7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
1/28
Product Manual PM STARTER-3
Group: Chiller
Date: October 2000
Supersedes: PM-STARTER-2
2000 McQuay International
Starters and Variable Frequency Drives
For Centrifugal Chillers
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
2/28
2 PM Starter-3
Table of Contents
Introduction.............................................................................................. 3
Low Voltage Starters (200 through 600 volts)........................................... 4
General Specifications............................................................................................................4
Types ........................................................................................................................................4
Standard Components ............................................................................................................5
Options.....................................................................................................................................6
McQuay Starter Model Codes ..............................................................................................7
General Arrangement..............................................................................................................8
Selection Procedure ................................................................................................................9
Specifications ........................................................................................................................11
Illustrations ............................................................................................................................11
Dimensions ............................................................................................................................13
Medium & High Voltage Starters (2300 to 6900 Volts)........................... 16
Starter Types ..........................................................................................................................16
Standard Components ..........................................................................................................17
Options...................................................................................................................................18
McQuay Starter Model Codes ............................................................................................19
Selection Procedure ..............................................................................................................19
Specification ..........................................................................................................................19
Dimensions ............................................................................................................................20
Variable Frequency Drives....................................................................... 23
General....................................................................................................................................23
Standard Components ..........................................................................................................23Options...................................................................................................................................25
General Arrangement............................................................................................................25
VFD Dimensions ...................................................................................................................26
Power Factor Correction........................................................................ 27
Initial Issue October 1998
"McQuay "is registered trademarks of McQuay International1996 McQuay International
"Illustrations and data represent the McQuay International products at the time of publication and we reserve
the right to make changes in design and construction at anytime without notice"
Our facility is ISO Certified
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
3/28
PM Starter-3 3
Introduction
McQuay offers a wide selection of conventional motor starting equipment as well as Variable Frequency
Drives (VFD) that are starters with the additional capability of regulating compressor motor speed.
Starters For low voltage (200 through 600 volts) there are wye-delta closed transition, autotransformer
and solid state starters. Medium voltage (2300 through 6900 volts) starters are across-the-line full voltage,
autotransformer reduced voltage, and primary reactor reduced voltage starters. Starters can be mounted
and wired on the unit for most chiller sizes or they can be free-standing with wiring between the chiller andstarter provided by the installer. A line-up of medium voltage starters can also be accommodated. A wide
range of options is available for individual job requirements.
Motor starters can be furnished by the customer provided they meet McQuay Starter Specifications and
are approved by McQuay.
Variable Frequency Drives While known and specified for their ability to control compressor motor speed
for efficiency enhancement, VFDs also perform starting and motor protection functions. They are
available for only 3/60/460-480 service.
VFDs are available only from McQuay and when purchased as part of the original chiller purchase.
Basic Electrical TermsLocked rotor amps (LRA): The amount of current that a specific motor will draw at start-up when full
voltage is applied across the line. LRA may be 6 to 8 times FLA or possibly higher in some cases.
Inrush current: The amount of current that a specific motor and starter combination will draw during start-
up. Normal inrush current will be substantially less than LRA for all starter types except for across-the-
line starters.
Full load amps (FLA): The maximum amps the motor is designed for.
Rated load amps (RLA): Actual amperage that the motor draws for a specific application. Centrifugal
compressor motors operate at a RLA significantly below their maximum full load amps. RLA is used to
determine electrical component sizing.
Starting torque: Minimum torque required to begin the motors rotation.
Interrupting capacity: The maximum fault current that a circuit breaker or fused disconnect can
successfully interrupt. As the rating increases, the construction becomes heavier duty. For disconnect
switches with fuses, the rating is based on 0 to 600 volts. For circuit breakers, the voltage and amperage
relationship is considered with interrupting capacity decreasing as voltage increases.
Withstand rating: There is a period of time that the short circuit current passes to the shorted circuit
before the protection device can open. This time can be as long as 0.020 seconds (one cycle). The
withstand rating of a starter is the maximum short circuit current that it can pass safely without emitting
sparks or debris.
Bypass contactor: Contactors that bypass auto-transformers, reactors or SCRs and allow full power to
reach the motor.
Phase amps: The current draw inside the delta connection of a wye-delta motor winding, and is equal to
0.577 x RLA of the motor for a specific load.
Open transition: Reduced voltage starter characteristic when the motor is temporarily disconnected from
power at the time the starter changes from the starting mode to the final operating mode. A second smaller
inrush spike will occur. McQuay does not recommend use of this type of starter.
Closed transition: Reduced voltage starter characteristic when the motor is NOT temporarily disconnected
from the line during the transition from starting mode to operating mode. The electrical load is transferred
to resistors during the transition phase and a second inrush spike is suppressed.
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
4/28
4 PM Starter-3
Low Voltage Starters (200 through 600 volts)
General Specifications
Agency Approvals
All controllers are continuous duty AC magnetic type constructed in accordance with National Electric
Manufacturers Associations (NEMA) Standard for Industrial Controls and Systems (ICS). The lowvoltage starters comply with the requirements of the Canadian Standard Association (CSA) and a CSA
label is offered as an option. Underwriters Laboratory (UL) certification for Standard 508 is included
and a UL label is provided with low voltage starters .. Starters can be modified to meet most federal,
state and local codes.
Contactor Duty
Contactors are capable of carrying the specified current on a continuous basis and also handle locked
rotor amps on a temporary basis without damage.
Storage and Operating Environment
Starters can be stored at temperatures from -40F to 140F (-40C to 60C). Operating range is from 32F
to 104F (0C to 40C) with a maximum relative humidity of 95%.
Enclosure and Cable Penetrations
Unless stated otherwise, the starter enclosures for low voltage starters are NEMA 1 with gaskets.
Standard construction for free standing starters allows main power to enter the top of the starter and
load side connections through the bottom, lower sides, or back near the floor.
