Installation, Operation, and Maintenance Manual IOM 1210-1 Group: Chiller Part Number: IOM1210-1 Date: August 2014 Magnitude® Magnetic Bearing Centrifugal Chillers Model WMC, C Vintage 125 to 400 Tons (440 to 1400 kW) HFC-134a Refrigerant 50/60 Hz
Table of Contents Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operator Responsibilities . . . . . . . . . . . . . . . . . . . . . 20 The Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Operator Schools . . .
Introduction Introduction This manual provides installation, operation, and maintenance information for McQuay WMC Magnitude® centrifugal chillers with the MicroTech® II controller. WARNING Electric shock hazard. Improper handling of this equipment can cause personal injury or equipment damage. This equipment must be properly grounded.
Introduction General Description McQuay Magnitude® Centrifugal Chillers are complete, selfcontained, automatically controlled, fluid-chilling units featuring oil-free, magnetic bearing compressors. All Magnitude® chillers are equipped with a single evaporator and a single condenser along with either one or two compressors depending on the model. Magnitude® chillers are designed for indoor, non-freezing installation only.
Introduction The Control System Figure 3: Control Panel The centrifugal MicroTech® II control system consists of an operator interface touch screen (OITS), a microprocessorbased unit controller, and compressor on-board controllers, providing monitoring and control functions required for the efficient operation of the chiller.
Installation Receiving and Handling Nameplates The unit should be inspected immediately after receipt for possible damage. All McQuay International centrifugal water chillers are shipped FOB factory and all claims for handling and shipping damage are the responsibility of the consignee. Installation There are several identification nameplates on the chiller: • The unit nameplate is located on the Unit Control Panel. Both the Model No. and Serial No. are unique to the unit and will identify it.
Installation Unit Dimensions and Shipping Weight Figure 6: WMC125-200S (2-pass, right-hand configuration, with grooved connections) L W H Figure 7: WMC145-400D (2-pass, right-hand configuration, with grooved connections) W L H Table 1: WMC125-400 Dimensions and Shipping Weights Model Heat Exchanger Length in (mm) Width * in (mm) Height in (mm) Shipping Weight ** lb (kg) WMC125S E2209 / C2009 134.3 (3411) 43.5 (1105) 81.0 (2057) 5086 (2307) WMC145S E2209 / C2009 134.3 (3411) 43.
Installation Mounting Field installed water piping to the chiller must include: • air vents at the high points. The unit must be mounted on a concrete or steel base. Make sure that the floor or structural support is adequate to support the full operating weight of the complete unit. • a cleanable 20-mesh water strainer in water inlet lines. • a flow proving device for both the evaporator and condenser to prevent freeze up. Flow switches, thermal dispersion switches, or Delta-P switches can be used.
Installation Condenser Water Temperature Control Condenser water control is an important consideration in chiller plant design since condenser water temperature will directly impact chiller operation and efficiency. When the ambient wet bulb temperature is lower than peak design, the entering condenser water temperature from the cooling tower can be allowed to fall, improving chiller performance. However, operational issues may occur when the condenser water temperatures are either too high or too low.
Installation Relief Valves As a safety precaution and to meet code requirements, each chiller is equipped with pressure relief valves located on the condenser and evaporator for the purpose of relieving excessive refrigerant pressure (caused by equipment malfunction, fire, etc.) to the atmosphere. the three-way valve is pulled back completely, the valve is in “Back Seated Position” and all refrigerant will flow through the front outlet port as shown in Figure 10.
Installation Field Insulation If the optional factory-installation of thermal insulation is not ordered, insulation should be field installed to reduce heat loss and prevent condensation from forming. Insulation should cover: • the evaporator barrel, tube sheet, and waterboxes. • the suction line from the top of the evaporator to the compressor inlet flange. DANGER • the liquid line from the expansion valve to the evaporator inlet, including the expansion valve.
