Water-Cooled Scroll Compressor Chillers

Transcription

1 Installation, and Maintenance Manual IMM WGZ-2 Group: Chiller Part Number: Effective: October 2005 Supercedes: IOMM WGZ-1 Water-Cooled Scroll Compressor Chillers WGZ 030AW To WGZ 120AW, Packaged Water-Cooled Chiller WGZ 030AA To WGZ 120AA, Chiller with Remote Condenser 30 to 120 Tons, 105 to 420 kw Hz, R-22

2 Table of Contents Introduction...3 General Description...3 Nomenclature...3 Inspection...3 Installation...4 Vibration Isolators...6 Water Piping...10 Flow Switch...13 Glycol Solutions...13 Condenser Water Piping...14 Minimum Flow Rates...15 Water Pressure Drop...16 Refrigerant Piping...18 Unit with Remote Condenser...18 Factory-Mounted Condenser...22 Dimensional Data...23 Physical Data...27 AW Water-Cooled...27 AA Remote Condenser...30 Operating Limits...31 Components...32 Wiring...33 Unit Configuration...34 Electrical Data...35 Field Wiring Diagram...41 Control Panel Layout...44 Motor Protection Module...44 Start-Up and Shutdown Pre Start-up...45 Start-up...45 Weekend or Temporary Shutdown...46 Start-up after Temporary Shutdown...46 Extended Shutdown...46 Start-up after Extended Shutdown...47 System Maintenance General...48 Electrical Terminals...49 Compressor Lubrication...49 Sight glass and Moisture Indicator...49 Crankcase Heaters...50 Optional Controls...50 Phase/Voltage Monitor (Optional)...50 Hot Gas Bypass (Optional)...51 Maintenance Schedule System Service Troubleshooting Chart...55 Warranty Statement Manufactured in an ISO Certified facility "McQuay" is a registered trademark of McQuay International 2005 McQuay International Illustrations and data cover McQuay International products at the time of publication and we reserve the right to make changes in design and construction at anytime without notice. 2 WGZ 030A through 120A IMM WGZ-2

3 Introduction General Description McQuay Type WGZ water chillers are designed for indoor installations and are available with water-cooled condensers (Model AW), or arranged for use with remote air-cooled or evaporative condensers (Model AA). Each water-cooled unit is completely assembled and factory wired before evacuation, charging and testing. They consist of hermetic scroll compressors, brazed-plate evaporator, water-cooled condenser (WGZ-AW), and complete refrigerant piping. Units manufactured for use with remote condensers (Models WGZ-AA) have all refrigerant specialties factory-mounted and connection points for refrigerant discharge and liquid lines. Liquid line components that are included are manual liquid line shutoff valves, charging valves, filter-driers, liquid line solenoid valves, sight glass/moisture indicators, and thermal expansion valves. Other features include compressor crankcase heaters, and a MicroTech II microprocessor controller. The electrical control center includes all equipment protection and operating controls necessary for dependable automatic operation. The compressors are not fused as standard, but can be protected by optional circuit breakers or fuses, or can rely on a field-installed, fused disconnect switch for protection. Nomenclature W G Z A W Water-Cooled Global W = Water-Cooled Condenser A = Unit Less Condenser Design Vintage Scroll Compressor Nominal Capacity (Tons) Inspection When the equipment is received, all items should be carefully checked against the bill of lading to be sure of a complete shipment. All units must be carefully inspected for damage upon arrival. All shipping damage must be reported to the carrier and a claim must be filed with the carrier. The unit serial plate should be checked before unloading the unit to be sure that it agrees with the power supply available. Physical damage to unit after acceptance is not the responsibility of McQuay. Note: Unit shipping and operating weights are given in the physical data tables beginning on page 27. IMM WGZ-2 WGZ 030A through 120A 3

4 Installation Note: Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations, and experienced with this type of equipment. WARNING Avoid contact with sharp edges. Personal injury can result. Handling Every model WGZ-AW water chiller with water-cooled condensers is shipped with a full refrigerant charge. For shipment, the charge is contained in the condenser and is isolated by the condenser liquid shutoff valve and the compressor discharge valve common to a pair of compressors. A holding charge is supplied in remote condenser models, WGZ-AA. The operating charge must be field supplied and charged. WARNING If the unit has been damaged, allowing the refrigerant to escape, there can be danger of suffocation in the area since the refrigerant will displace the air. Be sure to review Environmental Protection Agency (EPA) requirements if damage occurred. Avoid exposing an open flame to the refrigerant. Moving the Unit Shipping skids are an option and if not supplied, some means such as dollies or skids must be field furnished to protect the unit from accidental damage and to permit easy handling and moving. Figure 1, Lifting the Unit (2) 2 Lifting Holes Removable Lifting Bar It is recommended that all moving and handling be performed with skids or dollies under the unit when possible and that they not be removed until the unit is in the final location. 4 WGZ 030A through 100A IMM WGZ-2

5 Never put the weight of the unit against the control box. In moving, always apply pressure to the base on the skids only and not to the piping or other components. A long bar will help move the unit easily. Avoid dropping the unit at the end of the roll. If the unit must be hoisted, lift the unit from the removable lifting arms factory-bolted to each end of the unit adjacent to the tube sheet by attaching cables or chains to the end of the arms. A spreader bar must be used to protect the piping, control panel and other areas of the chiller (see Figure 1). The arms should be removed and discarded after use. Do not attach slings to piping or equipment. Do not attempt to lift the unit by lifting points mounted on the compressors. They are for lifting only the compressor should one need to be removed from the unit. Move unit in the upright horizontal position at all times. Set unit down gently when lowering from the truck or rollers. Table 1, Lifting Loads Model Package Units (lbs. L1 L2 L3 L4 Shipping Weight Less Condenser Units (lbs) Shipping L1 L2 L3 L4 Weight WGZ WGZ WGZ WGZ WGZ WGZ WGZ WGZ WGZ WGZ WGZ WGZ WGZ Location WGZ chillers are designed for indoor application and must be located in an area where the surrounding ambient temperature is 40 F (4 C) or above. A good rule of thumb is to place units where ambient temperatures are at least 5 F (3 C) above the leaving water temperature. Because of the electrical control devices, the units should not be exposed to the weather. A plastic cover over the control box is supplied as temporary protection during shipment. A reasonably level and sufficiently strong floor is required for the water chiller. If necessary, additional structural members should be provided to transfer the weight of the unit to the nearest beams. Note: Unit shipping and operating weights are given in Table 1 and in the physical data tables beginning on page 27. Space Requirements for Connections and Servicing The chilled water and condenser water (on units with a water-cooled condenser) piping enters and leaves the unit from the right side when looking at the control panel. Left-hand condenser connections are an option. A clearance of at least 3 feet (1219 mm), or more if codes require, should be provided beyond this piping and on all other sides and ends of the unit for general servicing or for changing the compressors, if it ever becomes necessary. IMM WGZ-2 WGZ 030A through 120A 5

6 On units equipped with a water-cooled condenser (Type WGZ-AW) clearance should also be provided for cleaning or removal of condenser tubes on one end of the unit. The clearance for cleaning depends on the type of apparatus used, but can be as much as the length of the condenser (10 feet, 3050 mm). Tube replacement requires the tube length of 10 feet (3050 mm) plus one to two feet of workspace. This space can often be provided through a doorway or other aperture. Allow a minimum of 4-foot clearance in front of the control panel. Placing the Unit The small amount of vibration normally encountered with the water chiller makes this unit particularly desirable for basement or ground floor installations where the unit can be mounted directly to the floor. The floor construction should be such that the unit will not affect the building structure, or transmit noise and vibration into the structure. Vibration Isolators It is recommended that isolators be used on all upper level installations or in areas where vibration transmission is a consideration. Figure 2, Isolator Locations 4 1 LB LF RB FRF 3 2 Water Connections Transfer the unit as indicated under Moving the Unit. In all cases, set the unit in place and level with a spirit level. When spring-type isolators are required, install springs running under the main unit supports. The unit should be set initially on Control Panel shims or blocks at the listed spring free height. When all piping, wiring, flushing, charging, etc., is completed, the springs are adjusted upward to loosen the blocks or shims that are then removed. A rubber anti-skid pad should be used under isolators if hold-down bolts are not used. Installation of spring isolators requires flexible piping connections and at least three feet of flexible electrical conduit to avoid straining the piping and transmitting vibration and noise. Table 2, Weights & Vibration Mountings Unit Size ARRANGEMENT WGZ-AW, WITH WATER-COOLED CONDENSERS Opr. Wt. Corner Weight Lbs (kg) Neoprene-In-Shear Mountings Spring-Flex Mountings Lbs. (kg) (1219) (267) (294) (1250) (271) (299) (1298) (279) (309) (1344) (286) (318) (1385) (292) (325) (1455) (312) (350) (1725) (386) (435) Continued next page 692 (314) 713 (323) 744 (337) 773 (350) 802 (363) 826 (374) 940 (426) 762 (345) 787 (356) 824 (373) 8 (389) 894 (405) 927 (420) 1057 (479) RP-4 Black RP-4 Black RP-4 Black RP-4 Black White White White White 6 WGZ 030A through 100A IMM WGZ-2