As an option, the normal low voltage freestanding starter depth can be increased to 28" deep to allow
space for a bottom power inlet or a top side power connection. Medium and high voltage cabinets are
30 deep and allow various wiring configurations without extended depth. Cabinet dimensions can
also change to accommodate disconnect switches, power factor correction capacitors and other
devices.
Adequate separation of high and low voltage sections and proper mechanical and electrical interlocksare provided to meet all safety and operating codes.
Motors
Type
Semi-hermetic, squirrel cage induction, 3-phase, 50/60 Hertz, 2 pole, single speed. Speed,
3550 rpm at nominal shaft horsepower at 60 Hertz, 2960 rpm at 50 Hertz. Continuous duty at
minimum of 15 years with a maximum number of starts expected of 15,000 and a minimum
delay between starts of 20 minutes.
Leads
Low voltage; 600 volts and below, will have six leads and are suitable for use with wye-delta, across-the-
line, auto-transformer, or solid state starters.
TypesThree types of reduced inrush low voltage starters are offered; wye-delta closed transition,
autotransformer, and solid state starters. The objective of these starters is to reduce the starting inrush
current while allowing the motor to generate enough torque to start. Reduced voltage starters also
allow a soft start which means that the motor gradually accelerates to normal operating speed. The
centrifugal chiller capacity control starts the compressor unloaded to minimize current and torque
requirements.
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
5/28
PM Starter-3 5
Wye-Delta Closed Transition
This starter (sometimes called star-delta) is the most popular type for centrifugal chiller applications.
It reduces inrush current by first connecting the three motor windings in a wye configuration to
reduce the maximum inrush current to 33.3% of locked rotor amps and producing 33.3% of normal
starting torque. After a brief delay, the electrical load is momentarily transferred to resistors while the
motor windings are changed to the delta configuration. The resistors minimize the second inrush
current when the delta configuration becomes active. Open transition starters (without the resistors) are
not recommended. These starters are excellent for centrifugal compressors because of the wye-deltas
low inrush current, low starting torque and low initial cost.
Autotransformer
This starter type uses a transformer per phase with 50%, 65%, and 80% taps. The taps determine the
initial voltage and resulting inrush amps that will reach the motor. For centrifugal compressors, the 65%
tap is used allowing 42% of normal inrush current and produces 42% of starting torque. The 50% tap
will usually not produce enough starting torque and the 80% tap allows unnecessary inrush (64% of
LRA). After a designated time period, a bypass contactor closes allowing normal current to flow to the
motor and bypasses the transformers.
Solid State Starters
Solid state starters are another excellent type of starter for centrifugal compressors. This starter usessolid state switching devices called SCRs (Silicon Controlled Rectifiers) that control the flow of current
to the motor during start up.
The SCRs control the amount of voltage that reaches the motor which in turn controls the motors
acceleration and current inrush. Eventually, full voltage is applied and a bypass contactor is energized.
The contactor bypasses the SCRs and allows full current to the motor. The compressor size and motor
characteristics determine Setpoints. Starting torque requirements necessitate approximately three times
the rated load amps of the compressor motor.
Solid state starters are generally used in applications where it is desirable to provide precise control of
motor starting characteristics. The inrush current may possibly, but not necessarily, be reduced below
wye-delta starters.
Standard ComponentsThe following components are standard on all types of low voltage starters:
Main Control Relays
Starters are equipped with redundant motor control relays with coils in parallel and contacts in series to
interlock the starter with the chiller. These two relays constitute the only means of energizing the motor
contractors. No other devices (manual or automatic) with the capability of energizing the starter can be
used. The starter is controlled by the unit microprocessor.
Motor Protection and Overloads
Starter includes devices to provide monitoring and protection functions. These controls include: Solid state overload (overcurrent) protection
Phase unbalance protection
Phase reversal and phase loss protection
Under and over voltage protection
Adjustable overload to closely match motor performance
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
6/28
6 PM Starter-3
Three current transformers to measure motor current and a fourth current transformer for input to
the chiller microprocessor.
Control Voltage Transformer
The starter is provided with a 3KVA control transformer with both secondary and primary fuses to
supply control power to the chiller.
Surge CapacitorsIn wye-delta and autotransformer applications, surge capacitors are provided as standard in low
voltage starters or motor terminal box to protect the compressor motor from voltage spikes.
Surge capacitors are not used with solid state starters.
Terminals
Solderless mechanical connectors to handle wire sizes indicated by the NEC.
OptionsA variety of options are available for low voltage starters and are dependent on the
chiller mounting method. The options are listed below and their availability is shown in
Table 1.
Auxiliary Relay
Two normally open and two normally closed contacts.
Motor Metering Devices
Analog ammeters and voltmeters with 3-phase selector switches.
Deluxe Motor Metering System
The deluxe motor metering system is the IQDP-4130 which includes digital readouts of 3-phase
amps, 3-phase volts, watt-hours, watts, volt-amps, VAR-hours, power factor, and frequency, all in a
single device.
Lightning Arrestors
Ground Fault Protection Relay
Pilot Lights
NEMA Modifications
The standard enclosure is NEMA 1 with additional gasketing.
NEMA 3R -- Rain resistant construction
NEMA 4 -- Rain tight construction
NEMA 12 -- Dust tight construction
Notes:
1. The UL label, and CSA certification are available for NEMA 1 only.
2. If UL/CSA is required for NEMA 3R, 4, 12, contact factory.
3. Motor terminal mounted starters for WSC063, WSC079, WSC087, WDC063, WDC079 and
WDC087 are only available with NEMA 1 enclosures.
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
7/28
PM Starter-3 7
Lug Size Options
A wide range of lug sizes for field power wire connections are available and are shown on the
starter certified drawings.