IOM 1210-1 • MAGNITUDE® MODEL WMC CHILLERS 12
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www.DaikinApplied.com 15 NOTES: UNIT CONTROL BOX FACTORY ASSEMBLY: JUMPERS WJ1 AND WJ2 MUST ONLY BE CONNECTED TO TERMINAL BLOCK 33. CHILLER FACTORY ASSEMBLY: IF OPTIONAL GFP1 IS USED THEN REMOVE JUMPER WJ1. OTHERWISE COMPLETE CONNECTION WJ1 TO TERMINAL BOLOCK 38.
Installation Communication Setup for Multiple Chillers On multi-chiller Model WMC applications, up to four Model WMC chillers can be LAN interconnected by field RS485 interconnecting wiring (refer to Lines 165-174 on “Figure 12: Wiring Index”) with the addition of an accessory communication isolation board between each chiller connected. (The total number of isolation boards needed is one less than the number of chillers connected.
Installation Pre-Start Checklist Pre-Start Checklist – Centrifugal Chillers Must be completed, signed and provided to Daikin Applied Service Dept. at least 2 weeks prior to requested start date. Job Name Installation Location Customer Order Number Model Number(s) E.O./G.O.
Operation Operator Responsibilities 6. Dual compressor unloading As load decreases, the compressors will unload to sustain the water temperature set point by reducing speed until the minimum speed limit has been reached. If further unloading is required, the IGV assemblies will close as required to satisfy the load. It is important that the operator become familiar with the equipment and the system before attempting operation.
Operation Operator Interface Touch Screen (OITS) Enabling To enable the chiller and its compressors when the “Control Source” is “Switches” or “BAS,” all four rocker switches and the Remote Switch, if included, need to be closed (in the ON position). The following sections outline the operation of the OITS panel. If the “Control Source” is set to “Local” and a Remote Switch is being used, the position of the Remote Switch will be ignored. In that case, only the four rocker switches need to be closed.
Operation Figure 15: OITS Screen Layout SET SCREENS HOME SCREEN Figure 16: Home View Screen HISTORY SCREENS SET PRESS SET PRESS VIEW HOME SCREEN SETPOINTS PRESS SET PRESS SET HISTORY TIMERS PRESS VIEW ALARMS VALVE SERVICE PRESS HISTORY TREND OR ALARM HISTORY TOWER MOTOR MODES WATER VIEW SCREENS HOME SCREEN VIEW DETAIL VIEW SCREEN BAR GRAPHS (I) Alarm • A red ALARM button will appear to the right of the SET button should an alarm occur.
Operation Detail View Screen Table 4: COMPRESSOR STATUS Possibilities Complete STATUS Text (in priority sequence) Pressing the VIEW button on the bottom of the Home View Screen accesses the Detail View Screen, shown in Figure 17. The Detail View Screen can also be accessed by pressing the VIEW button from any other screen that contains the VIEW button.
Operation The Compressor State Information is basically a compilation of the events that the chiller sequences through at startup. A green light indicates that a particular sequence requirement has been satisfied. It is recommended that this information be viewed during the startup sequence. One can see the requirements light up as they are met and quickly see why a non-start may have occurred. For instance, the “Evap Flow OK” item will light when the evaporator flow switch is closed by flow.
Operation Figure 23: Unit Inputs/Outputs Information The Bar Graphs Screen (Figure 25) is accessed by pressing the BAR GRAPHS button from the View Menu Screen (Figure 24). If information is present on the right side of the View Menu Screen before pressing the BAR GRAPHS button, that information will appear to the right of the Bar Graphs Screen as well. In Figure 25, for example, the Compressor State Information is shown to the right of the screen.
Operation SET Screens The Setpoint Screens on the Operator Interface Touch Screen (OITS) are used to input the many setpoints associated with equipment of this type. MicroTech® II provides a simple method for accomplishing this. (Note that if the OITS is unavailable, the controller can be used to change setpoints.
