INTRODUCTION

This manual covers only the mechanical aspects of WHR chillers equipped with the MicroTech reciprocating chiller con-
trol. All of the operating, safety control and installation requirements of the MicroTech control are coveted in the separate
Installation and Maintenance Bulletin 493, which must be consulted before startup and operation is attempted.

GENERAL DESCRIPTION
McQuay Type WHR SEASONPAK water chillers are de- port type thermal expansion valves. Other features include
signed for indoor installations and are compatible with either compressor crankcase heaters, recycling pumpdown during
air or water as a condensing medium. Each unit is complete- “on” or “off” seasons, compressor lead-lag switch to alter-
ly assembled and factory wired before evacuation, charging nate the compressor starting sequence, and sequenced star-
and testing. Each unit consists of multiple accessible hermetic ting of compressors.
compressors, replaceable tube dual circuit shell-and-tube The electrical control center includes. all safety and operat-
evaporator, water cooled condenser, and complete or partial ing controls necessary for dependable automatic operation.
refrigerant piping depending on the condensing medium. Compressors are not fused, but may be protected by op-
Liquid line components that are included are manual liquid tional circuit breakers, or may rely on the field installed
line shutoff valves, charging valves, filter-driers, liquid line fused disconnect for protection.
solenoid valves, sightglass/moisture indicators, and balance

NOMENCLATURE
W HR - 040 D W - Basic Unit with Single Water Cooled Condenser per Refrigerant Circuit

H- Basic Unit with Dual Water Cooled Condensers per Refrigerant Circuit

Nominal Capacity (Tons)

INSPECTION
When the equipment is received, all items should be careful- be checked before unloading the unit to be sure that it agrees
ly checked against the bill of lading to insure a complete ship- with the power supply available. Physical damage to unit after
ment. All units should be carefully inspected for damage upon acceptance is not the responsibility of McQuay.
arrival. All shipping damage should be reported to the car- NOTE: Unit shipping and operating weights are available
rier and a claim should be filed. The unit serial plate should in the physical data table (pages 21 through 23).

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. CAUTION: Sharp edges are a potential injury hazard.
Avoid contact.
HANDLING
Every model WHR SEASONPAK water chiller with water Should the unit be damaged, allowing the refrigerant to
cooled condensers (Arrangements W and H) is supplied with escape, there may be danger of suffocation in the equipment
a full refrigerant charge. A holding charge is supplied in con- area since the refrigerant will displace the air. Avoid expos-
denserless models (Arrangement A). For shipment the charge ing an open flame to refrigerant. Care should be taken to avoid
is contained in the condenser and is isolated by the manual rough handling or shock due to dropping the unit. NEVER
condenser liquid valve and the compressor discharge ser- LIFT, PUSH OR PULL UNIT FROM ANYTHING OTHER
vice valve. THAN THE BASE.

MOVING THE UNIT I

The McQuay SEASONPAK water chiller is mounted on heavy Figure 1.
wooden skids to protect the unit from accidental damage and
to permit easy handling and moving.
It is recommended that all moving and handling be per-
formed with the skids under the unit when possible and that
the skids not be removed until the unit is in the final location.
When moving the unit, dollies or simple rollers can be
used under the skids.
Never put the weight of the unit against the control box.
In moving, always apply pressure to the base on skids on-
ly and not to the piping or shells. A long bar helps move the
unit easily. Avoid dropping the unit at the end of the roll.
If the unit must be hoisted, it is necessary to lift the unit
by attaching cables or chains at the lifting holes in the
evaporator tube sheets. Spreader bars must be used to pro-
tect the control cabinet and other areas of the chiller (see
Figure 1).

IM 508 / Page 3
 Do not attach slings to piping or equipment. Move unit in optional acoustical enclosure, there will be extension brackets
the upright horizontal position at all times. Set unit down gently attached to the evaporator tube sheets. These brackets will
when lowering from the trucks or rollers. be used for hoisting the unit and should be removed when
NOTE: On unit sizes 120 through 240D, ordered with the unit is in place.

LOCATION
Unit is designed for indoor application and must be located trol box is supplied as temporary protection during transfer.
in an area where the surrounding ambient temperatures are A reasonably level and sufficiently strong floor is all that
40°F or above. A good rule of thumb is to place units where is required for the SEASONPAK water chiller. If necessary,
ambients are at least 5 degrees above the leaving water additional structural members should be provided to transfer
temperature. the weight of the unit to the nearest beams.
Because of the electrical control devices, the units should NOTE: Unit shipping and operating weights are available
not be exposed to the weather. A plastic cover over the con- in the physical data table, pages 21 through 23.

SPACE REQUIREMENTS FOR CONNECTIONS AND SERVICING

The chilled water piping for all units enters and leaves the Figure 2. Clearance requirements
cooler from the rear, with the control box side being the front
side of the unit. A clearance of 3 to 4 feet should be pro-
vided for this piping and for replacing the filter-driers, for ser-
vicing the solenoid valves, or for changing the compressors,
should it ever become necessary.
The condenser water piping enters and leaves the shell
from the ends. Work space must be provided in case water
regulating valves are being used and for general servicing.
Clearance should be provided for cleaning condenser tubes
or for removing cooler tubes on one end of the unit as
specified in Table 1. It is also necessary to leave a work area FRONT
on the end opposite that used for replacement of a cooler tube. 0' I 20
Table 1. Minimum recommended clearance requirements

0 Minimum clearance required for removal and replacement of cooler tubes

(either end).

PLACING THE UNIT

The small amount of vibration normally encountered with the vibration isolator section for additional mounting information.
SEASONPAK water chiller makes this unit particularly desir- NOTE: On the WHR 120D thru 240D, shipping bolts are
able for basement or ground floor installations where the unit used to secure the compressor rails to the evaporator
can be bolted directly to the floor. The floor construction brackets. Remove these and discard after unit is mounted and
should be such that the unit will not affect the building struc- before unit is started.
ture, or transmit noise and vibration into the structure. See

VIBRATION ISOLATORS
Rubber-in-shear or spring isolators can be furnished and field Figure 3. Isolator Locations
placed under each corner of the package. It is recom-
mended that a rubber-in-shear pad be used as the minimum
REPlR a
isolation on all upper level installations or areas in which vibra-
;04 3 0
tion transmission is a consideration.
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 run-
ning under the main unit supports. Adjust spring type mount-
ings so that upper housing clears lower housing by at least
l/4 ” and not more than l/z “. A rubber anti-skid pad should be
used under isolators if hold-down bolts are not used.
Vibration eliminators in all water piping connected to the
SEASONPAK water chiller are recommended to avoid strain-
ing the piping and transmitting vibration and noise.

