device of condenser
AO High Level
modulation valve or VFD pumps in range of 6400-32000, factory default
76
setting is 32000.
Note: Change of above settings may cause interference or abnormal control malfunction, consult
McQuay service engineer before change.
9.1.5.6 Schedule
A 7-day, 24-hours („HOUR:MINUTE‟) programmable start/stop schedule of the chiller can be
programmed through the „Schedule settings‟ screen by pressing the [Schedule] button. Press the
[Next] or [Previous] button to switch between pages.
Figure 9.1.17 Schedule set
Figure 9.1.18 Continues
Chiller will run as per user-set schedule when the [use schedule] function is enabled on the „Mode
Select‟ screen (refer to section 1.1 Control mode selection).
77
9.1.5.7 Sensor offset
The „Sensor Offset‟ setting menu enables user to correct any differences between the actual
pressure/temperature and the sensor reading. Press the [Sensor Off.] button to enter the „Sensor
Offset‟ menu to add correctional factors to the temp/pressure values as read by sensors 1. This is
explained using the following formula.
Actual temperature/pressure value = correctional factor + sensor reading
Should there be no differences between the sensor reading and the actual temperature/pressure, the
correctional factor is zero.
Please note that the „Sensor offset‟ setting does not calibrate the sensor, but adds a correctional factor
to the value of the sensor as read by the chiller microprocessor, such that the value can be corrected.
Figure 9.1.19 Sensor offset
Adds a leaving chilled water temperature correctional factor in the range of -9.9 to
Evap L-T
9.9 ℃.Default factory setting is 0℃.
Adds an entering chilled water temperature correctional factor in the range of -9.9 to
Evap E-T
9.9 ℃. Default factory setting is 0℃.
Adds a leaving condenser water temperature correctional factor in the range of -9.9
Cond L-T
to 9.9 ℃. Default factory setting is 0℃.
Adds an entering condenser water temperature correctional factor in the range of

Cond E-T
-9.9 to 9.9 ℃. Default factory setting is 0℃.
78
Adds a discharge pressure correctional factor in the range of -9.9 to 9.9 ℃.
Dis T
Default factory setting is 0 ℃.
Adds a discharge temperature correctional factor in the range of -999 to 999 kPa.
Dis.P
Adds a suction pressure correctional factor in the range of -999 to 999 kPa. Default
Suct. P
factory setting is 0 kPa.
Adds a oil pressure correctional factor in the range of -999 to 999 kPa. Default
Oil Press
9.1.6 Alarm
In case of alarm, the compressor will shut off and alarm light lit up. To restart the compressor after
problem has been rectified, press the [clear] button located on the main menu.
The following is a list of the alarms：
1. Discharge superheat pre-alarm/alarm;
2. Suction pressure pre-alarm/alarm;
3. Discharge pressure pre-alarm/alarm;
4. Phase sequence protection alarm;
5. Evap Freeze Protect;
6. Cond Water Flow switch alarm;
7. Evap Water Flow switch alarm;
8. Oil level switch alarm;
9. Oil DP alarm;
10. Discharge T alarm;
11. Low pressure switch alarm;
12. High pressure switch alarm;
13. Motor overheat alarm;
14. Motor overload alarm;
15. Wye-delta transition fault;
16. Unloading fault;
Press the [Alarm] button in the main tool bar for active alarm and alarm history.
79
Figure 9.1.20 Active Alarms interface
Clear Clears active alarm.

History Press this button to switch to alarm history screen.
ESC Press this button to return to the main menu as shown in figure 1.
It will show as follows by pressing the button of [His.]:

Figure 9.1.21 Alarm History interface
Clear Clears alarm history.

