Im - 1044 - 110711 Iom

Installation and Maintenance Manual IM 1044-2
Centrifugal Compressor Water Chillers Group: Chillers

REV
Part Number: 331374801 0A
Date: November 2011
Models WSC,WDC,WCC,HSC
(Includes High Voltage 10/11kV WDC/WCC models)
© 2011 McQuay International

Table of Contents
Introduction................................... 3 Prestart System Checklist ......................... 37
General Description.................................... 3 Operation ..................................... 38
Application ................................................. 3 Operator Responsibilities.......................... 38
Installation..................................... 4 Standby Power .......................................... 38
Receiving and Handling ............................. 4 MicroTech II Control ............................ 38
Location and Mounting .............................. 5 Capacity Control System .......................... 40
Operating/Standby Limits........................... 6 Surge and Stall.......................................... 42
System Water Volume................................. 6 Lubrication System................................... 42
Low Condenser Water Temperature Hot Gas Bypass ........................................ 43
Operation .................................................... 7 Condenser Water Temperature.................. 44
Water Piping ............................................... 9 Maintenance ................................ 45
Field Insulation Guide .............................. 13 Pressure/Temperature Chart...................... 45
Physical Data and Weights ....................... 15 Routine Maintenance ................................ 45
Complete Unit Physical Data.................... 17 Annual Shutdown ..................................... 49
Oil Coolers................................................ 19 Annual Startup .......................................... 49
Oil Heater ................................................. 22 Repair of System....................................... 50
Relief Valves............................................. 22 Oil Analysis .............................................. 51
Electrical................................................... 23 Maintenance Schedule ................ 54
Power Wiring............................................ 23
Long Term Storage...................... 56
Installation Instructions for 10/11kV Motor
Units ......................................................... 25 Service Programs ........................ 57
Remote Starter Display Wiring................. 29 Operator Schools......................... 57
Control Power Wiring............................... 29 Warranty Statement ................... 57
Multiple Chiller Setup .............................. 33
Hazard Identification
! DANGER
Dangers indicate a hazardous situation which will result in death or serious injury if not avoided.
! WARNING
Warnings indicate potentially hazardous situations, which can result in property damage, severe personal injury, or death if not
avoided.
! CAUTION
Cautions indicate potentially hazardous situations, which can result in personal injury or equipment damage if not avoided.
Document: IM 1044
Issue Date: September 2009
Revision Date: November 2011
Replaces: August 2011
©2011 McQuay International. Illustrations and data cover the McQuay International product at the time of publication and we reserve the right to make
changes in design and construction at anytime without notice. ™® The following are trademarks or registered trademarks of their respective companies:
BACnet from ASHRAE; LONMARK, LonTalk, LONWORKS, and the LONMARK logo are managed, granted and used by LONMARK International under a
license granted by Echelon Corporation; ElectroFin from AST ElectroFin Inc.; Modbus from Schneider Electric; FanTrol, MicroTech II, Open Choices, and
SpeedTrol from McQuay International; Loctite from Henkel Company; 3M, Scotchfil and Scotchkote from the 3M Company; Victaulic from Victaulic Company;
Megger from Megger Group Limited.
2 Centrifugal Chillers IM 1044-2

Introduction
General Description
McQuay Centrifugal Water Chillers are complete, self-contained, automatically controlled fluid chilling units.
Each unit is completely assembled and factory tested before shipment. Models WSC/WDC/WCC are cooling-
only and Models HSC are cooling with heat recovery accomplished in a bundle of condenser tubes separate from
the cooling tower tube bundle.
In the WSC and HSC series, each unit has one compressor connected to a condenser and evaporator. The WDC
series is equipped with two compressors operating in parallel on a single evaporator and condenser. The WCC
series is equipped with two compressors, each operating on one refrigerant circuit of a two circuit evaporator and
condenser. Information in this manual referring to WSC and WDC also applies to WCC and HSC units except
where specifically noted.
The chillers use refrigerant R-134a to reduce the size and weight of the package compared to negative pressure
refrigerants, and since R-134a operates at a positive pressure over the entire operation range, no purge system is
required. The controls are pre-wired, adjusted and tested. Only normal field connections such as piping, electrical
and interlocks, etc. are required, thereby simplifying installation and increasing reliability. Most necessary
equipment protection and operating controls are factory installed in the control panel.
The basic sizes of units are the 063, 076, 079, 087, 100, 113 and 126. They provide a cooling capacity range from
200 to 2700 tons. In this manual all references to the WSC models will equally apply to other models unless
specifically referenced otherwise.
High Voltage Models
Certain 100, 113, and 126 size WDC and WCC units are available in high-voltage (10/11kV). These models will
have different dimensions, weights, and installation details than the standard low/medium voltage models. See
your Certified Dimension Drawing for details specific to your unit. See page Error! Bookmark not defined. for
the procedure to mount the terminal box on the unit on 10/11 kV units.
Application
The procedures presented in this manual apply to the standard WSC/WDC/WCC family of chillers and HSC heat
recovery chillers. Refer to the Operating Manual, OM CentrifMicro-II for details of operation of the MicroTech
II unit controller (latest version available on www.mcquay.com).
All McQuay centrifugal chillers are factory tested prior to shipment and must be initially started at the job site by
a factory trained McQuay service technician. Failure to follow this startup procedure can affect the equipment
warranty. The standard limited warranty on this equipment covers parts that prove defective in material or
workmanship. Specific details of this warranty can be found in the warranty statement furnished with the
equipment.
Cooling towers used with McQuay centrifugal chillers are normally selected for maximum condenser inlet water
temperatures between 75°F and 90°F (24°C and 32°C). Lower entering water temperatures are desirable from the
standpoint of energy reduction, but a minimum does exist. For recommendations on optimum entering water
temperature and cooling tower fan control, consult McQuay Product Manual PM WSC/WDC, Applications
Section, available on www.mcquay.com. Heat recovery models, HSC, basically operate the same as cooling-only
units. The heat recovery function is controlled externally to the chiller as explained later in this manual.
W D C 063
W = Water-cooled Chiller Model, Based on
H = Heat Impeller Diameter
Centrifugal Compressor
D = Dual Compressor
S = Single Compressor
C = Dual, Counterflow
IM 1044-2 Centrifugal Chillers 3

Installation
Receiving and Handling

The unit should be inspected immediately after receipt for possible damage.
All McQuay centrifugal water chillers are shipped FOB factory and all claims for handling and shipping damage
are the responsibility of the consignee.
Insulation corners from the evaporator's rigging hole locations are shipped loose and should be glued in place
after the unit is finally placed. Neoprene vibration pads are also shipped loose. Check that these items have been
delivered with the unit.
If so equipped, leave the shipping skid in place until the unit is in its final position. This will aid in handling the
equipment.
Extreme care must be used when rigging the equipment to prevent damage to the control panels or refrigerant
piping. See the certified dimension drawings included in the job submittal for the center of gravity of the unit.
Consult the local McQuay sales office for assistance if the drawings are not available.
The unit can be lifted by fastening the rigging hooks to the four corners of the unit where the rigging eyes are
located (see Figure 1). Spreader bars must be used between the rigging lines to prevent damage to the control
panels, piping and motor terminal boxes.
Figure 1, WSC Major Component Locations Operator Interface

Panel
Unit Control
Panel Rigging
Compressor Control
Panel, At Rear Locations
(6) Available
Rigging
Locations
(6) Available
Evaporator
Compressor Starter,
Mounting Optional
Condenser

Figure 2, WDC Major Component Location
Oil Sump,
Pump, Heaters
Motor
Terminal Box
Rigging
Eyes
Rigging
Eyes
Condenser
Dual Relief
Valves
Common Oil
Cooler Water Lubrication &
Compressor Condenser
Connections
Control Boxes
Notes:
1. Chilled water and condenser connection location can vary. Check markings on unit or consult unit certified drawings for connection
locations on specific units.
2. WCC two-circuit units have separate evaporator and condenser relief valves on each circuit.
Location and Mounting

The unit must be mounted on a level concrete or steel base and must be located to provide service clearance at one
end of the unit for possible removal of evaporator tubes and/or condenser tubes. Evaporator and condenser tubes
are rolled into the tube sheets to permit replacement if necessary. The length of the vessel should be allowed at
one end. Doors or removable wall sections can be utilized for tube clearance. Minimum clearance at all other
points, including the top, is 3 feet (1 meter). The National Electric Code (NEC) can require four feet or more
clearance in and around electrical components and must be checked.
The chillers are designed for indoor installation only. Special procedures must be executed to prevent damage if
freezing indoor temperatures are possible.

Operating/Standby Limits
 Water in vessels and oil cooler: 32F to 122F (0C to 50C)
 Without water in vessels and oil cooler: 0F to 140F (-18C to 60C)
 WMC without water in vessels: 0F to 130F (-18C to 54.4 C)
 Equipment room temperature, operating: 32F to 104F (0C to 40C)
 Maximum entering condenser water temperature, startup: design plus 5 degrees F (2.7 degrees C)
 Maximum entering condenser water temperature, operating: job specific design temperature
 Minimum entering condenser water temperature, operating: see page 6.
 Minimum leaving chilled water temperature: 38F (3.3C)
 Minimum leaving chilled fluid temperature with correct anti-freeze fluid: 15F (9.4C)
 Maximum entering chilled water temperature, operating: 90F (32.2C)
 Maximum oil cooler/VFD entering temperature: 90F (32.2C)
 Minimum oil cooler/VFD entering temperature: 42F (5.6C)
Vibration Pads
The shipped-loose neoprene vibration pads should be located under the corners of the unit (unless the job
specifications state otherwise). They are installed to be flush with the sides and outside edge of the feet. Most
WSC units have six mounting feet although only the outer four are required. Six pads are shipped and the installer
can place pads under the middle feet if desired.
Mounting
Make sure that the floor or structural support is adequate to support the full operating weight of the complete unit.
It is not necessary to bolt the unit to the mounting slab or framework; but should this be desirable, 1 1/8" (28.5
mm) mounting holes are provided in the unit support at the four corners.
Note: Units are shipped with refrigerant and oil valves closed to isolate these fluids for shipment.
Valves must remain closed until start-up by the McQuay technician.
Nameplates
There are several identification nameplates on the chiller:
 The unit nameplate is located on the side of the Unit Control Panel. It has a Style No. XXXX and Serial No.
XXXX. Both are unique to the unit and will identify it. These numbers should be used to identify the unit for
service, parts, or warranty questions. This plate also lists the unit refrigerant charge.
 Vessel nameplates are located on the evaporator and condenser. Along with other information, they have a
National Board Number (NB) and serial number, either of which identify the vessel (but not the entire unit).
 A compressor nameplate is located on the compressor itself and contains identification numbers.
System Water Volume

All chilled water systems need adequate time to recognize a load change, respond to that load change and
stabilize, without undesirable short cycling of the compressors or loss of control. In air conditioning systems, the
potential for short cycling usually exists when the building load falls below the minimum chiller plant capacity or
on close-coupled systems with very small water volumes.
Some of the things the designer should consider when looking at water volume are the minimum cooling load, the
minimum chiller plant capacity during the low load period and the desired cycle time for the compressors.
Assuming that there are no sudden load changes and that the chiller plant has reasonable turndown, a rule of
thumb of “gallons of water volume equal to two to three times the chilled water gpm flow rate” is often used.
A properly designed storage tank should be added if the system components do not provide sufficient water
volume.

Low Condenser Water Temperature Operation
When ambient wet bulb temperature are lower than design, the condenser water temperature can be allowed to
fall. Lower temperatures will improve chiller performance.
Up to 600 Tons
McQuay centrifugal chillers up to 600 Tons are equipped with electronic expansion valves (EXV) and will start
and run with entering condenser water temperatures as low as shown in Figure 3 or as calculated from the
following equation on which the curves are based.
Figure 3, Minimum Entering Condenser Water Temperature (EXV)
Minimum Entering Condenser Water Temperature - 10 F Range
65.0
44 LChWT
42 LChWT
60.0 46 LChWT
55.0
50.0
ECWT, F
45.0
40.0
35.0
30.0
0 10 20 30 40 50 60 70 80 90 100 110
Percent Load
Min. ECWT = 5.25 + 0.88*(LWT) - DTFL*(PLD/100) + 22*(PLD/100)2

 ECWT = Entering condenser water temperature
 LWT = Leaving chilled water temperature
 DTFL = Chilled Water Delta-T at full load
 PLD = The percent chiller load point to be checked
For example; at 44F LWT, 10 degree F Delta-T, and 50% full load operation, the entering condenser water
temperature could be as low as 44.5F. This provides excellent operation with water-side economizer systems.
Over 600 Tons
Chillers over 600 Tons are equipped with thermal expansion valves (TXV) and will start and run with entering
condenser water temperatures as low as calculated by the following equation and shown in the chart following.
Min. ECWT = 7.25 + LWT– 1.25* DTFL(PLD/100) + 22*(PLD/100) 2
 ECWT = Entering condenser water temperature
 LWT = Leaving chilled water temperature
 DTFL = Chilled Water Delta-T at full load
 PLD = The percent chiller load point to be checked

Figure 4, Minimum Entering Condenser Water Temperature (TXV)
Minimum Entering Condenser Water Temperature - 10 F Range
65.0
44 LChWT
42 LChWT
60.0 46 LChWT
55.0
50.0
ECWT, F
45.0
40.0
35.0
30.0
0 10 20 30 40 50 60 70 80 90 100 110
Percent Load
For example; at 44F LWT, 10 degree F Delta-T, and 50% full load operation, the entering condenser water
temperature could be as low as 50.5F. This provides excellent operation with water-side economizer systems.
Depending on local climatic conditions, using the lowest possible entering condenser water temperature may
be more costly in total system power consumed than the expected savings in chiller power would suggest, due
to the excessive fan power required.
Cooling tower fans must continue to operate at 100% capacity at low wet bulb temperatures. As chillers are
selected for lower kW per ton, the cooling tower fan motor power becomes a higher percentage of the total
peak load chiller power. McQuay’s Energy Analyzer program can optimize the chiller/tower operation for
specific buildings in specific locales.
Even with tower fan control, some form of water flow control, such as tower bypass, is recommended.
Figure 5 illustrates two temperature actuated tower bypass arrangements. The “Cold Weather” scheme provides
better startup under cold ambient air temperature conditions. The check valve may be required to prevent
entraining air at the pump inlet.
Figure 5, Bypass, Mild Weather Operation Bypass, Cold Weather Operation

Water Piping
Water Pumps
Avoid the use of 3600/3000-rpm (two-pole motor) pump motors. It is not uncommon to find that these pumps
operate with objectionable noise and vibration.
It is also possible to build up a frequency beat due to the slight difference in the operating rpm of the pump motor
and the McQuay centrifugal motor. McQuay encourages the use of 1750/1460 rpm (four-pole) pump motors.
Vessel Drains at Start-up
Unit vessels are drained of water in the factory and are shipped with the drain plugs in the heads removed and
stored in the control panel or with open ball valves in the drain hole. Be sure to replace plugs or close the valves
prior to filling the vessel with fluid.
Evaporator and Condenser Water Piping
All evaporators and condensers come standard with Victaulic AWWA C-606
groove nozzles (also suitable for welding), or optional flange connections. The
installing contractor must provide matching mechanical connections or
transitions of the size and type required.
Victaulic connections are AWWA C-606 on 14-inch and larger sizes. Field
supply transitions if Victaulic brand AGS® (Advanced Groove System) type
grooves are used on the field piping.
The tower connections are always the inboard pair of connections. In the figure
to the right, the condenser connections are “left-hand” when viewed from the
front of the unit (Unit Control Panel and Interface Panel side), so in this case, the
right-hand condenser connections would be for the tower. If the condenser
connections were on the other end (“right-hand”), the tower connections would
be the left-hand pair of connections.
Note: Certain WSC units with a 2-pass configuration and copper tubing may
have an “over/under” connection configuration on the evaporator, rather than the side-by-side configuration
shown here. Consult Certified Drawings for exact configuration and dimensions.
Important Note on Welding
If welding is to be performed on the mechanical or flange connections, remove the solid-state temperature sensor
and thermostat bulbs from the wells to prevent damage to those components. Also properly ground the unit or
severe damage to the MicroTech II unit controller can occur.
Note: ASME certification will be revoked if welding is performed on a vessel shell or tube sheet.
Water pressure gauge connection taps and gauges must be provided in the field piping at the inlet and outlet
connections of both vessels for measuring the water pressure drops. The pressure drops and flow rates for the
various evaporators and condensers are job specific and the original job documentation can be consulted for this
information. Refer to the nameplate on the vessel shell for identification.
Be sure that water inlet and outlet connections match certified drawings and stenciled nozzle markings. The
condenser is connected with the coolest water entering at the bottom to maximize subcooling.
! CAUTION
When common piping is used for both heating and cooling modes, care must be taken to provide that water flowing through
the evaporator cannot exceed 110°F which can cause the relief valve to discharge refrigerant or damage controls.
The piping must be supported to eliminate weight and strain on the fittings and connections. Piping must also be
adequately insulated. A cleanable 20-mesh water strainer must be installed in both water inlet lines. Sufficient
shutoff valves must be installed to permit draining the water from the evaporator or condenser without draining
the complete system.