Extended Warranty On Parts Only, or Parts & labor
Main Disconnect (with Padlockable Handle)
Non-fused
Fused, 600 volt fuse clips only, fuses by others
Circuit breaker
Power Factor Correction Capacitors
The McQuay chiller selection program prints out the unit power factor and will also
calculate capacitor size for power factor correction.
Table 1, Starter Option Availability
OptionMotor Terminal Mount
063, 079, 087 OnlyFree Standing or
Unit Mount
Ammeter X XVoltmeter X X
IQ-DP-4130 X XLightning Arrestors X
Ground Fault Protection X XIndicating Lights X
4-Pole Auxiliary Relay X XPower Factor Correction
Capacitors X
NEMA 3R XNEMA 4 XNEMA 12 X
California Code X X
Non-Fused Disconnect X XFused Disconnect X
Circuit Breaker X XExtended Warranty X X
McQuay Starter Model CodesThe McQuay starter codes adapt the Cutler Hammer codes for order entry and drawing
identification as follows:
WSR 089 A 5A
Starter
Type:
Wye-Delta=089
Auto Trans=060
Solid State=031
Size
A=Free Standing
E=Motor Terminal Mount
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
8/28
8 PM Starter-3
General ArrangementLow voltage starters can be supplied in several different mounting arrangements
depending on the chiller size and starter type. See Table 2 for availability.
Motor Terminal Mounted: The starter is mounted on the chiller unit with the back
of the starter against the motor terminal box and wired directly from the starter to
the motor. This arrangement is available only on WSC/WDC 063, 079, or 087 units.
See cover photograph.
Unit Mounted: The starter is factory mounted on the side of the chiller unit and
connected to the motor with conduit and cable. Available on models WSC/WDC
048/050.
Free standing: Floor mounted separate from the chiller unit and field wired to the
compressor motor. This is available on all units and is the only starter arrangement
available for WDC 100 and 126.
Brackets and cable: Starters for WSC 100 and 126 units may be shipped separately
from the chiller unit and furnished with mounting brackets and interconnecting
cables for field mounting and connection by others. This option must be clearly
specified when chillers are ordered since brackets are welded onto the evaporator
during its construction.
Table 2, Starter Mounting Arrangements
Size
Motor Terminal
Mount
(72 in. High)
NOTE (1)
Unit Mount
(72 in. High)
Free Standing
(90 in. High)
Brackets &
Cables
(90 in. High)
WSC/WDC 050 X X
WSC/WDC 063 X X
WSC/WDC 079 X X
WSC/WDC 087 X X
WSC 100, 126 X X
WDC 100, 126 X
NOTE: 888 amp maximum
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
9/28
PM Starter-3 9
Selection ProcedureUse the following procedure to select the proper starter size:
Step 1. Refer to the McQuay MS-85 selection program to obtain the compressor RLA. Find the LRA-
Delta (LRAD), from the rating side of the MS85 program, by clicking on the "Order Data"
button in the upper right corner. The value can also be found in the Motor Data Table in the
centrifugal product manual.
Step 2. Determine the starter type required and check the mounting arrangement from Table 2.
Step 3. Select the starter size from Table 3 that is above the maximum rated load amps (RLA). If the
initial starter size has a maximum LRAD that is greater than the LRAD of the motor, the initial
selection is acceptable. If the motor LRAD is greater than the starter LRAD, use the next larger
starter. The starter must meet RLA andLRAD requirements.
Table 3, Starter Size Selections
Wye-Delta Starter Auto-Transformer StarterSolid State
Starter
SizeMax
RLA
240/
480V
LRAD
600V
LRAD
Main
Lug
Rating
Siz
e
Max.
RLA
240/
480V
LRAD
600V
LRADSize
Max.
RLA
3A 156 859 859 5kA 3A 90 496 496 13 1353D 207 1385 909 10kA 3D 120 496 496 18 180
4A 233 1880 1880 10kA 4A 135 1080 1080 24 240
4D 365 2728 2196 18ka 4D 211 1575 1268 30 304
5A 467 3637 3117 18kA 5A 270 2100 1800 36 360
5D 623 4018 3291 18kA 5D 361 2320 1900 42 420
6A 935 5785 4625 18kA 6A 540 4000 3240 65 650
6D 1212 7794 7274 18kA 6D 760 4560 4560 85 850
7A 1400 8660 8417 30kA 7A 810 5000 4860
Notes:1. The A designation represents a NEMA rated all-purpose starter that is applicable to any motor application. These
starters have a lower maximum RLA and LRA rating to be suitable for unknown applications. Some owners and designers
desire only NEMA rated starters.
2. The D designation represents a definite purpose starter (such as a centrifugal chiller motor) where the duty and
application is known. The D starters meet the National Electric Code but are not specifically covered by NEMAstandards. It is common for definite purpose starters to be used with centrifugal starters.
3. Main lug rating is main lugs only short circuit rating.
Step 4. Select the disconnect/breaker option (if required) from Table 6
Step 5. With the size and type known, find overall starter dimensions from the table below. Detailed
dimension drawings are in the Dimension Section beginning on page 13.
Table 4, Starter Dimensions
Type Height, in. Width, in. Depth, in.
Wye-Delta, Free-Standing, Size 3A to 6A 90 36 21
Solid State, Free-Standing, Size 13 to 85 90 36 21
Motor Terminal Mount 72 36 15
Low Voltage Disconnect and Circuit Breaker Options
Non-fused disconnect
A molded case switch without an automatic trip, includes a through-the-door handle which can be
used to break all power to the starter and chiller.
Fusible disconnect switch (less fuses)
A fused disconnect switch is identical to the non-fused disconnect except that a fuse block is added.
It is industry practice for the installer to supply the fuses. Fuses are NOT included. The interrupting
capacity for 200 to 600 volts is 100,000 amps. Refer to the chart below for fuse sizes.
