Daikin McQuay. Centrifugal Chiller Dual Compressor WDC, TDC, HDC 048, 050. Last Manufactured: 2007

Transcription

1 Replacement Parts List No Revision L 2/207 Daikin McQuay Centrifugal Chiller Dual Compressor WDC, TDC, HDC 048, 050 Last Manufactured: 2007 To find your Daikin Applied parts distributor, call or visit

2 Contents Parts List Revision History... 3 Nomenclature Nameplate Locations and Part s... 4 Unit Dataplate... 5 Model - Unit, Style - Unit, Serial - Unit... 5 Model - Complete Electrical Legend... 0 Control Box- MicroTech 200 Mounting of Unit Control Panel and Lube Box... Front Panel & Inside of Micro Control Door Assembly... 2 Interior Panel Sensors... 5 Compressor Lube Box Assembly Control Box- MicroTech II Unit Control Box & Operator Interface Panel... 8 Mounting Components... 8 Compressor Control Box Mounting Components... 9 Unit Control Box Detail - Until 5/ Unit Control Box Detail- 5/05 and Later Compressor Control Box Detail Way SA/SB Solenoid Valve & Tubing Cables and Sensors Starter- Factory Installed Units with MicroTech 200 Control Box Units with MicroTech II Control Box Starter- Field Installed Units with MicroTech 200 Control Box... 3 Units with MicroTech II Control Box Differential Pressure Switch Hot Gas Bypass Condenser & Evaporator Valves- Relief Valves, Shutoff Valves Liquid Line Expansion Valve, Ball Valve, King Valve, Flanges, Gaskets, O'Rings,Tubing Diagram Liquid Line Insulation Condenser Nomenclature Liquid Line Flange, Heads, Gaskets, Tubes Evaporator Nomenclature Liquid Line Flange, Heads, Gaskets, Tubes Compressor Nomenclature Mounting Brackets and Hardware Motor Drain Lines, Motor Cooling Lines, Oil Drain Lines Suction and Discharge Lines Front End Inlet Section Main Gear Train- High Speed Section Impeller, High Speed Gear & Associated Parts, Volute, Seals, Gears- Pinion & Bull Main Gear Train- Low Speed Section Low Speed Gear, Lock Plate, Bearings, Seals Gear Cover, Deflector, Lee Plug, Pipe Plugs... 6 Crankcase Heater... 6 Oil Circuit and Spin Down Oil Cooler, Spin Down Piston, Valves, Oil Lines, Mist Eliminator, Seals Oil Oil Pump Motor Section Critcal Parts List... CPL RPL / Page 2

3 Parts List Revision History Revision Date Description A thru I Revision history details archived. J 04/2 Page 6- Corrected Code 0 to Code E (was D) = Marine Box-Flanged. Page 8- Expanded and clarified info for OITS panel. Removed Ref Page 2- Corrected retrofit kit p/n to (was ) in footnote *. Page 25- Added "Until 7/05" to title. Page 26- Added page for "4-Way SA/SB Solenoid Valve & Tubing, 7/05 & later". Page 3- Removed Starter Back Cover Plate. Page 37- Added p/n's for change in 4/06 to EEXV. This affected Ref. 70, 702, 703, 704 & 70. Changed Ref. 76 for 22" to (was ) and Ref. 77 for 22" to (was P56LAAAAA). Added footnote 2. Page 38- Changed ref. 209 to one p/n for all evap sizes. Added footnote. Pages 45,46- Removed Head p/n info (deleted 2 pages). Added note to contact McQuay Parts for Head p/n's. Added page to expand and clarify info for Ref. 352 Head Gaskets. Pages 48,49- Removed Head p/n info (deleted 2 pages). Added note to contact McQuay Parts for Head p/n's. Added page to expand and clarify info for Ref. 352 Head Gaskets. Page 57- Added Ref. 44 Brass Union (until 7/05), Fitting (7/05 & later). Added footnote 3. Page 59- Corrected p/n to K (was K) in footnote 2. Page 60- Corrected descriptions for Ref. 438 to "Bearing- Pinion, Rear" and Ref. 440 to "Bearing- Pinion, Front". Page 68- Corrected footnote 3 to "...contact McQuay Parts..." (was SMG). K /6 Page 8: Corrected descriptions for Ref. 5 OITS Cables. Added Power Cord w/ac Adapter. Pages 2 and 22: Updated description for BACnet to MS/TP, was RS232. Page 48: Corrected description for Evaporator Gaskets. Page 58: Corrected p/n for O-Ring Kit in Footnote, was K. Page 63: Corrected p/n for O-Ring Kit in chart and in Footnote, was K. Page CPL: Added new page for Critical Parts List. L 2/7 Cover: Added Last Manufactured date. Daikin Applied, 3600 Industrial Park Blvd., P.O. Box 55, Minneapolis, MN (763) RPL / Page 3

4 Nomenclature Nameplate Locations and Part s Unit Dataplate pn: (units with factory mounted starters) pn: (units with free standing starters) Unit Dataplate pn: (units with factory mounted starters) pn: (units with free standing starters) End View- MicroTech 200 Units End View- MicroTech II Units Evaporator Dataplate pn: (until 8/03) pn: (8/03 & later) Compressor Dataplate pn: Compressor Dataplate pn: Condenser Dataplate pn: (until 8/03) pn: (8/03 & later) Front View RPL / Page 4

5 Nomenclature Unit Dataplate Units w/ Factory Mounted Starter Units w/ Free Standing Starter Model - Unit WDC 050 K Unit Model WDC= Water- Cooled Dual Compressor Centrifugal Chiller HDC= Water- Cooled Dual Compressor Centrifugal Chiller with Heat Recovery Condenser TDC= Templifier, Dual Compressor Centrifugal Impeller type H, J, K, M (050 only) Impeller Size 048= 4.8" Diameter 050= 5.0" Diameter Style - Unit E Always 'E' 6- Digit G.O. G.O. Item Serial - Unit STN U Plant Identification Abbreviation STN = Staunton U= Unit Year of Manufacture 00= = = = = 2004 etc. Serial (build sequence) Month of Manufacture 0= January 07= July 02= February 08= August 03= March 09= September 04= April 0= October 05= May = November 06= June 2= December RPL / Page 5