Victaulic Couplings
Use the following steps when installing Victaulic couplings:
1. Check for smooth pipe between the pipe end and the groove. Remove any indentations, projections, or
weld seams. Failure to do this can result in a leaking joint.
2. Apply a thin coat of Victaulic or silicon lubricant to the gasket lips and exterior.
3. Position the gasket over the pipe end without overhanging the pipe.
4. Join the pipes together and slide the gasket into position, centering it between the groves.
5. Install the housing halves over the gasket, making sure that the housing’ keys engage the groves on both
pipes.
6. Install the bolts and thread the nuts on hand tight. Make sure that the oval heads of the bolts seat properly
in the bolt holes.
7. Tighten the nuts evenly by alternating sides until metal to metal contact is made on the housing bolt pads.
Make sure that the housing keys completely engage the pipe grooves.
Flow Switch
A water flow switch must be installed in the vessel outlet piping to signal the presence of adequate water flow
to the vessels before the unit can start. They also serve to shut down the unit in the event that water flow is
interrupted to guard against evaporator freeze-up or excessive discharge pressure.
Thermal dispersion flow switches are available from McQuay as a factory-mounted option. It is mounted in an
evaporator and condenser water nozzle and factory wired.
A paddle type flow switch can be supplied by the owner for field mounting and wiring.
Figure 6, Flow Switch Mounting
Flow direction marked
on switch
I in. (25mm) NPT flow

switch connection
Tee
If flow switches, by themselves, are being used, electrical connections in the Unit Control Panel must be made
from the common T3-S terminal to terminal CF for the condenser switch and T3-S to terminal EF for the
evaporator switch. See Figure 19, Field Wiring Diagram on page 32. The normally open contacts of the flow
switch must be wired between the terminals. Flow switch contact quality must be suitable for 24 VAC, low
current (16ma). Flow switch wire must be in separate conduit from any high voltage conductors (115 VAC and
higher).
Table 1, Flow Switch Flow Rates
Pipe Size inch 1 1/4 1 1/2 2 2 1/2 3 4 5 6 8
(NOTE) 204 (5)
mm 32 (2) 38 (2) 51 63 (3) 76 102 (4) 127 (4) 153 (4)
gpm 5.8 7.5 13.7 18.0 27.5 65.0 125.0 190.0 205.0
Min. Flow
Lpm 1.3 1.7 3.1 4.1 6.2 14.8 28.4 43.2 46.6
Adjst
. No gpm 3.7 5.0 9.5 12.5 19.0 50.0 101.0 158.0 170.0
Flow Lpm 0.8 1.1 2.2 2.8 4.3 11.4 22.9 35.9 38.6
gpm 13.3 19.2 29.0 34.5 53.0 128.0 245.0 375.0 415.0
Max. Flow
Adjst Lpm 3.0 4.4 6.6 7.8 12.0 29.1 55.6 85.2 94.3
. No gpm 12.5 18.0 27.0 32.0 50.0 122.0 235.0 360.0 400.0
Flow Lpm 2.8 4.1 6.1 7.3 11.4 27.7 53.4 81.8 90.8
See notes next page.

Notes from previous page:
1. A segmented 3-inch paddle (1, 2, and 3 inches) is furnished mounted, plus a 6-inch paddle loose.
2. Flow rates for a 2-inch paddle trimmed to fit the pipe.
3. Flow rates for a 3-inch paddle trimmed to fit the pipe.
4. Flow rates for a 3-inch paddle.
5. Flow rates for a 6-inch paddle
6. There is no data for pipe sizes above 8-inch. A switch minimum setting should provide protection against no
flow and close well before design flow is reached.
Alternatively, for a higher margin of protection, normally open auxiliary contacts in the pump starters can be
wired in series with the flow switches as shown in Figure 19, Field Wiring Diagram on page 32.
! CAUTION
Freeze Notice: Neither the evaporator nor the condenser is self-draining;
Both must be blown out to help avoid damage from freezing.
The piping should also include thermometers at the inlet and outlet connections and air vents at the high points.
The water heads can be interchanged (end for end) so that the water connections can be made at either end of the
unit. If this is done, new head gaskets must be used and control sensors relocated.
In cases where the water pump noise can be objectionable, vibration isolation sections are recommended at both
the inlet and outlet of the pump. In most cases, it will not be necessary to provide vibration eliminator sections in
the condenser inlet and outlet water lines. But they can be required where noise and vibration are critical.
Cooling Towers
The condenser water flow rate must be checked to be sure that it conforms to the system design. Some form of
temperature control is also required if an uncontrolled tower can supply water below about 65F (18C). If tower
fan control is not adequate, a tower bypass valve is recommended. Unless the system and chiller unit are
specifically for condenser bypass or variable condenser flow is not recommended since low condenser flow rates
can cause unstable operation and excessive tube fouling.
The condenser water pumps must cycle on and off with the unit. See Figure 19, Field Wiring Diagram on page 32
for wiring details.
Tower water treatment is essential for continued efficient and reliable unit operation. If not available in-house,
competent water treatment specialists can be contracted.
Heat Recovery Chillers
HSC heat recovery chillers control the chilled water leaving temperature. The cooling load determines
compressor loading and unloading, the same as in a conventional chiller. A heat recovery chiller’s control
algorithms are identical to a conventional cooling-only chiller.
The temperature of the hot water being supplied from the recovery condenser to the heating load is established by
manipulating the cooling tower water temperature. The 3-way cooling tower bypass valve is controlled by the
heating water inlet temperature to the recovery bundle of the condenser. Based on the signal the 3-way valve gets
from the heating hot water sensor, it will bypass sufficient water around the tower to force the tower condenser
water loop high enough for the recovery bundle to produce the desired hot water temperature.
The chilled water and its control system do not sense that the condensing pressure and condenser water
temperatures are being regulated in this manner.

Figure 7, Heat Recovery Schematic
HEAT LOAD
AUXILIARY
HEATER
OPEN TC
CIRCUIT RECOVERY
TOWER CONDENSER
TOWER HEAT RECOVERY

CONDENSER CHILLER
TC
LEGEND
TC TEMPERATURE CONTROL POINT EVAPORATOR
PUMP
COOLING
LOAD

Field Insulation Guide
Figure 8, Insulation Requirements, Cooling-only Units

Physical Data and Weights
Evaporator
The standard insulation of cold surfaces includes the evaporator and non-connection water head, suction piping,
compressor inlet, motor housing, and motor coolant outlet line.
Insulation is UL recognized (File # E55475). It is 3/4" thick ABS/PVC flexible foam with a skin. The K factor is
0.28 at 75°F. Sheet insulation is fitted and cemented in place forming a vapor barrier, then painted with a resilient
epoxy finish that resists cracking.
The insulation complies to, or has been tested in accordance, with the following:
ASTM-C-177 ASTM-C-534 Type 2 UL 94-5V
ASTM-D-1056-91-2C1 ASTM E 84 MEA 186-86-M Vol. N
CAN/ULC S102-M88
Refrigerant-side design pressure is 200 psi (1380 kPa) on WSC/WCC/HSC units and 180 psi (1242 kPa) on WDC
units. Water-side is 150 psi (1034 kPa) on all.
In the event insulation is to be field-installed, none of the cold surfaces identified above will be factory insulated.
Required field insulation is shown beginning on page 13. Approximate total square footage of insulation surface
required for individual packaged chillers is tabulated by evaporator code and can be found below.
Table 2, Evaporator Physical Data
MWB Cover
Water Insulation Vessel Dry Add for
Evaporator Only,
WSC WDC WCC Volume Area Weight MWB
Code 2 Weight
gal (L) sq ft (m ) lb (kg) lb (kg)
lb (kg)
E2009 X 31 (117) 82 (7.6) 2543 (1152) 478 (217) 148 (67)
E2012 X 37 (139) 84 (7.8) 2862 (1296) 478 (217) 148 (67)
E2209 X 38 (145) 66 (6.1) 2708 (1227) 600 (272) 175 (79)
E2212 X 45 (170) 90 (8.3) 3071 (1391) 600 (272) 175 (79)
E2216 X 79 (301) 144 (13.4) 4200 (1903) 600 (272) 175 (79)
E2416 X 110 (415) 157 (14.6) 5170 (2343) 700 (317) 240 (109)
E2609 X 61 (231) 76 (7.1) 3381 (1532) 899 (407) 302 (137)
E2612 X 72 (273) 102 (9.4) 3880 (1758) 899 (407 302 (137)
E2616 X 126 (478) 162 (15.0) 5645 (2558) 899 (407 302 (137)
E3009 X 74 (281) 86 (8.0) 4397 (1992) 1386 (628) 517 (234)
E3012 X 89 (336) 115 (10.6) 5075 (2299) 1386 (628) 517 (234)
E3016 X 157 (594) 207 (19.2) 7085 (3211) 1386 (628) 517 (234)
E3609 X 128 (484) 155 14.4) 5882 (2665) 2115 (958) 805 (365)
E3612 X 152 (574) 129 (11.9) 6840 (3099) 2115 (958) 805 (365)
E3616 X 243 (918) 239 (22.2) 9600 (4351) 2115 (958) 805 (365)
E3620 X 219 (827) 207 (19.2) 8298 (3764) 2115 (958) 805 (365)
E4212 X 222 (841) 148 (13.7) 8922 (4042) 2836 (1285) 1181 (535)
E4216 X 347 (1313) 264 (24.5) 12215 (5536) 2836 (1285) 1181 (535)
E4220 X 481 (1819) 330 (30.6) 15045 (6819) 2836 (1285) 1181 (535)
E4220 X 319 (1208) 242 (22.5) 10853 (4923) 2836 (1285) 1181 (535)
E4812 X 327 (1237) 169 (15.6) 11125 (5040) 4578 (2074) 1837 (832)
E4816 X 556 (2106) 302 (281) 16377 (7429) 4578 (2074) 1837 (832)
E4820 X 661 (2503) 377 (35.0) 17190 (7791) 4578 (2074) 1837 (832)
E4820 X 456 (1728) 276 (25.6) 14618 (6630) 4578 (2074) 1837 (832)
Notes:
1. Water capacity is based on standard tube configuration and standard heads and may vary depending on tube counts.
2. Vessel weight includes the shell, maximum tubes, and standard heads, no refrigerant.
3. MWB, marine water box, weight add is the water box weight minus a standard dished head weight.

Condenser
With positive pressure systems, the pressure variance with temperature is always predictable, and the vessel
design and relief protection are based upon pure refrigerant characteristics. R-134a requires ASME vessel design,
inspection and testing and uses spring-loaded pressure relief valves. When an over pressure condition occurs,
spring-loaded relief valves purge only that refrigerant required to reduce system pressure to their set pressure, and
then close.
Refrigerant side design pressure is 200 psi (1380 kPa) on WSC/WCC/HSC units and 225 psi (1552 kPa) on WDC
units. Water side design is 150 psi (1034 kPa) on all.
Pumpdown
To facilitate compressor service, all McQuay centrifugal chillers are designed to permit pumpdown and isolation
of the entire refrigerant charge in the unit’s condenser. Dual compressor units and single compressor units
equipped with the optional suction shutoff valve can also be pumped down into the evaporator.
Table 3, Condenser Physical Data
Pumpdown Water Number of
Condenser Vessel Weight
WSC WDC WCC Capacity Capacity Relief
Code lb. (kg)
lb. (kg) gal. (L) Valves
C1809 X 597 (271) 43 (162) 1887 (856) 2
C1812 X 845 (384) 44 (166) 2050 (930) 2
C2009 X 728 (330) 47 (147) 1896 (860) 2
C2012 X 971 (440) 62 (236) 2528 (1147) 2
C2209 X 822 (372) 73 (278) 2596 (1169) 2
C2212 X 1183 (537) 76 (290) 2838 (1287) 2
C2216 X 1489 (676) 114 (430) 3861 (1751) 2
C2416 X 1760 (799) 143 (540) 4647 (2188) 2
C2609 X 1242 (563) 83 (314) 2737 (1245) 2
C2612 X 1656 (751) 111 (419) 3650 (1660) 2
C2616 X 2083 (945) 159 (603) 5346 (2425) 2
C3009 X 1611 (731) 108 (409) 3775 (2537) 2
C3012 X 2148 (975) 144 (545) 5033 (3383) 2
C3016 X 2789 (1265) 207 (782) 6752 (3063) 4
C3612 X 2963 (1344) 234 (884) 7095 (3219) 2
C3616 X 3703 (1725) 331 (1251) 9575 (4343) 4
C3620 X 4628 92100) 414 (1567) 12769 (5797) 4
C4212 X 3796 (1722) 344 (1302) 9984 (4529) 2
C4216 X 5010 (2273) 475 (1797) 12662 (5743) 4
C4220 X 5499 (2494) 634 (2401) 17164 (7785) 4
C4220 X 5499 (2497) 634 (2400) 17964 (8156) 4
C4812 X 4912 (2228) 488 (1848) 12843 (5826) 4
C4816 X 5581 (2532) 717 (2715) 18807 (8530) 4
C4820 X 7034 (3191) 862 (3265) 23106 (10481) 4
C4820 X 8307 (3768) 727 (2753) 18907 (8576) 4
1. Condenser pumpdown capacity based on 90% full at 90F.
2. Water capacity based on standard configuration and standard heads and may vary depending on tube counts.
3. See Relief Valves section for additional information.
Compressor
Table 4, Compressor Weights
Compressor Size  063 079 087 100 113 126
Weight lb. (kg)  2000 (908) 3200 (1440) 3200 (1440) 6000 (2700) 6000 (2700) 6000 (2700)