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
10/28
10 PM Starter-3
Table 5, Fuse Sizes
Fuse Class Fuse Range ( amps) RLA Range (amps) C enter line D im. H ol e to Ho le
(in)
Mounting Pattern
220 A, Class J 110A to 200A 81A to 160A 4.375 2 bolt
400A, Class J 225A to 400A 161A to 322A 5.25 2 bolt
600A, Class J 450A to 600A 323A to 480A 6.00 2 bolt
800A, Class L 601A to 899A 481A to 640A 6.25 2 bolt
1220A, Class L 1000A to 1200A 641A to 960A 6.25 (1), 9.375 (2) 4 bolt
2000A, Class L 1350A to 2000A 961A to 1289A 6.25 (1), 9.375 (2) 4 bolt
Notes:1. Inside hole to inside hole
2. Outside hole to outside hole
Thermal-magnetic Circuit Breakers
Thermal-magnetic circuit breakers are available with standard, high and ultra high interrupting
capacity.
Highest interrupting capacity circuit breakers, Tri-Pac
The Tri-Pac is a combination fuse and breaker unit that offers the highest interrupting capacity.
The interrupting capacity for 200 to 600 volts is 200,000 amps. Available only on free-standing
starters.
Table 6, Ratings and Interrupting Capacity (kA) for Circuit Breakers, Wye-Delta, Solid
State, and Autotransformer Starters
Non-Fusible
Disconnect
Fusible Disconnect
(Free-standing Only)Standard Interrupting Circuit Breaker
Interrupting
Capacity(kA)
Max
RLA Fram
eRating
Fram
eRating
Fuse
Clip
Fuse
Clas
s
Fram
eRating
240 V 480 V 600 V
156 K-SW 200 K-SW 200 200 J JD 250 65 25 18
296 K-SW 400 K-SW 400 400 J KD 400 65 35 25
444 K-SW 600 K-SW 600 600 J LD 600 65 35 25
606 K-SW 800 K-SW 800 800 L MDL 800 65 50 25
888 NDK 1200 NDK 1200 1200 L ND 1200 65 50 25
1185 RDK 1600 RDK 1600 2000 L RD 1600 125 65 50
1481 RDK 2000 RDK 2000 2000 L RD 2000 125 65 50
High Interrupting Circuit Breaker Ultra-High Interrupting Circui t Breaker
Interrupting Capacity (kA) Interrupting Capacity (kA)Max
RLAFram
eRating
240 V 480 V 600 VFrame Rating
240 V 480 V 600 V
156 HJD 250 100 65 25 JDC 250 200 100 35
296 HKD 400 100 65 35 KDC 400 200 100 50
444 HLD 600 100 65 35 LDC 600 200 100 50
606 HMDL 800 100 65 35 NDC 800 200 100 50
888 HND 1200 100 65 35 NDC 1200 200 100 50
1185 RD 1600 125 65 50 RDC 1600 200 100 65
1481 RD 2000 125 65 50 RDC 2000 200 100 65
Tri-Pac Circuit Breaker (Freestanding Only)
Max RLA Frame Rating 240 V 480 V 600 V
296 LA 400 200 200 200
606 NB 800 200 200 200
1185 PB 1600 200 200 200
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
11/28
PM Starter-3 11
SpecificationsDetailed specifications for customers wishing to specify and purchase their own starters are contained
in McQuay Drawing (Specification) 359A999. Contact your local McQuay representative for a current
copy.
Illustrations
Figure 1, Wye-Delta Closed Transition Starter
SurgeCapacitor
Optional
Metering
MotorTerminals
Incoming
Power
I Q 500
Overload
Current
Transformer
Control
Transformer
Main
Contactors
Resistor
Contactor
Transition
Resistors
Motor Control
Relays (MCR)
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
12/28
12 PM Starter-3
Figure 2, Solid State Starter w/ Disconnect
Incoming
Terminals
Motor
Terminal
Motor
Control
Signal
Silicon
Controlled
Rectifiers
(SCR)
Control
Transformer
Motor
Control
Relays
(MCR)
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
13/28
PM Starter-3 13
Dimensions
Figure 3, Free-Standing, Wye-Delta, 36 Inch Wide
NOTES:
1. Enclosure height A = 90 in.
2. Enclosures are designed for incoming line cables at
top, outgoing load cables at bottom. Other wiring
practices may result in cable routing difficulties.
3. Use standard incoming lugs table for all
combination and non-combination units.
Note 1: Outgoing lug size applies to all Wye-Delta starters
Incoming LugsMain Lugs
Only
Outgoing Lugs(Note 1)
Max
RLANo. Size No. Size
156 1 #6-350 1 #6 - 2/0
207 1 #6-350 1 #6 - 4/0233 1 #6-350 1 #6 - 4/0365 2 #4-500 1 #6 - 300518 2 #4-500 1 #1/0 - 500623 3 #2-600 2 #1/0 - 500888 3 #2-600 2 #1/0 - 5001212 4 250-600 2 #2-600
Fused & Non-Fused Disconnect Switch
Terminals
MaxRLA
Type FuseType
Incoming Lugs
156 200A K-SW J (1) #6-250
296 400A K-SW J(1) 750 or
(2) 1/0-300
444 600A K-SW J (2) #2-600
606 800A K-SW L (4) 3/0-750
888 1200A NDK MCS L (4) 4/0-500
Series-C Circuit Breaker Standard, High, or Ultra-High Interrupting Capacity
Circuit Breaker Option Terminal InformationMax. RLA
Frame Incoming Lugs
156 J (1) #4-350
296 K (2) 2/0-250 or (1) 2/0-500
365 L (1) 4/0-600
444 L (2) 250-350
606 M (2) #1-500
623 M (3) 3/0-400
888 N (4) 4/0-500
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
14/28
14 PM Starter-3
1. Enclosures are designed for incoming
line cables at top, outgoing load cables
at bottom. Other wiring practices may
result in cable routing difficulties.2. Use standard incoming lugs table for al
combination and non-combination
units.
