601 B - 04/11 C Product Manual Date: November 2004 Water cooled water chillers WHR 103.2÷451.4 cooling capacity from 338 t o 1571 kW 50 Hz - refrigerant: HCFC22, HFC407C Supersedes: 601 B - 03/05 B McQuay is participating in the Eurovent Certification Programme. Product are as listed in the Eurovent Directory of Certified Products and on the web site www.eurovent-certification.com
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601 B - 04/11 CP r o d u c t M a n u a l
Date: November 2004
Water cooled water chillers
WHR 103.2÷451.4cooling capacity from 338 t o 1571 kW50 Hz - refrigerant: HCFC22, HFC407C
Supersedes: 601 B - 03/05 B
McQuay is participating in the Eurovent Certification Programme.Product are as listed in the Eurovent Directory of Certified Productsand on the web site www.eurovent-certification.com
WHR water cooled water chillers
601 B - 04/11 C - pag. 2
McQuay Int'l introduces their newest water cooled waterchiller type WHR equipped with semihermetic reciprocatingcompressors and microprocessor control system. McQuayhave once again succeeded in developing a high qualityproduct with extraordinary performance which is able to sa-tisfy HVAC application, industrial refrigeration an icestoreapplication. For more than 60 years, McQuay have desi-gned and built successful line of products.The latest techno-logy is included in the new WHR chiller range equipped withsemihermetic reciprocating compressor and unsurpassedadvanced features. All units are equipped with microproces-sor control which optimises the unit operation also impro-ving the interface with devices for remote monitoring.
McQuay water cooled reciprocating compressorchiller advantagesL ow operating costsThe McQuay WHR chillers use the most reliable and effi-cient components in the industry. Semi-hermetic compres-sors series 800S and 900S offer an operating economy thatat partial load conditions is uncomparable with the most ag-gressive competitors. The unloading system with multiplecapacity steps reduction the electrical consumption to theplant requirement. The use of a single evaporator providedwith multiple refrigerant circuits improves the unit perfor-mance at partial load operation.
Low installation costsAll units are completely factory assembled and lower waterconnections required on site reduces the installation cost. Arigid steel base with lifting points permits quick unit rigging.
Power and control panel mounted on the shorter side of theunit determines a more optimized location of unit inside thechillers room, allowing easy maintenance and control. WHRunit are fully wired and supplied with a single power con-nection. Extensive quality control operation tests assuretrouble-free installation and start-up.
Full factory testingPressure vessels tests are performed on all units then eva-cuated and charged with refrigerant HCFC 22.Upon request the ozone safe refrigerants HFC 407Cis also available. All safety and operating controls are pro-perly checked and calibrated at the factory. A complete per-formance test simulates the given conditions. A second se-ries of tests may also be performed at customer's presence.Before shipment, each unit is re-checked for pressure andrefrigerant charge control.
Code requirementsChiller rating: EN 12055.Pressure vessel approval: PED.Elect. & Safety Codes: IEC 204-1 CEI 44-5.Safety Codes: CEI-EN 60204-1.Quality Stds: ISO 9001:2000.
High flexible designWHR units are available in 26 sizes covering a range from338 kW to 1571 kW nominal cooling capacity. Thanks totheir versatility and wide range of accessories units can beused in the air conditioning field, low temperature industrialplant and icestore applications.
ReliabilityThe use of McQuay semihermetic reciprocating compres-sors and the most advanced and efficient control system as-sures reliable functioning. Each refrigerant circuit comescomplete with multiple safety devices which prevent com-pressor damage.
ServiceabilityMcQuay semi-hermetic compressors have easily servicea-ble mechanical parts, electric motor maintenance and lubri-cation. All multiple compressor units use independent refri-gerant circuits. They permit shut-down, routine maintenanceand service of one of the circuit while the others maintainthe system operation.
Microprocessor chiller controllerMicroprocessor is installed as standard on all WHR watercooled liquid chillers.
The microprocessor chiller controllerdisplays the setpoint and all other control parameters thatcan be also modified and reselected. The controller has pre-cision for two setpoint operation for use with water/glycol so-lutions in ice storage applications (see option 07 CB for lowwater temperature down to -8° C). Failures and fault indica-tion are controlled and displayed by LED. The microproces-sor can be connected to a remote monitoring system and toa printer via a RS422 serial comunication port.
