I&M Manual_WGZ-1

7/24/2019 I&M Manual_WGZ-1

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Installation, and Maintenance Manual IMM WGZC

Group: Chiller

Part Number: 331975201

Effective: February 2010

Supercedes: April 2009

Water-Cooled Scroll Compressor Chillers

WGZ 030CW to WGZ 200CW, Packaged Water-Cooled Chiller

WGZ 030CA to WGZ 200CA, Chiller with Remote Condenser

30 to 200 Tons, 105 to 700 kW

60 Hz, R-410A


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2 WGZ 030C through 200C IMM WGZC

Table of Contents

Introduction ....................................... 3Nomenclature ........................................ 3

Installation ......................................... 4Vibration Isolators................................. 6

Limitations of Operation ................ 11

Water Piping .................................... 12Flow Switch ........................................ 15Glycol Solutions.................................. 15Condenser Water Piping...................... 17

Pressure Drops................................. 17

Refrigerant Piping........................... 20Unit with Remote Condenser .............. 20Factory-Mounted Condenser............... 25

Dimensions ....................................... 26

Packaged Chillers................................ 26Chillers with Remote Condenser......... 29

Physical Data.................................... 32Packaged Chillers................................ 32Chillers with Remote Condenser......... 35Operating Limits ................................. 36Components ........................................ 37

Wiring............................................... 38

Unit Configuration .......................... 39

Electrical Data ................................. 40

Electrical Notes ................................... 53Field Wiring Diagram ......................... 55Control Panel Layout .......................... 57Motor Protection Module.................... 57

Start-Up and Shutdown..................58Pre Start-up.......................................... 58Start-up................................................ 58Weekend or Temporary Shutdown...... 59Start-up after Temporary Shutdown.... 59Extended Shutdown ............................ 59Start-up after Extended Shutdown ...... 60

System Maintenance .......................61General................................................ 61Electrical Terminals............................. 62Compressor Lubrication...................... 62Sightglass and Moisture Indicator....... 62Crankcase Heaters............................... 63Optional Controls................................ 63Phase/Voltage Monitor (Optional) ...... 63Hot Gas Bypass (Optional) ................. 64

Maintenance Schedule....................65

System Service.................................66Troubleshooting Chart ........................ 68

Warranty Statement .......................69

Manufactured in an ISO Certified facility

Cover Picture: WGZ 200C, Nominal 200 ton chiller

2009 McQuay International. Illustrations and data cover the McQuay International product at the time of publication and we reserve the right to

make changes in design and construction at anytime without notice. The following are trademarks or registered trademarks of their respective

companies: BACnet from ASHRAE; LONMARK, LonTalk, LONWORKS, and the LONMARK logo are managed, granted and used by LONMARK

International under a license granted by Echelon Corporation; Compliant Scroll from Copeland Corporation; ElectroFin from AST ElectroFin Inc.;

Modbus from Schneider Electric; FanTrol, MicroTech II, Open Choices, and SpeedTrol from McQuay International


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IMM WGZC WGZ 030C through 200C 3

Introduction

General Description

McQuay Type WGZ water chillers are designed for indoor installations and are available with

water-cooled condensers (Model WGZ-CW), or arranged for use with remote, air-cooled or

evaporative condensers (Model WGZ-CA). Each water-cooled unit is completely assembled andfactory wired before evacuation, charging and testing. They consist of hermetic scroll

compressors, brazed-plate evaporators on Models WGZ 030 to 130( shell-and-tube on Models

WGZ 150 to 200), water-cooled condenser (WGZ-CW), and complete refrigerant piping.

Units manufactured for use with remote condensers (Models WGZ-CA) have all refrigerant

specialties factory-mounted and connection points for refrigerant discharge and liquid lines.

Liquid line components that are included are manual liquid line shutoff valves, charging valves,

filter-driers, liquid line solenoid valves, sight glass/moisture indicators, and expansion valves.

Other features include compressor crankcase heaters, and a MicroTech IImicroprocessor

controller.

The electrical control center includes all equipment protection and operating controls necessaryfor dependable automatic operation.

The compressors are not fused as standard, but can be protected by optional circuit breakers or

fuses, or can rely on a field-installed, fused disconnect switch for protection.

Nomenclature

W G Z 100 - C W

Inspection

When the equipment is received, all items should be carefully checked against the bill of lading to

be sure of a complete shipment. All units must be carefully inspected for damage upon arrival. All

shipping damage must be reported to the carrier and a claim must be filed with the carrier. The

unit serial plate should be checked before unloading the unit to be sure that it agrees with the

power supply available. Physical damage to unit after acceptance is not the responsibility of

McQuay.

Note: Unit lifting weights are given in the physical data tables beginning on page 5.Corner operating weights are given on page 7

Water-Cooled

Global

Scroll Compressor Nominal Capacity (Tons)

W = Water-Cooled Condenser

A = Unit Less Condenser

Design Vintage


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Installation

Note: Installation and maintenance are to be performed only by qualified personnelwho are familiar with local codes and regulations, and experienced with this type ofequipment.

! WARNING

Avoid contact with sharp edges. Personal injury can result

Handling

Every model WGZ-CW water chiller with water-cooled condensers is shipped with a full

refrigerant charge. For shipment, the charge is contained in the condenser and is isolated by

the condenser liquid shutoff valve and the compressor discharge valve common to a pair of

compressors.

A holding charge of nitrogen/helium is supplied in remote condenser models, WGZ-CA and

must be removed prior to charging with refrigerant. The operating charge must be field

supplied and charged.

Moving the Unit The packaged unit skid option is strongly recommended for ease ofhandling and to help prevent damage if a crane is not available for rigging at site.Properly

designed field supplied skids or dollies are acceptable. Do not push unit along a floor without

them. The condenserless models (AGZ-CA) are manufactured with a base suitable for movingwith rollers.

Figure 1, Lifting the Unit

! WARNING

If the unit has been damaged, allowing the refrigerant to escape, there can be danger of suffocation in the area since refrigerant will displace the air. Be sure to review Environmental Protection Agency (EPA) requirements if damage occu

Avoid exposing an open flame to the refrigerant

331926901 REV. 0A

WGZ150-200CUNIT SHOWN

SPREADER BARS MUSTBE USED FOR STABILITY

DURING LIFTING OFALL SIZE UNITS

RemovableLiftingBar

(2) 2

LiftingHoles


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All moving and handling of packaged units (illustrated above) must be performed with skids

or dollies under the unit and they should not be removed until the unit is in the final location.

Never put the weight of the unit against the control box.

All moving and handling of packaged units (illustrated above) must be performed with skids

or dollies under the unit and they should not be removed until the unit is in the final location.

Never put the weight of the unit against the control box.

In moving, always apply pressure to the base on the skids only and not to the piping or othercomponents. A long bar will help move the unit easily. Avoid dropping the unit at the end of

the roll.

If the unit must be hoisted, lift the unit from the removable lifting arms factory-bolted to each

end of the unit adjacent to the tube sheet by attaching cables or chains to the end of the arms.

A spreader bar must be used to protect the piping, control panel and other areas of the chiller

(see Figure 1). The arms should be removed and discarded after use.

Do not attach slings to piping or equipment. Do notattempt to lift the unit by lifting points

mounted on the compressors. They are for lifting only the compressor should one need to be

removed from the unit. Move unit in the upright horizontal position at all times. Set unit

down gently when lowering from the truck or rollers.