7 IMM WGZ-2 WGZ 030A through 120A 7 Corner Weight Lbs (kg) Neoprene-In-Shear Mountings Spring-Flex Mountings Unit Size Opr. Wt. Lbs. (kg) (1823) 916 (415) 1033 (468) 975 (442) 1100 (498) RP-4 Black RP-4 Black RP-4 Black RP-4 Black White White White White (1943) 958 (434) 1082 (490) 1056 (478) 1193 (540) RP-4 Black RP-4 Black RP-4 Black RP-4 Black CP-2 CP-2 CP-2 CP (2031) 974 (441) 1103 (500) 1129 (511) 1278 (579) RP-4 Black RP-4 Black RP-4 Black RP-4 Black CP-2 CP-2 CP-2 CP (2096) 989 (448) 1121 (508) 1170 (534) 1337 (6) RP-4 Black RP-4 Black RP-4 Black RP-4 Black CP-2 CP-2 CP-2 CP (2120) 1010 (459) 1140 (518) 1178 (535) 1342 (9) RP-4 Black RP-4 Black RP-4 Black RP-4 Black CP-2 CP-2 CP-2 CP (2136) 1015 (461) 1145 (520) 1195 (543) 1350 (613) RP-4 Black RP-4 Black RP-4 Black RP-4 Black CP-2 CP-2 CP-2 CP-2 ARRANGEMENT WGZ-AA, FOR REMOTE CONDENSER Corner Weight Lbs (kg) Neoprene-In-Shear Mountings Spring-Flex Mountings Unit Size Opr. Wt. Lbs. (kg) (979) 468 (212) 502 (227) (2) 616 (279) Purple Purple Orange Orange (998) 472 (214) 507 (230) 590 (267) 634 (287) Purple Purple Orange Orange (1022) 477 (216) 514 (233) 9 (276) 657 (297) Purple Purple Orange Orange (1055) 487 (220) 526 (238) 633 (287) 684 (310) Purple Purple Orange Orange (1074) 488 (221) 528 (239) 650 (295) 704 (319) Purple Purple Orange Orange (1135) 526 (238) 578 (262) 668 (303) 734 (332) Purple Purple Orange Orange (1255) 619 (280) 674 (305) 707 (320) 770 (349) Orange Orange (1333) 672 (304) 736 (333) 732 (332) 801 (363) Orange Orange (1429) 702 (318) 771 (349) 801 (363) 880 (399) Orange (1482) 700 (317) 771 (349) 857 (388) 944 (427) Orange (1516) 697 (316) 773 (350) 890 (403) 987 (447) Orange (1532) 707 (320) 783 (355) 895 (406) 990 (449) CP-2 CP-2 CP-2 CP (1546) ) 783 (355) 910 (413) 1005 (456) CP-2 CP-2 CP-2 CP-2

8 Table 3, Spring Flex Isolators Housing CP-2 Spring Color Red Purple Orange White Max. Load Each Lbs. (kg) 450 (204) 0 (272) 750 (340) 900 (408) 1100 (498) 1300 (589) 1800 (815) Defl. In. (mm) 1.22 ( (29.7) 1.06 (26.9) 1.02 (25.9) 0.83 (21.0) 0.74 (18.7) 1.02 (25.9) Dimensions In. (mm) A B C D E 7.5 (190.5) 7.5 (190.5) 7.5 (190.5) 7.5 (190.5) 7.5 (190.5) 7.5 (190.5) 10.2 (259.1) 6.0 (152.4) 6.0 (152.4) 6.0 (152.4) 6.0 (152.4) 6.0 (152.4) 6.0 (152.4) 9.0 (228.6) 4.7 (119.4) 4.7 (119.4) 4.7 (119.4) 4.7 (119.4) 4.7 (119.4) 4.7 (119.4) 7.7 (195.6) NOTE: housing contains one spring. CP-2 housing contains two identical springs. 2.7 (68.6) 2.7 (68.6) 2.7 (68.6) 2.7 (68.6) 2.7 (68.6) 2.7 (68.6) 2.7 (68.6) 5.5 (139.7) 5.5 (139.7) 5.5 (139.7) 5.5 (139.7) 5.5 (139.7) 5.5 (139.7) 5.75 (146.0) Housing Part Number Spring Part Number B A B A B A B A B A B A B-00 (2) A-00 Table 4, Neoprene-in-Shear Isolators Type R-4 Black Max. Load Each Lbs. (kg) 750 (339) 1100 (498) 1500 (679) Defl. In. (mm) 0.25 (6.4) 0.25 (6.4) 0.25 (6.4) Dimensions In. (mm) A B C D (1) E H L W 2.5 (63.5) 2.5 (63.5) 3.75 (95.3) 0.5 (12.7) 0.5 (12.7) 0.5 (12.7) Note (1) "D" is the mounting hole diameter. 4.1 (104.1) 4.1 (104.1) 5.0 (127.0) 0.56 (14.2) 0.56 (14.2) 0.56 (14.2) 0.25 (6.4) 0.25 (6.4) 0.25 (6.4) 1.75 (44.4) 1.75 (44.4) 1.6 (41.1) 5.5 (165) 5.5 (165) 6.5 (165.1) 3.4 (85.7) 3.4 (85.7) 4.6 (116.8) McQuay Part Number A A A-04 8 WGZ 030A through 100A IMM WGZ-2

9 Figure 3, Spring Flex Mounting. CP-2 Figure 5, Spring Flex Mounting, Figure 4, Neoprene-in-Shear Mounting, Figure 6, Neoprene-in-Shear, R4 IMM WGZ-2 WGZ 030A through 120A 9

10 Water Piping Vessel Drains at Start-up Condensers are drained of water in the factory and are shipped with condenser drain plugs in the heads removed and stored in a bag in the control panel. Be sure to replace plugs prior to filling the vessel with fluid. General Due to the variety of piping practices, it is advisable to follow the recommendations of local authorities for code compliance. They can supply the installer with the proper building and safety codes required for a safe and proper installation. Basically, the piping should be designed with a minimum number of bends and changes in elevation to keep system cost down and performance up. Other piping design considerations include: 1. All piping should be installed and supported to prevent the chiller connections from bearing any strain or weight of the system piping. 2. Vibration eliminators to reduce vibration and noise transmission to the building. 3. Shutoff valves to isolate the unit from the piping system during unit servicing. 4. Manual or automatic air vent valves at the high points of the system. Drains should be placed at the lowest points in the system. 5. Some means of maintaining adequate system water pressure (e.g., expansion tank or regulating valve). 6. Temperature and pressure indicators located within 3 feet (0.9 meters) of the inlet and outlet of the vessels to aid in unit servicing. 7. A strainer or some means of removing foreign matter from the water before it enters the pump is recommended. It should be placed far enough upstream to prevent cavitation at the pump inlet (consult pump manufacturer for recommendations). The use of a strainer will prolong pump life and thus maintain system performance. Important Note A cleanable 40-mesh strainer must also be placed in the water line just prior to the inlet of the evaporator. This will aid in preventing foreign material from entering and decreasing the performance of the evaporator. 8. If the unit is used as a replacement chiller on a previously existing piping system, the system should be thoroughly flushed prior to unit installation. Regular water analysis and chemical water treatment on the evaporator and condenser is recommended immediately upon equipment start-up. 9. In the event glycol is added to the water system, as an afterthought for freeze protection, recognize that the refrigerant suction pressure will be lower, cooling performance less, and water side pressure drop will be higher. If the percentage of glycol is large, or if propylene glycol is used instead of ethylene glycol, the added pressure drop and loss of performance could be substantial. Reset the freezestat and low leaving water alarm temperatures. The freezestat is factory set to default at 36 F (2.2 C). Reset the freezestat setting to approximately 4 to 5 F (2.3 to 2.8 C) below the leaving chilled water setpoint temperature. See the section titled Glycol Solutions for additional information concerning the use of glycol. 10. A preliminary leak check of the water piping should be made before filling the system. 10 WGZ 030A through 100A IMM WGZ-2

11 Note: A water flow switch or pressure differential switch must be mounted in the evaporator outlet water line to signal that there is water flow before the unit will start. Figure 7, Typical Field Evaporator Water Piping Air Vent Strainer Inlet P Vibration Eliminators Isolation Valves Outlet Drain Flow Switch NOTE: Water piping must be supported independently from the unit. System Water Volume It is important to have adequate water volume in the system to provide an opportunity for the chiller to sense a load change, adjust to the change, and then stabilize. As the expected load change becomes more rapid, a greater water volume is needed. The system water volume is the total amount of water in the evaporator, air handling equipment, and associated piping. If the water volume is too low, operational problems can occur including rapid compressor cycling, rapid loading and unloading of compressors, erratic refrigerant flow in the chiller, improper motor cooling, shortened equipment life and other undesirable occurrences. For normal comfort cooling applications where the cooling load changes relatively slowly, we recommend a minimum system volume of four minutes times the flow rate (GPM). For example, if the design chiller flow rate is 120 gpm, we recommend a minimum system volume of 480 gallons (120 gpm x 4 minutes). For process applications where the cooling load can change rapidly, additional system water volume is needed. A process example would be the quenching of hot metal objects. The load would be very stable until the hot metal is dipped into the water tank. Then, the load would increase drastically. Since there are many other factors that can influence performance, systems can successfully operate below these suggestions. However, as the water volume decreases below these guidelines, the possibility of problems increases. Variable Chilled Water Flow Reducing chilled water flow in proportion to load can reduce total system power consumption. Certain restrictions apply to the amount and rate of flow change. The rate of flow change should be a maximum of 10 percent of the change, per minute. Do not reduce flow lower than the part load minimum flows listed on page 15. Chilled Water Piping The system water piping must be flushed thoroughly prior to making connections to the unit evaporator. It is required that a 40-mesh strainer be installed in the return water line before the inlet to the chiller. Lay out the water piping so the chilled water circulating pump discharges into the evaporator inlet. IMM WGZ-2 WGZ 030A through 120A 11

12 The return water line must be piped to the evaporator inlet connection and the supply water line must be piped to the evaporator outlet connection. If the evaporator water is piped in the reverse direction, a substantial decrease in capacity and efficiency of the unit will be experienced. A flow switch must be installed in the horizontal piping of the supply (evaporator outlet) water line to prove water flow before starting the unit. Drain connections should be provided at all low points in the system to permit complete drainage of the system. Air vents should be located at the high points in the system to purge air out of the system. The evaporators are not equipped with vent or drain connections and provision must be made in the entering and leaving chilled water piping for venting and draining. Pressure gauges should be installed in the inlet and outlet water lines to the evaporator. Pressure drop through the evaporator should be measured to determine water flow from the flow/pressure drop curves on page 16. Vibration eliminators are recommended in both the supply and return water lines. Chilled water piping should be insulated to reduce heat loss and prevent condensation. Complete unit and system leak tests should be performed prior to insulating the water piping. Insulation with a vapor barrier would be the recommended type of insulation. If the vessel is insulated, the vent and drain connections must extend beyond the proposed insulation thickness for accessibility. Chillers not run in the winter should have their water systems thoroughly drained if subject to sub-freezing temperatures. If the chiller operates year-round, or if the system is not drained for the winter, the chilled water piping exposed to sub-freezing ambient temperatures should be protected against freezing by wrapping the lines with a heater cable. In addition, an adequate percentage of glycol should be added to the system to further protect the system during low ambient temperature periods. It should be noted that water piping that has been left drained is subject to more corrosion than if filled with water. Use of a Vapor Corrosion Inhibitor (VCI) or some other protection should be considered. Chilled Water Sensor Figure 8, Thermostat Well Location Suction Circuit #1 Suction Circuit #2 Leaving Chilled Water Sensor Liquid Circuit #2 Liquid Circuit #1 The chilled water sensor is factory installed in the leaving water connection on the evaporator. Care should be taken not to damage the sensor cable or lead wires when working around the unit. It is also advisable to check the lead wire before running the unit to be sure that it is firmly anchored and not rubbing on the frame or any other component. If the sensor is ever removed from the well for servicing, care must be taken to not wipe off the heat-conducting compound supplied in the well. CAUTION The thermostat bulb should not be exposed to water temperatures above 125 F (51.7 C) since this will damage it. 12 WGZ 030A through 100A IMM WGZ-2

