Catalog CAT WMC-4 Water-Cooled Oil-Free Chiller With Magnetic Bearing Compressors Model WMC 145S – 290D 125 to 290 Tons, 440 to 970 kW 3/60/460, 3/50/400 R-134a 1 Catalog WMC-4
Cutaway View of Magnetic Bearing Compressor, Nominal 75 Tons Compressor Major Running Gear Components ® MICROTECH II Controller, Operator Interface, Home Screen 2 Catalog WMC-4
TABLE OF CONTENTS THE NEW COMPRESSOR TECHNOLOGY .......4 WMC 145D, 150D Dual Compressor .................. 34 Environmental Responsibility ................................ 4 Single Point Connection....................................... 35 Greater Reliability .................................................. 5 WMC250D and 290D Dual Compressor ............. 35 Exceptional Control................................................ 5 Single Point Connection.......................................
The New Compressor Technology Next Generation Centrifugal – Here Today The industry’s next generation of centrifugal chillers is here today with McQuay’s model WMC. The new technology begins with centrifugal compressors utilizing frictionless magnetic bearings for oil-free operation, integral variable-frequency drives, and high-speed direct drive technology. The high efficiency compressor is matched with highly efficient heat exchange vessels to make an impressive chiller.
Greater Reliability Oil Handling Equipment Removed With magnetic bearings operating in a magnetic electrical field instead of oil lubricated ball or roller friction type bearings as the basis of design, the oil handling equipment is removed. There is no need for oil pumps, oil reservoirs, controls, starter, piping, heaters, oil coolers, oil filters, water regulating valves or oil relief valves that are needed to maintain oil quality.
Variable Frequency Drives The Compressor Technology Compressor unloading and subsequent chiller capacity reduction is accomplished by a compressor-mounted variable frequency drive. It operates in conjunction with the inlet guide vanes. The VFDs are an important factor in providing the tremendous energy savings at part load operation. The advanced, magnetic bearing, permanent magnet synchronous motor technology used in the WMC chillers offers many owner benefits.
Benefit Summary Highest Efficiency- in its size range; as low as .375 kW/ton. Increased Reliability - This frictionless magnetic bearing design needs no oil management system. With no oil to coat the heat transfer surfaces, a gain in heat exchanger efficiency can be realized. Ultra Quiet- A compressor sound level less than 73 dBA, with virtually no structure-borne vibration, eliminates the need for expensive sound attenuation accessories. Easy to handle - The compressor weight of 264 lbs. (120 kg.
Control Features ® The operator interface panel has a 15-inch Super VGA touch-screen, utilizing graphics to provide clear and concise information on the chiller status, (see page 11) alarms, trends, and setpoint adjustment. Should the touch-screen become inoperable, the unit and compressor controllers will continue uninterrupted operation of the chiller.
Figure 4, Control Panel The control system of the WMC chillers consists of two major components: the unit control panel, as shown to the right, and the operator interface panel as shown on the extreme left of the unit featured on the cover. Note that the touch screen panel is on an adjustable arm so that it can be positioned comfortably for the operator.
MicroTech II Control Features and Benefits FEATURE BENEFIT Easy integration into Building Management System via McQuay’s exclusive Open Choice™ communication module Designer can select any BAS supplier using standard open protocols and know the MicroTech II control will interface with it.
The MicroTech II controller's memory retains a record of faults and the time/date stamp. The controller's memory (no batteries required) can retain and display the cause of the current fault and the last twenty-five fault conditions. This method for retaining the fault is extremely useful for trouble shooting and maintaining an accurate record of unit performance and history. The controller features a two-level password security system to provide protection against unauthorized use.
MicroTech II Controller Increases Chiller Operating Economy Many standard features have been incorporated into MicroTech II control in order to maintain the operating economy of McQuay centrifugal chillers. In addition to replacing normal relay logic circuits, we’ve enhanced the controller's energy saving capabilities with the following features: • Direct control of water pumps.
Communication Capabilities Versatile Communications Capabilities Give You Even More Control For complete flexibility there are four ways to interface with the MicroTech II controller: 1. Direct entry and readout locally at the operator interface panel on the unit. 2.
Table 1, Typical Data Point Availability Typical Data Points1 (W = Write, R = Read) Capacity Limit Output Capacity Limit Setpoint Chiller Enable Chiller Limited Chiller Local/Remote Chiller Mode Output Chiller Mode Setpoint Chiller On/Off Chiller Status Compressor Discharge Temp Compressor Percent RLA Compressor Run Hours Compressor Select Compressor Starts R W W R R R W R R R R R W R Cond EWT Cond Flow Switch Status Cond LWT Cond Pump Run Hours Cond Refrigerant Pressure Cond Sat.