Operation Procedure for Changing a Setpoint 7. Setpoints with numeric values can be changed in two ways: A list of setpoints along with their default value, available setting range, and password authority can be found in the tables under each Setpoint Screen, starting on page 28. Follow the steps listed below in order to change a setpoint. • Select the desired value by pressing the numbered buttons on the Numeric Keypad. Press ENTER to enter the value or CANCEL to cancel the transaction.
Operation TIMERS Setpoints Figure 28: TIMERS Setpoint Screen NOTE: Grayed out setpoints do not apply to this model chiller. Table 5: TIMERS Setpoint Settings Description No. Default Range Password Comments Full Load Timer 6 300 sec 0 to 999 sec M Time compressor must load (without unloading) before vanes are considered fully open. This setpoint does not apply to this model chiller.
Operation ALARMS Setpoints Figure 29: ALARMS Setpoint Screen Table 6: ALARMS Setpoint Settings Description No. Default Range Password Comments Condenser Freeze Protect 11 34.0 °F -9.0 to 45.0 °F T Minimum condenser saturated temperature to start pump Evaporator Freeze Protect 10 34.0 °F -9.0 to 45.
Operation Cooling Tower Bypass VALVE Setpoints Figure 30: Tower Bypass VALVE Setpoint Screen Table 7: Tower Bypass VALVE Setpoint Settings (See page 32 for complete explanation.) Description No.
Operation Cooling TOWER Fan Setpoints Figure 31: Cooling TOWER Fan Setpoint Screen Table 8: Tower Fan Setpoint Settings (See page 32 for complete explanation.) Description No.
Operation Explanation of Tower Control Settings Figure 34: TOWER Setpoint - SP2 - (II) VALVE SP There are five possible tower control strategies: (I) NONE, (II) VALVE SP, (III) VALVE STAGE, (IV) VFD STAGE, and (V) VALVE SP / VFD STAGE. These control strategies are selected from the TOWER Setpoint Screen (see Figure 31 on page 31) using Setpoint 2. (In the following pages, “SP” means “Setpoint.”) An explanation of each control strategy follows this paragraph.
Operation Figure 37: (III) VALVE STAGE Valve Opening vs. Temperature As shown in Figure 39, the default minimum and maximum VFD speeds are 20% and 100%, respectively. These minimum and maximum values are adjustable anywhere between 0% and 100%. Additional fans stage on when the VFD speed reaches the maximum value that was set. Valve Opening (%) 100 80 (V) VALVE SP / VFD STAGE: This control strategy is tower fan control with a VFD and bypass valve control. See Figure 40 and Figure 41.
Operation BAS Alternate each of the five tower control strategies are provided next. MicroTech® In control strategies (I) through (V), the chiller II is directly controlling the cooling tower fan staging, variable frequency drives, and bypass valves. As an alternative, a BAS can control these components based on a signal from the MicroTech® II controller. See Figure 42. (I) NONE: Tower Fan Staging Only (This is the default setting but it is NOT a recommended control strategy.
Operation (III) VALVE STAGE: Tower staging with bypass valve controlled by fan stage Setpoint Screen, use the following on the VALVE Setpoint Screen: a. SP2. Set the VALVE TARGET. This setpoint is usually 5°F below the minimum fan stage setpoint established in SP8 of the TOWER Setpoint Screen. This keeps full flow through the tower until the last fan is staged off. The default for SP2 is 65°F. A. TOWER Setpoint Screen b. SP4. Set VALVE DEADBAND. The default of 1.0°F is a good place to start. B.
Operation MOTOR Setpoint Screen Figure 43: MOTOR Setpoint Screen Table 9: MOTOR Setpoint Settings Description No. Default Range Password Comments Nominal Capacity 10 100 0 to 9999 Tons T Determines when to shut off a compressor. ONLY applies to multi-chiller setup. Maximum LWT Rate 9 0.5 °F/min 0.1 to 5.0 °F/min M Inhibits loading if LWT change exceeds the setpoint value Minimum LWT Rate 8 0.1 °F/min 0.1 to 5.