13 Flow Switch A water flow switch must be mounted in the leaving evaporator and condenser water line to prove adequate water flow before the unit can start. This will safeguard against slugging the compressors on start-up. It also serves to shut down the unit in the event that water flow is interrupted to guard against evaporator freeze-up. A flow switch is available from McQuay under part number It is a paddle type switch and adaptable to any pipe size from 1 in. (25 mm) to 6 in. (152 mm) nominal. Certain minimum flow rates are required to close the switch and are listed in Table 5. Electrical connections in the unit control center should be made at terminals 33 and 43 (chilled water) and 41 and 53 (condenser water). The normally open contacts of the flow switch should be wired between these two terminals. There is also a set of normally closed contacts on the switch that could be used for an indicator light or an alarm to indicate when a no flow condition exists. 1. Apply pipe sealing compound to only the threads of the switch and screw unit into 1 in. (25 mm) reducing tee. The flow arrow must be pointed in the correct direction. 2. Piping should provide a straight length before and after the flow switch of at least five times the pipe diameter without any valves, elbows, or other flow restricting elements. 3. Trim flow switch paddle if needed to fit the pipe diameter. Make sure paddle does not hang up in pipe. CAUTION Make sure the arrow on the side of the switch is pointed in the direction of flow. The flow switch is designed to handle the control voltage and should be connected according to the wiring diagram (see wiring diagram inside control box door). Incorrect installation will cause improper operation and possible evaporator damage. Table 5, Flow Switch Flow Rates Pipe Size inch 2 2 1/ mm (125) (150) gpm Flow Minimum Lpm Adjustment No gpm Flow Lpm gpm Flow Maximum Lpm Adjustment No gpm Flow Lpm Glycol Solutions When using a glycol solution, the chiller capacity, flow rate, evaporator pressure drop, and chiller power input can be calculated using the following formulas and reference to Table 6 for ethylene glycol and Table 7 for propylene glycol. 1. Capacity, Capacity is reduced compared to that with plain water. To find the reduced value, multiply the chiller s capacity when using water by the capacity correction factor C to find the chiller s capacity when using glycol. 2. Flow, To determine evaporator gpm (or ΔT) knowing ΔT (or gpm) and capacity: Glycol GPM = 24 x Glycol Capacity ΔT x Flow Correction G From Tables IMM WGZ-2 WGZ 030A through 120A 13

14 For Metric Applications -- Determine evaporator lps (or ΔT) knowing ΔT (or lps) and kw: kw Glycol Lps = 4.18 x ΔT x Flow Correction G from Tables 3. Pressure Drop, To determine glycol pressure drop through the cooler, enter the water pressure drop graph on page 15 at the actual glycol flow. Multiply the water pressure drop found there by P to obtain corrected glycol pressure drop. 4. Power, To determine glycol system kw, multiply the water system kw by factor K. Test coolant with a clean, accurate, glycol solution hydrometer (similar to that found in service stations) to determine the freezing point. Obtain percent glycol from the freezing point found in Table 6 or Table 7. On glycol applications the supplier normally recommends that a minimum of 25% solution by weight be used for protection against corrosion or the use of additional inhibitors. Note: The effect of glycol in the condenser is negligible. As glycol increases in temperature, its characteristics have a tendency to mirror those of water. Therefore, for selection purposes, there is no derate in capacity for glycol in the condenser. Table 6, Ethylene Glycol Percent Freezing Point P (Pressure C (Capacity) K (Power) G (Flow) Glycol F C Drop) Table 7, Propylene Glycol Percent Freezing Point P (Pressure C (Capacity) K (Power) G (Flow) Glycol F C Drop) CAUTION Do not use automotive antifreeze. Industrial glycols must be used. Automotive antifreeze contains inhibitors that causes plating on copper tubes. The type and handling of glycol used must be consistent with local codes. Condenser Water Piping Arrange the condenser water so the water enters the bottom connection of the condenser. The condenser water will discharge from the top connection. Failing to arrange the condenser water as stated above will negatively affect the capacity and efficiency. Install pressure gauges in the inlet and outlet water lines to the condenser. Pressure drop through the condenser should be measured to determine flow on the pressure drop/flow curves on page 17. Vibration eliminators are recommended in both the supply and return water lines. Install a 20-mesh strainer in the inlet piping to the condenser. 14 WGZ 030A through 100A IMM WGZ-2

15 Water-cooled condensers can be piped for use with cooling towers, well water, or heat recovery applications. Cooling tower applications should be made with consideration of freeze protection and scaling problems. Contact the cooling tower manufacturer for equipment characteristics and limitations for the specific application. Head pressure control must be provided if the entering condenser water can fall below F. The WGZ condenser has two refrigerant circuits with a common condenser water circuit. This arrangement makes head pressure control with discharge pressure actuated control valves difficult. If for some reason the tower water temperature cannot be maintained at a F minimum, or when pond, lake, or well water that can fall below F (15 C) is used as the condensing medium, special discharge pressure control must be used. A water recirculating system with recirculating pump as shown in Figure 9 is recommended. This system also has the advantage of maintaining tube velocity to help prevent tube fouling. The pump should cycle with the chiller. Figure 9, Recirculating Discharge Pressure Control System Circuit #1 Inlet Circuit #2 Inlet Temperature Control Valve Condenser Condenser Water Circuit #1 Outlet Circuit #2 Outlet Minimum Flow Rates Design Full Load Chilled Water Flows The evaporator flow rates and pressure drops shown on the following page are for full load design purposes. The maximum flow rate and pressure drop are based on a 6-degree temperature drop. Avoid higher flow rates with resulting lower temperature drops to prevent potential control problems resulting from very small control bands and limited start up/shut off temperature changes. The minimum flow and pressure drop is based on a full load evaporator temperature drop of 16-degrees. Minimum Flows for Variable Flow Pumping Systems This design full load minimum flow is not to be confused with the part load minimum flow rate that must be maintained for chillers operating in primary variable flow pumping systems. As chiller load drops, the flow rate for this pumping system also reduces. See the following table for the minimum part load flow rates. Other design practices for variable flow systems requiring a range of evaporator flow rates can be found on page 11. These minimum flow rates assume that flow will be reduced proportionally to the cooling load. Table 8, Minimum Part Load Flow Rates WGZ Model Minimum Part Load Flow IMM WGZ-2 WGZ 030A through 120A 15

16 Water Pressure Drop Figure 10, Evaporator Water Pressure Drop, WGZ 030A through 120A Flow Rate (L/s) WGZ 050 WGZ 080 WGZ 040 WGZ 0 WGZ 030 Pressure Drop (ft of water) WGZ Pressure Drop (kpa) WGZ 070 WGZ 035 WGZ 055 WGZ 090 WGZ Flow Rate (GPM) 700 WGZ Model Minimum Flow Nominal Flow Maximum Flow Inch-Pound S.I. Inch-Pound S.I. Inch-Pound S.I. GPM Ft. L/S kpa GPM Ft. L/S kpa GPM Ft. L/S kpa Note: Minimum, nominal, and maximum flows are at a 16 F, 10 F, and 6 F chilled water temperature range respectively and at ARI tons. See previous page. 16 WGZ 030A through 100A IMM WGZ-2

17 Figure 11, Condenser Water Pressure Drop, WGZ 030AW through 120AW Flow Rate (L/s) WGZ 080 WGZ 050, 055 WGZ 090 WGZ 040, Pressure Drop (ft of water) WGZ 030, 035 WGZ Pressure Drop (kpa) WGZ WGZ Flow Rate (GPM) 700 WGZ Model Minimum Flow Nominal Flow Maximum Flow Flow Rate Pressure Drop Flow Rate Pressure Drop Flow Rate Pressure Drop gpm L/s ft. kpa gpm L/s ft. kpa gpm L/s ft. kpa IMM WGZ-2 WGZ 030A through 120A 17

18 Refrigerant Piping Unit with Remote Condenser General Refrigerant piping, to and from the unit, should be sized and installed according to the latest ASHRAE Handbook. It is important that the unit piping be properly supported with sound and vibration isolation between tubing and hanger, and that the discharge lines be looped at the condenser and trapped at the compressor to prevent refrigerant and oil from draining into the compressors. Looping the discharge line also provides greater line flexibility. The discharge gas valves, liquid line solenoids, filter-driers, moisture indicators, and thermostatic expansion valves are all factory mounted as standard equipment with the water chiller. For remote condenser application (WGZ-AA) such as air-cooled or evaporative condenser, the chillers are shipped with an R-22 holding charge. Some special order units may have R-407c refrigerant. The unit is evacuated in the factory to 500 microns before charging with a holding charge of R-22 (407c) refrigerant. The unit is leak tested after charging and before shipment. The liquid line has a shutoff valve upstream from the liquid line solenoid valve and a copper tube cap to be brazed on this line after test to seal this line for shipment. The discharge line has a ball valve installed between the compressor and the discharge stub tube with a copper tube cap brazed on the line after test to seal it for shipment. The discharge gas valves, liquid line solenoids, filter-driers, moisture indicators, and thermostatic expansion valves are all factory-mounted as standard equipment with the water chiller. DANGER Do not apply heat, such as a brazing torch, to a sealed unit, vessel, or component. Internal gases can increase the internal pressure and cause a life-threatening explosion. Open the system when heating. The short line between a valve and brazed end cap can be drilled to vent it. Note that the valve may leak and the entire unit charge may be open to the cap. It is important that the unit be kept tightly closed until the remote condenser is installed, piped to the unit and the high side evacuated. NOTE: it is possible to maintain a positive refrigerant pressure in the unit when a small leak is present. Therefore, add refrigerant to the unit to achieve sufficient pressure to allow a good leak test and carefully leak test the unit. Correct any leaks found. When the field piping has been leak tested, evacuated, and is ready to charge, the unit valves can be opened and the system charged. Alternate method: an alternate method is to open up the unit to the field piping and to pressure test, evacuate and charge the entire system together at one time. Many people feel that this is a more straight-forward approach. Refrigerant piping, to and from the unit, should be sized and installed according to the latest ASHRAE Handbook. It is important that the unit piping be properly supported with sound and vibration isolation between tubing and hanger, and that the discharge lines be looped at 18 WGZ 030A through 100A IMM WGZ-2

