Water-Cooled Scroll Compressor Chillers - Daikin...

Installation, and Maintenance Manual IMM WGZC

Group: Chiller Part Number: 331975201 Effective: October 2008 Supercedes: June 2008

Water-Cooled Scroll Compressor Chillers

WGZ 030CW to WGZ 200CW, Packaged Water-Cooled Chiller

WGZ 030CA to WGZ 200CA, Chiller with Remote Condenser

30 to 200 Tons, 105 to 700 kW 60 Hz, R-410A

2 WGZ 030C through 200C IMM WGZC

Table of Contents

Introduction ....................................... 3 Nomenclature ........................................ 3

Installation ......................................... 4 Vibration Isolators................................. 6

Water Piping .................................... 11 Flow Switch ........................................ 14 Glycol Solutions.................................. 14 Condenser Water Piping...................... 16

Pressure Drops................................. 16 Refrigerant Piping........................... 19

Unit with Remote Condenser .............. 19 Factory-Mounted Condenser............... 24

Dimensions ....................................... 25 Packaged Chillers................................ 25 Chillers with Remote Condenser......... 28

Physical Data.................................... 31 Packaged Chillers................................ 31 Chillers with Remote Condenser......... 34 Operating Limits ................................. 35 Components ........................................ 36

Wiring............................................... 37 Unit Configuration .......................... 38 Electrical Data ................................. 39

Electrical Notes ................................... 52 Field Wiring Diagram ......................... 54 Control Panel Layout .......................... 56 Motor Protection Module.................... 56

Start-Up and Shutdown.................. 57 Pre Start-up.......................................... 57 Start-up................................................ 57 Weekend or Temporary Shutdown ...... 58 Start-up after Temporary Shutdown .... 58 Extended Shutdown ............................ 58 Start-up after Extended Shutdown ...... 59

System Maintenance ....................... 60 General ................................................ 60 Electrical Terminals............................. 61 Compressor Lubrication...................... 61 Sightglass and Moisture Indicator....... 61 Crankcase Heaters ............................... 62 Optional Controls ................................ 62 Phase/Voltage Monitor (Optional) ...... 62 Hot Gas Bypass (Optional) ................. 63

Maintenance Schedule .................... 64 System Service................................. 65

Troubleshooting Chart ........................ 67 Warranty Statement ....................... 68

Manufactured in an ISO Certified facility

Cover Picture: WGZ 200C, Nominal 200 ton chiller

©2007 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; Compliant Scroll from Copeland Corporation; ElectroFin from AST ElectroFin Inc.; Modbus from Schneider Electric; FanTrol, MicroTech II, Open Choices, and SpeedTrol from McQuay International

IMM WGZC WGZ 030C through 200C 3

Introduction

General Description McQuay Type WGZ water chillers are designed for indoor installations and are available with water-cooled condensers (Model WGZ-CW), or arranged for use with remote, air-cooled or evaporative condensers (Model WGZ-CA). Each water-cooled unit is completely assembled and factory wired before evacuation, charging and testing. They consist of hermetic scroll compressors, brazed-plate evaporators on Models WGZ 030 to 130( shell-and-tube on Models WGZ 150 to 200), water-cooled condenser (WGZ-CW), and complete refrigerant piping.

Units manufactured for use with remote condensers (Models WGZ-CA) have all refrigerant specialties factory-mounted and connection points for refrigerant discharge and liquid lines.

Liquid line components that are included are manual liquid line shutoff valves, charging valves, filter-driers, liquid line solenoid valves, sight glass/moisture indicators, and thermal expansion valves.

Other features include compressor crankcase heaters, and a MicroTech II™ microprocessor controller.

The electrical control center includes all equipment protection and operating controls necessary for dependable automatic operation.

The compressors are not fused as standard, but can be protected by optional circuit breakers or fuses, or can rely on a field-installed, fused disconnect switch for protection.

Nomenclature

W G Z 100 - C W

Inspection When the equipment is received, all items should be carefully checked against the bill of lading to be sure of a complete shipment. All units must be carefully inspected for damage upon arrival. All shipping damage must be reported to the carrier and a claim must be filed with the carrier. The unit serial plate should be checked before unloading the unit to be sure that it agrees with the power supply available. Physical damage to unit after acceptance is not the responsibility of McQuay.

Note: Unit lifting weights are given in the physical data tables beginning on page 5. Corner operating weights are given on page 6

Water-Cooled

Global

Scroll Compressor Nominal Capacity (Tons)

W = Water-Cooled Condenser A = Unit Less Condenser

Design Vintage


Installation

Note: Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations, and experienced with this type of equipment.

! WARNING Avoid contact with sharp edges. Personal injury can result

Handling Every model WGZ-CW water chiller with water-cooled condensers is shipped with a full refrigerant charge. For shipment, the charge is contained in the condenser and is isolated by the condenser liquid shutoff valve and the compressor discharge valve common to a pair of compressors.

A holding charge is supplied in remote condenser models, WGZ-CA. The operating charge must be field supplied and charged.

Moving the Unit The skid option is strongly recommended for ease of handling and to help prevent damage if a crane is not available for rigging at site. Figure 1, Lifting the Unit

It is recommended that all moving and handling be performed with skids or dollies under the unit and that they not be removed until the unit is in the final location. Never put the weight of the unit against the control box.

In moving, always apply pressure to the base on the skids only and not to the piping or other components. A long bar will help move the unit easily. Avoid dropping the unit at the end of the roll.

! WARNING If the unit has been damaged, allowing the refrigerant to escape, there can be danger of suffocation in the area since the

refrigerant will displace the air. Be sure to review Environmental Protection Agency (EPA) requirements if damage occurred. Avoid exposing an open flame to the refrigerant

331926901 REV. 0A

WGZ150-200CUNIT SHOWN

SPREADER BARS MUSTBE USED FOR STABILITY

DURING LIFTING OFALL SIZE UNITS

RemovableLiftingBar

(2) 2”LiftingHoles


If the unit must be hoisted, lift the unit from the removable lifting arms factory-bolted to each end of the unit adjacent to the tube sheet by attaching cables or chains to the end of the arms. A spreader bar must be used to protect the piping, control panel and other areas of the chiller (see ). The arms should be removed and discarded after use. Do not attach slings to piping or equipment. Do not attempt to lift the unit by lifting points mounted on the compressors. They are for lifting only the compressor should one need to be removed from the unit. Move unit in the upright horizontal position at all times. Set unit down gently when lowering from the truck or rollers.

Table 1, Lifting Loads WGZ-CW Package Units (lbs.) WGZ CA Less Condenser Units (lbs) Model

WGZ-C L1 L2 L3 L4 Shipping Weight L1 L2 L3 L4 Shipping

Weight WGZ 030 606 633 599 573 2410 415 430 374 361 1580 WGZ 035 632 646 616 603 2496 442 445 392 390 1670 WGZ 040 639 659 630 611 2539 443 451 399 392 1685 WGZ 045 639 667 639 612 2558 444 460 407 393 1704 WGZ 050 655 689 664 631 2639 451 468 416 400 1735 WGZ 055 655 698 673 632 2658 451 476 425 402 1754 WGZ 060 655 712 688 633 2688 451 484 433 404 1771 WGZ 070 929 874 942 1001 3746 649 595 556 606 2406 WGZ 080 1066 927 1001 1151 4145 765 635 598 720 2717 WGZ 090 1076 849 1059 1343 4327 806 653 623 770 2851 WGZ 100 1059 781 1118 1515 4474 829 681 657 801 2968 WGZ 115 1054 802 1146 1506 4508 830 710 689 805 3035 WGZ 130 1055 828 1181 1505 4568 831 737 716 807 3091 WGZ 150 1684 1516 1602 1780 6581 1204 1142 1184 1249 4779 WGZ 175 1814 1528 1637 1943 6921 1245 1149 1198 1299 4891 WGZ200 1829 1550 1677 1979 7036 1265 1178 1235 1326 5004

See Figure 2 on the following page for location of lifting points.

Location WGZ chillers are designed for indoor application and must be located in an area where the surrounding ambient temperature is 40°F (4°C) or above. A good rule of thumb is to place units where ambient temperatures are at least 5°F (3°C) above the leaving water temperature. Because of the electrical control devices, the units should not be exposed to the weather. A plastic cover over the control box is supplied as temporary protection during shipment. A reasonably level and sufficiently strong floor is required for the water chiller. If necessary, additional structural members should be provided to transfer the weight of the unit to the nearest beams.

Space Requirements for Connections and Servicing The chilled water and condenser water (on units with a water-cooled condenser) piping enters and leaves the unit from the right side when looking at the control panel. Left-hand condenser connections are an option. A clearance of at least 3 feet (1219 mm), or more if codes require, should be provided beyond this piping and on all other sides and ends of the unit for general servicing or for changing the compressors, if it ever becomes necessary.


Control Panel

WaterConnections

4

1

3

2

LB

LF

RB

FRF

On units equipped with a water-cooled condenser (Type WGZ-CW) clearance should also be provided for cleaning or removal of condenser tubes on one end of the unit. The clearance for cleaning depends on the type of apparatus used, but can be as much as the length of the condenser (10 feet, 3050 mm). Tube replacement requires the tube length of 10 feet (3050 mm) plus one to two feet of workspace. This space can often be provided through a doorway or other opening. Allow a minimum of 4-foot clearance in front of the control panel. Placing the Unit The small amount of vibration normally encountered with the water chiller makes this unit particularly desirable for basement or ground floor installations where the unit can be mounted directly to the floor. The floor construction should be such that the unit will not affect the building structure, or transmit noise and vibration into the structure. NOTE: Springs are Model CP1E, one spring per housing.

Vibration Isolators It is recommended that isolators be used on all upper level installations or in areas where vibration transmission is a consideration. Figure 2, Isolator Locations

Transfer the unit as indicated under “Moving the Unit.” In all cases, set the unit in place and level with a spirit level. When spring-type isolators are required, install springs running under the main unit supports.

The unit should be set initially on shims or blocks at the listed

spring free height. When all piping, wiring, flushing, charging, etc., is completed, the springs are adjusted upward to loosen the blocks or shims that are then removed. A rubber anti-skid pad should be used under isolators if hold-down bolts are not used. Installation of spring isolators requires flexible piping connections and at least three feet of flexible electrical conduit to avoid straining piping and transmitting vibration and noise.

Table 2, WGZ-CW Packaged, Mounting Weights & Vibration Mounting Location Unit Mounting Weights, Lbs

(k )Spring-Flex Mountings R-I-S Mountings

Size M1 M2 M3 M4 M1 M2 M3 M4 M1 M2 M3 M4

ID-900 ID-900 ID-900 ID-900 RP-3 RP-3 RP-3 RP-3 030 625 653 618 591 Green Green Green Green Gray Gray Gray Gray ID-900 ID-900 ID-900 ID-900 RP-3 RP-3 RP-3 RP-3

035 651 665 635 621 Green Green Green Green Gray Gray Gray Gray

ID-900 ID-900 ID-900 ID-900 RP-3 RP-3 RP-3 RP-3 040 662 683 653 633

Green Green Green Green Gray Gray Gray Gray










WGZ-CW Packaged, Mounting Weights & Vibration Mounting Location, Continued Mounting Weights, Lbs Spring-Flex Mountings R-I-S Mountings Unit

Size M1 M2 M3 M4 M1 M2 M3 M4 M1 M2 M3 M4 ID-1350 ID-1350 ID-1350 ID-1350 RP-4 RP-4 RP-4 RP-4070 964 907 978 1038 Purple Purple Purple Purple Brown Brown Brown Brown

ID-1350 ID-1350 ID-1350 ID-1350 RP-4 RP-4 RP-4 RP-4 080 1106 962 1039 1195 Purple Purple Purple Purple Brown Brown Brown Brown

ID-1800 ID-1800 ID-1800 ID-1800 RP-4 RP-4 RP-4 RP-4 090 1121 884 1103 1399 Green Green Green Green Brown Brown Brown Brown

ID-1800 ID-1800 ID-1800 ID-2400 RP-4 RP-4 RP-4 RP-4 100 1108 817 1169 1585 Green Green Green Gray Brick Red Brick Red Brick Red Brick Red



ID-2400 ID-2400 ID-2400 ID-2400 RP-4 RP-4 RP-4 RP-4 150 1886 1690 1794 1993 Gray Gray Gray Gray Brick Red Brick Red Brick Red Brick Red

ID-2400 ID-2400 ID-2400 ID-2400 RP-4 RP-4 RP-4 RP-4 170 2033 1710 1835 2178 Gray Gray Gray Gray Brick Red Brick Red Brick Red Brick Red

ID-2400 ID-2400 ID-2400 ID-2400 RP-4 RP-4 RP-4 RP-4 200 2047 1730 1877 2215 Gray Gray Gray Gray Brick Red Brick Red- Brick Red Brick Red WR

Table 3, WGZ-CA, Remote Condenser, Mounting Weights & Vibration Mounting Location Unit Mounting Weights, Lbs Spring-Flex Mountings R-I-S Mountings Size M1 M2 M3 M4 M5 M6 M1 M2 M3 M4 M5 M6 M1 M2 M3 M4 M5 M6

ID-900 ID-900 ID-510 ID-510 RP-3 RP-3 RP-3 RP-3030 476 501 322 307 N/A N/A

Green Green Black Black N/A N/A

Lime Lime Lime Lime N/A N/A



















ID-900 ID-900 ID-675 ID-900 RP3 RP3 RP3 RP3 070 738 651 509 577 N/A N/A

Green Green Purple Green N/A N/A

Gray Gray Gray Gray N/A N/A


Green Green Purple Green N/A N/A



Black Black Red Black N/A N/A





ID-1020 ID-1020 ID-680 ID-1020 RP-3 RP-3 RP-3 RP-3115 957. 764 621 778 N/A N/A







WGZ-CA, Remote Condenser, Mounting Weights & Vibration Mounting Location, Continued Unit Mounting Weights, Lbs Spring-Flex Mountings R-I-S Mountings Size M1 M2 M3 M4 M5 M6 M1 M2 M3 M4 M5 M6 M1 M2 M3 M4 M5 M6

ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4150 821 793 763 931 968 1003 Black Black Black Black Black Black Brown Brown Brown Brown Brown Brown

ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 170 863 812 750 919 986 1047 Black Black Black Black Black Black Brown Brown Brown Brown Brown Brown

ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4 200 875 831 784 947 1000 1057 Black Black Black Black Black Black Brown Brown Brown Brown Brown Brown

Table 4, WGZ-CW, Packaged, Isolator Kit Numbers Model Number ⇒ 030-060 070-080 090 100-130 150-200

Spring-Flex 332320501 332320502 332320503 332320504 332320505 R-I-S 332325501 332325502 332325502 332325503 332325503

Table 5, WGZ-CA, Remote Condenser, Isolator Kit Numbers Model Number ⇒ 030-060 070-080 090-115 130 150-200

Spring-Flex 332320506 332320507 332320508 332320509 332320510 R-I-S 332325504 332325501 332325501 332325501 332325505

Figure 3, Spring Flex Mounting. CP-2


Figure 4, Neoprene-in-Shear Mounting, RP-3

DRAWING NUMBER 3319880

2.50

1.75 (R)

.25

MOUNTING MOLDED INDURULENE. WEATHERRESISTANT (WR)

ø 3.38

4.135.50

ø .56 DIA.2 HOLES

1/2-13 TAP

LOCATING PIN TOBE INSTALLED HERE

ALL

DIMENSIONS ARE IN DECIMAL INCHES

Table 6, Spring Flex Mounting, CP-1


Table 7, Neoprene-in-Shear, RP-4

NOTES:

MOUNT MATERIAL TO BE DURULENE RUBBER.1.

MOLDED STEEL AND ELASTOMER MOUNT FOR2.OUTDOOR SERVICE CONDITIONS.

3. RP-4 MOUNT VERSION WITH STUD IN PLACE.ALL DIMENSIONS ARE IN DECIMAL INCHES

DRAWING NUMBER 3314814

1.13 ± .25APPROX.

1.63

.38

DURULENEMATERIAL

RAISED GRIP RIBS

3.003.755.00

6.25

3.87.56 TYP.

4.63

R.28TYP.

R.250 TYP.R.750 TYP.RECESSED

GRIP RIBS

ø .500-13NC-2B

R4

R4

VM

&C V

M&

C


Water Piping

Vessel Drains at Start-up Condensers are drained of water in the factory and are shipped with the condenser drain plugs in the heads removed and stored in a bag in the control panel. Be sure to replace plugs prior to filling the vessel with fluid.

General Due to the variety of piping practices, it is advisable to follow the recommendations of local authorities for code compliance. They can supply the installer with the proper building and safety codes required for a safe and proper installation.

Basically, the piping should be designed with a minimum number of bends and changes in elevation to keep system cost down and performance up. Other piping design considerations include:

1. All piping should be installed and supported to prevent the chiller connections from bearing any strain or weight of the system piping.

2. Vibration eliminators to reduce vibration and noise transmission to the building. 3. Shutoff valves to isolate the unit from the piping system during unit servicing. 4. Manual or automatic air vent valves at the high points of the system. Drains should be placed at

the lowest points in the system. 5. Some means of maintaining adequate system water pressure (e.g., expansion tank or regulating

valve). 6. Temperature and pressure indicators located within 3 feet (0.9 meters) of the inlet and outlet of

the vessels to aid in unit servicing. 7. A strainer or some means of removing foreign matter from the water before it enters the pump is

recommended. It should be placed far enough upstream to prevent cavitation at the pump inlet (consult pump manufacturer for recommendations). The use of a strainer will prolong pump life and thus maintain system performance.

Important Note A cleanable 40-mesh strainer must also be placed in the water line just prior to the inlet of the evaporator on Models WGZ 030 to 130. A 20-mesh is satisfactory on Models WGZ 150 to 200. This will aid in preventing foreign material from entering and decreasing the performance of the evaporator.

8. If the unit is used as a replacement chiller on a previously existing piping system, the system should be thoroughly flushed prior to unit installation. Regular water analysis and chemical water treatment on the evaporator and condenser is recommended immediately upon equipment start-up.

9. In the event glycol is added to the water system, as an afterthought for freeze protection, recognize that the refrigerant suction pressure will be lower, cooling performance less, and water side pressure drop will be higher. If the percentage of glycol is large, or if propylene glycol is used instead of ethylene glycol, the added pressure drop and loss of performance could be substantial. Reset the freezestat and low leaving water alarm temperatures. The freezestat is factory set to default at 36°F (2.2°C). Reset the freezestat setting to approximately 4° to 5°F (2.3° to 2.8°C) below the leaving chilled water setpoint temperature. See the section titled “Glycol Solutions” for additional information concerning the use of glycol.

10. A preliminary leak check of the water piping should be made before filling the system.


Note: A water flow switch or pressure differential switch must be mounted in the evaporator outlet water line to signal that there is water flow before the unit will start.

Table 8, Typical Field Evaporator Water Piping, WGZ 030 to 130 Air

Vent

FlowSwitch

VibrationEliminators

Drain

Outlet

Inlet

PIsolationValves

Strainer

NOTE: Water piping must be supported independently from the unit.

Figure 5, Typical Field Evaporator Water Piping, WGZ 150 to 200

Vent

Drain

GateValve

WaterStrainer

VibrationEliminatorValved

PressureGauge

In

OutProtect All Field Piping

Against Freezing

Flow

VibrationEliminator

FlowSwitch

BalancingValve

GateValve

Flow

Liquid

Suction

NOTE: Inlet and outlet connections may be reversed on some units. Check unit dimension drawing.

System Water Volume It is important to have adequate water volume in the system to provide an opportunity for the chiller to sense a load change, adjust to the change, and then stabilize. As the expected load change becomes more rapid, a greater water volume is needed. The system water volume is the total amount of water in the evaporator, air handling equipment, and associated piping. If the water volume is too low, operational problems can occur including rapid compressor cycling, rapid loading and unloading of compressors, erratic refrigerant flow in the chiller, improper motor cooling, shortened equipment life and other undesirable occurrences.

For normal comfort cooling applications where the cooling load changes relatively slowly, a minimum system volume of two to three minutes times the flow rate (GPM) is recommended. For example, if the design chiller flow rate is 120 gpm, we recommend a system volume of 240 to 360 gallons.