Operation Compressor Capacity Control Demand Limit Compressor capacity is determined by the status of the leaving chilled water temperature (LWT), which is a direct indicator of whether the chiller is producing enough cooling to satisfy the cooling load. The LWT is compared to the active chilled water setpoint, and compressor loading or unloading ensues, considering any capacity overrides that may be in effect.
Operation MODES Setpoints Figure 44: MODES Setpoint Screen NOTE: Grayed out setpoints do not apply to this model chiller. Table 10: MODES Setpoint Settings Description No. Default Range Password Comments Compr # 2 Stage Sequence # 14 1 1,2, … (# of Compressors) M Sets sequence number for # 2 compressor. If set to 1, it is always first to start. If set to 2, it is always second to start.
Operation WATER Setpoints Figure 45: WATER Setpoint Screen NOTE: Grayed out setpoints do not apply to this model chiller. Table 11: WATER Setpoint Settings Description No. Default Range Password Comments Maximum Reset Delta T 9 0.0°F 0.0 to 20.0 °F M Set the maximum reset that can occur, in degrees F if LWT reset is selected or max reset at 20 mA input if 4-20 mA is selected in SP7 Start Reset Delta T 8 10.0°F 0.0 to 20.
Operation Leaving Water Temperature (LWT) Reset Service Screen The Active Leaving Water variable shall be set to the current Leaving Water Temperature (LWT) setpoint unless modified by one of the reset methods below. (The current LWT setpoint is Cool LWT as determined by the chiller mode.) The type of reset in effect is determined by the LWT Reset Type setpoint (Setpoint 7 of the WATER Setpoint Screen). The Service Screen (Figure 47) is accessed by pressing the SET button from any SET screen.
Operation HISTORY Screens Figure 48: Date and Time Properties Window The OITS is capable of storing two types of history: trend history and alarm history. These two types are described in the following sections. Trend History Screen The Trend History Screen (Figure 49) is accessed by clicking the HISTORY button at the bottom of any screen that contains this button. The HISTORY button will toggle between the Trend History Screen and the Alarm History Screen, discussed next.
Operation Alarm History Screen The Alarm History Screen (Figure 50) is accessed from the Trend History Screen by pressing the HISTORY button again. Figure 50: Alarm History Screen Although the Alarm History Screen only displays the eight most current alarms, a record of ALL alarms is stored in the OITS PC. Note that this record may include alarms that occurred when the chiller was in the factory. This record is maintained even if the OITS PC is powered off.
Operation To Download Alarm History: • Make sure that the “History File” text field on the right side of the Alarm History Screen shows “ALARMS.” If it shows a date instead, press the ALARMS button. • Take note of the file size of the alarm history by viewing the “Size” text field. Press the COPY to USB button and watch the file size in the “Size” text field count up to the noted file size.
Operation Possible Alarms and Events There are three types of alarms: faults, problems, and warnings. In addition to these three alarms, there are also "events." See the following tables for examples of faults, problems, warnings, and events that can occur. Separate tables are shown based on whether the alarm source is the unit or the compressor. NOTE: In the "Alarm Reset" column of the following tables, itallics indicate special alarm conditions or severity.
Operation Table 13: Compressor Fault Alarms Description OITS Alarm Message Alarm Reset Compressor Current Overload Trip #1 COMPR STOP - Motor Current Overload Auto-clears Compressor Current Overload Trip #2 COMPR STOP - Motor Current Overload Auto-clears Locked off if UL Limit is exceeded High Motor Temperature Comp 1 COMPR STOP - High Motor Temperature Auto-clears High Motor Temperature Comp 2 COMPR STOP - High Motor Temperature Auto-clears Locked off if Tripped 3x in 50 min Overvoltage On C
Operation Problem Alarms Problems do not cause compressor shutdown but do limit operation of the chiller.