Table 1, Lifting Loads

WGZ-CW Package Units (lbs.) WGZ CA Less Condenser Units (lbs)ModelWGZ-C L1 L2 L3 L4

ShippingWeight

L1 L2 L3 L4ShippingWeight

WGZ 030 606 633 599 573 2410 415 430 374 361 1580

WGZ 035 632 646 616 603 2496 442 445 392 390 1670

WGZ 040 639 659 630 611 2539 443 451 399 392 1685

WGZ 045 639 667 639 612 2558 444 460 407 393 1704

WGZ 050 655 689 664 631 2639 451 468 416 400 1735

WGZ 055 655 698 673 632 2658 451 476 425 402 1754

WGZ 060 655 712 688 633 2688 451 484 433 404 1771

WGZ 070 929 874 942 1001 3746 649 595 556 606 2406

WGZ 080 1066 927 1001 1151 4145 765 635 598 720 2717

WGZ 090 1076 849 1059 1343 4327 806 653 623 770 2851

WGZ 100 1059 781 1118 1515 4474 829 681 657 801 2968

WGZ 115 1054 802 1146 1506 4508 830 710 689 805 3035

WGZ 130 1055 828 1181 1505 4568 831 737 716 807 3091

WGZ 150 1684 1516 1602 1780 6581 1204 1142 1184 1249 4779

WGZ 175 1814 1528 1637 1943 6921 1245 1149 1198 1299 4891

WGZ200 1829 1550 1677 1979 7036 1265 1178 1235 1326 5004

See Figure 2on the following page for location of lifting points.

Location

WGZ chillers are designed for indoor application and must be located in an area where

the surrounding ambient temperature is 40F (4C) or above. A good rule of thumb is toplace units where ambient temperatures are at least 5F (3C) above the leaving water

temperature.

Because of the electrical control devices, the units should not be exposed to the weather.

A plastic cover over the control box is supplied as temporary protection during shipment.

A reasonably level and sufficiently strong floor is required for the water chiller. If

necessary, additional structural members should be provided to transfer the weight of the

unit to the nearest beams.


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Control Panel

WaterConnections

4

1

3

2

LB

LF

RB

FRF

Space Requirements for Connections and Servicing

The chilled water and condenser water (on units with a water-cooled condenser) piping

enters and leaves the unit from the right side when looking at the control panel. Left-hand

condenser connections are an option. A clearance of at least 3 feet (1219 mm), or more if

codes require, should be provided beyond this piping and on all other sides and ends of

the unit for general servicing or for changing the compressors, if it ever becomes

necessary.

On units equipped with a water-cooled condenser (Type WGZ-CW) clearance should also

be provided for cleaning or removal of condenser tubes on one end of the unit. The

clearance for cleaning depends on the type of apparatus used, but can be as much as the

length of the condenser (10 feet, 3050 mm). Tube replacement requires the tube length of

10 feet (3050 mm) plus one to two feet of workspace. This space can often be provided

through a doorway or other opening.

Allow a minimum of 4-foot clearance in front of the control panel.

Placing the UnitThe small amount of vibration normally encountered with the water chiller makes this

unit particularly desirable for basement or ground floor installations where the unit can be

mounted directly to the floor. The floor construction should be such that the unit will not

affect the building structure, or transmit noise and vibration into the structure. NOTE:Springs are Model CP1E, one spring per housing.

Vibration IsolatorsIt is recommended that isolators be used on all upper level installations or in areas where

vibration transmission is a consideration.

Figure 2, Isolator Locations

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 runningunder the main unit supports.

The unit should be set initially

on shims or blocks at the listed

spring free height. When all piping, wiring, flushing, charging, etc., is completed, the

springs are adjusted upward to loosen the blocks or shims that are then removed.

A rubber anti-skid pad should be used under isolators if hold-down bolts are not used.

Installation of spring isolators requires flexible piping connections and at least three feet of

flexible electrical conduit to avoid straining piping and transmitting vibration and noise.


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Table 2, WGZ-CW Packaged, Mounting Weights & Vibration Mounting Location

Unit Mounting Weights, Lbs (kg) Spring-Flex Mountings R-I-S Mountings

Size M1 M2 M3 M4 M1 M2 M3 M4 M1 M2 M3 M4

ID-900 ID-900 ID-900 ID-900 RP-3 RP-3 RP-3 RP-3030 625 653 618 591

Green Green Green Green Gray Gray Gray Gray













ID-1350 ID-1350 ID-1350 ID-1350 RP-4 RP-4 RP-4 RP-4070 964 907 978 1038Purple Purple Purple Purple Brown Brown Brown Brown


Purple Purple Purple Purple Brown Brown Brown Brown


Green Green Green Green Brown Brown Brown Brown


Green Green Green Gray Brick Red Brick Red Brick Red Brick Red






Gray Gray Gray Gray Brick Red Brick Red Brick Red Brick Red


Gray Gray Gray Gray Brick Red Brick Red Brick Red Brick Red


Gray Gray Gray Gray Brick Red Brick Red- Brick Red Brick Red WR

NOTES:

1. ID 900 has one spring per housing.

2. ID 1350, ID 1800, ID 2400 have two springs per housing.


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Table 3, WGZ-CA, Remote Condenser, Mounting Weights & Vibration Mounting Location

Unit Mounting Weights, Lbs Spring-Flex Mountings R-I-S Mountings

Size M1 M2 M3 M4 M5 M6 M1 M2 M3 M4 M5 M6 M1 M2 M3 M4 M5

ID-900 ID-900 ID-510 ID-510 RP-3 RP-3 RP-3 RP-3030 476 501 322 307 N/A N/A

Green Green Black BlackN/A N/A

Lime Lime Lime LimeN/A


Green Green Black Black

N/A N/A

Lime

Lime

Lime

Lime

N/A
















ID-900 ID-900 ID-675 ID-900 RP3 RP3 RP3 RP3

070 738 651 509 577 N/A N/A Green Green Purple Green N/A N/A Gray Gray Gray Gray N/A


Green Green Purple GreenN/A N/A

Gray Gray Gray GrayN/A


Black Black Red BlackN/A N/A





ID-1020 ID-1020 ID-680 ID-1020 RP-3 RP-3 RP-3 RP-3115 957. 764 621 778 N/A N/A






ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 RP-4 RP-4 RP-4 RP-4 RP-4 150 821 793 763 931 968 1003Black Black Black Black Black Black Brown Brown Brown Brown Brown B

ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 RP-4 RP-4 RP-4 RP-4 RP-4 170 863 812 750 919 986 1047

Black Black Black Black Black Black Brown Brown Brown Brown Brown B

ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 RP-4 RP-4 RP-4 RP-4 RP-4 200 875 831 784 947 1000 1057

Black Black Black Black Black Black Brown Brown Brown Brown Brown B

NOTES:

1. ID 510, ID 675 and ID 900 have one spring per housing.

2. ID 680 and ID 1020 have two springs per housing.

Table 4, WGZ-CW, Packaged, Isolator Kit Numbers

Model Number 030-060 070-080 090 100-130 150-200Spring-Flex 332320501 332320502 332320503 332320504 332320505

R-I-S 332325501 332325502 332325502 332325503 332325503

Table 5, WGZ-CA, Remote Condenser, Isolator Kit Numbers

Model Number 030-060 070-080 090-115 130 150-200

Spring-Flex 332320506 332320507 332320508 332320509 332320510

R-I-S 332325504 332325501 332325501 332325501 332325505


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Figure 3, Spring Flex Mounting. Two-Spring

Figure 4, Neoprene-in-Shear Mounting, RP-3

DRAWING NUMBER 3319880

2.50

1.75 (R)

.25

MOUNTING MOLDED INDURULENE. WEATHERRESISTANT (WR)

3.38

4.13

5.50

.5 DIA.2 HOLES

1/2-13 TAP

LOCATING PIN TOBE INSTALLED HERE

ALL

DIMENSIONS ARE IN DECIMAL INCHES


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Table 6, Spring Flex Mounting, One-Spring

Table 7, Neoprene-in-Shear, RP-4

NOTES:

MOUNT MATERIAL TO BE DURULENE RUBBER.1.

MOLDED STEEL AND ELASTOMER MOUNT FOR.OUTDOOR SERVICE CONDITIONS.

. RP-4 MOUNT VERSION WITH STUD IN PLACE.

ALL DIMENSIONS ARE IN DECIMAL INCHES

DRAWING NUMBER 3314814

1.13 .25APPROX.