Complete Unit Physical Data
Table 5 Unit Weights, Single Compressor, WSC
Unit Refrig. Max. Unit Weight Without Starter Max. Unit Weight With Starter
Evaporator /
Unit Charge (1)
Condenser Size Shipping Operating Shipping Operating
Lbs. (kg)
lbs. (kg) lbs. (kg) lbs. (kg) lbs. (kg)
WSC063 2009 / 1809 410 (186) 8412 (3816) 8949 (4059) 9612 (4360) 10149 (4604)
WSC063 2012 / 1812 539 (244) 9284 (4211) 9955 (4516) 10484 (4756) 11155 (5060)
WSC063 2209 / 2009 479 (217) 9119 (4136) 9841 (4464) 10319 (4681) 11040 (5008)
WSC063 2212 / 2012 631 (286) 10182 (4619) 11077 (5025) 11382 (5163) 12277 (5569)
WSC063 2209 / 2209 495 (224) 9416 (4271) 10235 (4643) 10616 (4815) 11435 (5187)
WSC063 2212 / 2212 651 (295) 10557 (4789) 11570 (5248) 11757 (5333) 12770 (5792)
WSC063 2609 / 2209 651 (295) 10248 (4648) 11258 (5107) 11448 (5193) 12458 (5651)
WSC063 2612 / 2212 859 (389) 11577 (5251) 12817 (5806) 12777 (5796) 14017 (6358)
WSC063 2609 / 2609 686 (311) 10984 (4982) 12228 (5547) 12184 (5527) 13428 (6091)
WSC063 2612 / 2612 905 (410) 12494 (5667) 14020 (6359) 13694 (6203) 15220 (6904)
WSC063 3009 / 2609 825 (374) 12892 (5848) 14246 (6462) 14092 (6392) 15446 (7006)
WSC063 3012 / 2612 1098 (497) 13903 (6306) 15569 (7062) 15103 (6851) 16769 (7606)
WSC079 2209 / 2209 495 (224) 10140 (4600) 10959 (4971) 11340 (5144) 12159 (5515)
WSC079 2212 / 2212 651 (295) 11281 (5117) 12294 (5577) 12481 (5661) 13494 (6121)
WSC079 2609 / 2209 651 (295) 10980 (4981) 11990 (5439) 12180 (5525) 13190 (5983)
WSC079 2612 / 2212 859 (389) 12309 (5592) 13548 (6145) 13509 (6128) 14749 (6690)
WSC079 2609 / 2609 686 (311) 11716 (5314) 12960 (5879) 12916 (5859) 14160 (6423)
WSC079 2612 / 2612 905 (410) 13226 (5999) 14752 (6692) 14426 (6544) 15952 (7236)
WSC079 3009 / 2609 825 (374) 12892 (5848) 14246 (6462) 14092 (6392) 15446 (7006)
WSC079 3012 / 2612 1098 (497) 14635 (6638) 16301 (7394) 15835 (7183) 17501 (7938)
WSC079 3009 / 3009 855 (387) 14076 (6385) 15644 (7096) 15276 (6929) 16844 (7640)
WSC079 3012 / 3012 1147 (520) 16119 (7312) 18061 (8192) 17319 (7856) 19261 (8737)
WSC079 3609 / 3009 1173 (531) 15913 (7218) 17929 (8133) 17113 (7762) 19129 (8677)
WSC079 3612 / 3012 1563 (708) 18340 (8319) 20807 (9438) 19540 (8863) 22007 (9982)
WSC087 2609 / 2209 651 (295) 10980 (4981) 11990 (5439) 12180 (5525) 13190 (5983)
WSC087 2612 / 2212 859 (389) 12309 (5583) 13549 (6146) 13509 (6128) 14749 (6690)
WSC087 2609 / 2609 686 (311) 11716 (5314) 12960 (5879) 12916 (5859) 14160 (6423)
WSC087 2612 / 2612 905 (410) 13226 (5999) 14752 (6692) 14426 (6544) 15592 (7073)
WSC087 3009 / 2609 825 (374) 12892 (5848) 14246 (6462) 14092 (6392) 15446 (7006)
WSC087 3012 / 2612 1098 (497) 14635 (6638) 16301 (7394) 15835 (7183) 17501 (7938)
WSC087 3009 / 3009 862 (390) 14076 (6385) 15644 (7096) 15276 (6929) 16844 (7640)
WSC087 3012 / 3012 1147 (520) 16118 (7311) 18060 (8192) 17318 (7855) 19260 (8736)
WSC087 3609 / 3009 1173 (531) 15913 (7218) 17929 (8133) 17113 (7762) 19129 (8677)
WSC087 3612 / 3012 1563 (708) 18339 (8319) 20806 (9438) 19539 (8863) 22006 (9982)
WSC087 3612 / 3612 1635 (740) 20584 (9337) 23799 (10795) 21784 (9881) 24999 (11340)
WSC100 3612 / 3012 1563 (708) 21578 (9788) 24045 (10907) 22778 (10332) 25245 (11451)
WSC100 3612 / 3612 1635 (740) 23826 (10807) 27041 (12266) 25026 (11352) 28241 (12810)
WSC100 4212 / 3612 2081 (943) 26457 (12001) 30260 (13726) 27657 (13545) 31460 (14270)
WSC100 4212 / 4212 2164 (980) 29298 (13290) 34024 (15433) 30498 (13834) 35224 (15978)
WSC100 4812 / 4212 2688 (1217) 32024 (14526) 37623 (17066) 33224 (15070) 38823 (17610)
WSC113 3612 / 3012 1563 (708) 21578 (9788) 24045 (10907) 22778 (10332) 25245 (11451)
WSC113 3612 / 3612 1635 (740) 23826 (10807) 27041 (12266) 25026 (11352) 28241 (12810)
WSC113 4212 / 3612 2081 (943) 26457 (12001) 30260 (13726) 27657 (13545) 31460 (14270)
WSC113 4212 / 4212 2164 (980) 29298 (13290) 34024 (15433) 30498 (13834) 35224 (15978)
WSC113 4812 / 4212 2688 (1217) 32024 (14526) 37623 (17066) 33224 (15070) 38823 (17610)
WSC113 4812 / 4812 2867 (1299) 35016 (15883) 41817 (18968) 36216 (16427) 43017 (19513)
WSC126 3612 / 3012 1563 (708) 21680 (9834) 24147 (10953) 22880 (10378) 25347 (11497)
WSC126 3612 / 3612 1635 (740) 23928 (10854) 27143 (12312) 25128 (11398) 28343 (12856)
WSC126 4212 / 3612 2081 (943) 26457 (12001) 30260 (13726) 27657 (12545) 31460 (14270)
WSC126 4212 / 4212 2164 (980) 29298 (13290) 34024 (15433) 30498 (13834) 35224 (15978)
WSC126 4812 / 4212 2164 (980) 32024 (14526) 37623 (17066) 33224 (15070) 38823 (17610)
WSC126 4812 / 4812 2867 (1299) 35016 (15883) 41817 (18968) 36216 (16427) 43017 (19513)
With starters (factory mounted) applies only to low voltage (200 to 600 volts) equipment.

Table 6 Unit Weights, Dual Compressor, WDC/WCC
Max. Unit Weight Without Starter Max. Unit Weight With Starter (1)
Evaporator / Condenser
Unit Shipping Operating Shipping Operating
Size
lbs. (kg) lbs. (kg) lbs. (kg) lbs. (kg)
WDC063 2416 / 2416 18673 (8470) 20422 (9263) 21407 (9710) 23156 (10503)
WDC063 2416 / 2616 19365 (8784) 21294 (9577) 22099 (10024) 23848 (10817)
WDC063 2616 / 2416 19282 (8746) 21207 (9639) 22016 (9986) 23763 (10779)
WDC063 2616 / 2616 20025 (9083) 22091 (9939) 22759 (10323) 24646 (11179)
WDC063 3016 / 3016 23545 (10680) 26405 (11830) 26279 (11920) 28815 (13070)
WDC063 3616 / 3016 27763 (12604) 31018 (14082) 30163 (13694) 33418 (15172)
WDC063 3616 / 3616 32027 (14540) 35115 (15942) 33427 (15176) 37515 (17032)
WDC079 3016 / 3016 25131 (11399) 27671 (12551) 27531 (12488) 30071 (13640)
WDC079 3616 / 3016 28763 (13047) 32018 (14523) 31163 (14135) 34418 (15612)
WDC079 3616 / 3616 32027 (14527) 36115 (16382) 34427 (15616) 38515 (17470)
WDC079 4216 / 4216 44470 (20189) 51463 (23364) 47204 (21431) 54197 (24605)
WDC087 3016 / 3016 26157 (11865) 28697 (13017) 28891 (13105) 31431 (14257)
WDC087 3616 / 3016 29789 (13512) 33044 (14989) 32523 (14752) 35778 (15322)
WDC087 3616 / 3616 33053 (14993) 37141 (16847) 35787 (16233) 39875 (18087)
WDC087 4216 / 4216 44470 (20189) 51463 (23364) 47204 (21431) 54197 (24605)
WDC100, 113 3616 / 3616 41816 (18967) 46513 (21098) See Note 2 See Note 2
WDC100, 113, 126 (<7kV) 4216 / 4216 50470 (22893) 57463 (26065) See Note 2 See Note 2
WCC100, 113, 126 (<7kV) 3620 / 3620 37645 (17091) 41334 (19268) See Note 2 See Note 2
WDC100, 113, 126 (10/11kV) 4216/4216 55760 (25292) 63536 (28219) See Note 2 See Note 2
WCC100, 113, 126 (10/11kV) 4220/4220 55987 (25395) 63262 (28695) See Note 2 See Note 2
WCC100, 113, 126 (10/11kV) 4820/4820 65768 (29832) 75761 (34365) See Note 2 See Note 2
With starters (factory mounted) applies only to low voltage (200 to 600 volts) equipment.
Unit not available with factory mounted starters.

Oil Coolers
McQuay centrifugal chillers have a factory-mounted, water-cooled oil cooler, temperature-controlled water
regulating valve and solenoid valve per compressor. WSC/HSC single compressor cooling water connections are
located near the compressor and are shown on the specific unit certified drawings. Also see Figure 11 on page 21.
Dual compressor chillers, WDC/ 063 - 126 and WCC 100 - 126 are equipped as above, but the water piping for the
two oil coolers is factory-piped to a common inlet and outlet connection located in the tube sheet under the
evaporator. The exception to this is the WDC 100 and 126 with 16-foot shells, where the common connections are
centered at the rear of the unit. See Figure 12 on page 21.
Field water piping to the inlet and outlet connections must be installed according to good piping practices and
include stop valves to isolate the cooler for servicing. A cleanable filter (40 mesh maximum), and drain valve or
plug must also be field-installed. The water supply for the oil cooler should be from the chilled water circuit or from
a clean, independent source, no warmer than 80F (27C), such as city water. When using chilled water, it is
important that the water pressure drop across the evaporator is greater than the pressure drop across the oil cooler or
insufficient oil cooler flow will result. If the pressure drop across the evaporator is less than the oil cooler, the oil
cooler must be piped across the chilled water pump, provided that its pressure drop is sufficient. The water flow
through the oil cooler will be adjusted by the unit's regulating valve so that the temperature of oil supplied to the
compressor bearings (leaving the oil cooler) is between 95F and 105F (35C and 40C).
NOTE: The system must be designed for the highest cooling water temperature possible, which may occur for a
short time during startup.
Table 7, WSC, Oil Cooler Data
Hot Side
Cold Side Water
POE Lube
WSC 063 - 087
Flow, gpm 9.9 11.9 2.9 2.0 1.54
Inlet Temperature, F 118.0 80.0 65.0 55.0 45.0
Outlet Temperature, F 100.0 87.3 94.5 98.3 101.4
Pressure Drop, psi - 4.3 0.3 0.14 0.09
WSC 100 - 126
Flow, gpm 15.8 21.9 5.11 3.5 2.7
Pressure Drop, psi - 3.78 0.23 0.11 0.07
Table 8, WSC with Mounted VFD, Oil Cooler Data

Hot Side
Cold Side Water
POE Lub.
WSC/HSC 063 - 087
Flow, gpm 9.9 13.4 4.0 2.9 2.3
Pressure Drop, ft. - 30.5 6.7 4.8 3.6
WSC/HSC 100 - 126
Flow, gpm 15.8 24.4 7.0 5.0 4.0
Pressure Drop, ft. - 30.6 15.7 11.4 9.3
NOTES:
1. WDC and WCC dual compressor units will have twice the cooling water flow rate of the comparable WSC chiller and the
pressure drop will be the same.
2. Pressure drops include valves on the unit.

Table 9, Freestanding VFD, Cooling Requirements
Cooling Cooling Cooling Cooling
Water Water Water Water
WSC/HSC 063 - 087
Flow, gpm 1.5 1.0 0.9 0.7
Inlet Temperature, F 80.0 65.0 55.0 45.0
Outlet Temperature, F 114 114 114 114
Pressure Drop, ft. 13.0 6.8 4.8 3.6
WSC/HSC 100 - 126
Flow, gpm 2.5 1.9 1.5 1.3
Inlet Temperature, F 80.0 65.0 55.0 45.0
Outlet Temperature, F 114 114 114 114
Pressure Drop, ft. 25.2 15.7 11.4 9.3
Compressors using chilled water for oil cooling will often start with warm "chilled water" in the system until the
chilled water loop temperature is pulled down. Data given above includes that condition. As can be seen, with
cooling water in the 45F to 65F (7C to 18C) range, considerably less water will be used, and the pressure
drop will be greatly reduced.
When supplied with city water, the oil piping must discharge through a trap into an open drain to prevent
draining the cooler by siphoning. The city water can also be used for cooling tower makeup by discharging it
into the tower sump from a point above the highest possible water level.
NOTE: Particular attention must be paid to chillers with variable chilled water flow through the
evaporator. The pressure drop available at low flow rates can very well be insufficient to supply the oil
cooler with enough water. In this case an auxiliary booster pump can be used or city water employed.
Figure 9, Oil Cooler Piping Across Chilled Water Pump
PUMP
CHILLER
OIL COOLER S
STOP
SOLENOID VALUE
VALVE
STOP
VALVE
STRAINER
MAX. 40 MESH
DRAIN VALVE
OR PLUG

Figure 10, Oil Cooler Piping With City Water
OIL COOLER S
SOLENOID
VALVE
STOP COOLING TOWER

WATER VALVE
SUPPLY
STRAINER COOLING TOWER MAKEUP
MAX. 40 DISCHARGE ABOVE
MESH HIGHEST POSSIBLE
DRAIN VALVE
WATER LEVEL
OR PLUG
OPEN
DRAIN
Figure 11, Oil Cooler Connections, WSC/HSC Units
Oil Compressor
Reservoir Controller & Lub
Control Box
Solenoid Valve
Inlet
Connection
Temperature
(I id )
Control Valve
Outlet
Connection
(O id )
Figure 12, Oil Cooler Connections, WDC 100/126, 16 Foot Shells
Solenoid Valves
Note:
All other WDC units
Temperature
have oil cooler
Control Valves
connections located on
the right hand tube
Inlet Connection
sheet under the
Outlet Connection evaporator.