General characteristicsStructureThe chiller is equipped with brackets directly installed onheat exchangers. The evaporator and the suction piping areappropriately insulated to prevent condensation. Unit is pro-vided with lifting holes.
Semi-hermetic CompressorsThese are of the reciprocating type with multiple cylindersand suction and discharge valves. Forced oil lubrication isachieved throughtout with a fully reversible direct driven oilpump. The crankcase oil heater is activated when the com-pressor stops and prevents oil dilution by liquid refrigerantand maintains the correct oil viscosity. Electric motors areprotected from temperature overloads by the thermistorsembedded into each of the 3 phases of the stator. The newWHR units can be equipped with the exclusive McQuayMQC-S 800 or 900 series compressors, to achieve maxi-mum energy efficiency at part load conditions. WHR units
601 B - 04/11 C - pag. 3
are equipped as standard with the McQuay 800 or 900 se-ries part winding compressors with unloading system for ca-pacity control.
EvaporatorThe evaporator is a direct expansion shell-and-tube typeconstructed with a carbon steel shell and seamless high ef-ficiency copper tubes. It is equipped with a baffled shell sideto ensure the appropriate water flowing outside the tubesobtaining the maximum heat exchange with the lowest pres-sure drop. Externally the tube-bundle is protected by 10 mmthickness closed-cell insulation material. Evaporator waterconnections of victaulic type are equipped with a waternozzle to be welded on the plant piping system. They aredesigned inspected and stamped in accordance with the lo-cal national standard required for the chiller (ISPESL, SDM,TÜV, SA). Spring loaded relief valves are installed on eva-porator.
CondensersCondensers are shell and cleanable, through-tube type.The unit has indenpendent condensers, one per circuit.Each condenser has a carbon steel and seamless, integral-ly finned high efficiency copper tubes, roll expanded intoheavy carbon steel tube sheets. Water heads are remova-ble and include vent and drain plugs. Condensers comecomplete with liquid shut-off valve, spring loaded reliefvalve.
Refrigerant circuitsEach refrigerant circuit is completely independent and com-plete with all control and regulation devices such as: stopvalves, gauges, solenoid stop valves, filter driers, liquidsight glass and thermostatic expansion valves. Refrigerantcircuits perform a pump down when the compressor stops.
Power and starting panelThe panel includes the main switch with key locked doors,fuses and contactors, safety switch and cut-out switch foreach compressor, a signal lamp indicates unit fault condi-tion, emergency stop button and auxiliary circuit transfor-mer. Unit standard voltage is 400V/3ph/50Hz.
Control devicesThe panel is provided with adequate space for the installa-tion of the microprocessor control which includes: tempera-ture and pressure sensors (thermistors and transducers)keypad/display data setup, ADI board, output board. Allcontrol devices and sensors are factory assembled andtested.
• Access password to prevent unauthorized access• Alarm condition display • Display of inputs recorded
Analogic inputs:
• Entering evaporator water temperature• Leaving evaporator water temperature• Refrigerant pressure
MicroTech (option 70) is the safer and more reliable chillercontrol on the market today. It provides balanced peforman-ce of chiller operations, unaltered leaving chilled watertemperature granting the minimum compressor load and anenergy saving, reducing the compressors starts. The sys-tem controls the compressors activity to keep the chiller run-ning efficiently. The touch-sensitive membrane keypad in-cludes a two line LCD display for monitoring and setup of allthe chiller parametres. By means of automatic safety andprotection devices the Microprocessor controls the maincomponents of the unit is reversing the start sequence andthe compressor unloading. The reading and the setpointschange can be operated on site or monitored from a remotelocation with the possibility to modify the unit function. Mi-croTech (optional) is a simple and self analysing systemwhich controls temperatures, pressures, regulation set-points and systems status. It can be also programmed by aninternal clock to follow an operating schedule. The Micro-Tech has a password security system to provide protectionagainst unauthorized use and to avoid unauthorized changeof parameters. Its memory can retain and display the causeof the fault and the last system fault conditions. An openprotocol (only with option 72) is provided for monitoring,controlling and changing of data with the most efficient buil-ding automation systems. This comunication permits a dras-tic cost reduction for improving the plant operating efficien-cy. The liquid crystal display is backlight for easy viewing inall light conditions. It has touch-sensitive membrane keyswitches to provide positive operator feedback.