1.63

.38

DURULENEMATERIAL

RAISED GRIP RIBS

3.00

3.75

5.00

6.25

3.87

.56 TYP.

4.63

R.28TYP.

R.250 TYP.

R.750 TYP.RECESSEDGRIP RIBS

.500-13NC-2B

R4

R4

VM&C

VM&C


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Limitations of Operation

1. Maximum allowable condenser water pressure is 232 psig (1599 kPa).

2. Maximum condenser LWT is 115F (46.1C).

3. Maximum design saturated discharge temperature (SDT) is 140F (60C). SDT=Condensingtemperature + discharge line loss.

4. Maximum condenser leaving water temperature is 115F (41.6C).

5. Maximum allowable water temperature to evaporator when not operating is 100F (37.8C).

Maximum entering water temperature for operating cycle is 90F (32.2C) (during system

changeover from heating to cooling cycle).

6. Minimum design leaving water temperature from the evaporator without anti-freeze protection is

40F (4.4C).

7. Contact your McQuay representative for operation with tower condenser water entering the chiller

below 60F (15.6C).

8. The maximum altitude for air-cooled condensers is 8,000 feet.9. Consult factory for ambient operation below 0F (-17.8C) for air-cooled applications.


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Water Piping

Vessel Drains at Start-upCondensers are drained of water in the factory and are shipped with the condenser drain plugs in the

heads removed and stored in a bag in the control panel. Be sure to replace plugs prior to filling the

vessel with fluid.

GeneralDue to the variety of piping practices, it is advisable to follow the recommendations of local

authorities for code compliance. They can supply the installer with the proper building and safety

codes required for a safe and proper installation.

Basically, the piping should be designed with a minimum number of bends and changes in elevation

to keep system cost down and performance up. Other piping design considerations include:

1. All piping should be installed and supported to prevent the chiller connections from bearing anystrain or weight of the system piping.

2. Vibration eliminators to reduce vibration and noise transmission to the building.

3. Shutoff valves to isolate the unit from the piping system during unit servicing.

4. Manual or automatic air vent valves at the high points of the system. Drains should be placed atthe lowest points in the system.

5. Some means of maintaining adequate system water pressure (e.g., expansion tank or regulatingvalve).

6. Temperature and pressure indicators located within 3 feet (0.9 meters) of the inlet and outlet ofthe vessels to aid in unit servicing.

7. A strainer or some means of removing foreign matter from the water before it enters the pump isrecommended. It should be placed far enough upstream to prevent cavitation at the pump inlet

(consult pump manufacturer for recommendations). The use of a strainer will prolong pump life

and thus maintain system performance.

Important NoteA cleanable 40-mesh strainer must also be placed in the water line just prior to the inletof the evaporator on Models WGZ 030 to 130. A 20-mesh is satisfactory on Models WGZ150 to 200. This will aid in preventing foreign material from entering and decreasing theperformance of the evaporator.

8. If the unit is used as a replacement chiller on a previously existing piping system, the systemshould be thoroughly flushed prior to unit installation. Regular water analysis and chemical

water treatment on the evaporator and condenser is recommended immediately upon equipment

start-up.

9. In the event glycol is added to the water system, as an afterthought for freeze protection,recognize that the refrigerant suction pressure will be lower, cooling performance less, and

water side pressure drop will be higher. If the percentage of glycol is large, or if propyleneglycol is used instead of ethylene glycol, the added pressure drop and loss of performance

could be substantial. Reset the freezestat and low leaving water alarm temperatures. The

freezestat is factory set to default at 36F (2.2C). Reset the freezestat setting to approximately

4 to 5F (2.3 to 2.8C) below the leaving chilled water setpoint temperature. See the section

titled Glycol Solutions for additional information concerning the use of glycol.

10.A preliminary leak check of the water piping should be made before filling the system.


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Note: A water flow switch or pressure differential switch must be mounted in theevaporator outlet water line to signal that there is water flow before the unit will start.

Table 8, Typical Field Evaporator Water Piping, WGZ 030 to 130AirVent

FlowSwitch

VibrationEliminators

Drain

Outlet

Inlet

PIsolationValves

Strainer

NOTE: Water piping must be supported independently from the unit.

Figure 5, Typical Field Evaporator Water Piping, WGZ 150 to 200

Vent

Drain

GateValve

WaterStrainer

VibrationEliminatorValved

PressureGauge

In

OutProtect All Field Piping

Against Freezing

Flow

VibrationEliminator

FlowSwitch

BalancingValve

GateValve

Flow

Liquid

Suction

NOTE: Inlet and outlet connections may be reversed on some units. Check unit

dimension drawing.

System Water VolumeIt is important to have adequate water volume in the system to provide an opportunity for the chiller

to sense a load change, adjust to the change, and then stabilize. As the expected load change

becomes more rapid, a greater water volume is needed. The system water volume is the total

amount of water in the evaporator, air handling equipment, and associated piping. If the water

volume is too low, operational problems can occur including rapid compressor cycling, rapid

loading and unloading of compressors, erratic refrigerant flow in the chiller, improper motor

cooling, shortened equipment life and other undesirable occurrences.

For normal comfort cooling applications where the cooling load changes relatively slowly, a

minimum system volume of two to three minutes times the flow rate (GPM) is recommended. For

example, if the design chiller flow rate is 120 gpm, we recommend a system volume of 240 to 360

gallons.

For process applications where the cooling load can change rapidly, additional system water

volume is needed. A process example would be the quenching of hot metal objects. The load would

be very stable until the hot metal is dipped into the water tank. Then, the load would increase

drastically.

Since there are many other factors that can influence performance, systems can successfully operate

below these suggestions. However, as the water volume decreases below these guidelines, the

possibility of problems increases.


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Suction

Circuit #1SuctionCircuit #2

LiquidCircuit #2

LiquidCircuit #1

Leaving ChilledWater Sensor

Variable Chilled Water FlowReducing chilled water flow in proportion to load can reduce total system power consumption.

Certain restrictions apply to the amount and rate of flow change. The rate of flow change should

be a maximum of 10 percent of the change, per minute. Do not reduce flow lower than the part

load minimum flows listed on page 17.

Chilled Water PipingThe system water piping must be flushed thoroughly prior to making connections to the unit

evaporator. It is required that a 40-mesh strainer be installed in the return water line before the

inlet to the chiller. Lay out the water piping so the chilled water circulating pump discharges into

the evaporator inlet.

The return water line must be piped to the evaporator inlet connection and the supply water line

must be piped to the evaporator outlet connection. If the evaporator water is piped in the reverse

direction, a substantial decrease in capacity and efficiency of the unit will be experienced.

A flow switch must be installed in the horizontal piping of the supply (evaporator outlet) water

line to prove water flow before starting the unit.

Drain connections should be provided at all low points in the system to permit complete drainage

of the system. Air vents should be located at the high points in the system to purge air out of the

system. The evaporators are not equipped with vent or drain connections and provision must be

made in the entering and leaving chilled water piping for venting and draining.

Pressure gauges should be installed in the inlet and outlet water lines to the evaporator. Pressure

drop through the evaporator should be measured to determine water flow from the flow/pressure

drop curves beginning on page 18. Vibration eliminators are recommended in both the supply and

return water lines.

Chilled water piping should be insulated to reduce heat loss and prevent condensation. Complete

unit and system leak tests should be performed prior to insulating the water piping. Insulation

with a vapor barrier would be the recommended type of insulation. If the vessel is insulated, the

vent and drain connections must extend beyond the proposed insulation thickness for

accessibility.

Chillers not run in the winter should have their water systems thoroughly drained if subject to

sub-freezing temperatures. If the chiller operates year-round, or if the system is not drained forthe winter, the chilled water piping exposed to sub-freezing ambient temperatures should be

protected against freezing by wrapping the lines with a heater cable. In addition, an adequate

percentage of glycol should be added to the system to further protect the system during low

ambient temperature periods. It should be noted that water piping that has been left drained is

subject to more corrosion than if filled with water. Use of a Vapor Corrosion Inhibitor (VCI) or

some other protection should be considered.