Active Press this button to switch to active alarm screen.
Note: Alarm history is saved in touch screen memory not in CPU226, thus once power off; all the alarm
histories will be cleared and will not be shown on screen anymore.
80
Prolegomenon
81
Control Mode Select
Manual Operation
Mode
Output Test
Compressor Test
Hardware
Information
System
Screen Setup
Reset alarm
Reset
Chiller Information
Data Compressor
Information
Capacity Slide
Calibration
System Setup
Chiller Capacity PID

Setup
Set
Alarm Setup
CDS WTR Flow PID

Setup
Schedule Setup Page
Sensor Offsets
Active Alarm
Alarm
Alarm History
82
9.2.1 Mode
compressor test.
Mode Description
Schedule To control chiller on/off by pre-set time schedule, refer to section 9.2.5.6.
Test
9.2.1.3 and 9.2.1.4
User name Description

83
Ignore Remote/Use Press this button to disable/enable local control (on/off) of the chiller.
remote
Schedule

The following interface will be displayed as follows by pressing [Operate] in Control Mode Select
interface
84
Figure 9.2.4 Start/Stop interface
Start/ Stop Press [Start] for start of the unit and [Stop] for shutoff of the unit.
Load Press this button to increase compressor load.
Unload Press this button to decrease compressor load.
Press this button to interchange between Auto and Manual mode. During Auto
mode, chiller‟s control automatically adjusts its capacity according to field
condition. During Manual mode, the chiller capacity can be adjusted manually
Auto/Manual
by pressing the [Load] and [Unload] buttons. When one mode is selected,
chiller will operate under the selected mode until a change is made by the
operator.
Soft switch for Compressor #1. Press this button will change the display
between “C1 Auto” and “C1 stop”. When “C1 Auto” mode displayed，Comp 1
will operate automatically according to control logic settings. By pressing [C1
Auto] this button will change to “C1 stop” which means compressor 1 will be
C1 Auto/C1 Stop compulsively switched off. This switch has a priority on controlling compressor
starts- compressor can not start again if not pressing this button to “C1 Auto”.
Note: Only dual compressor PFS has compressor soft switch as there is no
dry contact hard switch on control panel. PFS.1 and PFS.3 unit have dry
contact switch on control panel so this soft switch is not required.
C2 Auto/C2 Stop The same as C1 Auto/C1 Stop.
85
Press “Mode” button to return to the [Control mode select] menu.
9.2.1.3 Output test
The following interface will be displayed as follows by pressing [Output Test] in the Control Mode
Select interface. This menu enables user to test chiller internal control wiring connection to the
following parameters.
Figure 9.2.5 Output Test interface
Feed oil Oil feed solenoid valve, both1#&2# (1# denotes Comp 1, 2# denotes Comp 2)
Return oil Oil return solenoid valve,both1#&2#.
Load Compressor loading solenoid valve, both1#&2#.
Unload Compressor unloading solenoid valve, both1#&2#.

Liquid Liquid solenoid valve on liquid supply line.
86
Tower Cooling tower fan.

Caution: To prevent oil back to the oil separator from the compressor oil chamber, the test of
oil feed valve is not allowed when the high/low pressure is not built up
Press “Operate” button to return to [Manual operation] menu.
Press the [Comp Test] button to the following compressor testing screen. Prior to bringing the chiller
into actual operation, the compressor testing function lets the operator to perform test on the chiller
such as, compressor motor‟s rotating direction.
3S Test Press this button to perform a three-second running test on this chiller; the main
purpose is to check compressor running rotation, both1#&2# .(1# denotes Comp 1,
2# denotes Comp 2).
87
16S Test Press this button to perform a sixteen-second running test on this chiller, the main
purpose is to check compressor abnormal noise, starter wye-delta transition, etc.
both1#&2#.
Lift Press Displays the difference between discharge and suction pressure for compressor. A
correct compressor rotation determined by a positive „Lift Press‟ value, otherwise a
Note: compressor test can only be performed when control mode [use test] is selected.(Refer to 1.1 )
9.2.2 System

Figure 9.2.7 Information of the touch screen

88

9.2.3 Reset
9.2.4 Data
view the operating condition of the chiller
89
Figure 9.2.9 Chiller information
Displays the active set point of leaving water temperature of the

Active Set point evaporator, Active set point=Local spt + Remote CHW offset, refer to
section 9.2.5.1.

When displays Call means the Remote switch is on, and No Call means
Cooling Call Received
it is off.
Evap Pump Hrs/Starts Displays running hours and start times of the chilled water pump.
Cond Pump Hrs/Starts Displays running hours and start times of the cooled water pump.

Press lower right [1#] or [2#] on above menu will switch the interface to compressor information to
display compressor temp and pressure in real time.
90
Figure 9.2.10 Compressor Information interface
Displays the value differential between the discharge temperature and the
Disch Superht
compressor‟s saturated discharge temperature.