Available versionsThe WHR units are available in 3 versions:
WHR ST - standard
WHR LR - special execution without water condensers butequipped with liquid receivers, one per refrigerant circuitand copper connection to be welded on the remotecondenser. This unit version is specially designed for remo-te air condenser application or evaporating gas condensers.
WHR ME - special execution without condensers. Similar tothe LR version but without the liquid receiver that must beincluded in the plant circuit.
Accessories and options01 - 100% total heat recovery (R) produced with tubebundle placed in a single shell with the water condensers.Heat exchangers heads are provided with 2 connections forentering/leaving heat recovery water and 2 separateconnections for condensing water.
601 B - 04/11 C - pag. 4
De-superheaters (D) produced with plate to plate steelbrazed welded heat exchangers (one per each circuit pla-ced on discharge side of compressor hot gas).
Heat pump version - HP.Water to water heat pump isa special arrangement of the basic unit equipped with dou-ble set point. A manual change over switch "heat/cool" se-lects the running mode. The cycle is reversible only on wa-ter side by exchanging the water connections from the eva-porator to the condenser and viceversa. The condensersare insulated to increase the heat recovery efficiency. Theheat pump version always requires the installation of Micro-Tech control system (option 70).
Brine double set point version (CB). Dual leavingglycol mixture temperature set points. The lower setpointcan go down to -8°C.
PW compressor thermal overload relays. Safety de-vice against compressor motor overloading in addition tothe standard thermal protection installed on the electricalwindings.
Phase monitor. The phase monitor controls the vol-tage values on the supply line stopping the unit when thecalibration threshold is reached (± 10%). This safety deviceis automatically reset.
Ammeter and Voltmeter. Digital meter of unit ampdraw and voltage values installed inside the electricalcontrol panel.
Condenser power factor correction. Installed on theelectrical control panel to ensure it conforms to the plant ru-les (McQuay advises maximum 0,9).
Flow switch.For field installation on evaporator andcondensers pipes to prevent freeze up under low tempera-ture conditions. It must be wired to the power panel termi-nals by the customer.
CU-NI condensers 90-10. The heat exchangers arefitted with CU-NI tubes and special protection inside boththe end covers to work with sea water.
Suction shut-off valve. Installed on the suction portserviceable during the routine maintenance and serviceoperation on compressors (standard on HFC 407C).
High temperature control. It includes a pressurestaton high pressure circuit and a thermostat on evaporator wa-ter inlet. This option permits the compressor unloadingwhen the condensing pressure exceeds the limit allowed orwhen the water temperature is higher than 20°C.
Wooden box packing. Box complete closed to protectthe unit during the shipment by sea.
Open cage packing. To protect the units during theloading/unloading and transportation operations.
Rubber antivibration isolators. They are available forfield installation to reduce vibrations transmission throughthe unit base.
Spring antivibration isolators. Supplied for field in-stallation to reduce vibrations transmission through the unitbase. Ideal for unit installation on roofs and metallic struc-tures.
Sound proof cabinet on compressors. Made ofsheet metal internally insulated to reduce the sound noiselevel of the compressors.
Unit test. The units are normally tested at the testbench prior to the shipment. On request, a second test can
be carried out, at customer's presence, in accordance withthe procedures indicated in the test application form. (Not
available for units with glycol mixtures).
601 B - 04/11 C - pag. 5
Table 1 - Operating limitsHCFC 22 HFC 407C
Min/ Max leaving evaporator water temperature Min/Max entering evaporator water temperature Min/Max evaporator water t Min/Max leaving condenser water temperature
° C°C°C°C
4/98/174/8
30/50
4/98/174/8
30/45 Min/Max entering condenser water temperature Min/Max condenser water t (1 pass) Min/Max condenser water t (2 passes) Min/Max leaving heat rec. cond. water temp.