Unit Design Features Variable Frequency Drive Efficiency: The variable frequency drive option is a technology that has been used for decades to control motor speed on a wide variety of motordrive applications. When applied to centrifugal compressor motors, significant gains in part load performance can be realized.
the U.S. Department of Transportation for refrigerant shipping containers, as well as ASME vessel codes. When service is required, the refrigerant charge can be pumped down into either the condenser or evaporator by compressor operation and use of a refrigerant transfer unit. Elimination of the cost and space requirements of an external pumpout system on most jobs is a major McQuay advantage. Electronic Expansion Valve Controlled refrigerant flow over the entire capacity range saves energy and dollars.
Part Load Efficiency Chillers usually spend 99% of their operating hours under part load conditions and most of this time at less than 60% of design capacity. One compressor of a dual chiller operates with the full heat transfer surface of the entire unit. For example, one 75-ton compressor on a 150-ton dual chiller utilizes 150 tons of evaporator and condenser surface. This results in very high unit efficiency and also increases the compressor’s capacity.
The ARI Standard 550/590-98 for Centrifugal or Screw Water-Chilling Packages and associated manuals define certification and testing procedures and performance tolerances of all units that fall within the application rating conditions. Leaving chilled water temp.: 40°F to 48°F (44°F standard) Entering condenser water temp.: 60°F to 95°F Leaving chilled water temp.: 44°F Evap. waterside field fouling allowance: 0.0001 Chilled water flow rate: 2.4 gpm/ton Entering condenser water temp.
Chiller Identification WMC centrifugal chillers are selected by computer and identified by their components on the selection printout as a Model #.
Pressure Drop Curves NOTE: The -B and -C designations shown on the curves refer to vessel tube count, which is determined by the computer selection program. Figure 10, Single Pass Evaporators WMC Evap - Water Side Pressure Drop (1 pass) 30 E2212-B 25 E2212-C E2212-D E2209-B 20 EPD - ft E2209-C E2209-D E2612-B 15 E2609-B 10 5 0 0 500 1000 1500 2000 2500 EGPM - gpm Figure 11, Single Pass Condensers WMC Cond - Water Side Pressure Drop (1 pass) 18.0 16.0 C2012-B 14.0 C2012-C C2009-B 12.
Figure 12, 2-Pass Evaporators WMC Evap - Water Side Pressure Drop (2 pass) 60 E2212-B 50 E2212-C E2212-D E2209-B 40 EPD - ft E2209-C E2209-D 30 E2612-B E2609-B 20 10 0 0 200 400 600 800 1000 1200 EGPM - gpm Figure 13, 2-Pass Condensers WMC Cond - Water Side Pressure Drop (2 pass) 35.0 C2012-B 30.0 C2012-C C2009-B 25.0 C2009-C CPD - ft C2212-B 20.0 C2212-C C2209-B 15.0 C2209-C 10.0 5.0 0.
Figure 14, 3-Pass Evaporators WMC Evap - Water Side Pressure Drop (3 pass) 90 E2212-C 80 E2212-D E2209-C 70 EPD - ft E2209-D 60 E2612-B 50 E2609-B 40 30 20 10 0 0 200 400 600 800 EGPM - gpm Figure 15, 3-Pass Condensers WMC Cond - Water Side Pressure Drop (3 pass) 60.0 C2012-C C2009-C 50.0 C2212-C C2209-C CPD - ft 40.0 30.0 20.0 10.0 0.
Sound Data The following sound pressure ratings are for measurements one meter from the unit and in accordance with ARI Standard 575. The ratings are for the various part loads shown and at the center bands. Note that there is a considerable lowering of sound level as the units unload. Octave band values are flat dB, A weighted values are dBa. The 25 percent values are with one compressor running. Table 2, WMC 145S Sound Pressure (dB),50/60 Hz Percent Load 63 125 250 100 75 50 25 34.58 34.46 34.
Dimensions Figure 16, WMC 145S (NOTE: See page 28 for notes.