Table 10, Cooling Water Connection Sizes
WDC 063-087,
Model WSC/HSC 063-087, WDC/WCC 100-126
WSC/HSC 100-126
Conn Size (in.) ¾ in. 1 in. 1 ½ in.
Oil Heater
The oil sump is equipped with an immersion heater that is installed in a tube so that it can be removed without
disturbing the oil.
Relief Valves
As a safety precaution and to meet code requirements, each
chiller is equipped with pressure relief valves located on the
condenser, evaporator, and oil sump vessel for the purpose
of relieving excessive refrigerant pressure (caused by
equipment malfunction, fire, etc.) to the atmosphere. Most
codes require that relief valves be vented to the outside of a
building, and this is a desirable practice for all installations.
Relief piping connections to the relief valves must have
flexible connectors.
Note: Remove plastic shipping plugs (if installed) from the

inside of the valves prior to making pipe connections.
Whenever vent piping is installed, the lines must be run in
accordance with local code requirements; where local codes
do not apply, the latest issue of ANSI/ASHRAE Standard 15
code recommendations must be followed.
Condensers have two relief valves as a set with a three-way

valve separating the two valves (large condensers will have
two such sets). One valve remains active at all times and the
second valve acts as a standby. See pages 15 and 16 for the
number of valve on specific vessels.
Table 11, Relief Valve Data
Chiller Relief Valve Location Pressure Setting Discharge Cap.
Evaporator Top of Evaporator 200 psi 75.5 lb air/min
WSC/WPV
Condenser Top of Condenser 200 psi 75.5 lb air/min
Evaporator Top of Evaporator 180 psi 68.5 lbair/min
WDC
Condenser Top of Condenser 225 psi 84.4 lb air/min
Oil Sump Oil Pump Top of Oil Sump Cover 200 psi 5.0 lb air/min
Figure 13, Condenser 3-Way Valve

Refrigerant Vent Piping
Relief valve connection sizes are one-inch FPT and are in the quantity shown in Table 2 and Table 3 on page 15.
Twin relief valves mounted on a transfer valve are used on the condenser so that one relief valve can be shut off
and removed, leaving the other in operation. Only one of the two is in operation at any time. Where four valves
are shown in the table, they consist of two valves, each mounted on two transfer valves. Only two relief valves of
the four are active at any time.
Vent piping is sized for only one valve of the set since only one can be in operation at a time. In no case would a
combination of evaporator and condenser sizes require more refrigerant than the pumpdown capacity of the
condenser. Condenser pumpdown capacities are based on the current ANSI/ASHRAE Standard 15 that
recommend 90% full at 90°F (32C). To convert values to the older AHRI standard, multiply pumpdown capacity
by 0.888.
Sizing Vent Piping (ASHRAE Method)
Relief valve pipe sizing is based on the discharge capacity for the given evaporator or condenser and the length of
piping to be run. Discharge capacity for R-134a vessels is calculated using a complicated equation that accounts
for equivalent length of pipe, valve capacity, Moody friction factor, pipe ID, outlet pressure and back pressure.
The formula, and tables derived from it, is contained in ASHRAE Standard 15.
McQuay centrifugal units have relief valve settings of 180 psi, 200 psi, and 225 psi, and resultant valve discharge
capacities of 68.5 # air/min, 75.5 # air/min, and 84.4 # air/min respectively.
Using the ASHRAE formula and basing calculations on the 225 psi design yields a conservative pipe size, which
is summarized in Table 12. The table gives the pipe size required per relief valve. When valves are piped together,
the common piping must follow the rules set out in the following paragraph on common piping.
Table 12. Relief Valve Piping Sizes
Equivalent length (ft) 2.2 18.5 105.8 296.7 973.6 4117.4
Pipe Size inch (NPT) 1 1/4 1 1/2 2 2 1/2 3 4
Moody Factor 0.0209 0.0202 0.0190 0.0182 0.0173 0.0163
NOTE: A 1-inch pipe is too small for the flow from the valves. A pipe increaser must always be installed at the valve outlet.
Common Piping
According to ASHRAE Standard 15, the pipe size cannot be less than the relief valve outlet size. The discharge
from more than one relief valve can be run into a common header, the area of which cannot be less than the sum
of the areas of the connected pipes. For further details, refer to ASHRAE Standard 15. The common header can
be calculated by the formula:
0.5
DCommon   D2  D2 .... Dn2 
1 2
The above information is a guide only. Consult local codes and/or latest version of ASHRAE Standard 15 for
sizing data.
Electrical
Wiring, fuse and wire size must be in accordance with the National Electric Code (NEC). Standard NEMA
motor starters require modification to meet McQuay specifications. Refer to McQuay Specification R35999901
or McQuay Product Manual PM WSC/WDC.
Important: Voltage unbalance not to exceed 2% with a resultant current unbalance of 6 to 10 times the voltage
unbalance per NEMA MG-1 Standard. This is an important restriction that must be adhered to.
Power Wiring
Power Factor Correction Capacitors
Do not use power factor correction capacitors withcentrifugal chillers with a compressor VFD. Doing so can
cause harmful electrical resonance in the system. Correction capacitors are not necessary since VFDs inherently
maintain high power factors

WARNING
Qualified and licensed electricians must perform wiring. Shock hazard exists.
Power wiring to compressors must be in proper phase sequence. Motor rotation is set up for clockwise rotation
facing the lead end with phase sequence of 1-2-3. Care must be taken that the proper phase sequence is carried
through the starter to compressor. With the phase sequence of 1-2-3 and L1 connected to T1 and T6, L2
connected to T2 and T4, and L3 connected to T3 and T5, rotation is proper. See diagram in terminal box cover.
The McQuay start-up technician will determine the phase sequence.
CAUTION
Connections to terminals must be made with copper lugs and copper wire.
Care must be taken when attaching leads to compressor terminals.

Use only copper supply wires with ampacity based on 75°C conductor rating. (Exception: for equipment rated over
2000 volts, 90°C or 105°C rated conductors should be used).
Note: Do not make final connections to motor terminals until wiring has been checked and approved by a McQuay
technician.
Under no circumstances should a compressor be brought up to speed unless proper sequence and rotation have
been established. Serious damage can result if the compressor starts in the wrong direction. Such damage is not
covered by product warranty.
It is the installing contractor's responsibility to insulate the compressor motor terminals when the unit voltage is
600 volts or greater. This is to be done after the McQuay start-up technician has checked for proper phase
sequence and motor rotation. Following this verification by the McQuay technician, the contractor should obtain
and apply the following items on medium voltage (above 600 volts) applications.
Materials required:
1. Loctite brand safety solvent (12 oz. package available as McQuay part number 350A263H72)
2. 3M Co. Scotchfil™ brand electrical insulation putty (available in a 60-inch roll as McQuay part number
350A263H81)
3. 3M Co. Scotchkote brand electrical coating (available in a 15 oz. can with brush as McQuay Part Number
350A263H16)
4. Vinyl plastic electrical tape
The above items are available at most electrical supply outlets.
Application procedure:
1) Disconnect and lock out the power source to the compressor motor.
2) Using the safety solvent, clean the motor terminals, motor barrel adjacent to the terminals, lead lugs, and
electrical cables within the terminal 4OX to remove all dirt, grime, moisture and oil.
3) Wrap the terminal with Scotchfil putty, filling in all irregularities. The final result should be smooth and
cylindrical.
4) Doing one terminal at a time, brush the Scotchkote coating on the motor barrel to a distance of up to '/2"
around the terminal and on the wrapped terminal, the rubber insulation next to the terminal, and the lug and
cable for approximately 10". Wrap additional Scotchfil insulation over the Scotchkote coating.
5) Tape the entire wrapped length with electrical tape to form a protective jacket.
6) Finally, brush on one more coat of Scotchkote coating to provide an extra moisture barrier.

Installation Instructions for 10/11kV Motor Units
The 10/11 kV motors have additional installation requirements compare to lower voltage motors.
Installing Motor Terminal Box

For safety and shipping considerations, the chiller is shipped with a disposable protective shield over the
motor terminals and a separate field-installed terminal box.
! CAUTION
Exert extreme care when mounting the compressor motor terminal box on the compressor to avoid damage to the
motor terminals. Terminal damage can result in costly and time consuming repair.
Unbolt the protective shield covering the compressor motor terminals and discard.
Install the shipped-loose terminal box as follows:
1. A mounting gasket is shipped with the terminal box. Mount it on the face of the compressor terminal
housing (see Figure 14) using an appropriate adhesive to hold it in place until the terminal box is
mounted. The gasket must be located such that the gasket holes align with the threaded holes in the
casting.
2. Remove the terminal box door before lifting the terminal box helps to keep the box balanced. Lift using
lifting straps attached to the side lifting tabs. The top tab is used as a tie-off for balance, not for the main
weight of lifting.
3. To assist in mounting the box and to provide protection to the motor terminals, screw two
¼-20 x 12 in. all-thread into top and bottom holes of the casting (see Figure 14) to provide mounting
guides for aligning the box
4. Mount the box over the two all-threads using them as a guide and carefully position the box against the
compressor (gasket). Avoid contact with the motor terminals.
5. Mount the box using ¼-20 x 0.75 in. bolts in all the empty holes.
Figure 14, Compressor Terminal Housing
Terminal Housing
All-thread Locations
Insulate this area of the compressor

terminal housing
Gasket Mounting Face
6. Remove the two all-thread and replace with two ¼-20 x 0.75 in. bolts.

Insulating Motor Terminals
1. Insulate motor housing around terminals using thermal

foam.
2. Thermally insulate the motor terminals.
 Use “SCOTCH” Sealant Tape on each end of
terminal on glass.
 Install full length plus heat shrink tube (see picture to
right.)
 Shrink with heat gun.
3. Install the flexible buss bars. (see picture at right) using a

backing wrench and tighten as shown below. The buss
bars are factory connected to the box main power
terminals and field connected to the motor terminals
 Use Scotch® Linerless Rubber Splicing Tape to cover

the compressor terminal housing extending into the
terminal box. See Figure 14.
 Top wrap with “SCOTCH” Sealant Tape starting at
base terminal and going out 2-in. onto the buss-bar.
 Top wrap with "SCOTCH" 70 SELF-FUSING
SILICONE RUBBER ELECTRICAL TAPE 70 starting
at base terminal and going out 2-in.onto the buss-bar.
 Top coat all this the 3M™ Scotchkote™ Electrical
Coating 14853 (clear liquid)

Connecting Power Leads
Power leads are brought in through a removable plate on the top of the terminal box (see Figure 15).
The terminal box power connectors are made to the landing points shown in Figure 15captive and
attached with a bolt already in the connector.
Figure 15, Terminal Box Mounted, Front View
Line Power Entry
Insulate this area

with rubber
splicing tape.
Buss Connection
to Compressor
Terminals (3)
Line Power Landing Points (3) Flexible Buss Bar (3)
Figure 16, Terminal Box Mounted, Side View

Control Wiring
Power leads are brought in through a removable plate on the top of the terminal box (see Figure 15).
The terminal box power connectors are made to the landing points shown in Figure 15captive and
attached with a bolt already in the connector.
Figure 17, Control Wiring
Rear Motor
Temperature
Sensors Cable
Front Motor Temperature

Sensors Cable
Compressor to Terminal Box

Each sensor location cable has four wires connected to the motor by a M12 4-pin connector and to
the Thermistor Controller in the terminal box. Connections are as follows:
Front Temperature Sensors connect to the controller’s J2 terminal strip.

Brown---B1
White----B2
Blue------B3
Black-----Ground
Rear Temperature Sensors connect to the controller’s J6 terminal strip.
Brown---B6
White----B7
Blue------B8
Black-----Ground
Factory FO “Black Box” Factory Wired
Wired Isolator Fiber Optic
Motor Terminal Box to Chiller Control Panel
Cables
Field wiring is required between the terminal box and
the chiller control panel to transmit motor information
to the chiller. Data from the compressor is sent to a
“Black Box” fiber isolator via a factory-wired fiber
optic cable (to isolate motor voltage from the chiller
controls). A cable is factory connected to terminals 33,
34, 35, and 36 on CTB1 in the chiller control box.
This cable is field installed into the motor terminal Land wires on terminal strip TTB1
box and wires in it connected to like terminal numbers
on terminal strip TTB1 located in the small lower box of
the motor terminal box.

Remote Starter Display Wiring
Remote mounted wye-delta, solid state, and across-the-line
starters require field wiring to activate the optional ammeter
display or the full metering display on the chiller’s operator
interface panel. The wiring is from the D3 board in the starter to
the compressor controller and to the bias block; both located in
the compressor control panel.
Wiring Connection on Starter for Optional Display
Figure 18, Field Wiring for Optional Display
Control Power Wiring

The control circuit on the McQuay centrifugal packaged chiller is designed for 115-volts. Control power can
be supplied from three different sources:
1. If the unit is supplied with a factory-mounted starter or VFD, the control circuit power supply is
factory-wired from a transformer located in the starter or VFD.
2. A freestanding starter or VFD furnished by McQuay, or by the customer to McQuay
specifications, will have a control transformer in it and requires field wiring to terminals in the
compressor terminal box.
3. Power can be supplied from a separate circuit and fused at 25 amps inductive load. The control
circuit disconnect switch must be tagged to prevent current interruption. Other than for service
work, the switch is to remain on at all times in order to keep oil heaters operative and
prevent refrigerant from diluting in oil.