For process applications where the cooling load can change rapidly, additional system water volume is needed. A process example would be the quenching of hot metal objects. The load would be very stable until the hot metal is dipped into the water tank. Then, the load would increase drastically.

Since there are many other factors that can influence performance, systems can successfully operate below these suggestions. However, as the water volume decreases below these guidelines, the possibility of problems increases.


SuctionCircuit #1SuctionCircuit #2

LiquidCircuit #2LiquidCircuit #1

Leaving ChilledWater Sensor

Variable Chilled Water Flow Reducing chilled water flow in proportion to load can reduce total system power consumption. Certain restrictions apply to the amount and rate of flow change. The rate of flow change should be a maximum of 10 percent of the change, per minute. Do not reduce flow lower than the part load minimum flows listed on page 16. Chilled Water Piping The system water piping must be flushed thoroughly prior to making connections to the unit evaporator. It is required that a 40-mesh strainer be installed in the return water line before the inlet to the chiller. Lay out the water piping so the chilled water circulating pump discharges into the evaporator inlet. The return water line must be piped to the evaporator inlet connection and the supply water line must be piped to the evaporator outlet connection. If the evaporator water is piped in the reverse direction, a substantial decrease in capacity and efficiency of the unit will be experienced. A flow switch must be installed in the horizontal piping of the supply (evaporator outlet) water line to prove water flow before starting the unit. Drain connections should be provided at all low points in the system to permit complete drainage of the system. Air vents should be located at the high points in the system to purge air out of the system. The evaporators are not equipped with vent or drain connections and provision must be made in the entering and leaving chilled water piping for venting and draining. Pressure gauges should be installed in the inlet and outlet water lines to the evaporator. Pressure drop through the evaporator should be measured to determine water flow from the flow/pressure drop curves beginning on page 17. Vibration eliminators are recommended in both the supply and return water lines. Chilled water piping should be insulated to reduce heat loss and prevent condensation. Complete unit and system leak tests should be performed prior to insulating the water piping. Insulation with a vapor barrier would be the recommended type of insulation. If the vessel is insulated, the vent and drain connections must extend beyond the proposed insulation thickness for accessibility. Chillers not run in the winter should have their water systems thoroughly drained if subject to sub-freezing temperatures. If the chiller operates year-round, or if the system is not drained for the winter, the chilled water piping exposed to sub-freezing ambient temperatures should be protected against freezing by wrapping the lines with a heater cable. In addition, an adequate percentage of glycol should be added to the system to further protect the system during low ambient temperature periods. It should be noted that water piping that has been left drained is subject to more corrosion than if filled with water. Use of a Vapor Corrosion Inhibitor (VCI) or some other protection should be considered.

Figure 6 Thermostat Well Location, WGZ 030 - 130

The chilled water sensor is factory installed in the leaving water connection on the evaporator. Care should be taken not to damage the sensor cable or lead wires when working around the unit. It is also advisable to check the lead wire before running the unit to be sure that it is firmly anchored and not rubbing on the frame or any other component. If the sensor is ever removed from the well for servicing, care must be taken to not wipe off the heat-conducting compound supplied in the well.


! CAUTION The thermostat bulb should not be exposed to water temperatures above 125°F (51.7°C) since this will damage it.

Flow Switch A water flow switch must be mounted in the leaving evaporator and condenser water lines to prove adequate water flow before the unit can start. This will safeguard against slugging the compressors on start-up. It also serves to shut down the unit in the event that water flow is interrupted to guard against evaporator freeze-up. Factory-mounted and wired evaporator and condenser flow switches are available as an option If the optional factory flow switch is not supplied, a flow switch is available from McQuay under part number 01750330. It is a “paddle” type switch and adaptable to any pipe size from 1 in. (25 mm) to 6 in. (152 mm) nominal. Certain flow rates are required to open the switch and are listed in Table 9. Wire from switch terminals Y and R to panel terminals 33 and 43 (chilled water) and 41 and 53 (condenser water). There is also a set of normally closed contacts on the switch that could be used for an indicator light or an alarm to indicate when a “no flow” condition exists.

1. Apply pipe sealing compound to only the threads of the switch and screw unit into 1 in. (25 mm) reducing tee. The flow arrow must be pointed in the correct direction.

2. Piping should provide a straight length before and after the flow switch of at least five times the pipe diameter without any valves, elbows, or other flow restricting elements.

! CAUTION Make sure the arrow on the side of the switch is pointed in the direction of flow. The flow switch is designed to handle the control voltage and should be connected according to the wiring diagram

Table 9, Paddle-Type Flow Switch Flow Rates inch 1 1/4 1 1/2 2 2 1/2 3 4 5 6 8 Pipe Size

NOTES (x) mm 32 (2) 38 (2) 51 63 (3) 76 102 (4) 127 (4) 153 (4) 204 (5) gpm 5.8 7.5 13.7 18.0 27.5 65.0 125.0 190.0 205.0 Flow Lpm 1.3 1.7 3.1 4.1 6.2 14.8 28.4 43.2 46.6 gpm 3.7 5.0 9.5 12.5 19.0 50.0 101.0 158.0 170.0

Min. Adjst. No

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 Flow Lpm 3.0 4.4 6.6 7.8 12.0 29.1 55.6 85.2 94.3 gpm 12.5 18.0 27.0 32.0 50.0 122.0 235.0 360.0 400.0

Max. Adjst. No

Flow Lpm 2.8 4.1 6.1 7.3 11.4 27.7 53.4 81.8 90.8 NOTES: 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.

Glycol Solutions Chiller capacity, flow rate, evaporator pressure drop, and power input for glycol solutions can be calculated using the following formulas and reference to Table 10 for ethylene and Table 11 for propylene glycol.

1. Capacity, Capacity is reduced compared to that with plain water. To find the reduced value, multiply the chiller’s capacity when using water by the capacity correction factor C to find the chiller’s capacity when using glycol.

2. Flow, To determine evaporator gpm (or ΔT) knowing ΔT (or gpm) and capacity:

TablesFromGCorrectionFlowxT

CapacityGlycolxGPMGlycol

Δ=

24


For Metric Applications -- Determine evaporator lps (or ΔT) knowing ΔT (or lps) and kW:

TablesfromGCorrectionFlowxTx

kWLpsGlycolΔ

=18.4

3. Pressure Drop, To determine glycol pressure drop through the cooler, enter the water pressure drop graph on page 16 at the actual glycol flow. Multiply the water pressure drop found there by P to obtain corrected glycol pressure drop.

4. Power, To determine glycol system kW, multiply the water system kW by factor K.

Test coolant with a clean, accurate, glycol solution hydrometer (similar to that found in service stations) to determine the freezing point. Obtain percent glycol from the freezing point found in Table 10 or Table 11. On glycol applications the supplier normally recommends that a minimum of 25% solution by weight be used for protection against corrosion or the use of additional inhibitors.

Note: The effect of glycol in the condenser is negligible. As glycol increases in temperature, its characteristics have a tendency to mirror those of water. Therefore, for selection purposes, there is no derate in capacity for glycol in the condenser.

Table 10, Ethylene Glycol Freezing Point Percent

Glycol °F °C C (Capacity) K (Power) G (Flow) P (Pressure

Drop) 10 26 -3 0.991 0.996 1.013 1.070 20 18 -8 0.982 0.992 1.040 1.129 30 7 -14 0.972 0.986 1.074 1.181 40 -7 -22 0.961 0.976 1.121 1.263 50 -28 -33 0.946 0.966 1.178 1.308

Table 11, Propylene Glycol Freezing Point Percent

Glycol °F °C C (Capacity) K (Power) G (Flow) P (Pressure

Drop) 10 26 -3 0.987 0.992 1.010 1.068 20 19 -7 0.975 0.985 1.028 1.147 30 9 -13 0.962 0.978 1.050 1.248 40 -5 -21 0.946 0.971 1.078 1.366 50 -27 -33 0.929 0.965 1.116 1.481

! CAUTION

Do not use automotive antifreeze. Industrial glycols must be used. Automotive antifreeze contains inhibitors that causes plating on copper tubes. The type and handling of glycol used must be consistent with local codes.


Circuit #1 Outlet

Condenser

TemperatureControlValve

CondenserWater

Circuit #2 Outlet

Circuit #1 Inlet

Circuit #2 Inlet

Condenser Water Piping Arrange the condenser water so the water enters the bottom connection of the condenser. The condenser water will discharge from the top connection. Failing to arrange the condenser water as stated above will negatively affect the capacity and efficiency. Install pressure gauges in the inlet and outlet water lines to the condenser. Pressure drop through the condenser should be measured to determine flow on the pressure drop/flow curves on page 18. Vibration eliminators are recommended in both the supply and return water lines. Install a 20-mesh strainer in the inlet piping to the condenser. Water-cooled condensers can be piped for use with cooling towers, well water, or heat recovery applications. Cooling tower applications should be made with consideration of freeze protection and scaling problems. Contact the cooling tower manufacturer for equipment characteristics and limitations for the specific application. Head pressure control must be provided if the entering condenser water can fall below 60°F. The WGZ condenser has two refrigerant circuits with a common condenser water circuit. This arrangement makes head pressure control with discharge pressure actuated control valves difficult. If the tower water temperature cannot be maintained at a 60°F minimum, or when pond, lake, or well water that can fall below 60°F (15°C) is used as the condensing medium, special discharge pressure control must be used. A water recirculating system with recirculating pump as shown in Table 12 is recommended. This system also has the advantage of maintaining tube velocity to help prevent tube fouling. The pump should cycle with the chiller. Table 12, Recirculating Discharge Pressure Control System

Pressure Drops The evaporator flow rates and pressure drops shown on the following page (Figure 7) are for full load design purposes. The maximum flow rate and pressure drop are based on a 6-degree temperature drop. Avoid higher flow rates with resulting lower temperature drops to prevent potential control problems resulting from very small control bands and limited start up/shut off temperature changes.

The minimum flow and pressure drop is based on a full load evaporator temperature drop of 16-degrees. Condenser pressure drops are shown in Figure 8 on page 18.


Figure 7, Evaporator Pressure Drop, WGZ 030C – WGZ 200C

Minimum Flow Nominal Flow Maximum Flow Inch-Pound S.I. Inch-Pound S.I. Inch-Pound S.I.

WGZ-C Model

GPM Ft. L/S kPa GPM Ft. L/S kPa GPM Ft. L/S kPa 030 45.0 4.7 2.8 14.1 72.0 11.0 4.5 32.9 120.0 27.6 7.6 82.4 035 51.9 4.9 3.3 14.6 83.0 11.4 5.2 34.0 138.3 28.5 8.7 85.4 040 61.1 5.1 3.9 15.2 97.8 11.8 6.2 35.4 163.0 29.7 10.3 88.8 045 68.2 5.2 4.3 15.5 109.1 12.1 6.9 36.1 181.8 30.2 11.5 90.4 050 76.7 5.8 4.8 17.2 122.6 13.4 7.7 40.1 204.4 33.6 12.9 100.6 055 84.6 6.1 5.3 18.1 135.4 14.1 8.5 42.2 225.6 35.4 14.2 105.9 060 90.8 6.6 5.7 19.7 145.2 15.6 9.2 46.5 242.0 39.2 15.3 117.1 070 106.3 3.7 6.7 10.9 170.0 8.6 10.7 25.6 283.4 21.2 17.9 63.3 080 117.5 4.3 7.4 12.8 187.9 10.0 11.9 29.9 313.2 25.0 19.8 74.9 090 132.1 4.5 8.3 13.3 211.3 10.5 13.3 31.3 352.1 26.1 22.2 78.1 100 146.6 4.9 9.3 14.6 234.6 11.4 14.8 34.1 391.1 28.7 24.7 85.8 115 169.3 4.5 10.7 13.5 270.9 10.5 17.1 31.4 451.5 26.4 28.5 78.9 130 188.1 4.2 11.9 12.6 301.0 9.8 19.0 29.5 501.6 24.7 31.6 73.9 150 219.9 5.0 15.0 351.8 12.8 38.3 586.4 35.5 106.1 175 254.0 7.2 21.5 406.3 18.5 55.3 677.2 51.4 153.6 200 282.2 8.6 25.7 451.4 22.0 65.8 752.4 61.0 182.3

Notes: 1. Minimum, nominal, and maximum flows are at a 16-degree F, 10-degree F, and 6-degree F chilled water temperature range

respectively and at ARI tons.

Pres

sure

Dro

p (ft

of w

ater

)

Flow Rate (GPM)


Figure 8, Condenser Pressure Drop, WGZ 030C – WGZ 200C

Min. Flow & PD Nom. Flow & PD Max. Flow & PD

IP SI IP SI IP SI Unit Model Nom Tons

GPM Ft. L/S kPa GPM Ft. L/S kPa GPM Ft. L/S kPa

WGZ030C 30 56.1 2.4 3.5 7.2 89.7 6.3 5.7 18.8 149.5 17.4 9.4 52.0

WGZ035C 35 64.9 3.4 4.1 10.2 103.8 8.6 6.5 25.7 173.0 23.9 10.9 71.4

WGZ040C 41 76.3 2.7 4.8 8.1 122.1 6.9 7.7 20.6 203.5 19.3 12.8 57.7

WGZ045C 46 85.3 3.6 5.4 10.8 136.5 9.2 8.6 27.5 227.5 25.7 14.4 76.8

WGZ050C 51 96.4 2.9 6.1 8.7 154.2 7.5 9.7 22.4 257.0 20.7 16.2 61.9

WGZ055C 57 105.8 3.8 6.7 11.4 169.2 9.7 10.7 29.0 282.0 26.8 17.8 80.1

WGZ060C 63 113.4 4.5 7.2 13.5 181.5 11.6 11.5 34.7 302.5 32.3 19.1 96.5

WGZ070C 71 132.8 4.1 8.4 12.3 212.4 10.4 13.4 31.1 354.0 29.0 22.3 86.7

WGZ080C 78 146.8 3.7 9.3 11.1 234.9 9.5 14.8 28.4 391.5 26.5 24.7 79.2

WGZ090C 88 165.0 3.4 10.4 10.2 264 8.8 16.7 26.3 440.0 24.5 27.8 73.2

WGZ100C 98 183.4 3.4 11.6 10.2 293.4 8.8 18.5 26.3 489.0 24.4 30.9 72.9

WGZ115C 113 211.7 4.8 13.4 14.3 338.7 12.3 21.4 36.8 564.5 34.1 35.6 101.9

WGZ130C 128 235.1 6.1 14.8 18.2 376.2 15.5 23.7 46.3 627.0 43.1 39.6 128.8

WGZ150C 147 274.9 6.2 17.3 18.5 439.8 15.8 27.7 47.2 733.0 43.8 46.2 130.9

WGZ170C 169 317.4 5.5 20.0 16.4 507.9 14.0 32.0 41.8 846.5 38.9 53.4 116.3

WGZ200C 188 352.7 7.4 22.3 22.1 564.3 18.8 35.6 56.2 940.5 52.3 59.3 156.3

Pres

sure

Dro

p (ft

of w

ater

)

Flow Rate (GPM)


Refrigerant Piping

Unit with Remote Condenser General Refrigerant piping, to and from the unit, should be sized and installed according to the latest ASHRAE Handbook. It is important that the unit piping be properly supported with sound and vibration isolation between tubing and hanger, and that the discharge lines be looped at the condenser and trapped at the compressor to prevent refrigerant and oil from draining into the compressors. Looping the discharge line also provides greater line flexibility.

NOTE: Do not install any refrigerant piping underground.

The discharge gas valves, liquid line solenoids, filter-driers, moisture indicators, and thermostatic expansion valves are all factory mounted as standard equipment with the water chiller.

For remote condenser application (WGZ-CA) such as air-cooled or evaporative condenser, the chillers are shipped with an R-410A holding charge. The unit is evacuated in the factory to 500 microns before charging with the holding. The unit is leak tested after charging and before shipment.

The liquid line has a shutoff valve upstream from the liquid line solenoid valve and a copper tube cap to be brazed on this line after test to seal this line for shipment.

The discharge line has a ball valve installed between the compressor and the discharge stub tube with a copper tube cap brazed on the line after test to seal it for shipment.

The discharge gas valves, liquid line solenoids, filter-driers, moisture indicators, and thermostatic expansion valves are all factory-mounted as standard equipment with the water chiller.

! DANGER Do not apply heat, such as a brazing torch, to a sealed unit, vessel, or component. Internal gases can increase the internal pressure and cause a life-threatening explosion. Open the system when heating. The short line between a valve and brazed end cap can be drilled to vent it. Note that the valve may leak and the entire unit charge may be open to the cap.

It is important that the unit be kept tightly closed until the remote condenser is installed, piped to the unit and the high side evacuated. NOTE: it is possible to maintain a positive refrigerant pressure in the unit when a small leak is present. Therefore, add refrigerant to the unit to achieve sufficient pressure to allow a good leak test and carefully leak test the unit. Correct any leaks found.

When the field piping has been leak tested, evacuated, and is ready to charge, the unit valves can be opened and the system charged.

Alternate method: an alternate method is to open up the unit to the field piping and to pressure test, evacuate and charge the entire system together at one time. Many people feel that this is a more straight-forward approach.

After the equipment is properly installed, leak tested, and evacuated, it can be charged with R-410A, and run at design load conditions. Add charge until the liquid line sight glass is clear, with no bubbles flowing to the expansion valve. Total operating charge will depend on the air-cooled condenser used and volume of the refrigerant piping.


NOTE: On WGZ-CA units (units with remote condensers), the installer is required to record the refrigerant charge by stamping the total charge and the charge per circuit on the serial plate in the appropriate blocks provided for this purpose.

The following discussion is intended for use as a general guide to the piping of air-cooled condensers.

Discharge lines must be designed to handle oil properly and to protect the compressor from damage that can result from condensing liquid refrigerant in the line during shutdown. Total friction loss for discharge lines of 3 to 6 psi (20.7 to 41.4 kPa) is considered good design. Careful consideration must be given for sizing each section of piping to insure that gas velocities are sufficient at all operating conditions to carry oil. If the velocity in a vertical discharge riser is too low, considerable oil can collect in the riser and the horizontal header, causing the compressor to lose its oil and result in damage due to lack of lubrication. When the compressor load is increased, the oil that had collected during reduced loads can be carried as a slug through the system and back to the compressor, where a sudden increase of oil concentration can cause liquid slugging and damage to the compressor.

Any horizontal run of discharge piping should be pitched away from the compressor approximately 1/8 inch (6.4 mm) per foot (meter) or more. This is necessary to move, by gravity, any oil lying in the header. Oil pockets must be avoided because oil needed in the compressor would collect at such points and the compressor crankcase can become starved.

It is recommended that any discharge lines coming into a horizontal discharge header rise above the centerline of the discharge header. This is necessary to prevent any oil or condensed liquid from draining to the compressor heads when the compressor is not running.

In designing liquid lines, it is important that the liquid reach the expansion valve without flash gas since this gas will reduce the capacity of the valve. Because “flashing” can be caused by a pressure drop in the liquid line, the pressure losses due to friction and changes in static head should be kept to a minimum.

A check valve must be installed in the liquid line in all applications where the ambient temperature can drop below the equipment room temperature. This prevents liquid migration to the condenser, helps maintain a supply of refrigerant in the liquid line for initial start-up, and keeps liquid line pressure high enough on “off” cycle to keep the expansion valve closed.

On systems as described above, a relief valve or relief-type check valve, must be used in the liquid line as shown in piping systems (shown in and Its purpose is to relieve dangerous hydraulic pressures that could be created as cool liquid refrigerant trapped in the line between the check valve and the expansion or shutoff valve warms up. Install a relief device in the hot gas piping at the condenser coil as shown in and Figure 10. Install a discharge check valve in the discharge line, in a horizontal run, close to the condenser.

Recommended Line Sizing The following tables provide recommended line sizing for the field piping. Final design should be based on ASHRAE design standards.