19 the condenser and trapped at the compressor to prevent refrigerant and oil from draining into the compressors. Looping the discharge line also provides greater line flexibility. NOTE: Do not run refrigerant piping underground. After the equipment is properly installed, leak tested, and evacuated, it can be charged with R-22, and run at design load conditions. Add charge until the liquid line sight glass is clear, with no bubbles flowing to the expansion valve. Total operating charge will depend on the aircooled condenser used and volume of the refrigerant piping. NOTE: On WGZ-AA units (units with remote condensers), the installer is required to record the refrigerant charge by stamping the total charge and the charge per circuit on the serial plate in the appropriate blocks provided for this purpose. The following discussion is intended for use as a general guide to the piping of air-cooled condensers. Discharge lines must be designed to handle oil properly and to protect the compressor from damage that can result from condensing liquid refrigerant in the line during shutdown. Total friction loss for discharge lines of 3 to 6 psi (20.7 to 41.4 kpa) is considered good design. Careful consideration must be given for sizing each section of piping to insure that gas velocities are sufficient at all operating conditions to carry oil. If the velocity in a vertical discharge riser is too low, considerable oil can collect in the riser and the horizontal header, causing the compressor to lose its oil and result in damage due to lack of lubrication. When the compressor load is increased, the oil that had collected during reduced loads can be carried as a slug through the system and back to the compressor, where a sudden increase of oil concentration can cause liquid slugging and damage to the compressor. Any horizontal run of discharge piping should be pitched away from the compressor approximately 1/8 inch (6.4 mm) per foot (meter) or more. This is necessary to move, by gravity, any oil lying in the header. Oil pockets must be avoided because oil needed in the compressor would collect at such points and the compressor crankcase can become starved. It is recommended that any discharge lines coming into a horizontal discharge header rise above the centerline of the discharge header. This is necessary to prevent any oil or condensed liquid from draining to the compressor heads when the compressor is not running. In designing liquid lines, it is important that the liquid reach the expansion valve without flash gas since this gas will reduce the capacity of the valve. Because flashing can be caused by a pressure drop in the liquid line, the pressure losses due to friction and changes in static head should be kept to a minimum. A check valve must be installed in the liquid line in all applications where the ambient temperature can drop below the equipment room temperature. This prevents liquid migration to the condenser, helps maintain a supply of refrigerant in the liquid line for initial start-up, and keeps liquid line pressure high enough on off cycle to keep the expansion valve closed. On systems as described above, a relief valve or relief-type check valve, must be used in the liquid line as shown in piping systems (shown in Figure 12 and Figure 13). Its purpose is to relieve dangerous hydraulic pressures that could be created as cool liquid refrigerant trapped in the line between the check valve and the expansion or shutoff valve warms up. A relief device is also recommended in the hot gas piping at the condenser coil as shown in Figure 12 and Figure 13. Install a discharge check valve in the discharge line, in a horizontal run, close to the condenser. IMM WGZ-2 WGZ 030A through 120A 19

20 Typical Arrangements Figure 12 illustrates a typical piping arrangement involving a remote air-cooled condenser located at a higher elevation than the compressor and receiver. This arrangement is commonly encountered when the air-cooled condenser is on a roof and the compressor and receiver are on grade level or in a basement equipment room. Notice, in both illustrations, that the hot gas line is looped at the bottom and top of the vertical run. This is done to prevent oil and condensed refrigerant from flowing back into the compressor and causing damage. The highest point in the discharge line should always be above the highest point in the condenser coil. It is advisable to include a purging vent at this point to extract non-condensables from the system. Figure 13 illustrates another very common application where the air-cooled condenser is located on essentially the same level as the compressor and receiver. The discharge line piping in this case is not too critical. The principal problem encountered with this arrangement is that there is frequently insufficient vertical distance to allow free drainage of liquid refrigerant from the condenser coil to the receiver. The receiver is used when it is desired to have refrigerant storage capacity, in addition to the pumpdown capability of the condenser. 20 WGZ 030A through 100A IMM WGZ-2

21 Figure 12, Condenser Above Compressor and Optional Receiver Installation Check Valve Relief Valve Purge Valve Condenser Pitch Subcooler Discharge Line Relief Valve (Vent to Outdoors or to Condenser Side of Liquid Line Check Valve) Preferred Subcooler Hook-up To Evap. Receiver Bypass Receiver Check Valve Loop Figure 13, Condenser and Compressor on Same Level, Optional Receiver Installation Check Valve Relief Valve Purge Valve Discharge Line Pitch Condenser Subcooler Check Valve Relief Valve (Vent to Outdoors or to Condenser Side of Liquid Line Check Valve) Preferred Subcooler Hook-up To Evap. Receiver Bypass Check Valve Receiver The receiver shown is optional and not used on many installations. It is bypassed during normal operation. IMM WGZ-2 WGZ 030A through 120A 21

22 Factory-Mounted Condenser Units with the standard water-cooled, factory-mounted condenser are provided with complete refrigerant piping and full operating refrigerant charge at the factory. There is a remote possibility on water-cooled units utilizing low temperature pond or river water as a condensing medium, and if the water valves leak, that the condenser and liquid line refrigerant temperature could drop below the equipment room temperature on the off cycle. This problem only arises during periods when cold water continues to circulate through the condenser and the unit remains off due to satisfied cooling load. If this condition occurs: 1. Cycle the condenser pump off with the unit. 2. Check the liquid line solenoid valve for proper operation. Relief Valve Piping The ANSI/ASHRAE Standard 15, Safety Standard for Refrigeration Systems, specifies that pressure relief valves on vessels containing Group 1 refrigerant (R-22) shall discharge to the atmosphere at a location not less than 15 feet (4.6 meters) above the adjoining ground level and not less than 20 feet (6.1 meters) from any window, ventilation opening or exit in any building. The piping must be provided with a rain cap at the outside terminating point and with a drain at the low point on the vent piping to prevent water buildup on the atmospheric side of the relief valve. In addition, a flexible pipe section should be installed in the line to eliminate any piping stress on the relief valve(s). The size of the discharge pipe from the pressure relief valve should not be less than the size of the pressure relief outlet. When two or more vessels are piped together, the common header and piping to the atmosphere should not be less than the sum of the area of each of the lines connected to the header. NOTE: Fittings should be provided to permit vent piping to be easily disconnected for inspection or replacement of the relief valve. Figure 14, Relief Valve Piping 22 WGZ 030A through 100A IMM WGZ-2

23 Dimensional Data WGZ-AW Water-Cooled Figure 15, WGZ 030AW through WGZ 055AW Door Swing W Evaporator Recommended for Servicing H Y Z L A MicroTech II User Interface Evaporator Inlet Control Connection Outlet Condenser Outlet Inlet Power Connections (2).875" (22 mm) (4).875" (22 mm) Mounting Holes Relief Valves (1) Each End T X WGZ Model Number Maximum Overall Dimensions in (mm) Chilled Water Connection in. (mm) Victaulic Condenser Water Connections in. (mm) Victaulic Center of Gravity L W H Size A Size T X Y Z (3406) (813) (1613) (76) (2903) (102) (76.2) (1596) (680) (340) (3406) (813) (1613) (76) (2926) (102) (76.2) (17) (682) (340) (3406) (813) (1613) (76) (2959) (102) (76.2) (1618) (682) (340) (3406) (813) (1613) (76) (2992) (102) (76.2) (1627) (688) (340) (3406) (813) (1613) (76) (3025) (102) (76.2) (1640) (688) (340) (3406) (813) (1613) (76) (3073) (102) (76.2) (1614) (693) (338) See NOTES on the bottom of page 24. IMM WGZ-2 WGZ 030A through 120A 23

24 Figure 16, WGZ-0AW through WGZ-120AW Door Swing Clearance W Evaporator Recommended for Servicing H Y Z MicroTech II User Interface L A Control Connection Inlet Evaporator Outlet Condenser Outlet Inlet Power Connections (2).875" (22 mm) WGZ Model Number T Maximum Overall Dimensions in (mm) (4).875" (22 mm) Diameter Mounting Holes X Chiller Water Connection in. (mm) Victaulic Condenser Water Connections in. (mm) Victaulic Relief Valves (1) Each End Center of Gravity L W H Size A Size T X Y Z (3663) (813) (1676) (76) (2980) (127) (263) (1549) (775) (340) (3764) (813) (1676) (76) (3036) (127) (367) (1525) (804) (340) (3764) (813) (1676) (76) (3114) (127) (367) (1553) (834) (340) (3785) (813) (1676) (76) (3216) (127) (388) (1591) (843) (340) (3785) (813) (1676) (76) (3274) (127) (388) (1614) (839) (340) (3785) (813) (1676) (76) (3274) (127) (390) (18) (854) (340) (3785) (813) (1676) (76) (3274) (127) (390) (1555) (870) (340) NOTES 1. Allow a minimum of three feet (one meter) service clearance on all four sides of the unit. Allow sufficient space at one end for tube cleaning or replacement. 24 WGZ 030A through 100A IMM WGZ-2

25 2. Allow two additional inches in width for the optional disconnect switch handle. WGZ-AA Remote Condenser Figure 17, Dimensions, WGZ 030AA WGZ 055AA Door Swing Clearance W Recommended for Servicing "G" Disch Conn "E" Liquid Conn H Y Z L A MicroTech II User Interface "G" Disch. System #2 "G" Disch. System #1 Control Connection Inlet Evaporator Outlet T B D C "E" Liquid System #2 "E" Liquid System # F Power Connections (2) (22 mm) (4) (22 mm) Mounting Holes X WGZ Model Maximum Overall Dimensions In. (mm) Evaporator Connection In. (mm) Victaulic Refrigerant Piping Connections System #1 System #2 Connection Size L W H Size A Liquid F Discharge C Liquid D Discharge B (3186) (813) (1613) (76) (2903) (1386) (996) (1363) (1101) (3186) (813) (1613) (76) (2926) (1386)) (996) (1363) (1101) (3186) (813) (1613) (76) (2959) (1386) (996) (1363) (1101) (3186) (813) (1613) (76) (2992) (1386) (996) (1363)) (1101) (3186) (813) (1613) (76) (3025) (1386) (996) (1363) (1101) (3186) (813) (1613) (76) (3073 (1546) (1132) (1203) (964) See NOTES on the bottom of page 24. Liquid E.875 (22).875 (22).875 (22).875 (22).875 (22).875 (22) (29) Center of Gravity Discharge G T X Y Z (29) (51) (1677) (788) (356) (29) (51)) (1689) (792) (356) (29) (51) (1702) (796) (356) (29) (51)) (1712) (801 (354) (29) (51) (1728) (804) ( (29) (35) (51)) (1692) (809) (351) IMM WGZ-2 WGZ 030A through 120A 25

