WSC, WME and WMC Centrifugal Chillers Reassembly of ... · The following label is used in this...

64
Installation Manual IM 1128 Group: Chiller Part Number: 331375601 REV: 01 Effective: May 2011 Supersedes: IM Knockdown-2 WSC, WME and WMC Centrifugal Chillers Reassembly of Knockdown Shipments STARTER COMPRESSOR OIL PUMP UNIT CONTROLLER EVAPORATOR CONDENSER SUPPORT

Transcript of WSC, WME and WMC Centrifugal Chillers Reassembly of ... · The following label is used in this...

Page 1: WSC, WME and WMC Centrifugal Chillers Reassembly of ... · The following label is used in this manual to indicate immediate or potential hazards. It is the responsibility of the owner

Installation Manual IM 1128

Group: Chiller

Part Number: 331375601 REV: 01

Effective: May 2011

Supersedes: IM Knockdown-2

WSC, WME and WMC Centrifugal Chillers Reassembly of Knockdown Shipments

STARTER

COMPRESSOR

OIL PUMP

UNITCONTROLLER

EVAPORATOR

CONDENSER

SUPPORT

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2 Field Installation Procedure IM 1128

Table of Contents WSC Chiller Introduction ............................................................................... 3

Type I Reassembly............................................................................................ 5

Type II Reassembly ........................................................................................ 14 Unit Photographs .................................................................................................................26

Type III Reassembly....................................................................................... 28

Field Insulation Guide ................................................................................... 29

Dimensions and Weights ................................................................................ 31 Type I...................................................................................................................................31 Type II .................................................................................................................................33

Shipping Lists ................................................................................................. 38

WMC Introduction......................................................................................... 42 Type IV Disassembly-Reassembly.......................................................................................43 Type V Disassembly-Reassembly........................................................................................43

WME Introduction......................................................................................... 48

Type I Reassembly.......................................................................................... 49

Type II Reassembly ........................................................................................ 50

Type III Reassembly....................................................................................... 53 Knockdown Dimensions......................................................................................................54 Piping Removal ...................................................................................................................55 Compressor Removal and Re-Attachment...........................................................................60 Compressor Removal and Re-Attachment...........................................................................61

Recognize Safety Symbols, Words, and Labels

The following label is used in this manual to indicate immediate or potential hazards. It is the

responsibility of the owner and installer to read and comply with all safety information and instructions

accompanying these symbols. Improper installation, operation and maintenance can void the warranty.

! DANGER

Dangers indicate a hazardous situation which will result in death or serious injury if not avoided.

! WARNING

Warnings indicate potentially hazardous situations, which can result in property damage, severe personal injury, or death if not avoided.

! CAUTION

Cautions indicate potentially hazardous situations, which can result in personal injury or equipment damage if not avoided.

©2010 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: Magnitude, MicroTech E, from McQuay International, Victaulic from

Victaulic Company

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IM 1128 Field Installation Procedure 3

WSC Chiller Introduction

It is estimated that fifty percent of retrofit applications require partial or complete disassembly of the

chiller. McQuay offers three solutions to the disassembly and reassembly effort on Model WSC, single

compressor centrifugal chillers.

TYPE I: The compressor is removed and put on a skid. All associated wiring and piping possible will

remain on the vessel stack. The remaining loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5-psi helium holding charge.

3. The compressor will not be insulated at the factory. An insulation kit will be shipped with the unit.

4. The starter will ship loose. Bracket and cable kit to be included for unit-mounted starters and/or

cableway for mini-cabinet starters.

5. The evaporator will be insulated at the factory.

6. Refrigerant will not be shipped with the unit and must be secured locally and furnished and

installed by the installer.

7. Lubricant will be shipped in containers from the factory for field installation.

8. All field piping connections will be Victaulic, O-ring face seal or copper brazing.

9. All free piping ends will be capped.

10. Touch-up paint will be included.

11. The unit will undergo the rigorous, full McQuay test program at the factory.

12. Contact local McQuay Factory Service for pricing and scheduling of required installation

supervision.

TYPE II: The compressor with its terminal box is removed and placed on a skid. The condenser,

evaporator, oil pump, oil cooler and tube sheet supports will remain connected only by their attachment

bolts, ready for field disassembly and reassembly in the building. All wiring and piping that

interconnects the components will be removed. The loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels have a 5-psi helium holding charge.

3. The compressor will not be insulated at the factory. An insulation kit will be shipped with the unit

and will also include a container of adhesive.

4. Only the evaporator shell will be factory insulated. Loose insulation will be shipped for the

suction line and remaining surface areas.

5. The starter will ship loose.

6. Refrigerant will not be shipped with the unit and must be secured locally and furnished and

installed by the installer.

7. Lubricant will be shipped in containers from the factory for field installation.

8. All field piping connections will be Victaulic, flanged, O-ring face seal or copper brazing.

9. Bracket and cable kit will be included for all unit-mounted starters and/or cableway for mini-

cabinet starters.

10. All free piping ends will be capped.

11. Touch-up paint and stick-on wire ties will be included.

12. A bolted bracket instead of a weld will mount the oil pump.

13. The discharge piping assembly will have a bolted flange connection (instead of welded) at the

condenser. This assembly will ship loose.

14. Piping that remains attached to a component will be supported if it is not rigid.

15. The chiller will not be run-tested at the factory but the compressor, oil pump assembly and heat

exchangers will be tested as sub-assemblies.

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4 Field Installation Procedure IM 1128

16. The control panels are shipped separately but have all sensors wired in, labeled and tied up.

Matching labels will exist at the sensor connection on the unit.

17. Contact local McQuay Factory Service for pricing and scheduling of required installation

supervision.

TYPE III: The unit ships fully assembled and is field ready to knockdown. Included are the vessel

bolt-on connection brackets, the discharge stack bolt-on flanges at the condenser and the bolt-on oil

pump assembly.

1. The unit is shipped fully charged with refrigerant and lubricant.

2. The unit will be factory insulated and painted.

3. All electrical and sensor wiring will be fastened as usual.

4. The starter will ship per order instructions.

5. Touch up paint and stick-on wire ties will be included.

6. This unit will be fully tested at the factory.

7. Labels will be provided with the instructions to mark piping, electrical wiring and sensor wiring.

NOTE: If disassembly involves breaking any refrigerant connection, the refrigerant charge must be

pumped down and isolated in the condenser.

Typical WSC Centrifugal Chiller

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IM 1128 Field Installation Procedure 5

Type I Reassembly

Description

TYPE I: The compressor with its terminal box is removed and placed on a skid as a separate package.

The suction piping is removed and shipped loose. All other piping will be disconnected from the

compressor and remain attached to the vessel stack, where possible. Wiring and sensors to the

compressor will be disconnected, rolled up and tied to the control panels. The remaining loose parts

will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5-psi helium holding charge.

3. The compressor will not be insulated at the factory. An insulation kit will be shipped with the unit

and will also include a container of adhesive.

4. The unit vessel stack will be insulated at the factory.

5. This unit will be tested with a full refrigerant charge at the factory and the charge will be removed

after testing.

6. Refrigerant will not be shipped with the unit and must be secured locally and furnished and

installed by the installer.

7. Bracket and cable kit will be included for all unit-mounted starters and/or cableway for mini-

cabinet starters.

8. All free piping ends will be capped.

9. Touch-up paint and stick-on wire ties will be included.

10. Lubricant will be shipped in containers from the factory.

11. The starter will ship loose.

12. All field piping connections will be Victaulic, flanged, O-ring face seal or copper brazing.

13. The unit control panel and compressor control panel will be attached to the unit with loose sensor

wires tied up behind the panel.

Reassembly Steps

NOTE: Additional instructions may be shown on the assembly drawings.

1. Mount the compressor on the stack. Be careful to avoid damaging lines already mounted on the unit.

Mounting bolts, washers and nuts are shipped loose. Leave the mounting bolts loose until the suction

and discharge lines are installed and aligned.

During assembly, bolts holding block-off plates (motor cooling connection, for example), are used for

reassembly of the component. See Figure 1 or Figure 2 for the location and description of the block-

offs.

2. Do not remove block-offs until ready to install piping. The compressor and vessels have a Schrader

valve on their block-off plates to be used for relieving the helium holding charge.

! WARNING

Remove compressor and vessel holding charge through the Schrader valve in the block-off plates before attempting to loosen any fittings on them. Failure to do so can cause severe bodily injury.

3. Install the suction and discharge piping (see Figure 3). Before tightening the Victaulic couplings,

position the suction and discharge piping so that the compressor can be aligned to give the best fit-up.

When this is achieved, secure the compressor mounting bolts and proceed with installing the Victaulic

couplings using a light coating of Victaulic lubrication.

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6 Field Installation Procedure IM 1128

4. Install the liquid injection line (see Figure 4). The liquid injection line is attached to the condenser

and has shipping straps securing it to the evaporator and condenser. It, and the compressor, each have

a block-off. Note that any given injection line may be configured somewhat differently than shown on

the drawing.

5. Install the motor cooling line (see Figure 5) using the same procedure as the liquid injection line.

6. Install the motor drain line (see Figure 6) using the same procedure as the liquid injection line.

7. Piping for the optional hot gas bypass is shipped mounted on the unit except for models WSC100,

WSC113 and WSC126 with vessel stacks sizes E36C30, E36C36, E42C36, E42C42, E48C42 and

E48C48. These units have the piping assembly shipped loose for field mounting. See Figure 7.

8. Install the compressor lubrication lines. There are four lines as shown in Figure 8:

a. Thrust pump return, injects lubricant from the compressor thrust pump (thrust bearing) into

the lubricant supply line.

b. Oil drain, drains lubricant from the compressor to the sump.

c. Vent line, vents refrigerant from the sump back to the compressor suction.

d. Oil supply, supplies lubricant from the pump in the sump to the compressor.

There is a variety of fitting types employed on the oil lines. Reconnect the compression fittings, bolt

on the flanges using new gaskets furnished, and re-sweat the sweat connections.

9. Install the four-way solenoid on the compressor suction housing.

10. Install compressor wiring using Figure 9 (including notes) as a guide. Figure 9 shows connections for

both Type I and Type II arrangements. Only the connections listed below are required to be made for

Type I. The wire end that has been disconnected, and its attachment point on the compressor, will

each have a label attached (VC for the vane close switch, for example) for matching purposes.

a. Guardistor, G1 (and G2 on some units), terminal box located on side of motor housing.

b. Compressor heaters, CP1 (and CP2 on some units), located on the bottom of the compressor.

c. Vane load/unload solenoids, SA and SB, located on the four-way solenoid assembly.

d. Vane close switch, VC, located on compressor next to the discharge housing.

e. Vane open switch, VO, located on suction end of compressor.

f. High pressure switch, HPS, located on compressor discharge nozzle.

11. If the unit has been ordered with a starter or VFD as unit mounted, brackets for mounting it and

interconnection cables to the compressor motor will be included as ship loose items. Control wiring as

shown in Figure 9 and Figure 13 (field wiring diagram), will also be required. The field wiring

diagram located on the control panel door should also be consulted as it will be current. If the unit has

a free standing starter, use normal field procedures for mounting and wiring.

Normal procedure of leak testing, triple evacuation, and charging with refrigerant and lubricant must

be followed prior to the start up procedure.

12. Insulate the compressor motor, suction line, and other miscellaneous areas with the included insulation

and adhesive after leak testing. See Field Insulation Guide on page 29.

This completes the reassembly procedure.

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IM 1128 Field Installation Procedure 7

Figure 1, WSC 063 - 087 Compressor Connections

RIGHT VIEW

R331311301C0100

15" MTR. HSG.LEFT VIEW(20" MTR.HSG.)

MOTOR COOLINGREFRIGERANT

FROM COND. BTM

OIL LINE VENTFROM TOP FRONT

OF OIL PUMP

ATTACH TAG TO ONETERMINAL INSIDE BOX

4-WAY SOLENOID VALVE

LIQUIDINJECTION

FROM COND. BTM.

OIL THRUST RETURNTO OIL LINE TEE

OIL DRAIN TO TOP BACK OF OIL PUMP

MOTOR DRAINTO EVAP BOTTOM

MOTOR DRAIN

OIL OUT TO SA AND SBSOLENOID VALVES AND

OIL PRESSURE TRANSDUCER

MOTOR DRAINTO EVAP BOTTOM

MOTOR COOLINGFROM COND. BTM.

OIL SUPPLYFROM OIL COOLER

Notes:

1. New O-rings and gaskets are in a plastic bag.

2. Compressor is charged with 5-psi of helium.

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8 Field Installation Procedure IM 1128

Figure 2, WSC 100-126 Compressor Connections

LEFT VIEW(22" MTR. HSG.)

20" MTR. HSG.