6 Nomenclature Model - Complete WDC 050K AE 0B Y Y B E246 RE 2LA B CC Y B C226 RLYY Code: LAYYY D4 370 CCYY YY B A IB 2LEYSA 22YY2YYY 044 H H2 B Code: B Y R Y A A 055 U B C Y Y Y Y Y Code: Model Type WDC= Water Cooled Dual Compressor Centrifugal Chiller HDC= Water Cooled Dual Compressor Heat Recovery Chiller TDC= Centrifugal Dual Compressor Templifier 2. Compressor Size/Impeller Type 048 (4.8" impeller) 050 (5.0" impeller): 048H, 048J, 048K, 050H, 050J, 050K, 050M 3. Gear Ratio Code (speed code) ZT, ZU, ZV, ZW, Z2, ZY, ZZ, AA, AB, AC, AD, AE, AF, AG, AH, AJ, AK, AL 4. Motor Horsepower/Voltage first 2 digits= horsepower, third digit= voltage 0= 05HP 3= 35HP 5= 50HP 60 Hz. Codes N= 200V B= 208V P= 220V V= 230V 4= 400V A= 440V R= 460V S= 480V D= 575V Q= 46V M= 2400V C= 3300V L= 460V 3= 2300V T= 4600V 2= 6600V 50 Hz. Codes E= 220V Y= 346V F= 380V G= 400V K= 45V H= 440V Z= 500V J= 3300V 6= 3000V 8= 6000V 9= 6600V 5. Refrigerant Contamination Protection Y= None 6. Sound Control Y= None W= Suction Shut Off Valve 7. Compressor Revision Level A= Rev. Level A B= Rev. Level B 8. Evaporator Description E222= Standard Evap., 22" Dia./2' Long E242= Standard Evap., 24" Dia./2' Long E262= Standard Evap., 26" Dia./2' Long E226= Standard Evap., 22" Dia./6' Long E246= Standard Evap., 24" Dia./6' Long E266= Standard Evap., 26" Dia./6' Long 9. Evaporator Tube Description first digit= Tube Count/ second digit= Tube type Tube Count 22" diameter; Q= 74 R= 88 S= 26; 24" diameter: Q= 246 R= 262 S= 29 T= 307; 26" diameter: P= 298 Q= 39 R= 346 S= 268. Tube Type E= Turbo EFP.025 Wall; F= Turbo EFP.028 Wall; Q= Turbo EFP.035 Wall 0. Evaporator Head Description first digit= of Water Passes:, 2, 3 second digit= Inlet Nozzle Location: L= Left R= Right third digit= Nozzle Type: A= Victaulic (std.); B= Flanged; C= Marine Box- Victaulic; E = Marine Box- Flanged. Evaporator Design Pressures first digit= Refrigerant Side Pressure: B= 80 PSIG; C= 200 PSIG; D= 225 PSIG second digit= Waterside Pressure: = 50 PSIG ASME; 2= 250 PSIG ASME; 3= 350 PSIG ASME; 4= 50 PSIG Non-ASME; 5= 300 PSIG None-ASME RPL / Page 6

7 2. Evaporator Leaving Water Temperature Code is listed in tenths of F (example 0450= 45.0 F) 3. Evaporator Tube Sheet & Head Material first digit= Tube Sheet Material: C= Carbon Steel (std.); N= Monel Clad; S= Stainless Steel Clad; T= Titanium Clad Steel second digit= Head Material: C= Carbon Steel (std.); E= Epoxy Coated 4. Evaporator Tube Cleaning System Y= None B= WSA Brushes 5. Evaporator Model Revision A= Revision A B= Revision B 6. Condenser Description C222= Standard Cond., 22" Dia./2' Long C226= Standard Cond., 22" Dia./6' Long S222= Split-Head Cond., 22" Dia./2' Long S226= Split-Head Cond., 22" Dia./6' Long 7. Tower Condenser Tube Description/Heat Recovery (Split Head Condenser Only) Tube Description first & third digit= Tube Count/ second & fourth digit= Tube type Tube Count 22" diameter: Q= 244 R= 304 S= 305 T= 347 U= 363 Tube Type L= Turbo CSL.025 Wall; N= Turbo CSL.028 Wall; P= Turbo CSL.035 Wall If there is no Heat Recovery Condenser digits 3 & 4= Y 8. Tower Condenser Head Description/Heat Recovery (Split Head Condenser Only) Head Description first & fourth digit= of Water Passes:, 2, 3 second & fifth digit= Inlet Nozzle Location: L= Left R= Right third digit= Nozzle Type: A= Victaulic (std.); B= Flanged; C= Marine Box- Victaulic; D= Marine Box- Flanged sixth digit= Nozzle Type: A= Victaulic (std.); B= Flanged If there is no Heat Recovery Condenser digits 4, 5 & 6= Y 9. Condenser Design Pressures first digit= Refrigerant Side Pressure: C= 200 PSIG; D= 225 PSIG; E= 250 PSIG; F= 275 PSIG; G= 300 PSIG second digit= Waterside Pressure: = 50 PSIG ASME; 2= 250 PSIG ASME; 3= 350 PSIG ASME; 4= 50 PSIG Non-ASME (std.); 5= 300 PSIG None-ASME 20. MaximumCondenser Leaving Water Temperature Code is listed in tenths of F (example 370= 37.0 F) 2. Condenser Tube Sheet & Head Material first & third digit= Tube Sheet Material: C= Carbon Steel (std.); N= Monel Clad; S= Stainless Steel Clad; T= Titanium Clad Steel second & fourth digit= Head Material: C= Carbon Steel (std.); E= Epoxy Coated If there is no Heat Recovery Condenser digits 3 & 4= Y 22. Condenser Tube Cleaning System YY= None Tower Cond./None HR Cond. YB= None Tower Cond./WSA Brushes HR Cond. BY= WSA Brushes Tower/None HR Cond. BB= WSA Brushes Tower/WSA Brushes HR Cond. 23. Condenser Model Revision A= Revision A B= Revision B 24. Pressure Vessel Code A= ASME (standard); B= Belgian; D= TUV (German); E= TUV (Austrian); J= Australian; K= Swiss; P= Chinese 25. Refrigerant Type 34=Refrigerant 34a Nomenclature Model - Complete Continued 26. Refrigerant Weight Total weight divided by 0 rounded to next whole number (example: 85/0= 082) 27. Main Expansion Valve/ Pilot Valve first digit= Main Expanion Valve: G= 50 ton; H= 80 ton; I= 250 ton; J= 300 ton second digit= Pilot Valve: A= 4 ton (R34a) B= 9 ton (R34a) D= 4 ton (TSC units) E= 9 ton (TSC units) RPL / Page 7