26 Figure 18, Dimensions WGZ 0AA 120AA Door Swing Clearance W Evaporator Recommended for Servicing H Y Z MicroTech II User Interface L A Control Connection Inlet Evaporator Outlet Condenser Outlet Inlet Power Connections (2).875" (22 mm) T (4).875" (22 mm) Diameter Mounting Holes X Relief Valves (1) Each End WGZ Model Number Maximum Overall Dimensions in (mm) Chiller Water Connection in. (mm) Victaulic Condenser Water Connections in. (mm) Victaulic Center of Gravity L W H Size A Size T X Y Z (3663) (813) (1676) (76) (2980) (127) (263) (1549) (775) (340) (3764) (813) (1676) (76) (3036) (127) (367) (1525) (804) (340) (3764) (813) (1676) (76) (3114) (127) (367) (1553) (834) (340) (3785) (813) (1676) (76) (3216) (127) (388) (1591) (843) (340) (3785) (813) (1676) (76) (3274) (127) (388) (1614) (839) (340) (3785) (813) (1676) (76) (3274) (127) (390) (18) (854) (340) (3785) (813) (1676) (76) (3274) (127) (390) (1555) (870) (340) Notes: 1. Allow a minimum of 3 ft (1 meter) service clearance on all 4 sides of the unit. Allow sufficient space on one end for condenser tube cleaning and replacement. Allow 4 ft clearance in front of the control panel. 2. Allow two additional inches in width for optional disconnect switch. 26 WGZ 030A through 100A IMM WGZ-2

27 Physical Data AW Water-Cooled Table 9, WGZ 030AW WGZ 055AW WGZ UNIT SIZE Unit ARI conditions tons, (kw) (1) 31.6 (111.1) 34.9 (122.7) 40.1 (141) 44.2 (155) 48.6 (171) 54.3 (191) No. Circuits COMPRESSORS (2) Nominal Tons Number Unloading Steps, % 27 / 50 / / 50 / / 50 / / 50 / / 50 / / 50 / 77 Oil Charge per Compressor oz., (l) 140 (4.1) 140 (4.1) 140 (4.1) 140 (4.1) 140 (4.1) 140 (4.1) CONDENSER Number No. Refrigerant Circuits Diameter, in., (mm) 10 (254) 10 (254) 10 (254) 10 (254) 10 (254) 10 (254) Tube Length, in., (mm) 120 (3048) 120 (3048) 120 (3048) 120 (3048) 120 (3048) 120 (3048) Design W.P.PSIG, (kpa): Refrigerant Side 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) Water Side 232 (1599) 232 (1599) 232 (1599) 232 (1599) 232 (1599) 232 (1599) No. of Passes Pump-Out Capacity, lb., (kg) (3) 279 (126.6) 273 (123.8) 2 (117.9) 253 (114.8) 240 (108.9) 234 (106.1) Connections: Water In & Out, in, (mm) Victaulic 4 (102) 4 (102) 4 (102) 4 (102) 4 (102) 4 (102) Relief Valve, Flare In., (mm) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) Purge Valve, Flare In., (mm) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) Vent & Drain, in. (mm) FPT ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) Liquid Subcooling Integral Integral Integral Integral Integral Integral EVAPORATOR Number No. Refrigerant Circuits Water Volume, gallons, (l) 3.9 (14.7) 4.3 (16.4) 5 (18.9) 5.7 (21.4) 6.3 (23.9) 7.2 (27.3) Refrig. Side D.W.P. Psig, (kpa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) Water Side D.W.P,. psig, (kpa) 363 (2503) 363 (2503) 363 (2503) 363 (2503) 363 (2503) 363 (2503) Water Connections: Inlet & Outlet, in., (mm) Victaulic 3 (76) 3 (76) 3 (76) 3 (76) 3 (76) 3 (76) Drain & Vent (NPT INT.) Field Field Field Field Field Field UNIT DIMENSIONS Length In., (mm) (3406) (3406) (3406) (3406) (3406) (3406) Width In., (mm) 32 (813) 32 (813) 32 (813) 32 (813) 32 (813) 32 (813) Height In., (mm) 63.5 (1613) 63.5 (1613) 63.5 (1613) 63.5 (1613) 63.5 (1613) 63.5 (1613) UNIT WEIGHTS Operating Weight, lb., (kg) 2691 (1223) 27 (1252) 2864 (1299) 2966 (1345) 3058 (1387) 3213 (1457) Shipping Weight, lb., (kg) 2641 (1198) 2696 (1223) 2772 (1257) 2853 (1294) 2918 (1324) 3063 (1389) Cir # 1,Opn. Charge, lb., (kg) R (599) 50 (22.5) 47 (21.3) 46 (20.8) 44 (20.0) 45 (20.2) Cir # 2,Opn. Charge, lb., (kg) R (599) 50 (22.5) 47 (21.3) 46 (20.8) 44 (20.0) 45 (20.2) Notes: 1. Certified in accordance with ARI Standard 550/ All units have two parallel compressors per circuit % Full R-22 at 90 F (32 C) per unit. IMM WGZ-2 WGZ 030A through 120A 27

28 Table 10, WGZ-0AW - WGZ-100AW WGZ UNIT SIZE Unit ARI conditions tons, (kw) (1) 59.6 (209) 68.0 (239) 78.0 (274) 84.4 (297) 93.7 (330) No. Circuits COMPRESSORS (2) Nominal Tons Number (2) Unloading Steps, % 25 / 50 / / 50 / / 50 / / 50 / / 50 / 75 Oil Charge, per compressor oz. (l) 140 (4.1) 140 (4.1) 148 (4.3) 148 (4.3) 200 (5.9) 200 ( (5.9 CONDENSER Number No. Refrigerant Circuits Diameter, in. (mm) 14 (356) 14 (356) 14 (356) 14 (356) 14 (356) Tube Length, in. (mm) 120 (3048) 120 (3048) 120 (3048) 120 (3048) 120 (3048) Design W.P., psig (kpa): Refrigerant Side 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) Water Side 232 (1599) 232 (1599) 232 (1599) 232 (1599) 232 (1599) No. of Passes Pump-Out Capacity lb., (kg) (3) 481 (218.2) 462 (209.6) 449 (203.7) 429 (194.6) 409 (185.5) Water Connections, Victaulic: Water In & Out, in., (mm) (4) 5 (127) 5 (127) 5 (127) 5 (127) 5 (127) Relief Valve, Flare in., (mm) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) Purge Valve, Flare in. (mm) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) Vent & Drain, in. (mm) FPT ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) ½ (12.7) Liquid Subcooling Integral Integral Integral Integral Integral EVAPORATOR Number No. Refrigerant Circuits Water Volume, gallons (l) 8.1 (30.7) 9.2 (34.9) 10.8 (40.7) 12.8 (48.3) 13.9 (52.5) Refrigerant Side D.W.P., psig, (kpa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) Water Side D.W.P., psig, (kpa) 363 (2503) 363 (2503) 363 (2503) 363 (2503) 363 (2503) Water Connections, Victaulic: In & Out, in. (mm) 3 (76) 3 (76) 3 (76) 3 (76) 3 (76) Drain & Vent, Field Field Field Field Field UNIT DIMENSIONS Length, in. (mm) (3663) (3726) (3726) 149 (3784) 149 (3784) Width, in. (mm) 32 (813) 32 (813) 32 (813) 32 (813) 32 (813) Height, in. (mm) 66 (1676) 66 (1676) 66 (1676) 66 (1676) 66 (1676) UNIT WEIGHTS Operating Wt, lb., (kg) 3809 (1728) 4025 (1826) 4289 (1945) 4478 (2031) 4627 (2099) Shipping Wt, lb. (kg) 3590 (1628) 3806 (1726) 4037 (1831) 4178 (1895) 4287 (1945) Cir # 1,Opn. Charge, lb.,(kg) R (39.3) 84 (37.9) 82 (37.0) 76 (34.3) 76 (34.3) Cir # 2,Opn. Charge, lb.,(kg) R (39.3) 84 (37.9) 82 (37.0) 76 (34.3) 76 (34.3) Notes: 1. Certified in accordance with ARI Standard 550/ All units have two parallel compressors per circuit % Full R-22 at 90 F (32 C) per unit. 28 WGZ 030A through 100A IMM WGZ-2

29 Table 11, WGZ 110 AW AW WGZ UNIT SIZE Unit ARI conditions tons, (kw) (1) (373) (411) No. Circuits 2 2 COMPRESSORS (2) Nominal Tons Number (2) Unloading Steps 27 / 50 / / 50 / 75 Oil Charge, per compressor oz. (l) 200 ( ( ( (5.9) CONDENSER Number 1 1 No. Refrigerant Circuits 2 2 Diameter, in. (mm) 14 (356) 14 (356) Tube Length, in. (mm) 120 (3048) 120 (3048) Design W.P., psig (kpa): Refrigerant Side 450 (3102) 450 (3102) Water Side 232 (1599) 232 (1599) No. of Passes 2 2 Pump-Out Capacity lb., (kg) (3) 409 (185.5) 409 (185.5) Water Connections, Victaulic: Water In & Out, in., (mm) (4) 5 (127) 5 (127) Relief Valve, Flare in., (mm) ½ (12.7) ½ (12.7) Purge Valve, Flare in. (mm) ½ (12.7) ½ (12.7) Vent & Drain, in. (mm) FPT ½ (12.7) ½ (12.7) Liquid Subcooling Integral Integral EVAPORATOR Number 1 1 No. Refrigerant Circuits 2 2 Water Volume, gallons (l) 13.9 (52.5) 13.9 (52.5) Refrigerant Side D.W.P., psig, (kpa) 450 (3102) 450 (3102) Water Side D.W.P., psig, (kpa) 363 (2503) 363 (2503) Water Connections, Victaulic: In & Out, in. (mm) 3 (76) 3 (76) Drain & Vent, Field Field UNIT DIMENSIONS Length, in. (mm) 149 (3785) 149 (3785) Width, in. (mm) 32 (813) 32 (813) Height, in. (mm) 66 (1677) 66 (1677) UNIT WEIGHTS Operating Wt, lb., (kg) 4828 (2190) 5010 (2273) Shipping Wt, lb. (kg) 4488 (2036) 4670 (2118) Cir #1,Opn. Charge, lb., (kg) R (39) 85 (39) Cir #2,Opn. Charge, lb., (kg) R (39) 85 (39) Notes: 1. Certified in accordance with ARI Standard 550/ All units have two parallel compressors per circuit % Full R-22 at 90 F (32 C) per unit. IMM WGZ-2 WGZ 030A through 120A 29