Figure 6 Thermostat Well Location, WGZ 030 - 130

The chilled water sensor is factory installed in the leaving water

connection on the evaporator. Care should be taken not to damage

the sensor cable or lead wires when working around the unit. It isalso advisable to check the lead wire before running the unit to be

sure that it is firmly anchored and not rubbing on the frame or any

other component. If the sensor is ever removed from the well for

servicing, care must be taken to not wipe off the heat-conducting

compound supplied in the well.


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! CAUTION

The thermostat bulb should not be exposed to water temperatures above 125F (51.7C)since this will damage it.

Flow SwitchA water flow switch must be mounted in the leaving evaporator and condenser water lines to

prove adequate water flow before the unit can start. This will safeguard against slugging the

compressors on start-up. It also serves to shut down the unit in the event that water flow is

interrupted to guard against evaporator freeze-up.

Factory-mounted and wired evaporator and condenser flow switches are available as an option

If the optional factory flow switch is not supplied, a flow switch is available from McQuay under

part number 01750330. It is a paddle type switch and adaptable to any pipe size from 1 in. (25

mm) to 6 in. (152 mm) nominal. Certain flow rates are required to open the switch and are listed

in Table 9. Wire from switch terminals Y and R to panel terminals 33 and 43 (chilled water) and

41 and 53 (condenser water). There is also a set of normally closed contacts on the switch that

could be used for an indicator light or an alarm to indicate when a no flow condition exists.

1. Apply pipe sealing compound to only the threads of the switch and screw unit into 1 in. (25 mm)reducing tee. The flow arrow must be pointed in the correct direction.

2. Piping should provide a straight length before and after the flow switch of at least five times thepipe diameter without any valves, elbows, or other flow restricting elements.

! CAUTION

Make sure the arrow on the side of the switch is pointed in the direction of flow. The flowswitch is designed to handle the control voltage and should be connected according to thewiring diagram

Table 9, Paddle-Type Flow Switch Flow Rates

inch 1 1/4 1 1/2 2 2 1/2 3 4 5 6 8Pipe SizeNOTES (x) mm 32 (2) 38 (2) 51 63 (3) 76 102 (4) 127 (4) 153 (4) 204 (5)

gpm 5.8 7.5 13.7 18.0 27.5 65.0 125.0 190.0 205.0Flow

Lpm 1.3 1.7 3.1 4.1 6.2 14.8 28.4 43.2 46.6

gpm 3.7 5.0 9.5 12.5 19.0 50.0 101.0 158.0 170.0

Min.

Adjst. NoFlow Lpm 0.8 1.1 2.2 2.8 4.3 11.4 22.9 35.9 38.6

gpm 13.3 19.2 29.0 34.5 53.0 128.0 245.0 375.0 415.0Flow

Lpm 3.0 4.4 6.6 7.8 12.0 29.1 55.6 85.2 94.3

gpm 12.5 18.0 27.0 32.0 50.0 122.0 235.0 360.0 400.0

Max.

Adjst. No

Flow Lpm 2.8 4.1 6.1 7.3 11.4 27.7 53.4 81.8 90.8

NOTES:

1. A segmented 3-inch paddle (1, 2, and 3 inches) is furnished mounted, plus a 6-inch paddle loose.

2. Flow rates for a 2-inch paddle trimmed to fit the pipe.

3. Flow rates for a 3-inch paddle trimmed to fit the pipe.

4. Flow rates for a 3-inch paddle.

5. Flow rates for a 6-inch paddle.

Glycol Solutions

Chiller capacity, flow rate, evaporator pressure drop, and power input for glycol solutions can becalculated using the following formulas and reference to Table 10for ethylene and Table 11for

propylene glycol.

1. Capacity,Capacity is reduced compared to that with plain water. To find the reduced value,multiply the chillers capacity when using water by the capacity correction factor C to find

the chillers capacity when using glycol.

2. Flow, To determine evaporator gpm (or T) knowing T (or gpm) and capacity:

TablesFromGCorrectionFlowxT

CapacityGlycolxGPMGlycol

24


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For Metric Applications -- Determine evaporator lps (or T) knowing T (or lps)

and kW:

TablesfromGCorrectionFlowxTx

kWLpsGlycol

18.4

3. Pressure Drop, To determine glycol pressure drop through the cooler, enter the waterpressure drop graph on page 17at the actual glycol flow. Multiply the water pressure

drop found there by P to obtain corrected glycol pressure drop.

4. Power, To determine glycol system kW, multiply the water system kW by factor K.

Test coolant with a clean, accurate, glycol solution hydrometer (similar to that found in

service stations) to determine the freezing point. Obtain percent glycol from the freezing

point found in Table 10 or Table 11. On glycol applications the supplier normally

recommends that a minimum of 25% solution by weight be used for protection against

corrosion or the use of additional inhibitors.

Note: The effect of glycol in the condenser is negligible. As glycol increases intemperature, its characteristics have a tendency to mirror those of water.

Therefore, for selection purposes, there is no derate in capacity for glycol in thecondenser.

Table 10, Ethylene Glycol

Freezing PointPercentGlycol F C

C (Capacity) K (Power) G (Flow)P (Pressure

Drop)

10 26 -3 0.991 0.996 1.013 1.070

20 18 -8 0.982 0.992 1.040 1.129

30 7 -14 0.972 0.986 1.074 1.181

40 -7 -22 0.961 0.976 1.121 1.263

50 -28 -33 0.946 0.966 1.178 1.308

Table 11, Propylene Glycol

Freezing PointPercent

Glycol F C C (Capacity) K (Power) G (Flow)

P (Pressure

Drop)

10 26 -3 0.987 0.992 1.010 1.068

20 19 -7 0.975 0.985 1.028 1.147

30 9 -13 0.962 0.978 1.050 1.248

40 -5 -21 0.946 0.971 1.078 1.366

50 -27 -33 0.929 0.965 1.116 1.481

! CAUTION

Do not use automotive antifreeze. Industrial glycols must be used. Automotive antifreezecontains inhibitors that causes plating on copper tubes. The type and handling of glycol usedmust be consistent with local codes.


17/72


Circuit #1Outlet

Condenser

Temperature

ControlValve

CondenserWater

Circuit #2Outlet

Circuit #1Inlet

Circuit #2Inlet

Condenser Water PipingArrange the condenser water so the water enters the bottom connection of the condenser.

The condenser water will discharge from the top connection. Failing to arrange the

condenser water as stated above will negatively affect the capacity and efficiency.

Install pressure gauges in the inlet and outlet water lines to the condenser. Pressure drop

through the condenser should be measured to determine flow on the pressure drop/flowcurves on beginning on page 17Error! Bookmark not defined.. Vibration eliminators

are recommended in both the supply and return water lines. Install a 20-mesh strainer in

the inlet piping to the condenser.

Water-cooled condensers can be piped for use with cooling towers, well water, or heat

recovery applications. Cooling tower applications should be made with consideration of

freeze protection and scaling problems. Contact the cooling tower manufacturer for

equipment characteristics and limitations for the specific application.

Head pressure control must be provided if the entering condenser water can fall below

60F. The WGZ condenser has two refrigerant circuits with a common condenser water

circuit. This arrangement makes head pressure control with discharge pressure actuated

control valves difficult.

If the tower water temperature cannot be maintained at a 60F minimum, or when pond,

lake, or well water that can fall below 60F (15C) is used as the condensing medium,

special discharge pressure control must be used. A water recirculating system with

recirculating pump as shown in Figure 7 is recommended. This system also has the

advantage of maintaining tube velocity to help prevent tube fouling. The pump should

cycle with the chiller.

Figure 7, Recirculating Discharge Pressure Control System

Pressure Drops

The evaporator flow rates and pressure drops shown on the following page (Figure 8) are for full load

design purposes. The maximum flow rate and pressure drop are based on a 6-degree temperature drop.