DANGER
If a separate control power source is used, the following must be done to avoid severe personal injury or death from
electrical shock: Place a notice on the unit that multiple power sources are connected to the unit.
Place a notice on the main and control power disconnects that another source of power to the unit exists.
In the event a transformer supplies control voltage, it must be rated at 3 KVA, with an inrush rating of 12 KVA
minimum at 80% power factor and 95% secondary voltage. For control wire sizing, refer to NEC. Articles 215
and 310. In the absence of complete information to permit calculations, the voltage drop should be physically
measured.
Table 13, Control Power Line Sizing
Maximum Length, ft (m) Wire Size (AWG) Maximum Length, ft (m) Wire Size (AWG)
0 (0) to 50 (15.2) 12 120 (36.6) to 200 (61.0) 6
50 (15.2) to 75 (22.9) 10 200 (61.0) to 275 (83.8) 4
75 (22.9) to 120 (36.6) 8 275 (83.8) to 350 (106.7) 3
Notes:
1. Maximum length is the distance a conductor will traverse between the control power source and the unit control panel.
2. Panel terminal connectors will accommodate up to number 10 AWG wire. Larger conductors will require an
intermediate junction box.
The Unit On/Off switch located in the Unit Control Panel should be turned to the "Off" position any time
compressor operation is not desired.
Wiring for Optional BAS Interface
The optional Building Automation System (BAS) interface utilizing the MicroTech II unit controller’s
Open Choices feature is field wired and will be set-up by the McQuay startup service technician. The
following manuals explain the wiring and mounting procedures:
LONWORKS > IM 735
BACnet > IM 906
MODBUS > IM 743
Flow Switches
Water flow interlock terminals are provided on the Unit Control Panel terminal strip for field-mounted
switches. See the Field Wiring Diagram on page 32 or on the cover of the control panel for proper connections.
The purpose of the water flow interlocks is to prevent compressor operation until such time as both the
evaporator water and condenser water pumps are running and flow is established. If flow switches are not
furnished factory-installed and wired, they must be furnished and installed by others in the field before the unit
can be started.
System Pumps
Operation of the chilled water pump can be to 1) cycle the pump with the compressor, 2) operate continuously,
or 3) start automatically by a remote source.
The cooling tower pump must cycle with the machine. The holding coil of the cooling tower pump motor
starter must be rated at 115 volts, 60 Hz, with a maximum volt-amperage rating of 100. A control relay is
required if the voltage-amperage rating is exceeded. See the Field Wiring Diagram on page 32 or in the cover
of control panel for proper connections.
All interlock contacts must be rated for no less than 10 inductive amps. The alarm circuit provided in the
control center utilizes 115-volts AC. The alarm used must not draw more than 10 volt amperes.
See OM CentriMicro II for MicroTech II unit controller details.
Control Panel Switches
Three On/Off switches are located in the upper left corner of the main Unit Control Panel, which is adjacent to the
operator interface panel, and have the following function:

 UNIT shuts down the chiller through the normal shutdown cycle of unloading the compressor(s) and
provides a post-lube period.
 COMPRESSOR one switch for each compressor on a unit, executes an immediate shutdown without the
normal shutdown cycle.
 CIRCUIT BREAKER disconnects optional external power to system pumps and tower fans.
A fourth switch located on the left outside of the Unit Control Panel and labeled EMERGENCY STOP SWITCH
stops the compressor immediately. It is wired in series with the COMPRESSOR On/Off switch.
Surge Capacitors
All units (except those with solid state starters or VFDs) are supplied with standard surge capacitors to protect
compressor motors from electrical damage resulting from high voltage spikes.
 For unit-mounted starters, the capacitors are factory-mounted and wired in the starter enclosure.
 For free-standing starters, the capacitors are mounted in the motor terminal box and must be connected to
the motor terminals with leads less than 18 inches (460 mm) long when the motor is being wired.
NOTES for Following Wiring Diagram
1. Compressor motor starters are either factory mounted and wired, or shipped separate for field mounting and wiring. If
provided by others, starters must comply with McQuay specification 359A999. All line and load side power conductors
must be copper.
2. If starters are freestanding, then field wiring between the starter and the control panel is required. Minimum wire size
for 115 Vac is 12 GA for a maximum length of 50 feet. If greater than 50 feet, refer to McQuay for recommended wire
size minimum. Wire size for 24 Vac is 18 GA. All wiring to be installed as NEC Class 1 wiring system. All 24 Vac
wiring must be run in separate conduit from 115 Vac wiring. Main power wiring between starter and motor terminal is
factory-installed when units are supplied with unit-mounted starters. Wiring of free-standing starter must be wired in
accordance with NEC and connection to compressor motor terminals must be made with copper wire and copper lugs
only. Control wiring on free-standing starters is terminated on a terminal strip in the motor terminal box (not the unit
control panel). Wiring from the unit control panel to the motor terminal is done in the factory.
3. For optional sensor wiring, see unit control diagram. It is recommended that DC wires be run separately from 115 Vac
wiring.
4. Customer furnished 24 or 120 Vac power for alarm relay coil can be connected between UTB1 terminals 84 power
and 51 neutral of the control panel. For normally open contacts, wire between 82 & 81. For normally closed contacts,
wire between 83 & 81. The alarm is operator programmable. The maximum rating of the alarm relay coil is 25 VA.
5. Remote on/off control of unit can be accomplished by installing a set of dry contacts between terminals 70 and 54.
6. Evaporator and condenser paddle type flow switches or water pressure differential switches are required and must be
wired as shown. If field supplied pressure differential switches are used then these must be installed across the vessel
and not the pump. Factory-mounted thermal dispersion flow sensors are available as an option.
7. Customer supplied 115 Vac, 20 amp power for optional evaporator and condenser water pump control power and
tower fans is supplied to unit control terminals (UTBI) 85 power / 86 neutral, PE equipment ground.
8. Optional customer supplied 115 Vac, 25 VA maximum coil rated chilled water pump relay (EP 1 & 2) can be wired as
shown. This option will cycle the chilled water pump in response to building load.
9. The condenser water pump must cycle with the unit. A customer supplied 115 Vac 25 VA maximum coil rated
condenser water pump relay (CP1 & 2) is to be wired as shown.
10. Optional customer supplied 115 Vac, 25 VA maximum coil rated cooling tower fan relays (CL - C4) can be wired as
shown. This option will cycle the cooling tower fans in order to maintain unit head pressure.
11. Auxiliary 24 Vac rated contacts in both the chilled water and condenser water pump starters must be wired as shown.
12. For VFD, Wye-Delta, and solid state starters connected to six (6) terminal motors. The conductors between the starter
and motor carry phase current and selection shall be based on 58 percent of the motor rated load amperes (RLA).
Wiring of free-standing starter must be in accordance with the NEC and connection to the compressor motor terminals
shall be made with copper wire and copper lugs only. Main power wiring between the starter and motor terminals is
factory-installed when chillers are supplied with unit-mounted starters.
13. Optional Open Choices BAS interfaces. The locations and interconnection requirements for the various standard
protocols are found in their respective installation manuals, obtainable from the local McQuay sales office and also
shipped with each unit:
Modbus IM 743 LonWorks IM 735 BACnet IM 906
14. The “Full Metering” or “Amps Only Metering” option will require some field wiring when free-standing starters are used.
Wiring will depend on chiller and starter type. Consult the local McQuay sales office for information on specific
selections.

Figure 19, Field Wiring Diagram
MICROTECH CONTROL
BOX TERMINALS
(115V) (24V)
GND PE 54
85
POWER
* NOTE 7
86
NEUTRAL
* NOTE 10 70
H
80
* COOLING O 55
TOWER C4 74 H
A
FOURTH O
86
STAGE
STARTER EP2
A C
86
* NOTE 10
H 79
* COOLING O
TOWER C3 73
A H
THIRD O
STAGE
STARTER EP1
A C
78
77
* NOTE 10
H 76
* COOLING O
TOWER C2 75
A
SECONDH
STAGE
STARTER
H
O
* NOTE 10 A C
H CP2
* COOLING O
C1 T3-S
TOWER A
FIRST EF
STAGE
STARTER CF
81
COMMON
82(NO) ALARM RELAY
A (NOTE 4)
83(NC)
84
POWER
H
52
O
COOLING TOWER
71
BYPASS VALVE 1-10 VDC CP1
A C
71
1-10 VDC
COOLING TOWER VFD 53
MICROTECH STARTER LOAD SIDE TERMINBALS

COMPRESSOR CONTROL VFD
- FOR DC VOLTAGE AND 4-20 MA
L1 L2 L3
BOX TERMINALS CONNECTIONS (SEE NOTE 3)
U V W
CTB1
NOTE 2 - FOR DETAILS OF CONTROL REFER
115 VAC
GND T1 T6 T2 T4 T3 T5 TO UNIT CONTROL SCHEMATIC
PE COMPRESSOR TERMINALS 330342101
CP1 L1
STARTER LOAD SIDE TERMINBALS
CP2 L2 WYE-DELTA - COMPRESSOR CONTROL
23(5A) 23 T1 T2 T3
T4 T5 T6 SCHEMATIC 330342201
COMPRESSOR 24(5) 24
- LEGEND: 330343001
MOTOR 25 25
T1 T2 T3 T4 T5 T6
STARTER COMPRESSOR TERMINALS * FIELD SUPPLIED ITEM
(NOTE 1) 1 1
2 2 SOLID STATE
NOTE 12
T1 T2 T3
3 3
4 4
6 11 T1 T6 T2 T4 T3 T5
COMPRESSOR TERMINALS
11 11
12 12
22 22 MEDIUM AND HIGH VOLTAGE
T1 T2 T3
-LOAD- NOTE 2 LESS
THAN
30V
OR T1 T2 T3
24VAC COMPRESSOR TERMINALS 330387901-0A

Multiple Chiller Setup
Single compressor chillers WSC and dual compressor chillers WDC and WCC have their main control components
factory wired to an internal pLAN network so that the components can communicate with each other, within the
chiller itself. On multi-chiller applications, up to four chillers, either single, or dual compressor, can be
interconnected by this internal pLAN. All that is required is simple field RS485 interconnecting wiring, the addition
of accessory communication isolation board(s) 485OPDR (McQuay P/N 330276202), and some MicroTech II
control settings (see special WCC instructions at the end of this section). The 485OPDR isolation board can be
purchased with the unit or separately, during or after chiller installation. The number of chillers minus one boards are
required. Note: pLAN is optimized for parallel chiller installations only.
pLAN Setup
Interconnecting MicroTech II pLAN RS485 wiring should be installed by the installing contractor prior to start-up.
The McQuay start-up technician will check the connections and make the necessary set point settings.
1. With no pLAN connections between chillers, disconnect chiller control power and set the pLAN addresses as
shown in Table 14.
2. With all manual switches off, turn on control power to each chiller and set each OITS address (see Note 2 on
page 34).
3. Verify correct nodes on each OITS Service Screen.
4. Connect chillers together (pLAN, RS485 wiring) as shown in Figure 16. The first chiller in the connection can
be designated as Chiller A. The isolation board is attached to the DIN rail adjacent to the Chiller A unit
controller. The isolation board has a pigtail that is plugged into J10 on the controller. Most chillers will already
have a universal communication module (UCM) that connects the controller to the touchscreen already plugged
onto J10. If this is the case, plug the isolation module pigtail into the empty RJ11 pLAN port on the UCM. This
is equivalent to plugging into the unit controller directly.
Next, interconnecting wiring is needed between Chiller A and Chiller B.
Two Chillers: If only two chillers are to be connected, Belden M9841 (RS 485 Spec Cable) is wired from the
485OPDR isolation board (terminals A, B, and C) on Chiller A to the J11 port on the unit controller of Chiller B.
At J11, the shield connects to GND, the blue/white wire to the (+) connection, and the white/blue to the (-)
connection.
Note that Chiller B does not have an isolation board. The last chiller (B in this case) to be connected does not
need an isolation board.
Three or More Chillers: If three or more chillers are to be connected, the interconnecting wiring is still made to
Chiller B’s J11 port. The second chiller (Chiller B) must have a 485OPDR isolator board that will be plugged
into Chiller B’s UCM pLAN port. Chiller B will look like Chiller A.
The wiring from Chiller B to Chiller C will be the same as A to B. That is, Belden cable connects from A, B, and
C on B’s 485OPDR board to chiller C’s L11 port. Chiller C has no 485OPDR isolation board.
The procedure is repeated to the fourth chiller if four chillers are interconnected.
5. Verify correct nodes on each OITS Service Screen.

Figure 20, Communication Wiring
PIGTAIL
Chiller A
P P J10 J11
485
OPDR UCM
C B A
UNIT CONTROL
BLU/WHT
WHT/BLU
SHIELD
Chiller B
485 P P J10 (+) (-)
OPDR UCM PORT J11 PORT
C B A
UNIT CONTROL
BLU/WHT
WHT/BLU
SHIELD
(+) (-)
Chiller C
J11 Port
UNIT CONTROL
NOTE: A fourth chiller, Chiller D would be connected to chiller C same as chiller C to chiller B.
Table 14, pLAN Address and DIP Switch Settings for Controllers Using pLAN
Chiller Comp 1 Comp 2 Unit Reserved Operator Reserved
(1) Controller Controller Controller Interface (2)
Dec. 1 2 5 6 7 8
A
Bin. 100000 010000 101000 011000 N/A 000100
Dec. 9 10 13 14 15 16
B
Bin. 100100 010100 101100 011100 N/A 000010
Dec. 17 18 21 22 23 24
C
Bin. 100010 010010 101010 011010 N/A 000110
Dec. 25 26 29 30 31 32
D
Bin. 100110 010110 101110 011110 N/A 000001
NOTES:
1. Up to four single or dual compressors can be interconnected.
2. Operator Interface Touch Screen (OITS) setting is not a DIP switch setting. The OITS address is selected by
selecting the ‘service’ set screen. Then, with the Technician level password active, select the ‘pLAN Comm’
button. Buttons A(7), B(15), C(23), D(31) will appear in the middle of the screen, then select the letters for the
OITS address for the chiller that it is on. Then close the screen. Note that A is the default setting from the factory.
3. For the pCo2 controller, the pLAN address can be confirmed by viewing the DIP switch positions and comparing
to the table above (Bin. rows). Up is ‘On’, indicated by ‘1’. Down is ‘Off’, indicated by ‘0’.

4. For the pCo3 controller, there are no DIP switches as shown below.
The pLAN address can only be confirmed as follows:

A) Disconnect pLAN (connectors J10 and J11) from all pCo2 and pCo3 controller(s).
B) Cycle power to the controller and then hold down both the Left Arrow (alarm) and the Up Arrow keys
simultaneously as the controller completes its Self-Test routine. The controller will then show you the present pLAN
address of the controller. Verify that the pLAN address matches the desired address from the above table (Dec.
rows). If the address needs to be changed, follow the instructions displayed on the pCo3 controller’s LCD display.
Press enter when done.
C) Only after all controllers pLAN addresses have been set/confirmed can the pLAN network connectors be re-
connected.
MicroTech II Operator Interface Touch Screen (OITS) Settings

Settings for any type of linked multiple compressor operation must be made to the MicroTech II controller.
Settings on a dual compressor unit are made in the factory prior to shipment, but must be verified in the field
before startup. Settings for multiple chiller installations are set in the field on the Operator Interface Touch Screen
as follows:
Maximum Compressors ON – SETPOINTS - MODES screen, Selection #10 ‘= 2 for a dual, 4 for 2 duals, 3 for
three separate, single compressor chillers, etc. If all compressors in the system are to be available as normal
running compressors, then the value entered in #10 should equal the total number of compressors. If any
compressors are for standby and not operated in normal rotation, they should not be included in the compressor
count in Selection #10. The Max Comp ON setting can be made in only one touchscreen, the system will observe
the highest number set on all chillers-it is a global setting.
Sequence and Staging – SETPOINTS - MODES screen, Selection #12 & #14; #11 & #13. Sequence sets the
sequence in which compressors will start. Setting one or more compressors to “1” evokes the automatic lead/lag
feature and is the normal setting. The compressor with least starts will start first and the compressor with
maximum hours will stop first, and so on. Units with higher numbers will stage on in sequence.

The Modes setpoints will do several different types of operation (Normal, Efficiency, Standby, etc.) as described
in the operating manual.
The same Modes setting must be replicated on each chiller in the system.
Nominal Capacity – SETPOINTS - MOTOR screen, Selection #14. The setting is the compressor design tons.
Compressors on dual units are always of equal capacity.
WCC Settings
Since the WCC is essentially two chillers combined into one counterflow, single pass, dual-circuit chiller, the
compressor on the downstream circuit (leaving chilled water) must always be designated as the Stage 1
compressor-first on, last off.
Operating Sequence
For multiple-chiller, parallel operation, the MicroTech II controllers are tied together by a pLAN network and
stage and control compressor loading among the chillers. Each compressor, single or dual compressor chiller, will
stage on or off depending on the sequence number programmed into it. For example, if all are set to “1”, the
automatic lead/lag will be in effect.
When chiller #1 is fully loaded, the leaving chilled water temperature will rise slightly. When the Delta-T above
setpoint reaches the Staging Delta-T, the next chiller scheduled to start will receive a start signal and start its
pumps if they are set up to be controlled by the Microtech controller. This procedure is repeated until all chillers
are running. The compressors will load-balance themselves.
If any of the chillers in the group are dual compressor, they will stage and load according to the staging
instructions.
See OM CentrifMicro II (current revision) for a complete description of the various staging sequences available.