Table 13, Equivalent Feet for Fittings Fitting Type 7/8 1 1/8 1 3/8 1 5/8 2 1/8 2 5/8 3 1/8

Elbows 90º Standard 2.0 2.6 3.3 4.0 5.0 6.0 7.5 90º Long Radius 1.4 1.7 2.3 2.6 3.3 4.1 5.0 90º Street 3.2 4.1 5.6 6.3 8.2 10 12 45º Standard 0.9 1.3 1.7 2.1 2.6 3.2 4.0 45º Street 1.5 2.1 3.0 3.4 4.5 5.2 6.4

180º Bend 3.2 4.1 5.6 6.3 8.2 10 12

Tees Full Size 1.4 1.7 2.3 2.6 3.3 4.1 5.0 Reducing 2.0 2.6 3.3 4.0 5.0 6.0 7.5 Valves Globe Valve, Open 22 29 38 43 55 69 84 Gate Valve, Open 0.9 1.0 1.5 1.8 2.3 2.8 3.2 Angle Valve, Open 9.0 12 15 18 24 29 35

Table 14, Maximum Line Size for Oil Carry Up a Discharge Riser, R-410A

Unit Size WGZ 030

WGZ 035

WGZ 040

WGZ 045

WGZ 050

WGZ 055

WGZ 060

WGZ 070

WGZ 080

WGZ 090

Line Size (in.)

1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8

Unit Size WGZ 100

WGZ 115

WGZ 130

WGZ 150

WGZ 170

WGZ 200

Line Size (in.)

2 5/8 3 1/8 3 1/8 2 5/8 3 1/8 3 1/8

Table 15, Recommended Liquid Line Size, R-410A Recommended Liquid Line Size (in.)

Up to Up to Up to Up to Up to Unit Model WGZ-CB

ConnectionSize at Unit

(in.) 50 Equiv. Ft 75 Equiv. Ft 100 Equiv. Ft 125 Equiv. Ft 150 Equiv. FtWGZ 030 7/8" 7/8 " 7/8 " 7/8 " 7/8 " 7/8 " WGZ 035 7/8" 7/8 " 7/8 " 7/8 " 7/8 " 1 1/8 " WGZ 040 7/8" 7/8 " 7/8 " 7/8 " 1 1/8 " 1 1/8 " WGZ 045 7/8" 7/8 " 7/8 " 7/8 " 1 1/8 " 1 1/8 " WGZ 050 7/8" 7/8 " 7/8 " 7/8 " 1 1/8 " 1 1/8 " WGZ 055 7/8" 7/8 " 7/8 " 1 1/8” 1 1/8 " 1 1/8 " WGZ 060 7/8" 7/8 “ 7/8 " 1 1/8 " 1 1/8 " 1 1/8 " WGZ 070 1 1/8” 1 1/8” 1 1/8 " 1 1/8 " 1 1/8 " 1 1/8” WGZ 080 1 1/8” 1 1/8 " 1 1/8 " 1 1/8” 1 1/8” 1 1/8” WGZ 090 1 1/8” 1 1/8 " 1 1/8 " 1 1/8” 1 1/8” 1 1/8” WGZ 100 1 1/8” 1 1/8 " 1 1/8 " 1 1/8” 1 1/8” 1 1/8” WGZ 115 1 1/8” 1 1/8 " 1 1/8 " 1 1/8” 1 3/8” 1 3/8” WGZ 130 1 1/8” 1 1/8 " 1 3/8” 1 1/8” 1 3/8” 1 3/8” WGZ 150 1 3/8” 1 3/8” 1 1/8 " 1 3/8” 1 3/8” 1 3/8” WGZ 170 1 3/8” 1 3/8” 1 1/8 " 1 3/8” 1 3/8” 1 3/8” WGZ-200 1 3/8” 1 3/8” 1 1/8 " 1 3/8” 1 3/8” 1 3/8”


Table 16, Recommended Horizontal or Downflow Discharge Line Size, R-410A Recommended Discharge Line Sizes

Up to Up to Up to Up to Up to Unit Model

AGZ-CB

Connection Size

At Unit 50 Equiv. Ft 75 Equiv. Ft 100 Equiv. Ft 125 Equiv. Ft 150 Equiv. FtWGZ 030 1 3/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8" WGZ 035 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" WGZ 040 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" WGZ 045 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" WGZ 050 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" WGZ 055 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" WGZ 060 1 3/8" 1 3/8" 1 5/8” 1 5/8” 1 5/8” 1 5/8” WGZ 070 1 3/8" 1 3/8" 1 5/8” 1 5/8” 1 5/8” 1 5/8” WGZ 080 1 5/8” 1 5/8” 1 5/8” 1 5/8” 1 5/8” 1 5/8” WGZ 090 1 5/8” 1 5/8” 1 5/8” 1 5/8” 1 5/8” 1 5/8” WGZ 100 1 5/8” 1 5/8” 1 5/8” 1 5/8” 1 5/8” 1 5/8” WGZ 115 1 5/8” 1 5/8” 1 5/8” 2 1/8" 2 1/8" 2 1/8" WGZ 130 1 5/8” 1 5/8” 2 1/8" 2 1/8" 2 1/8" 2 1/8" WGZ 150 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8" WGZ 170 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8" WGZ 200 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 5/8"

Typical Arrangements Figure 9 illustrates a typical piping arrangement involving a remote air-cooled condenser located at a higher elevation than the compressor and receiver. This arrangement is commonly encountered when the air-cooled condenser is on a roof and the compressor and receiver are on grade level or in a basement equipment room. Notice, in both illustrations, that the hot gas line is looped at the bottom and top of the vertical run. This is done to prevent oil and condensed refrigerant from flowing back into the compressor and causing damage. The highest point in the discharge line should always be above the highest point in the condenser coil. It is advisable to include a purging vent at this point to extract non-condensables from the system.

Figure 10 illustrates another very common application where the air-cooled condenser is located on essentially the same level as the compressor and receiver. The discharge line piping in this case is not too critical. The principal problem encountered with this arrangement is that there is frequently insufficient vertical distance to allow free drainage of liquid refrigerant from the condenser coil to the receiver.

The receiver is used when it is desired to have refrigerant storage capacity, in addition to the pumpdown capability of the condenser.


Condenser

Relief Valve

Check Valve

Purge Valve

Discharge Line

Loop

Receiver

ReceiverBypass

ToEvap.

PreferredSubcoolerHook-up

Relief Valve(Vent to Outdoorsor to Condenser Sideof Liquid LineCheck Valve)

Pitch

CheckValve

Subcooler

Condenser

Relief Valve

Check Valve

Purge Valve

Relief Valve(Vent to Outdoorsor to Condenser Sideof Liquid LineCheck Valve)

Pitch

CheckValve

Discharge Line

Receiver

ReceiverBypass

ToEvap.

PreferredSubcoolerHook-up

CheckValve

Subcooler

Figure 9, Condenser Above Compressor and Optional Receiver Installation

Figure 10, Condenser and Compressor on Same Level, Optional Receiver Installation The receiver shown is optional and not used on many installations. It is bypassed during normal operation.


Factory-Mounted Condenser Units with the standard water-cooled, factory-mounted condenser are provided with complete refrigerant piping and full operating refrigerant charge at the factory.

There is a remote possibility on water-cooled units utilizing low temperature pond or river water as a condensing medium, and if the water valves leak, that the condenser and liquid line refrigerant temperature could drop below the equipment room temperature on the “off” cycle. This problem only arises during periods when cold water continues to circulate through the condenser and the unit remains off due to satisfied cooling load.

If this condition occurs:

1. Cycle the condenser pump off with the unit. 2. Check the liquid line solenoid valve for proper operation.

Relief Valve Piping The ANSI/ASHRAE Standard 15, Safety Standard for Refrigeration Systems, specifies that pressure relief valves on vessels containing Group 1 refrigerant (R-22) “shall discharge to the atmosphere at a location not less than 15 feet (4.6 meters) above the adjoining ground level and not less than 20 feet (6.1 meters) from any window, ventilation opening or exit in any building.” The piping must be provided with a rain cap at the outside terminating point and with a drain at the low point on the vent piping to prevent water buildup on the atmospheric side of the relief valve. In addition, a flexible pipe section should be installed in the line to eliminate any piping stress on the relief valve(s).

The size of the discharge pipe from the pressure relief valve should not be less than the size of the pressure relief outlet. When two or more vessels are piped together, the common header and piping to the atmosphere should not be less than the sum of the area of each of the lines connected to the header.

NOTE: Fittings should be provided to permit vent piping to be easily disconnected for inspection or replacement of the relief valve.

Table 17, Relief Valve Piping


Dimensions Packaged Chillers Figure 11, WGZ 030CW through WGZ 060CW

CHILLER WATER CONNECTION SIZE (NOM) VICTAULIC

CONDENSER WATER CONNECTION SIZE (NOM) VICTAULIC

CENTER OF GRAVITY WGZ MODEL NUMBER

IN (MM) A IN (MM) X Y Z WGZ030C 2.5 (64) 107.4 (2728) 4 (102) 59.2 22.4 14.1

WGZ035C 2.5 (64) 108.4 (2753) 4 (102) 59.9 22.8 14.2

WGZ040C 2.5 (64) 109.8 (2789) 4 (102) 59.6 22.8 14.2

WGZ045C 2.5 (64) 111.5 (2832 4 (102) 59.2 22.9 14.2

WGZ050C 2.5 (64) 113.3 (2878) 4 (102) 59.0 23.3 14.2

WGZ055C 2.5 (64) 115.0 (2921) 4 (102) 58.7 23.4 14.2

WGZ060C 2.5 (64) 116.7 (2965) 4 (102) 58.0 23.6 14.3

CONDENSER

INLET

121.13075

9.7246

134.63419

3.8

REF.98 " X "

" Y "

3.9100

.875 DIA MOUNTING HOLES (4)

INLET

OUTLET

OUTLET

RELIEF VALVES

MICROTECH II USER INTERFACE

VENT

DRAIN

CIRCUIT 1CIRCUIT 2

30.1763

32.8832

" Z "

" Y "

23.5597

2.051

20.0508

29.0737

13.3338

32.0813

8.0204

14.0354

29.2742

44.91139

12.4314

63.41609

40.01016

EVAPORATOR

REMOVABLEDISC. HANDLE

REMOVE BRKT.FOR SHIPPING

ONLYPOWER

CONNECTIONS

CONTROLCONNECTION

.88 KNOCKOUTSON OPPOSITE SIDE

.88 KNOCKOUTS

"A"

CONTROL BOX

WATERCONNECTIONS

L1 / M1 L2 / M2

L3 / M3L4 / M4

WGZ030C-060CPackaged Unit

331929701


Figure 12, WGZ 070CW through WGZ 130CW

MAXIMUM OVERALL DIMENSIONS

IN (MM) CENTER OF GRAVITY WGZ MODEL

NUMBER

“L” “W” “H”

CHILLER WATER

CONNECTION IN(MM)

VICTAULIC SIZE (NOM)

“A”

CONDENSER WATER

CONNECTION IN(MM)

VICTAULIC SIZE (NOM)

“T”

“X” “Y” “Z”

WGZ070C 143.3 (3639)

35.0 (889)

65.5 (1664) 3 (76) 114.9

(2918) 4 (102) 8.0 (203) 62.4 28.6 15.0

WGZ080C 149.6 (3799)

35.0 (889)

65.5 (1664) 3 (76) 115.3

(2930) 4 (102) 14.3 (363) 64.8 29.3 15.1

WGZ090C 149.4 (3795)

35.0 (889)

65.5 (1664) 3 (76) 117.1

(2975) 4 (102) 14.1 (359) 67.7 29.6 16.1

WGZ100C 149.4 (3795)

35.0 (889)

65.5 (1664) 3 (76) 118.0

(2997) 4 (102) 14.1 (359) 69.7 29.9 17.1

WGZ115C 149.4 (3795)

35.0 (889)

65.5 (1664) 3 (76) 121.6

(3088) 4 (102) 14.1 (359) 68.8 30.2 17.1

WGZ130C 149.4 (3795)

35.0 (889)

65.5 (1664) 3 (76) 124.7

(3167) 4 (102) 14.1 (359) 67.8 30.4 17.1

CONDENSER

121.13075"T" 14.2

361

"L"

"A"

" X "

4.0102


INLET

INLET

OUTLET

OUTLET

EVAPORATOR

RELIEF VALVES


VENT

DRAIN

CIRCUIT 2 CIRCUIT 1

29.0737

13.0330

32.3821

"W"

" Y "

" Z "

23.5597

2.051

10.0253

17.9454

32.8834

57.61462

14.5369

20.0508

"H"

32.081340.01016

40.21021

REMOVABLEDISC. HANDLE REMOVE BRKT.

FOR SHIPPINGONLY

POWERCONNECTIONS

CONTROLCONNECTION


.88 KNOCKOUTS

CONTROL BOX

WATERCONNECTIONS

L1 / M1 L2 / M2

L3 / M3L4 / M4

WGZ070-130CWPackaged Chiller

331929801


Figure 13, WGZ 150CW through WGZ 200CW




IN (MM) IN (MM) X Y Z WGZ150C 8 (203) 5 (127) 68.7 38.6 14.9 WGZ170C 8 (203) 5 (127) 66.3 38.3 15.0 WGZ200C 8 (203) 5 (127) 66.6 38.7 15.1

CONDENSER

EVAPORATOROUTLET

10.9276

145.13685

14.2361

170.24322

" X "

" Y "

4.0102

INLET

OUTLET

EVAPORATORINLET

RELIEF VALVES


VENT

VENT

DRAIN DRAIN

29.0737

13.3337

33.8859

36.5

T.B.D.927

77.71973

" Z "

23.5597

2.051

15.5394

17.0432

9.6243

18.3464

36.9

EVAPINLET/

OUTLET

938

32.0813

5.0127

40.01016

41.21046


.88 KNOCKOUT

REMOVABLEDISC HANDLE


ONLY

CONTROLCONNECTION


POWERCONNECTIONS

23.5596

77.21961

1.334

CIRCUIT 1CIRCUIT 2

WGZ150CW-200CWPackaged Chiller

331929901


Chillers with Remote Condenser Figure 14, WGZ 030CA through WGZ 060CA




IN (MM) A IN (MM) X Y Z WGZ030CA 2.5 (64) 21.6 (550) 4 (102) 67.3 22.8 13.3

WGZ035CA 2.5 (64) 20.6 (523) 4 (102) 68.3 23.8 13.4

WGZ040CA 2.5 (64) 19.2 (488) 4 (102) 67.9 23.9 13.5

WGZ045CA 2.5 (64) 17.5 (444) 4 (102) 67.3 24.0 13.5

WGZ050CA 2.5 (64) 15.8 (400) 4 (102) 67.2 24.5 13.5

WGZ055CA 2.5 (64) 14.0 (356) 4 (102) 66.6 24.6 13.5

WGZ060CA 2.5 (64) 12.3 (312) 4 (102) 66.1 24.7 13.6

WGZ030-060CA REMOTE CONDENSER UNIT

331929711" X "

" Y "

137.03480

12.3312

6.0152

20.2512


CIRCUIT 1CIRCUIT 2

1.38 DISCHARGECONNECTIONS

.88 LIQUIDCONNECTIONS

30.3770

" Z "

23.5597

2.051

30.0762

2.051

20.0508

34.0864

40.01016

6.0152

6.0151

16.5419

60.01524

EVAPORATOR

REMOVABLEDISC. HANDLE REMOVE BRKT.

FOR SHIPPINGONLY

POWERCONNECTIONS

CONTROLCONNECTION


.88 KNOCKOUTSISOLATOR HOLES (4)

OUTLET

INLET

LIQUIDCONNECTIONS

EVAP. ANDDISCHARGECONNECTIONS

25.9657

41.51054

" A "

27.4696 38.2

971 87.92234 98.8

2509

11.4289

10.4263

OUTLET

INLET


Figure 15, WGZ 070CA through WGZ 130CA


COND. WATER

CONN. SIZE VICTAULIC

REFRIGERANT PIPING

CONNECTION SIZE

CENTER OF GRAVITY (IN.)

WGZ MODEL

NUMBER IN (MM) A IN (MM) B DISC. C LIQ.

T LEFT

OVERHANGX Y Z

WGZ070C 3 (76) 14.1 (359) 4 (102) 1.38 OD 1.13 OD N/A 71.5 29.3 14.9

WGZ080C 3 (76) 13.7 (348) 4 (102) 1.62 OD 1.13 OD 6.3 (161) 74.9 30.1 15.0

WGZ090C 3 (76) 11.9 (303) 4 (102) 1.62 OD 1.13 OD 6.6 (167) 75.7 30.4 15.1

WGZ100C 3 (76) 11.0 (280) 4 (102) 1.62 OD 1.13 OD 6.6 (167) 75.2 30.6 15.2

WGZ115C 3 (76) 7.5 (190) 4 (102) 1.62 OD 1.13 OD 6.6 (167) 73.8 30.8 15.2

WGZ130C 3 (76) 4.4 (111) 4 (102) 1.62 OD 1.13 OD 6.6 (167) 72.6 30.9 15.3

" T "

" Y "

" X "137.03480

12.3312

6.0152

23.2588

MICROTECH II USER INTERFACECIRCUIT 1CIRCUIT 2

DISCHARGE CONNECTIONS "B"

LIQUID CONNECTIONS "C"

32.3821

23.5597

2.051

30.0762

2.051" Z "

20.0508

34.0864

40.01016

6.0152

60.01524

4.0101

15.5394

EVAPORATOR



ONLYPOWERCONNECTIONS

CONTROLCONNECTION


.88 KNOCKOUTS

ISOLATOR HOLES (4)

OUTLET

INLET

LIQUIDCONNECTIONS

EVAP. ANDDISCHARGECONNECTIONS

52.01322

18.5469

27.3694

"A "

13.3338

12.4±.25316±6.35

38.2971 89.2

2266 98.82509

OUTLET

INLET

WGZ070-130CAUnit less condenser

331929811

21.0533

95.02413

21.05332.0

51

30.0762

2.051

%%c.75

ISOLATOR HOLES IN THEBOTTOM OF THE BASE

19

CONTROL BOX

CIRCUIT 1CIRCUIT 2

L1 L2

L3L4

M1 M2

M3M4

EVAP WATERCONNECTIONS


Figure 16, WGZ 150CA through WGZ 200CA



IN (MM) X Y Z WGZ150C 8 (203) 79.1 43.2 15.3

WGZ170C 8 (203) 80.1 43.6 15.4

WGZ200C 8 (203) 79.7 44.0 15.4

" Y "

" X "

154.03912

2.051

MICROTECH IIUSER INTERFACE

CIRCUIT 1CIRCUIT 2

WGZ150-200CA REMOTE CONDENSER UNIT

331929911

2.051

30.0762

2.051

" Z "

5.0127

12.0305

35.5902

3.076

75.01905

12.0305

34.0864

40.01016

4.0101

5.0127



ONLY

CONTROLCONNECTION


.88 KNOCKOUTSISOLATOR HOLES (6)

POWERCONNECTIONS

(QTY 3)

LIQUIDCONNECTIONS

106.52705

33.9862

42.11069 119.3

3030

34.2867

24.9631

74.71898

17.4443

6.0152

23.2588

OUTLETINLET

1.62 O.D. DISCHARGECONNECTIONS

1.38 O.D. LIQUIDCONNECTIONS

CIRCUIT 1 CIRCUIT 2

2.360 7.9

200

14.5368

13.4340

3.690

EVAPORATORINLET/OUTLET

DISCHARGECIRCUIT 1 DISCHARGE

CIRCUIT 2

21.0533

30.0762

2.051

2.051

21.0533

58.01473

54.01372

.75

ISOLATOR HOLES IN THEBOTTOM OF THE BASE

19

CONTROL BOX

CIRCUIT 1CIRCUIT 2

L1 L2

L3L4

M1 M3

M4M6

M2

M5


Physical Data

Packaged Chillers Table 18, WGZ 030CW – WGZ 055CW WGZ UNIT SIZE 30 35 40 45 50 55 Unit capacity @ ARI tons, (kW) 30.0 (105.5) 34.6 (121.7) 40.7 (143.1) 45.5 (160.0) 51.4 (180.8) 56.4 (198.4) No. Circuits 2 2 2 2 2 2