8 28. Controller Options MicroTech 200 first digit= Control Type: M= MicroTech second digit= Sensor Functions: A= Outdoor Air (OA) Thermistor S20; B= OA and HR; H= Heat Recovery(HR) Thermistors S2/S22 third digit= Language: E= English Language/English Units; M= English Language/Metric Units; J= Japanese; C= Chinese fourth digit= Instruments: M= Modem; Y= None fifth digit= Special Functions: A= Analog Outputs; B= Analog Outputs & Signal Converter; S= Signal Converter sixth digit= Enclosure: A= NEMA ; B= NEMA 4; C= NEMA 2 MicroTech II first digit= Control Type: 2= MicroTech II second digit= Size: L= Large; S= Small; H= Heat Recovery third digit= Language: E= English Language fourth digit= Instruments: M= Modem; Y= None fifth digit= Communications: B= BACnet; E= BACnet w/ethernet; L= LonWorks; M= MODBUS; P= Serial Port w/modem; S= Serial Port (RS232) sixth digit= Enclosure: A= NEMA 29. Starter Options first digit= Starter Type: 2= Wye-Delta Closed; 3= Across-The-Line; 4= Auto Transformer; 5= Primary Reactor; 6= Solid State V= Variable Frequency Drive second digit= Enclosure: 2= 72" High/Unit Mounted X 2; 5= 90" X 36" X 2" free standing; 7= Medium/High Voltage 90" X 36" X 36" free standing; 9= Med/High Voltage 90" X 36" X 36" free standing; A= 90" High for Field Mounting w/brackets & Cables; L= VFD free standing; M= VFD unit mounted; Q= 72" High Terminal Mounted X 2; R= 72" High Terminal Mounted third digit= Meters: Y= None fourth digit= Disconnect: Y= None fifth digit= Surge Protection Capacitor: 2= Surge Capacitor mounted in Compressor Motor Terminal Box; S= Surge Capacitor mounted in Starter Box; Y= None sixth digit= Phase Loss/Rotation Protection: Y= None seventh digit= Ground Fault Protection: Y= None eighth digit= Load Balance: Y= None 30. Rated Load Amps Actual RLA 3. Hot Gas Bypass H= Hot Gas Bypass (standard on HSC & TSC) Y= None 32. Insulation first digit= Condenser & Evaporator Shell Insulation: H= ¾" Closed Cell Foam Insulation on Evaporator Shell, Suction Piping, Compressor Inlet, MotorBarrel + High Humidity 2= Closed Cell Foam Insulation on Condenser Shell Only 3= -½" Closed Cell Foam Insulation on Evap. Shell, ¾" Insulation on Suction Piping, Comp. Inlet, MotorBarrel + High Humidity 5= Code H + Code 2 6= Sound Insulation on Condenser & Discharge Line 7= Sound Insulation on Discharge Line Only D= Daikin Specifications M= Code H + Code 7 N= Code 3 + Code 7 S= Code H + Code 6 T= Code 3 + Code 6 Y= None second digit= Condenser & Evaporator Head Insulation: Y= None; = Return Heads Only; 2= Return & Connection Heads 33. Water Pressure Differential Switch E= Evaporator C= Condenser B= Both Evaporator & Condenser Y= None 34. Paint = Standard Painting 35. Packaging = Standard Wood Skid; 2= Open Export Crate; 3= Totally Enclosed Export Crate; 4= Shipping Bag w/wood Skid 5= Shipping Bag Only; 6= Shipping Bag w/ Totally Enclosed Export Crate; 7= Shipping Bag w/open Export Crate; Y= None 36. Refrigerant Tag A= Full Factory Charge B= Holding Charge Nomenclature Model - Complete Continued RPL / Page 8

9 Nomenclature Model - Complete Continued 37. Miscellaneous Y= None X= Special (specials not covered in the normal code string) 38. Oil Cooler R= Refrigerant Cooled (standard) S= Water Cooled w/factory Solenoid 39. Rebate Y= None R= Rebate 40. Testing = Standard Factory Performance Test 2, 9, A, B, C, D, E, F, G, H, J, Q, S= Various Witness Tests 3, 4, 5, 6, 7, 8, K, L, M, N, P, R, T= Various Certified Performance Tests Y= None 4. Approval Listing A= ARI Approval U= UL C= Canadian UL V= ARI + UL D= Canadian ARI + UL Y= None 42. Latest Unit Model Revision A= Revision A 43. Tons Actual Tons 44. Startup Y= Export- No Startup U= Domestic Startup 7= Canadian Startup 45. Labor Warranty Y= Export Order, no labor warranty B= Domestic Order, st year labor warranty 7= Canadian Order, st year labor warranty 46. Extended Warranties Y= None C= Extended year parts; D= Extended year parts + Labor; E= Extended 2 year parts; F= Extended 2 year parts + Labor; G= Extended 3 year parts; H= Extended 3 year parts + Labor; J= Extended 4 year parts; K= Extended 4 year parts + Labor; (L thru S apply to Compressor/Drive Train Only) L= Extended year parts; M= Extended year parts + Labor; N= Extended 2 year parts; O= Extended 2 year parts + Labor; P= Extended 3 year parts; Q= Extended 3 year parts + Labor; R= Extended 4 year parts; S= Extended 4 year parts + Labor; 47. Inspections = Inspections Y= None 48. Purchased Labor 2= Purchased Labor Y= None 49. Supervision Services 3= Supervision Services Y= None 50. On-Site Instructions 4= On-Site Instructions 5= Traning Schools 6= Service Contracts 5. Refrigerant Warranty 0 thru 5= actual number of years 52.Delayed Warranty Start Y= None RPL / Page 9