RIGHT VIEW

BOTTOM VIEW

OIL VENT

OIL SUPPLY

MOTOR COOLING

OIL DRAIN

DISCHARGEBLOCKOFF REF. DRAIN

REF.DRAIN REF. DRAIN

MOTOR COOLING

MOTOR DRAIN MOTOR DRAIN

LIQUID INJECTION

UNSWEAT LINE ANDSHUT VALVE

FROM TOP FRT.OF OIL PUMP

FROM CONDENSERBOTTOM

TO TOP BACKOF OIL PUMP

TO EVAP.BOTTOM

TO EVAP.BOTTOM

TO EVAP.BOTTOM

TO EVAP.BOTTOM

TO EVAP.BOTTOM

FROM COND.BOTTOM

FROM COND. BOTTOM

4 WAY SOLENOID VALVE

OIL THRUST RETURN TO OIL LINE TEE

TO OIL COOLER

R331311301D0200

OIL OUT TO SA AND SBSOLENOID VALVES AND

OIL PRESSURE TRANSDUCER

Notes:

1. New O-rings and gaskets are in a plastic bag.

2. Compressor is charged with 5-psi of helium.

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IM 1128 Field Installation Procedure 9

Figure 3, Suction and Discharge Piping

R331311308C0100

BOLT-ONBLOCKOFF PLATE

TYPE II

UNITS RECEIVE SLIP-ON ASME

FLANGES

TYPES II & III

TYPES I & II

TYPES I & II VICTAULIC

BLOCKOFF PLATE

INSTALL SUCTIONPIPING

EVAPORATOR AND CONDENSER ARE EVACUATED AND CHARGED WITH 30 PSI OF HELIUM.

TYPES I & II

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10 Field Installation Procedure IM 1128

Figure 4, Liquid Injection Lines

R331311303C0100

MECHANICALBREAK POINT

MECHANICALBREAK POINT

LIQUID INJECTION LINES(NOT ALL VARIATIONS SHOWN)

TYPE IBLOCKOFF

TYPE IBLOCKOFF

NOTE:

The liquid injection line (above) and the motor cooling line (below) are attached to the condenser and have

shipping straps securing them to the evaporator and condenser. The lines and the compressor, each have block-

off plates, resulting in extra bolts.

Figure 5, Motor Cooling Lines

TORQUE TO58 FT/LBS

R331311304C0100

MECHANICALBREAK POINT

MECHANICALBREAK POINT

MOTOR COOLING LINES(NOT ALL VARIATIONS SHOWN)

TYPE IBLOCKOFF

TYPE IBLOCKOFF

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IM 1128 Field Installation Procedure 11

Figure 6, Motor Drain Line

R331311305C0100

20" MOTOR REF. DRAIN CONNECTION

(REAR VIEW)

15" MOTOR REF. DRAIN CONNECTION

(REAR VIEW)

MOTOR HOUSINGDRAIN LINE

MOTOR DRAIN LINE(NOT ALL VARIATIONS SHOWN)

MECHANICALBREAK POINT

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12 Field Installation Procedure IM 1128

Figure 7, Optional Hot Gas Bypass Piping

R331311307C0100

HOT GASBYPASSLINE

HOT GASBYPASSPILOTLINE

SHUT OFFVALVE

EXPANSIONVALVE

CONNECTION TODISCHARGE NOZZLE

EVAPORATOR

BOTTOM

MECHANICALBREAK POINTS

MECHANICALBREAK POINT

MECHANICALBREAK POINT

MECHANICALBREAK POINT

FLOW

FLOW

FLOW

NOTE: THIS LINE IS NOT ALWAYS PRESENT. SOME UNITS HAVE ELECTRONIC VALVES.

BLOCKOFFTYPE II UNITS

INSTALL HOT GAS PIPING

TYPE I UNITS

INSTALL HOT GAS PIPING ON WSC MODELS100, 113, & 126 WITH STACK SIZESE36C30, E36C36, E42C36, E42C42,

E48C42, E48C48

Figure 8, Oil and Water Lines

R331311302C0200

OIL VENT

OF THRUST RETURN LINE

OIL SUPPLY

RESWEAT LINEABOVE REDUCER

RESWEAT LINEABOVE TEE

TYPES I & II

TYPES I & II

INSTALL TOP PORTION

TYPES I AND IIINSTALL

INSTALL WATER LINES

TYPE II

INSTALL TOP PORTION

OF LINE

TYPES I & II

TYPES I AND IIINSTALLOIL DRAIN

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IM 1128 Field Installation Procedure 13

Figure 9, Electrical and Sensors, Compressor Control Box and Connections

R331311501C0100

N7

N7

155

155155

154

GUARDISTOR

CONNECT LEAD 155TO TERMINAL IF 2nd

BOX IS NOT USED.

2nd TERMINAL BOXUSED ON SELECTEDMOTORS.

HIGHPRESSURE

SWITCH

E9

E7

NUMBER OF HEATERS MAY VARYDUE TO COMPRESSOR SIZE. JUNCTION BOX NOT ON ALL UNITS.

SECOND HEATER CABLE FROM COMPR.ON WSC063-087 ONLY.}

3 21 E4

E6

05

0708

E5

OIL PUMPHEATERS

{TO STARTER

COMPRESSORHEATERS

CS

04

CS

05

CS

07

CS

09

CS

10

CS

06

CS

03

CS

02

CS

01

HOT GASSOLENOID

LIQ. INJ.SOLENOID

OPTION

135136

133134

141142

139140

132

131

137138

OIL COOLERSOLENOID

VANE CONTROLSOLENOIDS

VANECLOSE

SWITCH

146

145

VANEOPEN

SWITCH

103104

VFD SPEEDSIGNAL

102101

(ON VFD ONLY)

LI HG

VO

VC

SA

SB

OC

VFD

LE

AV

ING

EV

AP

WA

TE

R T

EM

P.

OIL

FE

ED

TE

MP.

CO

MP

R. D

ISC

HA

RG

E T

EM

P.

CO

MP

R.

SU

CT

ION

TE

MP.

OIL

SU

MP

TE

MP.

CO

ND

. P

RE

SS

. S

EN

SO

R

EV

AP. P

RE

SS

. S

EN

SO

R

OIL

FE

ED

PR

ES

S. S

EN

SO

R

OIL

SU

MP

PR

ES

S. S

EN

SO

R

VANE

LOAD

VANEUNLOAD

JUNCTION BOX ON COMPRESSORMOUNTING BRACKET NEAR THESUCTION PIPE.

OPH

G2

G1

CP1

CP2

HPS

CO

MP

RE

SS

OR

CO

NT

RO

L B

OX

CCB POWER

10 LEADS 4 LEADS

(ON COMPRESSOR)

(ON VFD)

(ON SUPPLYWATER LINE)

(ON COMPR.FRONT)

(ON COMPR. NEXTTO DISCHARGE)

(ON COMPR.FRONT)

(ON HOTGAS LINE)

(ON LIQUIDINJ. LINE)

(ON DISCHARGENOZZLE)

Note:

1. Reference compressor controller schematic for detailed wiring connections.

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14 Field Installation Procedure IM 1128

EVAPORATORTUBE SHEET

TUBE SHEETSUPPORT

PLATE

CONDENSERTUBE SHEET

BOLTED

BOLTED

WELDED

TWO ANGLE PLATES,ONE WELDED TO EVAP.ONE WELDED TO COND.THEN BOLTED TOGETHER.

Type II Reassembly

Description

TYPE II: The compressor with its terminal box is removed and shipped on a skid. The condenser,

evaporator, oil sump, oil cooler and tube sheet support plates will remain connected only by their

attachment bolts, ready for field disassembly on site and subsequent reassembly in the building. All

wiring and piping that interconnects the components will have been removed and will require

reinstallation. The loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5-psi helium holding charge.

3. The compressor will not be insulated at the factory. An insulation kit will be shipped with the unit

and will also include a container of adhesive.

4. Only the evaporator shell will be factory insulated. Loose insulation will be shipped for the

remaining surface areas.

5. The starter will ship loose.

6. The refrigerant will be field supplied.

7. All field piping connections will be Victaulic, flanged, O-ring face seal or copper brazing.

8. Bracket and cable kit will be included for all unit-mounted starters and/or cableway for mini-cabs.

9. All free piping ends will be capped.

10. Touch-up paint and stick-on wire ties will be included.

11. A bolted bracket instead of a weld will mount the oil pump.

12. The discharge piping assembly will have a bolted flange connection (instead of welded) at the

condenser. This assembly will ship loose.

13. Piping that remains attached to a component will be supported if it is not rigid.

14. The chiller will not be run-tested at the factory but the compressor, oil pump assembly and heat

exchangers will be tested as sub-assemblies.

15. The control panels are shipped separately but have all sensors wired in, labeled and tied up.

Matching labels will exist at the sensor connection to the unit.

Reassembly Steps

NOTE: Additional instructions may be shown on the assembly drawings.

The Type II arrangement is shipped with the evaporator, condenser, tube sheet support plate, oil cooler

and oil sump bolted together. This provides structural support during transit and also allows several

options for disassembly.

Figure 10, Component Disassembly

In most cases for narrow entry, the condenser will be

separated by unbolting it from the evaporator angle

bracket and from the tube sheet support plate. This

leaves the evaporator and the support plate that has

the mounting foot extended under where the

condenser used to be. Therefore, the evaporator is

usually unbolted from the two support plates, which

can then be easily handled by themselves.

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IM 1128 Field Installation Procedure 15

! WARNING

Remove compressor and vessel holding charge through the Schrader valve in the block-off plates before attempting to loosen any fittings on them. Failure to do so can cause severe bodily injury.

1. Disassemble the unit to the extent required by the site conditions. Rig the components to their final

location and reassemble them using the fasteners that came with the unit.

2. The compressor and its suction and discharge piping should be installed on the stack before any other

lines are attached. Mount the compressor on the stack. Mounting bolts, washers and nuts are shipped

loose. Leave the mounting bolts loose until the suction and discharge lines are in place and aligned.

Install the suction and discharge piping. Before tightening the Victaulic couplings, position the suction

and discharge piping so that the compressor can be aligned to give the best fit-up. When this is

achieved, secure the compressor mounting bolts and proceed with installing the Victaulics using a light

coating of Victaulic lubricant. See Figure 3.

3. Install the liquid line using Figure 11 as a guide. Commonly used arrangements are illustrated. The

bottom two arrangements illustrate lines with electronic valves used on some size units. Due to the

variety of vessel combinations available, variation on specific units will occur.

4. Install the motor cooling line using Figure 5 as a guide.

5. Install the liquid injection line (see Figure 4). Note that any given injection line may be configured

somewhat differently than shown on the drawing.

6. If the oil cooler and oil sump have been removed on the job site, reinstall them using the fasteners that

came on the unit. See Figure 12 for piping between the cooler and sump and the cooling water piping.

See Figure 8 for the balance of the four oil lines connected to the compressor. There are a variety of

fitting types employed on the oil lines. Reconnect the compression fittings, bolt on the flanges using

new gaskets/O-rings furnished, and re-sweat the sweat connections.

Due to the wide variety of model arrangements, some or all of the oil piping may be shipped loose.

When possible, the cooler and sump will be shipped mounted to their back plate with as much piping

remaining as possible.

7. Install the four-way solenoid valve assembly on the compressor suction housing.

8. Install the two control panels; the compressor panel is mounted adjacent to the oil sump and the unit

panel is on top of the evaporator. Wire and sensor leads have been disconnected at their terminus and

labeled. They remain connected at the panels and rolled up. Their destinations have matching labels,

which simplifies the installation. Compressor panel sensor labels are prefixed with CS, unit panel labels

with US. Use the following drawings as a guide for installing wiring and sensors:

Compressor panel detail ........................................Figure 18

Unit panel wiring and connections ........................Figure 15

Unit panel detail.....................................................Figure 19

Unit panel sensor locations....................................Figure 16 and Figure 17

Flow switch wiring detail ......................................Figure 20

9. If the unit has been ordered with a starter or VFD as unit mounted, brackets for mounting it and

interconnection cables to the compressor motor will be included as ship loose items. Control wiring as

shown in Figure 9 will also be required. If the unit has a free-standing starter, use normal field

procedures for mounting and wiring.

Normal procedure of leak testing, triple evacuation, and charging with refrigerant and lubricant must be

followed prior to the start up procedure.

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16 Field Installation Procedure IM 1128

10. Insulate the compressor, suction line, and other miscellaneous areas with the included insulation and

glue after leak testing. See Field Insulation Guide on page 29.

This completes the reassembly procedure.

Figure 11, Liquid Line Installation

SHOWN IS E36/C36 STACKWITH 20-INCH MOTOR

R331311306C0100

VIEW B

SEE VIEW B

TOP OFEVAPORATOR

FROM PILOTTX VALVE

EVAPORATOR

CONNECTION

CONDENSERSHUTOFF VALVECONNECTION

TO TOP OFEVAPORATOR

TO TOP OF

EVAPORATOR

EVAPORATORCONNECTION

CONDENSERSHUTOFF VALVECONNECTION

FLOW

FLOW

PLUG

EVAP. BLOCKOFF

LIQUID LINES(NOT ALL VARIATIONSSHOWN)

LIQUIDLINES

FLOW

FLOW

(VIEW 'B')

(VIEW 'B')

LIQUID LINE

LIQUID LINE

PILOT LINE

PILOT LINE

RESWEAT PILOT LINEABOVE THE SHUTOFF VALVE

RESWEAT PILOT LINEABOVE THE SHUTOFF VALVE

PILOT LINESHUT OFFVALVE

MECHANICALBREAK POINT

MECHANICALBREAK POINT

MECHANICALBREAK POINT

MECHANICALBREAK POINT

CONDENSERSHUTOFFVALVE

TYPE IIKNOCKDOWNONLY

NOTE: The bottom two liquid lines show the typical arrangement with electronic expansion valves. Liquid flow can be

in different directions depending on the valve size.