30 AA Remote Condenser Table 12, WGZ-030AA - WGZ-055AA WGZ UNIT SIZE F LWT, 125 F SDT tons, (kw) 29 (103) 31.6 (112) 36.6 (130) 40.7 (144) 44.7 (158) 49.8 (177) No. Circuits COMPRESSORS Nominal Tons Number (Note 1) Unloading Steps, % 27 / 50 / / 50 / / 50 / / 50 / / 50 / / 50 / 77 Oil Charge, per compressor oz, (l) 140 (4.1) 140 (4.1) 140 (4.1) 140 (4.1) 140 (4.1) 140 (4.1) Discharge Valve In., (mm) (28) (28) (28) (28) (28) (28) (35) EVAPORATOR No. Refrigerant Circuits Water Volume, gallons, (l) 3.9 (14.7) 4.3 (16.4) 5 (18.9) 5.7 (21.4) 6.3 (23.9) 7.2 (27.3) Refrig. Side D.W.P. Psig, (kpa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) Water Side D.W.P. Psig, (kpa) 363 (2503) 363 (2503) 363 (2503) 363 (2503) 363 (2503) 363 (2503) Water Connections, Victaulic: Inlet & Outlet, in., (mm) (1) 3 (76) 3 (76) 3 (76) 3 (76) 3 (76) 3 (76) Drain & Vent Field Field Field Field Field Field UNIT DIMENSIONS Length In., (mm) (3109) (3109) (3109) (3109) (3109) (3134) Width In., (mm) 32 (813) 32 (813) 32 (813) 32 (813) 32 (813) 32 (813) Height In., (mm) 63.5 (1613) 63.5 (1613) 63.5 (1613) 63.5 (1613) 63.5 (1613) 63.5 (1613) UNIT WEIGHTS Operating Weight, lb., (kg) 2169 (983) 2211 (1002) 2263 (1025) 2335 (1058) 2376 (1076) 2510 (1137) Shipping Weight, lb., (kg) 2248 (1018) 2285 (1035) 2331 (1056) 2392 (1084) 2424 (1098) 2558 (1159) Holding Charge, lb., (kg) R-22 Per Circuit 6.0 (2.7) 6.1 (2.8) 6.4 (2.9) 6.6 (3) 7.0 (3.2) 9.7 (4.4) Table 13, WGZ-0AA - WGZ-100AA WGZ UNIT SIZE F LWT, 125 F SDT tons, (kw) 54.9 (195) 62.1 (220) 73.0 (256) 80.0 (281) 87.5 (307) No. Circuits COMPRESSORS Nominal Horsepower Number (3) Unloading Steps, % 25 / 50 / / 50 / / 50 / / 50 / / 50 / 75 Oil Charge oz 140 (4.1) 140 (4.1) 148 (4.3) 148 (4.3) 148 (4.3) 148 (4.3) 200 (5.9) 200 (5.9) 200 (5.9) EVAPORATOR No. Refrigerant Circuits Water Volume, gallons (l) 8.1 ( (34.9) 10.8 (40.7) 12.8 (48.3) 13.9 (52.5) Refrigerant Side D.W.P., psig, (kpa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) Water Side D.W.P., psig, (kpa) 363 (2503) 363 (2503) 363 (2503) 363 (2503) 363 (2503) Water Connections: Inlet & Outlet, in. (mm) (2) 3 (76) 3 (76) 3 (76) 3 (76) 3 (76) Drain & Vent Field Field Field Field Field UNIT DIMENSIONS Length, in. (mm) 140 (3556) (3620) (3620) (3677) (3677) Width, in. (mm) 32 (813) 32 (813) 32 (813) 32 (813) 32 (813) Height, in. (mm) 66 (1676) 66 (1676) 66 (1676) 66 (1676) 66 (1676) UNIT WEIGHTS Operating Wt, lb., (kg) 2784 (1261) 2953 (1338) 3164 (1433) 3280 (1486) 3345 (1515) Shipping Wt, lb. (kg) 2833 (1283) 3001 (1359) 3198 (1449) 3295 (1493) 3238 (1468) Holding Charge, lb. (kg) R (4.5) 10.5 (4.7) 11.1 (5) 11.8 (5.4) 12.3 (5.6) Notes: 1. All units have two compressors per circuit in parallel. 2. Condenser and field piping not included 30 WGZ 030A through 100A IMM WGZ-2

31 Table 14, WGZ-100AA WGZ-120AA WGZ UNIT SIZE F LWT, 125 F SDT tons, (kw) 99.1 (348) (384) No. Circuits 2 2 COMPRESSORS Nominal Horsepower Number (3) Unloading Steps, % 27 / 50 / / 50 / 75 Oil Charge oz 200 (5.9) 200 (5.9) 200 (5.9) 200 (5.9) EVAPORATOR No. Refrigerant Circuits 2 2 Water Volume, gallons (l) 13.9 (52.5) 13.9 (52.5) Refrigerant Side D.W.P., psig, (kpa) 450 (3102) 450 (3102) Water Side D.W.P., psig, (kpa) 363 (2503) 363 (2503) Water Connections: Inlet & Outlet, in. (mm) (2) 3 (76) 3 (76) Drain & Vent Field Field UNIT DIMENSIONS Length, in. (mm) (3677) (3677) Width, in. (mm) 32 (813) 32 (813) Height, in. (mm) 66 (1676) 66 (1676) UNIT WEIGHTS Operating Wt, lb., (kg) 3345 (1515) 3405 (1544) Shipping Wt, lb. (kg) 3238 (1468) 3298 (1495) Cir #1 Hldg Chg, lb. (kg) R-22 Per Circuit 15 (6.8) 15 (6.8) Notes: 1. Victaulic 2. Condenser and field piping not included 3. All units have two compressors per circuit in parallel. Operating Limits Maximum allowable condenser water pressure is 232 psig (1599 kpa). Maximum allowable cooler water pressure is 363 psig (2509 kpa). Maximum design saturated discharge temperature is 140 F ( C). Maximum allowable water temperature to cooler in a non-operating cycle is 100 F (37.8 C). Maximum entering water temperature for operating cycle is 90 F (32.2 C) (during system changeover from heating to cooling cycle). Minimum leaving water temperature from the cooler without freeze protection is 40 F (4.4 C). Minimum entering tower condenser water temperature is F (15.6 C). For remote air-cooled condensers, the temperature difference between the saturated discharge temperature and the outside air temperature (TD) must be between 15 and 30 degrees F and the saturated discharge temperature cannot exceed 125 F. IMM WGZ-2 WGZ 030A through 120A 31

32 Components Figure 19, Compressor Locations Evaporator Evaporator and Condenser Connections Circuit 2 Circuit 1 Control Panel Table 15, Major Components Unit System #1 System #2 Evap. Cond. Expansion Valve Size Vessel Vessel Comp. #1 Comp. #3 Comp. #2 Comp. #4 Size Size System #1 System #2 030 ZR90K3 ZR90K3 ZR11M3 ZR11M3 AC250-70DQ C OVE-20-CP100 OVE-20-CP ZR11M3 ZR11M3 ZR11M3 ZR11M3 AC250-78DQ C OVE-20-CP100 OVE-20-CP ZR12M3 ZR12M3 ZR12M3 ZR12M3 AC250-90DQ C OVE-20-CP100 OVE-20-CP ZR12M3 ZR12M3 ZR16M3 ZR16M3 AC DQ C OVE-30-CP100 OVE-30-CP ZR16M3 ZR16M3 ZR16M3 ZR16M3 AC DQ C OVE-30-CP100 OVE-30-CP ZR16M3 ZR16M3 ZR19M3 ZR19M3 AC DQ C OVE-30-CP100 Y929-VCP100 0 ZR19M3 ZR19M3 ZR19M3 ZR19M3 AC DQ C Y929-VCP100 Y929-VCP ZR19M3 ZR19M3 ZR250KC ZR250KC AC DQ C OVE-40-CP100 OVE-40-CP ZR250KC ZR250KC ZR250KC ZR250KC AC DQ C OVE-40-CP100 OVE-40-CP ZR250KC ZR250KC ZR300KC ZR300KC AC DQ C OVE-55-CP100 OVE-55-CP ZR300KC ZR300KC ZR300KC ZR300KC AC DQ C OVE-55-CP100 OVE-55-CP ZR300KC ZR300KC ZR380KC ZR380KC AC DQ C OVE-55-CP100 OVE-70-CP ZR380KC ZR380KC ZR380KC ZR380KC AC DQ C OVE-70-CP100 OVE-70-CP WGZ 030A through 100A IMM WGZ-2

33 Wiring Field Wiring, Power The WGZ A vintage chillers are built standard with compressor contractors and power terminal block, designed for single power supply to the unit. Optional power connections include a non-fused disconnect switch mounted in the control box or multi-point power connection. A factory installed control circuit transformer is standard. Optionally, a field-installed control power source can be wired to the unit. Circuit breakers for backup compressor short circuit protection are standard on all units. Wiring and conduit selections must comply with the National Electrical Code and/or local requirements. An open fuse indicates a short, ground, or overload. Before replacing a fuse or restarting a compressor, the trouble must be found and corrected. Tables in the Electrical Data section (page 35) give specific information on recommended wire sizes. Unit power inlet wiring must enter the control box (right side) through a patch plate provided for field terminating conduit. (Refer to control panel dimension drawings for general location of power inlet and components.) NOTE: Use only copper conductors in main terminal block. Terminations are sized for copper only. Field Wiring, Control A factory-mounted control transformer is provided to supply the correct control circuit voltage. The transformer power leads are connected to the power block PB1 or disconnect switch DS1. Interlock Wiring, Condenser Pump Starter or Air Cooled Condenser Fan Starter Provisions are made for interlocking a condenser pump starter, tower fans, a tower bypass valve, or up to eight air-cooled condenser fan contactors to be controlled by the MicroTech II unit controller. Condenser fan operation can also be controlled by pressure switches supplied with the condenser. Coil voltage must be 115 volts with a maximum of 20 VA. An evaporator and condenser (water-cooled units only) flow switch is necessary on all units. It is also advisable to wire a chilled water pump interlock in series with the flow switch for additional freeze protection. Ambient Air Sensor Units with a remote air-cooled condenser will have an outdoor air sensor furnished with the unit, inside the control panel and wired to the correct terminals. It must be installed outdoors in a location that will give the true outdoor temperature that the condenser coils will see. Splicing of the sensor lead may be required. The sensor must be installed for the unit to operate. Optional Remote Interface Panel The box containing the optional remote interface panel will have installation instructions, IOM- MT II Remote, in it. IMM WGZ-2 WGZ 030A through 120A 33