10 Electrical Legend Sch. Sym. Description Location M, 2M Contactor Starter S, 2S Energizing Contactor Starter ADI Analog/Digital Input Board MicroTech 200 Control Box AOX Analog Output Board MicroTech 200 Control Box CAP Capacitor Lube Box (MicroTech 200) or Compressor Control Box (MicroTech II) CB Circuit Breaker MicroTech 200 or MicroTech II Unit Control Box CF Condenser Flow Switch Tube Sheet Support- MicroTech II Units CHW Evaporator Flow Switch Tube Sheet Support- MicroTech 200 Units CR Relay MicroTech II Compressor Control Box CS0- CS0 Sensors- Compressor Controller Throughout Unit- MicroTech II (see MicroTech II section for sensor placement) CTB, CTB2 Terminal Block Compressor Controller- MicroTech II Units CW Condenser Flow Switch Tube Sheet Support- MicroTech 200 Units DIST/ISO Dist. & Isolation Board MicroTech II Unit Controller EF Evaporator Flow Switch Tube Sheet Support- MicroTech II Units FVC Flux Vector Control VFD Panel (Code 29-= V) HP High Pressure Switch MicroTech 200 Panel HR Relay MicroTech II Compressor Controller KDI Keypad/Display MicroTech 200 Panel LR Relay MicroTech II Compressor Controller MCB Main Control Board MicroTech 200 Panel MCR Motor Control Relay Starter Panel OBA Output Board MicroTech 200 Panel OIM Operator Interface Module VFD Panel (Code 29-= V) OITS Operator Interface Touch Screen MicroTech II Units OL Oil Pump Overload Lube Box (MicroTech 200) or Compressor Control Panel (MicroTech II) OP Oil Pump Contactor Lube Box (MicroTech 200) or Compressor Control Panel (MicroTech II) pc02 Main Controller MicroTech II Unit Controller PHP High Pressure Transducer Discharge Nozzle plan LAN Cable Connects MicroTech II Controllers RES Transition Resistor Starter RMI Remote Meter Interface VFD (Code 29-= V) S00- S22 Sensor- MicroTech 200 Throughout the Unit (see MicroTech 200 section for sensor placement) SA/SB 4- Way Vane Speed Solenoid Lube Box (MicroTech 200 Units) or (Needle Valves) Compressor Gear Housing (MicroTech II Units) SC Signal Converter MicroTech 200 Control Box or MicroTech II Compressor Control Box T, T2, T3 Main Control Transformer Starter T2 24V Control Transformer MicroTech 200 Control Box T3 8V Control Transformer MicroTech 200 Control Box TB,TB2 Terminal Block Junction Box used w/field supplied starter TR Timing Relay Starter TRP Transition Resistance Protector Starter TSW Toggle Switch- Templifier MicroTech 200 Control Box (TSC or TDC only) US02- US0 Sensor- Unit Controller Throughout Unit- MicroTech II (see MicroTech II section for sensor placement) UTB Unit Control Terminal Block MicroTech II Unit Control Box VC Vane Close Switch Lube Box- MicroTech 200 Unit VR Voltage Relay Lube Box- MicroTech 200 Unit or MicroTech II Compressor Control Box RPL / Page 0

11 Control Box- MicroTech 200 Mounting of Unit Control Panel and Lube Box Lube Box Mounting MicroTech 200 Control Box Mounting Ref. Description Part Qty. No. 4 Shelf- Long Shelf- Short Screw Washer- Plain Washer- Lock Coupling- Half Union Screw- Cap Nut- Hex Washer- Lock Control Box- MicroTech Screw Washer- Plain Washer- Lock Nut- Hex Bracket- Lube Box 22" & 26" Evaporator " Evaporator Bracket- Control Box 22" Evaporator " Evaporator " Evaporator Lube Box Long shelf used on units with free standing starters (unit mounted junction boxes); Short shelf used on units with factory mounted starters. 2 See following pages for component detail. 3 Qty. is 6 for units with free standing starters (long shelf). RPL / Page

12 Control Box- MicroTech 200 Front Panel & Inside of Micro Control Door Assembly Inside of Micro Door Ass'y Ref. Description Part Qty. No. 42 Toggle Switch- Contrast Control Membrane Switch- Control English Language Japanese Language Chinese Language KDI Control Cover- KDI Board Hinge- Painted Latch- Door Lock Door- Power Door- Control N/S Cover- Sensor N/S= Not Shown on Diagram. RPL / Page 2

13 Control Box- MicroTech 200 Interior Panel Diagram Modem Detail See Detail above Micro Door Ass'y (see previous page) RPL / Page 3

14 Control Box- MicroTech 200 Interior Panel Components Ref. Description Specification Part Qty. No. 02 Main Controller- MicroTech M ADI Board until 3/ ADI Board 3/03 and later Mount- ADI Board Cord Set- PCB Interface Ribbon Cable 50C 8/24 OB Ribbon Cable 50C 3" Clip, Flat- Cable Terminal Block AD AD Transformer- Control.03 KVA 24/8V Terminal Block 9 Pole Row Cover- Terminal Block Bracket- Terminal Block Insulation- Fishpaper Board- Signal Converter SC Spacer- Signal Converter Toggle Switch (TSC Templifier Only) TSW Output Board 24 SM Board- Guardistor Circuit Breaker 3A P Transformer 50 VA 20/24V Terminal Block Unit & Field Varistor 30 VRMS Ferrules- Dual Wires 8 mm Mount- Circuit Board Socket, Relay- High Pressure Relay- High Pressure HP Relay- Output Board AOX Board 4 Channel Mount- AOX Board Cord Set 9" 28AWG Bracket- Magnetic Latch Magnetic Latch Fastener- Magnetic Latch Gasket.2 X Bushing- Snap In 2.00" Bushing- Snap In.50" Plug- Terminal Housing 4 Pin Female Plug- Terminal Housing 6 Pin Female Terminal- Socket 24-8 AWG Modem 4.4 BAUD Cord Set- Modem Gasket.25 X Bracket- Modem Mounting Bracket- Vertical, Modem Controller needs to be programmed. The Unit serial number is required to properly program the controller. RPL / Page 4