Figure 17, WMC 150D, 2-Pass Evaporator, 2-Pass Condenser See page 28 for notes.) 6.9 (175.3) 19.2 (487.7) 12.6 (320.0) 13.2 (335.3) Inlet 18.2 (462.3) Outlet 0 1.13 QTY. 8 3.7 (93.9) 39.3 (998.2) 31.2 (792.5) “A” 26.5 (673.1) “B” 1.0” FPT Relief Valves 8.0” QTY. 2 Evaporator 78.0 (1981.2) Out 42.7 6.0” QTY. 2 (1084.6) In “C” 5.2 (132.1) 8.0 (203.2) 8.0 (203.2) 330654401_2 Pass Evap Production Unit WMC Unit 150D Condenser 1.4 (35.5) 5.2 (132.1) 26.5 (673.1) 35.0 (889.0) 4.0 (101.
Figure 18 WM C 250D, 2-Pass Evaporator, 2-Pass Condenser (NOTE: See page 28 for notes.
Catalog WMC-4 4.0 101.60 14.8 374.65 44.8 1136.65 67.5 1715.62 TOP FRONT END BOX 5 71.8 1824.37 RELIEF VALVE 4 83.0 2108.60 TOP OF COMPR. 5,10,12 76.0 1930.50 TOP UNIT CTRL BOX 5 5 11.1 280.92 30.1 765.05 38.1 968.25 Z IN OUT OUT LEFT VIEW Y IN 38.4 975.64 5 35.3 896.90 5 43.5 1105.18 O.I.T.S. LF LB 5,7,8 17.1 434.98 11.1 282.58 28.3 718.29 CONDENSER RELIEF VALVES 3 60.2 1529.50 EVAPORATOR RELIEF VALVES 3 11.1 282.58 25.2 638.89 EVAPORATOR & SUCTION PIPE RELIEF VALVES 3,4 29.
Drawing Notes 1. All dimensions are in Inches and [Millimeters] unless noted otherwise. 2. Manufacturing Tolerances, final connections to unit must allow for +/- 0.5 inch (12.7mm) manufacturing tolerances. 3. Relief Valves, Vessels, 1.00-inch FPT (25.4 mm) evaporator and condenser relief valves must be piped per ANSI / ASHRAE 15. Number of relief valves is 1 per evaporator and 2 per condenser (one is use at a time). Notes 3 on drawing. Suction Pipe, 0.
Figure 20, Mounting/Lifting Weights LB RB “A “B” RF LF Circuit #2 Circuit #1 Control Panel WMC Model Vessel Models (Size) 145S 145D 150D 250D 290D E2209/C2009 E2209/C2209 E2212/C2012 E2609/C2209 E2612/C2212 Electric Panels Shipping Weight, lbs (kg) LF 1097 (497) 1396 (634) 2450 (1112) 1817 (824) 1983 (899) RF 1115 (506) 2249 (1021) 1918 (871) 1744 (791) 2163 (981) LB 1587 (720) 1305 (592) 1965 (892) 2056 (933) 2358 (1070) RB 1614 (732) 2102 (954) 1528 (694) 1974 (895) 2572 (1167) Total 5413 (
Marine Water Box Dimensions with Victaulic or Flanged Connections Marine water boxes are an available option on all McQuay refers to our standard dished heads as evaporator and condenser sizes. Epoxy coating of “dished heads”. Some manufacturers refer to them, or the water boxes and clad tube sheets are available similar devices as “water boxes”. They are not for extreme duty applications. Caution: There is “marine water boxes” with removable end covers as some nomenclature confusion in the industry.
Physical Data and Weights Evaporator Refrigerant-side design pressure is 200 psi (1380 kPa). Water-side is 150 psi (1034 kPa). Approximate total square footage of insulation surface required for individual packaged chillers is tabulated by evaporator code and can be found below. The suction elbow and compressor also require insulation. Table 7, Evaporator Physical Data WMC Model Evaporator Model Tube Length 145S, 145D 150D 250D 290D E2209 E2212 E2609 E2612 9 ft. 12 ft. 9 ft. 12 ft.
Relief Valves Vessel Relief Valves Relief valve connection sizes are 1 inch FPT and are in the quantity shown in Table 7 and Table 8. Relief valves must be piped to the outside of the building in accordance with ANSI/ASHRAE 152001. The new 2001 standard has revised the calculation method compared to previous issues. Twin relief valves, mounted on a transfer valve, are used on the condenser so that one relief valve can be shut off and removed for testing or replacement, leaving the other in operation.