Net Press Displays the value differential between oil supply pressure and the suction
91
pressure.
Wait Time
Run Hrs Displays the total operating time of the compressor.

On [Comp1# Information] interface, press the lower right [2#] will go into the [Comp 2# Information]
interface.
9.2.5 Set
Username and Password. All system settings (except leaving chilled water set point) are password
protected.
Figure 9.2.11 System setup
Set leaving evaporator water temperature in the 3 to 15℃ range via

Local Spt
human interface touch screen. Factory default setting is 7℃.
Remote CHW offset Setting the offset value by remote analog signal(4-20mA) in the range of
92
0-10℃.Factory default setting is 0℃.
Start DT temperature and the user set point. Chiller starts when [Start DT] exceeds
a user preset value in the 1 to 5℃ range. Default factory setting is 2℃
Stop DT
setting is -2℃
Corresponding saturated condenser temp of discharge pressure settings

Sat Cond Setpoint for the control of condenser water modulating valve or condenser water
Pulldown Rate
Min Capacity
93
value).
Table9.2.3 Effects on increasing PID gains
Kd Small Change Decrease Decrease Small Change
94
NOTE: Correlations as shown in above may not be exactly accurate, because K p, Ki, and Kd are
dependent of each other. In fact, changing one of these variables can change the effect of the
other two. For this reason, the table should only be used as a reference and user assumes all
responsibility on changing the PID settings, and McQuay takes no responsibility should the
performance of the chiller be compromised.
Gain
factory setting loading is is 0.8 and unloading 0.6.
Sample
Integral
Differential
Period
Pulse Time
95
9.2.5.3 Alarm setup

Ice Protect
Dis.T Alarm
96
Suct P Alarm
kPa range. Alarm light on the control cabinet flashes, LCD displays alarm
Dis.P Pre-Alarm
Dis.P alarm
Oil DP Alarm
Timing delay of evaporator chilled water flow/PD switch alarm, setting
EDP Delay
CDP Delay
9.2.5.4 Cap. Offset
Capacity calibration menu (by pressing the [Cap. Offset] button) allows user to recalibrate the
97
value.
Figure 9.2.14 spring piston of the capacity sensor
Figure 9.2.15 Capacity Slide Calibration interface
98
Lower Lim
Upper Lim
Demand Limit drop-down menu. A 0-10V/4-20MA current signal will be sent to CPU to limit
the capacity if [remote] been selected.
Sets the maximum cooling load the unit can produce. can be set at the local
Dmd Capacity Spt and remote mode, ranges from 50% to 100％ with a factory default setting
100％.
Press button [next] on the [Capacity Slide Calibration] interface will go into the [Demand Limit Setup]
interface.
Press button [previous] on the [Demand Limit Setup] interface will go into the [Capacity Slide
Calibration] interface.
99
Gain
Sets the sampling rate of the controller in the 10 to 90 seconds range. Default
Sample
factory setting is 10 seconds.
Integral
Differential
Period
Sets the lower limit of analog signal to control device of condenser modulation
AO Low Level
valve or VFD pumps in range of 6400-32000, factory default setting is 6400.
Sets the upper limit of analog signal to control device of condenser modulation
AO High Level
Note: Change of above settings may cause interference or control malfunction, consult McQuay
service engineer before change.
9.2.5.6 Schedule
100
Select‟ screen (refer to section 1.1 Control mode selection).
9.2.5.7 Sen. offset
Offset‟ menu to add correctional factors to the temp/pressure values as read by sensors 1. This is

101
Figure 9.2.19 Sensor offset
Lvg Evap
Ent Evap
Lvg Cond Adds a leaving condenser water temperature correctional factor in the range of -9.9
102
Ent Cond
Adds a discharge pressure (Comp 1 )correctional factor in the range of -9.9 to
1# Dis T
9.9 ℃. Default factory setting is 0 ℃.
Adds a discharge pressure (Comp 2 )correctional factor in the range of -9.9 to