COMPRESSORS Nominal Tons 7.5 7.5 9 9 10 10 12 12 13 13 13 15 Number Per Circuit 2 2 2 2 2 2 2 2 2 2 2 2

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT Staging, Circuit #1 in Lead 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 23 / 50 / 73 / 100Staging, Circuit #2 in Lead 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 27 / 50 / 77 / 100Oil Charge per Compressor oz., (l) 85 (2.5) 110 (3.3) 110 (3.3) 110 (3.3) 110 (3.3) 110 (3.3)

CONDENSER Number 1 1 1 1 1 1 No. Refrigerant Circuits 2 2 2 2 2 2 Diameter, in., (mm) 10 (254) 10 (254) 10 (254) 10 (254) 10 (254) 10 (254) Tube Length, in., (mm) 120 (3048) 120 (3048) 120 (3048) 120 (3048) 120 (3048) 120 (3048) Design W.P.PSIG, (kPa): Refrigerant Side 500 (3447) 500 (3447) 500 (3447) 500 (3447) 500 (3447) 500 (3447) Water Side 232 (1599) 232 (1599) 232 (1599) 232 (1599) 232 (1599) 232 (1599) Pump-Out Capacity, lb., (kg) (3) 245.8 (111.7) 245.8 (111.7) 228.2 (103.7) 228.2 (103.7) 205.4 (93.4) 205.4 (93.4)

Conn.In & Out, in, (mm) Victaulic 4 (102) 4 (102) 4 (102) 4 (102) 4 (102) 4 (102)

Relief Valve, Flare In., (mm) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) Purge Valve, Flare In., (mm) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) Vent & Drain, in. (mm) NPT ¼ (6.4) ¼ (6.4) ¼ (6.4) ¼ (6.4) ¼ (6.4) ¼ (6.4) Liquid Subcooling Integral Integral Integral Integral Integral Integral

EVAPORATOR, BRAZED-PLATE Number 1 1 1 1 1 1 No. Refrigerant Circuits 2 2 2 2 2 2 Water Volume, gallons, (l) 1.9 (7.1) 2.2 (8.3) 2.4 (9.1) 2.9 (11.0) 3.4 (12.8) 3.7 (14.0) Refrig. Side D.W.P. Psig, (kPa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) Water Side D.W.P,. psig, (kPa) 653 (4500) 653 (4500) 653 (4500) 653 (4500) 653 (4500) 653 (4500)

Conn. In & Out, in. (mm) Victaulic 2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65)

Relief Valve, Flare in., (mm) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) Vent & Drain Field Field Field Field Field Field

UNIT DIMENSIONS Length In., (mm) 136.0 (3455) 136.0 (3455) 136.0 (3455) 136.0 (3455) 136.0 (3455) 136.0 (3455) Width In., (mm) 32.8 (832) 32.8 (832) 32.8 (832) 32.8 (832) 32.8 (832) 32.8 (832) Height In., (mm) 63.4 (1609) 63.4 (1609) 63.4 (1609) 63.4 (1609) 63.4 (1609) 63.4 (1609)

UNIT WEIGHTS Operating Weight, lb., (kg) 2486 (1128) 2572 (1167) 2631 (1193) 2650 (1202) 2752 (1248) 2771 (1257) Shipping Weight, lb., (kg) 2410 (1093) 2496 (1132) 2539 (1152) 2558 (1160) 2639 (1197) 2658 (1206) Cir # 1,Opn. Charge, lb.,(kg) R410a 45 (20.5) 45 (20.5) 47 (21.4) 47 (21.4) 47 (21.4) 50 (22.7) Cir # 2,Opn. Charge, lb.,(kg) R410a 45 (20.5) 45 (20.5) 47 (21.4) 47 (21.4) 47 (21.4) 50 (22.7)

Notes: 1. Certified in accordance with ARI Standard 550/590-2003. 2. 90% Full R-410a at 90°F (32°C) per unit.


Table 19, WGZ060CW - WGZ100CW WGZ UNIT SIZE 60 70 80 90 100 Unit capacity @ ARI tons, (kW) (1) 60.5 (212.8) 70.8 (249.0) 78.3 (275.4) 88.0 (309.5) 97.8 (344.0) No. Circuits 2 2 2 2 2

COMPRESSORS Nominal Tons 15 15 15/20 15/20 20 20 20 26 26 26 Number per Circuit4 2 2 2 2 2 2 2 2 2 2

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT Staging, 4 Stages, Circuit #1 in Lead 25 / 50 / 75 / 100 22 / 50 / 72 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100Staging, 4 Stages, Circuit #2 in Lead 25 / 50 / 75 / 100 22 / 50 / 72 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100

Oil Charge, per compressor oz. (l) 110 (3.3) 110 (3.3) 158 (4.7)

110 (3.3) 158 (4.7) 158 (4.7) 158

(4.7) 230 (6.8) 230 (6.8)

CONDENSER Number 1 1 1 1 1 No. Refrigerant Circuits 2 2 2 2 2 Diameter, in. (mm) 10 (254) 14 (356) 14 (356) 14 (356) 14 (356) Tube Length, in. (mm) 120 (3048) 120 (3048) 120 (3048) 120 (3048) 120 (3048) Design W.P., psig (kPa): Refrigerant Side 500 (3447) 500 (3447) 500 (3447) 500 (3447) 500 (3447) Water Side 232 (1599) 232 (1599) 232 (1599) 232 (1599) 232 (1599) No. of Passes 2 2 2 2 2 Pump-Out Capacity lb., (kg) (3) 205.4 (93.4) 415.1 (188.7) 397.5 (180.7) 371.1 (168.7) 344.7 (156.7) Conn. In & Out, in., (mm) Victaulic 4 (102) 4 (102) 4 (102) 4 (102) 4 (102) Relief Valve, Flare in., (mm) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) Purge Valve, Flare in. (mm) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) Vent & Drain, in. (mm) NPT ¼ (6.4) ¼ (6.4) ¼ (6.4) ¼ (6.4) ¼ (6.4) Liquid Subcooling Integral Integral Integral Integral Integral

EVAPORATOR, BRAZED-PLATE Number 1 1 1 1 1 No. Refrigerant Circuits 2 2 2 2 2 Water Volume, gallons (l) 4.2 (15.9) 6.4 (24.3) 6.6 (24.9) 7.5 (28.4) 8.0 (30.2) Refrigerant Side D.W.P., psig, (kPa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) Water Side D.W.P., psig, (kPa) 653 (4500) 653 (4500) 653 (4500) 653 (4500) 653 (4500)

Conn. In & Out, in. (mm) Victaulic 2.5 (65) 3 (76) 3 (76) 3 (76) 3 (76)

Relief Valve, Flare in., (mm) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) Vent & Drain Field Field Field Field Field

UNIT DIMENSIONS Length, in. (mm) 136.0 (3455) 143.3 (3639) 149.6 (3799) 149.4 (3795) 149.4 (3795) Width, in. (mm) 32.8 (832) 35.0 (889) 35.0 (889) 35.0 (889) 35.0 (889) Height, in. (mm) 63.4 (1609) 65.5 (1664) 65.5 (1664) 65.5 (1664) 65.5 (1664)

UNIT WEIGHTS Operating Wt, lb., (kg) 2801 (1271) 3887 (1763) 4302 (1951) 4507 (2044) 4678 (2122) Shipping Wt, lb. (kg) 2688 (1219) 3746 (1699) 4145 (1880) 4327 (1963) 4474 (2029) Cir # 1,Opn. Charge, lb, (kg) R410a 50 (22.7) 74 (34.1) 80 (36.4) 80 (36.4) 90 (40.9) Cir # 2,Opn. Charge, lb.,(kg) R410a 50 (22.7) 74 (34.1) 80 (36.4) 80 (36.4) 90 (40.9) Notes: 1. Certified in accordance with ARI Standard 550/590-2003.- 2. Units WGZ030 to 130 have two parallel compressors per circuit. Units WGZ150 to 200 have three parallel compressors per circuit. 3. 90% Full R-410a at 90°F (32°C) per unit.


Table 20, WGZ115CW - WGZ200CW WGZ UNIT SIZE 115 130 150 170 200

Unit capacity @ ARI. tons, (kW) (1) 112.9 (397.1) 125.4 (441.0) 146.6 (515.6) 169.3 (595.4) 188.1 (661.5) No. Circuits 2 2 2 2 2

COMPRESSORS Nominal Tons 26/30 26/30 30 30 26 26 26 30 30 30 Number Per Circuit 2 2 2 2 3 3 3 3 3 3

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT

Staging, 4 Stages, Circuit #1 in Lead 22 / 50 / 72 / 100 25 / 50 / 75 / 100 17 / 33 / 50 / 67 / 83 / 100

15 / 33 / 48 / 67 / 81 / 100

17 / 33 / 50 / 67 / 83 / 100

Staging, 4 Stages, Circuit #2 in Lead 22 / 50 / 72 / 100 25 / 50 / 75 / 100 17 / 33 / 50 / 67 83 / 100

19 / 33 / 52 / 67 86 /100

17 / 33 / 50 / 67 / 83 / 100

Oil Charge, per compressor oz. (l) 230 (6.8 )/ 213 (6.3)

230 (6.8 )/ 213 (6.3) 213 (6.3) 230 (6.8) 230 (6.8) 213 (6.3) 213 (6.3)

CONDENSER Number 1 1 1 1 1 No. Refrigerant Circuits 2 2 2 2 2 Diameter, in. (mm) 14 (356) 14 (356) 16 (406.4) 16 (406.4) 16 (406.4) Tube Length, in. (mm) 120 (3048) 120 (3048) 144 (3658) 144 (3658) 144 (3658) Design W.P., psig (kPa): Refrigerant Side 500 (3447) 500 (3447) 500 (3447) 500 (3447) 500 (3447) Water Side 232 (1599) 232 (1599) 232 (1599) 232 (1599) 232 (1599) Pump-Out Capacity lb., (kg) (3) 344.7 (156.7) 344.7 (156.7) 572.3 (260.1) 508.9 (231.3) 508.9 (231.3) Water Conn In & Out, in., (mm) (4) 4 (102) 4 (102) 5 (127) 5 (127) 5 (127) Relief Valve, Flare in., (mm) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) Purge Valve, Flare in. (mm) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) Vent & Drain, in. (mm) FPT ¼ 6.4) ¼ 6.4) ¼ 6.4) ¼ 6.4) ¼ 6.4) Liquid Subcooling Integral Integral Integral Integral Integral

EVAPORATOR, BRAZED-PLATE ⇒ SHELL-AND-TUBE Number 1 1 1 1 1 No. Refrigerant Circuits 2 2 2 2 2 Water Volume, gallons (l) 8.5 (32.1) 10.5 (39.7) 57.6 (218.0) 56.9 (215.4) 56.9 (215.4) Refrigerant Side D.W.P., psig, (kPa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) Water Side D.W.P., psig, (kPa) 653 (4500) 653 (4500) 150 (1034) 150 (1034) 150 (1034) Water Conn.In & Out, in. (mm) Victaulic 3 (76) 3 (76) 8 (203) 8 (203) 8 (203) Relief Valve, Flare in., (mm) ⅝ (15.9) ⅝ (15.9) Drain & Vent size, in. (mm) Field Field ½ (12.7) ½ (12.7) ½ (12.7)

UNIT DIMENSIONS Length, in. (mm) 149.4 (3795) 149.4 (3795) 170.2 (4322) 170.2 (4322) 170.2 (4322) Width, in. (mm) 35.0 (889) 35.0 (889) 36.5 (927) 36.5 (927) 36.5 (927) Height, in. (mm) 65.5 (1664) 65.5 (1664) 77.7 (1973) 77.7 (1973) 77.7 (1973)

UNIT WEIGHTS Operating Wt, lb., (kg) 4712 (2137) 4772 (2165) 7370 (3343) 7758 (3519) 7873 (3571) Shipping Wt, lb. (kg) 4508 (2045) 4568 (2072) 6581 (2985) 6921 (3139) 7036 (3192) Cir #1, Op. Charge, lb., (kg) R-410a 100 (45.5) 100 (45.5) 150 (68.2) 150 (68.2) 150 (68.2) Cir #2, Op. Charge, lb., (kg) R-410a 100 (45.5) 100 (45.5) 150 (68.2) 150 (68.2) 150 (68.2) Notes: 1. Certified in accordance with ARI Standard 550/590-2003. 2. Units WGZ030 to 130 have two parallel compressors per circuit, units WGZ150 to 200 have three parallel compressors per circuit. 3. 90% Full R-410a at 90°F (32°C) per unit.


Chillers with Remote Condenser Table 21, WGZ030CA - WGZ055CA WGZ UNIT SIZE 30 35 40 45 50 55

Tons, (kW), 44°F LWT, 125°F SDT 26.6 (93.5) 30.5 (107.3) 35.2 (123.8) 39.8 (139.9) 45.8 (161.0) 50.3 (176.8) No. Circuits 2 2 2 2 2 2 COMPRESSORS Nominal Tons 7.5 7.5 9 9 10 10 12 12 13 13 13 15 Number per Circuit 2 2 2 2 2 2 2 2 2 2 2 2 Staging, Circuit #1 in Lead 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 23 / 50 / 73 / 100Staging, Circuit #2 in Lead 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 27 / 50 / 77 / 100Oil Charge, per comp. oz, (l) 85 (2.5) 110 (3.3) 110 (3.3) 110 (3.3) 110 (3.3) 110 (3.3) EVAPORATOR, BRAZED PLATE No. Refrigerant Circuits 2 2 2 2 2 2 Water Volume, gallons, (l) 1.9 (7.1) 2.2 (8.3) 2.4 (9.1) 2.9 (11.0) 3.4 (12.8) 3.7 (14.0) Refrig. Side D.W.P. Psig, (kPa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) Water Side D.W.P. Psig, (kPa) 653 (4500) 653 (4500) 653 (4500) 653 (4500) 653 (4500) 653 (4500) Inlet & Outlet, in., (mm) (1) 2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65) Relief Valve, Flare in., (mm) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) Drain & Vent Field Field Field Field Field Field UNIT DIMENSIONS Length In., (mm) 137.0 (3480) 137.0 (3480) 137.0 (3480) 137.0 (3480) 137.0 (3480) 137.0 (3480) Width In., (mm) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864) Height In., (mm) 60.0 (1524) 60.0 (1524) 60.0 (1524) 60.0 (1524) 60.0 (1524) 60.0 (1524) UNIT WEIGHTS Operating Weight, lb., (kg) 1606 (728) 1698 (770) 1715 (778) 1738 (788) 1773 (804) 1795 (814) Shipping Weight, lb., (kg) 1580 (717) 1670 (758) 1685 (764) 1704 (773) 1735 (787) 1754 (796) Holding charge/ circuit, lb. (kg) 10.0 (4.5) 10.0 (4.5) 10.0 (4.5) 10.0 (4.5) 10.0 (4.5) 10.0 (4.5)

Table 22, WGZ060CA - WGZ100CA WGZ UNIT SIZE 60 70 80 90 100

Tons, (kW) 44°F LWT, 125°F SDT 53.9 (189.5) 61.3 (215.7) 68.6 (242.0) 77.7 (273.3) 86.6 (304.5) No. Circuits 2 2 2 2 2 COMPRESSORS Nominal Tons 15 15 15/20 15/20 20 20 20 26 26 26 Number Per Circuit 2 2 2 2 2 2 2 2 2 2 Staging, Circuit #1 in Lead 25 / 50 / 75 / 100 22 / 50 / 72 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 Staging, Circuit #2 in Lead 25 / 50 / 75 / 100 22 / 50 / 72 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 Oil Charge, per compressor oz. (l) 110 (3.3) 110 (3.3) 158 (4.7) 158 (4.7) 230 230 (6.8) EVAPORATOR, BRAZED PLATE No. Refrigerant Circuits 2 2 2 2 2 Water Volume, gallons (l) 4.2 (15.9) 6.4 (24.3) 6.6 (24.9) 7.5 (28.4) 8.0 (30.2) Refrigerant Side D.W.P., psig, (kPa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) Water Side D.W.P., psig, (kPa) 653 (4500) 653 (4500) 653 (4500) 653 (4500) 653 (4500) Inlet & Outlet, in. (mm) (2) 2.5 (63) 3 (76) 3 (76) 3 (76) 3 (76) Relief Valve, Flare in., (mm) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) Drain & Vent Field Field Field Field Field UNIT DIMENSIONS Length, in. (mm) 137.0 (3480) 137.0 (3480) 137.0 (3480) 137.0 (3480) 137.0 (3480) Width, in. (mm) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864) Height, in. (mm) 60.0 (1524) 60.0 (1524) 60.0 (1524) 60.0 (1524) 60.0 (1524) UNIT WEIGHTS Operating Wt, lb., (kg) 1816 (824) 2474 (1122) 2787 (1264) 2928 (1328) 3050 (1383) Shipping Wt, lb. (kg) 1771 (803) 2406 (1091) 2717 (1232) 2851 (1293) 2968 (1346) Holding charge/ circuit, lb. (kg) 10.0 (4.5) 15 (6.8) 15 (6.8) 15 (6.8) 15 (6.8)

Notes: 1. Condenser and field piping not included.


Table 23, WGZ115CA – WGZ200CA WGZ UNIT SIZE 115 130 150 170 200

Tons, (kW)44°F LWT, 125°F SDT 100.1 (352.2) 111.4 (391.7) 129.9 (456.8) 150.2 (528.3) 170.6 (599.8) No. Circuits 2 2 2 2 2 COMPRESSORS Nominal Tons 26/30 26/30 30 30 26 26 26 30 30 30 Number Per Circuit 2 2 2 2 3 3 3 3 3 3

Staging, Circuit #1 in Lead 22 / 50 / 72 / 100 25 / 50 / 75 / 100 17 / 33 / 50 / 67 / 83 / 100

15 / 33 / 48 / 67 / 81 / 100

17 / 33 / 50 / 67 / 83 / 100

Staging, Circuit #2 in Lead 22 / 50 / 72 / 100 25 / 50 / 75 / 100 17 / 33 / 50 / 67 / 83 / 100

19 / 33 / 52 / 67 / 86 / 100

17 / 33 / 50 / 67 / 83 / 100

Oil Charge, per compressor oz. (l) 230 (6.8 ) 213 (6.3) 213 (6.3) 230 (6.8) 230 (6.8) 213 (6.3) 213 (6.3)

EVAPORATOR, BRAZED PLATE------------------------------------------------⇒ SHELL-AND-TUBE No. Refrigerant Circuits 2 2 2 2 2 Water Volume, gallons (l) 8.5 (32.1) 10.5 (39.7) 57.6 (218.0) 56.9 (215.4) 56.9 (215.4) Refrigerant Side D.W.P., psig, 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) Water Side D.W.P., psig, (kPa) 653 (4500) 653 (4500) 150 (1034) 150 (1034) 150 (1034) Water Connections: In & Out, in. (mm), victaulic 3 (76) 3 (76) 8 (203) 8 (203) 8 (203) Relief Valve, Flare in., (mm) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) ⅝ (15.9) Drain & Vent Field Field ½ (12.7) ½ (12.7) ½ (12.7) UNIT DIMENSIONS Length, in. (mm) 137.0 (3480) 137.0 (3480) 154.0 (3912) 154.0 (3912) 154.0 (3912) Width, in. (mm) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864) Height, in. (mm) 60.0 (1524) 60.0 (1524) 75.0 (1905) 75.0 (1905) 75.0 (1905) UNIT WEIGHTS Operating Wt, lb., (kg) 3120 (1415) 3194 (1449) 5279 (2395) 5385 (2443) 5498 (2494) Shipping Wt, lb. (kg) 3035 (1377) 3091 (1402) 4779 (2168) 4891 (2219) 5004 (2270) Holding charge/ circuit, lb. (kg) 15 (6.8) 15 (6.8) 20 (9.1) 20 (9.1) 20 (9.1)

Notes: 1. Condenser and field piping not included

Operating Limits • Equipment room temperature limits, operating or standby: 32°F to 104°F (0°C to 40°C) • Maximum allowable condenser water pressure is 232 psig (1599 kPa). • Maximum design saturated discharge temperature is 140°F (60°C). • Maximum allowable water temperature to cooler in a non-operating cycle is 100°F (37.8°C). Maximum

entering water temperature for operating cycle is 90°F (32.2°C) (during system changeover from heating to cooling cycle).