Page 4 I IM 508
 Table 3. Spring Flex Isolators Figure 4. Spring Flex Mountings

ADJUST MOUNTING SO UPPER

HOUSING CLEAR3 LOWER HOUSING
‘/2” DIA SY AT LEAST %S 8 NOT
POSITIONING PIN

ACOUSTICAL NON-SKID
NEOPRENEPAD

Figure 5. Single Neoprene-in-Shear

Mounting “D” D,A

“S” DIA
POSITIONING PIN

WATER PIPING
GENERAL
Since regional piping practices vary considerably, local or- the water before it enters the unit or the pump is recom-
dinances and practices will govern the selection and installa- mended. It should be placed far enough upstream to prevent
tion of piping. In all cases local building and safety codes and cavitation at the pump inlet (consult pump manufacturer for
ordinances should be studied and complied with. recommendations). The use of a strainer will prolong pump
All piping should be installed and supported to prevent the life and thus keep system performance up.
unit connections from bearing any strain or weight of the A preliminary leak check of the water piping should be
system piping. made before filling the system.
Vibration eliminators in all water piping connected to the Shutoff valves should be provided at the unit so that nor-
unit are recommended to avoid straining the piping and mal servicing can be accomplished without draining the
transmitting pump noise and vibration to the building system.
structure. A WATER FLOW SWITCH OR PRESSURE DIFFERENTIAL
It is recommended that temperature and pressure indicators SWITCH MUST BE MOUNTED IN THE WATER LINES TO
be installed within 3 feet of the inlet and outlet of the shells THE EVAPORATOR TO ASSURE WATER FLOW BEFORE
to aid in the normal checking and servicing of the unit. STARTING THE UNIT
A strainer or some means of removing foreign matter from

CHILLED WATER PIPING

The water flow entering the cooler must always be on the end maintained by using an expansion tank or a combination
nearest the expansion valves and cooler refrigerant connec- pressure relief and reducing valve.
tions to assure proper expansion valve operation and unit All chilled water piping should be insulated to prevent con-
capacity (see pages 16 thru 20). densation on the lines. If insulation is not of the self-contained
Design the piping so that it has a minimum number of vapor barrier type, it should be covered with a vapor seal.
changes in elevation. Include manual or automatic vent valves Piping should not be insulated until completely leak tested.
at the high points of the chilled water piping, so that air can Vent and drain connections must extend beyond pro-
be vented from the water circuit. System pressures can be posed insulation thickness for accessibility.

Page 6 I IM 508
 CHILLED WATER SENSOR
On units WHR-040D thru 240D. the chilled water sensor is Table 5.
factory installed in the leaving water connection on the
evaporator. For detailed specifications regarding the chilled
water sensor or any other sensors/transducers, refer to IM 493.
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 leadwire before running the unit to be sure that it
is firmly anchored and not rubbing on the frame or any other
component. Should the sensor ever be removed from the well Figure 6. Thermostat Well Installation
for servicing, care should be taken as not to wipe off the heat TEMPERATURE SENSOR
conducting compound supplied in the well. LOCATICJN
NOTE: See IM 493 for additional thermostat information.
CAUTION: The thermostat bulb should not be exposed to
water temperatures above 125°F since this will damage the
control.

FLOW SWITCH
A WATER FLOW SWITCH MUST SE MOUNTED in either the Fioure 7.
entering or leaving water line to insure that there will be ade-
quate water flow and cooling load to the evaporator before
FLOW SWITCH
the unit can start. This will safeguard against slugging the
compressors on startup. 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 under ordering number
1750338-00. It is a “paddle” type switch and adaptable to any
pipe size from 1” to 6” nominal. Certain minimum flow rates
are required to close the switch and are listed in Table 6. In-
stallation should be as shown in Figure 7. The flow switch
should be wired per actual unit wiring diagram found on the
inside of the unit control panel door or refer to IM 493.
Apply pipe sealing compound to only the threads of the
switch and screw unit into D”x D”x 1” reducing tee (see
Figure 7). The flow arrow must be pointed in the correct
direction.
Piping should provide a straight length before and after
the flow switch of at least five times the pipe diameter.
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 VIEW FROM END OF COOLER
pointed in the proper direction of flow. The flow switch is
designed to handle the control voltage and should be con-
nected according to the wiring diagram (see wiring diagram
inside control box door).

Table 6. Flow Switch Minimum Flow Rates

1 6.00
1% 9.80
l'h 12.70
2 18.80
2 % 24.30
3 30.00
4 39.70
5 58.70

IM 508 I Page 7
 GLYCOL SOLUTIONS
The system glycol capacity, glycol solution flow rate in gpm, Test coolant with a clean accurate glycol solution hydrometer
and pressure drop through the cooler may be calculated us- (similar to that found in service stations) to determine freez-
ing the following formulas and table. ing point. Then obtain percent glycol from the freezing point
table below.
CAPACITY - Capacity is reduced from that with plain
water. To find the reduced value multiply the chiller’s water
system tonnage by the capacity correction factor C to find
the chiller’s capacity in the glycol system.
0 1 32°F 1 1.000 j 1.000 1 1.00 1 1.00
GPM -To determine gpm (or /I T) knowing n T (or gpm) 10 1 24'F 1 0.990 / 0.994 1 1.01 1 1.06
and tons: 20 15'F 0.981 ' 0.988 1.04 1.12
30 4°F 0.974 0.984 1.08 1.18
Glvcol
, gp:pm = 24 x Tons (WW x G (from table) 40 -12°F 0.968 0.981 1.13 1.24
A T 50 -33°F 0.964 0.980 1.20 1.30

PRESSURE DROP -To determine glycol pressure drop

through the cooler, enter the water pressure drop graph
on page 9 at the glycol gpm. Multiply the water pressure CONDENSER - The use of a glycol solution in the heat
drop found there by P to obtain corrected glycol pressure recovery condensers will not affect heat recovery capacity.
drop.

1.30

1.25

1.20

100

lb i0 3b 4-o
PERCENT BY VOLUME

% ETHYLENE GLYCOL BY WEIGHT

Page 8 I IM 508
 CONDENSER WATER PIPING
GENERAL - For proper performance, the condenser water modulation. These typical systems, depending on the specific
must enter the bottom connection of the condenser. Water application, must maintain a constant condensing pressure,
cooled condensers may be piped for use with cooling towers, regardless of temperature conditions and must assure
well water or heat recovery applications. Cooling tower ap- enough head pressure for proper thermal expansion valve
plications should be made with consideration to freeze pro- operation. Note also that both systems assure full water flow
tection and scaling problems. For specific applications, con- to the tower.
tact cooling tower manufacturer for equipment characteristics
and limitations. HEAD PRESSURE CONTROL, WELL WATER SYSTEM -
Where well water is used for condensing refrigerant, a direct
HEAD PRESSURE CONTROL, TOWER SYSTEM - Some acting water regulating valve is recommended (see Figure
means of controlling operating head pressure must be pro- 10). The valve is normally installed at the outlet of the con-
vided. Minimum condensing temperature allowed is 80°F. denser. On shutdown, the valve will close and, in this way,
Minimum entering tower condenser water temperature is prevent water siphoning out of the condenser. Siphoning
70°F. Typical systems are shown in Figures 8 and 9. In Figure causes drying of the waterside of the condenser and rapid
8, a three-way pressure actuator water regulating valve is build-up of fouling. When no valve is used, a loop at the outlet
used for cooling applications, In Figure 9 the capacity of the end is recommended (See Figure 10).
cooling tower is controlled through damper and/or fan