Prestart System Checklist
Yes No N/A
Chilled Water
Piping complete.................................................................................................................   
Water system filled, vented ...............................................................................................   
Pumps installed, (rotation checked), strainers cleaned......................................................   
Strainer installed at evaporator inlet   
Controls (3-way, face and bypass dampers, bypass valves, etc.) operable .......................   
Water system operated and flow balanced to meet unit design requirements ...................   
Condenser Water (*)
Cooling tower flushed, filled and vented .........................................................................   
Pumps installed, (rotation checked), strainers cleaned .....................................................   
Strainer installed at condenser inlet   
Controls (3-way, bypass valves, etc.) operable ................................................................   
Water system operated and flow balanced to meet unit requirements .............................   
Electrical
115-volt service completed, but not connected to control panel ......................................   
Power leads connected to starter; load leads run to compressor ready for
connection when service engineer is on hand for start-up ............................................   
(Do not connect starter or compressor terminals)
All interlock wiring complete between control panel and complies with specifications .   
Starter complies with specifications .................................................................................   
Pump starters and interlock wired ....................................................................................   
Cooling tower fans and controls wired ............................................................................   
Wiring complies with National Electrical Code and local codes .....................................   
Condenser pump starting relay (CWR) installed and wired .............................................   
Miscellaneous
Oil cooler water piping complete (units with water cooled oil coolers only) ..................   
Relief valve piping complete ...........................................................................................   
Thermometer wells, thermometers, gauges, control wells, controls, etc., installed .........   
Minimum system load of 80% of machine capacity available for testing
and adjusting controls ......................................................................................................   
(*) Includes heating hot water on heat recovery units.
Note: This checklist must be completed and sent to the local McQuay service location two
weeks prior to start-up.

Operation
Operator Responsibilities
It is important that the operator become familiar with the equipment and the system before attempting to operate the
chiller. In addition to reading this manual, the operator should study operation manual OM CentrifMicro II (latest
edition) and the control diagram furnished with the unit before starting, operating, or shutting it down.
During the initial startup of the chiller the McQuay technician will be available to answer any questions and instruct
in the proper operating procedures.
It is recommended that the operator maintain an operating log for each individual chiller unit. In addition, a separate
maintenance log should be kept of the periodic maintenance and servicing activities.
This McQuay centrifugal chiller represents a substantial investment and deserves the attention and care normally
given to keep this equipment in good working order. If the operator encounters abnormal or unusual operating
conditions, it is recommended that a McQuay service technician be consulted.
McQuay International conducts training for centrifugal operators at its factory Training Center in Staunton, Virginia,
several times a year. These sessions are structured to provide basic classroom instruction and include hands-on
operating and troubleshooting exercises. For further information, contact your McQuay representative.
Standby Power
It is essential that any centrifugal chiller connected to standby power come to a complete stop before being restarted
on grid power. This is usually not an issue when running on grid power and experiencing a grid power failure since
the chiller’s control will shut down the chiller and disconnect it from the power source for the stop-to-start setpoint
time. It will have come to a complete stop before restarting.
Attempting to switch back and forth from regular grid line power and auxiliary power while the compressor is
running can result in extreme transient torque that will severely damage the compressor.
MicroTech II Control

Figure 21, MicroTech II Control Panel
All chillers are equipped with the McQuay MicroTech II

control system consisting of:
 Operator touchscreen interface panel (shown at the
left). It consists of a 15-inch Super VGA color screen
and a floppy drive. See Figure 21.
 Unit Control Panel containing the MicroTech II unit
controller and miscellaneous switches and field
connection terminals.
 Compressor Control Panel for each compressor
containing the MicroTech II compressor controller
and lube system control components.
NOTE: Detailed information on the operation of the MicroTech II control is contained in the OM CentrifMicro II.

Figure 22, Unit Control Panel
ON/OFF
Switches
UTB1 Unit
Terminal Block
110-volt
Circuit Breaker
pLAN Termination Unit

& Control Power Controller
Isolation Board
Emergency
OFF Switch
Figure 23, Compressor Control Panel
115-volt Circuit Breaker Latch Relay
Terminal Board CTB1 Heater Relay
Compressor Relay
Bias Block for Starter
Display Option Connection Oil Pump Contactor
115V-24V Transformers (3)

Oil Pump Overload
Relay Reset Button
AC-DC Signal Converter

Oil Pump Starting Capacitor
Guardistor Board Terminal Board, CTB2
pLAN Connection
Compressor Microprocessor
RS485 Serial Card for

Starter Display Option
Connection
Transducer/Converter Board
5VDC Output, 0-5V Input

Capacity Control System
The opening or closing of the inlet vanes controls the quantity of refrigerant entering the impeller thereby
controlling the compressor capacity. The vane movement occurs in response to oil flow from the SA or SB 4-way
solenoid valves, which in turn, respond to instructions from the unit microprocessor as it senses leaving chilled
water temperature. This oil flow activates a sliding piston that rotates the vanes.
Vane Operation
The hydraulic system for the inlet guide vane capacity control operation consists of a 4-way normally open
solenoid valve located in the oil management control panel or on the compressor close to the suction connection.
Oil under pressure from the oil filter is directed by the 4-way valve to either or both sides of the piston, depending
on whether the control signal is to load, unload, or hold.
To open the vanes (loading compressor), solenoid SA is de-energized and SB is energized, allowing oil flow from
port SA to one side of the piston. The other side drains through port SB.
To close the vanes (unload compressor), valve SB is de-energized and valve SA is energized to move the piston
and vanes toward the unload position.
When both solenoid valves SA and SB are de-energized, full oil pressure is directed to both sides of the piston
through ports SA and SB, and the vanes are held in that position. Refer to Figure 26 and Figure 27 for solenoid
action. Note that both solenoids cannot be energized simultaneously.
Vane Speed Metering Valves
The speed at which the capacity control vanes are opened or closed can be adjusted to suit system operating
requirements. Adjustable needle valves in the oil drain lines are used to control the rate of bleed-off and
consequently the “vane speed”. These needle valves are part of the 4-way solenoid valve assembly located in the
compressor lube box (Figure 25).
The valves are normally factory set so that the vanes will move from fully closed to fully opened in the time
periods shown in Table 15 on page 40.
Figure 24, Needle Valve Location

The speed must be slow enough to prevent over-controlling
and hunting. The left adjusting screw is the SB needle
valve for adjusting the vane OPENING speed for loading
the compressor. Turn this screw clockwise to decrease the
vane opening speed and counterclockwise to increase the
opening speed.
The right adjusting screw is the SA needle valve for
adjusting the CLOSING speed to unload the compressor.
The same adjustment method applies; clockwise to
decrease closing, counterclockwise to increase vane
closing. These adjustments are sensitive. Turn the adjusting
screws a few degrees at a time. The vane speed is factory
set and varies by compressor size.
The start-up technician may readjust the vane
speed at initial start-up to meet job conditions.
Open (Load) Close (Unload)

Table 15, Vane Speed Factory Setting
Compressor Model Opening Time Closing Time
CE063 - CE100 3 - 5 min. 1 - 2 min
CE126 5 - 8 min. 1 - 2 min.

Figure 25, Oil Sump and Compressor Controller Panel
Back Seat Port
Oil Pump
Relief Valve Contactor
Oil Pump
Oil Sump Capacitor
Compressor
MicroTech II
Solenoid controller
Valve
Cooling
Water Inlet
Temperature
Control Valve Cooling
Water Outlet
NOTE: 4-way solenoid valve and vane close switches are located on the compressor
suction inlet. The mechanical high-pressure cutout is located in the discharge line.
Figure 26, Vane Control Solenoid Operation
LEGEND
HOLDING
Oil Under Pressure
Compressor Floating Piston Linked to Inlet Vanes

Unloader
Opens Vanes
Cylinder
Closes Vanes
Four-Way Solenoid Piston Drain

Valve Located on To Oil
Compressor or #3 Outlet Pump Sump
in Lube Box
SB Section “SB”
De-energized
Section “SA”
SA
De-energized
Adjustable Needle Valves
#1 Inlet
Integral With Four-Way
From Oil
Solenoid Valve
Pump Discharge

Figure 27, Vane Control Solenoid Operation, Continued
LEGEND
OPENING Oil Under Pressure

Oil Sump Pressure
To Oil
#3 Outlet Pump Sump
Drain From Piston
SB Section “SB”
Energized
Section “SA”
SA
De-energized
#1 Intlet
From Oil
Pump Discharge
CLOSING
Piston Drain
To Oil
Pump Sump
#3 Outlet
SB Section “SB”
De-energized
Section “SA”
SA
Energized
Drain From Piston #1 Intlet
From Oil
Pump Discharge
Surge and Stall

Stall and surge are a characteristic of all centrifugal compressors. These conditions occur when low load combines
with high compressor lift. In a stall, discharge gas has insufficient velocity leaving the impeller to reach the volute
and just “sits” or stalls in the diffuser section. The compressor sound level goes way down due to no flow and the
impeller starts to heat up. In surge, the heated discharge gas alternately flows back through the impeller and then
reverses to the volute about every two seconds. Extreme noise and vibration occur. The compressor is equipped
with a temperature sensor that shuts it off if these conditions occur.
Lubrication System
The lubrication system provides lubrication and heat removal for compressor bearings and internal parts. In
addition, the system provides lubricant under pressure to hydraulically operate the unloading piston for
positioning the inlet guide vanes for capacity control. WDC, dual compressor chillers, have completely
independent lubrication systems for each compressor.
Only the recommended lubricant, as shown in Table 16, can be used for proper operation of the hydraulic system
and bearing lubrication system. Each unit is factory-charged with the correct amount of the recommended
lubricant. Under normal operation, no additional lubricant is needed. Lubricant must be visible in the sump sight
glass at all times.
Compressor sizes, CE063 through CE126, utilize a separate lubricant pump located in the sump. The sump
includes the pump, motor, heater and lubricant/vapor separator system. The lubricant is pumped through the
external oil cooler and then to the oil filter located inside the compressor housing. WSC/WDC/WCC 063-126
units, single or dual compressor, all utilize a water-cooled oil cooler for each compressor.
The oil coolers maintain the proper oil temperature under normal operating conditions. The coolant flow control
valve maintains 95°F to 105°F (35°C to 41°C). Lubrication protection for coast down in the event of a power
failure is accomplished by a spring-loaded piston in models CE063 through 100. When the oil pump is started, the

piston is forced back against the spring by the oil pressure, compressing the spring, and filling the piston cavity
with oil. When the pump stops, the spring pressure on the piston forces the oil back out to the bearings.
In model CE126 the compressor coast down lubrication is supplied from a gravity feed oil reservoir.
A typical flow diagram is shown in Figure 28.
Table 16, Approved Polyolester Oils For R-134a Units
Compressor Models CE063 - 126
Mobil Artic EAL 46;
Lubricant Designation
ICI Emkarate RL32H(2)
McQuay Part Number
55 Gal. Drum 735030432, Rev 47
5 Gal. Drum 735030433, Rev 47
1 Gal. Can 735030435, Rev 47
Compressor Oil Label 070200106, Rev OB
NOTES:
1. Approved oil from two suppliers can be mixed, although they have slightly different viscosity.
2. Lubricant from either supplier can be furnished when ordering by McQuay part number.
Figure 28, Typical Oil Flow Diagram
NOTES:
1. Connections are not necessarily in correct relative location.
2. R = relief valve, P = pressure sensor, T = temperature sensor, S = solenoid valve
Hot Gas Bypass

All units can be equipped with an optional hot gas bypass system that feeds discharge gas directly into the
evaporator when the system load falls below 10% compressor capacity.
Light load conditions are signaled by measurement of the percentage of RLA amps by the MicroTech II
controller. When the RLA drops to the setpoint, the hot gas bypass solenoid valve is energized, making hot gas
bypass available for metering by the hot gas regulating valve. This hot gas provides a stable refrigerant flow and
keeps the chiller from short cycling under light load conditions. It also reduces surge potential on heat recovery
units.
The factory setpoint for bringing on hot gas bypass is 40% of RLA.
Condenser Water Temperature
When the ambient wet bulb temperature is lower than design, the entering condenser water temperature can be
allowed to fall, improving chiller performance.
McQuay chillers will start with entering condenser water temperature as low as 55F (42.8C) providing the
chilled water temperature is below the condenser water temperature.
The minimum operating entering condenser water temperature is a function of the leaving chilled water
temperature and load.
Even with tower fan control, some form of water flow control such as tower bypass must be used.

Maintenance
Pressure/Temperature Chart
HFC-134a Temperature Pressure Chart
°F PSIG °F PSIG °F PSIG °F PSIG
6 9.7 46 41.1 86 97.0 126 187.3

8 10.8 48 43.2 88 100.6 128 192.9
10 12.0 50 45.4 90 104.3 130 198.7
12 13.2 52 47.7 92 108.1 132 204.5
14 14.4 54 50.0 94 112.0 134 210.5
16 15.7 56 52.4 96 115.9 136 216.6
18 17.1 58 54.9 98 120.0 138 222.8
20 18.4 60 57.4 100 124.1 140 229.2
22 19.9 62 60.0 102 128.4 142 235.6
24 21.3 64 62.7 104 132.7 144 242.2
26 22.9 66 65.4 106 137.2 146 249.0
28 24.5 68 68.2 108 141.7 148 255.8
30 26.1 70 71.1 110 146.3 150 262.8
32 27.8 72 74.0 112 151.1 152 270.0
34 29.5 74 77.1 114 155.9 154 277.3
36 31.3 76 80.2 116 160.9 156 284.7
38 33.1 78 83.4 118 166.0 158 292.2
40 35.0 80 86.7 120 171.1 160 299.9
42 37.0 82 90.0 122 176.4 162 307.8
44 39.0 84 93.5 124 181.8 164 315.8
Routine Maintenance
Lubrication
CAUTION
Improper servicing of the lubrication system, including the addition of excessive or incorrect oil, substitute quality oil filter,
or any mishandling can damage the equipment. Only authorized and trained service personnel should attempt this
service. For qualified assistance, contact your local McQuay service location.
After the system is once placed into operation, no other additional oil is required except in the event that repair
work becomes necessary to the oil pump, or unless a large amount of oil is lost from the system due to a leak.
If oil must be added with the system under pressure, use a hand pump with its discharge line connected to the
backseat port of the valve in the lubricant drain from the compressor to the sump. See Figure 25 on page 41. The
POE oils used with R-134a are hygoscopic and care must be exercised to avoid exposure to moisture (air).
The condition of compressor oil can be an indication of the general condition of the refrigerant circuit and
compressor wear. An annual oil check by a qualified laboratory is essential for maintaining a high level of
maintenance. It is useful to have an oil analysis at initial startup to provide a benchmark from which to compare
future tests. The local McQuay service office can recommend suitable facilities for performing these tests.
Table 17 gives the upper limits for metals and moisture in the polyolester lubricants required by McQuay chillers.