Electrical Data Wiring, fuse and wire size must be in accordance with the National Electric Code (NEC). Important: The voltage to these units must be within ±10% of nameplate voltage and the voltage unbalance between phases must not exceed 2% per NEMA MG-1, 1998 Standard. Power Wiring The standard power wiring connection to WMC chillers is multi-point, i.e. a separate power supply to each of the two circuit’s terminal box.
General Note: The RLA for use in the following tables is obtained by the selection of a specific unit by McQuay. When shipped, a unit will bear the specific RLA, stamped on the nameplate, for the selected operating conditions. The tables below are for 60 Hz, 460 volts and 50 Hz, 400 volts.
Single-point Connection, Optional Table 14, WMC 145D, 150D Electrical Data RLA (Per Compressor) LRA Minimum Circuit Field Wire Ampacity (MCA) Quantity Wire GA Max Fuse Size 52 to 53 Amps 72 117 to 120 3 1 GA 150 Amps 54 to 57 Amps 72 122 to 129 3 1 GA 175 Amps 58 to 61 Amps 72 131 to 138 3 1/0 175 Amps 62 to 65 Amps 72 140 to 147 3 1/0 200 Amps 68 to 69 Amps 94 153 to 156 3 2/0 200 Amps 70 to 76 Amps 94 158 to 171 3 2/0 225 Amps 77 to 85 Amps 94 174 to 192 3 3
Single Point Connection, Optional RLA (Per Compressor) LRA Minimum Circuit Field Wire Ampacity (MCA) Quantity Wire GA Max Fuse Size 72 to 76 Amps 110 163 to 172 3 3/0 225 Amps 77 Amps 110 174 3 3/0 250 Amps 78 to 88 Amps 110 176 to 199 3 4/0 250 Amps 89 to 92 Amps 110 201 to 208 3 250 MCM 250 Amps 93 to 100 Amps 110 210 to 226 3 250 MCM 300 Amps 101 to 107 Amps 132 228 to 241 3 250 MCM 300 Amps 108 to 113 Amps 132 244 to 255 3 250 MCM 350 Amps 114 to 120 Amp
Figure 23, Field Wiring Diagram MICROTECH CONTROL BOX TERMINALS (115V) (24V) UTB1 GND PE 54 * REMOTE ON/OFF (NOTE 5) 85 POWER * NOTE 7 NEUTRAL * NOTE 10 * COOLING TOWER FOURTH STAGE STARTER 55 74 C4 * MODE SWITCH 70 80 H O 86 * NOTE 8 H A O 86 A EP2 86 C NOTE 11 * NOTE 10 * COOLING TOWER THIRD STAGE STARTER O C3 * NOTE 8 73 A H O * NOTE 10 O C2 EWI-1 75 A (NOTE 6) SWITCH DELTA P FLOW OR EVAP.
Power Factor The full load power factor exceeds 0.90 for all capacity selections. VFD Line Harmonics Despite their many benefits, care must be taken when applying VFDs due to the effect of line harmonics on the building electric system. VFDs cause distortion of the AC line because they are nonlinear loads, that is, they don't draw sinusoidal current from the line. They draw their current from only the peaks of the AC line, thereby flattening the top of the voltage waveform.
The power line noise emissions associated with variable frequency and variable speed drives can cause disturbances in nearby equipment.
Application Considerations Pumps To avoid the possibility of objectionable harmonics in the system piping, 4-pole, 1800/1500 rpm system pumps should be used. The condenser water pump(s) must be cycled off when the last chiller of the system cycles off. This will keep cold condenser water from migrating refrigerant to the condenser. Cold liquid refrigerant in the condenser can make start up difficult.
power and fan power must be examined. On the other hand, the low condenser water temperatures can be easy and economical to achieve in mild climates with low wet bulb temperatures. Figure 27, Tower Bypass, Cold Weather Operation Even with tower fan control, some form of water flow control such as tower bypass must be used. The MicroTech II control is capable of controlling tower fans and bypass valve. Figure 26 and Figure 27 illustrate two temperature actuated tower bypass arrangements.
Vibration Mounting All interlock contacts must be rated for no less than 10 inductive amps. The alarm circuit provided in the control center utilizes 115-volts AC. The alarm used must not draw more than 10volt amperes. The WMC chillers are almost vibration-free. Consequently, floor mounted spring isolators are not usually required. Rubber mounting pads are shipped with each unit.
The necessary procedure for reconnecting power from the generator back to the utility grid is shown below. These procedures are not peculiar to McQuay units only, but should be observed for any chiller manufacturer. 1. Set the generator to always run five minutes longer than the unit start-to-start timer, which could be set from 15 to 60 minutes. The actual setting can be viewed on the operator interface panel on the Setpoint/Timer screen. 2.