COOLING TOWER SYSTEMS-HEAD PRESSURE CONTROL

Figure 8. 3-Way Water Valve Figure 9. Fan Modulation

REGULATING VALVES
TO COOLING TOWER
COOLING

BYPASS BALANCING
VALVES OR COCKS

Figure 10. Well Water Cooling System

I
LOOP REOUIAED WHEN NO
REGULATING VALVE IS USED

DIRECT ACTlNG WATER

REGULATING VALVE

Page 10 I IM 508
Single circuit heat recovery employs a standard water manufacturer for information on specific applications.
cooled chiller equipped with heavier electrical components An auxiliary heat source is necessary if the available con-
and a 380 psig high pressure limit switch. These modifica- denser heat is not sufficient to satisfy all of the heat load.
tions allow leaving condenser water temperatures up to 135°F The auxiliary heat source must be located between the con-
for building or process heating applications. denser and the heat load and the control should be inter-
A typical heat recovery arrangement will include a closed locked with the closed circuit tower to prevent auxiliary
circuit cooling tower used to reject unwanted condenser heat heating while rejecting heat to the ambient.
to the outdoor ambient air. The cooling tower should be When the heating load is satisfied, a two-position, three-
sized to reject all the condenser heat during summer design way valve is set to divert condenser water around the heat
operation. This insures proper operation in the nonheat- load and the auxiliary heat source. Whether operating in sum-
recovery mode. Use of a closed circuit tower is normally re- mer or winter, the chiller is always controlled by the cooling
quired in order to prevent fouling of heating coils in the heat load and not the heating load.
recovery loop. Condenser water remains free of contamina-
tion from minerals and impurities normally contained in make- TYPICAL OPERATION - On a call for cooling, the chiller
up water in an open cooling tower. starts and hot condenser water flows through the diverting
If a closed circuit cooling tower is to be located in an am- valve to the closed circuit cooling tower rejecting heat to the
bient temperature below freezing, protection against coil and outdoors. The tower dampers modulate to maintain a pro-
sump freeze-up must be provided. Coil freeze protection can per entering condenser water temperature which will give ef-
be provided by using a glycol solution or by maintaining a ficient operation by means of the proportional controller T2
heat load on the coil at all times and maintaining water flow located in the outlet fluid line of the tower.
through the coil. Sump water freeze protection can be pro- When a heating load is sensed by mode switch Tl, the
vided by locating the spray water circulating pump and sump three-way valve is switched to allow condenser water to flow
tank inside a heated space or by placing heating coils in the through the heating circuit. The proportional controller T2 is
sump. Head pressure and water temperature are normally also reset upwards to give the desired water temperature for
controlled by the tower capacity control. Adequate capacity heat recovery. The unused condenser heat will be rejected
control is usually obtained by fan cycling and regulating out through the closed circuit tower. If the condenser heat
dampers located in the fan discharge. This will maintain a of rejection cannot satisfy the heating load after an ap-
constant tower water temperature. Consult the closed circuit propriate delay, the auxiliary heat source will be activated.

Figure 11. Typical Single Condenser (Per Refrigerant Circuit) Heat Recovery

PUMP

HEATRECOVERY
CONDENSER TWO POSITION
DIVERTING VALVE

COOLING LOAD

NOTE: The schematic shows one refrigerant circuit. Models with two refrigerant circuits have two condensers

IM 508 I Page 11
 DUAL CONDENSER HEAT RECOVERY - ARRANGEMENT H

Dual condenser heat recovery chiller models have two water the cooling tower manufacturer for information on specific
cooled condensers per refrigerant circuit. The upper con- applications.
denser is the heat recovery condenser and is piped into the If the available condenser heat cannot satisfy all of the heat
building’s hot water system. The lower condenser is the tower load, an auxiliary heat source must be provided. The aux-
condenser and is piped to an open cooling tower. Condens- iliary heat source should be located between the heat
ing is done in either the tower condenser or heat recovery recovery condenser and the heat load and interlocked with
condenser, or partial condensing is done in each. The tower the cooling tower so that auxiliary heat is not being supplied
and heat recovery water circuits are independent and do not unless the cooling tower is modulated down all the way. The
intermix. This use of an open tower and the closed heat chiller operation is always controlled by the building’s cool-
recovery loop prevents fouling of the building’s heating ing load and not the heating load.
system.
A subcooling circuit is provided in the tower condenser to TYPICAL OPERATION - On a call for cooling the chiller
provide optimum cooling efficiency. When the unit is starts. If a heating load is sensed by mode switch Tl , the heat
operating on maximum heat recovery, the cooling tower will recovery water pump Pl will start and the cooling tower
be modulated down to its minimum capacity, usually about dampers will modulate to control the heat recovery condenser
5% of full capacity. This provides subcooling for the system by means of proportional temperature controller T3. If max-
during heat recovery operation. Water can be heated up to imum heat recovery is required, the tower dampers close and
135°F in the heat recovery condensers to satisfy a heating the fans shut off. The tower will then provide only subcool-
load. If all of the condenser heat of rejection cannot be ing. If more heat is required than the heat recovery con-
used, the remainder is rejected out through the cooling tower. densers can provide, the auxiliary heat source is activated.
The cooling tower should be sized to reject all of the con- When mode switch Tl senses that a heating load no longer
denser heat during summer operation. Freeze protection for exists, the heat recovery pump shuts off and the cooling tower
the cooling tower must be provided if it is to operate in below modulates to control the entering tower condenser water
freezing temperatures, Adequate capacity control must be temperature by means of proportional controller T2 and a sen-
provided to maintain a constant water temperature leaving sor located in the tower sump. Proportional controller T2 is
the cooling tower. Head pressure and water temperature are set at a temperature lower than T3 to provide optimum
controlled by the tower capacity control. Fan cycling and efficiency.
modulating fan discharge dampers should be used. Consult

Figure 12. Typical Dual Condenser (Per Circuit) Heat Recovery

COOLING TOWER

COOLER

PUMP

‘&k’ ------j

NOTE: The schematic shows one refrigerant circuit. Heat recovery WHR models with two refrigerant circuits
have two heat recovery condensers and two tower condensers.