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IM 1128 Field Installation Procedure 17

Figure 12, 16 Inch Oil Sump / Oil Cooler Assembly

R331311302C0100

WATER SUPPLY

WATER RETURN

THRUST RETURNOIL LINE

OILSUPPLY

WATERRETURN

WATERSUPPLY

OIL SUPPLY TOVALVE ON COMP.

OIL DRAIN LINE

OIL VENT LINE

DUE TO DIFFERENT PIPE ROUTINGSSOME OR ALL PIPING SHOWN MAYBE SHIPPED LOOSE

FLOW

FL

OW

FL

OW

FLOW

FLOW

FLOW

FLOW

FLOW

PRESSU

RE

EQUALIZATIO

N

PLUG

PLUG

OILCOOLER

Notes:

1. Piping arrangements will vary according to specific model.

2. Oil sump is shipped without oil on Type I and Type II knockdown units.

3. Type III knockdown units are shipped with oil.

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18 Field Installation Procedure IM 1128

Figure 13, Typical Field Connection Diagram, WSC Unit

80

CP2

CP1

H

O

A

C4

H

A

O

C3

H

A

O

79

78

77

74

73

54

CF

86

EF

86

C

25

1

2

11

11

12

22

1

2

6

11

12

22

NOTE 2

NOTE 2

(115V) (24V)

25

55

70

H

A

O

H

A

O

H

O

A C

H

O

A C

H

O

A C

C2

C1 T3-S

PE

L1

L2CP2

CP1

24

23(5A)

24(5)

23

3

4

3

4

76

75

PE

85

86

81

84

A82(NO)

83(NC)

POWER

EP2

EP1

L1 L2 L3

GND

T4 T5 T6T1 T2 T3

T4 T5 T6T1 T2 T3

T1 T2 T3

T3T1 T2

U V W

T4 T3 T5T1 T6 T2

T1 T2 T3

T4 T3 T5T1 T6 T2

GND

LESSTHAN30VOR24VAC

53

71

71

52

1-10 VDC

1-10 VDC

MICROTECH CONTROLBOX TERMINALS

* COOLINGTOWER

FOURTHSTAGE

STARTER

* COOLINGTOWER

THIRDSTAGE

STARTER

* COOLINGTOWER

SECONDSTAGE

STARTER

* COOLINGTOWER

FIRSTSTAGE

STARTER

COOLING TOWERBYPASS VALVE

COOLING TOWER VFD

ALARM RELAY(NOTE 4)

MICROTECHCOMPRESSOR CONTROL

BOX TERMINALSCTB1

-LOAD-

COMPRESSORMOTOR

STARTER(NOTE 1)

115 VAC

STARTER LOAD SIDE TERMINBALSVFD

STARTER LOAD SIDE TERMINBALSWYE-DELTA

STARTER LOAD SIDE TERMINBALSSOLID STATE

STARTER LOAD SIDE TERMINBALSMEDIUM AND HIGH VOLTAGE

COMPRESSOR TERMINALS

COMPRESSOR TERMINALS

COMPRESSOR TERMINALS

COMPRESSOR TERMINALS

NOTE 12

- FOR DC VOLTAGE AND 4-20 MA CONNECTIONS (SEE NOTE 3)

- FOR DETAILS OF CONTROL REFER TO UNIT CONTROL SCHEMATIC 330342103

- COMPRESSOR CONTROL SCHEMATIC 330342203

- LEGEND: 330343003

* FIELD SUPPLIED ITEM

* NOTE 7

* NOTE 10

* NOTE 10

* NOTE 10

* NOTE 10

330387901-0A

COMMON

NEUTRAL

POWER

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IM 1128 Field Installation Procedure 19

Figure 14, Compressor Control Panel Electrical and Sensor Connections

R331311501C0100

N7

N7

155

155155

154

GUARDISTOR

CONNECT LEAD 155TO TERMINAL IF 2nd

BOX IS NOT USED.

2nd TERMINAL BOXUSED ON SELECTEDMOTORS.

HIGHPRESSURE

SWITCH

E9

E7

NUMBER OF HEATERS MAY VARYDUE TO COMPRESSOR SIZE. JUNCTION BOX NOT ON ALL UNITS.

SECOND HEATER CABLE FROM COMPR.ON WSC063-087 ONLY.}

3 21 E4

E6

05

0708

E5

OIL PUMPHEATERS

{TO STARTER

COMPRESSORHEATERS

CS

04

CS

05

CS

07

CS

09

CS

10

CS

06

CS

03

CS

02

CS

01

HOT GASSOLENOID

LIQ. INJ.SOLENOID

OPTION

135136

133134

141142

139140

132

131

137138

OIL COOLERSOLENOID

VANE CONTROLSOLENOIDS

VANECLOSE

SWITCH

146

145

VANEOPEN

SWITCH

103104

VFD SPEEDSIGNAL

102101

(ON VFD ONLY)

LI HG

VO

VC

SA

SB

OC

VFD

LE

AV

ING

EV

AP

WA

TE

R T

EM

P.

OIL

FE

ED

TE

MP.

CO

MP

R.

DIS

CH

AR

GE

TE

MP.

CO

MP

R.

SU

CT

ION

TE

MP

.

OIL

SU

MP

TE

MP

.

CO

ND

. P

RE

SS

. S

EN

SO

R

EV

AP.

PR

ES

S.

SE

NS

OR

OIL

FE

ED

PR

ES

S.

SE

NS

OR

OIL

SU

MP

PR

ES

S.

SE

NS

OR

VANE

LOAD

VANEUNLOAD

JUNCTION BOX ON COMPRESSORMOUNTING BRACKET NEAR THESUCTION PIPE.

OPH

G2

G1

CP1

CP2

HPS

CO

MP

RE

SS

OR

CO

NT

RO

L B

OX

CCB POWER

10 LEADS 4 LEADS

(ON COMPRESSOR)

(ON VFD)

(ON SUPPLYWATER LINE)

(ON COMPR.FRONT)

(ON COMPR. NEXTTO DISCHARGE)

(ON COMPR.FRONT)

(ON HOTGAS LINE)

(ON LIQUIDINJ. LINE)

(ON DISCHARGENOZZLE)

Note: Reference compressor controller schematic for detailed wiring connections.

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20 Field Installation Procedure IM 1128

Figure 15, Unit Controller Electrical and Sensor Connections

R331311502C0100

REFERENCE THE UNIT CONTROLLER SCHEMATICFOR DETAILED WIRING CONNECTIONS

US03

US04

US05

US09

US10

UNIT CONTROL BOX

US025

1

52

53

54

55

56

57

58

59

60

61

62

63

70

70

70

71

71

71

72

73

74

75

76

77

78

79

80

81

82

83

84

85

86

86

86

PE

PE

R

MICROTECH II T M

AIR C ONDI TIONI NG

J11J12 J13 J14 J15

J1J2

B1

B2

B3

GN

D

+V

DC J3

B4

BC

4

B5

BC

5 J4 J5 J6

J19J20

Y5

Y6

B9

BC

9

B10

BC

10

ID1

7

ID1

8

IDC

17

J16 J17 J18

J21 J22 J23

SERIAL CARDPRINTER CARD

EXPANSION MEMORY

J7 J8

UNIT COMP 1 COMP 2 CIRCUIT BKR.

ON-(IN)

OFF-(OUT)

PUMP/TOWER

OPERATORINTERFACE

PANEL

}

}

}

}

COND. GPM SENSOR(FIELD OPTION)

EVAP. GPM SENSOR

(FIELD OPTION)

TOWER BYPASS/TOWER VFD(FIELD OPTION)

WATER RESET/REMOTE START-STOP/MODE/DEMAND LIMIT(FIELD OPTION)

}

}

}

}WATER PUMPS(FIELD INSTALLED)

TOWER STAGING(FIELD INSTALLED)

ALARMS(FIELD INSTALLED)

POWER(FIELD INSTALLED)

J3

J4

J5

J6

UTB1

CONTROLLERpCO2

152

C. N.O.

151

N.O.C.

149150

EF CF

149

,15

1

150 1

52

249

,25

1

250 2

52

T3S

1

T3S

2

EF

1

CF

1

EF

2

CF

2

EF BLACK

CF BLACK

EF WHITE

CF WHITE

EF & CF BROWN

EF & CF BLUE

MASS FLOW

SENSOR OPTION

EVAPORATORFLOW SWITCH

CONDENSER

FLOW SWITCH

7 LEADS

ENTERING EVAP. WATER TEMP.

ENTERING COND. WATER TEMP.

LEAVING COND. WATER TEMP.

LIQUID LINE TEMP.

ENTERING HEAT RECOVERY

LEAVING HEAT RECOVERY

(OPTIONAL)

(OPTIONAL)

OIP

UC POWER

FS POWER

pLAN

UNIT CONTROLLER

FLOW SWITCH

CONNECT THESE LEADSTO THE COMPRESSOR

CONTROL BOX

COMMUNICATION

TYPE II KNOCKDOWN ONLY

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IM 1128 Field Installation Procedure 21

Figure 16, Unit Electrical and Sensor Locations

R3313115

CS10

US04

CS05

US05

CS04

CS09CS02

CS03

&

&

EVAPORATOR

STANDARD PRESSURE TRANSDUCER

STANDARD TEMPERATURE SENSOR

OPTIONAL TEMPERATURE SENSOR

SEE DETAIL A

SEE DETAIL C

SEE DETAIL E

SEE DETAIL D

SEE DETAIL D

SEE DETAIL D

SEE DETAIL F

CS01

US02

US10

US09 US03

CS07

CS06

CS08

FRONT VIEW AT COMPRESSOR

FIELDOPTION

US05SEE DETAIL E

EVAPORATOR

WITH ELECTRONIC EXPANSION VALVE

REAR VIEW SHOWN WITH PILOT OPERATED EXPANSION VALVE

LEGEND

SEE DETAIL B

SEEDETAIL D

Note: See Figure 17 for reference detail drawings.

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22 Field Installation Procedure IM 1128

Figure 17, Unit Sensor Location Details

R331311503C0200

DETAIL "C"

TU

BE

CS09

DETAIL "D"

US02

DETAIL "E"

US05

US03 US04 CS10

US10US09

CS05

CS05

DETAIL "F”

SUCTION NOZZLE END

OF COMPRESSOR

SENSOR/H.P. SWITCH LOCATION

STANDARD UNIT W/O HOT GAS

CS06

CS06

USE A VALVE COREW/ THIS DEVICE

USE A VALVE COREW/ THIS DEVICE

CS01

VALVE CORE

CONNECTION.MUST BE IN

DETAIL "A"

ONEPLACEONLY

UNIT WITH HOT GAS

DETAIL 'B'

SENSORNUMBER DESCRIPTION

US03

US04

US05

US02

EVAP. LEAVING WATER TEMP.

EVAP. ENTERING WATER TEMP.

CS01

CS02

COND. ENTERING WATER TEMP.

US09

COND. LEAVING WATER TEMP.

US10

EVAP. REFRIGERANT PRESSURE

COND. REFRIGERANT PRESSURE

LIQUID LINE TEMPERATURE

CS03

CS06

CS04

COMP. DISCHARGE TEMP.

OIL FEED TEMPERATURE

OIL SUMP TEMPERATURE

OIL SUMP PRESSURE

OIL FEED GAUGE PRESSURE

% COMPRESSOR AMPS (STARTER)

ENT. HEAT RECOVERY TEMP.

LVG. HEAT RECOVERY TEMP.

SENSORNUMBER DESCRIPTION

CS05

CS07

COMP SUCTION TEMPERATURE

CS08

CS09

CS10

UNIT CONTROL SENSORS

COMPRESSOR CONTROL SENSORS

HIGH PRESSURE SWITCHDO NOT USE A VALVE

CORE WITH THIS DEVICE

HIGH PRESSURE SWITCHDO NOT USE A VALVE

CORE WITH THIS DEVICE

DISCHARGE PRESSURETRANSDUCER

DISCHARGE PRESSURETRANSDUCER

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IM 1128 Field Installation Procedure 23

Figure 18, Compressor Control Box

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24 Field Installation Procedure IM 1128

Figure 19, Unit Control Box

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IM 1128 Field Installation Procedure 25

Figure 20, Flow Switch Wiring

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26 Field Installation Procedure IM 1128

Unit Photographs Figure 21, WSC 087, Photo

Figure 22, WSC 100, Photo

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IM 1128 Field Installation Procedure 27

Figure 23, WSC 126, Photo

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28 Field Installation Procedure IM 1128

Type III Reassembly

Description

TYPE III: The unit ships fully assembled and is field ready to knockdown. Included are the vessel

bolt-on connection brackets, the discharge stack bolt-on flanges at the condenser and the bolt-on oil

pump assembly.

1. The unit is shipped fully charged with refrigerant and lubricant.

2. The unit will be factory insulated and painted.

3. All electrical and sensor wiring will be fastened as usual.

4. The starter will ship per order instructions.

5. Touch up paint and stick on wire ties will be included.

6. This unit will be fully tested at the factory.

7. Labels will be provided with the instructions to mark piping, electrical wiring and sensor wiring.

Reassembly Steps

Type III units offer a variety of disassembly opportunities. In some cases the condenser and tube

support plate are removed to meet narrow entrance requirements. Sometimes the compressor and unit

control panel are removed for low height situations. Other possibilities exist.

Therefore it is difficult to prescribe step-by-step procedures. Various sections of this manual can be

used where applicable, bearing in mind that the unit is fully charged with refrigerant and lubricant.