Figure 4, Free Standing, Solid State, Sizes 13 - 85, 36 Inch Wide
NOTES:
Outgoing LugsSiz
e
Max
RLA No. Size
13 135 2 #4-500
18 180 2 2/0-300
24 240 2 2/0-300
30 304 2 2/0-300
36 360 2 4/0-500
42 420 2 4/0-500
65 650 4 4/0-500
85 850 4 4/0-500
99 1000 4 4/0-500
Fused & Non-Fused Disconnect Switch
Terminals
Max
RLAType
Fuse
Type
Incoming
Lugs
156 200A K-SW J (1) #6-250
296 400A K-SW J(1) 750 or
(2) 1/0-300
444 600A K-SW J (2) #2-600
606 800A K-SW L (4) 3/0-750
888 1200A NDK MCS L (4) 4/0-500
Main Lugs OnlySeries-C Circuit Breaker: Standard, High, or Ultra-High Interrupting
Capacity
Circuit Breaker Option Terminal InformationMax RLA No. IncomingLugs Max. RLA Frame Incoming Lugs
156 1 350 156 J (1) #4-350
207 1 350 296 K (2) 2/0-250 or (1) 2/0-500
233 1 350 365 L (1) 4/0-600
365 2 500 444 L (2) 250-350
518 2 500 606 M (2) #1-500
623 3 600 623 M (3) 3/0-400
888 3 600 888 N (4) 4/0-500
1000 4 600 1000 R (4) 1-600
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
15/28
PM Starter-3 15
Figure 5, Motor Terminal Mounted, WSC/WDC 063, 079, 087 and
Unit Mounted WSC/WDC 048-050
Notes:
1. Enclosures for top entry only.2. See chiller unit drawings for location of
the starter on the unit.
Incoming Lugs
Main Lugs Only
Outgoing Lugs
(Note 1)Max
RLANo. Size No. Size
156 1 #6-350 1 #6 - 2/0
207 1 #6-350 1 #6 - 4/0
233 1 #6-350 1 #6 - 4/0
365 2 #4-500 1 #6 - 300
518 2 #4-500 1 #1/0 - 500
623 3 #2-600 2 #1/0 - 500
888 3 #2-600 2 #1/0 - 500
Fused & Non-Fused Disconnect Switch
Terminals
Max
FLAType
Fuse
Type
Incoming
Lugs
156 200A K-SW J (1) #6-250
296 400A K-SW J(1) 750 or
(2) 1/0-300
444 600A K-SW J (2) #2-600
606 800A K-SW L (4) 3/0-750
888 1200A NDK MCS L (4) 4/0-500
Series-C Circuit Breaker Standard, High, or Ultra-High Interrupting Capacity
Circuit Breaker Option Terminal InformationMax. RLA
Frame Incoming Lugs
156 J (1) #4-350
296 K (2) 2/0-250 or (1) 2/0-500
365 L (1) 4/0-600
444 L (2) 250-350
606 M (2) #1-500
623 M (3) 3/0-400
888 N (4) 4/0-500
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
16/28
16 PM Starter-3
Medium & High Voltage Starters (2300 to 6900 Volts)
Agency Approvals
All controllers are continuous duty AC magnetic type constructed in accordance with National Electric
Manufacturers Associations (NEMA) Standard for Industrial Controls and Systems (ICS). Medium
voltage starters are rated as NEMA Class E2. Medium voltage starters have UL and CSA labels available
as an option. Starters can be modified to meet most federal, state and local codes.
Contactor Duty
Contactors are capable of carrying the specified current on a continuous basis and also handle locked
rotor amps on a temporary basis without damage.
Storage and Operating Environment
Starters can be stored at temperatures from -40F to 140F (-40C to 60C). Operating range is from 32F to
104F (0C to 40C) with a maximum relative humidity of 95%.
Enclosure and Cable Penetrations
Unless stated otherwise, the starter enclosures for medium and high voltage starters are NEMA 1 with
gaskets. Standard construction for free standing starters allows main power to enter the top of the starter
and load side connections through the bottom, lower sides, or back near the floor.
As an option, the normal low voltage freestanding starter depth can be increased to 28" deep to allow
space for a bottom power inlet or a top side power connection. Medium and high voltage cabinets are
30 deep and allow various wiring configurations without extended depth. Cabinet dimensions can also
change to accommodate disconnect switches, power factor correction capacitors and other devices.
Adequate separation of high and low voltage sections and proper mechanical and electrical interlocks are
provided to meet all safety and operating codes.
Motors
Semi-hermetic, squirrel cage induction, 3-phase, 50/60 Hertz, 2 pole, single speed, 3550 rpm at nominal
shaft horsepower at 60 Hertz, 2960 rpm at 50 Hertz. Continuous dutyat minimum of 15 years with a
maximum number of starts expected of 15,000 and a minimum delay between starts of 20 minutes.
Leads
Medium and high voltage; 2300 to 6900 volts, will have three leads and are suitable for across-the-line,
auto-transformer, and primary reactor starters.
Starter TypesMedium and high voltage starter types are across-the-line, reduced voltage autotransformer, and reduced
voltage primary reactor. They are designed as freestanding only.
Across-the-Line Starter
Across-the-line starters are very simple and consist of a primary contactor that allows locked rotor amps
to reach the motor when energized. These starters are low cost, provide the highest starting torque, and
can be used with any standard motor.
Autotransformer Starter
The autotransformer starter operation was discussed in the low voltage starter section. As with low
voltage starters, they are factory wired at the 65% tap for centrifugal compressors providing 42% starting
torque and 45% inrush current.