Page 12 / IM 508
 REFRIGERANT PIPING
UNIT WITH REMOTE CONDENSER-ARRANGEMENT A
General - For remote condenser application such as an air discharge header. This is necessary to prevent any oil or con-
cooled condenser, the chillers are shipped containing a densed liquid from draining to the top heads when the com-
Refrigerant 22 holding charge. It is important that the unit be pressor is not running.
kept tightly closed until the remote condenser is installed, In designing liquid lines it is important that the liquid reach
piped to the unit and the high side evacuated. the expansion valve with no presence of flash gas since this
Refrigerant piping, to and from the remote unit, should be gas will reduce the capacity of the valve. Because “flashing”
sized and installed according to the latest ASHRAE Hand- can be caused by a pressure drop in the liquid lines, the
book. It is important that the piping be properly suported with pressure losses due to friction and changes in static head
sound and vibration isolation between tubing and hanger and should be kept to a minimum.
that the discharge lines be looped at the condenser and A check valve must be installed in the liquid line in all ap-
trapped at the compressor to prevent refrigerant and oil from plications where the ambient temperature can get below the
draining into the compressor discharge manifold. Looping the equipment room temperature. This prevents liquid migration
discharge line also provides greater line flexibility. to the condenser, helps maintain a supply of refrigerant in the
The discharge gas valve(s), liquid line solenoid(s), filter- liquid line for initial startup and keeps liquid line pressure high
drier(s), moisture indicator(s), and thermostatic expansion enough on “off” cycle to keep the expansion valve closed.
valve(s) are all provided as standard equipment with the On systems as described above, a relief valve or relief type
SEASONPAK water chiller. check valve must be used in the liquid line as shown in pip-
A liquid line shutoff valve must be added in the field on ing systems (Figure 14) to relieve dangerous hydraulic
condenserless units (Arrangement A) between the liquid line pressures that could be created as cool liquid refrigerant in
filter-drier and remote condenser. the line between the check valve and expansion or shutoff
After the equipment is properly installed, the unit may be valve warms up. A relief device is also recommended in the
charged with Refrigerant 22, then run at design load condi- hot gas piping at the condenser coil as shown in Figures 14
tions, adding charge until the liquid line sightglass is clear, through 16.
with no bubbles flowing to the expansion valve. Total operating
charge will depend on the air cooled condenser used and Typical Arrangements - Figure 14 illustrates a typical pip-
the length of external piping, but generally will be similar to ing arrangement involving a remote air cooled condenser
the water cooled charge shown in Tables 16, 17, and 18, pages located at a higher elevation than the compressor and
21 through 23. receiver. This arrangement is commonly encountered when
NOTE: On the Arrangement A units (units with remote con- the air cooled condenser is on a roof and the compressor and
densers), the installer is required to record the refrigerant receiver are on grade level or in a basement equipment room.
charge by stamping the total charge and the charge per cir- In this case, the design of the discharge line is very critical.
cuit on the serial plate in the appropriate blocks provided for If properly sized for full load condition, the gas velocity might
this purpose. be too low at reduced loads to carry oil up through the
SEASONPAK water chillers without condensers require field discharge line and condenser coil. Reducing the discharge
piping to a remote condenser of some type. The design of line size would increase the gas velocity sufficiently at re-
refrigerant piping when using air cooled condensers involves duced load conditions; however, when operating at full load,
a number of considerations not commonly associated with the line might be greatly undersized and thereby create an
other types of condensing equipment. The following discus- excessive refrigerant pressure drop. If this condition occurs,
sion is intended for use as a general guide to sound, it can be overcome in one of the two following ways:
economical and trouble-free piping of air cooled condensers.
1. The discharge line may be properly sized for the desired
Discharge lines must be designed to handle oil properly
pressure drop at full load condition and an oil separator
and to protect the compressor from damage that may result
installed at the bottom of the trap on the discharge line
from condensing liquid refrigerant in the line during shutdown.
from the compressor.
Total friction loss for discharge lines of 3 to 6 psi is considered
good design. Careful consideration must be given for sizing 2. A double riser discharge line may be used as shown in
each section of piping to insure that gas velocities are suffi- Figure 15, page 15. Line ‘A” should be sized to carry the
cient at all operating conditions to carry oil. If the velocity in oil at a minimum load condition and line “B” should be
a vertical discharge riser is too low, considerable oil may col- sized so that at the full load condition, both lines would
lect in the riser and the horizontal header, causing the com- carry oil properly.
pressor to lose its oil and result in damage due to lack of
Notice in all illustrations that the hot gas line is looped at
lubrication. When the compressor load is increased, the oil
the bottom and top of the vertical run. This is done to pre-
that had collected during reduced loads may be carried as
vent oil and condensed refrigerant from flowing back into the
a slug through the system and back to the compressor, where
compressor and causing damage. The highest point in the
a sudden increase of oil concentration may cause liquid slug-
discharge line should always be above the highest point in
ging and damage to the compressor.
the condenser coil; it is advisable to include a purging vent
Any horizontal run of discharge piping should be pitched
at this point to release noncondensables from the system.
away from the compressor approximately l/4” per foot or more.
Figure 16 illustrates another very common application
This is necessary to move by gravity any oil lying in the header.
where the air cooled condenser is located on essentially the
Oil pockets must be avoided as oil needed in the compressor
same level as the compressor and receiver. The discharge
would collect at such points and the compressor crankcase
line piping in this case is not too critical. The principal pro-
may become starved.
blem encountered with this arrangement is that there is fre-
It is recommended that any discharge lines coming into a
quently insufficient vertical distance to allow free drainage of
horizontal discharge header rise above the center line of the
liquid refrigerant from the condenser coil to the receiver.

IM 508 / Page 13
 UNIT WITH FACTORY MOUNTED CONDENSER(S)

Units with factory mounted condensers are provided with lem only arises during periods when cold water continues to
complete refrigerant piping and full operating refrigerant circulate through the condenser and the unit remains off due
charge at the factory. to satisfied cooling load.
There is a remote possibility on Arrangement W units utiliz- If this condition occurs:
ing low temperature pond or river water as a condensing 1. Cycle the condenser pump off with the unit.
medium, and if the water valves leak, that the condenser and 2. Check the liquid line solenoid valve for proper operation.
liquid line refrigerant temperature could get below the equip- If these valves are closing liquid tight as designed, no
ment room temperature on the off cycle. This could open the recycling of pumpdown should occur.
expansion valve and cause recycling pumpdown. This prob-

RELIEF VALVE PIPING

The ANSMASHRAE Standard 15-1978 specifies that pressure Figure 13. Relief Valve Piping
relief valves on vessels containing Group 1 refrigerants (R-12,
R-22 and R-500) “shall discharge to the atmosphere at a loca-
tion not less than 15 feet above the adjoining ground level
and not less than 20 feet from any window, ventilation open-
ing or exit in any building.” The piping must be provided with
a rain cap at the outside terminating point and 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
shall 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 shall not be less than
the sum of the area of the relief valve outlets connected to
the header. Fittings should be provided to permit vent pip-
ing to be easily disconnected for inspection or replacement
of the relief valve.

NOTE: Provide adequate fittings in piping to permit repair

or replacement of relief valve. RELIEF VALVE
(SET AT 4% PSI1

REFRIGERANT PIPING

Figure 14. Condenser Above Compressor and Receiver

PURGE VALVE
REM3 VALVE

GHECK VALVE’
iPREFERRED,

SUBCOOLER HOOKUP
DISCHARGE LINE

RELIEF VALVE (VENT TO

OUTDOORS OR TO CONDENSER
SIDE OF IIOUID LINE CHECK
VALVE)

Page 14 I IM 508
 CONTROL CENTER
All electrical controls are enclosed in a control center with justable controls are covered and can be adjusted without fear
locking, hinged access door(s). A partition separates the ad- of contacting line voltage.
justable safety controls from the starting and operating con- Please refer to IM 493 for control section layout, all low
trots. A “deadfront” panel covers all starting and operating voltage field wiring and normal sequence of operation for units
controls so that no electrical contacts or terminals are ex- equipped with MicroTech control.
posed. The deadfront panel is hinged for servicing. The ad-

POWER PANEL LAYOUT

Figure 27. WHR-040D thru 1lOD Figure 28. WHR12OD thru 240D
Right Side, High Voltage Control Section Right Side, High Voltage Power Section
1 0 0

pq” &,

NOTES:
1. PBl and Pf32 are used with multiple point power wiring.
2. Circuit breakers and overloads are provided as an option. The power panel
could contain one, both, or neither of these options.

WIRING
FIELD WIRING, POWER
The WHR “D” vintage chillers are built standard with com- tional Electrical Code and/or local requirements.
pressor contactors and power terminal block, designed for An open fuse indicates a short, ground, or overload. Before
single power supply to unit. Optional power connections in- replacing a fuse or restarting a compressor or fan motor, the
clude a nonfused disconnect switch mounted in the control trouble must be found and corrected. Tables in the Electrical
box or multi-point power connection. Data section give specific information on recommended wire
A factory installed control circuit transformer is available sizes.
as an option with single power supply or disconnect switch; Unit power inlet wiring must enter the top of the control box
it is not available with multi-point option. (right side) through a patch plate provided for field terminating
On water cooled units only, optional compressor overloads conduit. (Refer to control panel layout drawings for general
are available, allowing reduced unit ampacity ratings and location of power inlet and components.)
smaller field wiring.
Optional circuit breakers are available for backup com- WARNING: Use only copper conductors in main terminal
pressor short circuit protection on 040D thru 110D units and block. If the power input conductors are aluminum, use a com-
are standard on all four (4) compressor units 120D thru 240D. pression splice to change to copper before terminating in
Wiring and conduit selections must comply with the Na- block.

TYPICAL CONTROL AND SAFETY WIRING DIAGRAMS

Refer to IM 493 for typical control and safety wiring or actual unit wiring diagrams.

CURRENT TRANSFORMER
The typical power wiring diagrams shown on pages 19 thru 35 include the current transformer
(CTI) wiring shown in Figure 29. CT1 provides a O-4 vdc signal to the MicroTech panel which
is then converted to XXX% RLA.