Avoid higher flow rates with resulting lower temperature drops to prevent potential control problems

resulting from very small control bands and limited start up/shut off temperature changes.

The minimum flow and pressure drop is based on a full load evaporator temperature drop of 16-degrees.

Condenser pressure drops are shown on the page following evaporator drops.


18/72


Figure 8, Evaporator Pressure Drop, WGZ 030C WGZ 200C

Minimum Flow & PD Nominal Flow & PD Maximum Flow & PD

Inch-Pound S.I. Inch-Pound S.I. Inch-Pound S.I.WGZ-C

Model

Ref

#GPM Ft. L/S kPa GPM Ft. L/S kPa GPM Ft. L/S kPa

WGZ030C A 45 4.7 2.8 14.1 72 11 4.5 32.9 120 27.6 7.6 82.4WGZ035C B 51.9 4.9 3.3 14.6 83 11.4 5.2 34 138.3 28.5 8.7 85.4

WGZ040C C 61.1 5.1 3.9 15.2 97.8 11.8 6.2 35.4 163 29.7 10.3 88.8

WGZ045C D 68.2 5.2 4.3 15.5 109.1 12.1 6.9 36.1 181.8 30.2 11.5 90.4

WGZ050C E 76.7 5.8 4.8 17.2 122.6 13.4 7.7 40.1 204.4 33.6 12.9 100.6

WGZ055C F 84.6 6.1 5.3 18.1 135.4 14.1 8.5 42.2 225.6 35.4 14.2 105.9

WGZ060C G 90.8 6.6 5.7 19.7 145.2 15.6 9.2 46.5 242 39.2 15.3 117.1

WGZ070C H 106.3 3.7 6.7 10.9 170 8.6 10.7 25.6 283.4 21.2 17.9 63.3WGZ080C I 117.5 4.3 7.4 12.8 187.9 10 11.9 29.9 313.2 25 19.8 74.9

WGZ090C J 132.1 4.5 8.3 13.3 211.3 10.5 13.3 31.3 352.1 26.1 22.2 78.1

WGZ100C K 146.6 4.9 9.3 14.6 234.6 11.4 14.8 34.1 391.1 28.7 24.7 85.8

WGZ115C L 169.3 4.5 10.7 13.5 270.9 10.5 17.1 31.4 451.5 26.4 28.5 78.9

WGZ130C M 188.1 4.2 11.9 12.6 301 9.8 19 29.5 501.6 24.7 31.6 73.9

WGZ150C N 219.9 5.5 13.9 351.8 12.8 22.2 38.3 586.4 32.0 37

WGZ170C O 254 7.9 16 406.3 18.5 25.6 55.3 677.2 46.4 42.7

WGZ200C P 282.2 9.5 17.8 451.4 22 28.5 65.8 752.4 55.1 47.5

Notes: Minimum, nominal, and maximum flows are at a 16 F, 10 F, and 6 F chilled water temperature range respectively atARI tons.

900 1000

CBD K

LJIA

EFG

H

0

6

12

18

24

27

30

9

21

15

60

90

40 50 60 70 80 90 100 200 300 400 500 600

PresureDrop(ftofwater)

Flow Rate (GPM)

700 800

O

P

N

M


19/72


Figure 9, Condenser Pressure Drop, WGZ 030C WGZ 200C

Minimum Flow & PD Nominal Flow & PD Maximum Flow & PD

Inch-Pound SI Inch-Pound SI Inch-Pound SIUnit ModelRef

#GPM Ft. L/S kPa GPM Ft. L/S kPa GPM Ft. L/S kPa

WGZ030C A 56.1 2.4 3.5 7.2 89.7 6.3 5.7 18.8 149.5 17.4 9.4 52.0

WGZ035C B 64.9 3.4 4.1 10.2 103.8 8.6 6.5 25.7 173.0 23.9 10.9 71.4

WGZ040C C 76.3 2.7 4.8 8.1 122.1 6.9 7.7 20.6 203.5 19.3 12.8 57.7

WGZ045C D 85.3 3.6 5.4 10.8 136.5 9.2 8.6 27.5 227.5 25.7 14.4 76.8

WGZ050C E 96.4 2.9 6.1 8.7 154.2 7.5 9.7 22.4 257.0 20.7 16.2 61.9

WGZ055C F 105.8 3.8 6.7 11.4 169.2 9.7 10.7 29.0 282.0 26.8 17.8 80.1

WGZ060C G 113.4 4.5 7.2 13.5 181.5 11.6 11.5 34.7 302.5 32.3 19.1 96.5

WGZ070C H 132.8 4.1 8.4 12.3 212.4 10.4 13.4 31.1 354.0 29.0 22.3 86.7

WGZ080C I 146.8 3.7 9.3 11.1 234.9 9.5 14.8 28.4 391.5 26.5 24.7 79.2

WGZ090C J 165.0 3.4 10.4 10.2 264 8.8 16.7 26.3 440.0 24.5 27.8 73.2WGZ100C K 183.4 3.4 11.6 10.2 293.4 8.8 18.5 26.3 489.0 24.4 30.9 72.9

WGZ115C L 211.7 4.8 13.4 14.3 338.7 12.3 21.4 36.8 564.5 34.1 35.6 101.9

WGZ130C M 235.1 6.1 14.8 18.2 376.2 15.5 23.7 46.3 627.0 43.1 39.6 128.8

WGZ150C N 274.9 6.2 17.3 18.5 439.8 15.8 27.7 47.2 733.0 43.8 46.2 130.9

WGZ170C O 317.4 5.5 20.0 16.4 507.9 14.0 32.0 41.8 846.5 38.9 53.4 116.3

WGZ200C P 352.7 7.4 22.3 22.1 564.3 18.8 35.6 56.2 940.5 52.3 59.3 156.3

P

ressureDrop(ftofwater)

Flow Rate (GPM)


20/72


Refrigerant Piping

Unit with Remote CondenserGeneral

Refrigerant piping, to and from the unit, should be sized and installed according to the

latest ASHRAE Handbook. It is important that the unit piping be properly supported with

sound and vibration isolation between tubing and hanger, and that the discharge lines be

looped at the condenser and trapped at the compressor to prevent refrigerant and oil from

draining into the compressors. Looping the discharge line also provides greater line

flexibility.

NOTE:Do not install any refrigerant piping underground.

The discharge gas valves, liquid line solenoids, filter-driers, moisture indicators, and

expansion valves are all factory mounted as standard equipment with the water chiller.

For remote condenser application (WGZ-CA) such as air-cooled or evaporative

condenser, the chillers are shipped with a nitrogen/helium holding charge. The unit is

evacuated in the factory to 500 microns before charging with the nitrogen.

The liquid line has a shutoff valve upstream from the liquid line solenoid valve and a

copper tube cap to be brazed on this line after test to seal this line for shipment.

The discharge line has a ball valve installed between the compressor and the discharge

stub tube with a copper tube cap brazed on the line after test to seal it for shipment.

The discharge gas valves, liquid line solenoids, filter-driers, moisture indicators, and

expansion valves are all factory-mounted as standard equipment with the water chiller.

! DANGER

Do not apply heat, such as a brazing torch, to a sealed unit, vessel, or component. Internalgases can increase the internal pressure and cause a life-threatening explosion. Open thesystem when heating. The short line between a valve and brazed end cap can be drilled to

vent it. Note that the valve may leak and the entire unit charge may be open to the cap.

It is important that the unit be kept tightly closed until the remote condenser is installed,

piped to the unit and the high side evacuated.

When the field piping has been leak tested, evacuated, and is ready to charge, the unit

valves can be opened and the system is ready to pressure test, evacuate and charge the

entire system together at one time.

After the equipment is properly installed, leak tested, and evacuated, it can be charged

with R-410A, and run at design load conditions. Add charge until the liquid line sight

glass is clear, with no bubbles flowing to the expansion valve. Total operating charge will

depend on the air-cooled condenser used and volume of the refrigerant piping.NOTE:On WGZ-CA units (units with remote condensers), the installer is required to record

the refrigerant charge by stamping the total charge and the charge per circuit on the serial plate

in the appropriate blocks provided for this purpose.