°C°C°C°C
Min/Max entering heat rec. cond. water temp. Min/Max heat recovery cond. water t (1 pass) Min/Max heat recovery cond. water t (2 passes) Min/Max leaving brine evap. water temperature
°C°C°C°C
25/454/89/1730/50
25/404/89/1730/45
25/454/89/17-8/3
25/404/8
9/17-8/3
Min/Max entering brine evap. water temperature °C -3/7 -3/7
Nomenclature WHR 103.2 ST 022Water cooled water chillers
Unit size: 103 tons (1 ton=3,52kW)
No. of compressors: 234
Version: ST Standard versionME Condenserless versionLR Version with liquid reciever
McQuay compressor No./seriesNo. of refrigerant circuitNo. of reduction steps (standard)Refrigerant charge (HCFC 22) kgNo. of evaporatorTotal water volume HCFC 22, HFC 407 l
Max water pressure bar
804/8042
804/9042
462
467
904/9042
904/8062
472
488
1106
1103
16 16
1100
1203
16 16
806/8062
806/9062
490
497
906/90624
1041
1991
195
16 16
1190
16No. of condenserTotal water volume HCFC 22, HFC 407C l
Max water pressure barNo. of heat recovery condenserTotal water volume HCFC 22, HFC 407C l
Add. refrigerant charge kg
241
244
16 16
246
253
16 162
82288
22 24
292
2106
26 31Shipping weight standard unitOperating weight standard unit
kgkg
Shipping weight heat recovery unit (R)Shipping weight heat recovery unit (R)
kgkg
Shipp. weight condenserless unit (ME)Oper. weight condenserless unit (ME)
kgkg
Shipping weight liquid rec. unit (LR)Operating weight liquid rec. unit (LR)
kgkg
24902655
25072669
25782803
26062828
25222681
27763045
26322851
31953531
21082275
21202289
22782445
22902459
21302301
23582648
23002471
25182808
260
263
16 16
265
162
1202
126
32 34
2130
3628773145
29103177
33113649
33563695
2952321534103747
24512739
24702762
26112899
26302922
2508280126582951
601 B - 04/11 C - pag. 6
Notes:(1) Nominal cooling capacity are based on: 12/7 °C entering/leaving evaporator water temperature; 30/35°C entering/leaving condenser water temperature.
McQuay compressor No./seriesNo. of refrigerant circuitNo. of reduction steps (standard)Refrigerant charge (HCFC 22) kgNo. of evaporatorTotal water volume HCFC 22, HFC 407C l
Max water pressurel
bar
906/8082
906/9082
4109
4119
808/9082
908/9082
4124
4134
1186
1264
16 16
1259
1254
16 16
2x906+8063
3x9063
6149
6156
2x906+80836
1611
2681
268
16 16
1262
16No. of condenserTotal water volume HCFC 22, HFC 407C l
Max water pressure barNo. of heat recovery condenserTotal water volume HCFC 22, HFC 407C l
Add. refrigerant charge kg
267
272
16 16
274
279
16 162
1342
144
38 42
2148
2158
44 48Shipping weight standard unitOperating weight standard unit
kgkg
Shipping weight heat recovery unit (R)Shipping weight heat recovery unit (R)
kgkg
Shipp. weight condenserless unit (ME)Oper. weight condenserless unit (ME)
kgkg
Shipping weight liquid rec. unit (LR)Operating weight liquid rec. unit (LR)
kgkg
30773341
31683510
35503893
36454066
32853631
33333678
37844218
38434280
26152909
26963078
27653059
38463228
27863168
28153202
29363318
29653352
296
298
16 16
2101
162
1922
196
52 54
2202
5646745139
46085076
50605654
50065606
4719518551325735
37554240
36754167
40844569
40044496
3768425840974587
601 B 04/11 C - pag. 7
Physical data WHR 282.3÷451.4
Notes:(1) Nominal cooling capacity are based on: 12/7 °C entering/leaving evaporator water temperature; 30/35°C entering/leaving condenser water temperature.