Once the starting sequence begins, the motor is not disconnected from the line that prevents a second
inrush spike from occurring. A bypass contactor is provided for across-the-line operation after the start
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
17/28
PM Starter-3 17
up cycle is completed. Autotransformer starters are a good choice because of their efficiency and
flexibility.
Primary Reactor Starter
Primary reactor starters are a medium voltage starter that uses a reactor in series with the motor to
reduce inrush current. These starters have a higher inrush current for the same starting torque as an
autotransformer starter The starters are factory wired at the 65% tap which produces 42% starting
torque and 65% inrush current. A bypass contactor is provided for across-the-line operation after thestart up cycle is completed.
Standard Components
Across-the Line
Across-the-line starters contain the standard components listed below.
Reduced Voltage Primary Reactor
In addition to the standard components listed below, these starters also contain:
Drawout magnetic, three-pole, vacuum break shorting assembly
Three-phase starting reactor, factory set at the 65% tap
Reduced Voltage Auto-Transformer
In addition to the standard components listed below, these starters contain:
Drawout magnetic, three-pole, vacuum break shorting contactor
Drawout magnetic, two-pole, vacuum break starting contactor
Open delta starting auto-transformer factory set at 65%
Main Control Relays
Starters are equipped with redundant motor control relays with coils in parallel and contacts in series to
interlock the starter with the chiller. These two relays constitute the only means of energizing the motor
contractors. No other devices (manual or automatic) with the capability of energizing the starter can be
used. The starter is controlled by the unit microprocessor.
Motor Protection and Overloads
The starter includes overload protection functions. These controls include:
Solid state overload (overcurrent) protection
Phase unbalance protection
Phase reversal and phase loss protection.
Adjustable overload to closely match motor performance
Three current transformers to measure motor current and a fourth current transformer for input tothe chiller microprocessor.
Undervoltage (UV) Relay
The undervoltage relay is an adjustable three-phase protection system that is activated when the
voltage falls below a predetermined safe value and is factory set at 85% of nominal.
Control Voltage Transformer
The starter is provided with a 3KVA control transformer with both secondary and primary fuses to
supply control power to the chiller.
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
18/28
18 PM Starter-3
Additional Standard Components
Mechanical type solderless connectors to handle wire sizes indicated by the NEC.
Three isolated vertical line contactors
Three-pole, gang operated non-load break isolating switch
Three vertically mounted current limiting power fuse blocks (fuses included)
Magnetic three-pole, vacuum break contactor
Single phase control circuit transformer Vertically mounted control circuit primary current limiting fuses
Current transformers
Load terminals
Control circuit terminal blocks and secondary fuses
Phase failure and reversal relay
Options
Motor Metering Devices
Analog ammeters and voltmeters with 3-phase selector switches..
Deluxe Motor Metering System
The deluxe motor metering system is the IQDP-4130 which includes digital readouts of 3-phase amps, 3-
phase volts, watt-hours, watts, volt-amps, VAR-hours, power factor, and frequency, all in a single
device.
Protection Devices
Overvoltage relay.
Lightning arrestors.
Ground Fault Protection
Surge Capacitors
Pilot Devices
Indicating lights, additional electrical interlocks and control relays.
NEMA Modifications
NEMA modifications for the NEMA 1-Gasketed standard enclosure include:
NEMA 3R -- Rain resistant construction
NEMA 12 -- Dust tight construction
Certifications and Approvals (Optional Adder)
UL certification for full voltage starters
UL certification for reduced voltage starters
CSA certification for full voltage starters
CSA certification for reduced voltage starters
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
19/28
PM Starter-3 19
Power Factor Correction Capacitors
See the Power Factor Correction section at the rear of this manual for selection information.
McQuay Starter Model CodesThe McQuay starter codes adapt the Cutler Hammer codes for order entry and drawing
identification as follows:
WSR 202 M 04
Selection ProcedureSelect the correct size from Table 7 and options from the previous page.
Table 7, Starter Size Selection
Size 01 02 03 04 05 06 07
Max. RLA 18 27 32 46 55 65 88
Size 08 09 10 11 12 13
Max. RLA 107 125 148 172 204 255
Notes for medium voltage starters
Full voltage enclosures are 90" tall, 36" wide and 30" deep.
Reduced voltage enclosures are 90" tall, 72"wide and 30" deep.
Add 10" to height if main horizontal bus is required.
All starters are supplied with current limiting fuses and a non-load break isolation switch.
Load-break fused disconnect is available as an option. Consult factory.
IMPORTANT --- ISOLATION SWITCH Medium voltage starters are constructed to allow
components to slide out of the cabinet for servicing and repair. The non-load break isolation switch
disconnects the power to electrical components within the starter for safety of service personnel.
The standard enclosure is designed for the vacuum contactors to slide out. Contact the factory if
optional roll out construction is desired.
Medium voltage starters have a wide range of special options and application flexibility that is not
available with low voltage starters. Contact the factory for special needs.
SpecificationDetailed specification for customers wishing to specify and purchase their own starters are contained in
McQuay Drawing (Specification) 359A999. Contact your local McQuay representative for a current
copy.
Starter
Type:
Across-the-Line=202
Auto Trans=602
Primary Reactor=502
Size: 01 to 13
Voltage:
M=2300V to 4800V
H=5000V to 6900V
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
20/28
20 PM Starter-3
Dimensions
Figure 6, Free Standing, Full Voltage (see notes on page 23)
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
21/28
PM Starter-3 21
Figure 7, Free Standing, Reduced Voltage Auto-Transformer and Primary Reactor
(see notes on page 23)
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
22/28
22 PM Starter-3
Detail Notes:
A - .75 diameter, typical of 4 holes. Mounting studs must extend a minimum of 2.50"
above grade.
B - HV conduit space, line and load for two high starters, upper starter cable should
enter in rear half of conduit space and lower starter should enter in front half of
conduit space (line connection w/o main bus).