The following discussion is intended for use as a general guide to the piping of air-cooled

condensers.

Discharge lines must be designed to handle oil properly and to protect the compressor from

damage that can result from condensing liquid refrigerant in the line during shutdown. Total

friction loss for discharge lines of 3 to 6 psi (20.7 to 41.4 kPa) is considered good design.


21/72


Careful consideration must be given for sizing each section of piping to insure that gas

velocities are sufficient at all operating conditions to carry oil. If the velocity in a vertical

discharge riser is too low, considerable oil can collect in the riser and the horizontal header,

causing the compressor to lose its oil and result in damage due to lack of lubrication. When the

compressor load is increased, the oil that had collected during reduced loads can be carried as

a slug through the system and back to the compressor, where a sudden increase of oil

concentration can cause liquid slugging and damage to the compressor.

Any horizontal run of discharge piping should be pitched away from the compressor

approximately 1/8 inch (6.4 mm) per foot (meter) or more. This is necessary to move, by

gravity, any oil lying in the header. Oil pockets must be avoided because oil needed in the

compressor would collect at such points and the compressor crankcase can become starved.

It is recommended that any discharge lines coming into a horizontal discharge header rise

above the centerline of the discharge header. This is necessary to prevent any oil or condensed

liquid from draining to the compressor heads when the compressor is not running.

In designing liquid lines, it is important that the liquid reach the expansion valve without flash

gas since this gas will reduce the capacity of the valve. Because flashing can be caused by a

pressure drop in the liquid line, the pressure losses due to friction and changes in static head

should be kept to a minimum.

A check valve must be installed in the liquid line in all applications where the ambient

temperature can drop below the equipment room temperature. This prevents liquid migration

to the condenser, helps maintain a supply of refrigerant in the liquid line for initial start-up,

and keeps liquid line pressure high enough on off cycle to keep the expansion valve closed.

On systems as described above, a relief valve or relief-type check valve, must be used in the

liquid line as shown in piping systems (shown in and Its purpose is to relieve dangerous

hydraulic pressures that could be created as cool liquid refrigerant trapped in the line between

the check valve and the expansion or shutoff valve warms up. Install a relief device in the hot

gas piping at the condenser coil as shown in and Figure 11. Install a discharge check valve in

the discharge line, in a horizontal run, close to the condenser.

Recommended Line SizingThe following tables provide recommended line sizing for the field piping. Final design

should be based on ASHRAE design standards.


22/72


Table 12, Equivalent Feet for Fittings

Fitting Type 7/8 1 1/8 1 3/8 1 5/8 2 1/8 2 5/8 3 1/8

Elbows

90Standard 2.0 2.6 3.3 4.0 5.0 6.0 7.5

90Long Radius 1.4 1.7 2.3 2.6 3.3 4.1 5.0

90Street 3.2 4.1 5.6 6.3 8.2 10 12

45Standard 0.9 1.3 1.7 2.1 2.6 3.2 4.045Street 1.5 2.1 3.0 3.4 4.5 5.2 6.4

180Bend 3.2 4.1 5.6 6.3 8.2 10 12

Tees

Full Size 1.4 1.7 2.3 2.6 3.3 4.1 5.0

Reducing 2.0 2.6 3.3 4.0 5.0 6.0 7.5

Valves

Globe Valve, Open 22 29 38 43 55 69 84

Gate Valve, Open 0.9 1.0 1.5 1.8 2.3 2.8 3.2

Angle Valve, Open 9.0 12 15 18 24 29 35

Table 13, Maximum Line Size for Oil Carry Up a Discharge Riser, R-410A

Unit Size WGZ030

WGZ035

WGZ040

WGZ045

WGZ050

WGZ055

WGZ060

WGZ070

WGZ080

WGZ090

Line

Size (in.)1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8

Unit SizeWGZ

100

WGZ

115

WGZ

130

WGZ

150

WGZ

170

WGZ

200

Line

Size (in.)2 5/8 3 1/8 3 1/8 2 5/8 3 1/8 3 1/8

Table 14, Recommended Liquid Line Size, R-410A

Recommended Liquid Line Size (in.)

Up to Up to Up to Up to Up to

Unit Model

WGZ-CB

Connection

Size at Unit(in.) 50 Equiv. Ft 75 Equiv. Ft 100 Equiv. Ft 125 Equiv. Ft 150 Equiv. Ft

WGZ 030 7/8" 7/8 " 7/8 " 7/8 " 7/8 " 7/8 "

WGZ 035 7/8" 7/8 " 7/8 " 7/8 " 7/8 " 1 1/8 "

WGZ 040 7/8" 7/8 " 7/8 " 7/8 " 1 1/8 " 1 1/8 "

WGZ 045 7/8" 7/8 " 7/8 " 7/8 " 1 1/8 " 1 1/8 "

WGZ 050 7/8" 7/8 " 7/8 " 7/8 " 1 1/8 " 1 1/8 "

WGZ 055 7/8" 7/8 " 7/8 " 1 1/8 1 1/8 " 1 1/8 "

WGZ 060 7/8" 7/8 7/8 " 1 1/8 " 1 1/8 " 1 1/8 "

WGZ 070 1 1/8 1 1/8 1 1/8 " 1 1/8 " 1 1/8 " 1 1/8

WGZ 080 1 1/8 1 1/8 " 1 1/8 " 1 1/8 1 1/8 1 1/8

WGZ 090 1 1/8 1 1/8 " 1 1/8 " 1 1/8 1 1/8 1 1/8

WGZ 100 1 1/8 1 1/8 " 1 1/8 " 1 1/8 1 1/8 1 1/8WGZ 115 1 1/8 1 1/8 " 1 1/8 " 1 1/8 1 3/8 1 3/8

WGZ 130 1 1/8 1 1/8 " 1 3/8 1 1/8 1 3/8 1 3/8

WGZ 150 1 3/8 1 3/8 1 1/8 " 1 3/8 1 3/8 1 3/8

WGZ 170 1 3/8 1 3/8 1 1/8 " 1 3/8 1 3/8 1 3/8

WGZ-200 1 3/8 1 3/8 1 1/8 " 1 3/8 1 3/8 1 3/8


23/72


Table 15, Recommended Horizontal or Downflow Discharge Line Size, R-410A

Recommended Discharge Line Sizes

Up to Up to Up to Up to Up toUnit Model

AGZ-CB

Connection

Size

At Unit 50 Equiv. Ft 75 Equiv. Ft 100 Equiv. Ft 125 Equiv. Ft 150 Equiv. Ft

WGZ 030 1 3/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"

WGZ 035 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8"

WGZ 040 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8"WGZ 045 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8"

WGZ 050 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8"

WGZ 055 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8"

WGZ 060 1 3/8" 1 3/8" 1 5/8 1 5/8 1 5/8 1 5/8

WGZ 070 1 3/8" 1 3/8" 1 5/8 1 5/8 1 5/8 1 5/8

WGZ 080 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8

WGZ 090 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8

WGZ 100 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8

WGZ 115 1 5/8 1 5/8 1 5/8 2 1/8" 2 1/8" 2 1/8"

WGZ 130 1 5/8 1 5/8 2 1/8" 2 1/8" 2 1/8" 2 1/8"

WGZ 150 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8"

WGZ 170 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8"

WGZ 200 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 5/8"

Typical Arrangements

Figure 10 illustrates a typical piping arrangement involving a remote air-cooled condenser

located at a higher elevation than the compressor and receiver. This arrangement is commonly

encountered when the air-cooled condenser is on a roof and the compressor and receiver are on

grade level or in a basement equipment room.

Notice, in both illustrations, that the hot gas line is looped at the bottom and top of the vertical

run. This is done to prevent oil and condensed refrigerant from flowing back into thecompressor and causing damage. The highest point in the discharge line should always be

above the highest point in the condenser coil. It is advisable to include a purging vent at this

point to extract non-condensables from the system.