• Minimum leaving water temperature from the cooler without freeze protection is 40°F (4.4°C). • Minimum entering tower condenser water temperature is 60°F (15.6°C). • For remote air-cooled condensers, the temperature difference between the saturated discharge temperature

and the outside air temperature (TD) must be between 15 and 35 degrees F and the saturated discharge temperature cannot exceed 135°F.

WGZ 030C through 200C IMM WGZC

Components Figure 17, Compressor Locations

4 2 3 1

Circuit 2 Circuit 1 Control Panel

EvaporatorEvaporator andCondenserConnections

NOTE: Models WGZ 150 to 200 add a #5 compressor to circuit #1 and a #6 compressor to circuit #2.

Table 24, Major Components

System #1 System #2 Expansion Valve WGZ-C Unit Size Comp. #1 Comp. #3 Comp. #2 Comp. #4

Evap. Vessel

Size

Cond. Vessel

Size System #1 System #2

30 ZP90KCE ZP90KCE ZP90KCE ZP90KCE ACH130-90DQ C1010-47 OZE-20-GA-BP15 OZE-20-GA-BP15


40 ZP120KCE ZP120KCE ZP120KCE ZP120KCE ACH130118DQ C1010-57 OZE-20-GA-BP15 OZE-20-GA-BP15











150 (3) ZP295KCE (3) ZP295KCE EV34191111/9NS C1612-156 SEHI100-30-S SEHI100-30-S




Wiring Field Wiring, Power The WGZ “C” vintage chillers are supplied standard with compressor contactors and power terminal block, designed for multi-point power supply to the unit, no compressor circuit breakers. Available options are:

• Single-point connection to power block with compressor circuit breakers • Single-point connection to disconnect switch with compressor circuit breakers • High short circuit current rating with single-point disconnect switch • Multi-point connection to disconnect switch, no compressor circuit breakers

A factory installed control circuit transformer is standard. Optionally, a field-installed control power source can be wired to the unit. Wiring and conduit selections must comply with the National Electrical Code and/or local requirements. An open fuse indicates a short, ground, or overload. Before replacing a fuse or restarting a compressor, the trouble must be found and corrected. Tables in the Electrical Data section (page 39) give specific information on recommended wire sizes. Unit power inlet wiring must enter the control box through the right side. A 7/8-inch pilot knockout is provided. (Refer to control panel picture on page 56 for general location of power inlet.)

NOTE: Use only copper supply conductors. Terminations are sized for copper only.

Field Wiring, Control A factory-mounted control transformer supplies the correct control circuit voltage. The transformer power leads are connected to the power block PB1 or disconnect switch DS1.

Interlock Wiring, Condenser Pump Starter or Air Cooled Condenser Fan Starter Provisions are made for interlocking a condenser pump starter, tower fans, a tower bypass valve, or up to eight air-cooled condenser fan contactors to be controlled by the MicroTech II unit controller. Condenser fan operation can also be controlled by pressure switches supplied with the condenser. Coil voltage must be 115 volts with a maximum of 20 VA. An evaporator and condenser (water-cooled units only) flow switch is necessary on all units. It is also advisable to wire a chilled water pump interlock in series with the flow switch for additional freeze protection. Control wiring must enter the control box through a 7/8-inch knockout provided on the panel upper left side.

Ambient Air Sensor Units with a remote air-cooled condenser will have an outdoor air sensor furnished with the unit, inside the control panel and wired to the correct terminals. It must be installed outdoors in a location that will give the true outdoor temperature that the condenser coils will see. Splicing of the sensor lead may be required. The sensor must be installed for the unit to operate.

Optional Remote Interface Panel The box containing the optional remote interface panel will have installation instructions, IOM- MT II Remote, in it.


Unit Configuration

WGZ 030CW to 130CW have two refrigerant circuits, two tandem scroll compressors (total of four), a single two-circuited brazed plate evaporator, a single two-circuited water-cooled condenser, interconnecting refrigerant piping and a control panel with associated sensors and transducers. Models WGZ 150CW to 200CW have two trio-compressors (total of 6) and a shell-and-tube evaporator.

Table 25, Schematic Piping Diagram (One of Two Circuits)

Comp#2

Comp#1

Condenser CondenserWater

EvaporatorChilledWater

S

F-D

T

S S

CV

SP

P1

LWT

T

T

Legend:

Temperature Sensor

Pressure Transducer

Pressure (High Pressure Cutout)

Temperataure Sensor, LeavingChilled Water Control

TT

TP

P1

LWT

Relief Valve

Schrader Fitting

Thermal Expansion Valve

Sight Glass / Moisture Indicator

Charging Valve

TS

CV

SSolenoid Valve

F-D Filter-Drier

Angle Valve

Ball Valve

NOTE: Standard condenser connections are on the control panel end.

IMM WGZC WGZ 030C through 200C

Electrical Data Table 26, Compressor Amp Draw

Rated Load Amps Per Compressor Rated Load Amps Per Compressor Locked Rotor Amps Standard Unit w/o Ext. OL's Optional Unit with Ext. OL's Across-The-Line Starting

Circuit 1 Circuit 2 Circuit 1 Circuit 2 Circuit 1 Circuit 2

WGZ Unit Size

Volts

No.1 No.3 No.5 No.2 No.4 No.6 No.1 No.3 No.5 No.2 No.4 No.6 No.1 No.3 No.5 No.2 No.4 No.6208 29.5 29.5 - 29.5 29.5 - 22.4 22.4 - 22.4 22.4 - 195 195 - 195 195 - 230 29.5 29.5 - 29.5 29.5 - 20.0 20.0 - 20.0 20.0 - 195 195 - 195 195 - 460 14.7 14.7 - 14.7 14.7 - 12.0 12.0 - 12.0 12.0 - 95 95 - 95 95 -

030

575 12.2 12.2 - 12.2 12.2 - n/a n/a - n/a n/a - 80 80 - 80 80 -

208 30.1 30.1 - 30.1 30.1 - 25.0 25.0 - 25.0 25.0 - 225 225 - 225 225 - 230 30.1 30.1 - 30.1 30.1 - 23.2 23.2 - 23.2 23.2 - 225 225 - 225 225 - 460 16.7 16.7 - 16.7 16.7 - 12.0 12.0 - 12.0 12.0 - 114 114 - 114 114 -

035

575 12.2 12.2 - 12.2 12.2 - n/a n/a - n/a n/a - 80 80 - 80 80 -

208 33.3 33.3 - 33.3 33.3 - 28.6 28.6 - 28.6 28.6 - 239 239 - 239 239 - 230 33.3 33.3 - 33.3 33.3 - 25.6 25.6 - 25.6 25.6 - 239 239 - 239 239 - 460 17.9 17.9 - 17.9 17.9 - 12.8 12.8 - 12.8 12.8 - 125 125 - 125 125 -

040

575 12.8 12.8 - 12.8 12.8 - n/a n/a - n/a n/a - 80 80 - 80 80 -

208 48.1 48.1 - 48.1 48.1 - 30.5 30.5 - 30.5 30.5 - 245 245 - 245 245 - 230 48.1 48.1 - 48.1 48.1 - 28.0 28.0 - 28.0 28.0 - 245 245 - 245 245 - 460 18.6 18.6 - 18.6 18.6 - 14.4 14.4 - 14.4 14.4 - 125 125 - 125 125 -

045

575 14.7 14.7 - 14.7 14.7 - 12.0 12.0 - 12.0 12.0 - 100 100 - 100 100 -

208 51.3 51.3 - 51.3 51.3 - 36.0 36.0 - 36.0 36.0 - 300 300 - 300 300 - 230 51.3 51.3 - 51.3 51.3 - 32.8 32.8 - 32.8 32.8 - 300 300 - 300 300 - 460 23.1 23.1 - 23.1 23.1 - 16.8 16.8 - 16.8 16.8 - 150 150 - 150 150 -

050

575 19.9 19.9 - 19.9 19.9 - 13.6 13.6 - 13.6 13.6 - 109 109 - 109 109 -

208 51.3 51.3 - 55.8 55.8 - 36.0 36.0 - 44.0 44.0 - 300 300 - 340 340 - 230 51.3 51.3 - 55.8 55.8 - 32.8 32.8 - 40.0 40.0 - 300 300 - 340 340 - 460 23.1 23.1 - 26.9 26.9 - 16.8 16.8 - 20.0 20.0 - 150 150 - 173 173 -

055

575 19.9 19.9 - 23.7 23.7 - 13.6 13.6 - 16.0 16.0 - 109 109 - 26.9 26.9 -

208 55.8 55.8 - 55.8 55.8 - 44.0 44.0 - 44.0 44.0 - 340 340 - 340 340 - 230 55.8 55.8 - 55.8 55.8 - 40.0 40.0 - 40.0 40.0 - 340 340 - 340 340 - 460 26.9 26.9 - 26.9 26.9 - 20.0 20.0 - 20.0 20.0 - 173 173 - 173 173 -

060

575 23.7 23.7 - 23.7 23.7 - 16.0 16.0 - 16.0 16.0 - 132 132 - 132 132 -

208 55.8 73.9 - 55.8 73.9 - 44.0 54.4 - 44.0 54.4 - 340 505 - 340 505 - 230 55.8 73.9 - 55.8 73.9 - 40.0 49.6 - 40.0 49.6 - 340 505 - 340 505 - 460 26.9 30.4 - 26.9 30.4 - 20.0 24.8 - 20.0 24.8 - 173 225 - 173 225 -

070

575 23.7 24.6 - 23.7 24.6 - 16.0 20.0 - 16.0 20.0 - 132 180 - 132 180 -

208 73.9 73.9 - 73.9 73.9 - 54.4 54.4 - 54.4 54.4 - 505 505 - 505 505 - 230 73.9 73.9 - 73.9 73.9 - 49.6 49.6 - 49.6 49.6 - 505 505 - 505 505 - 460 30.4 30.4 - 30.4 30.4 - 24.8 24.8 - 24.8 24.8 - 225 225 - 225 225 -

080

575 24.6 24.6 - 24.6 24.6 - 20.0 20.0 - 20.0 20.0 - 180 180 - 180 180 -

208 73.9 73.9 - 89.1 89.1 - 54.4 54.4 - 64.8 64.8 - 505 505 - 544 544 - 230 73.9 73.9 - 89.1 89.1 - 49.6 49.6 - 58.4 58.4 - 505 505 - 544 544 - 460 30.4 30.4 - 41.9 41.9 - 24.8 24.8 - 29.6 29.6 - 225 225 - 272 272 -

090

575 24.6 24.6 - 32.1 32.1 - 20.0 20.0 - 23.2 23.2 - 180 180 - 218 218 -

208 89.1 89.1 - 89.1 89.1 - 64.8 64.8 - 64.8 64.8 - 544 544 - 544 544 - 230 89.1 89.1 - 89.1 89.1 - 58.4 58.4 - 58.4 58.4 - 544 544 - 544 544 - 460 41.9 41.9 - 41.9 41.9 - 29.6 29.6 - 29.6 29.6 - 272 272 - 272 272 -

100

575 32.1 32.1 - 32.1 32.1 - 23.2 23.2 - 23.2 23.2 - 218 218 - 218 218 -


Table 26, Compressor Amp Draw, Continued Rated Load Amps Per Compressor Rated Load Amps Per Compressor Locked Rotor Amps

Standard Unit w/o Ext. OL's Optional Unit with Ext. OL's Across-The-Line Starting Circuit 1 Circuit 2 Circuit 1 Circuit 2 Circuit 1 Circuit 2

WGZ Unit Size

Volts

No.1 No.3 No.5 No.2 No.4 No.6 No.1 No.3 No.5 No.2 No.4 No.6 No.1 No.3 No.5 No.2 No.4 No.6208 89.1 109.6 - 89.1 109.6 - 64.8 86.3 - 64.8 86.3 - 544 599 - 544 599 - 230 89.1 109.6 - 89.1 109.6 - 58.4 78.0 - 58.4 78.0 - 544 599 - 544 599 - 460 41.9 54.5 - 41.9 54.5 - 29.6 39.0 - 29.6 39.0 - 272 310 - 272 310 -

115

575 32.1 49.4 - 32.1 49.4 - 23.2 31.2 - 23.2 31.2 - 218 239 - 218 239 -

208 109.6 109.6 - 109.6 109.6 - 83.2 86.3 - 83.2 86.3 - 599 599 - 599 599 - 230 109.6 109.6 - 109.6 109.6 - 75.2 78.0 - 75.2 78.0 - 599 599 - 599 599 - 460 54.5 54.5 - 54.5 54.5 - 37.6 39.0 - 37.6 39.0 - 310 310 - 310 310 -

130

575 49.4 49.4 - 49.4 49.4 - 30.4 31.2 - 30.4 31.2 - 239 239 - 239 239 -

208 89.1 89.1 89.1 89.1 89.1 89.1 64.8 64.8 64.8 64.8 64.8 64.8 544 544 544 544 544 544 230 89.1 89.1 89.1 89.1 89.1 89.1 58.4 58.4 58.4 58.4 58.4 58.4 544 544 544 544 544 544 460 41.9 41.9 41.9 41.9 41.9 41.9 29.6 29.6 29.6 29.6 29.6 29.6 272 272 272 272 272 272

150

575 32.1 32.1 32.1 32.1 32.1 32.1 23.2 23.2 23.2 23.2 23.2 23.2 218 544 218 218 218 218

208 89.1 89.1 89.1 109.6 109.6 109.6 64.8 64.8 64.8 86.3 86.3 86.3 544 544 544 599 599 599 230 89.1 89.1 89.1 109.6 109.6 109.6 58.4 58.4 58.4 78.0 78.0 78.0 544 544 544 599 599 599 460 41.9 41.9 41.9 54.5 54.5 54.5 29.6 29.6 29.6 39.0 39.0 39.0 272 272 272 310 310 310

170

575 32.1 32.1 32.1 49.4 49.4 49.4 23.2 23.2 23.2 31.2 31.2 31.2 218 544 218 239 239 239

208 109.6 109.6 109.6 109.6 109.6 109.6 86.3 86.3 86.3 86.3 86.3 86.3 599 599 599 599 599 599 230 109.6 109.6 109.6 109.6 109.6 109.6 78.0 78.0 78.0 78.0 78.0 78.0 599 599 599 599 599 599 460 54.5 54.5 54.5 54.5 54.5 54.5 39.0 39.0 39.0 39.0 39.0 39.0 310 310 310 310 310 310

200

575 49.4 49.4 49.4 49.4 49.4 49.4 31.2 31.2 31.2 31.2 31.2 31.2 239 239 239 239 239 239 NOTES: 1. Compressor RLA values are for wire sizing purposes only and do not reflect normal operating current draw. 2. External compressor overloads only available on packaged water-cooled units, except Models WGZ 030CW – 040CW @ 575V

Table 27, Maximum Fuse Size Maximum Fuse Size

Single Point Multiple Point Power Supply Power Supply Power Supply Power Supply

without Ext. OL's with Ext. OL's Without Ext. OL's With External OL's

WGZ Unit Size

Voltage 3-Phase

Total Unit Total Unit Circ.#1 Circ.#2 Circ.#1 Circ.#2 208 150 110 90 90 70 70 230 150 100 90 90 60 60 460 70 60 45 45 35 35

030

575 60 N/A 35 35 N/A N/A

208 150 125 90 90 80 80 230 150 110 90 90 70 70 460 80 60 50 50 35 35

035

575 60 N/A 35 35 N/A N/A

208 175 150 100 100 90 90 230 175 125 100 100 80 80 460 90 60 50 50 40 40

040

575 60 N/A 40 40 N/A N/A

208 250 150 150 150 90 90 230 250 125 150 150 90 90 460 90 70 60 60 45 45

045

575 70 60 45 45 35 35


Table 27, Maximum Fuse Size, Continued Single Point Multiple Point

Power Supply Power Supply Power Supply Power Supply without Ext. OL's with Ext. OL's Without Ext. OL's With External OL's

WGZ Unit Size

Voltage 3-Pha

Total Unit Total Unit Circ.#1 Circ.#2 Circ.#1 Circ.#2 208 250 175 150 150 110 110 230 250 150 150 150 100 100 460 110 80 70 70 50 50

050

575 100 70 60 60 40 40

208 250 200 150 175 115 125 230 250 175 150 175 100 125 460 125 90 70 80 50 60

055

575 110 70 60 70 40 50

208 250 225 175 175 125 125 230 250 200 175 175 125 125 460 125 100 80 80 60 60

060

575 110 80 70 70 50 50

208 350 250 200 200 150 150 230 350 225 200 200 150 150 460 150 110 90 90 70 70

070

575 125 90 70 70 60 60

208 350 250 225 225 175 175 230 350 250 225 225 150 150 460 150 125 90 90 80 80

080

575 125 100 80 80 60 60

208 400 300 225 250 175 200 230 400 250 225 250 150 175 460 175 125 90 125 80 90

090

575 150 110 80 100 60 70

208 450 300 250 250 200 200 230 450 300 250 250 175 175 460 200 150 125 125 90 90

100

575 150 110 100 100 70 70 208 500 400 300 300 250 250 230 500 350 300 300 225 225 460 250 175 150 150 110 110

115

575 200 125 125 125 90 90 208 500 400 350 350 250 250 230 500 350 350 350 250 250 460 250 175 175 175 125 125

130

575 250 150 150 150 100 90 208 600 450 350 350 250 250 230 600 400 350 350 225 225 460 300 200 175 175 125 125

150

575 225 150 125 125 90 90 208 700 500 350 450 250 350 230 700 450 350 450 225 300 460 350 225 175 225 125 150

170

575 300 175 125 200 90 125 208 700 600 450 450 350 350 230 700 500 450 450 300 300 460 350 250 225 225 150 150

200

575 350 200 200 200 125 125

NOTE :"Maximum Fuse Sizes" are selected at approximately 225% of the largest compressor RLA, plus 100% of all other loads.


Table 28, Wire Sizing Amps, Single Point Power Minimum Circuit Ampacity

(MCA) Power Supply Power Supply

Field Wire

Quantity

Wire Gauge 75°C

Field Wire Quantity

Wire Gauge 75°C

WGZ Unit Size

Volts Single Point

Power Supply Without Ext

OL's (Note #3)

Single Point Power Supply With Ext OL's

(Note #3) Without External OL's With External Overloads

208 126 95 3 #1 3 #3 230 126 85 3 #1 3 #4 460 63 51 3 #6 (Note 1) 3 #6 (Note 1

030

575 52 N/A 3 #6 (Note 1 -- --

208 128 106 3 #1 3 #2 230 128 99 3 #1 3 #3 460 71 51 3 #6 (Note 1 3 #6 (Note 1

035

575 52 N/A 3 #6 (Note 1 -- --

208 142 120 3 1/0 3 #1 230 142 109 3 1/0 3 #2 460 76 55 3 #6 (Note 1 3 #6 (Note 1

040

575 55 N/A 3 #6 (Note 1 -- --

208 205 130 3 4/0 3 #1 230 205 118 3 4/0 3 #1 460 79 62 3 #4 3 #6 (Note 1

045

575 63 51 3 #6 (Note 1 3 #6 (Note 1

208 218 153 3 4/0 3 2/0 230 218 140 3 4/0 3 1/0 460 98 72 3 #3 3 #4

050

575 85 58 3 #4 3 #6 (Note 1

208 228 171 3 4/0 3 2/0 230 228 156 3 4/0 3 2/0 460 107 79 3 #2 3 #4

055

575 93 63 3 #3 3 #6 (Note 1

208 237 187 3 250 3 3/0 230 237 170 3 250 3 2/0 460 114 85 3 #2 3 #4

060

575 101 68 3 #2 3 #4

208 278 211 3 300 3 4/0 230 278 192 3 300 3 3/0 460 122 96 3 #1 3 #3

070

575 103 77 3 #2 3 #4

208 314 232 3 400 3 250 230 314 211 3 400 3 4/0 460 129 106 3 #1 3 #2

080

575 105 85 3 #2 3 #4

208 348 255 3 500 3 250 230 348 231 3 500 3 250 460 155 116 3 2/0 3 #1

090

575 122 92 3 #1 3 #3

Continued next page.