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IM 1128 Field Installation Procedure 29

Field Insulation Guide

Figure 24, Insulation Requirements

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30 Field Installation Procedure IM 1128

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IM 1128 Field Installation Procedure 31

Dimensions and Weights

Type I The following table gives the dimensions and weight of the chiller with the compressor and starter/VFD

removed and the dimensions and weight of the shipped-loose compressor.

Table 1, Type I, Dimensions & Weights

Chiller w/o Comp. Compressor Unit Size Vessel Code

Unit Width Unit Height Unit Weight Width Height Weight

063 E2009 / C1809 57.1 (1450.6) 61.6 (1564.4) 5212 (2366) 44.0 (1118.6) 25.1 (638.3) 2000 (908)

063 E2209 / C2009 57.1 (1450.6) 64.0 (1624.8) 5919 (2687) 44.0 (1118.6) 25.1 (638.3) 2000 (908)

063 E2209 / C2209 57.1 (1450.6) 64.0 (1624.8) 6216 (2882) 44.0 (1118.6) 25.1 (638.3) 2000 (908)

063 E2609 / C2209 57.1 (1450.6) 67.5 (1715.0) 7048 (3200) 44.0 (1118.6) 25.1 (638.3) 2000 (908))

063 E2609 / C2609 57.1 (1450.6) 73.1 (1857.8) 7784 (3534) 44.0 (1118.6) 25.1 (638.3) 2000 (908)

063 E3009 / C2609 56.8 (1441.7) 75.7 (1922.0) 9692 (4400) 44.0 (1118.6) 25.1 (638.3) 2000 (908)

063 E2012 / C1812 57.1 (1450.6) 61.6 (1564.4) 6084 (2762) 44.0 (1118.6) 25.1 (638.3) 2000 (908)

063 E2212 / C2012 57.1 (1450.6) 64.0 (1624.8) 6982 (3170) 44.0 (1118.6) 25.1 (638.3) 2000 (908))

063 E2212 / C2212 57.1 (1450.6) 64.0 (1624.8) 7357 (3340) 44.0 (1118.6) 25.1 (638.3) 2000 (908)

063 E2612 / C2212 57.1 (1450.6) 67.5 (1715.0) 8377 (3803) 44.0 (1118.6) 25.1 (638.3) 2000 (908)

063 E2612 / C2612 57.1 (1450.6) 73.1 (1857.8) 9294 (4219) 44.0 (1118.6) 25.1 (638.3) 2000 (908)

063 E3012 / C2612 56.8 (1441.7) 75.7 (1922.0) 10703 (4859) 44.0 (1118.6) 25.1 (638.3) 2000 (908)

079 E2209 / C2209 50.2 (1274.6) 62.3 (1581.7) 6940 (3151) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

079 E2609 / C2209 52.7 (1338.3) 63.9 (1622.8) 7780 (3532) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

079 E2609 / C2609 52.7 (1338.3) 69.5 (1765.6) 8516 (3866) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

079 E3009 / C2609 57.1 (1449.8) 74.0 (1878.6) 9692 (4400) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

079 E3009 / C3009 59.0 (1499.4) 79.4 (2016.8) 10876 (4938) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

079 E3609 / C3009 74.7 (1896.1) 78.8 (2001.0) 12713 (5772) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

079 E2212 / C2212 50.2 (1274.6) 62.3 (1581.7) 8081 (3669) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

079 E2612 / C2212 52.7 (1338.3) 63.9 (1622.8) 9109 (4135) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

079 E2612 / C2612 52.7 (1338.3) 69.5 (1765.6) 10026 (4552 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

079 E3012 / C2612 57.1 (1449.8) 74.0 (1878.6) 11435 (5191) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

079 E3012 / C3012 59.0 (1499.4) 79.4 (2016.8) 12919 (5865) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

079 E3612 / C3012 74.7 (1896.1) 78.8 (2001.0) 15140 (6874) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

Continued on next page.

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32 Field Installation Procedure IM 1128

Type 1, Dimensions & Weights, Continued

Chiller w/o Comp. Compressor Unit

Size Vessel Code

Unit Width Unit Height Unit Weight Width Height Weight

087 E2609 / C2209 52.7 (1338.3) 65.2 (1656.3) 7780 (3532) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

087 E2609 / C2609 52.7 (1338.3) 70.8 (1799.1) 8516 (3866) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

087 E3009 / C2609 57.1 (1449.8) 68.8 (1746.5) 9692 (4400) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

087 E3009 I C3009 59.5 (1510.5) 78.7 (1998.0) 10876 (4938) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

087 E3609 / C3009 74.7 (1896.1) 78.8 (2001.0) 12713 (5772) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

087 E2612 / C2212 52.7 (1338.3) 65.2 (1656.3) 9109 (4135) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

087 E2612 / C2612 52.7 (1338.3) 70.8 (1799.1) 10029 (4553) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

087 E3012 / C2612 57.1 (1449.8) 68.8 (1746.5) 11435 (5191) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

087 E3012 / C3012 59.5 (1510.5) 78.7 (1998.0) 12918 (5865) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

087 E3612 / C3012 74.7 (1896.1) 78.8 (2001.0) 15139 (6873) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

087 E3612 / C3612 80.7 (2049.3) 89.2 (2264.4) 17384 (7892) 43.6 (1108.2) 25.1 (638.3) 3200 (1452)

100 E3012 / C3012 67.4 (1712.2) 76.5 (1943.1) 13397 (6082) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

100 E3612 / C3012 77.2 (1961.6) 77.6 (1971.5) 15587 (7076) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

100 E3612 / C3612 83.2 (2114.0) 77.6 (1971.5) 17826 (8093) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

100 E4212 / C3612 86.2 (2190.5) 76.4 (1940.8) 20487 (9301) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

100 E4212 / C4212 92.2 (2342.9) 86.7 (2202.7) 23298 (10577) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

100 E4812 / C4212 98.2 (2495.3) 90.6 (2300.2) 26024 (11815) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

113 E3012 / C3012 67.4 (1712.2) 76.5 (1943.1) 13397 (6082) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

113 E3612 / C3012 77.2 (1961.6) 77.6 (1971.5) 15578 (7072) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

113 E3612 / C3612 83.2 (2114.0) 77.6 (1971.5) 17826 (8093) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

113 E4212 / C3612 86.2 (2190.5) 76.4 (1940.8) 20457 (9287) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

113 E4212 / C4212 92.2 (2342.9) 86.7 (2202.7) 23298 (10577) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

113 E4812 / C4212 98.2 (2495.3) 90.6 (2300.2) 26024 (11815) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

113 E4812 / C4812 104.2 (2647.7) 90.6 (2300.2) 29016 (13173) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

126 E3612 / C3012 77.2 (1961.6) 77.6 (1971.5) 15680 (7119) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

126 E3612 / C3612 83.2 (2114.0) 77.6 (1971.5) 17826 (8093) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

126 E4212 / C3612 86.2 (2190.5) 76.4 (1940.8) 20457 (9287) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

126 E4212 / C4212 92.2 (2342.9) 86.7 (2202.7) 23298 (10577) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

126 E4812 / C4212 98.2 (2495.3) 90.6 (2300.2) 26024 (11815) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

126 E4812 / C4812 104.2 (2647.7) 90.6 (2300.2) 29016 (13173) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

Notes: 1. The overall vessel length can vary depending on the specified tube length and pass arrangement. Consult the McQuay certified

submittal drawings, or unit dimensions in Catalog WSCWDC-4 for specific vessel lengths. 2. Allow plus / minus 1 inch (24.5mm) for factory manufacturing tolerance. 3. All dimensions are shown in inches (mm). All weights are shown in lbs (kg).

Page 33: WSC, WME and WMC Centrifugal Chillers Reassembly of ... · The following label is used in this manual to indicate immediate or potential hazards. It is the responsibility of the owner

IM 1128 Field Installation Procedure 33

Type II The following tables give the dimensions and weights of the various components as shipped.

Table,2 Type II Dimensions & Weights

Unit

Size Vessel Code

Cond.

Width

Cond.

Height

Front &

Back

Support

Width

Front &

Back

Support

Height

Evaporator

Width

Evaporator

Height

Compressor

Width

Compressor

Height

063 E2009 / C1809 31.8

(806.5) 36.8

(933.5) 8.0 (203.2)

22.9 (580.9)

34.6 (877.8)

28.8 (731.3)

44.0 (1118.6)

25.1 (638.3)

063 E2209 / C2009 30.5

(774.2) 36.8

(933.5) 8.0 (203.2)

22.9 (580.9)

34.6 (877.8)

35.4 (899.9)

44.0 (1118.6)

25.1 (638.3)

063 E2209 / C2209 30.5

(774.2) 36.8

(933.5) 8.0 (203.2)

22.1 (561.8)

34.6 (877.8)

35.4 (899.9)

44.0 (1118.6)

25.1 (638.3)

063 E2609 / C2209 30.5

(774.2) 36.8

(933.5) 8.0 (203.2)

22.1 (561.8)

39.2 (996.7)

35.9 (912.6)

44.0 (1118.6)

25.1 (638.3)

063 E2609 / C2609 36.0

(914.9) 42.3

(1073.2) 8.0 (203.2)

27.7 (704.6)

39.2 (996.7)

35.9 (912.6)

44.0 (1118.6)

25.1 (638.3)

063 E3009 / C2609 36.0

(914.9) 42.3

(1073.2) 8.0 (203.2)

27.0 (685.5)

42.6 (1081.0)

37.3 (948.4)

44.0 (1118.6)

25.1 (638.3)

063 E2012 / C1812 31.8

(806.5) 36.8

(933.5) 8.0 (203.2)

22.9 (580.9)

34.6 (877.8)

28.8 (731.3)

44.0 (1118.6)

25.1 (638.3)

063 E2212 / C2012 30.5

(774.2) 36.8

(933.5) 8.0 (203.2)

22.9 (580.9)

34.6 (877.8)

35.4 (899.9)

44.0 (1118.6)

25.1 (638.3)

063 E2212 / C2212 30.5

(774.2) 36.8

(933.5) 8.0 (203.2)

22.1 (561.8)

34.6 (877.8)

35.4 (899.9)

44.0 (1118.6)

25.1 (638.3)

063 E2612 / C2212 30.5

(774.2) 36.8

(933.5) 8.0 (203.2)

22.1 (561.8)

39.2 (996.7)

35.9 (912.6)

44.0 (1118.6)

25.1 (638.3)

063 E2612 / C2612 36.0

(914.9) 42.3

(1073.2) 8.0 (203.2)

27.7 (704.6)

39.2 (996.7)

35.9 (912.6)

44.0 (1118.6)

25.1 (638.3)

063 E3012 / C2612 36.0

(914.9) 42.3

(1073.2) 8.0 (203.2)

27.0 (685.5)

42.6 (1081.0)

37.3 (948.4)

44.0 (1118.6)

25.1 (638.3)

079 E2209 / C2209 30.5

(775.2) 33.1

(841.0) 8.0 (203.2)

20.6 (522.0)

32.8 (834.1)

31.5 (799.8)

43.6 (1108.2)

25.1 (638.3)

079 E2609 / C2209 30.5

(775.2) 35.9

(911.4) 8.0 (203.2)

20.6 (522.0)

36.7 (933.2)

33.2 (842.3)

43.6 (1108.2)

25.1 (638.3)

079 E2609 / C2609 30.5

(775.2) 39.3

(997.0) 8.0 (203.2)

26.2 (665.0)

36.7 (933.2)

33.2 (842.3)

43.6 (1108.2)

25.1 (638.3)

079 E3009 / C2609 36.0

(914.9) 39.3

(997.0) 8.0 (203.2)

25.4 (645.2)

40.1 (1017.8)

37.3 (948.4)

43.6 (1108.2)

25.1 (638.3)

079 E3009 / C3009 41.4

(1052.3) 45.8

(1162.1) 8.0 (203.2)

30.9 (783.8)

42.6 (1081.0)

37.3 (948.4)

43.6 (1108.2)

25.1 (638.3)

079 E3609 / C3009 41.9

(1063.5) 45.8

(1162.1) 8.0 (203.2)

25.5 (648.7)

48.1 (1222.2)

43.7 (1109.7)

43.6 (1108.2)

25.1 (638.3)

079 E2212 / C2212 30.5

(775.2) 33.1

(841.0) 8.0 (203.2)

20.6 (522.0)

32.8 (834.1)

31.5 (799.8)

43.6 (1108.2)

25.1 (638.3)

079 E2612 / C2212 30.5

(775.2) 35.9

(911.4) 8.0 (203.2)

20.6 (522.0)

36.7 (933.2)

33.2 (842.3)

43.6 (1108.2)

25.1 (638.3)

079 E2612 / C2612 30.5

(775.2) 39.3

(997.0) 8.0 (203.2)

26.2 (665.0)

36.7 (933.2)

33.2 (842.3)

43.6 (1108.2)

25.1 (638.3)

079 E3012 / C2612 36.0

(914.9) 39.3

(997.0) 8.0 (203.2)

25.4 (645.2)

40.1 (1017.8)

37.3 (948.4)

43.6 (1108.2)

25.1 (638.3)

079 E3012 / C3012 41.4

(1052.3) 45.8

(1162.1) 8.0 (203.2)

30.9 (783.8)

42.6 (1081.0)

37.3 (948.4)

43.6 (1108.2)

25.1 (638.3)

079 E3612 / C3012 41.9

(1063.5) 45.8

(1162.1) 8.0 (203.2)

25.5 (648.7)

48.1 (1222.2)

43.7 (1109.7)

43.6 (1108.2)

25.1 (638.3)

Table continued on next page.