15 Control Box- MicroTech 200 Sensors S6 S02 S5 S3 S20 S00 S4 S7 S0 S0 S2 S22 S8 S2 S09 S08 Ref. Description Part Qty. No. S00 Sensor- Evaporator Leaving Water Temp S0 Sensor- Evaporator Entering Water Temp S02 Sensor- Compressor Suction Temp S08 Sensor- Condenser Liquid Line Temp S09 Sensor- Condenser Entering Water Temp S0 Sensor- Condenser Leaving Water Temp S2 Sensor- Compressor Discharge Temp S3 Sensor- Oil Feed Temp S4 Sensor- Oil Sump Temp S5 Oil Vent Low Pressure Transducer S6 Evap. Refrigerant Low Press. Transducer S7 Cond. Refrigerant High Press. Transducer S8 Oil Feed Gauge High Pressure Transducer S20 Outdoor Air Sensor- 50 ft S2 Entering Heat Recovery Temp. Sensor S22 Leaving Heat Recovery Temp. Sensor N/S Boot- Transducer Protection N/S Cable- Pressure Transducer, 0 ft N/S Cable- Pressure Transducer, 5 ft N/S High Pressure Switch- 90 PSI N/S= Not Shown on Diagram. Sensors shown are typical for one control box/compressor. Each unit has two control boxes with identical sets of sensors. RPL / Page 5

16 Control Box- MicroTech 200 Compressor Lube Box Assembly Diagram 28 28A RPL / Page 6

17 Control Box- MicroTech 200 Compressor Lube Box Assembly Components Ref. Sch. Description Part Qty. No. Sym. Lube Box Assembly- Complete Box Cover VC Switch- Pressure Differential Washer SA SB 4 Way Solenoid Valve Connector.25F X.44T Coupling.25F Tee.25F X.25F X.25F Union- Brass.25F Mounting Channel Clamp- Terminal Block Terminal Block End Terminal Block Section Strap- Capacitor VR Relay- Voltage 8A CAP Capacitor 6 MFD 250V OL Overload until 5/ OL Overload 5/02 & later A Heater- Overload 5/02 & later only OP Contactor- Oil Pump 4P 2NO/2NC 2A Fitting.50" Jumper- Terminal Block Line Assy Line Assy Line Assy Line Assy RPL / Page 7

18 Control Box- MicroTech II Unit Control Box & Operator Interface Panel Mounting Components NOTE: Original design Operator Interface Panel shown. Mounting hardware is the same for all panels. Ref. Description Specification Part Qty. No. 5 Operator Interface Panel (OITS), Original until 5/05* Cable, 7-wire single, Original until 5/05* Connector Only, Original until 5/05* Operator Interface Panel w/cables, 2 Beige 5/05 & later* Operator Interface Panel w/vga & Serial cables, 5 Beige 5/05 & later* Operator Interface Panel w/ VGA & Serial cables, 5 Black 5/05 & later* Cable, 2V DC Power w/4 Pin Molex & 2 Plugs all 5/05 & later* Cable, Serial all 5/05 & later* Cable Kit (includes VGA & Serial cables) all 5/05 & later* Power Cord w/ac Adapter all 5/05 & later* Support Arm Assy, Beige (includes swivel pin, washers, & nut) Support Arm Assy, Black (includes swivel pin, washers, & nut) Block- Mount Shelf Screw Washer- Plain Washer- Lock Spring Washer- Lock Washer- Nylon Nut Screw * For units built /05 to 5/05, check unit to verify which panel is installed. Original panel had single cable, later panels have 3 cables. RPL / Page 8

19 Control Box- MicroTech II Compressor Control Box Mounting Components Compressor Control Box Ref. Description Specification Part Qty** No. 26 Plate- Mounting Screw Washer- Nylon Washer- Lock External Tooth Washer- Plain Washer- Lock Nut Screw Washer- Lock External Tooth Washer- Plain Washer- Lock Spring Nut Bracket- Evaporator 22" & 26" Evaporator Bracket- Evaporator 24" Evaporator ** Quantities are for the entire unit. RPL / Page 9

20 Control Box- MicroTech II Unit Control Box Detail - Until 5/05* Diagrams Modem Detail (Code 28= 2LEYPA) Unit Control Detail 7 8 RPL / Page 20

21 Control Box- MicroTech II Unit Control Box Detail - Until 5/05* Components Ref. Sch. Description Specification Part Qty. No. Sym. Enclosure- No Emergency Cut-Off Switch until 2/ Enclosure- w/emergency Cut-Off Switch 2/03 & later Bracket- Switches UTB Terminal Block w/rail pc02 Controller- with Display Large pc02 Controller- with Display Small CB Circuit Breaker 5 Amp SP Switch 25V Serial Gateway RS 232 Code 28, digit 5= P,S MODBUS Code 28, digit 5= M LonWorks Code 28, digit 5= L BACnet MS/TP Code 28, digit 5= B BACnet w/ethernet Code 28, digit 5= E Board- Distribution & Isolation with connectors Connector Large Controller Connector Small Controller Switch- Emergency Cut-Off Bracket- Modem Code 28= 2LEYPA Bracket- Modem Code 28= 2LEYPA Circuit Board- Modem Code 28= 2LEYPA Bracket Code 28= 2LEYPA Cord Set- Modem Code 28= 2LEYPA Cord Set- BACnet Code 28= 2LEYPA Serial Gateway- RS232 Code 28= 2LEYPA N/S Connector- Service N/S= Not Shown on diagram. Controller must be programmed before shipping. Unit serial number and software code (located on controller label) are required when ordering to insure proper software installation. Large controllers are standard, there are a few small controllers in the field (see code 28). * This control box was used with the original design operator interface panel (which is connected to the control box with one seven-wire cable). A new design flat screen operator interface panel can be retrofitted for use with this control box using retrofit kit p/n RPL / Page 2

22 Control Box- MicroTech II Unit Control Box Detail- 5/05 and Later Ref. Sch. Description Specification Part Qty. No. Sym. 2 Bracket- Switches UTB Terminal Block w/rail pc02 Controller- with Display CB Circuit Breaker 5 Amp SP Switch 25V Serial Gateway RS 232 Code 28, digit 5= P,S MODBUS Code 28, digit 5= M LonWorks Code 28, digit 5= L BACnet MS/TP Code 28, digit 5= B BACnet w/ethernet Code 28, digit 5= E Relay 24V Connector Holder- Relay Switch- Emergency Cut-Off UCM Board- Universal Communications PC Assy- Single Board PC N/S Connector- Service N/S= Not Shown on diagram. Controller must be programmed before shipping. Unit serial number and software code (located on controller label) are required when ordering to insure proper software installation. RPL / Page 22