B1 - HV conduit space (line w/o main bus).
B2 - HV conduit space (incoming line connection).
C - LV conduit space. For two high starters control wiring for upper starter should enter
in rear half of conduit space and lower starter control wiring should enter in front
half of conduit space.
D - Door dimensions to open doors 90 auxiliary compartment door. Not applicable for
two high starters.
E - HV conduit space, load.
F - HV conduit space, line only.
G - LV conduit space only.
H - For top entry load terminals located 32.50" from bottom of enclosure. For bottom
entry load term located 18.00" from bottom of enclosure.
H1 - For top entry load terminals located 76.00"from bottom of enclosure. For bottom
entry 61.00" from bottom of enclosure.
H2 - For top entry load terminals located 53.00" from bottom of enclosure. For bottom
entry load terminals located 40.50" from bottom of enclosure.
H3 - For top entry load terminals located 62.50" from bottom of enclosure. For bottom
entry load terminals located 48.00" from bottom of enclosure.
J - Load terminals located on left hand side of enclosure.
J1 - Load terminals located in reduced voltage enclosure on left hand side.
K - Maximum sill height 6.00" and maximum sill extension 3.00" for removal of contactor
w/o lifting device.
L - Line terminal for top cable entry.
M - Line terminal for bottom cable entry.
X - Steel bottom w/removable lead plates.
Y - Tolerances -0.0" + .25" per structure.
Z - Conduits to extend a maximum of 2" into structure.
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
23/28
PM Starter-3 23
Variable Frequency Drives
GeneralWSC and WDC single and dual compressor chillers can be equipped with Variable Frequency Drive
(VFD). A VFD modulates the compressor speed in response to load and evaporator and condenser
pressures as sensed by the microprocessor. Despite the small power penalty attributed to the VFD,
the chiller can achieve outstanding part load efficiency. VFDs really prove their worth when thereis reduced load combined with low compressor lift (lower condenser water temperatures)
dominating the operating hours. The drives provide two important operating benefits.
The traditional method of controlling centrifugal compressor capacity is by inlet guide vanes.
Capacity can also be reduced by slowing down the compressor speed and reducing the impeller tip
speed providing sufficient tip speed is retained to meet the chiller's discharge pressure
requirements. This method is more efficient than guide vanes by themselves.
In actual practice a combination of the two techniques is used. The microprocessor slows the
compressor (to a fixed minimum of full load speed) as much as possible considering the need for
speed to make the required compressor lift. Guide vanes take over to make up the difference. This
methodology provides the optimum efficiency under any circumstances.
Standard Components1) Incoming and outgoing power terminals.
2) Transformer to supply power to the control circuit, oil heaters, and oil pump.
3) Redundant motor control relays with coils in series.
4) The VFD is current rated at 2 kHz carrier frequency for all 2001000 HP drives. The drive is
capable of running at 110% of nameplate current continuously and provides a minimum of 150%
of this rated current for 5 seconds.
5) The VFD will not generate damaging voltage pulses at the motor terminals when applied within
500 feet of each other. Both Drive and Motor comply with NEMA MG1 section 30.40.4.2 which
specifies these limits at a maximum peak voltage of 1600 Volts and a minimum rise time of .1
microseconds.
6) Units drawing 240 amps or less are air-cooled. All others are water-cooled. Factory mounted
water-cooled VFDs are factory piped to chilled water inlet and outlet nozzles. Free-standing
water-cooled units require chilled water supply and return piping for the VFD cooling. VFD has
a liquid-cooled heat sink assembly enabling liquid cooling of the drive through a single inlet
and outlet connection point, dissipating 25,000 BTUs/Hr for 600 HP, 16,000 BTUs/Hr for 350 HP
and 20,000 BTUs/Hr for 450 HP. The cooling circuit maintains water temperature between 60F
and 104F (15C to 40C).
7) The VFD and options are cUL 508 listed. The drive and options are designed to comply with
the applicable requirement of the latest standards of ANSI, NEMA, National Electric Code NEC,
NEPU-70, IEEE 519-1992, FCC Part 15 Subpart J, CE 96.
8) The VFD is functionally tested under motor load. During this load test the VFD is monitored forcorrect phase current, phase voltages, and motor speed. Correct Current Limit operation is
verified by simulating a motor overload. Verification of proper factory presets by scrolling
through all parameters is performed to ensure proper microprocessor settings. The computer
port also verifies that the proper factory settings are loaded correctly in the drive.
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
24/28
24 PM Starter-3
9) The VFD has the following basic features:
a) An electronic overload circuit designed to protect an A-C motor operated by the VFD
output from extended overload operation on an inverse time basis. This Electronic
overload is UL and NEC recognized as adequate motor protection. No additional
hardware such as motor overload relays or motor thermostats are required.
b) An LED display that digitally indicates:
Frequency output
Voltage output
Current output
Motor RPM
Input kW
Elapsed Time
Time Stamped Fault Indication
DC Bus Volts
a) The capability of riding though power dips up to 10 seconds without a controller trip
depending on load and operating condition. In this extended ride through, the driveuses the energy generated by the rotating fan as a power source for all electronic
circuits.
b) RS232 Port and Windows based software for Configuration, Control, and Monitoring.
c) An isolated 0-20mA, 4-20mA or 0-4, 0-8, 0-10 volt analog speed input follower.
d) An isolated 0-10 V or 4-20 mA output signal proportional to speed or load.
e) Standard I/O Expansion Interface Card with the following features:
PI regulator for set point control
Four Isolated 24 VDC programmable digital inputs
An additional analog input for speed feedback to PI regulator
One Frequency Input (0 to 200 Hz) for digital control of current limit
Four programmable Isolated Digital Outputs (24 VDC rated)
One Form A output relay rated at 250 VAC or 24 VDC
Two NO/NC programmable output relays rated at 250 VAC or 24 VDC
1) The VFD includes the following protective circuits and features:
Motor current exceeds 200% of drive continuous current rating.