Page 34: WSC, WME and WMC Centrifugal Chillers Reassembly of ... · The following label is used in this manual to indicate immediate or potential hazards. It is the responsibility of the owner

34 Field Installation Procedure IM 1128

Type II Dimensions & Weights, Continued

Unit

Size Vessel Code

Cond.

Width

Cond.

Height

Front &

Back

Support

Width

Front &

Back

Support

Height

Evaporator

Width

Evaporator

Height

Compressor

Width

Compressor

Height

087 E2609 / C2209 30.5 (775.2) 36.8 (933.5) 8.0 (203.2) 20.6 (522.0) 39.2

(996.7) 35.9

(912.6) 43.6

(1108.2) 25.1

(638.3)

087 E2609 / C2609 36.0 (914.9) 41.8 (1060.5) 8.0 (203.2) 26.2 (665.0) 39.2

(996.7) 35.9

(912.6) 43.6

(1108.2) 25.1

(638.3)

087 E3009 / C2609 36.0 (914.9) 41.8 (1060.5) 8.0 (203.2) 25.4 (645.2) 42.6

(1081.3) 37.3

(948.4) 43.6

(1108.2) 25.1

(638.3)

087 E3009 / C3009 41.9 (1063.5) 45.8 (1162.1) 8.0 (203.2) 30.9 (783.8) 42.6

(1081.3) 37.3

(948.4) 43.6

(1108.2) 25.1

(638.3)

087 E3609 / C3009 41.9 (1063.5) 45.8 (1162.1) 8.0 (203.2) 25.5 (648.7) 48.1

(1222.2) 43.7

(1109.7) 43.6

(1108.2) 25.1

(638.3)

087 E2612 / C2612 36.0 (914.9) 41.8 (1060.5) 8.0 (203.2) 26.2 (665.0) 39.2

(996.7) 35.9

(912.6) 43.6

(1108.2) 25.1

(638.3)

087 E3012 / C2612 36.0 (914.9) 41.8 (1060.5) 8.0 (203.2) 25.4 (645.2) 42.6

(1081.3) 37.3

(948.4) 43.6

(1108.2) 25.1

(638.3)

087 E3012 / C3012 41.9 (1063.5) 45.8 (1162.1) 8.0 (203.2) 30.9 (783.8) 42.6

(1081.3) 37.3

(948.4) 43.6

(1108.2) 25.1

(638.3)

087 E3612 / C3012 41.9 (1063.5) 45.8 (1162.1) 8.0 (203.2) 25.5 (648.7) 48.1

(1222.2) 43.7

(1109.7) 43.6

(1108.2) 25.1

(638.3)

087 E3612 / C3612 46.2 (1173.2) 51.8 (1314.5) 8.0 (203.2) 35.9 (912.1) 48.1

(1222.2) 43.7

(1109.7) 43.6

(1108.2) 25.1

(638.3)

100 E3012 / C3012 41.0 (1041.9) 46.2 (1172.7) 8.0 (203.2) 28.6 (725.4) 48.4

(1229.6) 38.4

(974.6) 44.0

(1117.9) 31.5

(800.1)

100 E3612 / C3012 41.0 (1041.9) 46.2 (1172.7) 8.0 (203.2) 24.4 (619.5) 52.1

(1324.1) 44.1

(1120.6) 44.0

(1117.9) 31.5

(800.1)

100 E3612 / C3612 45.3 (1151.4) 52.1 (1322.3) 8.0 (203.2) 24.4 (619.5) 52.1

(1324.1) 44.1

(1120.6) 44.0

(1117.9) 31.5

(800.1)

100 E4212 / C3612 45.3 (1151.4) 52.1 (1322.3) 8.0 (203.2) 18.6 (473.5) 54.4

(1382.5) 51.5

(1307.6) 44.0

(1117.9) 31.5

(800.1)

100 E4212 / C4212 49.6 (1260.1) 57.6 (1462.0) 8.0 (203.2) 21.4 (543.3) 54.4

(1382.5) 51.5

(1307.6) 44.0

(1117.9) 31.5

(800.1)

100 E4812 / C4212 49.6 (1260.1) 57.6 (1462.0) 8.0 (203.2) 19.6 (498.9) 60.1

(1527.0) 57.1

(1449.6) 44.0

(1117.9) 31.5

(800.1)

113 E3012 / C3012 41.0 (1041.9) 46.2 (1172.7) 8.0 (203.2) 28.6 (725.4) 48.4

(1229.6) 38.4

(974.6) 44.0

(1117.9) 31.5

(800.1)

113 E3612 / C3012 41.0 (1041.9) 46.2 (1172.7) 8.0 (203.2) 24.4 (619.5) 52.1

(1324.1) 44.1

(1120.6) 44.0

(1117.9) 31.5

(800.1)

113 E3612 / C3612 45.3 (1151.4) 52.1 (1322.3) 8.0 (203.2) 24.4 (619.5) 52.1

(1324.1) 44.1

(1120.6) 44.0

(1117.9) 31.5

(800.1)

113 E4212 / C3612 45.3 (1151.4) 52.1 (1322.3) 8.0 (203.2) 18.6 (473.5) 54.4

(1382.5) 51.5

(1307.6) 44.0

(1117.9) 31.5

(800.1)

113 E4212 / C4212 49.6 (1260.1) 57.6 (1462.0) 8.0 (203.2) 21.4 (543.3) 54.4

(1382.5) 51.5

(1307.6) 44.0

(1117.9) 31.5

(800.1)

113 E4812 / C4212 49.6 (1260.1) 57.6 (1462.0) 8.0 (203.2) 19.6 (498.9) 60.1

(1527.0) 57.1

(1449.6) 44.0

(1117.9) 31.5

(800.1)

113 E4812 / C4812 53.9 (1369.1) 63.5 (1612.9) 8.0 (203.2) 19.6 (498.9) 60.1

(1527.0) 57.1

(1449.6) 44.0

(1117.9) 31.5

(800.1)

Table continued on next page.

Page 35: WSC, WME and WMC Centrifugal Chillers Reassembly of ... · The following label is used in this manual to indicate immediate or potential hazards. It is the responsibility of the owner

IM 1128 Field Installation Procedure 35

Type II Dimensions & Weights, Continued

Unit

Size Vessel Code

Cond.

Width

Cond.

Height

Front &

Back

Support

Width

Front &

Back

Support

Height

Evaporator

Width

Evaporator

Height

Compressor

Width

Compressor

Height

126 E3612 / C3012 41.0 (1041.9) 46.2 (1172.7) 8.0 (203.2) 24.4 (619.5) 52.1

(1324.1) 44.1

(1120.6) 44.0

(1117.9) 31.5

(800.1)

126 E3612 / C3612 45.3 (1151.4) 52.1 (1322.3) 8.0 (203.2) 24.4 (619.5) 52.1

(1324.1) 44.1

(1120.6) 44.0

(1117.9) 31.5

(800.1)

126 E4212 / C3612 45.3 (1151.4) 52.1 (1322.3) 8.0 (203.2) 18.6 (473.5) 54.4

(1382.5) 51.5

(1307.6) 44.0

(1117.9) 31.5

(800.1)

126 E4212 / C4212 49.6 (1260.1) 57.6 (1462.0) 8.0 (203.2) 21.4 (543.3) 54.4

(1382.5) 51.5

(1307.6) 44.0

(1117.9) 31.5

(800.1)

126 E4812 / C4212 49.6 (1260.1) 57.6 (1462.0) 8.0 (203.2) 19.6 (498.9) 60.1

(1527.0) 57.1

(1449.6) 44.0

(1117.9) 31.5

(800.1)

126 E4812 / C4812 53.9 (1369.1) 63.5 (1612.9) 8.0 (203.2) 19.6 (498.9) 60.1

(1527.0) 57.1

(1449.6) 44.0

(1117.9) 31.5

(800.1)

Notes: 1. The overall vessel length can vary depending on the specified tube length and pass arrangement. Consult the McQuay certified

submittal drawings, or unit dimensions in Catalog WSCWDC-4 for specific vessel lengths. 2. Allow plus / minus 1 inch (24.5mm) for factory manufacturing tolerance. 3. All dimensions are shown in inches (mm). All weights are shown in lbs (kg).

Page 36: WSC, WME and WMC Centrifugal Chillers Reassembly of ... · The following label is used in this manual to indicate immediate or potential hazards. It is the responsibility of the owner

36 Field Installation Procedure IM 1128

Type II Dimensions & Weights, Continued

Unit

Size Vessel Code

Oil Pump

Width

Oil Pump

Height

Condenser

Weight

Evaporator

Weight

Compressor

Weight

Unit Shipping

Weight

063 E2009 / C1809 20.8 (528.1) 30.6 (778.0) 1835 (831) 2543 (1152) 3200 (1440) 9612 (4360)

063 E2209 / C2009 20.8 (528.1) 30.6 (778.0) 2230 (1010) 2708 (1227) 3200 (1440) 10319 (4681)

063 E2209 / C2209 20.8 (528.1) 30.6 (778.0) 2511 (1137) 2708 (1227) 3200 (1440) 10616 (4815)

063 E2609 / C2209 20.8 (528.1) 30.6 (778.0) 2511 (1137) 3381 (1532) 3200 (1440) 11448 (5193)

063 E2609 / C2609 20.8 (528.1) 30.6 (778.0) 3210 (1454) 3381 (1532) 3200 (1440) 12184 (5527)

063 E3009 / C2609 20.8 (528.1) 30.6 (778.0) 3210 (1454) 4397 (1992) 3200 (1440) 14092 (6392)

063 E2012 / C1812 20.8 (528.1) 30.6 (778.0) 2183 (989) 2862 (1296) 3200 (1440) 10484 (4756)

063 E2212 / C2012 20.8 (528.1) 30.6 (778.0) 2677 (1213) 3071 (1391) 3200 (1440) 11382 (5163)

063 E2212 / C2212 20.8 (528.1) 30.6 (778.0) 3031 (1373) 3071 (1391) 3200 (1440) 11757 (5333)

063 E2612 / C2212 20.8 (528.1) 30.6 (778.0) 3031 (1373) 3880 (1758) 3200 (1440) 12777 (5796)

063 E2612 / C2612 20.8 (528.1) 30.6 (778.0) 3900 (1767) 3880 (1758) 3200 (1440) 13694 (6203)

063 E3012 / C2612 20.8 (528.1) 30.6 (778.0) 3900 (1767) 5075 (2299) 3200 (1440) 15103 (6851)

079 E2209 / C2209 18.8 (476.5) 29.1 (739.6) 2511 (1137) 2708 (1227) 3200 (1440) 11340 (5144)

079 E2609 / C2209 18.8 (476.5) 29.1 (739.6) 2511 (1137) 3381 (1532) 3200 (1440) 12180 (5525)

079 E2609 / C2609 18.8 (476.5) 29.1 (739.6) 3210 (1454) 3381 (1532) 3200 (1440) 12916 (5859)

079 E3009 / C2609 18.8 (476.5) 29.1 (739.6) 3210 (1454) 4397 (1992) 3200 (1440) 14092 (6392)

079 E3009 / C3009 18.8 (476.5) 29.1 (739.6) 4356 (1973) 4397 (1992) 3200 (1440) 15276 (6929)

079 E3609 / C3009 19.8 (501.9) 26.7 (678.9) 4356 (1973) 5882 (2665) 3200 (1440) 17113 (7762)

079 E2212 / C2212 18.8 (476.5) 29.1 (739.6) 3031 (1373) 3071 (1391) 3200 (1440) 12481 (5661)

079 E2612 / C2212 18.8 (476.5) 29.1 (739.6) 3031 (1373) 3880 (1758) 3200 (1440) 13509 (6128)

079 E2612 / C2612 18.8 (476.5) 29.1 (739.6) 3900 (1767) 3880 (1758) 3200 (1440) 14426 (6544)

079 E3012 / C2612 18.8 (476.5) 29.1 (739.6) 3900 (1767) 5075 (2299) 3200 (1440) 15835 (7183)

079 E3012 / C3012 18.8 (476.5) 29.1 (739.6) 5333 (2416) 5075 (2299) 3200 (1440) 17319 (7856)

079 E3612 / C3012 19.8 (501.9) 26.7 (678.9) 5333 (2416) 6840 (3099) 3200 (1440) 19539 (8863)

087 E2609 / C2209 19.8 (501.9) 26.7 (678.9) 2511 (1137) 3381 (1532) 3200 (1440) 12180 (5525)

087 E2609 / C2609 19.8 (501.9) 26.7 (678.9) 3210 (1454) 3381 (1532) 3200 (1440) 12916 (5859)

087 E3009 / C2609 19.8 (501.9) 26.7 (678.9) 3210 (1454) 4397 (1992) 3200 (1440) 14092 (6392)

087 E3009 / C3009 19.8 (501.9) 26.7 (678.9) 4356 (1973) 4397 (1992) 3200 (1440) 15276 (6929)

087 E3609 / C3009 19.8 (501.9) 26.7 (678.9) 4356 (1973) 5882 (2665) 3200 (1440) 17113 (7762)

087 E2612 / C2212 19.8 (501.9) 26.7 (678.9) 3031 (1373) 3880 (1758) 3200 (1440) 13509 (6128)

087 E2612 / C2612 19.8 (501.9) 26.7 (678.9) 3900 (1767) 3880 (1758) 3200 (1440) 14426 (6544)

087 E3012 / C2612 19.8 (501.9) 26.7 (678.9) 3900 (1767) 5075 (2299) 3200 (1440) 15835 (7183)

087 E3012 / C3012 19.8 (501.9) 26.7 (678.9) 5333 (2416) 5075 (2299) 3200 (1440) 17318 (7855)

087 E3612 / C3012 19.8 (501.9) 26.7 (678.9) 5333 (2416) 6840 (3099) 3200 (1440) 19539 (8863)

087 E3612 / C3612 19.8 (501.9) 26.7 (678.9) 7508 (3401) 6840 (3099) 3200 (1440) 21784 (9881)

Table continued on next page.