2# Dis T
9.9 ℃. Default factory setting is 0 ℃.
Discharge Adds a discharge temperature correctional factor in the range of -999 to 999 kPa.
Press Default factory setting is 0 kPa.
Suction Adds a suction pressure correctional factor in the range of -999 to 999 kPa. Default
Press factory setting is 0 kPa.
Adds a oil pressure (for Comp 1) correctional factor in the range of -999 to 999 kPa.
1# Oil P
Adds a oil pressure (for Comp 2) correctional factor in the range of -999 to 999 kPa.
2# Oil P
9.2.6 Alarm
1. Discharge superheat pre-alarm/alarm;
3. Discharge pressure pre-alarm/alarm;
6. Cond Water Flow switch alarm;
7. Evap Water Flow switch alarm;
9. 1# ,2# Oil DP alarm;
10.1# ,2# Discharge T alarm;
103
11. 1# ,2# Low pressure switch alarm;
12. 1# ,2# High pressure switch alarm;
13. 1# ,2# Motor overheat alarm;
14. 1# ,2# Motor overload alarm;
15. 1# ,2# Transition fault;
16. 1# ,2# Unload fault;

ESC Press this button to return to the main menu as shown in
figure 1.
104

ESC Press this button to return to the main menu as shown in
figure 1.
Note: Alarm history is saved in touch screen memory not in CPU226, thus once power off; all the alarm
histories will be cleared and will not be shown on screen anymore.
105
Prolegomenon
Note for Compressor nomenclature: Facing control panel, from left side to right side compressor #1,
#2 and #3 respectively.
106
Control Mode Select
Manual Operation
Mode
Output Test
Compressor Test
Hardware
Information
System
Screen Setup
Reset the alarm

Reset
Chiller Information
Data Compressor
Information
Capacity Slide
Calibration
System Setup
Chiller Capacity PID

Setup
Set
Alarm Setup
CDS WTR Flow PID

Setup
Schedule Setup Page
Sensor Offsets
Active Alarm
Alarm
Alarm History
107
9.3.1 Mode
compressor test.
Mode Description
Schedule To control chiller on/off by pre-set time schedule, refer to section 9.3.5.6.
Test
9.3.1.3 and 9.3.1.4
User name Description

108
Ignore Remote/Use Press this button to disable/enable local control (on/off) of the chiller.
remote
Schedule

The following interface will be displayed as follows by pressing [Operate] in the mode interface:
1#, 2# and 3# denotes compressor #1, compressor #2 and compressor #3.
109
Figure 9.3.4 Manual Operation interface
Load Press this button to increase compressor load individually.

Unload Press this button to decrease compressor load individually.
Press [Mode] button to return to the [Control mode select] menu.
9.3.1.3 Output test
The following interface will be displayed as follows by pressing [Output Test] in the Operate interface.
This menu enables user to test chiller internal control wiring connection to the following parameters.
Figure 9.3.5 Output Test interface 1
Press [Next] to Output Test Page 2
110
Figure 9.3.6 Output Test interface 2
Press [Previous] to Output Test Page 1

Tower1,2,3 Cooling tower fan 1,2,3.
Load Compressor loading solenoid valve.

Unload Compressor unloading solenoid valve.
Feed oil Oil feed solenoid valve.
Return oil Oil return solenoid valve.
Two liquid feed valves. PFS.3 unit has a main liquid line and a supplemental
Liquid 1&2
liquid line, each line equips a solenoid valve.
Caution: To prevent oil back to the oil separator from the compressor oil chamber, the test of
oil feed valve is not allowed when the high/low pressure differential is not built up
Press [Operate] button to return to [Manual operating] menu.
111
Press the [Compressor Test] button to the following compressor testing screen. Prior to bringing the
chiller into actual operation, the compressor testing function lets the operator to perform test on each
compressor individually.
Press this button to perform a three-second test run on this chiller; the main
3S Test
purpose is to check compressor running rotation.
Press this button to perform a sixteen-second test run on this chiller; the main
16S Test
purpose is to check compressor abnormal noise, and starter wye-delta transition.
Displays the difference between discharge and suction pressure for compressor. A
Lift Press correct compressor rotation determined by a positive „Lift Press‟ value, otherwise a
Note: compressor test can only be performed when control mode [use test] is selected.
9.3.2 System

112
Figure 9.3.8 Information of the touchscreen


113
9.3.3 Reset
9.3.4 Data
view the operating condition of the chiller.
Figure 9.3.10 Chiller Information
Displays the active set point of leaving water temperature of the evaporator,
Active Set point
Active set point=Local spt+Remote CHW offset, refer to section 5.1.
Cooling Call When displays Call means the Remote switch is on, and No Call means it is
Received off.
Evap Pump Displays running hours and start times of the chilled water pump.
Hrs/Starts
Cond Pump Displays running hours and start times of the cooled water pump.
Hrs/Starts
114
Press lower right [1#] [2#][3#]on above menu will switch the interface to compressor information to
display compressor temp and pressure in real time for each compressors.
Figure 9.3.11 Information interface by pressing 1#
115
Displays the value differential between the discharge temperature and

Disch Superht
the compressor‟s saturated discharge temperature.