Vessels Unit Marine water boxes Export packaging Provides tube access for inspection, cleaning, and removal without dismantling water piping. Can be either slat or full crate for additional protection during shipment. Units normally shipped in containers. Flanges (Victaulic® connections are standard) Shipping bag ANSI raised face flanges on either the evaporator or condenser. Mating flanges are by others. 0.028 or 0.035 in.
EMI filter NEMA 4 or NEMA 12 construction Factory-installed option. Radio interference filter. See page 38 for details. Ground Fault Protection Catalog WMC-4 Protects equipment from damage from line-toground fault currents less than those required for conductor protection.
Refrigerant Recovery Units Although McQuay chillers can pump the entire refrigerant charge into the condenser and valve it off, there are occasions when pumpout units are required, due purely to specification requirements or unusual job considerations. McQuay offers two sizes of refrigerant recovery units (Model RRU) and one recovery unit that is factory mounted on a storage vessel (Model PRU). Recovery units are ETL listed. Capacities for R-22 are ARI certified.
MODEL RRU570 Recovers at R-134a at 300 lb/min liquid and 5.7 lb/min vapor, ideal for the medium size chiller job. Rugged 3 hp open-drive compressor provides years of reliable service, even on refrigerants heavily contaminated with oil, air, moisture, or acids. Purging and switching from liquid to vapor recovery only involves turning 3-way valves-no switching of hoses is necessary. Suitable for most high-pressure refrigerants and blends. Equipped with aircooled condenser.
SPECIFICATIONS Sensitivity: As low as 1 PPM Range: 0 to 1000 PPM Power: 120/240 Volt, 50/60 Hz Operating 125°F Environment: Weight: 25 lbs. (11 kg) 32°F- Size: W=16.5in. D=6.75in. H=15in.
Figure 28, Refrigerant Monitor Diagram Warranty Statement Limited Warranty Consult your local McQuay Representative for warranty details. Refer to Form 933-430285Y. To find your local McQuay Representative, go to www.mcquay.com.
Specifications SECTION 15XXX MAGNETIC BEARING CENTRIFUGAL CHILLERS PART 1 — GENERAL 1.1 SUMMARY Section includes design, performance criteria, refrigerants, controls, and installation requirements for watercooled centrifugal chillers. 1.2 REFERENCES Comply with the following codes and standards ARI 550/590 ANSI/ASHRAE 15 1.3 NEC OSHA as adopted by the State ASME Section VIII SUBMITTALS Submittals shall include the following: A.
1.7 MAINTENANCE A. Maintenance of the chillers shall be the responsibility of the owner. PART 2 — PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. McQuay International B. (Approved Equal) 2.2 UNIT DESCRIPTION Provide and install as shown on the plans a factory assembled, charged, and run-tested water-cooled packaged chiller. Each unit shall be complete with two (one on Model WMC 145) multi-stage, oil-free, magnetic bearing, hermetic centrifugal compressors.
1. Evaporator and condenser shall be of the shell-and-tube type, designed, constructed, tested and stamped according to the requirements of the ASME Code, Section VIII. Regardless of the operating pressure, the refrigerant side of each vessel will bear the ASME stamp indicating compliance with the code and indicating a test pressure of 1.1 times the working pressure but not less than 100 psig. Provide intermediate tube supports at a maximum of 18 inch spacing. 2.
E. CHILLER CONTROL The unit shall have distributed microprocessor-based control architecture consisting of a 15-inch VGA touch-screen operator interface, a controller for each compressor and a unit controller. The touch-screen shall display the unit operating parameters, accept setpoint changes (password protected) and be capable of resetting faults and alarms.
The information communicated between the BAS and the factory mounted unit controllers shall include the reading and writing of data to allow unit monitoring, control and alarm notification as specified in the unit sequence of operation and the unit points list. For chillers communicating over a LONMARK network, the corresponding LONMARK eXternal Interface File (XIF) shall be provided with the chiller submittal data.
B. Factory Start-Up Services: Provide for as long a time as is necessary to ensure proper operation of the unit, but in no case for less than two full working days. During the period of start-up, the start-up technician shall instruct the owner’s representative in proper care and operation of the unit.
This document contains the most current product information as of this printing. For the most upto-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. (800) 432-1342 • www.mcquay.