McQuay compressor No./seriesNo. of refrigerant circuitNo. of reduction steps (standard)Refrigerant charge (HCFC 22) kgNo. of evaporatorTotal water volume HCFC 22, HFC 407C l
Max water pressure bar
2x808+9063
3x8083
6166
6171
2x808+9083
3x9083
6181
6201
1/1262
1/1481
16 16
1/1474
1/1461
16 16
2x806+2x9084
3x808+9064
8224
8223
4x80848
2281/1610
1/1625
16 16
1/1625
16No. of condenserTotal water volume HCFC 22, HFC 407C l
Max water pressure barNo. of heat recovery condenserTotal water volume HCFC 22, HFC 407C l
Add. refrigerant charge kg
3136
3136
16 16
3141
3150
16 163
2723
272
58 60
3282
3300
64 72Shipping weight standard unitOperating weight standard unit
kgkg
Shipping weight heat recovery unit (R)Shipping weight heat recovery unit (R)
kgkg
Shipp. weight condenserless unit (ME)Oper. weight condenserless unit (ME)
kgkg
Shipping weight liquid rec. unit (LR)Operating weight liquid rec. unit (LR)
McQuay compressor No./seriesNo. of refrigerant circuitNo. of reduction steps (standard)Refrigerant charge (HCFC 22) kgNo. of evaporatorTotal water volume HCFC 22, HFC 407C l
Max water pressure bar
806+808+2x9084
3x808+9084
8236
8228
2x808+2x9084
808+3x9084
8248
8258
1/1610
1/1617
16 16
1/1610
1/1602
16 16
4x90848
2681/1594
16No. of condenserTotal water volume HCFC 22, HFC 407C l
Max water pressure barNo. of heat recovery condenserTotal water volume HCFC 22, HFC 407C l
Add. refrigerant charge kg
4211
4211
16 16
4211
4221
16 164
4224
422
84 80
4422
4422
88 92Shipping weight standard unitOperating weight standard unit
kgkg
Shipping weight heat recovery unit (R)Shipping weight heat recovery unit (R)
kgkg
Shipp. weight condenserless unit (ME)Oper. weight condenserless unit (ME)
kgkg
Shipping weight liquid rec. unit (LR)Operating weight liquid rec. unit (LR)
kgkg
64437255
64997318
71298143
71818202
65457357
65937403
72358249
73058323
52016047
52656110
55496395
56136458
52916149
53156175
56396497
56636523
4221
164
422
9666297431734583555341620356896551
Electrical data ( HCFC22, HFC 407C )
601 B - 04/11 C - pag. 8
WHR unit size ( HCFC 22, HFC 407C) 103.2 107.2 113.2 132.2 143.2 162.2 173.2Standard voltage
Full load Amps (FLA) comp.1 A 115 115 122
400 V - 3f - 50 Hz (1)
122 155 155 178
Full load Amps (FLA) comp.2
Full load Amps (FLA) comp.3
A
A
Full load Amps (FLA) comp.4
Total full load Amps
A
A
115
-
122
-
-
230
-
237
122
-
155
-
-
244
-
277
155
-
178
-
-
310
-
333
178
-
-
356
Inrush current (2)
Max inrush current (3)
A
A
345
460
537
652
537
659
620
742
585
740
620
775
620
798
WHR unit size (HCFC 22, HFC 407C) 183.2 193.2 211.2 222.2 242.3 252.3 262.3Standard voltage
Full load Amps (FLA) comp.1 A 178 178 210
400 V - 3f - 50 Hz (1)
235 178 178 178
Full load Amps (FLA) comp.2
Full load Amps (FLA) comp.3
A
A
Full load Amps (FLA) comp.4
Total full load Amps
A
A
210
-
235
-
-
388
-
413
235
-
235
-
-
445
-
470
155
178
178
178
-
511
-
534
210
178
-
566
Inrush current (2)
Max inrush current (3)
A
A
750
928
747
925
747
957
747
982
620
953
620
976
620
1008
WHR unit size (HCFC 22, HFC 407C) 282.3 292.3 302.3 342.3 371.4 376.4 391.4Standard voltage
Full load Amps (FLA) comp.1 A 210 210 210
400 V - 3f - 50 Hz (1)
235 155 178 210
Full load Amps (FLA) comp.2
Full load Amps (FLA) comp.3
A
A
Full load Amps (FLA) comp.4
Total full load Amps
A
A
178
210
210
210
-
598
-
630
235
210
235
235
-
655
-
705
235
155
210
210
235
780
210
808
210
210
210
840
Inrush current (2)
Max inrush current (3)
A
A
750
1138
750
1170
750
1195
747
1217
808
1352
750
1348
750
1380
WHR unit size (HCFC 22, HFC 407C) 396.4 401.4 421.4 431.4 451.4Standard voltage
Full load Amps (FLA) comp.1 A 155 210
400 V - 3f - 50 Hz (1)
210 210 235
Full load Amps (FLA) comp.2
Full load Amps (FLA) comp.3
A
A
Full load Amps (FLA) comp.4
Total full load Amps
A
A
235
210
210
210
235
835
235
865
235
210
235
235
235
890
235
915
235
235
235
940
Inrush current (2)
Max inrush current (3)
A
A
747
1347
747
1377
747
1402
747
1427
747
1452
Notes:(1) Allowed voltage tollerance ± 10%.