Operation Events Events do not generate a warning message to the operator but they may notify the BAS, if used. Chiller operation may be affected by events.
Operation The Controller Navigating The controller is located in the control panel (see Figure 3 on page 5) adjacent to the OITS (see Figure 1 on page 4). Unit, compressor, evaporator, and condenser information is viewable on it, and all setpoints can be accessed from it. It is encouraged to use the controller to change setpoints only when the OITS is unavailable. The controller LCD screens read only in IP units of measure (inch-pounds and degrees Fahrenheit).
Operation 2nd Level Menu Selection VIEW < COMPRESSOR < UNIT < EVAPORATOR < CONDENSER In order to toggle between these two screens: Data Screen → 1. Use the DOWN arrow key to scroll to the “VIEW COMP (7)” screen. VIEW EVAPORATOR Suct SH = 000.0°F Approach = 00.0°F VIEW COMP (7) Hours = 00000 x10 Starts = 00000 . Other selections, such as VIEW → UNIT, will bring up a third level of menu screens. 2nd Level Menu Selection VIEW < COMPRESSOR < UNIT < EVAPORATOR < CONDENSER 2. Press the RIGHT arrow key.
Operation Table 19: Menu Matrix NOTE: The notation “blank mask page” indicates that the screen does not apply to this unit. VIEW UNIT VIEW EVAPORATOR VIEW COMPRESSOR VIEW UNIT STATUS(1) UNIT= Off GasVal 2 COMP#1 Off #2Run Ev/Cn Pmps= Off /Off VIEW UNIT WATER(1)°F In Out Delta Evap 00.0 00.0 00.0 Cond 00.0 00.0 00.0 VIEW UNIT REFRG (1) psi °F Sat Evap 000.0 000.0 Sat Cond 000.0 000.
Operation Table 19 continued: Menu Matrix NOTE: Screens listed in this table that have a gray background require a technician level password to manipulate. VIEW CONDENSER ALARM LOG VIEW CONDENSER Disch SH = 000.0°F Approach = 00.0 F Subcooling= 00.
Operation Editing Fields on the Controller After navigating to the desired screen (notice that the blinking cursor is in the top left corner of the screen when navigating data screens), editing is accomplished by pressing the ENTER key (lower-right key on the controller) until the desired field is selected. The selected field is indicated by the blinking cursor under it. The arrow keys then operate as follows: • DEFAULT (← Key): Set value to original factory setting.
Operation Configuring the Control Source Clearing Alarms In the event that the Building Automation System (BAS) – if used – or the OITS panel has become inoperative, the user can regain control of the chiller by reconfiguring the chiller control source to “Switches.
Operation Controller Inputs and Outputs The following tables list the controller inputs and outputs, both analog and digital.
Operation Table 23: Controller, Digital Outputs # Description Load Output OFF Output ON 1 Evaporator Water Pump #1 Pump Contactor Pump OFF Pump ON 2 Evaporator Water Pump #2 Pump Contactor Pump OFF Pump ON 3 Condenser Water Pump #1 Pump Contactor Pump OFF Pump ON 4 Condenser Water Pump #2 Pump Contactor Pump OFF Pump ON 5 Tower Fan #1 Fan Contactor Fan OFF Fan ON 6 Tower Fan #2 Fan Contactor Fan OFF Fan ON 7 Expansion Valve Calibration Digital Input (50K Ohms) Normal C
Operation Table 24 continued: Controller Setpoints Description Default Range PW 44. 0°F 35.0 to 80.0 °F O 3.0°F 0.0 to 10.0 °F T Leaving Water Cool LWT Startup Delta T Stop Delta T 3.0°F 0.0 to 3.0 °F T LWT Reset Type NONE NONE, RETURN, 4-20mA T Max Reset Delta T 0.0°F 0.0 to 20.0 °F T Start Reset Delta T 10. 0°F 0.0 to 20.0 °F T Timers Evap Recirculate 0.5 min 0.