Table 28, Wire Sizing Amps, Single Point Power, Continued Minimum Circuit Ampacity (MCA) Power Supply Power Supply

Field Wire Quantity

Wire Gauge 75°C

Field Wire Quantity

Wire Gauge 75°C

WGZ Unit Size

Volts Single Point

Power Supply Without Ext OL's

(Note #3)

Single Point Power Supply With Ext OL's

(Note #3) Without External OL's With External Overloads

208 379 276 3 500 3 300 230 379 248 3 500 3 250 460 178 126 3 3/0 3 #1

100

575 136 99 3 1/0 3 #3

208 427 324 6 (2) 4/0 3 400 230 427 292 6 (2) 4/0 3 400 460 208 147 3 4/0 3 1/0

115

575 176 117 3 3/0 3 #1

208 467 367 6 (2) 250 3 500 230 467 332 6 (2) 250 3 400 460 233 166 3 250 3 2/0

130

575 210 133 3 4/0 3 1/0

208 557 405 6 (2) 300 6 (2) 4/0 230 557 365 6 (2) 300 3 500 460 262 185 3 300 3 3/0

150

575 201 145 3 4/0 3 1/0

208 624 475 6 (2) 400 6 (2) 250 230 624 429 6 (2) 400 6 (2) 4/0 460 303 216 3 350 3 4/0

170

575 257 171 3 300 3 2/0

208 685 540 6 (2) 500 6 (2) 300 230 685 486 6 (2) 500 6 (2) 250 460 341 244 3 500 3 250

200

575 309 195 3 350 3 3/0

NOTES: 1. Field wire size must be #4 AWG if High Interrupt Switch or HSCCR is ordered 2. Unit wire sizing amps (MCA) are equal to 125% of the largest compressor-motor RLA plus 100% of RLA of all other loads in the circuit. 3. Single point power supply requires a single fused disconnect to supply electrical power to the unit. 4. Multiple point power supply requires two independent power supplies, each with separate fused disconnects. The control circuit will be

wired to Circuit #1 from the factory).


Table 29, Wire Sizing, Multi-point Power

Minimum Circuit Ampacity (MCA) Power Supply Without External OL's

Power Supply With External OL's

Without Ext OL's With External OL's Wire Gauge, 75C Wire Gauge,75C WGZ Unit Size

Volts Circuit No.1

Circuit No.2

Circuit No.1

Circuit No.2

Field Wire

QuantityCircuit No.1

Circuit No.2

Field Wire


Circuit No.2

208 67 67 51 51 3 #4 #4 3 #6 #6 230 67 67 45 45 3 #4 #4 3 #8 #8 460 33 33 27 27 3 #10 #10 3 #10 #10

030

575 28 28 N/A N/A 3 #10 #10 3 -- -- 208 68 68 57 57 3 #4 #4 3 #6 #6 230 68 68 53 53 3 #4 #4 3 #6 #6 460 38 38 27 27 3 #8 #8 3 #10 #10

035

575 28 28 N/A N/A 3 #10 #10 3 -- -- 208 75 75 65 65 3 #4 #4 3 #6 #6 230 75 75 58 58 3 #4 #4 3 #6 #6 460 41 41 29 29 3 #8 #8 3 #10 #10

040

575 29 29 N/A N/A 3 #10 #10 3 -- -- 208 109 109 69 69 3 #2 #2 3 #4 #4 230 109 109 63 63 3 #2 #2 3 #6 #6 460 42 42 33 33 3 #8 #8 3 #10 #10

045

575 33 33 27 27 3 #10 #10 3 #10 #10 208 116 116 81 81 3 #1 #1 3 #4 #4 230 116 116 74 74 3 #1 #1 3 #4 #4 460 52 52 38 38 3 #6 #6 3 #8 #8

050

575 45 45 31 31 3 #8 #8 3 #10 #10 208 116 126 81 99 3 #1 #1 3 #4 #3 230 116 126 74 90 3 #1 #1 3 #4 #3 460 52 61 38 45 3 #6 #6 3 #8 #8

055

575 45 54 31 36 3 #8 #6 3 #10 #8 208 126 126 99 99 3 #1 #1 3 #3 #3 230 126 126 90 90 3 #1 #1 3 #3 #3 460 61 61 45 45 3 #6 #6 3 #8 #8

060

575 54 54 36 36 3 #6 #6 3 #8 #8 208 149 149 112 112 3 1/0 1/0 3 #2 #2 230 149 149 102 102 3 1/0 1/0 3 #2 #2 460 65 65 51 51 3 #6 #6 3 #6 #6

070

575 55 55 41 41 3 #6 #6 3 #8 #8 208 167 167 123 123 3 2/0 2/0 3 #1 #1 230 167 167 112 112 3 2/0 2/0 3 #2 #2 460 69 69 56 56 3 #4 #4 3 #6 #6

080

575 56 56 45 45 3 #6 #6 3 #8 #8 208 167 201 123 146 3 2/0 4/0 3 #1 1/0 230 167 201 112 132 3 2/0 4/0 3 #2 1/0 460 69 95 56 67 3 #4 #3 3 #6 #4

090

575 56 73 45 53 3 #6 #4 3 #8 #6 208 201 201 146 146 3 4/0 4/0 3 1/0 1/0 230 201 201 132 132 3 4/0 4/0 3 1/0 1/0 460 95 95 67 67 3 #3 #3 3 #4 #4

100

575 73 73 53 53 3 #4 #4 3 #6 #6 208 227 227 173 173 3 4/0 4/0 3 2/0 2/0 230 227 227 156 156 3 4/0 4/0 3 2/0 2/0 460 111 111 79 79 3 #2 #2 3 #4 #4

115

575 94 94 63 63 3 #3 #3 3 #6 #6



Table 30, Wire Sizing, Multi-point Power, Continued

Minimum Circuit Ampacity (MCA) Power Supply Without External OL's

Power Supply With External OL's

Without Ext OL's With External OL's Wire Gauge, 75°C Wire Gauge,75°C WGZ Unit Size

Volts Circuit No.1

Circuit No.2

Circuit No.1

Circuit No.2

Field Wire


Circuit No.2

Field Wire


Circuit No.2

208 247 247 195 195 3 250 250 3 3/0 3/0 230 247 247 176 176 3 250 250 3 3/0 3/0 460 123 123 88 88 3 #1 #1 3 #3 #3

130

575 112 112 71 71 3 #2 #2 3 #4 #4 208 290 290 211 211 3 350 350 3 4/0 4/0 230 290 290 190 190 3 350 350 3 3/0 3/0 460 137 137 97 97 3 1/0 1/0 3 #3 #3

150

575 105 105 76 76 3 #2 #2 3 #4 #4 208 290 357 211 281 3 350 500 3 4/0 300 230 290 357 190 254 3 350 500 3 3/0 250 460 137 178 97 127 3 1/0 3/0 3 #3 #1

170

575 105 161 76 102 3 #2 2/0 3 #4 #2 208 357 357 281 281 3 500 500 3 300 300 230 357 357 254 254 3 500 500 3 250 250 460 178 178 127 127 3 3/0 3/0 3 #1 #1

200

575 161 161 102 102 3 2/0 2/0 3 #2 #2

NOTES 1. Unit wire sizing amps are equal to 125% of the largest compressor-motor RLA plus 100% of the other compressor RLA's... 2. Multiple Point power supply requires a separate fused disconnect for each circuit to supply electrical power to the unit. 3. External Compressor Overload option is only available with packaged units with water-cooled condenser....


Table 31, Single Point Connection Sizing, Without External Overloads

Factory-Installed Power Block

Factory-Installed HSCCR Disconnect Switch (Circuit Breaker)

Factory-Installed, Molded Case Disconnect Switch WGZ

Unit Size

Volts Power Block or Bus

Bar Lugs Size [2]

Connection Wire Range –

CU [3]

Switch Size [2]

Connection [3] Wire Range - CU

Switch Size [2]


208 175 (1) 2/0 - #14 250 (1) 350 - #4 250 (1) 350 - #4 230 175 (1) 2/0 - #14 250 (1) 350 - #4 250 (1) 350 - #4 460 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10

030

575 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10 208 175 (1) 2/0 - #14 250 (1) 350 - #4 250 (1) 350 - #4 230 175 (1) 2/0 - #14 250 (1) 350 - #4 250 (1) 350 - #4 460 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10

035

575 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10 208 175 (1) 2/0 - #14 250 (1) 350 - #4 250 (1) 350 - #4 230 175 (1) 2/0 - #14 250 (1) 350 - #4 250 (1) 350 - #4 460 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10

040

575 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10 208 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4 230 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4 460 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10

045

575 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10 208 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4 230 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4 460 175 (1) 2/0 - #14 250 (1) 350 - #4 125 (1) 3/0- #3

050

575 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10 208 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4 230 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4 460 175 (1) 2/0 - #14 250 (1) 350 - #4 125 (1) 3/0- #3

055

575 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10 208 380 (1) 500 - #4 400 (2) 500- 3/0 400 (2) 500- 3/0 230 380 (1) 500 - #4 400 (2) 500- 3/0 400 (2) 500- 3/0 460 175 (1) 2/0 - #14 250 (1) 350 - #4 125 (1) 3/0- #3

060

575 175 (1) 2/0 - #14 250 (1) 350 - #4 125 (1) 3/0- #3 208 380 (1) 500 - #4 600 (2) 500- 3/0 400 (2) 500- 3/0 230 380 (1) 500 - #4 600 (2) 500- 3/0 400 (2) 500- 3/0 460 175 (1) 2/0 - #14 250 (1) 350 - #4 250 (1) 350 - #4

070

575 175 (1) 2/0 - #14 250 (1) 350 - #4 125 (1) 3/0- #3 208 380 (1) 500 - #4 600 (2) 500- 3/0 400 (2) 500- 3/0 230 380 (1) 500 - #4 600 (2) 500- 3/0 400 (2) 500- 3/0 460 175 (1) 2/0 - #14 250 (1) 350 - #4 250 (1) 350 - #4

080

575 175 (1) 2/0 - #14 250 (1) 350 - #4 125 (1) 3/0- #3 208 380 (1) 500 - #4 600 (2) 500- 3/0 400 (2) 500- 3/0 230 380 (1) 500 - #4 600 (2) 500- 3/0 400 (2) 500- 3/0 460 175 (1) 2/0 - #14 400 (2) 500- 3/0 250 (1) 350 - #4

090

575 175 (1) 2/0 - #14 250 (1) 350 - #4 250 (1) 350 - #4 208 380 (1) 500 - #4 800 (4) 500- 250 600 (2) 500- 3/0 230 380 (1) 500 - #4 800 (4) 500- 250 600 (2) 500- 3/0 460 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4

100

575 175 (1) 2/0 - #14 250 (1) 350 - #4 250 (1) 350 - #4 208 760 (2) 500 - #4 800 (2) 500- #1 (Note #1) 600 (2) 500- 3/0 230 760 (2) 500 - #4 800 (2) 500- #1 (Note #1) 600 (2) 500- 3/0 460 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4

115

575 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4 208 760 (2) 500 - #4 800 (4) 500- 250 600 (2) 500- 3/0 230 760 (2) 500 - #4 800 (4) 500- 250 600 (2) 500- 3/0 460 380 (1) 500 - #4 400 (2) 500- 3/0 400 (2) 500- 3/0

130

575 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4



Single Point Connection Sizing, Without External Overloads, Continued

Factory-Installed Power Block

Factory-Installed HSCCR Disconnect Switch

Circuit Breaker

Factory-Installed Disconnect Switch Molded Case

WGZ Unit Size

Volts Power Block or Bus Bar Lugs Size [2]

See Note below

Connection Wire Range –

CU [3]

Switch Size [2]


Switch Size [2]


208 760 (2) 500 - #4 n/a -- 800 (4) 500- 250 230 760 (2) 500 - #4 n/a -- 800 (4) 500- 250 460 380 (1) 500 - #4 600 (2) 500- 3/0 400 (2) 500- 3/0

150

575 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4 208 760 (2) 500 - #4 n/a -- 800 (4) 500- 250 230 760 (2) 500 - #4 n/a -- 800 (4) 500- 250 460 380 (1) 500 - #4 400 (2) 500- 3/0 400 (2) 500- 3/0

170

575 380 (1) 500 - #4 400 (2) 500- 3/0 400 (2) 500- 3/0 208 760 (2) 500 - #4 n/a -- 800 (4) 500- 250 230 760 (2) 500 - #4 n/a -- 800 (4) 500- 250 460 380 (1) 500 - #4 600 (2) 500- 3/0 400 (2) 500- 3/0

200

575 380 (1) 500 - #4 600 (2) 500- 3/0 400 (2) 500- 3/0 NOTES: 1. The disconnect has special lugs 2. Unit wire sizing amps are equal to 125% of the largest compressor-motor RLA plus 100% of the other

compressor RLA's. 3. Single Point power supply requires a single fused disconnect to supply electrical electrical power to the unit 4. External Compressor Overload Option is only available with Packaged Units with Water Cooled Condenser. 5. “Size" is the maximum amperage rating for the terminals or the main electrical device. 6. "Connection" is the range of wire sizes that the terminals on the electrical device will accept.

Table 32, Single Point Connection Sizing, With External Overloads-

Factory Installed Power Block

Factory Installed HSCCR Disconnect Switch Circuit

Breaker

Factory Installed Disconnect Switch Molded

Case WGZ Unit Size

Volts Power Block or Bus Bar Lugs

Size [2,5])

Connection Wire Range CU

[6]

Switch Size [2,5]

Connection Wire Range

CU [6]

Switch Size [2,5]

Connection Wire Range – CU

[6]

208 175 (1) 2/0 - #14 250 (1) 350 - #4 125 (1) 3/0- #3 230 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10 460 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10

030

575 n/a - n/a - n/a - 208 175 (1) 2/0 - #14 250 (1) 350 - #4 125 (1) 3/0- #3 230 175 (1) 2/0 - #14 250 (1) 350 - #4 125 (1) 3/0- #3 460 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10

035

575 n/a - n/a - n/a - 208 175 (1) 2/0 - #14 250 (1) 350 - #4 250 (1) 350 - #4 230 175 (1) 2/0 - #14 250 (1) 350 - #4 125 (1) 3/0- #3 460 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10

040

575 n/a - n/a - n/a - 208 380 (1) 500 - #4 250 (2) 500- #1 250 (1) 350 - #4 230 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4 460 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10

045

575 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10 208 380 (1) 500 - #4 400 (2) 500- #4 (Note #1) 250 (1) 350 - #4 230 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4 460 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10

050

575 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10



Factory Installed Power Block

Factory Installed HSCCR Disconnect Switch (Circuit Breaker)

Factory Installed, Molded Case Disconnect Switch

WGZ Unit Size

Volts Power Block or Bus Bar Lugs

Size [2,5])

Connection Wire Range CU

[6]

Switch Size [2,5]


CU [6]

Switch Size [2,5]


CU [6]

208 380 (1) 500 - #4 400 (2) 500- #4 (Note #1) 250 (1) 350 - #4 230 380 (1) 500 - #4 400 (2) 500- #4 (Note #1) 250 (1) 350 - #4 460 175 (1) 2/0 - #14 250 (1) 350 - #4 100 (1) 1/0 - #10

055

575 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10 208 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4 230 380 (1) 500 - #4 400 (2) 500- #4 (Note #1) 250 (1) 350 - #4 460 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10

060

575 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10 208 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4 230 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4 460 175 (1) 2/0 - #14 250 (1) 350 - #4 125 (1) 3/0- #3

070

575 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10 208 380 (1) 500 - #4 400 (2) 500- 3/0 400 (2) 500- 3/0 230 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4 460 175 (1) 2/0 - #14 250 (1) 350 - #4 125 (1) 3/0- #3

080

575 175 (1) 2/0 - #14 150 (1) 350 - #4 100 (1) 1/0 - #10 208 380 (1) 500 - #4 600 (2) 500- 3/0 400 (2) 500- 3/0 230 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4 460 175 (1) 2/0 - #14 250 (1) 350 - #4 125 (1) 3/0- #3

090

575 175 (1) 2/0 - #14 250 (1) 350 - #4 100 (1) 1/0 - #10 208 380 (1) 500 - #4 600 (2) 500- 3/0 400 (2) 500- 3/0 230 380 (1) 500 - #4 600 (2) 500- 3/0 400 (2) 500- 3/0 460 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4

100

575 175 (1) 2/0 - #14 250 (1) 350 - #4 125 (1) 3/0- #3 208 760 (2) 500 - #4 600 (2) 500- 3/0 400 (2) 500- 3/0 230 760 (2) 500 - #4 600 (2) 500- 3/0 400 (2) 500- 3/0 460 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4

115

575 380 (1) 500 - #4 250 (1) 350 - #4 125 (1) 3/0- #3 208 760 (2) 500 - #4 600 (2) 500- 3/0 400 (2) 500- 3/0 230 760 (2) 500 - #4 600 (2) 500- 3/0 400 (2) 500- 3/0 460 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4

130

575 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4 208 760 (2) 500 - #4 800 (2) 500- #1 (Note #1) 600 (2) 500- 3/0 230 760 (2) 500 - #4 800 (4) 500- 250 600 (2) 500- 3/0 460 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4

150

575 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4 208 760 (2) 500 - #4 800 (4) 500- 250 600 (2) 500- 3/0 230 760 (2) 500 - #4 800 (2) 500- #1 (Note #1) 600 (2) 500- 3/0 460 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4

170

575 380 (1) 500 - #4 400 (2) 500- #4 (Note #1) 250 (1) 350 - #4 208 760 (2) 500 - #4 n/a -- 600 (2) 500- 3/0 230 760 (2) 500 - #4 800 (4) 500- 250 600 (2) 500- 3/0 460 380 (1) 500 - #4 400 (2) 500- 3/0 400 (2) 500- 3/0

200

575 380 (1) 500 - #4 400 (2) 500- 3/0 250 (1) 350 - #4 NOTES:

1. The disconnect has special lugs. 2. Unit wire sizing amps are equal to 125% of the largest compressor-motor RLA plus 100% of the other

compressor RLA's. 3. Single Point power supply requires a single fused disconnect to supply electrical power to the unit 4. External Compressor Overload Option is only available with Packaged Units with Water Cooled

Condenser. 5. “Size" is the maximum amperage rating for the terminals or the main electrical device. 6. "Connection" is the range of wire sizes that the terminals on the electrical device will accept.