(2) Inrush current of the largest compressor.
(3) Absorbed current of compressor n° 1 + (n° 2) + (n° 3) at full load + inrush current of last compressor (n° 4).
Sound pressure level WHR 103.2÷451.4 (HCFC 22, HFC 407C) standard unit
601 B - 04/11 C - pag. 9
WHR Sound pressure level at 1 m from the unit in free field (rif. 2 x 10 -5 )
unit size
103.2
6 3 H z
72,0
125 Hz
73,0
250 Hz
76,5
500 Hz
78,0
1000 Hz
78,5
2000 Hz
75,0
4000 Hz
69,0
8000 Hz
65,5
dBA
82,0
107.2
113.2
132.2
143.2
72,0
72,0
73,0
73,0
72,0
72,0
73,0
73,0
76,5
76,5
78,0
78,0
76,5
76,5
78,0
78,0
78,5
78,5
75,0
75,0
78,5
78,5
75,0
75,0
69,0
69,0
65,5
65,5
69,0
69,0
65,5
65,5
82,0
82,0
82,0
82,0
162.2
173.2
183.2
1 9 3 . 2
73,0
73,0
74,0
74,0
73,0
73,0
74,0
74,0
211.2
222.2
242.2
252.3
73,0
73,0
74,0
74,0
74,0
75,0
75,0
76,0
77,5
77,5
79,0
79,0
77,5
77,5
79,0
79,0
79,5
79,5
76,0
76,0
79,5
79,5
76,0
76,0
77,5
77,5
79,0
79,0
78,5
79,5
80,0
81,0
79,5
79,5
76,0
76,0
80,5
81,5
77,0
78,0
70,0
70,0
66,5
66,5
70,0
70,0
66,5
66,5
83,0
83,0
83,0
83,0
70,0
70,0
66,5
66,5
71,0
72,0
67,5
68,5
83,0
83,0
84,0
85,0
262.3
282.3
292.3
302.3
75,0
75,0
76,0
76,0
75,0
75,0
76,0
76,0
342.3
371.4
376.4
391.4
75,0
75,5
76,0
76,5
75,5
75,5
76,5
76,5
79,5
79,5
81,0
81,0
79,5
79,5
81,0
81,0
81,5
81,5
78,0
78,0
81,5
81,5
78,0
78,0
79,5
80,0
81,0
81,5
80,0
80,0
81,5
81,5
81,5
82,0
78,0
78,5
82,0
82,0
78,5
78,5
396.4
401.4
421.4
431.4
75,5
75,5
76,5
76,5
76,0
76,0
77,0
77,0
451.4 76,0 77,0
80,0
80,0
81,5
81,5
80,5
80,5
82,0
82,0
82,0
82,0
78,5
78,5
82,5
82,5
79,0
79,0
80,5 82,0 82,5 79,0
72,0
72,0
68,5
68,5
72,0
72,0
68,5
68,5
85,0
85,0
85,0
85,0
72,0
72,5
68,5
69,0
72,5
72,5
69,0
69,0
85,0
85,5
85,5
85,5
72,5
72,5
69,0
69,0
73,0
73,0
69,5
69,5
85,5
85,5
86,0
86,0
73,0 69,5 86,0
601 B - 04/11 C - pag. 10
Sound pressure level WHR 103.2÷451.4 (HCFC 22, HFC 407C) unit with sound proof cabinet
WHR Sound pressure level at 1 m from the unit in free field (rif. 2 x 10 -5 )