34 Unit Configuration The chiller unit has two refrigerant circuits, two tandem scroll compressors (total of four), a single two-circuited brazed plate evaporator, a single two-circuited water-cooled condenser, interconnecting refrigerant piping and a control panel with associated sensors and transducers. Figure 20, Schematic Piping Diagram (One of Two Circuits) T P S Chilled Water LWT Evaporator P 1 Comp #1 Comp #2 CV Condenser Condenser Water T S S F-D S Legend: T Temperature Sensor Relief Valve TP Pressure Transducer TS Schrader Fitting P 1 Pressure (High Pressure Cutout) Thermal Expansion Valve LWT S Temperataure Sensor, Leaving Chilled Water Control Solenoid Valve CV Sight Glass / Moisture Indicator Charging Valve Angle Valve F-D Filter-Drier Ball Valve 34 WGZ 030A through 100A IMM WGZ-2

35 Electrical Data Table 16, Compressor Amp Draw, WGZ WGZ 120 WGZ Unit Size Voltage Freq. (Hertz) Standard With External OL's Locked Rotor Amps Rated Load Amps Rated Load Amps Across-The-Line Per Compressor Per Compressor Per Compressor ( 2 Compr./Circuit) ( 2 Compr./Circuit) ( 2 Compr./Circuit) Circuit 1 Circuit 2 Circuit 1 Circuit 2 Circuit 1 Circuit NOTES: 1. Compressor RLA values are for wire sizing purposes only and do not reflect normal operating current draw. 2. External Overloads only available on Units with Single Power Supply and Water Cooled Condensers IMM WGZ-2 WGZ 030A through 120A 35

36 Table 17, Wire Sizing Amps, WGZ WGZ 120 WGZ Unit Size Voltage Freq. (Hertz) Minimum Circuit Ampacity (MCA) (1) Single Point Single Point Multiple Point Power Supply (2) Power Supply (2) Power Supply (3) Without Ext OL's With Ext OL's Circuit 1 Circuit NOTES: 1. Unit wire sizing amps are equal to 125% of the largest compressor-motor RLA plus 100% of RLA of all other loads in the circuit including control transformer. 2. Single point power supply requires a single fused disconnect to supply electrical power to the unit. 3. Multiple point power supply requires two independent power circuits with separate fused disconnects. (Two compressor circuits, control circuit will be wired to Circuit #1 from the factory) 36 WGZ 030A through 100A IMM WGZ-2

37 Table 18, Fuse Sizing, WGZ WGZ 120 WGZ Unit Size Voltage 3-Phase Freq. (Hertz) Recommended Fuse Size (1) Maximum Fuse Size (2) Single Point Single Pointwith/OL's Multiple Point without OL s Power Supply Power Supply Power Supply Total Unit Total Unit Cir. 1 Cir. 2 Single Point without OL s Power Supply Total Unit Single Pointwith OL's Power Supply Total Unit Multiple Point Power Supply Cir. 1 Cir NOTES: 1. "Recommended Fuse Size" are selected at approximately 175% of the largest compressor RLA, plus 100% of all other circuit load. 2. "Maximum Fuse Sizes" are selected at approximately 225% of the largest compressor RLA, plus 100% of all other loads. IMM WGZ-2 WGZ 030A through 120A 37

38 Table 19, Wire Sizing, WGZ WGZ 120 WGZ Unit Size Voltage 3-Phase Freq. (Hertz) Single Point Power Supply Without External OL's No. of Power Wires Wire Size With External OL's No. of Power Wires Wire Size No. Of Wires Multiple Point Power Supply Circuit #1 Circuit #2 Wire Size No. Of Wires Wire Size GA 3 2 GA 3 6 GA 3 4 GA GA 3 3 GA 3 6 GA 3 4 GA GA 3 8 GA 3 10 GA 3 10 GA 3 8 GA 3 8 GA 3 12 GA 3 10 GA GA 3 2 GA 3 4 GA 3 4 GA GA 3 2 GA 3 4 GA 3 4 GA GA 3 6 GA 3 10 GA 3 10 GA 3 8 GA 3 8 GA 3 10 GA 3 10 GA /0 3 1 GA 3 4 GA 3 4 GA /0 3 1 GA 3 4 GA 3 4 GA GA 3 6 GA 3 8 GA 3 8 GA 3 6 GA 3 8 GA 3 10 GA 3 10 GA /0 3 1/0 3 4 GA 3 3 GA /0 3 1 GA 3 4 GA 3 3 GA GA 3 6 GA 3 8 GA 3 8 GA 3 4 GA 3 6 GA 3 10 GA 3 8 GA /0 3 1/0 3 3 GA 3 3 GA /0 3 1/0 3 3 GA 3 3 GA GA 3 6 GA 3 8 GA 3 8 GA 3 4 GA 3 6 GA 3 8 GA 3 8 GA /0 3 2/0 3 3 GA 3 2 GA /0 3 1/0 3 3 GA 3 2 GA GA 3 4 GA 3 8 GA 3 6 GA 3 4 GA 3 6 GA 3 8 GA 3 8 GA /0 3 2/0 3 2 GA 3 2 GA /0 3 2/0 3 2 GA 3 2 GA GA 3 4 GA 3 6 GA 3 6 GA 3 3 GA 3 6 GA 3 8 GA 3 8 GA kcmil 3 4/0 3 2 GA 3 2/ kcmil 3 3/0 3 2 GA 3 2/ GA 3 3 GA 3 6 GA 3 4 GA 3 3 GA 3 4 GA 3 8 GA 3 6 GA kcmil kcmil 3 2/0 3 2/ kcmil 3 4/0 3 2/0 3 2/ GA 3 2 GA 3 4 GA 3 4 GA 3 2 GA 3 4 GA 3 6 GA 3 6 GA kcmil kcmil 3 2/0 3 3/ kcmil kcmil 3 2/0 3 3/ /0 3 2 GA 3 4 GA 3 3 GA 3 1 GA 3 3 GA 3 6 GA 3 4 GA kcmil kcmil 3 3/0 3 3/ kcmil kcmil 3 3/0 3 3/ /0 3 1 GA 3 3 GA 3 3 GA 3 1/0 3 3 GA 3 4 GA 3 4 GA kcmil kcmil 3 3/0 3 4/ kcmil kcmil 3 3/0 3 4/ /0 3 1/0 3 3 GA 3 2 GA 3 1/0 3 2 GA 3 4 GA 3 3 GA kcmil kcmil 3 4/0 3 4/ kcmil kcmil 3 4/0 3 4/ /0 3 2/0 3 2 GA 3 2 GA 3 2/0 3 1 GA 3 3 GA 3 3 GA 38 WGZ 030A through 100A IMM WGZ-2

39 Table 20, Single Point Connection Sizing, WGZ WGZ 120 WGZ Size Voltage 3-Phase Freq. Single Point Power Supply Disconnect Switch (Hertz) Size (1) Connection (3) Size (2) Connection (3) GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA kcmil GA - 2/ GA kcmil GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA kcmil GA - 2/ GA kcmil GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 400kcmil 250 6GA kcmil GA - 400kcmil 250 6GA kcmil GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 400kcmil 250 6GA kcmil GA - 400kcmil 250 6GA kcmil GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 400kcmil 250 6GA kcmil GA - 400kcmil 250 6GA kcmil GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 400kcmil 250 6GA kcmil GA - 400kcmil 250 6GA kcmil GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 400kcmil 400 (2) 3/0-500 kcmil GA - 400kcmil 400 (2) 3/0-500 kcmil GA - 2/ GA - 3/ GA - 2/ GA - 3/ (2) 2 GA - 500kcmil 400 (2) 3/0-500 kcmil (2) 2 GA - 500kcmil 400 (2) 3/0-500 kcmil GA - 400kcmil 250 6GA kcmil GA - 400kcmil 125 3GA - 3/ (2) 2 GA - 500kcmil 400 (2) 3/0-500 kcmil (2) 2 GA - 500kcmil 400 (2) 3/0-500 kcmil GA - 400kcmil 250 6GA kcmil GA - 400kcmil 250 6GA kcmil (2) 2 GA - 500kcmil 400 (2) 3/0-500 kcmil (2) 2 GA - 500kcmil 400 (2) 3/0-500 kcmil GA - 400kcmil 250 6GA kcmil GA - 400kcmil 250 6GA kcmil (2) 2 GA - 500kcmil 0 (2) 3/0-500 kcmil (2) 2 GA - 500kcmil 0 (2) 3/0-500 kcmil GA - 400kcmil 250 6GA kcmil GA - 400kcmil 250 6GA kcmil (2) 2 GA - 500kcmil 0 (2) 3/0-500 kcmil (2) 2 GA - 500kcmil 0 (2) 3/0-500 kcmil GA - 400kcmil 250 6GA kcmil GA - 400kcmil 250 6GA kcmil NOTES: 1. "Size" is the maximum amperage rating for the terminals or the main electrical device. 2. "Size" is the disconnect part number and not the amperage rating for the terminals or the main electrical device. 3. "Connection" is the range of wire sizes that the terminals on the electrical device will accept. IMM WGZ-2 WGZ 030A through 120A 39