Figure 18, Multi- Point Connection Sizing, Without External Overloads Power Terminal Block Factory Installed Disconnect

-Circuit #1 Circuit #2 Circuit #1 Circuit #2 Power Block or Bus Bar Lugs

Power Block or Bus Bar Lugs Molded Case Molded Case

WGZ Unit Size

Volts

Size (1) Connection (2)

Wire Range Size (1)

Connection (2) Wire Range

Switch Size (1)

Connection (2) Wire Range -

Copper

Switch Size (1)


Copper 208 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10 230 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10 460 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10

030

575 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10 230 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10 460 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10

035

575 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10 230 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10 460 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10

040

575 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 175 #14 - 2/0 175 #14 - 2/0 125 (1) 3/0- #3 125 (1) 3/0- #3 230 175 #14 - 2/0 175 #14 - 2/0 125 (1) 3/0- #3 125 (1) 3/0- #3 460 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10

045

575 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 175 #14 - 2/0 175 #14 - 2/0 125 (1) 3/0- #3 125 (1) 3/0- #3 230 175 #14 - 2/0 175 #14 - 2/0 125 (1) 3/0- #3 125 (1) 3/0- #3 460 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10

050

575 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 175 #14 - 2/0 175 #14 - 2/0 125 (1) 3/0- #3 250 (1) 350 - #4 230 175 #14 - 2/0 175 #14 - 2/0 125 (1) 3/0- #3 250 (1) 350 - #4 460 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10

055

575 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 175 #14 - 2/0 175 #14 - 2/0 250 (1) 350 - #4 250 (1) 350 - #4 230 175 #14 - 2/0 175 #14 - 2/0 250 (1) 350 - #4 250 (1) 350 - #4 460 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10

060

575 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 175 #14 - 2/0 175 #14 - 2/0 250 (1) 350 - #4 250 (1) 350 - #4 230 175 #14 - 2/0 175 #14 - 2/0 250 (1) 350 - #4 250 (1) 350 - #4 460 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10

070

575 175 #14 - 2/0 175 #14 - 2/0 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 175 (1) 2/0 - #14 175 (1) 2/0 - #14 250 (1) 350 - #4 250 (1) 350 - #4 230 175 (1) 2/0 - #14 175 (1) 2/0 - #14 250 (1) 350 - #4 250 (1) 350 - #4 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10

080

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 175 (1) 2/0 - #14 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4 230 175 (1) 2/0 - #14 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10

090

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10



Figure 19, Multi- Point Connection Sizing, Without External Overloads, Continued Power Terminal Block Factory Installed Disconnect

-Circuit #1 Circuit #2 Circuit #1 Circuit #2 Power Block or Bus Bar Lugs

Power Block or Bus Bar Lugs Molded Case Molded Case

WGZ Unit Size

Volts

Size (1) Connection (2)

Wire Range Size (1)

Connection (2) Wire Range

Switch Size (1)


Copper

Switch Size (1)


Copper 208 380 (1) 500 - #4 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4 230 380 (1) 500 - #4 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10

100

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 380 (1) 500 - #4 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4 230 380 (1) 500 - #4 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 125 (1) 3/0- #3 125 (1) 3/0- #3

115

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 380 (1) 500 - #4 380 (1) 500 - #4 400 (2) 500- 3/0 400 (2) 500- 3/0 230 380 (1) 500 - #4 380 (1) 500 - #4 400 (2) 500- 3/0 400 (2) 500- 3/0 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 250 (1) 350 - #4 250 (1) 350 - #4

130

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 125 (1) 3/0- #3 125 (1) 3/0- #3 208 380 (1) 500 - #4 380 (1) 500 - #4 400 (2) 500- 3/0 400 (2) 500- 3/0 230 380 (1) 500 - #4 380 (1) 500 - #4 400 (2) 500- 3/0 400 (2) 500- 3/0 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 250 (1) 350 - #4 250 (1) 350 - #4

150

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 125 (1) 3/0- #3 125 (1) 3/0- #3 208 380 (1) 500 - #4 380 (1) 500 - #4 400 (2) 500- 3/0 400 (2) 500- 3/0 230 380 (1) 500 - #4 380 (1) 500 - #4 400 (2) 500- 3/0 400 (2) 500- 3/0 460 175 (1) 2/0 - #14 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4

170

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 125 (1) 3/0- #3 250 (1) 350 - #4 208 380 (1) 500 - #4 380 (1) 500 - #4 400 (2) 500- 3/0 400 (2) 500- 3/0 230 380 (1) 500 - #4 380 (1) 500 - #4 400 (2) 500- 3/0 400 (2) 500- 3/0 460 380 (1) 500 - #4 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4

200

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 250 (1) 350 - #4 250 (1) 350 - #4 NOTES: 1. Unit wire sizing amps are equal to 125% of the largest compressor-motor RLA plus 100% of the other compressor RLA's. 2. Multiple-Point power supply requires a separate fused disconnect for each circuit to supply electrical power to the unit 3 . External Compressor Overload Option is only available with packaged units with water cooled condenser. - 5. "Size" is the maximum amperage rating for the terminals or the main electrical device. 6. "Connection" is the range of wire sizes that the terminals on the electrical device will accept.


Table 33, Multi- Point Connection Sizing, With External Overloads NOTE: (x) indicates note number.

Power Terminal Block Factory Installed Disconnect Switch -Circuit #1 -Circuit #2 Circuit.#1 Circuit.#2

Molded Case Molded Case WGZ Unit Size

Volts Power Block or Bus Bar Lug Size (1)

Connection (2)

Wire Range

Power Block or Bus Bar

Lugs Size (1)

Connection (2)

Wire Range Switch Size (1)

Connection (2) Wire Range - Copper

Switch Size (1)

Connection (2) Wire Range - Copper

208 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 230 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10

030

575 n/a - n/a - n/a - n/a - 208 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 230 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10

035

575 n/a - n/a - n/a - n/a - 208 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 230 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10

040

575 n/a - n/a - n/a - n/a - 208 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 230 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10

045

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 230 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10

050

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 125 (1) 3/0- #3 230 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10

055

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 175 (1) 2/0 - #14 175 (1) 2/0 - #14 125 (1) 3/0- #3 125 (1) 3/0- #3 230 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10

060

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 175 (1) 2/0 - #14 175 (1) 2/0 - #14 125 (1) 3/0- #3 125 (1) 3/0- #3 230 175 (1) 2/0 - #14 175 (1) 2/0 - #14 125 (1) 3/0- #3 125 (1) 3/0- #3 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10

070

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 175 (1) 2/0 - #14 175 (1) 2/0 - #14 250 (1) 350 - #4 250 (1) 350 - #4 230 175 (1) 2/0 - #14 175 (1) 2/0 - #14 125 (1) 3/0- #3 125 (1) 3/0- #3 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10

080

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 175 (1) 2/0 - #14 175 (1) 2/0 - #14 250 (1) 350 - #4 250 (1) 350 - #4 230 175 (1) 2/0 - #14 175 (1) 2/0 - #14 125 (1) 3/0- #3 250 (1) 350 - #4 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10

090

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10



Table 34, Multi- Point Connection Sizing, With External Overloads, Continued Power Terminal Block Factory Installed Disconnect Switch

-Circuit #1 -Circuit #2 Circuit.#1 Circuit.#2

Molded Case Molded Case WGZ Unit Size

Volts Power

Block or Bus Bar

Lugs Size (1)

Connection (2)

Wire Range

Power Block or Bus Bar Lugs

Size (1)

Connection (2)

Wire Range Switch Size (1)


Copper

Switch Size (1)


Copper

208 380 (1) 500 - #4 380 (4) (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4 230 380 (1) 500 - #4 380 (4) (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10

100

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 380 (1) 500 - #4 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4 230 380 (1) 500 - #4 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10

115

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 380 (1) 500 - #4 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4 230 380 (1) 500 - #4 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10

130

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 380 (1) 500 - #4 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4 230 380 (1) 500 - #4 380 (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 125 (1) 3/0- #3 125 (1) 3/0- #3

150

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 100 (1) 1/0 - #10 208 380 (1) 500 - #4 380 (1) 500 - #4 250 (1) 350 - #4 400 (2) 500- 3/0 230 380 (1) 500 - #4 380 (1) 500 - #4 250 (1) 350 - #4 400 (2) 500- 3/0 460 175 (1) 2/0 - #14 175 (1) 2/0 - #14 125 (1) 3/0- #3 250 (1) 350 - #4

170

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 100 (1) 1/0 - #10 125 (1) 3/0- #3 208 380 (1) 500 - #4 380 (1) 500 - #4 400 (2) 500- 3/0 400 (2) 500- 3/0 230 380 (1) 500 - #4 380 (1) 500 - #4 400 (2) 500- 3/0 400 (2) 500- 3/0 460 380 (1) 500 - #4 380 (4) (1) 500 - #4 250 (1) 350 - #4 250 (1) 350 - #4

200

575 175 (1) 2/0 - #14 175 (1) 2/0 - #14 125 (1) 3/0- #3 125 (1) 3/0- #3 NOTES: 1. Unit wire sizing amps are equal to 125% of the largest compressor-motor RLA plus 100% of the other compressor RLA's. 2. Multiple Point power supply requires a separate fused disconnect for each circuit to supply electrical power to the unit 3. External Compressor Overload Option is only available with Packaged Units with Water Cooled Condenser.

Electrical Notes Notes for “Electrical Data Single Point” Power: 1. If a separate 115V power supply is used for the control circuit, then the wire sizing amps is 10 amps for

all unit sizes. 2. Recommended power lead wire sizes for 3 conductors per conduit are based on 100% conductor ampacity

in accordance with NEC. Voltage drop has not been included. Therefore, it is recommended that power leads be kept short. All terminal block connections must be made with copper wire.

3. The recommended power lead wire sizes are based on an ambient temperature of 86°F (30°C). Ampacity correction factors must be applied for other ambient temperatures. Refer to the National Electrical Code Handbook.

4. Must be electrically grounded according to national and local electrical codes.


Voltage Limitations: 1. Within ± 10 percent of nameplate rating

2. Voltage unbalance not to exceed 2% with a resultant current unbalance of 6 to 10 times the voltage unbalance per NEMA MG-1, 1998 Standard. This is an important restriction that must be adhered to.

Notes for “Field Wiring Data” 1. Requires a single disconnect to supply electrical power to the unit. This power supply must either be

fused or use a circuit breaker. 2. All field wiring to unit power block or optional non-fused disconnect switch must be copper. 3. All field wire size values given in table apply to 75°C rated wire per NEC.

Supplemental Overloads Option Supplemental overloads option is used to reduce the required electrical service size and wire sizing to the water cooled version of WGZ chillers. The overloads reduce the electrical ratings for the compressor because water-cooled duty is less severe than air cooled duty. The overload option is only available for models with water-cooled condensers (not WGZ-CA models with air-cooled condensers).

Standard Panel Ratings (kA) WGZ-C Model Size Voltage

WGZ 030-035 WGZ 040-090 WGZ 100-200 208-230 5 10 10

460 5 5 10 575 5 5 10

Optional Panel Ratings (kA) Options, Single-Point Power Connection Only

Voltage High Short Circuit Current Rating

High Interrupt Disconnect Switch

208-230 100 100 460 65 65 575 25 25

NOTE High Short Circuit Current Rating (HSCCR) provides all panel components rated per above table and is so labeled. High Interrupt Disconnect Switch provides for only a disconnect switch with the rating, and the panel has no special labeling.

Circuit Breakers The circuit breaker used in the High Short Circuit panel option may have a higher trip rating than the unit Maximum Overload Protection (MOP) value shown on the unit nameplate. The circuit breaker is installed as a service disconnect switch and does not function as branch circuit protection, mainly that the protection device must be installed at the point of origin of the power wiring. The breaker (disconnect switch) is oversized to avoid nuisance trips at high ambient temperature conditions


Field Wiring Diagram Figure 20, WGZ 030CW – 200CW Field Wiring Diagram

FIELD WIRING FOR WGZ030-200C

DWG. 330538901 REV.0D

PACKAGE/ WITH CONDENSER WITH MICROTECH CONTROLLER

TO COMPRESSOR(S)AND FAN MOTORS

DISCONNECT(BY OTHERS)

3 PHASE

POWER

120VACCONTROL POWER

GND LUGUNIT MAIN

TERMINAL BLOCK

FUSED CONTROLCIRCUIT TRANSFORMER

OPTION

120 VAC

TB1

TB1-20

CHW PUMP RELAY (BY OTHERS)120 VAC 1.0 AMP MAX


N

FIELDSUPPLIED

OPTION 10AFUSE

(BY OTHERS)CONTROLCIRCUIT

FUSE2

1

N120 VAC

14

11

NOTE: ALL FIELD WIRING TO BEINSTALLED AS NEC CLASS 1WIRING SYSTEM WITH CONDUCTORRATED 600 VOLTS

SUPPLY

GND

ALARM BELL RELAY

FACTORY SUPPLIED ALARMFIELD WIRED

ALARMBELL

OPTION 10

15

CONTROLLER

70

68

HOT GAS BYPASS #2 SOLENOID24 VAC 1.0 AMP MAX.

70

67

HOT GAS BYPASS #1 SOLENOID24 VAC 1.0 AMP MAX.

65

63

LIQUID LINE #2 SOLENOID24 VAC 1.5 AMP MAX.

LESSEVAPORATORONLY

24 VAC

N

24 VAC

N

24 VAC

N

TB2

ICE MODE SWITCH(BY OTHERS)

51

52

42

60

40

53

43

55

49

50

ALARM BELLRELAY

ALARM BELL OPTION

BELL1 2

COM NO

AUTO

TIMECLOCK OFF

ON

MANUAL

AUTO OFF

ON

MANUAL

REMOTE STOPSWITCH

(BY OTHERS)

IF REMOTE STOPCONTROL IS USED,REMOVE LEAD 897FROM TERM. 40 TO 53.

897

4-20MA FOREVAP. WATER RESET

(BY OTHERS)

+

-

4-20MA FORDEMAND LIMIT(BY OTHERS)

+

GND

-

33

44

CHW FLOW SWITCH---MANDATORY–-

(BY OTHERS)NOR. OPEN PUMP AUX. CONTACTS (OPTIONAL)

41

54

CDW FLOW SWITCH---MANDATORY–-

(BY OTHERS)NOR. OPEN PUMP AUX. CONTACTS (OPTIONAL)

65

62

LIQUID LINE #1 SOLENOID24 VAC 1.5 AMP MAX.

N

24 VAC

N

N

120 VAC

120 VAC

120 VAC

120 VAC

CDW PUMP RELAY (BY OTHERS)120 VAC 1.0 AMP MAX

TOWER FAN #1 COIL (BY OTHERS)120 VAC 1.0 AMP MAX

TOWER FAN #2 COIL (BY OTHERS)120 VAC 1.0 AMP MAX

TB1-12

J15-NO8

TB1-12

J16-NO9

J16-NO10

TB3-90

TB3-91

TB3-92

79

80 N0-10 VDC

77

78 N0-10 VDC

COOLING TOWER BYPASS(BY OTHERS)


TB3


Figure 21, WGZ 030CA – 200CA Field Wiring Diagram (Remote Condenser)

FIELD WIRING FOR WGZ030-200C(REMOTE CONDENSER)

WITH MICROTECH CONTROLLERDWG. 330539001 REV.0D

TB2

ICE MODESWITCH

(BY OTHERS)

TO COMPRESSOR(S)AND FAN MOTORS


3 PHASEPOWER

120VACCONTROL POWER

UNIT MAINTERMINAL BLOCK

FUSED CONTROLCIRCUIT

TRANSFORMEROPTION

120 VAC

TB1

TB1-20

CHW PUMP RELAY(BY OTHERS)

120 VAC 1.0 AMP MAX


N

FIELDSUPPLIED

OPTION10A

FUSE

(BY OTHERS)

CONTROLCIRCUITFUSE

120 VAC

GND

ALARM BELL RELAY

FACTORY SUPPLIED ALARMFIELD WIRED

ALARM BELLOPTION

51

52

10

15

2

1

42

60

40

53

43

55

33

44

37

49

50

38

ALARM BELLRELAY

ALARM BELL OPTION

BELL1 2

COM NO

NOTE: ALL FIELD WIRING TO BEINSTALLED AS NEC CLASS 1WIRING SYSTEM WITH CONDUCTORRATED 600 VOLTS

SUPPLY

AUTOTIME

CLOCK OFF

ON

MANUAL

AUTO OFF

ON

MANUAL

REMOTE STOPSWITCH

(BY OTHERS)

IF REMOTE STOPCONTROL IS USED,REMOVE LEAD 897FROM TERM. 40 TO 53.

897

CHW FLOW SWITCH---MANDATORY–-

(BY OTHERS)

NOR. OPEN PUMP AUX.CONTACTS (OPTIONAL)

4-20MA FORCHW RESET(BY OTHERS)

+

GND

-

4-20MA FORDEMAND LIMIT(BY OTHERS)

+

GND

-

CONTROLLER

NOTE: CONDENSERFAN MOTORS CAN ALSOBE CONTROLLED BYPRESSURE SWITCHESON THE CONDENSER.

J18-NO13

J22-NO16

J22-NO17

J22-NO18

J16-NO9

J16-NO10

J16-NO11

120 VAC

120 VAC

120 VAC

120 VAC

120 VAC

120 VAC

120 VAC

FAN MOTOR #1 COIL (BY OTHERS)120 VAC 1.0 AMP MAX.

NTB1-12

J15-NO8120 VAC








TB3-90

TB3-91

TB3-94

TB3-92

TB3-93

TB3-95

TB3-96

TB3-97

N120 VAC

14

11

N0-10 VDC

77

78

N79

80

TB3



0-10 VDC

GND LUG


Control Panel Layout Table 35, Typical Control Panel, 4-Compressor Unit w/ Optional Disconnect Switch

1. Additional space provided in the upper right section for extra components required for optional multiple point power connection.

2. Front door has opening on top for access to the MicroTech II controller for viewing display and making keypad entries without opening the panel door.

Motor Protection Module The motor protection system consists of an external control module, located on each compressor, connected to a series of thermistors located in the motor windings and the compressor discharge port. If the windings experience an over-temperature condition or the discharge temperature is excessive, the module will trip and shut off the compressor for a 30-minute time delay.

(4) Compressor Circuit Breakers

(3) 120V/24V Transformers

LineV/120V Control Transformer

Control Transformer Fuses, Primary

Control Transformer Fuse, Secondary

Optional Disconnect Switch

Microtech Controller

(2) Circuit Mechanical Hi-Pressure

Switch Relays

(4) Compressor Contactors

Grounding Lug

Location for Optional External

Overloads

7/8-in. KO for control wiring

Switches

KO for Power Wiring


Start-Up and Shutdown

Complete operating instructions are contained in Operating Manual OM WGZC-Current.

Pre Start-up 1. The chilled-water system should be flushed and cleaned. Proper water treatment is required to prevent

corrosion and organic growth. 2. With main disconnect open, check all electrical connections in control panel and starter to be sure

they are tight and provide good electrical contact. Although connections are tightened at the factory, they can loosen enough in shipment to cause a malfunction.

3. Check and inspect all water piping. Make sure flow direction is correct and piping is made to correct connection on evaporator and condenser.

4. Open all water flow valves to the condenser and evaporator. 5. Flush the cooling tower and system piping to be sure the system is clean. Start evaporator pump and

manually start condenser pump and cooling tower. Check all piping for leaks. Vent the air from the evaporator and condenser water circuit, as well as from the entire water system. The cooler circuit should contain clean, treated, non-corrosive water.

6. Check to see that the evaporator water thermostat sensor is securely installed. 7. Making sure control stop switch S1 is open (off) and pumpdown switches PS1 and PS2 are on

“manual pumpdown,” place the main power and control disconnect switches to “on.” This will energize the crankcase heaters. Wait a minimum of 12 hours before starting the unit.

8. Check compressor oil level. Prior to start-up, the oil level should cover at least one-third of the oil sight glass located in the equalizing line between the compressors or on the compressor.

9. Check water pressure drop across evaporator and condenser, and see that water flow is correct (beginning on page 16) per the design flow rates.

10. Check the actual line voltage to the unit to make sure it is the same as called for on the compressor nameplate, within + 10%, and that phase voltage unbalance does not exceed 3%. Verify that adequate power supply and capacity is available to handle load.

11. Make sure all wiring and fuses are of the proper size. Also make sure that all interlock wiring is completed per McQuay diagrams.

12. Verify that all mechanical and electrical inspections by code authorities have been completed. 13. Make sure all auxiliary load and control equipment is operative and that an adequate cooling load is

available for initial start-up.

Start-up 1. Open the compressor discharge shutoff valves until backseated. Always replace valve seal caps. 2. Open the two manual liquid line shutoff valves. 3. Check to see that the unit circuit breakers are in the “off” position. 4. Check to see that the pumpdown switches, PS1 and PS2, are in the “manual pumpdown” position and

the control system switch S1 is in the “off” position. 5. Put the main power and control circuit disconnects to the “on” position. 6. Verify crankcase heaters have operated for at least 12 hours prior to start-up. Crankcase should be

warm to the touch. 7. Check that the MicroTech II controller is set to the desired chilled water temperature. 8. Start the system auxiliary equipment for the installation by turning on the time clock, ambient

thermostat and/or remote on/off switch and water pumps. 9. Check resets of all equipment protection controls.


10. Switch on the unit circuit breakers. 11. Set pumpdown switches PS1 and PS2 to “auto” for restart and normal operation. 12. Start the system by setting the system switch S1 to on. 13. After running the unit for a short time, check the oil level in each compressor crankcase, rotation of

condenser fans (if any), and check for flashing in the refrigerant sight glass. 14. After system performance has stabilized, it is necessary that the “Compressorized Equipment

Warranty Form” (Form No. 206036A) be completed to establish commencement of the warranty period. Be sure to list the pressure drop across both vessels. This form is shipped with the unit and after completion should be returned to the McQuayService Department through your sales representative.