23 Control Box- MicroTech II Compressor Control Box Detail Diagram RPL / Page 23

24 Control Box- MicroTech II Compressor Control Box Detail Components Ref. Sch. Description Specification Part Qty** No. Sym. pc02 Controller T2/T3/T4 Transformer 20V- 24V 00VA OP Contactor- Oil Pump 4P 2A 24VAC Coil OL Overload- Oil Pump 48DA8AA VR Relay- Voltage 8A CTB Terminal Block w/rail CAP Capacitor- 60 Hz. Units 6 MFD 250V CAP Capacitor- 50 Hz. Units 89 MFD 250V CB Circuit Breaker 6A LR/CR/HR Relay 24VAC 0A Mounting Rail- Relays Springs- Relay Hold Down Standoff- Nylon Post SC Signal Converter Board Guardistor Board CTB2 Terminal Block Board- Transducer 3 Transducers Cover Bushing Heater- Overload Connector Kit- Transducer Connector Kit- Controller Barrier ** Quantities are for one control box. Each unit has two identical compressor control boxes. Controller must be programmed before shipping. Unit serial number and software code (located on controller label) are required when ordering to insure proper software installation. RPL / Page 24

25 Control Box- MicroTech II 4- Way SA/SB Solenoid Valve & Tubing Until 7/ Port 'A' Inlet Port 'P' Exhaust Port 'E' 754 Port 'B' Ref. Description Specification Part Qty** No. 746 Connector.25" Flare x.44" Thread Fitting- Straight Thread Fitting- Straight Thread Fitting- Straight Thread Valve- SA/SB 4- Way Vane Control Pressure Differential Switch- VC Vane Close Bracket- SA/SB Valve Mounting Coupling.25" Flare Fitting- Nut Fitting- Sleeve Tube.25" D x 54" L Tube.25" D x 36" L Tube.25" D x 2" L Tee.25" ODS Tube.25" D x 22" L Screw Tube.25" D x 22" L Distributor.25" x.25" Tube.25" D x 52" L Flare Nut N/S MicroTech Pressure Connector N/S= Not Shown on above diagram. **Quantities listed are for ONE compressor. Each compressor has identical components. Connects to control box oil gauge transducer. Detail shown below Ref # Description Part No. Qty. 78 Tee Schrader Valve Tube RPL / Page 25

26 Control Box- MicroTech II 4- Way SA/SB Solenoid Valve & Tubing 7/05 and Later Port 'A' Inlet 755 Port 'P' Exhaust Port 'E' Port 'B' Ref. Description Specification Part Qty** No. 746 Connector.25" Flare x.44" Thread Fitting- Straight Thread Fitting- Straight Thread Valve- SA/SB 4- Way Vane Control Pressure Differential Switch- VC Vane Close Bracket- SA/SB Valve Mounting Fitting- Nut Fitting- Sleeve Tube.25" D x 54" L Tube.25" D x 36" L Tube.25" D x 2" L Tee.25" ODS Tube.25" D x 22" L Screw Tube.25" D x 22" L Distributor.25" x.25" Tube.25" D x 52" L Flare Nut N/S MicroTech Pressure Connector N/S= Not Shown on above diagram. **Quantities listed are for ONE compressor. Each compressor has identical components. Connects to control box oil gauge transducer. Detail shown below Ref # Description Part No. Qty. 78 Tee Shrader Valve Tube RPL / Page 26

27 Control Box- MicroTech II Cables and Sensors Diagrams HDC Only Unit Sensor Location and Details NOTE: The sensor diagram below shows the sensor layout for one compressor. Each compressor controller has an identical set of sensors and all compressor sensors (those labeled "CSXX") shown apply to either compressor Liquid Line Tubing Liquid Line Tubing RPL / Page 27

28 Control Box- MicroTech II Cables and Sensors Components Ref. Sch. Description Specification Part Qty. 5 No. Sym. 7 Cable- Operator Interface Panel until 5/ Connector Only Conduit Fitting.375" Conduit Fitting.250" Valve Core Sensor Well until 9/ Sensor Well 9/02 and later Cable, Empty- Comp Heater Cable- Oil Pump Heater Cable- Solenoids Cable- Differential Pressure Switches ** 49 Cable- Guardistor # Compressor Cable- Starter 2 Units with Factory Mounted Purchased Starter Units with Field Installed Purchased Starter Cable- Guardistor #2 Compressor CS05 Sensor Sensor *** 553 Boot- Transducer Cable- Transducer HP Switch- High Pressure until 6/ HP Switch- High Pressure 6/03 & later Cable- High Pressure Switch CS02/06 Transducer- High 40 PSI CS0/03 Transducer- Low 32 PSI plan Cable- plan between Unit & Compressor Controllers **** 998 Cable- Power between Unit & Compressor Controllers ***** ** There is one cable per DPS (see code 33). Each cable is 6 ft. of the above referenced p/n. *** Quantity is 2 on WSC/TSC units, 4 on HSC units. **** There are three cables unit controller to # comp. controller; unit controller to #2 comp. controller; #comp. controller to #2 comp. controller. Each cable is made from 5 feet of the above listed p/n. *****There are two cables each made from 5 feet of above listed part number. Cables contain 90 fitting p/n and Anti- Short bushing p/n See Starter section for all starter- related cables and mounting components. 3 CS04, CS07, CS09, CS0, US02, US03, US04, US05 [ US09 & US0 on HDC units only]. 4 Paste for sensor well is p/n Quantities listed are for the entire unit. 6 This cable was used with the original operator interface panel. The new flat screen panel uses a VGA cable and a serial cable which comes with the panel. Unit Control Sensor Application Sensor US02 US03 US04 US05 US09 US0 Application Evaporator Entering Water Temp. Condenser Entering Water Temp. Condenser Leaving Water Temp. Liquid Line Temp. Heat Recovery Entering Water Temp. Heat Recovery Leaving Water Temp. Compressor Control Sensor Application Sensor Application CS0 Oil Sump Pressure CS02 Oil Feed Gauge Pressure CS03 Evap. Refrigerant Pressure CS04 Oil Sump Temperature CS05 Compressor Suction Temp. CS06 Cond. Refrigerant Pressure CS07 Compressor Discharge Temp. CS08 % Compressor Amps (Starter) CS09 Oil Feed Temperature CS0 Evap. Leaving Water Temp. RPL / Page 28