IM 508 I Page 29
 STARTUP AND SHUTDOWN
This manual covers only the mechanical aspects of WHR chillers equipped with the MicroTech reciprocating chiller con-
trol. All of the operating, safety control and installation requirements of the MicroTech control are covered in the separate
Installation and Maintenance Bulletin 493, which must be consulted before startup and operation is attempted.

PRE STARTUP
1. With main disconnect open, check all electrical connec- pumpdown switches PSl and PS2 are on “manual pump-
tions in control panel and starter to be sure they are tight down,” throw the main power and control disconnect swit-
and provide good electrical contact. Although connec- ches to “on.” This will energize crankcase heaters. Wait
tions are tightened at the factory, they may have a minimum of 12 hours before starting up unit.
loosened enough in shipment to cause a malfunction.
8. Check compressor oil level. Prior to startup, the oil level
2. Check and inspect all water piping. Make sure flow direc- should cover at least one-third of the oil sightglass.
tion is correct and piping is made to correct connection
9. Check pressure drop across evaporator and condenser,
on evaporator and condenser.
and see that water flow is correct per the design flow rates
3. Open all water flow valves to the condenser and and data on page 9.
evaporator.
10. Check the actual line voltage to the unit to make sure
4. Flush the cooling tower and system piping to be sure the it is the same as called for on the compressor nameplate
system is clean. Start evaporator pump and manually within rtlO% and that phase voltage unbalance does not
start condenser pump and cooling tower. Check all pip- exceed 2%. Verify that adequate power supply and
ing for leaks. Vent the air from the evaporator and con- capacity is available to handle load.
denser water circuit as well as from the entire water
11. Make sure all wiring and fuses are of the proper size. Also
system. The cooler circuits should contain clean, non- make sure all interlock wiring is completed per McQuay
corrosive water.
diagrams.
5. If water regulating valves are provided, connect their
12. Verify that all mechanical and electrical inspections by
capillary to the manual valves provided on the con-
code authorities have been completed.
densers and open the manual valves.
13. Make sure all auxiliary load and control equipment is
6. Check to see that the water temperature thermostat sen-
operative and that an adequate cooling load is available
sor is installed in the entering water line to the chiller.
for initial startup.
7. Making sure control stop switch Sl is open (off) and

STARTUP
1. Open the compressor suction and discharge shutoff valves pre-start checkout found in IM 493 before system opera-
until backseated. Always replace valve seal caps. tion is attempted. After MicroTech pre-start checkout and
startup is complete be sure to complete the following
2. Open the manual liquid line shutoff valve.
mechanical startup requirements.
3. Verify crankcase heaters have operated for at least 12 hours
5. After system performance has stabilized, it is necessary
prior to startup. Crankcase should be warm.
that the “Compressorized Equipment Warranty Form”
4. After running the unit for a short time, check the oil level (Form No. 206036A) be completed to obtain full warranty
n each compressor crankcase, rotation of condenser fans benefits. Be sure to list the pressure drop across both
(if any), and check for flashing in the refrigerant sight- vessels. This form is shipped with the unit and after com-
glass. pletion should be returned to the McQuayService Depart-
ment through your sales representative.
At this point it will be necessary to complete MicroTech

TEMPORARY SHUTDOWN
1. Move the Circuit 1 and Circuit 2 switches to the “Pump- 2. After both circuits have pumped down, open the remote
down and Stop” position, causing each circuit to pump stop switch and the controller will stop the chilled water
down and stop. In this condition, the compressors will re- pump.
main off and no additional pumpdown will occur even if
evaporator pressure rises above the low pressure control
cut-in setpoint.

STARTUP AFTER TEMPORARY SHUTDOWN

Close the remote stop switch to enable the chiller. Move the the unit will stage as required. If the controller is not calling
Circuit 1 and Circuit 2 switches to the Auto position. If the for cooling the compressors may pump down and stop until
controller is calling for cooling, the compressors will start and there is a call for cooling.

Page 42 I IM 508
 EXTENDED SHUTDOWN
1. Move the Circuit 1 and Circuit 2 switches to the “Pump- 3. Close the manual liquid line shutoff valves.
down and Stop” position. After the compressors have shut
4. Close the compressor suction and discharge service valves
off, open the remote stop switch and the controller will stop
and oil equalization valves on four compressor units.
the chilled water pump.
2. Move the system switch to the “Emergency Stop” posi- 5. Tag all opened electrical disconnect switches to warn
against startup before opening the compressor sucton,
tion and turn off main power to the chiller and the chilled
discharge and liquid line service valves.
water pumps.

STARTUP AFTER EXTENDED SHUTDOWN

1. Inspect all equipment to see that it is in satisfactory At this point is will be necessary to complete MicroTech
operating condition. pre-start checkout found in IM 493 before system opera-
2. Remove all debris that has collected on the surface of the iion is attempted. After MicroTech pre-start checkout and
startup is complete be sure to complete the following
condenser coils (remote condenser models).
mechanical startup requirements.
3. Open the compressor suction and discharge valves until 8
After running the unit for a short time, check the oil level
backseated. Always replace valve seal caps.
in each copressor crankcase and for flashing in the
4. Open the manual liquid line shutoff valves. refrigerant sightglass (see Maintenance section).
5. Allow the crankcase heaters to operate for at least 12 hours
prior to startup.

SYSTEM MAINTENANCE
GENERAL
To assure smooth operation at peak capacity and to avoid ing may be accomplished by using a cold water spray,
damage to package components, a program of periodic in- brushing, vacuuming, or high pressure air. No tools should
spections should be set up and followed. The following items be used that could damage the coil tubes or fins.
are intended as a guide to be used during inspection and must A lead-lag switch is provided on all multiple compressor
be combined with sound refrigeration and electrical practices models to permit even distribution of wear on the com-
to assure trouble-free performance. pressors. This switch should be turned on on an annual basis.
The liquid line sightglass/moisture indicator on all circuits The compressor oil level must be checked periodically to
must be checked to be sure the glass is full and clear and be sure the level is at the center of the oil sightglass. Low
the moisture indicator indicates a dry condition. If the indicator oil level may cause inadequate lubrication and oil failure
shows that a wet condition exists or if bubbles show in the switch tripout. If the oil level is low and oil must be added,
glass, even with a full refrigerant charge, the filter-drier ele- use oils referred to in “Compressor Oil Level” section below.
ment must be changed. A pressure tap has been provided on the liquid line
Water supplies in some areas may tend to foul the water downstream of the filter-drier and solenoid valve but before
cooled condenser to the point where cleaning is necessary. the expansion valve. An accurate subcooled liquid pressure
The fouled condenser will be indicated by an abnormally high and temperature can be taken here. The pressure read here
condensing pressure and may result in nuisance tripouts. To could also provide an indication of excessive pressure drop
clean the condenser, a chemical descaling solution should through the filter-drier and solenoid valve due to a clogging
be used according to the manufacturer’s directions. filter-drier.
Systems with remote air cooled condensers require periodic NOTE: A normal pressure drop through the solenoid valve
cleaning of the finned surface of the condenser coil. Cleaning is approximately 3 psig at full load conditions.