Displays the value differential between oil supply pressure and the
Net Press
suction pressure.
Wait Time
Hours Displays the total operating time of the compressor.
9.3.5 Set
116
Username and Password. All system settings (except for leaving chilled water set point) are password
protected.
Figure 9.3.14 System Setup
Set leaving evaporator water temperature in the 3 to 15℃ range via

Local Spt
human interface touch screen. Factory default setting is 7℃.
Setting the offset value by remote analog signal(4-20mA) in the range of
Remote CHW offset 0-10℃.Factory default setting is 0℃.
temperature and the user set point. Chiller starts when [Start DT]
Start DT
exceeds a user preset value in the 1 to 5℃ range. Default factory setting
is 2℃

Stop DT
setting is -2℃
Corresponding saturated condenser temp of discharge pressure settings
Sat Cond Setpoint
for the control of condenser water modulating valve or condenser water
117
Pulldown Rate
Min Capacity
118
value).
Table 9.3.3 Effects on increasing PID gains
Kd Small Change Decrease Decrease Small Change
NOTE: Correlations as shown in above Table 9.3.3 may not be exactly accurate, because Kp,
Ki, and Kd are dependent of each other. In fact, changing one of these variables can change the
effect of the other two. For this reason, the table should only be used as a reference and user
assumes all responsibility on changing the PID settings, and McQuay takes no responsibility
should the performance of the chiller be compromised.
119
Gain
Sample
Integral
Differential
Sets the controller output period in the 2 to 60 seconds range. Default
Period
factory setting for loading is 6 seconds and unloading 4 seconds.
Pulse Time
9.3.5.3 Alarm setup

120

Ice Protect
Dis.T Alarm
Suct P Alarm
Dis.P Pre-Alarm kPa range. Alarm light on the control cabinet flashes, LCD displays alarm
121
Dis.P alarm
Oil DP Alarm
Timing delay of evaporator chilled water flow/PD switch alarm, setting ranges
EDP Delay
from 2S to 6S, factory default setting is 5S.
CDP Delay
9.3.5.4 Cap. Offset

The capacity calibration menu (by pressing the [Cap. Offset] button) allows user to recalibrate the
value.
122
Figure 9.3.17 Spring piston of the capacity sensor
Figure 9.3.18 Capacity Slide Calibration interface 1
Figure 9.3.19 Capacity Slide Calibration interface 2
123
Lower Lim
Upper Lim
Demand Limit
drop-down menu.
Sets the maximum cooling load the unit can produce. can be set at the local
Demand Capacity
and remote mode, ranges from 50% to 100％ with a factory default setting
Spt
100％.

Gain
Sets the sampling rate of the controller in the 10 to 90 seconds range. Default
Sample
factory setting is 10 seconds.
Integral
124
Differential
Period
Sets the lower limit of analog signal to control device of condenser modulation
AO Low Level
Sets the upper limit of analog signal to control device of condenser modulation
AO High Level
Note: Change of above settings may cause interference or abnormal control malfunction, consult
McQuay service engineer before change.
9.3.5.6 Schedule
125
Select‟ screen(refer to section 1.1 Control mode selection ).
9.3.5.7 Sensor offset
Offset‟ menu to add correctional factors to the temp/pressure values as read by sensors1. This is
126
Figure 9.3.23 Sensor offset interface 1
Figure 9.3.24 Sensor offset interface 2
Evap L-T
Evap E-T
Adds a leaving condenser water temperature correctional factor in the range of -9.9
Cond L-T