Operation Table 24 continued: Controller Setpoints Description Default Range PW 6 sec 0 to 999 sec T 1 0 to 99 T Bypass Valve, Step and Wait Control Step Derivative Gain 20 0 to 99 T Dead Band (D-Band) 1.0 0 to 200 T 600 sec 0 to 999 sec T 1 sec 0 to 999 sec T Proportional Gain (K) 80 0 to 999 sec T Dead Band (DB) 0 0 to 9.9 UOM T 500 ms 0 to 9999 ms T Tower Reset (Temp) 10 psi 0 to 20.0 psi T Tower Reset (Lift) 5.0 °F 0 to 10.
Operation Building Automation Systems (BAS) All MicroTech® II controllers with Open Choices™ are capable of BAS communications, providing easy integration and comprehensive monitoring, control, and two-way data exchange with open standard protocols such as LonTalk®, Modbus® or BACnet®. McQuay International unit controllers strictly conform to the interoperability guidelines of the LonMark® Interoperability Association and BACnet® International.
Maintenance Service Programs Water Treatment Daikin Applied offers a variety of maintenance services through the local McQuay International service office and can tailor these services to suit the needs of the building owner. Most popular among these services is the McQuay International Comprehensive Maintenance Contract. For further information concerning the many services available, contact your local McQuay International service office.
Maintenance Maintenance Schedule Table 25 provides an overview of recommended maintenance procedures along with how frequently these procedures should be performed. During Seasonal Shutdown X X During Seasonal Startup As Required By Performance Annually SemiAnnually Quarterly Monthly Table 25: Recommended Maintenance Schedule I. Compressor A. Analyze Compressor Fault Log X B. Check IGV operation X D. Check and tighten compressor electrical connections X II. MicroTech® II Controls A.
Appendix Definitions Active Amp Limit temperature every few seconds and subtracting them from the previous value over a rolling one-minute interval. Active amp limit is the actual amp limit imposed by an outside signal such as the load limit function. Error Active Capacity Limit In the context of this manual, “Error” is the difference between the actual value of a variable and the target setting or setpoint. The active capacity setpoint is the setting in effect at any given moment.
Appendix and the condenser flow loss is adjustable from 20 to 3s (default 20s). Load Balance Load balance is a technique that equally distributes the total unit load between two or more running compressors. Load Limit An external signal from the keypad, the BAS, or a 4-20 ma signal that limits the compressor loading to a designated percent of full load. Used to limit unit power input.
Appendix Suction Superheat = Suction Temperature – Evaporator Saturated Temperature VDC Volts, Direct Current; sometimes noted as vdc. VFD Variable Frequency Drive, a device located on the compressor used to vary the compressor speed. www.DaikinApplied.
Appendix Temperature / Pressure Chart Table 26: HFC-134a Temperature / Pressure Chart R-134a Temperature / Pressure Chart °F PSIG °F PSIG °F PSIG °F PSIG 6 9.7 46 41.1 86 97.0 126 187.3 8 10.8 48 43.2 88 100.6 128 192.9 10 12.0 50 45.4 90 104.3 130 198.7 12 13.2 52 47.7 92 108.1 132 204.5 14 14.4 54 50.0 94 112.0 134 210.5 16 15.7 56 52.4 96 115.9 136 216.6 18 17.1 58 54.9 98 120.0 138 222.8 20 18.4 60 57.4 100 124.1 140 229.2 22 19.
Daikin Applied Training and Development Now that you have made an investment in modern, efficient McQuay International equipment, its care should be a high priority. For training information on all McQuay International HVAC products, please visit us at www.DaikinApplied.com and click on Training, or call 540-248-9646 and ask for the Training Department. Warranty All McQuay International equipment is sold pursuant to its standard terms and conditions of sale, including Limited Product Warranty.