Page 37: WSC, WME and WMC Centrifugal Chillers Reassembly of ... · The following label is used in this manual to indicate immediate or potential hazards. It is the responsibility of the owner

IM 1128 Field Installation Procedure 37

Type II Dimensions & Weights, Continued

Unit

Size Vessel Code

Oil Pump

Width

Oil Pump

Height

Condenser

Weight

Evaporator

Weight

Compressor

Weight

Unit Shipping

Weight

100 E3012 / C3012 19.8 (501.9) 34.8 (884.4) 5333 (2416) 5075 (2299) 6000 (2700) 20597 (9343)

100 E3612 / C3012 19.8 (501.9) 34.8 (884.4) 5333 (2416) 6840 (3099) 6000 (2700) 22778 (10332)

100 E3612 / C3612 19.8 (501.9) 34.8 (884.4) 7508 (3401) 6840 (3099) 6000 (2700) 25026 (11352)

100 E4212 / C3612 19.8 (501.9) 34.8 (884.4) 7508 (3401) 8922 (4042) 6000 (2700) 27657 (13545)

100 E4212 / C4212 19.8 (501.9) 34.8 (884.4) 10267 (4651) 8922 (4042) 6000 (2700) 30498 (13834)

100 E4812 / C4212 19.8 (501.9) 34.8 (884.4) 10267 (4651) 11125 (5040) 6000 (2700) 33224 (15070)

113 E3012 / C3012 19.8 (501.9) 34.8 (884.4) 5333 (2416) 5075 (2299) 6000 (2700) 20597 (9343)

113 E3612 / C3012 19.8 (501.9) 34.8 (884.4) 5333 (2416) 6840 (3099) 6000 (2700) 22778 (10332)

113 E3612 / C3612 19.8 (501.9) 34.8 (884.4) 7508 (3401) 6840 (3099) 6000 (2700) 25026 (11352)

113 E4212 / C3612 19.8 (501.9) 34.8 (884.4) 7508 (3401) 8922 (4042) 6000 (2700) 27657 (13545)

113 E4212 / C4212 19.8 (501.9) 34.8 (884.4) 10267 (4651) 8922 (4042) 6000 (2700) 30498 (13834)

113 E4812 / C4212 19.8 (501.9) 34.8 (884.4) 10267 (4651) 11125 (5040) 6000 (2700) 33224 (15070)

113 E4812 / C4812 19.8 (501.9) 34.8 (884.4) 13077 (5924) 11125 (5040) 6000 (2700) 36216 (16427)

126 E3612 / C3012 19.8 (501.9) 34.8 (884.4) 5333 (2416) 6840 (3099) 6000 (2700) 22880 (10378)

126 E3612 / C3612 19.8 (501.9) 34.8 (884.4) 7508 (3401) 6840 (3099) 6000 (2700) 25128 (11398)

126 E4212 / C3612 19.8 (501.9) 34.8 (884.4) 7508 (3401) 8922 (4042) 6000 (2700) 27657 (12545)

126 E4212 / C4212 19.8 (501.9) 34.8 (884.4) 10267 (4651) 8922 (4042) 6000 (2700) 30498 (13834)

126 E4812 / C4212 19.8 (501.9) 34.8 (884.4) 10267 (4651) 11125 (5040) 6000 (2700) 33224 (15070)

126 E4812 / C4812 19.8 (501.9) 34.8 (884.4) 13077 (5924) 11125 (5040) 6000 (2700) 36216 (16427)

Notes:

1. The overall vessel length can vary depending on the specified tube length and pass arrangement. Consult the McQuay certified submittal drawings, or unit dimensions in Catalog WSCWDC-4 for specific vessel lengths.

2. The oil pump width is the dimension from front to back. The height is from the bottom of the sump to the top of the piping connections. Transporting the oil pump is usually not an issue when compared to the vessels.

3. Allow plus / minus 1 inch (24.5mm) for manufacturing tolerance. 4. All dimensions are shown in inches (mm). 5. All weights are shown in lbs. (kg).

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38 Field Installation Procedure IM 1128

Shipping Lists

Table 3, Type I WSC Knockdown Shipping List

LABEL DESCRIPTION LOOSE PARTS QTY.

FROM - TO REF. DWG. FACTORY

NOTES

COPPER PIPE ASSY’S

HOT GAS HOT GAS BYPASS

(OPTION) 1 DISCH. NOZZLE TO EVAP. BTM. R331311307

LEAVE OR REMOVE PER

DWG.

LIQUID INJECTION

LIQUID INJECTION N/A COND. BOTTOM TO COMPR. R331311303 BLOCK-OFF

AND SECURE

MOTOR COOLING

MOTOR COOLING N/A COND. TO MOTOR R331311304 BLOCK-OFF

AND SECURE

MOTOR DRAIN

MOTOR DRAIN (LARGE) N/A COMPRESSOR TO EVAP

BOTTOM R331311305

BLOCK-OFF AND SECURE

MOTOR DRAIN

MOTOR DRAIN (SMALL) N/A COMP. TO LARGE MOTOR

DRAIN R331311305

BLOCK-OFF AND SECURE

OIL DRAIN OIL PUMP DRAIN 1 COMP. TO OIL PUMP R331311302 REMOVE AND

CRATE

OIL VENT OIL PUMP VENT 1 COMP. TO OIL PUMP R331311302 REMOVE AND

CRATE

OIL RETURN OIL RETURN TUBE (THRUST) 1 COMP. TO OIL PUMP TEE

(NEAR COOLER) R331311302

REMOVE PART OF LINE AND

CRATE

OIL SUPPLY OIL SUPPLY TUBE 1 COMP. TO OIL COOLER BTM. R331311302 REMOVE PART OF LINE AND

CRATE

STEEL PIPE ASSY'S

SUCTION LINE 1 COMP. TO EVAP. R331311308 REMOVE AND

CRATE

DISCHARGE NOZZLE AND

CHECK VALVE 1 EA COMP. TO DISCHARGE PIPE R331311308

LEAVE OR REMOVE PER

DWG.

MISCELLANEOUS

073244408 TOUCH UP SPRAY PAINT

CANS 6

001358000 WIRE TIES 50

070183501 WIRE TIE STICK-ON MOUNTS 25

McQUAY LONMARK LABEL

BAG 1

LITERATURE AND SCHEMATIC

IN MANILLA ENVELOPE 1

STARTER SHROUD 1 IF PRESENT

STARTER BRACKETS 2 IF UNIT

MOUNTED

TERMINAL SHROUD 1 IF PRESENT

ISOLATOR PADS 6

OPERATOR INTERFACE

PANEL 1

LCD SUPPORT ARM 1

POWER CABLES 3 OR 6 IF UNIT

MOUNTED

CONTROL BOX WATER

HOSES 2

COMPRESSOR 4 WAY VALVE

ASSY 1

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IM 1128 Field Installation Procedure 39

LABEL DESCRIPTION LOOSE PARTS QTY.

FROM - TO REF. DWG. FACTORY

NOTES

COMPRESSOR INSULATION

KIT 1

O-RINGS AND GASKETS IN

PLASTIC BAG 1

735030433 OIL CONTAINERS (5 GAL. EA.) X SEE BOM FOR

QUANTITY

000986000 INSULATION GLUE (1 GAL.) 1

074646106 PRESSTITE THERMAL MASTIC 2

070217402 V-740 THERMAL COMPOUND 2

KNOCKDOWN REFERENCE

DWG. PACKET 1

MAJOR COMPONENTS

COMPRESSOR W/ SKID 1

STARTER W/ SKID 1

WSC UNIT STACK 1

Table 4, Type II WSC Knockdown Shipping List

LABEL DESCRIPTION LOOSE PARTS QTY.

FROM - TO REF. DWG. NOTES

COPPER PIPE ASSY'S

HOT GAS HOT GAS BYPASS

(OPTION) 1 DISCH. NOZZLE TO EVAP. BTM. R331311307

REMOVE AND CRATE

LIQUID INJECTION

LIQUID INJECTION 1 COND. BOTTOM TO COMPR. R331311303 REMOVE PART

OF LINE & CRATE

LIQUID LINE LIQUID LINE 1 COND. BTM. TO EVAP. BTM R331311306 REMOVE AND

CRATE

MOTOR COOLING

MOTOR COOLING 1 COND. TO MOTOR R331311304 REMOVE PART

OF LINE & CRATE

MOTOR DRAIN

MOTOR DRAIN (LARGE) N/A COMPRESSOR TO EVAP

BOTTOM R331311305

BLOCK-OFF AND SECURE

MOTOR DRAIN

MOTOR DRAIN (SMALL) N/A COMP. TO LARGE MOTOR

DRAIN R331311305

BLOCK-OFF AND SECURE

OIL DRAIN OIL PUMP DRAIN 1 COMP. TO OIL PUMP R331311302 REMOVE AND

CRATE

OIL VENT OIL PUMP VENT 1 COMP. TO OIL PUMP R331311302 REMOVE AND

CRATE

OIL RETURN OIL RETURN TUBE (THRUST) 1 COMP. TO OIL PUMP TEE

(NEAR COOLER) R331311302

REMOVE PART OF LINE AND

CRATE

OIL SUPPLY OIL SUPPLY TUBE 1 COMP. TO OIL COOLER BTM. R331311302 REMOVE PART OF LINE AND

CRATE

PILOT LINE PILOT - 1/4" FLEX TUBE 1 LIQ. LINE TO TOP OF EVAP. R331311306 REMOVE AND

CRATE

PILOT LINE PILOT VALVE LINE 1 COND. BTM. TO EXP. VALVE R331311306 REMOVE AND

CRATE

WATER RETURN

WATER RETURN 1 OIL COOLER TO FIELD

CONNECTION R331311302

REMOVE AND CRATE

WATER SUPPLY

WATER SUPPLY 1 OIL COOLER TO FIELD

CONNECTION R331311302

REMOVE AND CRATE

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40 Field Installation Procedure IM 1128

LABEL DESCRIPTION LOOSE PARTS QTY.

FROM - TO REF. DWG. FACTORY

NOTES

STEEL PIPE ASSY'S

SUCTION LINE 1 COMPRESSOR TO

EVAPORATOR R331311308

REMOVE AND CRATE

DISCHARGE LINE 1 COMPRESSOR TO

CONDENSER R331311308

REMOVE AND CRATE

DISCHARGE NOZZLE 1 IN DISCHARGE LINE R331311308 REMOVE AND

CRATE

CHECK VALVE 1 IN DISCHARGE LINE R331311308 REMOVE AND

CRATE

LABEL DESCRIPTION LOOSE PARTS QTY.

FROM - TO REF. DWG. NOTES

MISCELLANEOUS

PART NO.

073244408 TOUCH- UP SPRAY PAINT

CANS 12

001358000 WIRE TIES 100

070183501 WIRE TIE STICK-ON MOUNTS 50

McQUAY LONMARK LABEL

BAG 1

LITERATURE AND SCHEMATIC

IN MANILLA ENVELOPE 1

STARTER SHROUD 1 IF PRESENT

STARTER BRACKETS 2 IF UNIT

MOUNTED

TERMINAL SHROUD 1 IF PRESENT

ISOLATOR PADS 6

OPERATOR INTERFACE

PANEL 1

LCD SUPPORT ARM 1

POWER CABLES 3 OR 6 IF UNIT

MOUNTED

CONTROL BOX WATER

HOSES 2

COMPRESSOR 4 WAY VALVE

ASSY 1

COMPRESSOR INSULATION

KIT 1

SHEET INSULATION (HEADS,

BRACKETS ETC.) X SQ. FT.

SEE BOM FOR QUANTITY

O-RINGS AND GASKETS IN

PLASTIC BAG 1

735030433 OIL CONTAINERS (5 GAL. EA.) X SEE BOM FOR

QUANTITY

000986000 INSULATION GLUE (1 GAL.) 1

074646106 PRESSTITE THERMAL MASTIC 2

070217402 V-740 THERMAL COMPOUND 2

KNOCKDOWN REFERENCE

DWG. PACKET 1

Continued on the next page.

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IM 1128 Field Installation Procedure 41

LABEL DESCRIPTION LOOSE PARTS QTY.

FROM - TO REF. DWG. FACTORY

NOTES

MAJOR COMPONENTS

COMPRESSOR 1

STARTER 1

COMPRESSOR CONTROL BOX 1

UNIT CONTROL BOX 1

WSC UNIT STACK 1

Table 5, Type III WSC Knockdown Shipping List

LABEL DESCRIPTION LOOSE PARTS QTY.

FROM - TO REF. DWG. NOTES

MISCELLANEOUS

PART NO.