Figure 11 illustrates another very common application where the air-cooled condenser is

located on essentially the same level as the compressor and receiver. The discharge line piping

in this case is not too critical. The principal problem encountered with this arrangement is that

there is frequently insufficient vertical distance to allow free drainage of liquid refrigerant

from the condenser coil to the receiver.

The receiver is used when it is desired to have refrigerant storage capacity, in addition to the

pumpdown capability of the condenser.


24/72


Condenser

Relief Valve

Check Valve

Purge Valve

Discharge Line

Loop

Receiver

ReceiverBypass

ToEvap.

PreferredSubcoolerHook-up

Relief Valve(Vent to Outdoorsor to Condenser Sideof Liquid LineCheck Valve)

Pitch

CheckValve

Subcooler

Condenser

Relief Valve

Check Valve

Purge Valve

Relief Valve(Vent to Outdoorsor to Condenser Sideof Liquid LineCheck Valve)

Pitch

CheckValve

Discharge Line

Receiver

ReceiverBypass

ToEvap.

PreferredSubcoolerHook-up

CheckValve

Subcooler

Figure 10, Condenser Above Compressor and Optional Receiver Installation

Figure 11, Condenser and Compressor on Same Level, Optional Receiver

Installation

The receiver shown is optional and not used on many installations. It is bypassed during

normal operation.


25/72


Factory-Mounted CondenserUnits with the standard water-cooled, factory-mounted condenser are provided with

complete refrigerant piping and full operating refrigerant charge at the factory.

There is a remote possibility on water-cooled units utilizing low temperature pond or

river water as a condensing medium, and if the water valves leak, that the condenser and

liquid line refrigerant temperature could drop below the equipment room temperature on

the off cycle. This problem only arises during periods when cold water continues tocirculate through the condenser and the unit remains off due to satisfied cooling load.

If this condition occurs:

1. Cycle the condenser pump off with the unit.

2. Check the liquid line solenoid valve for proper operation.

Relief Valve Piping

The ANSI/ASHRAE Standard 15, Safety Standard for Refrigeration Systems, specifies

that pressure relief valves on vessels containing Group 1 refrigerant (R-410a) shall

discharge to the atmosphere at a location not less than 15 feet (4.6 meters) above the

adjoining ground level and not less than 20 feet (6.1 meters) from any window,

ventilation opening or exit in any building. The piping must be provided with a rain capat the outside terminating point and with a drain at the low point on the vent piping to

prevent water buildup on the atmospheric side of the relief valve. Also, a flexible pipe

section should be installed in the line to eliminate any piping stress on the relief valve(s).

The size of the discharge pipe from the pressure relief valve should not be less than the

size of the pressure relief outlet. When two or more vessels are piped together, the

common header and piping to the atmosphere should not be less than the sum of the area

of each of the lines connected to the header.

NOTE: Fittings should be provided to permit vent piping to be easilydisconnected for inspection or replacement of the relief valve.

Figure 12, Relief Valve Piping


26/72


Dimensions

Packaged Chillers

Figure 13, WGZ 030CW through WGZ 060CW

CHILLER WATER CONNECTIONSIZE (NOM) VICTAULIC

CONDENSER WATER

CONNECTION SIZE(NOM) VICTAULIC

CENTER OF GRAVITYWGZ MODELNUMBER

IN (MM) A IN (MM) X Y Z

WGZ030C 2.5 (64) 107.4 (2728) 4 (102) 59.2 22.4 14.1

WGZ035C 2.5 (64) 108.4 (2753) 4 (102) 59.9 22.8 14.2

WGZ040C 2.5 (64) 109.8 (2789) 4 (102) 59.6 22.8 14.2

WGZ045C 2.5 (64) 111.5 (2832 4 (102) 59.2 22.9 14.2

WGZ050C 2.5 (64) 113.3 (2878) 4 (102) 59.0 23.3 14.2

WGZ055C 2.5 (64) 115.0 (2921) 4 (102) 58.7 23.4 14.2

WGZ060C 2.5 (64) 116.7 (2965) 4 (102) 58.0 23.6 14.3

CONDENSER

INLET

121.13075

9.7246

134.63419

3.8

REF.98 " X "

" Y "

3.9100

.875 DIA MOUNTING HOLES (4)

INLET

OUTLET

OUTLET

RELIEF VALVES

MICROTECH II USER INTERFACE

VENT

DRAIN

CIRCUIT 1CIRCUIT 2

30.1763

32.8832

" Z "

" Y "

23.5597

2.051

20.0508

29.0737

13.3338

32.0813

8.0204

14.0354

29.2742

44.91139

12.4314

63.41609

40.01016

EVAPORATOR

REMOVABLEDISC. HANDLE

REMOVE BRKT.FOR SHIPPING

ONLYPOWER

CONNECTIONS

CONTROLCONNECTION

.88 KNOCKOUTSON OPPOSITE SIDE

.88 KNOCKOUTS

"A"

CONTROL BOX

WATERCONNECTIONS

L1 / M1 L2 / M2

L3 / M3L4 / M4

WGZ030C-060CPac kaged Unit

331929701


27/72



MAXIMUM OVERALL

DIMENSIONSIN (MM) CENTER OF GRAVITYWGZ MODELNUMBER

L W H

CHILLERWATER

CONNECTIONIN(MM)

VICTAULIC

SIZE (NOM)

A

CONDENSERWATER

CONNECTIONIN(MM)

VICTAULIC

SIZE (NOM)

T

X Y Z

WGZ070C143.3(3639)

35.0(889)

65.5(1664)

3 (76)114.9(2918)

4 (102)8.0

(203)62.4 28.6 15.0

WGZ080C149.6(3799)

35.0(889)

65.5(1664)

3 (76)115.3(2930)

4 (102)14.3(363)

64.8 29.3 15.1

WGZ090C149.4(3795)

35.0(889)

65.5(1664)

3 (76)117.1(2975)

4 (102)14.1(359)

67.7 29.6 16.1

WGZ100C149.4

(3795)

35.0

(889)

65.5

(1664)

3 (76)118.0

(2997)

4 (102)14.1

(359)

69.7 29.9 17.1

WGZ115C149.4(3795)

35.0(889)

65.5(1664)

3 (76)121.6(3088)

4 (102)14.1(359)

68.8 30.2 17.1

WGZ130C149.4(3795)

35.0(889)

65.5(1664)

3 (76)124.7(3167)

4 (102)14.1(359)

67.8 30.4 17.1

CONDENSER

121.13075"T"

14.2361

"L"

"A"

" X "

4.0102


INLET

INLET

OUTLET

OUTLET

EVAPORATOR

RELIEF VALVES


VENT

DRAIN

CIRCUIT 2 CIRCUIT 1

29.0737

13.0330

32.3821

"W"

" Y "

" Z "

23.5597

2.051

10.0253

17.9454

32.8834

57.6

1462

14.5369

20.0508

"H"

32.0813

40.01016

40.21021

REMOVABLEDISC. HANDLE REMOVE BRKT.