Cond E-T
Dis T Adds a discharge pressure correctional factor in the range of -9.9 to 9.9 ℃.
127
Default factory setting is 0 ℃.
Adds a discharge temperature correctional factor in the range of -999 to 999 kPa.
Dis.P
Adds a suction pressure correctional factor in the range of -999 to 999 kPa. Default
Suct. P
Adds a oil pressure correctional factor in the range of -999 to 999 kPa. Default
Oil Press
9.3.6 Alarm
1. Discharge superheat pre-alarm/alarm
3. Discharge pressure pre-alarm/alarm
6. No Cond Water Flow Fault;
7. No Evap Water Flow Fault;
9. 1# ,2# ,3# Oil DP alarm;
10. 1# ,2# ,3# Discharge T alarm;
11. 1# ,2#,3# Low pressure switch alarm;
12. 1# ,2# ,3# High pressure switch alarm;
13. 1# ,2# ,3# Motor overheat alarm;
14. 1# ,2# ,3# Motor overload alarm;
15. 1# ,2# ,3# Transition fault;
16. 1# ,2# ,3# Unload fault;
128



Note: Alarm history is saved in touch screen memory not in CPU226, thus once power off , all the
alarm histories will be cleared.
129
10. Fault diagnosis
10.1 Fault diagnostic table
Fault Description Fault analysis Control system active
01. High pressure alarm 1. Low condenser water flow.
2. Condenser water valve blockage.
3. High condenser water temperature. Comp shut off
4. Fouling in the condenser tube.
5. Air in the system.
02. High pressure switch alarm High pressure sensor failure Comp shut off
03. Low pressure alarm 1. Low leaving evap water
temperature.
2. Insufficient refrigerant. Comp shut off
3. Low evap water flow.

4. Liquid supply valve does not fully
open.
5. Outlet temperature sensor failure.

6. SV float valve not calibrated.
04. Compressor fail to load up 1. Display error.
to 100% 2. Low condenser water entering
temperature.
3. Compressor slide valve transducer
indication error
4. Transducer is not calibrated.
05. Motor overheat protection 1. Insufficient refrigerant. Unit shut off
2. Motor circuit malfunctioning or
temperature sensor failure
1 Discharge temperature sensor or Unit shut off
06. Discharge superheat too transmitter fails.
130
low 2 Low oil temperature.
3 Condenser water temperature rises too
fast.
07. Phase sequence protection 1 Incorrect power connection. Unit shut off
2 Voltage limit exceeded.
08. Compressor unloading 1 Display error.
failure 2 Unloading solenoid valve fails.
3 Oil filter clogs up.
09. Wye-Delta transfer failure The triangle contactor node failure Comp shut off
alarm
10. Comp low oil PD alarm 1 Cond water temp too low Comp shut off
2 Oil filter block
3 Oil feed solenoid valve failed
4 Oil transducer failed
11. Chilled water loss of flow 1 Low chilled water flow. Unit shut off & Pump
alarm 2 Chilled water pump fails. shut off
3 Water flow switch failure
12. Condenser water loss of 1 Low condenser water flow. Unit shut off
flow alarm 2 Condenser water pump failure.
3 Water flow switch failure
131
10.2 Oil lose analysis
Follow below process to check the unit when PFS, WPS.C oil loss:
132
133
134
135
136
137
138
11. Chiller maintenance parts packet
11.1 Chiller maintenance parts

a Lubricant oil: B# Z1502122
b Compressor oil filter: M7384-188
c O-ring of oil filter: M735073672
d Dry filter core: Z4203777
11.2 Wearing parts
PFS wearing parts
Item Material Name Application Part Number
1 Gasket for condenser cover/* PFS110.1-PFS200.1 W70404603

3 Gasket for evaporator cover/* PFS110.1-PFS200.1 W70404604
5 Gasket for evaporator cover/* PFS220.2-PFS510.3 W70404606
6 Sealing strip PFS Z4900006
7 Dry filter core F4 compressor Z4203777
8 Lubricant oil 68#(L) PFS Z2002122

9 Water temperature sensor PFS E8110207
10 Discharge temperature sensor PFS E8110209
11 Low pressure transducer MSP-400-016 PFS E8121019
12 High pressure switch PFS M074796402
13 Low pressure switch PFS E8134013
Heater with temperature control