CONTROL CENTER ELECTRICAL SERVICE

The electrical control center is relativelv easv to service since service on the control center:
indicator lights are provided to show unit status. Determine
1. Study the wiring diagram so that you understand the opera-
that the problem is actually in the control panel before
tion of the SEASONPAK water chiller.
proceeding.
By referring to the schematic wiring diagrams, the trouble 2. Before investigating trouble in the control center, check for
can be isolated to a particular section of the panel. burned out light bulbs by testing across the appropriate
WARNING: Warranty is voided if wiring is not in accordance terminals.
with specifications. A blown fuse or tripped protector indicates CAUTION: The panel is always energized to ground
a short ground or overload. Before replacing fuse or restar- even though the system switch is off. If it is necessary to
ting compressor, the trouble must be found and corrected. de-energize the complete panel including crankcase
It is important to have a qualified control panel electrician ser- heaters, pull main disconnect.
vice this panel. Unqualified tampering with the controls can
If motor or compressor damage is suspected, do not restart
cause serious damage to equipment and void the warranty.
until a qualified serviceman has checked the unit.
The following steps should be taken prior to attempting any

IM 508 I Page 43
 ELECTRICAL TERMINALS
CAUTION: Electric shock hazard. Turn off all power before continuing with following service.
All power electrical terminals should be retightened every six months, as they tend to loosen
in service due to normal heating and cooling of the wire.

OPERATING LIMITS
0 Maximum allowable condenser water pressure is 250 psig. ature for operating cycle is 90°F (during system change-
0 Maximum allowable cooler water pressure is 225 psig. over from heating to cooling cycle).
0 Maximum leaving condenser water temperature is 135” F. 0 Minimum leaving water temperature from the cooler with-
This corresponds to 340 to 350 psig head pressure. out freeze protection is 42°F.
0 Maximum allowable water temperature to cooler in a non- 0 Minimum entering tower condenser water temperature is
operating cycle is 105°F. Maximum entering water temper- 70°F.

COMPRESSOR OIL LEVEL

The oil level should be watched carefully upon initial startup than keeping the oil clean and dry.
and for sometime thereafter. If the system contains a refrigerant charge, close the suc-
At the present time, Suniso No. 3GS, Calumet R015, and tion valve and reduce crankcase pressure to 1 to 2 psig. Stop
Texaco WF32 oils are approved by Copeland for use in these the compressor and close the discharge valve.
compressors. The oil level should be maintained at about one- Add the required amount of oil. During the period the com-
third of the sightglass on the compressor body but is accept- pressor is exposed to the atmosphere, the refrigerant will
able at any height on the sightglass. generate a vapor pressure, retarding the entrance of con-
Oil may be added to the Copeland compressor through the taminants. Before resealing the compressor, purge the crank-
oil fill hole in the crankcase. To add oil, isolate the crankcase case by opening the suction valve slightly for 1 or 2 seconds.
and pour or pump in the necessary oil. If the system contains Close the oil port, open the compressor valves and restore
no refrigerant, no special precautions are necessary other the system to operation.

OIL EQUALIZATION
Some larger models with four compressors (WHR-180 thru pressures.
240D) come equipped with oil equalization lines connecting The oil equalization line contains a manual shutoff valve
the crankcase of both compressors in each refrigerant circuit. for isolating a compressor during service work. The ball valves
This allows the oil to move from one compressor crankcase are shipped in the closed position with a tag attached stating
to the other during normal operation, and balance between “Notice, Valve Shipped In Closed Position. Can Be Open For
the two when the compressors are off. This method of equali- Normal Operation.” When valves are closed for compressor
zation prohibits the oil level from dropping below the bottom service, make sure they are opened again for unit operation.
level of the sightglass. Some difference in crankcase oil levels For water cooled units, operation with oil equalization lines
will still exist during unit operation due to compressor internal closed should be satisfactory for most jobs.

REFRIGERANT SIGHTGLASS AND MOISTURE INDICATOR

The refrigerant sightglasses should be observed period- pressure drop in the line, possibly due to a clogged filter-drier
ically. (A monthly observation should be adequate.) A clear or a restriction elsewhere in the system. An element inside
glass of liquid indicates that there is adequate refrigerant the sightglass indicates what moisture condition corresponds
charge in the system to insure proper feed through the ex- to a given element color. If the sightglass does not indicate
pansion valve. Bubbling refrigerant in the sightglass indicates a dry condition after about 12 hours of operation, the unit
that the system is short of refrigerant charge. Refrigerant gas should be pumped down and the filter-driers changed.
flashing in the sightglass could also indicate an excessive

CRANKCASE HEATERS
The compressors are equipped with crankcase heaters. The (at least 12 hours) before the compressor is started. The
20 HP and larger model compressors have heaters inserted crankcase should be up to about 80°F before the system is
into the crankcase. The function of the heater is to keep the started up, to minimize lubrication problems on liquid slug-
temperature in the crankcase high enough to prevent refrig- ging of compressor on startup.
erant from migrating to the crankcase and condensing in the If the crankcase is cool (below 80°F) and the oil level in
oil during off-cycle. the sightglass is FULL to top, allow more time for oil to warm
When a system is to be started up initially in cold ambient, before starting the compressor.
the power to the heaters should be turned on for some time

Page 44 I IM 508
 SYSTEM SERVICE
NOTE: Service on this equipment is to be performed by qualified refrigeration personnel. Causes for repeated tripping of safety
controls must be investigated and corrected. CAUTION: Disconnect all power before doing any service inside the unit.

FILTER-DRIERS
To change the filter-drier, pump each refrigerant circuit down
by closing the manual liquid line shutoff valve while a com-
pressor is running. After both refrigerant circuits are pumped
down, move the system switch to the “Emergency Stop” posi-
tion. This will remove all liquid refrigerant from the evaporator
and section of liquid line up to the shutoff valve. Only a small
amount of vapor will remain in the liquid line/filter-drier sec-
tion. Front seat the compressor suction valve(s), Remove and
replace the filter-drier(s). Evacuate the lines through the li- NOTE: On Arrangement A units, the filter-drier cores are shipped in the unit
quid line manual shutoff valves to remove non-condensables control box and are to be Installed prior to evacuating and charging the unit.
that may have entered during filter replacement. A leak check
is recommended before returning the unit to operation.

LIQUID LINE SOLENOID VALVE

The liquid line solenoid valves, which are responsible for The coil can then be removed from the valve body by simply
automatic pumpdown during normal unit operation, do not removing a nut or snap-ring located at the top of the coil. The
normally require any maintenance. However, in the event of coil can then be slipped off its mounting stud for replacement.
failure they may require replacement of the solenoid coil or Be sure to replace the coil on its mounting stud before return-
of the entire valve assembly. ing the unit to operation.
The solenoid coil may be removed from the valve body To replace the entire solenoid valve, follow the steps involv-
without opening the refrigerant piping by moving Circuit 1 and ed when changing a filter-drier.
Circuit 2 switches to the “Pumpdown and Stop” position.

THERMOSTATIC EXPANSION VALVE

The expansion valve is responsible for allowing the proper Figure 30.
amount of refrigerant to enter the evaporator regardless of
cooling load. It does this by maintaining a constant superheat.
(Superheat is the difference between refrigerant temperature
as it leaves the evaporator and the saturation temperature cor-
responding to the evaporator pressure.) All WHR chillers are
factory set for between 8°F and 12°F superheat at full load. ,.._., Power Element
If it is necessary to increase the superheat setting of the valve, (Contains Diaphragm)
Inlet
remove the cap at the bottom of the valve to expose the ad-
justment screw. Turn the screw clockwise (when viewed from
the adjustment screw end) to increase the superheat and
counterclockwise to reduce superheat. Allow time for system
rebalance after each superheat adjustment.
The expansion valve, like the solenoid valve, should not nor-
mally require replacement, but if it does, the unit must be Adjustment Screw
pumped down by following the steps involved when chang-
ing a filter-drier.
If the problem can be traced to the power element only,
it can be unscrewed from the valve body without removing
the valve, but only after pumping the unit down.
NOTE: Superheat WIII vary with compressor unloading, but should be approx-
WARNING: Adjustment of expansion valve should only be imately as follows- between 6°F and 12°F at full load; between 6°F and 10°F
performed by a qualified service technician. at part load.