40 Table 21, Multiple Point Connection Sizing, WGZ WGZ 120 WGZ Unit Size Voltage 3-Phase Multiple Point - Circuit #1 Multiple Point - Circuit #2 Freq. Power Block Disconnect Switch Power Block Disconnect Switch (Hertz) Size (1) Connection (3) Size (2) Connection (3) Size (1) Connection (3) Size (2) Connection (3) GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 350kcmil GA - 2/ GA - 3/ GA - 2/ GA - 350kcmil GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 350kcmil GA - 2/ GA - 350kcmil GA - 2/ GA - 350kcmil GA - 2/ GA - 350kcmil GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 350kcmil GA - 400kcmil GA - 350kcmil GA - 2/ GA - 350kcmil GA - 400kcmil GA - 350kcmil GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 400kcmil GA - 350kcmil GA - 400kcmil GA - 350kcmil GA - 400kcmil GA - 350kcmil GA - 400kcmil GA - 350kcmil GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 400kcmil GA - 350kcmil GA - 400kcmil GA - 350kcmil GA - 400kcmil GA - 350kcmil GA - 400kcmil GA - 350kcmil GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 400kcmil GA - 350kcmil GA - 400kcmil GA - 350kcmil GA - 400kcmil GA - 350kcmil GA - 400kcmil GA - 350kcmil GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/ GA - 2/ GA - 3/0 NOTES: 1. "Size" is the maximum amperage rating for the terminals or the main electrical device. 2. "Size" is the disconnect part number and not the amperage rating for the terminals or the main electrical device. 3. "Connection" is the range of wire sizes that the terminals on the electrical device will accept. 40 WGZ 030A through 100A IMM WGZ-2

41 Field Wiring Diagram Figure 21, WGZ 030AW 120AW Field Wiring Diagram 3 PHASE POWER SUPPLY DISCONNECT (BY OTHERS) UNIT MAIN TERMINAL BLOCK GND LUG TO COMPRESSOR(S) AND FAN MOTORS NOTE: ALL FIELD WIRING TO BE INSTALLED AS NEC CLASS 1 WIRING SYSTEM WITH CONDUCTOR RATED 0 VOLTS FUSED CONTROL CIRCUIT TRANSFORMER OPTION 120 VAC FIELD SUPPLIED OPTION N 120VAC CONTROL POWER DISCONNECT (BY OTHERS) 10A FUSE (BY OTHERS) CHW PUMP RELAY (BY OTHERS) 120 VAC 1.0 AMP MAX TB TB1-20 CONTROL CIRCUIT FUSE 120 VAC N REMOTE STOP SWITCH (BY OTHERS) ICE MODE SWITCH (BY OTHERS) CONTROLLER TB3-92 J16-NO10 ALARM FACTORY SUPPLIED ALARM FIELD WIRED TOWER FAN #2 COIL (BY OTHERS) BELL 120 VAC 1.0 AMP MAX OPTION 10 ALARM BELL RELAY 15 TIME CLOCK AUTO OFF TB2 ON MANUAL AUTO ON OFF CDW PUMP RELAY (BY OTHERS) 120 VAC 1.0 AMP MAX TOWER FAN #1 COIL (BY OTHERS) 120 VAC 1.0 AMP MAX TB3-90 TB3-91 J15-NO8 TB1-12 J16-NO9 TB GND N N 120 VAC 120 VAC 120 VAC 120 VAC IF REMOTE STOP 897 CONTROL IS USED, REMOVE LEAD 897 FROM TERM. 40 TO 53. ALARM BELL RELAY COM NO BELL 1 2 ALARM BELL OPTION CHW FLOW SWITCH ---MANDATORY - (BY OTHERS) CDW FLOW SWITCH ---MANDATORY - (BY OTHERS) MANUAL NOR. OPEN PUMP AUX. CONTACTS (OPTIONAL) NOR. OPEN PUMP AUX. CONTACTS (OPTIONAL) 4-20MA FOR EVAP. WATER RESET (BY OTHERS) MA FOR DEMAND LIMIT (BY OTHERS) + - COOLING TOWER BYPASS (BY OTHERS) COOLING TOWER BYPASS (BY OTHERS) TB GND N N 0-10 VDC 0-10 VDC LESS EVAPORATOR ONLY LIQUID LINE #1 SOLENOID 24 VAC 1.5 AMP MAX. LIQUID LINE #2 SOLENOID 24 VAC 1.5 AMP MAX. HOT GAS BYPASS #1 SOLENOID 24 VAC 1.0 AMP MAX. HOT GAS BYPASS #2 SOLENOID 24 VAC 1.0 AMP MAX N N N N 24 VAC 24 VAC 24 VAC 24 VAC FIELD WIRING FOR WGZ A PACKAGE/ WITH CONDENSER WITH MICROTECH CONTROLLER DWG REV.0D IMM WGZ-2 WGZ 030A through 120A 41

42 Figure 22, WGZ 030AA 120AA Field Wiring Diagram (Remote Condenser) 3 PHASE POWER SUPPLY DISCONNECT (BY OTHERS) UNIT MAIN TERMINAL BLOCK GND LUG TO COMPRESSOR(S) AND FAN MOTORS NOTE: ALL FIELD WIRING TO BE INSTALLED AS NEC CLASS 1 WIRING SYSTEM WITH CONDUCTOR RATED 0 VOLTS FUSED CONTROL CIRCUIT TRANSFORMER OPTION 120 VAC REMOTE STOP SWITCH (BY OTHERS) ICE MODE SWITCH (BY OTHERS) CHW FLOW SWITCH ---MANDATORY - (BY OTHERS) FIELD SUPPLIED OPTION N 120VAC CONTROL POWER FACTORY SUPPLIED ALARM FIELD WIRED ALARM BELL OPTION ALARM BELL RELAY TIME CLOCK AUTO ON AUTO OFF MANUAL ON OFF MANUAL 4-20MA FOR CHW RESET (BY OTHERS) DISCONNECT (BY OTHERS) NOR. OPEN PUMP AUX. CONTACTS (OPTIONAL) A FUSE (BY OTHERS) CHW PUMP RELAY (BY OTHERS) 120 VAC 1.0 AMP MAX TB TB TB1-20 GND 897 N CONTROL CIRCUIT FUSE 120 VAC 120 VAC IF REMOTE STOP CONTROL IS USED, REMOVE LEAD 897 FROM TERM. 40 TO 53. ALARM BELL RELAY COM NO BELL 1 2 ALARM BELL OPTION 4-20MA FOR DEMAND LIMIT (BY OTHERS) GND COOLING TOWER BYPASS (BY OTHERS) COOLING TOWER BYPASS (BY OTHERS) 52 TB GND N N 0-10 VDC 0-10 VDC CONTROLLER TB3-90 J15-NO8 TB1-12 FAN MOTOR #1 COIL (BY OTHERS) 120 VAC 1.0 AMP MAX. TB3-91 J16-NO9 N 120 VAC 120 VAC NOTE: CONDENSER FAN MOTORS CAN ALSO BE CONTROLLED BY PRESSURE SWITCHES ON THE CONDENSER. FAN MOTOR #2 COIL (BY OTHERS) 120 VAC 1.0 AMP MAX. FAN MOTOR #3 COIL (BY OTHERS) 120 VAC 1.0 AMP MAX. FAN MOTOR #4 COIL (BY OTHERS) 120 VAC 1.0 AMP MAX. TB3-92 J16-NO10 TB3-93 J16-NO11 TB3-94 J18-NO VAC 120 VAC 120 VAC FAN MOTOR #5 COIL (BY OTHERS) 120 VAC 1.0 AMP MAX. TB3-95 J22-NO VAC FAN MOTOR #6 COIL (BY OTHERS) 120 VAC 1.0 AMP MAX. TB3-96 J22-NO VAC FIELD WIRING FOR WGZ A (REMOTE CONDENSER) WITH MICROTECH CONTROLLER DWG REV.0D FAN MOTOR #7 COIL (BY OTHERS) 120 VAC 1.0 AMP MAX. FAN MOTOR #8 COIL (BY OTHERS) 120 VAC 1.0 AMP MAX. TB3-97 J22-NO VAC 42 WGZ 030A through 100A IMM WGZ-2

43 Notes for Electrical Data Single Point Power: 1. If a separate 115V power supply is used for the control circuit, then the wire sizing amps is 10 amps for all unit sizes. 2. Recommended power lead wire sizes for 3 conductors per conduit are based on 100% conductor ampacity in accordance with NEC. Voltage drop has not been included. Therefore, it is recommended that power leads be kept short. All terminal block connections must be made with copper (type THW) wire. 3. The recommended power lead wire sizes are based on an ambient temperature of 86 F (30 C). Ampacity correction factors must be applied for other ambient temperatures. Refer to the National Electrical Code Handbook. 4. Must be electrically grounded according to national and local electrical codes. Voltage Limitations: 1. Within ± 10 percent of nameplate rating 2. Voltage unbalance not to exceed 2% with a resultant current unbalance of 6 to 10 times the voltage unbalance per NEMA MG-1, 1998 Standard. This is an important restriction that must be adhered to. Notes for Field Wiring Data 1. Requires a single disconnect to supply electrical power to the unit. This power supply must either be fused or use an HACR type circuit breaker. 2. All field wiring to unit power block or optional non-fused disconnect switch must be copper. 3. All field wire size values given in table apply to 75 C rated wire per NEC. Supplemental Overloads Option -- Supplemental overloads option is used to reduce the required electrical service size and wire sizing to the water cooled version of WGZ chillers. The overloads reduce the electrical ratings for the compressor because water-cooled duty is less severe than air cooled duty. The overload option is only available for models with water-cooled condensers (not WGZ-AA models with air-cooled condensers) and having single point electrical power connections. Refer to the electrical data on pages 35, 37, and 38 for the reduced electrical requirements IMM WGZ-2 WGZ 030A through 120A 43

44 Control Panel Layout Figure 23, Typical Control Panel MicroTech II Unit Controller (3) 24V Controller Transformers Terminal Strips 110V Control Transformer (CT) S1, PS1, PS2 Switches (4) Compressor Contactors Space for Optional Circuit Breakers and Multi-point Connection Disconnect Switch Grounding Lug NOTES: 1. Additional space provided in the upper right section for extra components required for optional multiple point power connection and optional circuit breakers. 2. Front door has opening on top for access to the MicroTech II controller for viewing display and making keypad entries without opening the panel door. Motor Protection Module The motor protection system consists of an external control module, located on each compressor, connected to a series of thermistors located in the motor windings and the compressor discharge port. If the windings experience an over-temperature condition or the discharge temperature is excessive, the module will trip and shut off the compressor for a 30- minute time delay. 44 WGZ 030A through 100A IMM WGZ-2