Weekend or Temporary Shutdown Move pumpdown switches PS1 and PS2 to the “manual pumpdown” position. After the compressors have pumped down, turn off the chilled water pump. Note: With the unit in this condition, it will not restart until these switches are turned back on. The unit has one-time pumpdown. It is important that the compressors pump down before the water flow to the unit is interrupted to avoid freeze-up in the evaporator.

Leave S1 on and power to the unit so that the crankcase heaters will remain energized.

Start-up after Temporary Shutdown 1. Start the water pumps. 2. With the control system switch S1 in the “on” position, move the pumpdown switches PS1 and PS2

to the “auto pumpdown” position. 3. Observe the unit operation for a short time, noting unusual sounds or possible cycling of compressors. 4. Check compressor crankcase heaters.

Extended Shutdown 1. Close the manual liquid line shutoff valves. 2. After the compressors have pumped down, turn off the water pumps. 3. Turn off all power to the unit. 4. Move the control service switch S1 to the “off” position. 5. Close the discharge shutoff valves on the compressor(s) and the liquid outlet valves at the condenser. 6. Tag all opened disconnect switches to warn against start-up before opening the compressor suction

and discharge valves. 7. Drain all water from the unit evaporator, condenser, and chilled water piping if the unit is to be shut

down during the winter and exposed to below freezing temperatures. Do not leave the vessels or piping open to the atmosphere over the shutdown period.


Start-up after Extended Shutdown 1. Inspect all equipment to see that it is in satisfactory operating condition. 2. Remove all debris that has collected on the surface of the condenser coils (remote condenser models)

or check the cooling tower, if present. 3. Open the compressor discharge valves until backseated. Always replace valve seal caps. 4. Open the manual liquid line shutoff valves. 5. Check circuit breakers. They must be in the “off” position. 6. Check to see that the pumpdown switches PS1 and PS2 are in the “manual shutdown” position and

the control system switch S1 is in the “off” position. 7. Put the main power and control circuit disconnects to the “on” position. 8. Allow the crankcase heaters to operate for at least 12 hours prior to start-up. 9. Start the chilled water pump and purge the water piping as well as the evaporator in the unit. 10. Start the system auxiliary equipment for the installation by turning on the time clock, ambient

thermostat and/or remote on/off switch. 11. Check that the MicroTech II controller is set to the desired chilled water temperature. 12. Check resets of all equipment protection controls. 13. Switch the unit circuit breakers to “on.” 14. Start the system by setting the system switch S1 to “on.”

CAUTION

Most relays and terminals in the control center are powered when S1 is closed and the control circuit disconnect is on. Therefore, do not close S1 until ready for start-up or

serious equipment damage can occur.

15. Set pumpdown switches PS1 and PS2 to the “auto pumpdown” position for restart and normal operation.

16. After running the unit for a short time, check the oil level in the compressor oil sight glass or in the compressor's equalizing lines for flashing indicating possible refrigerant in the oil (see Maintenance section beginning on page 60).


System Maintenance

General To provide smooth operation at peak capacity and to avoid damage to package components, a program of periodic inspections should be set up and followed. The following items are intended as a guide to be used during inspection and must be combined with sound refrigeration and electrical practices to provide trouble-free performance.

The liquid line sight glass/moisture indicator on all circuits must be checked to be sure that the glass is full and clear and that the moisture indicator indicates a dry condition. If the indicator shows that a wet condition exists or if bubbles show in the glass, even with a full refrigerant charge, the filter-drier element must be changed.

Water supplies in some areas can tend to foul the water-cooled condenser to the point where cleaning is necessary. The fouled condenser will be indicated by an abnormally high condenser approach temperature (saturated discharge temperature minus leaving condenser water temperature) and can result in nuisance trip-outs. To clean the condenser, mechanical cleaning or a chemical descaling solution should be used according to the manufacturer’s directions.

Systems with remote air-cooled condensers require periodic cleaning of the finned surface of the condenser coil.

Cleaning can be accomplished by using a cold water spray, brushing, vacuuming, or high-pressure air. No tools should be used that could damage the coil tubes or fins.

The compressor oil level must be checked periodically to be sure that the level is at the center of the oil sightglass located in the compressor's equalizing line or on the compressor itself. Low oil level can cause inadequate lubrication and if oil must be added, use oils referred to in the following “Compressor Lubrication” section.

A pressure tap has been provided on the liquid line downstream of the filter-drier and solenoid valve but before the expansion valve. An accurate subcooled liquid pressure and temperature can be taken here. The pressure read here could also provide an indication of excessive pressure drop through the filter-drier and solenoid valve due to a clogging filter-drier. Note: A normal pressure drop through the solenoid valve is approximately 3 psig (20.7 kPa) at full load conditions.

! CAUTION

Warranty may be affected if wiring is not in accordance with specifications. A blown fuse or tripped protector indicates a short ground or overload. Before replacing fuse or restarting compressor, the trouble must be found and corrected. It is important to have a qualified control panel electrician service this panel. Unqualified tampering with the controls can cause serious damage to equipment and void the warranty.


! DANGER

The panel is always energized to ground even when the system switch is off. To de-energize the complete panel including crankcase heaters, pull the main unit disconnect.

Failure to do so can result in severe personal injury or death.

If motor or compressor damage is suspected, do not restart until qualified service personnel have checked the unit. Electrical Terminals

! WARNING To avoid injury from electric shock hazard, turn off all power and perform lockout and tag-

out of source before continuing with the following service. Note that the unit might be powered from multiple sources.

All power electrical terminals should be re-tightened every six months, as they tend to loosen due to normal heating and cooling of the wire. Compressor Lubrication The oil level should be watched carefully upon initial start-up and regularly thereafter. All tandem and triple compressors on WGZ units come equipped with oil equalization lines connecting the crankcase of each set of compressors in each refrigerant circuit. This allows the oil to move from one compressor crankcase to the other during normal operation, and balance between the two when the compressors are off. The oil sight glass is located in the equalization line on one circuit of the WGZ 070 and both circuits of WGZ 080 through WGZ 100. All other models have the oil sight glass in the compressor body. In either case, the oil level should be 1/4 to 1/3 of the glass. The units are factory-charged with lubricant and one of the following lubricants must be used if lubricant is to be added to the system:

••• Copeland Ultra 22 CC ••• Mobil EAL™ Arctic 22 CC ••• ICI EMKARATE RL RL™ 32CF

Since POEs are very hygroscopic, they will quickly absorb moisture if exposed to air. Pump the lubricant into the unit through a closed transfer system. Avoid overcharging the unit. Oil can be added to the Copeland compressor through the oil fill hole in the crankcase. Special equipment is required to add oil and the work should be done by qualified refrigeration technicians with the proper training and equipment.

Sightglass and Moisture Indicator The refrigerant sight glasses should be observed periodically. A monthly observation should be adequate. A clear glass of liquid indicates that there is adequate refrigerant charge in the system to provide proper feed through the expansion valve. The sight glass should be clear when: • Ambient temperature is above 75°F (23°C) • Both compressors on a circuit are running • All fans on a circuit are running

Bubbling refrigerant in the sight glass may occur at other conditions and may indicate that the system is short of refrigerant charge. Refrigerant gas flashing in the sight glass could also indicate an excessive pressure drop in the line, possibly due to a clogged filter-drier or a restriction elsewhere in the system. An element inside the sight glass indicates what moisture condition corresponds to a given element color. If the sight glass does not indicate a dry condition after about 12 hours of operation, the unit should be pumped down and the filter-driers changed.


If the system is suspected of being short of refrigerant, a qualified service technician with EPA certification should be contacted to thoroughly check out the unit and add refrigerant if necessary.

Crankcase Heaters The compressors are equipped with crankcase heaters. The function of the heater is to keep the temperature in the crankcase high enough to prevent refrigerant from migrating to the crankcase and condensing in the oil during off-cycle. When a system is to be started up initially, the power to the heaters should be turned on for at least 12 hours before the compressors are started. The crankcase should be up to about 80°F (26.7°C) before the system is started up, to minimize lubrication problems or liquid slugging of compressor on start-up.

If the crankcase is cool (below 80°F) (26.7°C) and the oil level in the sight glass is full to top, allow more time for oil to warm before starting the compressor.

The crankcase heaters are on whenever power is supplied to the unit and the compressor is not running.

Optional Controls Phase/Voltage Monitor (Optional) The phase/voltage monitor is a device that provides protection against three-phase electrical motor loss due to power failure conditions, phase loss, and phase reversal. Whenever any of these conditions occur, an input relay is deactivated, disconnecting power to the thermostatic control circuit. The compressor does a rapid shutdown pump down.

The input relay remains deactivated until power line conditions return to an acceptable level. Trip and reset delays have been provided to prevent nuisance tripping due to rapid power fluctuations.

When three-phase power has been applied, the input relay should close and the “run light” should come on. If the relay does not close, perform the following tests.

1. Check the voltages between L1-L2, L1-L3, and L2-L3. These voltages should be approximately equal and within +10% of the rated three-phase line-to-line voltage.

2. If these voltages are extremely low or widely unbalanced, check the power system to determine the cause of the problem.

3. If the voltages are good, turn off the power and inter-change any two of the supply power leads at the disconnect switch.

This may be necessary, as the phase/voltage monitor is sensitive to phase reversal. Turn on the power. The relay should now close after the appropriate delay.

Factory settings are as follows: Voltage Setting, set at nameplate voltage. Trip Delay Time, 2 seconds Restart Delay Time, 60 seconds


Hot Gas Bypass (Optional) This option allows passage of discharge gas to the evaporator, permitting operation at lower loads than available with compressor unloading. It also keeps the velocity of refrigerant gas high enough for proper oil return at light load conditions.

The pressure regulating valve is a Sporlan® SHGBE-8 and factory set to begin opening at 69 psig and can be changed by changing the pressure setting. The adjustment range is 0 to 100 psig. To raise the pressure setting, remove the cap on the bulb and turn the adjustment screw clockwise. To lower the setting, turn the screw counterclockwise. Do not force the adjustment beyond the range it is designed for, as this will damage the adjustment assembly. The regulating valve opening point can be determined by slowly reducing the system load while observing the suction pressure. When the bypass valve starts to open, the refrigerant line on the evaporator side of the valve will begin to feel warm to the touch.

! WARNING The hot gas line can become hot enough to cause personal injury in a very short

time; care should be taken during valve checkout


Maintenance Schedule

I. Compressor A. Performance Evaluation (Log & Analysis) * O B. Motor • Meg. Windings X • Ampere Balance (within 10%) X • Terminal Check (tight connections, porcelain clean) X • Motor Cooling (check temperature) X C. Lubrication System • Oil Level O X • Oil Appearance (clear color, quantity) O

• Oil change if indicated by oil analysis X II. Controls A. Operating Controls • Check Settings and Operation X B. Protective Controls • Test Operation of: Alarm Relay X Pump Interlocks X High and Low Pressure Cutouts X III. Condenser B. Test Water Quality X C. Clean Condenser Tubes (or as required) X D. Eddycurrent Test - Tube Wall Thickness X E. Seasonal Protection X IV. Evaporator B. Test Water Quality X C. Clean Evaporator Tubes (or as required) X D. Eddycurrent Test - Tube Wall thickness (or as required) X E. Seasonal Protection X V. Expansion Valves A. Performance Evaluation (Superheat Control) X VI. Compressor - Chiller Unit A. Performance Evaluation O B. Leak Test: • Compressor Fittings and Terminal X • Piping Fittings X • Vessel Relief Valves X C. Vibration Isolation Test X D. General Appearance: • Paint X • Insulation X VII. Starter(s) A. Examine Contactors (hardware and operation) X B. Verify Overload Setting and Trip X C. Test Electrical Connections X VIII. Optional Controls A. Hot Gas Bypass (verify operation) X

Key: O = Performed by in-house personnel X = Performed by service personnel


System Service

! DANGER Service on this equipment is to be performed only by qualified refrigeration personnel. Causes for repeated tripping of equipment protection controls must be investigated and corrected. Disconnect all power before doing any service inside the unit or serious personal injury or death can occur.

NOTE: Anyone servicing this equipment must comply with the requirements set forth by the EPA concerning refrigerant reclamation and venting.

Filter-Driers To change the filter-drier, pump the unit down (with the compressor running) by closing the manual liquid line shutoff valve(s). The unit will start pumping down until it reaches the low-pressure cutoff setting of 58 psi.

Close the discharge valve. Remove the refrigerant in the liquid line with a recovery unit to EPA required pressure. Remove and replace the filter-drier(s). Evacuate the lines through the liquid line manual shutoff valve(s) to remove noncondensables that may have entered during filter replacement. A leak check is recommended before returning the unit to operation.

Liquid Line Solenoid Valve The liquid line solenoid valve(s), which are responsible for automatic pumpdown during normal unit operation, do not normally require any maintenance. However, in the event of failure they can require replacement of the solenoid coil or of the entire valve assembly.

The solenoid coil can be removed from the valve body without opening the refrigerant piping by moving pumpdown switch(es) PS1 and PS2 to the “manual” position.

The coil can then be removed from the valve body by simply removing a nut or snap-ring located at the top of the coil. The coil can then be slipped off its mounting stud for replacement. Be sure to replace the coil on its mounting stud before returning pumpdown switch(es) PS1 and PS2 to the “auto pumpdown” position.

To replace the entire solenoid valve, follow the steps for changing a filter-drier.

Thermostatic Expansion Valve The expansion valve is responsible for allowing the proper amount of refrigerant to enter the evaporator regardless of cooling load. It does this by maintaining a constant superheat. (Superheat is the difference between refrigerant temperature as it leaves the evaporator and the saturation temperature corresponding to the evaporator pressure). All WGZ chillers are factory set for between 8°F and 12°F (4.4°C to 6.7°C) superheat at full load.

To increase the superheat setting of the valve, remove the cap at the bottom of the valve to expose the adjustment screw. Turn the screw clockwise (when viewed from the adjustment screw end) to increase the superheat and counterclockwise to reduce superheat. Allow time for system rebalance after each superheat adjustment.

The expansion valve, like the solenoid valve, should not normally require replacement, but if it does, the unit must be pumped down by following the steps involved when changing a filter-drier.


If the problem can be traced to the power element only, it can be unscrewed from the valve body without removing the valve, but only after pumping the unit down.

Table 36, Thermostatic Expansion Valve

! CAUTION Adjustment of expansion valve should only be performed by a qualified service technician. Failure to do so can result in improper unit operation.

Note: Superheat will vary with compressor unloading, but should be approximately as follows: between 8°F and 12°F (4.4°C and 6.7°C) at full load; between 6°F and 10°F at part load.

Water-cooled Condenser The condenser is of the shell-and-tube type with water flowing through the tubes and refrigerant in the shell. External finned copper tubes are rolled into steel tube sheets and to the center dividing tube sheet. Integral subcoolers are incorporated on all units. All condensers are equipped with 500 psig (3104 kPa) relief valves. Normal tube cleaning procedures can be followed.

Evaporator The evaporator is a sealed, brazed-stainless steel plate unit. Normally no service work is required on the evaporator.


Troubleshooting Chart PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS

Compressor Will Not Run

1. Main switch, circuit breakers open. 2. Fuse blown. 3. Thermal overloads tripped or fuses

blown. 4. Defective contactor or coil. 5. System shut down by equipment

protection devices. 6. No cooling required. 7. Liquid line solenoid will not open. 8. Motor electrical trouble. 9. Loose wiring.

1. Close switch 2. Check electrical circuits and motor

winding for shorts or grounds. Investigate for possible overloading. Replace fuse or reset breakers after fault is corrected.

3. Overloads are auto reset. Check unit closely when unit comes back on line.

4. Repair or replace. 5. Determine type and cause of shutdown

and correct it before resetting protection switch.

6. None. Wait until unit calls for cooling. 7. Repair or replace coil. 8. Check motor for opens, short circuit, or

burnout. 9. Check all wire junctions. Tighten all

terminal screws.

Compressor Noisy or Vibrating

1. Flooding of refrigerant into crankcase. 2. Improper piping support on suction or

liquid line. 3. Worn compressor.

1. Check superheat setting of expansion valve.

2. Relocate, add or remove hangers. 3. Replace.

High Discharge Pressure

1. Condenser water insufficient or temperature too high.

2. Fouled condenser tubes (water-cooled condenser). Clogged spray nozzles (evaporative condenser). Dirty tube and fin surface (air cooled condenser).

3. Noncondensables in system. 4. System overcharge with refrigerant. 5. Discharge shutoff valve partially closed. 6. Condenser undersized (air-cooled). 7. High ambient conditions.

1. Readjust temperature control or water regulating valve. Investigate ways to increase water supply.

2. Clean.

3. EPA purge the noncondensables. 4. Remove excess refrigerant. 5. Open valve. 6. Check condenser rating tables against

the operation. 7. Check condenser rating tables against

the operation.

Low Discharge Pressure

1. Faulty condenser temp. regulation. 2. Insufficient refrigerant in system. 3. Low suction pressure. 4. Condenser too large. 5. Low ambient conditions.

1. Check condenser control operation. 2. Check for leaks. Repair and add charge. 3. See corrective steps for low suction

pressure below. 4. Check condenser rating table against the

operation. 5. Check condenser rating tables against

the operation.

High Suction Pressure

1. Excessive load. 2. Expansion valve overfeeding.

1. Reduce load or add additional equipment.

2. Check remote bulb. Regulate superheat.

Low Suction Pressure

1. Lack of refrigerant. 2. Evaporator dirty. 3. Clogged liquid line filter-drier. 4. Clogged suction line or compressor

suction gas strainers. 5. Expansion valve malfunctioning. 6. Condensing temperature too low. 7. Compressor will not unload. 8. Insufficient water flow.

1. Check for leaks. Repair and add charge. 2. Clean chemically. 3. Replace cartridge(s). 4. Clean strainers. 5. Check and reset for proper superheat.

Replace if necessary. 6. Check means for regulating condensing

temperature. 7. See corrective steps for failure of

compressor to unload. 8. Adjust flow.

Little or No Oil Pressure

1. Clogged suction oil strainer. 2. Excessive liquid in crankcase. 3. Low oil level. 4. Flooding of refrigerant into crankcase.

1. Clean. 2. Check crankcase heater. Reset

expansion valve for higher superheat. Check liquid line solenoid valve operation.

3. Add oil. 4. Adjust thermal expansion valve.


PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS

Compressor Loses Oil

1. Lack of refrigerant. 2. Velocity in risers too low (A-C only). 3. Oil trapped in line.

1. Check for leaks and repair. Add refrigerant.

2. Check riser sizes. 3. Check pitch of lines and refrigerant

velocities.

Motor Overload Relays or Circuit Breakers Open

1. Low voltage during high load conditions. 2. Defective or grounded wiring in motor or

power circuits. 3. Loose power wiring. 4. High condensing temperature. 5. Power line fault causing unbalanced

voltage. 6. High ambient temperature around the

overload relay

1. Check supply voltage for excessive line drop.

2. Replace compressor-motor. 3. Check all connections and tighten. 4. See corrective steps for high discharge

pressure. 5. Check Supply voltage. Notify power

company. Do not start until fault is corrected.

6. Provide ventilation to reduce heat.

Compressor Thermal Switch Open

1. Operating beyond design conditions. 2. Discharge valve partially shut.

1. Add facilities so that conditions are within allowable limits.

2. Open valve.

Freeze Protection Opens

1. Thermostat set too low. 2. Low water flow. 3. Low suction pressure.

1. Reset to 42°F (6°C) or above. 2. Adjust flow. 3. See “Low Suction Pressure.”

Warranty Statement

Limited Warranty Consult your local McQuay Representative for warranty details. Refer to Form 933-43285Y. To find your local McQuay Representative, go to www.mcquay.com.

(800) 432-1342 • www.mcquay.com IMM WGZC (10/08)

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. 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-00-A (09/08). To find your local representative, go to www.mcquay.com

http://www.mcquay.com/�

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