Table 17, Metal and Moisture Limits
Element Upper Limit (PPM) Action
Aluminum 50 1
Copper 100 1
Iron 100 1
Moisture 400 2
Silica 50 1
Total Acid Number (TAN) 0.19 3
Key to Action
1) Re-sample after 500 hours of unit operation.
a) If content increases less than 10%, change oil and oil filter and re-sample at normal interval (usually
annual).
b) If content increases between 11% and 24%, change oil and oil filter and re-sample after an additional
500 hours of operation.
c) If content increases more than 25%, inspect compressor for cause.
2) Re-sample after 500 hours of unit operation.
a) If content increases less than 10%, change filter-drier and re-sample at normal interval (usually
annual).
b) If content increases between 11% and 24%, change filter-drier and re-sample after an additional 500
hours of operation.
c) If content increases more than 25%, monitor for a water leak.
3) If TAN is less than 0.10, system is safe as far as acid is concerned.
a) For TAN between 0.10 and 0.19, re-sample after 1000 hours of operation.
b) For TAN above 0.19, change oil, oil filter, and filter-drier and resample at normal interval
Changing Oil Filters

McQuay chillers are at positive pressure at all times and do not leak contaminated moist air into the refrigerant
circuit, thereby eliminating the need for annual oil changes. An annual laboratory oil check is recommended to
check overall compressor condition.
The oil filter can be changed by simply isolating the filter cavities. Close the oil discharge line service valve at the
oil pump (at the filter on CE126). Remove the filter cover; some foaming can occur but the check valve should
limit leakage from other compressor cavities. Remove the filter, replace with new element, and replace filter cover
using a new gasket. Reopen the valve in the pump discharge line and purge air from the oil filter cavity.
When machine is operated again, the oil level must be checked to determine if oil needs to be added to maintain
the proper operating level.
Refrigerant Cycle
Maintenance of the refrigerant cycle includes maintaining a log of the operating conditions, and checking that the
unit has the proper oil and refrigerant charge.
At every inspection, the oil, suction, and discharge pressures should be noted and recorded, as well as condenser
and chiller water temperatures.
The suction line temperature at the compressor should be taken at least once a month. Subtracting the saturated
temperature equivalent of the suction pressure from this will give the suction superheat. Extreme changes in
subcooling and/or superheat over a period of time will indicate losses of refrigerant or possible deterioration or
malfunction of the expansion valves. Proper superheat setting is 0 to 1 degree F (0.5 degree C) at full load. Such a
small temperature difference can be difficult to measure accurately. Another method is to measure the compressor
discharge superheat, the difference between the actual discharge temperature and the saturated discharge
temperature. The discharge superheat should be between 14 and 16 degrees F (8 to 9 degrees C) at full load. The
liquid injection must be deactivated (by closing the valve in the feed line) when taking the discharge temperature.
The superheat will increase linearly to 55 degrees F (30 degrees C) at 10% load. The MicroTech II interface panel
can display all superheat and subcooling temperatures.

Figure 8. Typical Refrigerant Flow Diagram
1. Connections are not necessarily in correct relative location.

2. Filter is for burnout protection of the refrigerant.

Electrical System
Maintenance of the electrical system involves the general requirement of keeping contacts clean and
connections tight and checking on specific items as follows:
1. The compressor current draw should be checked and compared to nameplate RLA value. Normally, the
actual current will be lower, since the nameplate rating represents full load operation. Also check all
pump and fan motor amperages, and compare with nameplate ratings.
2. Inspection must verify that the oil heaters are operative. The heaters are insert-cartridge type and can be
checked by ammeter reading. They should be energized whenever power is available to the control
circuit, when the oil temperature sensor calls for heat, and when the compressor is inoperative. When the
compressor runs, the heaters are de-energized. The Digital Output screen and second View screen on the
operator interface panel both indicate when the heaters are energized.
3. At least once a quarter, all equipment protection controls except compressor overloads should be made to
operate and their operating points checked. A control can shift its operating point as it ages, and this must
be detected so the controls can be adjusted or replaced. Pump interlocks and flow switches should be
checked to be sure they interrupt the control circuit when tripped.
4. The contactors in the motor starter should be inspected and cleaned quarterly. Tighten all terminal
connections.
5. The compressor motor resistance to ground should be checked and logged semi-annually. This log will
track insulation deterioration. A reading of 50 megohms or less indicates a possible insulation defect or
moisture and must be further checked.
CAUTION
Never Megger a motor while in a vacuum. Severe motor damage can result.
6. The centrifugal compressor must rotate in the direction indicated by the arrow on the rear motor cover
plate, near the rotation sight glass. If the operator has any reason to suspect that the power system
connections have been altered, (phases reversed) the compressor must be jogged to check rotation. For
assistance, call the local McQuay service location.
Cleaning and Preserving

A common cause of service calls and equipment malfunction is dirt. This can be prevented with normal
maintenance. The system components most subject to dirt are:
1. Permanent or cleanable filters in the air handling equipment must be cleaned in accordance with the
manufacturer’s instructions; throwaway filters should be replaced. The frequency of this service will vary
with each installation.
2. Remove and clean strainers in chilled water system, oil cooler line and condenser water system at every
inspection.
3. Inspect the condenser tubes annually for fouling and clean if required. The dished water heads (aka end-
bells, water boxes) should be removed with care due to their weight. One method follows:
 After draining water, remove all but four head bolts at roughly 10 and 2 o’clock and 4 and 8 o’clock.
 Loosen the remaining four bolts to enable the head to be separated from the tube sheet sufficiently for
a clevis pin or hook to be inserted into an open bolt hole at the top of the head.
 Attach a hoist to the pin or hook, lift the head to remove weight from the remaining bolts, remove the
bolts and carefully remove the head.
 Do not try to install an eyebolt with machine threads into the head vent fitting, which has pipe threads.
 Reverse this procedure to mount the head, using a new gasket.

Annual Shutdown
Seasonal Servicing
Prior to shutdown periods and before starting up again, the following service procedures must be completed.
Where the chiller can be subject to freezing temperatures, the condenser and chiller must be drained of all water.
Dry air blown through the condenser will aid in forcing all water out. Removal of condenser heads is also
recommended. The condenser and evaporator are not self-draining and tubes must be blown out. Water permitted
to remain in the piping and vessels can rupture these parts if subjected to freezing temperature.
Forced circulation of antifreeze through the water circuits is one method of avoiding freeze up.
1. Take measures to prevent the shutoff valve in the water supply line from being accidentally turned on.
2. If a cooling tower is used, and if the water pump will be exposed to freezing temperatures, be sure to
remove the pump drain plug and leave it out so any water that can accumulate will drain away.
3. Open the compressor disconnect switch, and remove the fuses. If the transformer is used for control
voltage, the disconnect must remain on to provide power to the oil heater. Set the manual UNIT
ON/OFF switch in the Unit Control Panel to the OFF position.
4. Check for corrosion and clean and paint rusted surfaces.
5. Clean and flush water tower for all units operating on a water tower. Make sure tower blowdown or bleed-
off is operating. Set up and use a good maintenance program to prevent “liming up” of both tower and
condenser. It should be recognized that atmospheric air contains many contaminants that increase the need
for proper water treatment. The use of untreated water can result in corrosion, erosion, sliming, scaling or
algae formation. It is recommended that the service of a reliable water treatment company be used.
McQuay International assumes no responsibility for the results of untreated or improperly treated water.
6. Remove condenser heads at least once a year to inspect the condenser tubes and clean if required.
Annual Startup
A dangerous condition can exist if power is applied to a faulty compressor motor starter that has been burned
out. This condition can exist without the knowledge of the person starting the equipment.
This is a good time to check all the motor winding resistance to ground. Semi-annual checking and recording
of this resistance will provide a record of any deterioration of the winding insulation. All new units have well
over 100 megohms resistance between any motor terminal and ground.
Whenever great discrepancies in readings occur, or uniform readings of less than 50 megohms are obtained, the
motor cover must be removed for inspection of the winding prior to starting the unit. Uniform readings of less
than 5 megohms indicate motor failure is imminent and the motor should be replaced or repaired. Repair before
failure occurs can save a great deal of time and labor spent in the cleanup of a system after a motor burnout.
1. The control circuit must be energized at all times, except during service. If the control circuit has been off
and oil is cool, energize oil heaters and allow 24 hours for heater to remove refrigerant from the oil before
starting.
2. Check and tighten all electrical connections.
3. Replace the drain plug in the cooling tower pump if it was removed at shutdown time the previous season.
4. Install fuses in main disconnect switch (if removed).
5. Reconnect water lines and turn on supply water. Flush condenser and check for leaks.
6. Refer to Manual OM CentrifMicro II before energizing the compressor circuit.

Repair of System
Pressure Relief Valve Replacement
Current condenser designs use two relief valves separated by a three-way shutoff valve (one set). This three-way
valve allows either relief valve to be shut off, but at no time can both be shut off. In the event one of the relief
valves are leaking in the two valve set, these procedures must be followed:
 If the valve closest to the valve stem is leaking, back seat the three-way valve all the way, closing the port
to the leaking pressure relief valve. Remove and replace the faulty relief valve. The three-way shutoff
valve must remain either fully back seated or fully forward to normal operation. If the relief valve farthest
from the valve stem is leaking, front seat the three-way valve and replace the relief valve as stated above.
 The refrigerant must be pumped down into the condenser before the evaporator relief valve can be
removed.
Pumping Down
If it becomes necessary to pump the system down, extreme care must be used to avoid damage to the evaporator
from freezing. Always make sure that full water flow is maintained through the chiller and condenser while
pumping down. To pump the system down, close all liquid line valves. With all liquid line valves closed and water
flowing, start the compressor. Set the MicroTech II control to the manual load. The vanes must be open while
pumping down to avoid a surge or other damaging condition. Pump the unit down until the MicroTech II
controller cuts out at approximately 20 psig. It is possible that the unit might experience a mild surge condition
prior to cutout. If this should occur, immediately shut off the compressor. Use a portable condensing unit to
complete the pump down, condense the refrigerant, and pump it into the condenser or pumpout vessel using
approved procedures.
A pressure regulating valve must always be used on the drum being used to build the system pressure. Also, do not
exceed the test pressure given above. When the test pressure is reached disconnect the gas cylinder.
Pressure Testing
No pressure testing is necessary unless some damage was incurred during shipment. Damage can be determined
upon a visual inspection of the exterior piping, checking that no breakage occurred or fittings loosened. Service
gauges should show a positive pressure. If no pressure is evident on the gauges, a leak may have occurred,
discharging the entire refrigerant charge. In this case, the unit must be leak tested to determine the location of the
leak.
Leak Testing
In the case of loss of the entire refrigerant charge, the unit must be checked for leaks prior to charging the
complete system. This can be done by charging enough refrigerant into the system to build the pressure up to
approximately 10 psig (69 kPa) and adding sufficient dry nitrogen to bring the pressure up to a maximum of 125
psig (860 kPa). Leak test with an electronic leak detector. Halide leak detectors do not function with R-134a.
Water flow through the vessels must be maintained anytime refrigerant is added or removed from the system.
WARNING
Do not use oxygen or a mixture of R-22 and air to build up pressure as an explosion can occur causing
serious personal injury.
If any leaks are found in welded or brazed joints, or it is necessary to replace a gasket, relieve the test pressure in
the system before proceeding. Brazing is required for copper joints.
After making any necessary repair, the system must be evacuated as described in the following section.
Evacuation
After it has been determined that there are no refrigerant leaks, the system must be evacuated using a vacuum
pump with a capacity that will reduce the vacuum to at least 1000 microns of mercury.
A mercury manometer, or an electronic or other type of micron gauge, must be connected at the farthest point
from the vacuum pump. For readings below 1000 microns, an electronic or other micron gauge must be used.

The triple evacuation method is recommended and is particularly helpful if the vacuum pump is unable to obtain
the desired 1 millimeter of vacuum. The system is first evacuated to approximately 29 inches of mercury. Dry
nitrogen is then added to the system to bring the pressure up to zero pounds.
Then the system is once again evacuated to approximately 29 inches of mercury. This is repeated three times. The
first pulldown will remove about 90% of the noncondensables, the second about 90% of that remaining from the
first pulldown and, after the third, only 1/10-1% noncondensables will remain.
Charging the System

WSC and WDC water chillers are leak tested at the factory and shipped with the correct charge of refrigerant as
indicated on the unit nameplate. In the event the refrigerant charge was lost due to shipping damage, the system
should be charged as follows after first repairing the leaks and evacuating the system.
1. Connect the refrigerant drum to the gauge port on the liquid line shutoff valve and purge the charging line
between the refrigerant cylinder and the valve. Then open the valve to the mid-position.
2. Turn on both the cooling tower water pump and chilled water pump and allow water to circulate through the
condenser and the chiller. (It will be necessary to manually close the condenser pump starter.)
3. If the system is under a vacuum, stand the refrigerant drum with the connection up, and open the drum and
break the vacuum with refrigerant gas to a saturated pressure above freezing.
4. With a system gas pressure higher than the equivalent of a freezing temperature, invert the charging cylinder
and elevate the drum above the condenser. With the drum in this position, valves open, water pumps
operating, liquid refrigerant will flow into the condenser. Approximately 75% of the total requirement
estimated for the unit can be charged in this manner.
5. After 75% of the required charge has entered the condenser, reconnect the refrigerant drum and charging
line to the service valve on the bottom of the evaporator. Again purge the connecting line, stand the drum
with the connection up, and place the service valve in the open position.
IMPORTANT: At this point, the charging procedure should be interrupted and prestart checks made
before attempting to complete refrigerant charge. The compressor must not be started at this time.
(Preliminary check must first be completed.)
NOTE: It is of utmost importance that all local, national, and international regulations concerning the
handling and emission of refrigerants are observed.
Oil Analysis
Interpreting Oil Analysis Data
Oil wear metals analysis has long been recognized as a useful tool for indicating the internal condition of rotating
machinery and continues to be a preferred method for McQuay centrifugal chillers. McQuay Service or a number
of laboratories specializing in oil testing can do the test. To accurately estimate the internal condition it is essential
to properly interpret the oil wear test results.
Numerous test results from various testing laboratories have recommended action that has prompted unnecessary
concern by customers. Polyolester oils are excellent solvents and can readily dissolve trace elements and
contaminants. Most of these elements and contaminates eventually end up in the oil. Also, the polyolester oils
used in R-134a chillers are more hygroscopic than mineral oils and can contain much more water in solution. For
this reason, it is imperative that extra care be used when handling polyolester oils to minimize their exposure to
ambient air. Extra care must also be used when sampling to ensure that sample containers are clean, moisture-free
leak proof and non-permeable.
McQuay International has done extensive testing in conjunction with refrigerant and lubricating oil manufacturers
and has established guidelines to determine action levels and the type of action required. Table 1 indicates these
parameters.
In general McQuay International does not recommend changing lubricating oils and filters on a periodic basis.
The need to change lubricating oil and filters should be based on a careful consideration of oil analysis, vibration
analysis and knowledge of the operating history of the equipment. A single oil sample is not sufficient to estimate
the condition of the chiller. Oil analysis is only useful if employed to establish wear trends over time. Changing
lubricating oil and filter prior to when its needed will reduce the effectiveness of oil analysis as a tool in
determining machinery condition.
The following metallic elements or contaminates and their possible sources will typically be identified in an oil
wear analysis.
Aluminum
Typical sources of aluminum are bearings, impellers, seals or casting material. An increase in aluminum content
in the lubricating oil may be an indication of bearing, impeller or other wear. A corresponding increase in other
wear metals may also accompany an increase in aluminum content.
Copper
The source of copper can be the evaporator or condenser tubes, copper tubing used in the lubrication and motor
cooling systems or residual copper from the manufacturing process. The presence of copper may be accompanied
by a high TAN (total acid number) and high moisture content. High copper contents may also result from residual
mineral oil in machines which have been converted to R-134a. Some mineral oils contained wear inhibitors which
react with copper and result in high copper content in lubricating oil.
Iron
Iron in the lubricating oil can originate from compressor castings, oil pump components, shells, tube sheets, tube
supports, shaft material and rolling element bearings. High iron content may also result from residual mineral oil
in machines which have been converted to R-134a. Some mineral oils contain wear inhibitors which react with
iron and can result in a high iron content in the lubricating oil.
Tin
The source of tin may be from bearings.
Zinc
There is no zinc used in the bearings on McQuay chillers. The source, if any may be from additives in some
mineral oils.
Lead
The source of lead in McQuay centrifugal chillers is the thread sealant compounds used during chiller assembly.
The presence of lead in the lubricating oil in McQuay chillers does not indicate bearing wear.
Silicon
Silicon can originate from residual particles of silicon left from the manufacturing process, filter drier material,
dirt or anti-foam additives from residual mineral oil which may be present in machines that have been converted
to R-134a.
Moisture
Moisture in the form of dissolved water can be present in lubricating oil to varying degrees. Some polyolester oils
may contain up to 50 parts per million (ppm) of water from new unopened containers. Other sources of water may
be the refrigerant (new refrigerant may contain up to 10 ppm water), leaking evaporator condenser tubes or oil
coolers, or moisture introduced by the addition of either contaminated oil or refrigerant or improperly handled oil.
Liquid R-134a has the ability to retain up to 1400 ppm of water in solution at 100 degrees F. With 225 ppm of
water dissolved in liquid R-134a, free water would not be released until the liquid temperature reached -22
degrees F. Liquid R-134a can hold approximately 470 ppm at 15 degrees F (an evaporator temperature which
could be encountered in ice applications). Since free water is what causes acid production, moisture levels should
not be of a concern until they approach the free water release point.