29 Starter- Factory Installed Units with MicroTech 200 Control Box Cables, Mounting Components Ref. Description Specification Part Qty. No. 37 Bracket- Starter Mounting Cable To # Compressor Control Box Cable To #2 Compressor Control Box Cable To Compressor 44 RLA Max. Motors All Compressor Terminals RLA Max. Motors All Compressor Terminals RLA Max. Motors All Compressor Terminals RLA Max. Motors All Compressor Terminals RLA Max. Motors All Compressor Terminals RLA Max. Motors Compressor Terminals RLA Max. Motors Compressor Terminals RLA Max. Motors Compressor Terminals RLA Max. Motors Compressor Terminals RLA Max. Motors Compressor Terminals RLA Max. Motors Compressor Terminals RLA Max. Motors Compressor Terminals RLA Max. Motors Compressor Terminals Nut Angle Screw.50 x Washer- Lock.50 Nom Angle Bracket Cover- Terminal Box Screw 90-6 x Washer- Plain.5 ZPS Screw.37 x Washer- Lock.375 ZPS Nut Washer- Plain.375 ZPS Motor RLA is indicated on the compressor data plate. RPL / Page 29

30 Starter- Factory Installed Units with MicroTech II Control Box Cables, Mounting Components Ref. Description Specification Part Qty. No. 37 Bracket- Starter Mounting Cable To # Compressor Control Box Cable To #2 Compressor Control Box Cable To Compressor 44 RLA Max. Motors All Compressor Terminals RLA Max. Motors All Compressor Terminals RLA Max. Motors All Compressor Terminals RLA Max. Motors All Compressor Terminals RLA Max. Motors All Compressor Terminals RLA Max. Motors Compressor Terminals RLA Max. Motors Compressor Terminals RLA Max. Motors Compressor Terminals RLA Max. Motors Compressor Terminals RLA Max. Motors Compressor Terminals RLA Max. Motors Compressor Terminals RLA Max. Motors Compressor Terminals RLA Max. Motors Compressor Terminals Nut Screw.50 x Washer- Lock.50 Nom Angle Bracket Cover- Terminal Box Screw 90-6 x Washer- Plain.50 ZPS Screw Washer- Lock.375 ZPS Nut- Hex Washer- Plain.375 ZPS Motor RLA is indicated on the compressor data plate. RPL / Page 30

31 Starter- Field Installed Units with MicroTech 200 Control Box Junction Box JB JB2 Ref. Description Specification Part Qty. No. 2 Door Hinge- Painted Latch- Door Screw.37 x Washer- Lock.375 ZPS Back Panel Terminal- Power Terminal Block- 30 MA TB & TB Bushing.75" Diameter Terminal RLA Max. Motors Terminal 206 RLA Max. Motors Terminal RLA Max. Motors Terminal RLA Max. Motors Washer- Plain.375 ZPS Screw Washer- Plain Washer- Lock Shelf- Control/Terminal Boxes Bracket- Terminal Box 22" dia. evap Bracket- Terminal Box 24" dia. evap Bracket- Terminal Box 26" dia. evap Screw.25 x Washer- Plain.25 ZPS Washer- Lock.25 ZPS Nut- Hex Motor RLA is indicated on the compressor data plate. RPL / Page 3

32 Starter- Field Installed Units with MicroTech II Control Box Junction Box Diagram Junction Boxes Mounting End View Junction Box Assy Detail (typical for both) Terminal Block Assy (Detail Below) Junction Box Terminal Block Assy (typical for both) 896 RPL / Page 32

33 Starter- Field Installed Units with MicroTech II Control Box Junction Box Components Ref. Description Specification Part Qty. No. Box Assembly Door Hinge- Painted Screw- Backplate.37 x Washer, Lock- Backplate.375 ZPS Back Panel Terminal- Power Terminal Block- 30 MA TB & TB Bushing.75" Diameter Terminal RLA Max. Motors Terminal 238 RLA Max. Motors Terminal RLA Max. Motors Terminal 348 RLA Max. Motors Terminal 399 RLA Max. Motors Terminal 460 RLA Max. Motors Washer, Plain- Backplate.375 ZPS Screw- Junction Box to Shelf Washer, Plain- Junction Box to Shelf Washer, Lock- Junction Box to Shelf Extension- Control Box Cover- Control Box Extension Shelf- Terminal Box Bracket- Terminal Box 22" dia. evap Bracket- Terminal Box 24" dia. evap Bracket- Terminal Box 26" dia. evap Screw- Comp. Control Box to Extension x Washer, Lock- Comp. Control Box to Extension.64 ZPS Screw- Extension to Junction Box.25 x Washer, Lock- Extension to Junction Box.25 ZPS Nut, Hex- Extension to Junction Box Bracket- Terminal Block Terminal Block Cover- Terminal Block Hex Nut N/S Latch- Door N/S= Not Shown on Diagram. Motor RLA is indicated on the compressor data plate. RPL / Page 33