EVAPORATOR
The evaporator is of the direct expansion, shell-and-tube type down. Follow the steps involved when changing a filter-drier.
with refrigerant flowing through the tubes and water flowing These steps will insure a minimum amount of refrigerant loss
through the shell over the tubes. The tubes are internally when the evaporator is opened up. The tubes are mechanical-
finned to provide extended surface as well as turbulent flow ly expanded into the tube sheets (see Figure 31) at each end
of refrigerant through the tubes. Normally no service work is of the cooler. In order to remove the tubes, it is necessary
required on the evaporator. There may be instances where to break this bond by collapsing the tube. After doing this at
a tube will leak refrigerant into the water side of the system. both ends of the shell, the tube can be removed for replace-
In the cases where only one or two tubes leak, the problem ment. The new tube can then be inserted and re-expanded
can best be solved by plugging the tube at both ends. When into the tube sheet.
the tube must be replaced, the old tube can be removed and NOTE: The bond produced by expansion must be refrig-
replaced. erant tight. This bond must be produced by applying Locktite
To remove a tube, the unit should be temporarily pumped (red) to the fube and rolling it into the fube sheet.
IM 508 I Page 45
 After re-assembling the evaporator, a small amount of gauge attached to one of the end plugs, observing if there
refrigerant should be introduced by momentarily opening the is a loss of air pressure over a period of a minute or two.
manual liquid line valve. A leak check should then be per- Another method is to place a cork plug in each tube on both
formed on the evaporator. ends of the cooler and applying pressure to the shell of the
Tube removal can only take place after the leaking tube is cooler. After a period of time, the pressure will leak from the
located. One method that would work would be to subject each shell into the leaking tube or tubes and pop out the cork plug.
tube to air pressure by plugging each end and, with a pressure

Figure 31. Top View of Typical Dual Circuit Shell-and-Tube Evaporator

Water Baffles

Liquid Connections

Suction Connections

L Refrigerant Tubes

Shell

Water Nozzles

WATER COOLED CONDENSER

The condenser is of the shell-and-tube type with water flow- ment W units. Heat recovery units have integral subcoolers
ing through the tubes and refrigerant in the shell. External in the tower condensers. All condensers are equipped with
finned copper tubes are rolled into steel tube sheets. Integral 450 psig relief valves. Heat recovery condensers are free-
subcoolers are incorporated on 40 ton and larger Arrange- draining to the lower (tower) condensers and do not subcool.

HOT GAS BYPASS (OPTIONAL)

This option allows passage of discharge gas to the evaporator by changing the pressure of the air charge in the adjustable
permitting operation at lower loads than available with com- bulb. To raise the pressure setting, remove the cap on the
pressor unloading. It also keeps the velocity of refrigerant gas bulb and turn the adjustment screw clockwise. To lower the
high enough for proper oil return at light load conditions. A setting, turn the screw counterclockwise. Do not force the ad-
solenoid valve in the hot gas bypass line is wired in parallel justment beyond the range it is designed for, as this will
with the compressor unloader Ul. Thus, the hot gas solenoid damage the adjustment assembly.
cannot open unless the compressor is operating in an un- The regulating valve opening point can be determined by
loaded mode. If only one hot gas valve is specified for the slowly reducing the system load while observing the suction
unit, the hot gas bypass is wired in the first refrigerant circuit pressure. When the bypass valve starts to open, the refrigerant
and the lead-lag switches are therefore eliminated. The hot line on the evaporator side of the valve will begin to feel warm
gas bypass option is also available for the second refrigerant to the touch.
circuit whereby the lead-lag switches remain. CAUTION: The hot gas line may become hot enough to
The pressure regulating valve is factory set to begin open- cause injury in a very short time; care should be taken dur-
ing at 58 psig (32°F for R-22). This setting can be changed ing valve checkout.

Figure 32. Hot Gas Bypass Piping Diagram Figure 33. Hot Gas Bypass Adjustment Range

f I I b, TL”

30 40 50 60 70 80 90 100 110
TEMPERATURE (“F) AT BULB LOCATION

Page 46 I IM 508
 IN-WARRANTY RETURN MATERIAL PROCEDURE
COMPRESSOR
Copeland Refrigeration Corporation has stocking wholesalers model and unit serial numbers. Include the invoice and the
who maintain a stock of replacement compressors and ser- salvage value credit memo copies and we will reimburse the
vice parts to serve refrigeration contractors and servicemen. difference. In this transaction, be certain that the compressor
When a compressor fails in warranty, contact your local is definitely defective. If a compressor is received from the
sales representative, or Warranty Claims Department at the field that tests satisfactorily, a service charge plus a transpor-
address on the cover of this bulletin. You will be authorized tation charge will be charged against its original credit value.
to exchange the defective compressor at a Copeland whole- On all out-of-warranty compressor failures, Copeland offers
saler, or an advance replacement can be obtained. A credit the same field facilities for service and/or replacement as
is issued you by the wholesaler for the returned compressor described above. The credit issued by Copeland on the return-
after Copeland factory inspection of the inoperative com- ed compressor will be determined by the repair charge
pressor. If that compressor is out of Copeland’s warranty, a established for that particular unit.
salvage credit only is allowed. Provide full details; i.e., unit

COMPONENTS OTHER THAN COMPRESSORS

Material may not be returned except by permission of authoriz- should include part name, part number, model number and
ed factory service personnel at Minneapolis, Minnesota. A serial number of the unit involved.
“return goods” tag will be sent to be included with the returned Following our personal inspection of the returned part, and
material. Enter the information as called for on the tag in order if it is determined that the failure is due to faulty material or
to expedite handling at our factories and prompt issuance of workmanship, and in warranty, credit will be issued on
credits. customer’s purchase order.
The return of the part does not constitute an order for All parts shall be returned to the pre-designated factory,
replacement. Therefore, a purchase order must be entered transportation charges prepaid.
through your nearest McQuay representative. The order

IM 508 I Page 47
 TROUBLESHOOTING CHART

Compressor Will 1. Main switch, circuit breakers open. 1. Close switch.