A better indicator of a condition which should be of concern is the TAN (Total Acid Number). A TAN below
0.09 requires no immediate action. TANs above 0.09 require certain actions. In the absence of a high TAN
reading and a regular loss of refrigerant oil (which may indicate a heat transfer surface leak) a high moisture
content in an oil wear analysis is probably due to handling or contamination of the oil sample. It should be noted
that air (and moisture) can penetrate plastic containers. Metal or glass containers with gasket in the top will slow
moisture entry.
In conclusion, a single element of an oil analysis should not be used as the basis to estimate the overall internal
condition of a McQuay chiller. The characteristics of the lubricants and refrigerants, and knowledge of the
interaction of wear materials in the chiller must be considered when interpreting a wear metal analysis.
Periodic oil analysis performed by a reputable laboratory and used in conjunction with compressor vibration
analysis and operating log review can be helpful tools in estimating the internal condition of a McQuay chiller.
Normal Sample Intervals
McQuay International recommends that an oil analysis be performed annually. Professional judgment must be
exercised under unusual circumstances, for example, it might be desirable to sample the lubricating oil shortly
after a unit has been placed back into operation after it has been opened for service, as recommended from
previous sample results or after a failure. The presence of residual materials from a failure should be taken into
consideration in subsequent analysis. While the unit is in operation, the sample should be taken from a stream
of refrigerant oil, not in a low spot / quiet area.
Table 18, Upper Limit For Wear Metals And Moisture In Polyolester Oils In McQuay Centrifugal
Chillers
Elements Upper Limit (ppm) Action
Aluminum 50 1
Copper 100 1
Iron 100 1
Moisture 150 2 &3
Silica 50 1
Total Acid Number (TAN) .19 3
Key To Action
1. Re-sample after 500 hours of unit operation. If content increases less than 10%, change oil and filter and
re-sample at normal interval. If content increases 25% or more, inspect compressor.
2. Re-sample after 500 hours of unit operation. If content increases less than 10%, change filter drier and re-
sample at normal interval. If content increases 25% or more, monitor for water leak. Since POE lubricants
are hygroscopic, many times the high moisture level is due to inadequate handling and packaging. The
TAN reading MUST BE USED in conjunction with moisture readings
3. For TAN between .10 and .19, re-sample after 1000 hours of unit operation. If TAN increases above .19,
change oil, oil filter and filter drier and re-sample at normal interval.

Maintenance Schedule
Quarterly
As Req’d
Annually
Monthly
Weekly
Daily
5-Yr
Maintenance Check List Item
I. Unit
· Operational Log O
· Analyze Operational Log O
· Refrigerant Leak Test Chiller O
· Test Relief Valves or Replace X
II. Compressor
· Vibration Test Compressor X
A. Motor
· Meg. Windings (Note 1) X
· Ampere Balance (within 10% at RLA) O
· Terminal Check (Infrared temperature measurement) X
· Motor Cooling Filter Drier Pressure Drop X
B. Lubrication System
· Clean Oil Cooler Strainer (water) X
· Oil Cooler Solenoid Operation O
· Oil Appearance (clear color, quantity) O
- Oil Filter Pressure Drop O
· Oil Analysis (Note 5) X
· Oil change if indicated by oil analysis X
III. Controls
A. Operating Controls
· Calibrate Temperature Transducers X
· Calibrate Pressure Transducers X
· Check Vane Control Setting and Operation X
· Verify Motor Load Limit Control X
· Verify Load Balance Operation X
· Check Oil Pump Contactor X
B. Protective Controls
· Test Operation of:
Alarm Relay X
Pump Interlocks X
Guardistor and Surgeguard Operation X
High and Low Pressure Cutouts X
Oil Pump Pressure Differential Cutout X
Oil Pump Time Delay X
Continued on next page.

Maintenance Schedule, Cont.
Quarterly
As Req’d
Annually
Monthly
Weekly
Daily
5-Yr
Maintenance Check List Item
IV. Condenser
A. Evaluation of Temp Approach (NOTE 2) O
B. Test Water Quality V
C. Clean Condenser Tubes (NOTE 2) X X
D. Eddy current Test - Tube Wall Thickness V
E. Seasonal Protection X
V. Evaporator
A. Evaluation of Temp Approach (NOTE 2) O
B. Test Water Quality V
C. Clean Evaporator Tubes (NOTE 3) X
D. Eddy current Test - Tube Wall thickness V X
E. Seasonal Protection X
VI. Expansion Valves
A. Operational Evaluation (Superheat Control) X
VII. Starter(s)
A. Examine Contactors (hardware and operation) X
B. Verify Overload Setting and Trip X
C. Test Electrical Connections (Infrared temp measurement) X
VIII. Optional Controls
A. Hot Gas Bypass (verify operation) X
KEY:
O = Performed by in-house personnel.
X = Performed by McQuay authorized service personnel. (NOTE 4)
V = Normally performed by third parties.
NOTES:
1. Some compressors use power factory correction capacitors and all have a surge capacitor (excepting units with solid state
starters). The surge capacitor can be installed out of sight in the compressor motor terminal box. In all cases, capacitors
must be disconnected from the circuit to obtain a useful Megger reading. Failure to do so will produce a low reading. In
handling electrical components, only fully qualified technicians must attempt service.
2. Approach temperature (the difference between the leaving water temperature and the saturated refrigerant temperature)
of either the condenser or evaporator is a good indication of tube fouling, particularly in the condenser, where constant
flow usually prevails. McQuay's high efficiency heat exchangers have very low design approach temperatures, in the
order of one to one and one half degrees F.
The chiller unit controller can display the water and the saturated refrigerant temperatures. Simple subtraction will give
the approach. It is recommended that benchmark readings (including condenser pressure drop to confirm future flow
rates) be taken during startup and then periodically afterward. An approach increase of two-degrees or more would
indicate that excessive tube fouling could be present. Higher than normal discharge pressure and motor current are also
good indicators
3. Evaporators in closed fluid circuits with treated water or anti-freeze are not normally subject to fouling, hover it is
prudent to check the approach periodically. Some evaporators may have a mixture of ¾-inch and 1-inch tubes.
4. Performed when contracted for, not part of standard initial warranty service.
5. Oil filter change and compressor teardown and inspection should be done based on the results of the annual oil test
performed by a company specializing in this type of test. Consult McQuay Factory Service for recommendations.

Long Term Storage
This information applies to new units being stored waiting for startup or to existing units that may be
inoperative for a long period.
The chiller must be stored indoors and protected from any damage or corrosion. A McQuay service
representative must perform an inspection and leak test of unit on minimum quarterly schedule, to be paid by
the owner or contractor. McQuay will not be responsible for any refrigerant loss during the storage time or
repairs to unit during period of storage, or while moving the unit from original location to storage facility
and back to new installation location.
The following tasks must be performed:
1. As discussed above, the first and foremost task is to leak test the unit when it is in its final resting place.
If any leaks exist, repair them immediately. After the unit is stored, perform a periodic leak test.
2. It is possible that the unit could be bumped, hit or otherwise damaged while in storage; so in addition to
leak testing, a visual overall inspection should be done.
3. If there is concern about the possibilities of damage and loss of charge during storage, the customer can
pay to have the charge removed and stored in recovery cylinders. If this is done, pressurize it to about 20
psi with nitrogen .Monitor and maintain the pressure. Install a pressure gauge that can easily be read or
tie in a remotely alarm that can be monitored if pressure reduces. This is desirable if the unit is stored
with refrigerant or with a nitrogen holding charge.
4. If the unit has been shipped and not yet installed, keep it pumped down (as shipped from the factory) and
close all refrigerant valves.
5. Keep oil sump valves closed to avoid refrigerant migration to the oil sump. Over a long term, the
refrigerant will migrate to the oil tank and displace the oil. The oil will spill over in to the evap. through
the vent line and when the unit is powered up and the heaters turned on, the refrigerant will boil out and
the sump will be empty.
6. Clean and dry the unit and look for any chipped paint. Touch up as required to prevent rust.
7. If the storage area is subject to a high humidity, consider a shrink wrap or water resistant covering of
some sort. Desiccants must be placed inside electrical panels and starters (mounted or shipped loose) and
be renewed as recommended by manufacturer.
8. The operator touchscreen monitor, which is shipped loose, should be secured in a dry area. They are
subject to pilferage.
9. Regardless of the temperature of the storage area, make sure all vessel tubes are drained and blown dry
to prevent the minerals in the standing water, plus oxygen present, causing tube pitting. This includes the
oil cooler and water piping.
10. Restart by McQuay service technicians will be required and paid to McQuay by the owner or contractor.
It is prudent to take photos when the unit is stored to show that the conditions of storage have been met.
Also document all inspection reports and abnormal conditions found. If the unit has been in operation,
the run-time hours and number of starts must be documented prior to storage, along with the date the
unit taken was out of operation. The extended warranty coverage can be suspended during the storage
period-not to exceed 30 months. The remaining warranty time will restart once unit is reinstalled and
officially re-commissioned by McQuay.

Service Programs
It is important that an air conditioning system receive adequate maintenance if the full equipment life and full
system benefits are to be realized.
Maintenance should be an ongoing program from the time the system is initially started. A full inspection should
be made after 3 to 4 weeks of normal operation on a new installation, and on a regular basis thereafter.
McQuay offers a variety of maintenance services through the local McQuay service office, its worldwide service
organization, and can tailor these services to suit the needs of the building owner. Most popular among these
services is the McQuay Comprehensive Maintenance Contract.
For further information concerning the many services available, contact your local McQuay service office.
Operator Schools
Training courses for Centrifugal Maintenance and Operation are held through the year at the McQuay Training
Center in Staunton, Virginia. The school duration is three and one-half days and includes instruction on basic
refrigeration, MicroTech controllers, enhancing chiller efficiency and reliability, MicroTech troubleshooting,
system components, and other related subjects. Further information can be found on www.mcquay.com or call
McQuay at 540-248-0711 and ask for the Training Department.
Warranty Statement
Limited Warranty
All McQuay equipment is sold pursuant to McQuay’s Standard Terms and Conditions of Sale and
Limited Product Warranty. Consult your local McQuay Representative for warranty details. Refer
to form 933-430285Y. To find your local representative, go to www.mcquay.com

All McQuay equipment is sold pursuant to McQuay’s Standard Terms and Conditions of
Sale and Limited Product Warranty. Consult your local McQuay Representative for
warranty details. Refer to form 933-430285Y. To find your local representative, go to
www.mcquay.com
This document contains the most current product information as of this printing. For the most
up-to-date product information, please go to www.mcquay.com.
(800) 432-1342  www.mcquay.com

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Installation and Maintenance Manual IM 1044-2

Centrifugal Compressor Water Chillers Group: Chillers

Date: November 2011

© 2011 McQuay International

2 Centrifugal Chillers IM 1044-2

IM 1044-2 Centrifugal Chillers 3

Receiving and Handling

Figure 1, WSC Major Component Locations Operator Interface

4 Centrifugal Chillers IM 1044-2

Location and Mounting

IM 1044-2 Centrifugal Chillers 5

System Water Volume

6 Centrifugal Chillers IM 1044-2

Minimum Entering Condenser Water Temperature - 10 F Range

Min. ECWT = 5.25 + 0.88*(LWT) - DTFL*(PLD/100) + 22*(PLD/100)2

IM 1044-2 Centrifugal Chillers 7

Figure 5, Bypass, Mild Weather Operation Bypass, Cold Weather Operation

8 Centrifugal Chillers IM 1044-2

IM 1044-2 Centrifugal Chillers 9

I in. (25mm) NPT flow

10 Centrifugal Chillers IM 1044-2

IM 1044-2 Centrifugal Chillers 11

TOWER HEAT RECOVERY

12 Centrifugal Chillers IM 1044-2

IM 1044-2 Centrifugal Chillers 13

IM 1044-2 Centrifugal Chillers 15

16 Centrifugal Chillers IM 1044-2

IM 1044-2 Centrifugal Chillers 17

18 Centrifugal Chillers IM 1044-2

Table 8, WSC with Mounted VFD, Oil Cooler Data

IM 1044-2 Centrifugal Chillers 19

Figure 9, Oil Cooler Piping Across Chilled Water Pump

20 Centrifugal Chillers IM 1044-2

STOP COOLING TOWER

Figure 11, Oil Cooler Connections, WSC/HSC Units

Figure 12, Oil Cooler Connections, WDC 100/126, 16 Foot Shells

IM 1044-2 Centrifugal Chillers 21

Note: Remove plastic shipping plugs (if installed) from the

Condensers have two relief valves as a set with a three-way

Figure 13, Condenser 3-Way Valve

22 Centrifugal Chillers IM 1044-2

IM 1044-2 Centrifugal Chillers 23

Care must be taken when attaching leads to compressor terminals.

24 Centrifugal Chillers IM 1044-2

Installing Motor Terminal Box

Figure 14, Compressor Terminal Housing

Insulate this area of the compressor

IM 1044-2 Centrifugal Chillers 25

1. Insulate motor housing around terminals using thermal

3. Install the flexible buss bars. (see picture at right) using a

 Use Scotch® Linerless Rubber Splicing Tape to cover

26 Centrifugal Chillers IM 1044-2

Figure 15, Terminal Box Mounted, Front View

Line Power Entry

Insulate this area

Line Power Landing Points (3) Flexible Buss Bar (3)

Figure 16, Terminal Box Mounted, Side View

IM 1044-2 Centrifugal Chillers 27

Front Motor Temperature

Min. ECWT = 5.25 + 0.88(LWT) - DTFL(PLD/100) + 22*(PLD/100)2