073244408 TOUCH-UP SPRAY PAINT

CANS 6

001358000 WIRE TIES 50

070183501 WIRE TIE STICK-ON MOUNTS 25

McQUAY LONMARK LABEL

BAG 1

LITERATURE AND SCHEMATIC

IN MANILLA ENVELOPE 1

STARTER BRACKETS 2

IF UNIT MOUNTED &

SHIPPED LOOSE

ISOLATOR PADS 6

OPERATOR INTERFACE

PANEL 1

LCD SUPPORT ARM 1

POWER CABLES 3 OR 6 IF UNIT

MOUNTED

CONTROL BOX WATER

HOSES 2

IF UNIT MOUNTED

KNOCKDOWN REFERENCE

DWG. PACKET 1

331311601 ELEC. AND PIPING LABELS 1

MAJOR COMPONENTS

STARTER 1 IF SHIPPED

LOOSE

WSC UNIT 1

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42 Field Installation Procedure IM 1128

WMC Introduction

It is estimated that fifty percent of retrofit applications require partial or complete disassembly of the

chiller. McQuay offers two solutions to the disassembly and reassembly effort on WMC chillers.

WMC chillers are relatively easy to disassembly due to the small compressor size and the absence of a

lubrication system with its attendant components and piping.

TYPE IV Knockdown: The compressor(s), control panel, compressor power panel(s) are removed at

the factory and put on skids. The stripped vessel stack is shipped as a single piece. Discharge and

suction piping, liquid line and the compressor cooling line(s) are removed and crated. All associated

wiring and piping possible will remain on the vessel stack.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5-psi helium holding charge.

3. The suction line(s) is not insulated at the factory. An insulation kit will be shipped with the unit.

4. The evaporator will be insulated at the factory.

5. Refrigerant will not be shipped with the unit and must be secured locally and furnished and

installed by the installer.

6. All field piping connections will be flanged or copper brazing.

7. All free piping ends will be capped.

8. Touch-up paint will be included.

9. The unit will undergo the rigorous, full McQuay test program at the factory.

10. Contact local McQuay Factory Service for pricing and scheduling of required installation

supervision.

TYPE V Knockdown: The unit ships fully assembled and is ready for field knockdown. This option

allows components to be removed as required at the site. The unit dimension drawing gives sufficient

dimensions to determine what should be removed. Approximate reduction in unit size for Type IV

knockdown is shown below

Table 6, Dimension Reduction

Remove WMC Model

Compressor(s) Compressor(s)

& Panels Panels Only

Separate Vessels

145/150 -10” ht. -20” ht. 0 30 “ max. width

250/290 -7 “ ht. -22 “ ht. 0 30 “ max. width

1. The unit is shipped fully charged with refrigerant. Pump down or remove refrigerant before

breaking any refrigerant connection.

2. The unit will be factory insulated and painted.

3. All electrical and sensor wiring will be fastened as usual.

4. Touch up paint and stick-on wire ties will be included.

5. This unit will be fully tested at the factory.

6. Labels will be provided with the instructions to mark piping, electrical wiring and sensor wiring.

! WARNING

Prior to un-sweating any connection in the field, verify that there is no pressure or charge in lines. Failure to do so can result in property damage, severe personal injury, or death.

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IM 1128 Field Installation Procedure 43

Type IV Disassembly-Reassembly

Disassembly

Type IV Knockdown units are shipped disassembled except for the vessel stack and are shipped less

refrigerant, If the stack size or weight dictates further disassembly, the vessels can be separated by

disconnecting any interconnecting wiring and tubing and then unbolting them. The vessels and compressors

have a helium holding charge that must be released prior to attempting to open any connection.

Reassembly

1. Reassemble the vessel stack, if disassembled, and reconnect any wiring and tubing.

2. Mount the compressor(s) on the stack. Be careful to avoid damaging lines already mounted on the unit.

Mounting bolts, washers and nuts are shipped loose. Leave the mounting bolts loose until the suction and

discharge lines are installed and aligned.

During assembly, bolts holding block off plates (suction connection, for example), are used for reassembly

of the component. See Figure 25 for the location and description of the block offs.

3. Do not remove block offs until ready to install piping. The compressor and vessels have a Schrader valve

on their block off plates to be used for relieving the helium holding charge.

! WARNING

Remove compressor, piping or vessel holding charge through the Schrader valve in the block off plates before attempting to loosen any fittings on them. Failure to do so can cause severe bodily injury.

4. Install the suction and discharge line(s). See Figure 28. Tighten bolts after the entire line has been

installed and aligned. Insulate the suction line with the insulation and glue provided.

5. Install the liquid line and motor cooling lines. See Figure 29 and Figure 30.

6. Install control panel and compressor power panels by bolting to the horizontal support members.

7. If the unit has single-point power, connect the power leads from the terminal box under the control panel

to each power panel line side connection.

8. Connect any loose wiring.

9. Pressure (leak) test, evacuate, and charge with field supplied R-134a using standard refrigeration practice.

Type V Disassembly-Reassembly Type V units are designed for a wide range of disassembly and the degree of knockdown varies. Use

instructions and drawings from Type IV Disassembly-Reassembly instructions above. Observe the following

recommendations.

1. The chiller is shipped with the full refrigerant charge that must be pumped down into the condenser or

removed before breaking any refrigerant connection. Before attempting any disassembly, assume the

condenser isolation valves may have leaked and that any component of the chiller may be pressurized with

refrigerant. Exert the proper precautions with this caveat in mind.

2. Check that power has been removed from the unit. Before disconnecting any wire, it is prudent to label its

function and connection point to facilitate reconnection.

3. The refrigerant charge must be removed from the unit if the vessels are to be separated.

4. Some insulation repair and touch-up painting may be required.

5. See Type IV instructions for reassembly of components.

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44 Field Installation Procedure IM 1128

Table 7, Component Weight

Evaporator Condenser WMC Model

Compressor Power

Panel (Each) Control Panel Model Weight Model Weight

145S 282 295 100 E2209 2490 C2009 2142

145D 262 230 195 E2209 2490 C2009 2142

150D 262 230 195 E2212 2857 C2012 2615

250D 282 295 265 E2609 3259 C2209 2392

290D 282 295 265 E2612 3812 C2212 2942

400D 282 295 265 E3012 5075 C2612 3900

NOTES:

1. All weights in pounds.

2. “S” models have one compressor; “D” models have two compressors.

Table 8, Component Dimensions (Length x Width x Height)

NOTE: All dimensions in inches.

Figure 25, Type IV, Compressor Block Offs

Evaporator Condenser WMC Model

Compressor Power Panel

Control Panel Model Model

Stack

145S 32 x 22 x 18 22 x 12 x 48 16 x 9 x 74 2209 135 x 28 x 29 2009 128 x 36 x 33 135 x 36 x 60

145D 32 x 18 x 18 22 x 12 x 48 16 x 9 x 68 2209 135 x 28 x 29 2009 128 x 36 x 33 135 x 36 x 60

150D 32 x 18 x 18 22 x 12 x 48 16 x 9 x 68 2212 170 x 28 x 29 2012 164 x 36 x 33 170 x 36 x 60

250D 32 x 22 x 18 22 x 12 x 48 16 x 9 x 74 2609 130 x 32 x 33 2209 135 x 38 x 33 135 x 38 x 63

290D 32 x 22 x 18 22 x 12 x 48 16 x 9 x 74 2612 165 x 32 x 33 2212 170 x 38 x 33 170 x 38 x 63

400D 32 x 22 x 18 22 x 12 x 48 16 x 9 x 74 3012 169 x 36 x 36 2612 165 x44 x 36 169 x 44 x 72

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IM 1128 Field Installation Procedure 45

Figure 26, Type IV, Parts in Crates

Figure 27, Type IV, Bare Vessel Stack

Motor Cooling (4) Liquid Line Discharge Lines Suction Lines

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46 Field Installation Procedure IM 1128

Figure 28, Type V, Discharge Line Removal

Figure 29, Type V, Motor Cooling Line Removal

Suction Line (2)

Discharge Line (2)

Motor Cooling

Line (1)

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IM 1128 Field Installation Procedure 47

Figure 30, Type V, Liquid Line Removal

Liquid Line

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48 Field Installation Procedure IM 1128

WME Introduction

It is estimated that fifty percent of retrofit applications require partial or complete disassembly of the

chiller. McQuay offers three solutions to the disassembly and reassembly effort on Model WME,

magnetic bearing compressor chillers.

TYPE I ... Type I provides a moderate amount of disassembly. The compressor, suction and discharge

piping, and compressor VFD power panel are removed and put on a skid. The touchscreen and

mounting arm will ship in a separate container. All associated wiring and piping will remain attached if

possible. The remaining loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5 psi helium holding charge.

3. The compressor will not be insulated at the factory. An insulation kit will be shipped with the unit.

4. The compressor and VFD power panel will ship loose.

5. The control panel will ship separately and have all sensors wired in, labeled and tied up. Matching label

will exist on the sensor locations.

6. The vessel stack will be insulated at the factory.

7. Suction piping insulation and glue will be shipped with the unit for field installation.

8. Refrigerant will not be shipped with the unit and must be furnished and installed by the installer.

9. All field-piping connections will be grooved mechanical couplings, O-ring face seal or copper brazing.

10. Touch-up paint and stick-on wire ties will be included.

11. The unit will undergo the rigorous, full McQuay run-test program at the factory.

12. Contact local McQuay Factory Service for price quotation and scheduling.

TYPE II ... Type II provides a total knockdown of the unit. The compressor and VFD power panel are

removed and put on a skid. The touchscreen and mounting arm will ship in a separate container. The

condenser, evaporator, and tube sheet supports will remain connected only by the attachment bolts for

easy disassembly at the job site. All wiring and piping that interconnects the components will be

removed. The remaining loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5 psi helium holding charge.

3. The compressor will not be insulated at the factory. An insulation kit will be shipped with the

unit.

4. Only the evaporator shell will be factory insulated. Loose insulation and glue will be shipped for

the remaining surface areas.

5. The compressor and VFD power panel will ship loose.

6. Refrigerant will be field supplied and installed.

7. All field-piping connections will be grooved mechanical couplings, O-ring face seal or copper

brazing.

8. Touch-up paint and stick-on wire ties will be included.

9. The discharge piping and suction elbow will be shipped loose in a separate crate.

10. The unit will undergo the rigorous, full McQuay run-test program at the factory.

11. Contact local McQuay Factory Service for price quotation and scheduling.

Type III ... The units are shipped fully assembled, factory charged, run-tested, insulated and painted;

ready for disassembly at the job site. Included are the vessel bolt-on connection brackets, discharge line

bolt-on flanges at the condenser. Touch-up paint and stick-on wire ties will be included. Site

disassembly and reassembly must be supervised by McQuay startup personnel. Contact local McQuay

Factory Service for price quotation and scheduling.

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IM 1128 Field Installation Procedure 49

Type I Reassembly

TYPE I ... Type I provides a moderate amount of disassembly. The compressor, suction and discharge

piping, and compressor VFD power panel are removed and put on a skid. The touchscreen and

mounting arm will ship in a separate container. All associated wiring and piping will remain attached if

possible. The remaining loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5 psi helium holding charge.

3. The compressor will not be insulated at the factory. An insulation kit will be shipped with the unit.

4. The compressor and VFD power panel will ship loose.

5. The control panel will ship separately and have all sensors wired in, labeled and tied up. Matching label will

exist on the sensor locations.

6. The vessel stack will be insulated at the factory.

7. Suction piping insulation and glue will be shipped with the unit for field installation.

8. Refrigerant will not be shipped with the unit and must be furnished and installed by the installer.

9. All field-piping connections will be grooved mechanical couplings, O-ring face seal or copper brazing.

10. Touch-up paint and stick-on wire ties will be included.

11. The unit will undergo the rigorous, full McQuay run-test program at the factory.

12. Contact local McQuay Factory Service for price quotation and scheduling.

Reassembly Steps

NOTE: Additional instructions may be shown on the assembly drawings.

1. Mount the compressor on the stack. Be careful to avoid damaging lines already mounted on the

unit. Mounting bolts, washers and nuts are shipped loose. Leave the mounting bolts loose until the

suction and discharge lines are installed and aligned.

During assembly, bolts holding block-off plates (motor cooling connection, for example), are used

for reassembly of the component. See Figure 1 or Figure 2 for the location and description of the

block-offs.

2. Do not remove block-offs until ready to install piping. The compressor and vessels have a Schrader

valve on their block-off plates to be used for relieving the helium holding charge.

! WARNING

Remove compressor and vessel holding charge through the Schrader valve in the block-off plates before attempting to loosen any fittings on them. Failure to do so can cause severe bodily injury.

3. Install the suction and discharge piping (see Figure 3). Before tightening the Victaulic couplings,

position the suction and discharge piping so that the compressor can be aligned to give the best fit-

up. When this is achieved, secure the compressor mounting bolts and proceed with installing the

Victaulics using a light coating of Victaulic lubrication.

4. Install the liquid injection line The liquid injection line is attached to the condenser and has

shipping straps securing it to the evaporator and condenser. It, and the compressor, each have a

block-off.

5. Install the motor cooling line using the same procedure as the liquid injection line.

6. Install the motor drain line (see Figure 6) using the same procedure as the liquid injection line.

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50 Field Installation Procedure IM 1128

7. Install compressor wiring. The wire end that has been disconnected, and its attachment point on the

compressor, will each have a label attached (VC for the vane close switch, for example) for

matching purposes.