Not Run 2. Fuse blown. 2. Check electrical circuits and motor winding for shorts or grounds.
Investigate for posstble overloading. Replace fuse or reset
breakers after fault is corrected.
3. Thermal overloads tripped or fuses blown 3. Overloads are auto reset. Check unit closely when unit comes
back on line.
4. Defective contactor or coil. 4. Repair or replace.
5. System shut down by safety devices. 5. Determine type and cause of shutdown and correct it before reset-
ting safety switch.
6. No cooling requrred. 6. None. Wait until unit calls for cooling.
7. Liquid line solenoid will not open. 7. Repair or replace coil.
6. Motor electrical trouble. 6. Check motor for opens, short circuit, or burnout.
9. Loose wmng. 9. Check all wire junctions. Tighten all terminal screws.
Compressor Noisy 1. Flooding of refrigerant into crankcase. 1. Check superheat setting of expansion valve.
or Vibrating 2. Improper piping support on suction or liquid line. 2. Relocate, add or remove hangers
3. Worn compressor. 3. Replace.
High Discharge 1. Condenser water insufficient or temperature too high 1. Readjust temperature control or water regulating valve. Investigate
Pressure ways to increase water supply
2. Fouled condenser tubes (water cooled condenser). Clogged spray 2. Clean.
nozzles (evaporative condenser). Dirty tube and fin surface (air
cooled condenser).
3. Noncondensables in system. 3. Purge the noncondensabies.
‘4. System overcharged with refrigerant. 4. Remove excess refrigerant.
5. Discharge shutoff valve partially closed. 5. Open valve.
‘6. Condenser undersized. 6. Check condenser rating tables against the operation.
‘7. High ambient conditions. 7. Check condenser rating tables against the operation.
Low Discharge 1. Fault condenser temperature regulation. 1. Check condenser control operation.
Pressure 2. Suction shutoff valve partially closed. 2. Open valve.
3. Insufficient refrigerant in system. 3. Check for leaks. Repair and add charge.
4. Low suction pressure. 4. See corrective steps for low suction pressure below.
5. Compressor operating unloaded. 5. See corrective steps for failure of compressor to load.
‘6. Condenser too large. 6. Check condenser rating table against the operation.
‘7. Low ambient conditions. 7. Check condenser rating tables against the operation.
High Suction 1. Excessive load. 1. Reduce loador add additional equipment.
Pressure 2. Expansion valve overfeeding. 2. Check remote bulb. Regulate superheat.
3. Compressor unloaders open. 3. See corrective steps foffailure of compressor to load.
Low Suction 1. Lack of refrigerant. 1. Check for leaks. Reoarr and add charoe.”
Pressure 2. Evaporator dirty. 2. Clean chemically. ’
3. Clogged liquid line filter-drier. 3. Replace cartridge(s).
4. Clogged suction line or compressor suction gas strainers. 4. Clean strainers.
5. Expansion valve malfunctioning. 5. Check and reset for proper superheat. Replace if necessary.
6. Gasket failure in evaporator head ring. 6. Check fIP across evaporator.
7. Condensing temperature too low. 7. Check means for regulating condensing temperature.
0. Compressor will not unload. 6. See corrrective steps for failure of compressor to unload.
9. Insufficient water flow. 9. Adjust gpm.
Little or No Oil 1. Clogged suction oil strarner. 1. Clean.
Pressure 2. Excessive liquid in crankcase. 2. Check crankcase heater. Reset expansion valve for higher
superheat. Check liquid line solenoid valve operation.
3. Oil pressure gauge defective. 3. Repair or replace. Keep valve closed except when taking reading.
4. Low oil pressure safety switch defective. 4. Replace.
5. Worn oil pump. 5. Replace.
6. Oil pump reversing gear stuck in wrong position 6. Reverse direction of compressor rotation by switching compressor
leads.
7. Low oil level. 7. Add oil.
6. Loose fitting on oil lines. 6. Check and tighten system.
9. Pump housing gasket leaks. 9. Replace gasket.
10. Flooding of refrigerant into crankcase. 10. Adjust thermal expansion valve.
Compressor 1. Lack of refrigerant. TCheck for leaks and repair Add refrigerant.
Loses Oil ‘2. Velocity in risers too low. 2. Check riser sizes.
‘3. Oil trapped in line. 3. Check pitch of lines and refrigerant velocities.
4. Excessive compression ring blow-by. 4. Replace compressor.
Motor Overload 1. Low voltage during high load conditions. 1. Check supply voltage for excessive line drop.
Relays or Circuit 2. Defective or grounded wiring m motor or power circuits. 2. Replace compressor-motor.
Breakers Open 3. Loose power wiring. 3. Check all connections and tighten.
4. High condensing temperature. 4. See corrective steps for high discharge pressure.
5. Power line fault causing unbalanced voltage. 5. Check supply voltage. Notify power company. Do not start until
fault IS corrected
6. High ambient temperature around the overload relay. 6. Provide ventilation to reduce heat.
7. Failure of second starter to pull in on part windmg 7. Repair or replace starter or time delay mechanism.
start system.
Compressor Thermal 1. Operating beyond design conditrons. 1. Add facilities so that conditions are withrn allowable Irmrts.
Protector Switch Open 2. Discharge valve partially shut. 2. Open valve
3. Blown valve plate gasket. 3. Replace gasket.
Freeze Protection 1. Thermostat set too low. 1 Reset to 42’F or above.
Opens 2. Low water flow. 2. Adjust gpm.
3. Low suction oressure. 3. See “Low Suction Pressure ”

* Remote Condenser Models.

NOTE: FOR TROUBLESHOOTING PROCEDURES ON MICROTECH CONTROL REFER TO IM 493.

Page 48 I IM 508
 PRODUCT WARRANTY
SnyderGeneral Corporation, hereinafter referred to as the TIES. THERE IS NO IMPLIED WARRANTY OF MERCHAN-
“Company,” warrants that it will provide, at the Company’s TABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
option, either free replacement parts or free repair of com- IN NO EVENT AND UNDER NO CIRCUMSTANCES SHALL
ponent parts in the event any product manufactured by the THE COMPANY BE LIABLE FOR INCIDENTAL OR CONSE-
Company and used in the United States proves defective in QUENTIAL DAMAGES, WHETHER THE THEORY BE
material or workmanship within twelve (12) months from in- BREACH OF THIS OR ANY OTHER WARRANTY, NEGLI-
itial startup or eighteen (18) months from the date shipped GENCE OR STRICT TORT.
by the Company, whichever comes first. For additional con- This parts warranty and the optional extended warranties
sideration, the Company warrants that for four (4) years follow- extend only to the original user. Of course, abuse, misuse,
ing the initial warranty period it will provide, at the Company’s or alteration of the product in any manner voids the Com-
option, free replacement parts for the motor-compressor, or, pany’s warranty obligation. Neither the parts or extended war-
free replacement for any integral component of the motor- ranty obligates the Company to pay any labor or service costs
compressor which proves defective in material or workman- for removing or replacing parts, or any shipping charges.
ship. For an additional consideration, the Company warrants Refrigerants, fluids, oils, and expendable items such as filters
that for nine (9) years following the initial warranty period it are not covered by this warranty.
will provide free replacement of the heat exchanger in gas- The extended warranties apply only to integral components
fired or oil-fired furnaces which proves defective in material of the motor-compressor or heat exchanger, not to refrigerant
and workmanship. (Extended warranties for motor-compres- controls, electrical controls, or mechanical controls, or to
sors and heat exchangers are not applicable unless separately failures caused by failure of those controls.
purchased.) Attached to this warranty is a requirement for equipment
To obtain assistance under this parts warranty, extended containing motor-compressors and/or furnaces to report start-
motor-compressor warranty, or extended heat exchanger war- up information. The registration form accompanying the pro-
ranty, simply contact the selling agency. To obtain informa- duct must be completed and returned to the Company within
tion or to gain factory help: For brandnames Arcoaire and/or ten (10) days of original equipment start-up. If that is not done.
Comfortmaker contact SnyderGeneral Corporation, Warran- the date of shipment shall be presumed to be the date of start-
ty Department, 302 Nichols Drive, Hutchins, TX 75141, up and the warranty shall expire twelve (12) months from that
telephone (214) 2257351. For McQuay, Climate Control, Barry date.
Blower and JennFan brandnames, contact SnyderGeneral No person (including any agent, salesman, dealer or
Corporation, Warranty Claims Department, P. 0. Box 1551, distributor) has authority to expand the Company’s obligation
Minneapolis, MN 55440, telephone (612) 553-5330. beyond the terms of this express warranty, or to state that the
THIS WARRANTY CONSTITUTES THE BUYER’S SOLE performance of the product is other than that published by
REMEDY. IT IS GIVEN IN LIEU OF ALL OTHER WARRAN- the Company.

IM 508 I Page 49