34 Differential Pressure Switch Factory Mounted & Wired (Code 33= B, C or E) Switches, Wells, Power Cables, Fittings 667A 667C 4 Wiring- MicroTech 200 Control 667B 42 Well Detail (ref. 667) Until 5/ /A6: CHW- NO 57/A7: CH- NO 525/A25: CHW & CH- C Wiring- MicroTech II Control Ref. Description Part Qty.* No. 4 Cable- Evaporator DPS MicroTech 200 Control MicroTech II Control (until 5/04) ft. MicroTech II Control (5/04 & later) Cable- Condenser DPS MicroTech 200 Control MicroTech II Control (until 5/04) ft. MicroTech II Control (5/04 & later) Differential Pressure Switch (until 5/04) Differential Pressure Switch (5/04 & later) Elbow- 90 (until 5/04) Flare Nut (2 per tube) (until 5/04) Sensor Well (until 5/04) A Elbow (until 5/04) B Tube (until 5/04) C Nozzle (until 5/04) Well (5/04 & later) Bracket- Switch (until 5/04) Well N/S Fitting (5/04 & later) /250: EF- NO 52/252: CF- NO 49/249/5/25: EF & CF- C NOTES: The water pressure differential switch is an optional component. It is factory installed and wired when code 33= E (evaporator only), C (condenser only) or B (both condenser and evaporator). The switches used for either the MicroTech 200 or the MicroTech II control types are the same as are the wells. However the schematic designations are different. MicroTech 200 units designate the Evaporator & Condenser switches as CHW & CH, while the MicroTech II units designate the same switches as EF & CF. The only component part number difference of note are the power cables. *Quantities are based on the presence of both DPS (Code 33= B). If code 33= E or C part numbers 65 & 656 quantities are & 4 respectively, and only one cable (4 if C33= E or 42 if C33= C) is used. If only one DPS is used, the well (ref. # 667) has a quantity of (used on the vessel with the DPS) and (used on the vessel without the DPS). Differential Pressure Switch- None (Code 33= Y) Wells Ref. Description Part Qty. No. N/S Sensor Well (Evap & Cond in/out nozzles) N/S= Not shown on diagram RPL / Page 34

35 Hot Gas Bypass Valves, Connectors, Tubing Diagram RPL / Page 35

36 Hot Gas Bypass Valves, Connectors, Tubing Components Ref. Description Specification Part Qty. No. 92 Insulation- Tube.625" ft. 244 Tube Valve- Ball until 0/ Valve- Ball 0/03 & later Tube Tube- Hot Gas 22" Evaporator Tube- Hot Gas 24" & 26" Evaporator Until 4/ /06 & Later Tube- Hot Gas 22" Evaporator Tube- Hot Gas 24" & 26" Evaporator Until 4/ /06 & Later Valve- Hot Gas Bypass 27 Ton Until 4/ EEXV 4/06 & Later Coupling- Reducing.625" ODS x.375" ODS Until 4/ /06 & Later Tube Valve- Refrigerant Shut Off.38" ODS x.38" ODS Tee.25" ODS non- reducing Tube Until 4/ Tube 4/06 & Later Tube- Hot Gas 22" Evaporator Tube- Hot Gas 24" & 26" Evaporator Tee- Reducing 2.625" ODS x 2.625" ODS x.25 ODS Tube- Hot Gas Tee- Reducing 2.625" ODS x.625" ODS x.25 ODS Tube- Hot Gas 22" Evaporator Tube- Hot Gas 24" & 26" Evaporator Tube- Oil Drain 22" Evaporator Tube- Oil Drain 24" & 26" Evaporator Pipe 22" Evaporator Pipe 24" & 26" Evaporator P204LAAAAA 78 Pipe 22" Evaporator Pipe 24" & 26" Evaporator N/S Cable- Hot Gas Valve to Unit Control Box N/S= Not shown on diagram. Also has a welded adapter p/n The drawing illustrates the original design. In the new design (EEXV), there is a tube ref. # 70 and reducer ref. # 704 on both ends of the HGBP (EEXV) Valve. RPL / Page 36

37 Condenser & Evaporator Valves Relief Valves, Shutoff Valves Ref. Description Specification Part Qty. No. 206 Valve- 3 Way Shutoff " FPT Cap for 3 Way Shutoff Valve Elbow Pipe Nipple- 2" standard Pipe Nipple- 3" units with cond. sound insulation Valve- Evaporator Relief Valve- Relief Code 9-= D 225 PSI Code 9-= E 250 PSI Code 9-= F 275 PSI Code 9-= G 300 PSI Valve- Shutoff.625" Cap for Shutoff Valve Flare Cap.625" Code 32 must = 6*, S*, or T*. 2 Until 7/05, units with 22" Evaporator used p/n P/n is a direct replacement. RPL / Page 37

38 Liquid Line Expansion Valve, Ball Valve, King Valve, Flanges, Gaskets, O'Rings,Tubing Diagram Pilot Valve Tubing Ton TXV Tubing Ton TXV Tubing Condenser End View King Valve to Condenser Detail RPL / Page 38

39 Liquid Line Expansion Valve, Ball Valve, King Valve, Flanges, Gaskets, O'Rings,Tubing Components Ref. Description Specification Part Qty. No. 202 Valve- Shutoff 5/8" Flare Receiver Valve Cap- Shutoff Valve Bonnet- Flare Nut- Flare Bonnet- Flare Tee- Non Reducing ODS Coupling- Half Union.50F x.50p Tube Flange- Evap Inlet O'Ring- Evap. Inlet Screw.75 x Tube Valve- Shutoff 3/8" Flare Receiver Valve Cap- Shutoff Valve Tube Strainer Tube- Pilot E22/C22 Stack w/ 50 TXV E24/C22 & E26/C22 Stacks w/ 50 Ton TXV E22/C22 Stack w/ w/ 200, 250 or 300 Ton TXV E24/C22 & E26/C22 Stacks w/ w/ 200, 250 or 300 Ton TXV Expansion Valve- Pilot Tube Coupling- Half Union.50F x.25p Flange Kit Adapter Tube Assembly- Liquid Tube- Elbow ODS x ODS Tube- 50 Ton TXV Tube- 200/250/300 Ton TXV Reducer ODM x 2.25 ODS 50 Ton TXV Only Expansion Valve- Main 50 Ton (Code 27-= H) Flange Kit Set- 50 Ton TXV Pilot Operator Kit- 50 Ton TXV Expansion Valve- Main 200 Ton (Code 27-= I) Flange Kit Set- 200 Ton TXV Gasket Kit- 200 Ton TXV Expansion Valve- Main 250 Ton (Code 27-= J) Flange Kit Set- 250 Ton TXV Gasket Kit- 250 Ton TXV Expansion Valve- Main 300 Ton (Code 27-= K Flange Kit Set- 300 Ton TXV Gasket Kit- 300 Ton TXV Tube contains one () each; schrader valve p/n , valve cap p/n , valve core , sight glass saddle ( BEFORE 0/04) and sight glass cap p/n ( before 0/04). 2 This valve is no longer manufactured. When existing stock is depleted it may be replaced with p/n and qty. 2 reducers p/n RPL / Page 39