• Guardistor, G1 (and G2 on some units), terminal box located on side of motor housing.

• Vane load/unload solenoids, SA and SB, located on the four-way solenoid assembly.

• Vane close switch, VC, located on compressor next to the discharge housing.

• Vane open switch, VO, located on suction end of compressor.

• High pressure switch, HPS, located on compressor discharge nozzle.

8. Mount the VFD power panel on the brackets in the front of the unit and interconnect to the

compressor motor using the cables provided. Control wiring will also be required. The field wiring

diagram located on the control panel door should also be consulted.

9. Normal procedure of leak testing, triple evacuation, and charging with refrigerant and lubricant

must be followed prior to the start up procedure.

10. After leak testing, insulate the compressor motor, suction line, and other miscellaneous areas with

the included insulation and adhesive. The following components should be insulated:

Evaporator Evaporator water heads Expansion valve

Motor cooling lines Suction elbow VFD cooling line

Stator cooling line Evaporator tube sheets

This completes the reassembly procedure.

Type II Reassembly

TYPE II ... Type II provides a total knockdown of the unit. The compressor and VFD power panel

are removed and put on a skid. The touchscreen and mounting arm will ship in a separate container.

The condenser, evaporator, and tube sheet supports will remain connected only by the attachment

bolts for easy disassembly at the job site. All wiring and piping that interconnects the components

will be removed. The remaining loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5 psi helium holding charge.

3. A compressor insulation kit will be shipped with the unit.

4. Only the evaporator shell will be factory insulated. Loose insulation and glue will be shipped

for the remaining surface areas.

5. The compressor and VFD power panel will ship loose.

6. Refrigerant will be field supplied and installed.

7. All field-piping connections will be grooved mechanical couplings, O-ring face seal or copper

brazing.

8. Touch-up paint and stick-on wire ties will be included.

9. The discharge piping and suction elbow will be shipped loose in a separate crate.

10. The unit will undergo the rigorous, full McQuay run-test program at the factory.

11. Contact local McQuay Factory Service for price quotation and scheduling.

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IM 1128 Field Installation Procedure 51

EVAPORATORTUBE SHEET

TUBE SHEETSUPPORT

PLATE

CONDENSERTUBE SHEET

BOLTED

BOLTED

WELDED

TWO ANGLE PLATES,ONE WELDED TO EVAP.ONE WELDED TO COND.THEN BOLTED TOGETHER.

Reassembly Steps

NOTE: Additional instructions may be shown on the assembly drawings.

The Type II arrangement is shipped with the evaporator, condenser, tube and sheet support plate bolted

together. This provides structural support during transit and also allows several options for

disassembly.

Figure 31, Component Disassembly

In most cases for narrow entry, the condenser will be

separated by unbolting it from the evaporator angle

bracket and from the tube sheet support plate. This

leaves the evaporator and the support plate that has

the mounting foot extended under where the

condenser used to be. Therefore, the evaporator is

usually unbolted from the two support plates, which

can then be more easily handled by themselves.

! WARNING

Remove compressor and vessel holding charge through the Schrader valve in the block-off plates before attempting to loosen any fittings on them. Failure to do so can cause severe bodily injury.

11. Disassemble the unit to the extent required by the site conditions. Rig the components to their final

location and reassemble them using the fasteners that came with the unit.

12. The compressor and its suction and discharge piping should be installed on the stack before any other

lines are attached. Mount the compressor on the stack. Mounting bolts, washers and nuts are shipped

loose. Leave the mounting bolts loose until the suction and discharge lines are in place and aligned.

Install the suction and discharge piping. Before tightening the grooved mechanical couplings, position

the suction and discharge piping so that the compressor can be aligned to give the best fit-up. When this

is achieved, secure the compressor mounting bolts and proceed with installing the grooved mechanical

using a light coating of lubricant. See Figure 3.

13. Install the liquid line using Figure 11 as a guide. Due to the variety of vessel combinations available,

variation on specific units will occur.

14. Install the motor cooling line using Figure 5 as a guide.

15. Install the liquid injection line (see Figure 4). Note that any given injection line may be configured

somewhat differently than shown on the drawing.

16. Install the four-way solenoid valve assembly on the compressor suction housing.

17. Install the control panel; the unit panel is on top of the condenser. Wire and sensor leads have been

disconnected at their terminus and labeled. They remain connected at the panel and rolled up. Their

destinations have matching labels, which simplifies the installation. :

Compressor panel detail ........................................Figure 18

Unit panel wiring and connections ........................Figure 15

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52 Field Installation Procedure IM 1128

Unit panel detail .................................................... Figure 19

Unit panel sensor locations ................................... Figure 16 and Figure 17

Flow switch wiring detail...................................... Figure 20

18. The VFD as unit mounted on the condenser with brackets for mounting it and interconnection cables to

the compressor motor. Control wiring as shown in Figure 9 will also be required.

Normal procedure of leak testing, triple evacuation, and charging with refrigerant and lubricant must be

followed prior to the start up procedure.

19. Insulate the compressor, suction line, and other miscellaneous areas with the included insulation and

glue after leak testing. See Field Insulation Guide on page 29.

This completes the reassembly procedure.

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IM 1128 Field Installation Procedure 53

Type III Reassembly

Description

TYPE III: The unit ships fully assembled and charged and is field ready to knockdown as required

after refrigerant is pumped down or removed. Included are the vessel bolt-on connection brackets and

the discharge stack bolt-on flanges at the condenser.

1. The unit is shipped fully charged with refrigerant.

2. The unit will be factory insulated and painted.

3. All electrical and sensor wiring will be fastened as usual.

4. The VFD will be installed.

5. Touch up paint and stick on wire ties will be included.

6. This unit will be fully tested at the factory.

7. Labels will be provided with the instructions to mark piping, electrical wiring and sensor wiring.

Reassembly Steps

Type III units offer a variety of disassembly opportunities. In some cases the condenser and tube

support plate are removed to meet narrow entrance requirements. The compressor and VFD power

panel may be removed for low height situations. Other possibilities exist.

Therefore it is difficult to prescribe step-by-step procedures. Various sections of this manual can be

used where applicable, bearing in mind that the unit is fully charged with refrigerant.

! DANGER

Prior to un-sweating any connection in the field, verify there is no pressure or charge in the component or lines. Failure to do so can cause severe injury or dearth.

! CAUTION

Avoid applying excessive heat to valve seats when brazing or removing lines. Use cooling on valve components. Failure to do so will cause valve damage.

! CAUTION

Cover any opening to prevent foreign objects from entering. Failure to do so can cause equipment damage.

Table 9, Major Component Dimensions and Weights

Dimensions L x W x H Weight Component

in. mm lbs kg

E3012 Evaporator 169 x 43 x 38 4292 x 1081 x 955 5075 2299

E3612 Evaporator 171 x 48 x 44 4329 x 1222 x 1120 6840 3099

C2612 Condenser 165 x 36 x43 4181 x 915 x 1080 3900 1767

C3012 Condenser 169 x 42 x 46 4292 x 1065 x 1170 5333 2416

Compressor 35 x 45 x 20 889 x 1143 x 508 750 340

M2 VFD Power Panel 41 x 21 x 61 1035 x 533 x 1545 1850 804

M3 VFD Power Panel 54 x 24 x 60 1370 x 610 x 1523 2750 1197

Control Panel 17 x 7 x 17 432 x 178 x 432 75 33

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54 Field Installation Procedure IM 1128

Knockdown Dimensions

Figure 32, WME 0500 Chiller Height with Components Removed

Vessel Size/ Motor Code >>

E3612/C3012

M2 in (mm)

E3612/C3012

M3 in (mm)

E3012/C2612 M2

in (mm)

E3012/C2612

M3 in (mm)

A To Top of Compressor Brackets

Panels, Raceway, Compressor, Discharge Line , Suction Elbow Removed (Note 2)

69.8 (1773) 69.8 (1773) 62.0 (1575) 62.0 (1575)

B To Top of Discharge Flange

Panels, Raceway, Compressor Removed 76.2 (1935) 76.2 (1935) 68.4 (1737) 68.4 (1737)

C To Top of Compressor

Panels, Raceway, Removed 94.3 (2395) 94.3 (2395) 87.8 (2230) 87.8 (2230)

Total Unit height, No Components Removed 99.3 (2522) 98.8 (2510) 95.3 (2421) 94.8 (2408)

NOTES:

1. See specific unit dimension drawing for balance of dimensions.

2. The compressor mounting bracket is higher than the top of the evaporator tube sheet. This

knockdown arrangement is the lowest unit height without separating the vessels.

B C A

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IM 1128 Field Installation Procedure 55

Piping Removal

Figure 33, Refrigerant Piping to Compressor

Stator

Cooling

Return

Stator

Cooling

Supply

Discharge

Line and

Check

Valve

Liquid

Injection

Supply

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56 Field Installation Procedure IM 1128

Figure 34, Refrigerant Piping from Condenser

VFD Cooling

Supply,

Connected to

VFD Panel

Rotor

Cooling

Supply

Stator

Cooling

Supply

King

Valve

Expansion Valve

with Liquid

Injection Supply

Line Behind

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IM 1128 Field Installation Procedure 57

Figure 35, Refrigerant Connections at Compressor

Figure 36, Electric Connections at Compressor

Stator

Cooling

Supply

Rotor

Cooling

Return

Rotor Cooling

Supply

Power

300Vdc

Compressor

Wire Harness

Ethernet Low

Voltage and

Logic

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58 Field Installation Procedure IM 1128

Figure 37, Liquid Injection Piping

Figure 38, Stator Cooling Piping

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IM 1128 Field Installation Procedure 59

Figure 39, Rotor Cooling Lines

Figure 40, VFD Cooling Piping

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60 Field Installation Procedure IM 1128

Compressor Removal and Re-Attachment Figure 41, Compressor Removal/Re-Attachment, View #1

Figure 42, Compressor Removal/Re-Attachment, View #2

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IM 1128 Field Installation Procedure 61

Compressor Removal and Re-Attachment

Removal Preparation 1. Close the king valve at condenser liquid line outlet.

2. Close all other related shut-off valves.

3. Pump the refrigerant charge down into the condenser.

4. Ensure that the charge has been removed from the compressor and evaporator and that the discharge

check valve is holding the charge in the condenser.

5. Loosen and remove bolts on either side of the compressor discharge nozzle (see Figure 42, flag #1).

Compressor Removal 1. Loosen and remove bolts on either side of the cast suction elbow (see Figure 41, flag #2).

2. Remove rotor cooling return line on the underside of the compressor motor housing along with both

rotor cooling supply lines per Figure 39 noted as "mechanical break points”, and Figure 35,

3. Remove (2) DIN connectors from the solenoid coils (see flag #3 on Figure 37 and Figure 38).

4. Remove rotor stepping valve control wire (see flag #4 on Figure 39).The wire ties will have to be cut

away during this process.

5. The following wires coming from the VFD will need to be removed (Figure 36):

- 300v dc power supply ( yellow cable )

- 25 pin "D" shell connector

- power leads on the top of the motor housing

- Ethernet cable coming from the unit control box

6. Remove the wireway box assembly from the compressor to the back of the VFD.

7. Loosen the (4) bolts from the compressor's bottom mounting feet see Figure 41, flag #5). Do not

loosen or remove bolts securing the compressor brackets as height is pre-set from the factory.

8. Mount a 1/2-13 swivel lifting eye to the front tapped lifting hole on the compressor motor housing. (see

Figure 41, flag #6). The compressor weight is 1000 lbs.

Compressor Re-Attachment

The following gaskets and “O” rings required for compressor reassembly are shipped loose:

Table 10, WME 500 Type III Knockdown “O” Rings and Gaskets

Part No. Quantity Description Unit Location

070194992 1 “O” Ring Between suction nozzle and compressor inlet connection

350233017 1 “O” Ring Between suction nozzle and evaporator outlet flange

070199039 1 Gasket Between compressor discharge nozzle and upper discharge

pipe flange(Note 1)

735073620 1 “O” Ring Between the compressor volute and the discharge nozzle.

Notes:

1. There are four identical gaskets for the discharge pipe, all are not used.

2. Blank-off plates not shown but may be required for extended aperture opening. The discharge nozzle is the short

section of pipe with fittings between the compressor volute and the discharge pipe.

1. Set the suction elbow back on top of the evaporator and install the screws loosely at the evaporator

flange, being sure to inspect the O-rings for damage and replace if needed.

2. Set compressor on mounting brackets and install the (4) mounting bolts loosely. Install the gasket at

check valve and insert bolts through the spool piece.

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62 Field Installation Procedure IM 1128

3. Install (12) bolts at elbow to compressor and torque to 25 ft-lbs; do not over-tighten.

4. Install (18) bolts at evaporator flange to the suction line and torque to 62 ft-lbs; do not over-tighten.

5. Torque the (8) bolts to the spool piece at the check valve to 205 ft-lbs.

6. Re-install the wireway between the compressor and the VFD.

7. Re-attach all associated power wiring & Ethernet cable.

8. Evacuate the evaporator and VFD cooling lines to 300 microns for one hour.

9. Open all valves.

10. Perform refrigerant leak check to ensure all connections and fittings are securely fastened.

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IM 1128 Field Installation Procedure 63

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2010 McQuay International • (800) 432-1342 • www.mcquay.com IM 1128-2 (5/11)

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. To find your local representative, go to www.mcquay.com