Output phase-to-phase short circuit condition.
Total ground fault under any operating condition.
High input line voltage.
Low input line voltage.
Loss of input or output phase.
External fault. (This protective circuit shall permit wiring of remote N.C. safety
contact to shut down the drive).
Metal Oxide Varistors for surge suppression are provided at the VFD input
terminals.
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
25/28
PM Starter-3 25
VFD Model Sizes
VFD Model Max. Amps Power Cooling
VFD 019 170 3/60/460-480 Air
VFD 025 240 3/60/460-480 Air
VFD 047 414 3/60/460-480 Water
VFD 060 500 3/60/460-480 Water
VFD 072 643 3/60/460-480 Water
VFD 090 890 3/60/460-480 Water
VFD120 1157 3/60/460-480 Water
OptionsReactor
Used for control of line harmonics in some installations.
Incoming Line Termination (Chose one)
Terminal Block
Non-Fused Disconnect with through-the-door handle
Fused Disconnect with TD Fuses with through-the-door handle
Standard Interrupting Circuit Breaker with through-the-door handle
High Interrupting Circuit Breaker with through-the-door handle
Ultra High Circuit Breaker with through-the-door handle
Volts/Amps Meter with 3-phase Switch
Watt Transducer
General Arrangement
VFD Mounting
VFDs can be factory mounted on the same units and in the same location as conventional starters or
can be free-standing as shown below.
Chiller ModelMounted at Factory
(1)
Unit Mounted in Field Free-Standing
(2)
WSC, WDC 050 087 X X
WSC 100-126 X (3) X
WDC 100-126 X
Notes
1. Optional reactor is field mounted and wired to unit mounted VFD.
2. Optional reactor is factory mounted in the VFD enclosure.
3. Brackets and interconnecting cables shipped with unit
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
26/28
26 PM Starter-3
VFD Line Harmonics
Despite their many benefits, care must be taken when applying VFDs due to the effect of line
harmonics on the 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. Some
other nonlinear loads are electronic ballasts and uninterruptible power supplies.
Line harmonics and their associated distortion may be critical to AC drive users for threereasons:
1. Current harmonics can cause additional heating to transformers, conductors, and
switchgear.
2. Voltage harmonics upset the smooth voltage sinusoidal waveform.
3. High-frequency components of voltage distortion can interfere with signals transmitted on
the AC line for some control systems.
The harmonics of concern are the 5th, 7
th, 11
th, and 13
th. Even harmonics, harmonics divisible by
three, and high magnitude harmonics are usually not a problem.
Current Harmonics
An increase in reactive impedance in front of the VFD helps reduce the harmonic currents.Reactive impedance can be added in the following ways:
1. Mount the drive far from the source transformer.
2. Add line reactors
3. Use an isolation transformer.
Voltage Harmonics
Voltage distortion is caused by the flow of harmonic currents through a source impedance. A
reduction in source impedance to the point of common coupling (PCC) will result in a reduction
in voltage harmonnics. This may be done in the following ways:
1. Keep the PCC as far from the drives (close to the power source) as possible.
2. Increase the size (decrease the impedance) of the source tranformer.
3. Increase the capacity (decrease the impedance) of the busway or cables from the source to
the PCC.
4. Make sure that added reactance is "downstream" (closer to the VFD than the source) from
the PCC.
The IEEE 519-1991 Standard
The Institute of Electrical and Electronics Engineers (IEEE) has developed a
standard that defines acceptable limits of system current and voltage
distortion. A simple form is available from McQuay that allows McQuay to
determine compliance with IEEE 519-1991.
Line reactors, isolation transformers, or phase-shifting transformers may be
required on some installations.
VFD DimensionsDimensions for free-standing VFDs are available as Certified Drawings from the local McQuay
sales office.
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
27/28
PM Starter-3 27
Power Factor Correction
Many local codes and utility companies require power factor correction to improve the utilization of
power.
Voltage and current in alternating current systems travel through wires in a sine wave pattern
developing positive charges and negative charges. The number of sine waves or cycles per second
is called frequency. The most common frequencies are 50 Hz and 60 Hz (cycles per second).Induction devices such as electric motors and solenoid coils use energy to create magnetic fields to
perform their tasks. This magnetizing energy does not perform usable work and will cause the
current to lag the voltage, traveling in a slightly different sine wave. When electrical measurements
are made, only the mean values for voltage and amperage are measured. These measurements do
not indicate that the voltage and amperage have slipped.
This slippage can be corrected by applying power factor capacitors. These capacitors have the
reverse effect causing voltage to lag current. When capacitors are used with motors, the two
devices offset each other allowing voltage and amperage to travel more consistently. It is good
practice to select capacitors that will correct to a maximum of 95% of total correction. Capacitors are
sized in terms of KVAR (1000 volt amp reactive). Readily available low voltage sizes are 2.5, 5.0, 7.5,
10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 75 and 100 KVAR. For medium voltage applications, available
sizes are 25, 50, 100, 150 and 200 KVAR. Contact the factory for larger sizes.
Power factor correction capacitors should be connected to the load side of contactors except for
solid state starters. If field supplied capacitors are used with solid state starters, they must be
installed upstream of the starter. At least ten feet of wire is required between the capacitors and the
starter. A separate isolation contactor must be supplied to disconnect the capacitors during starter
ramp-up and ramp-down. When the capacitors for solid state starters are supplied by McQuay, the
isolation contactor is furnished and ten feet of wire is coiled within the starter enclosure. Use two
sets of capacitors for WDC dual compressor units.
The McQuay chiller selection program prints out the unit power factor and will also calculate
capacitor size for power factor correction.
7/31/2019 Centrifugal Chillers http://www.amazon.com/shops/POWERBOOKONE
28/28