14 PFS E3905014
function/200W
15 Oil heater relay 24VDC PFS E3531341
16 Relay 220VAC PFS E3531343
17 Transformer BK-1.5KVA 380V/220V PFS110.1-PFS170.1 E4232021
18 Transformer BK-2KVA 380V/220V PFS220.2-PFS510.3 E4234020
139
19 Main controller/UL508 PLC/CPU226 PFS E8211163
20 Discharge flange gasket PFS T3312053
21 Oil filter core F4 compressor M7384-188
22 HALLPLAS STAR KIT HS4221-205 HSS42212EBQA2-102KW M95813-401

25 KIT STAR BEARINGS F4 compressor M95813-404
26 KIT GASKET & O-RINGS F4 COMP F4 compressor M128810989
27 CAPACITY TRANSDUCER F4 compressor M95822-413
Note: * means improvise parts.
Compressor part number should comply with Suzhou factory P/N.
140

PFS Single Screw Water Cooled Chiller: Service Manual

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Service Manual SM

Sort：Water Cooled Chiller

PFS Single Screw Water Cooled Chiller

PFS 110.1 PFS 135.1 PFS 150.1

Thank you for purchasing McQuay chillers.

The manual expatiates on security cautions, as well as installation information.

Read these instructions thoroughly before installation and starting

2. Chiller Design Features

2.1 Chiller Design Features

High efficiency and reliable compressors\Multiple compressor design\Stepless capacity

2.2 Control Features

3.1 Main parts of chiller

PFS\ WPS.C can be categorized by compress quantity. Refer to Fig. 3-1

Refrigerant Feed Line

3.3 Electrical parts

3.3.1 Moulded Case Circuit Breaker: See Fig 3-7

CPU226: Refer to Fig 3-9

3.3.4 Pressure sensor: Refer to Fig 3-10

High pressure sensor: Working scope: 0~2500Kpa;

3.3.5 Temperature sensor

3.3.6 Capacity sensor

Below wiring diagram is for PFS.1:

Control parts feature and basic parameters

Test its output signal,

calculate the pressure

38 2 Capacity Sensor M95822-413 4-20mA 6400-32000 Test the output current,

Discharge temperature calculate the value by

4 Water temperature sensor E8110219 4-20mA -20-80℃ upper\lower limit can be

Test the high pressure

Test the low pressure

Moulded case circuit

9 Anti-freezing protector (℃) E8133004 -20℃-35℃ Ex-factory set point 2℃

3.7 Chiller Protection Set Point

Model PFS110.1 PFS135.1 PFS150.1 PFS220.2 PFS240.2 PFS265.2 PFS280.2 PFS300.2

U.S.RT 107.3 130.1 146.6 214.4 237.3 260.0 276.4 292.7

Cap. kW 377.5 457.7 515.5 754.0 834.4 914.3 972.0 1029.4

kCal/h 324,650 393,622 443,330 648,440 717,584 786,298 835,920 885,284

COP 5.97 6.03 6.22 5.84 5.89 5.85 5.95 6.04

IPLV 6.82 6.88 7.09 7.50 6.93 7.52 7.60 7.75

Type Semi-hermetic Single Screw Compressor

Starter Type Y-Δ

Capacity Control% 25%-100% Stepless 12.5%-100% Stepless

Type Shell & Tube Type

Type Flooded Type

Temp Control Chilled water outlet temperature PID control

Insulation Material Closed Foam Polyethylene

RLA A 120.5 137.5 147.5 244.6 261.6 281.3 291.4 301.5

L×W×H mm 3340×1443×1956 3462×1676×2235 3764×1676×2235

Model PFS330.3 PFS350.3 PFS370.3 PFS390.3 PFS410.3 PFS430.3 PFS450.3

U.S.RT 324.8 347.9 370.9 394.0 410.5 427.0 443.5

Cap. kW 1142.2 1223.5 1304.4 1385.7 1443.8 1501.8 1559.8

kCal/h 982,292 1,052,210 1,121,784 1,191,702 1,241,668 1,291,548 1,341,428

Power Input kW 193.4 205.8 218.9 231.7 238.8 246.9 253.9

COP 5.91 5.94 5.96 5.98 6.05 6.08 6.14

IPLV 7.44 7.54 7.58 7.51 7.56 7.65 7.72

Type Semi-hermetic Single Screw Compressor

Capacity Control% 8.3%-100%Stepless

Type Shell & tube type

Evaporator Type Flooded type