FOR SHIPPINGONLY

POWERCONNECTIONS

CONTROLCONNECTION


.88 KNOCKOUTS

CONTROL BOX

WATERCONNECTIONS

L1 / M1 L2 / M2

L3 / M3L4 / M4

WGZ070-130CWPackaged Chiller

331929801


28/72



CHILLER WATERCONNECTION SIZE(NOM) VICTAULIC

CONDENSER WATERCONNECTION SIZE(NOM) VICTAULIC


IN (MM) IN (MM) X Y Z

WGZ150C 8 (203) 5 (127) 68.7 38.6 14.9

WGZ170C 8 (203) 5 (127) 66.3 38.3 15.0

WGZ200C 8 (203) 5 (127) 66.6 38.7 15.1

CONDENSER

EVAPORATOROUTLET

10.9276

145.13685

14.2361

170.24322

" X "

" Y "

4.0

102

INLET

OUTLET

EVAPORATORINLET

RELIEF VALVES


VENT

VENT

DRAINDRAIN

29.0737

13.3337

33.8859

36.5

T.B.D.927

77.71973

" Z "

23.5597

2.051

15.5394

17.0432

9.6243

18.3464

36.9

EVAP

INLET/OUTLET

938

32.0813

5.0127

40.01016

41.21046


.88 KNOCKOUT

REMOVABLEDISC HANDLE


ONLY

CONTROLCONNECTION


POWERCONNECTIONS

23.5596

77.21961

1.334

CIRCUIT 1CIRCUIT 2

WGZ150CW-200CWPackaged Chiller

331929901


29/72


Chillers with Remote Condenser

Figure 16, WGZ 030CA through WGZ 060CA

CHILLER WATER CONNECTIONSIZE (NOM) VICTAULIC

CONDENSER WATER

CONNECTION SIZE(NOM) VICTAULIC

CENTER OF GRAVITYWGZ MODEL

NUMBER

IN (MM) A IN (MM) X Y Z

WGZ030CA 2.5 (64) 21.6 (550) 4 (102) 67.3 22.8 13.3

WGZ035CA 2.5 (64) 20.6 (523) 4 (102) 68.3 23.8 13.4

WGZ040CA 2.5 (64) 19.2 (488) 4 (102) 67.9 23.9 13.5

WGZ045CA 2.5 (64) 17.5 (444) 4 (102) 67.3 24.0 13.5

WGZ050CA 2.5 (64) 15.8 (400) 4 (102) 67.2 24.5 13.5

WGZ055CA 2.5 (64) 14.0 (356) 4 (102) 66.6 24.6 13.5

WGZ060CA 2.5 (64) 12.3 (312) 4 (102) 66.1 24.7 13.6

WGZ030-060CAREMOTE CONDENSER UNIT

331929711

" X "

" Y "

137.03480

12.3312

6.0152

20.2512


CIRCUIT 1CIRCUIT 2

1.38 DISCHARGECONNECTIONS

.88 LIQUIDCONNECTIONS

30.3770

" Z "

23.5597

2.051

30.0762

2.051

20.0508

34.0864

40.01016

6.0152

6.0151

16.5419

60.01524

EVAPORATOR

REMOVABLEDISC. HANDLE REMOVE BRKT.

FOR SHIPPING

ONLY

POWERCONNECTIONS

CONTROLCONNECTION


.88 KNOCKOUTS

ISOLATOR HOLES (4)

OUTLET

INLET

LIQUIDCONNECTIONS

EVAP. ANDDISCHARGECONNECTIONS

25.9657

41.51054

" A "

27.4696

38.2971 87.9

223498.82509

11.4289

10.4263

OUTLET

INLET


30/72



CHILLER WATERCONNECTION SIZE

(NOM) VICTAULIC

COND.

WATERCONN. SIZE

VICTAULIC

REFRIGERANTPIPING

CONNECTION SIZE

CENTER OF GRAVITY(IN.)

WGZMODEL

NUMBER

IN (MM) A IN (MM) B DISC. C LIQ.

T

LEFTOVERHANG

X Y Z

WGZ070C 3 (76) 14.1 (359) 4 (102) 1.38 OD 1.13 OD N/A 71.5 29.3 14.9

WGZ080C 3 (76) 13.7 (348) 4 (102) 1.62 OD 1.13 OD 6.3 (161) 74.9 30.1 15.0

WGZ090C 3 (76) 11.9 (303) 4 (102) 1.62 OD 1.13 OD 6.6 (167) 75.7 30.4 15.1

WGZ100C 3 (76) 11.0 (280) 4 (102) 1.62 OD 1.13 OD 6.6 (167) 75.2 30.6 15.2

WGZ115C 3 (76) 7.5 (190) 4 (102) 1.62 OD 1.13 OD 6.6 (167) 73.8 30.8 15.2

WGZ130C 3 (76) 4.4 (111) 4 (102) 1.62 OD 1.13 OD 6.6 (167) 72.6 30.9 15.3

" T "

" Y "

" X "

137.03480

12.3312

6.0152

23.2588

MICROTECH II USER INTERFACECIRCUIT 1CIRCUIT 2

DISCHARGE CONNECTIONS "B"

LIQUID CONNECTIONS "C"

32.3821

23.5597

2.051

30.0762

2.051" Z "

20.0508

34.0864

40.01016

6.0152

60.01524

4.0

101

15.5394

EVAPORATOR


REMOVE BRKFOR SHIPPIN

ONLYPOWER

CONNECTIONS

CONTROLCONNECTION


.88 KNOCKOUTS

ISOLATOR HOLES (4)

OUTLET

INLET

LIQUID

CONNECTIONS

EVAP. ANDDISCHARGECONNECTIONS

52.01322

18.5469

27.3694

"A "

13.3338

12.4.253166.35

38.2971

89.22266

98.82509

OUTLET

INLET

WGZ070-130CAUnit less condenser

331929811

1.533

5.2413

1.533

2.051

30.0

762

2.051

%%c.75

ISOLATOR HOLES IN THEBOTTOM OF THE BASE

19

CONTROL BOX

CIRCUIT 1CIRCUIT 2

L1 L2

L3L4

M1 M2

M3M4

EVAP WATERCONNECTIONS


31/72



CHILLER WATERCONNECTION SIZE

(NOM) VICTAULIC


IN (MM) X Y Z

WGZ150C 8 (203) 79.1 43.2 15.3

WGZ170C 8 (203) 80.1 43.6 15.4

WGZ200C 8 (203) 79.7 44.0 15.4

" Y "

" X "

154.03912

2.051

MICROTECH IIUSER INTERFACE

CIRCUIT 1CIRCUIT 2

WGZ150-200CAREMOTE CONDENSER UNIT

331929911

2.051

30.0762

2.051

" Z "

5.0127

12.0

305

35.5902

3.076

75.01905

12.0305

34.0864

40.01016

4.0101

5.0127



ONLY

CONTROLCONNECTION


.88 KNOCKOUTSISOLATOR HOLES (6)

POWERCONNECTIONS

(QTY 3)

LIQUIDCONNECTIONS

106.52705

33.9862

42.11069 119.3

3030

34.2867

24.9631

74.71898

17.4443

6.0152

23.2588

OUTLETINLET

1.62 O.D. DISCHARGECONNECTIONS

1.38 O.D. LIQUIDCONNECTIONS

CIRCUIT 1 CIRCUIT 2

2.360 7.9

200

14.5368

13.4340

3.690

EVAPORATORINLET/OUTLET

DISCHARGECIRCUIT 1 DISCHARGE

CIRCUIT 2

21.0533

30.0762

2.051

2.051

21.0533

58.01473

54.01372

.75

ISOLATOR HOLES IN THEBOTTOM OF THE BASE

19

CONTROL BOX

CIRCUIT 1CIRCUIT 2

L1 L2

L3L4

M1 M3

M4M6

M2

M5


32/72


Physical Data

Packaged Chillers

Table 16, WGZ 030CW WGZ 055CW

WGZ UNIT SIZE 30 35 40 45 50 55

Unit capacity @ ARI tons, (kW) 30.0 (105.5) 34.6 (121.7) 40.7 (143.1) 45.5 (160.0) 51.4 (180.8) 56.4 (198.4)

No. Circuits 2 2 2 2 2 2

COMPRESSORS

Nominal Tons 7.5 7.5 9 9 10 10 12 12 13 13 13 15

Number Per Circuit 2 2 2 2 2 2 2 2 2 2 2 2

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT

Staging, Circuit #1 in Lead 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 23 / 50 / 73 / 100


Oil Charge per Compressor oz., (l) 85 (2.5) 110 (3.3) 110 (3.3) 110 (3.3) 110 (3.3) 110 (3.3)

CONDENSER

Number 1 1 1 1 1 1

No. Refrigerant Circuits 2 2 2 2 2 2

Diameter, in., (mm) 10 (254) 10 (254) 10 (254) 10 (254) 10 (254) 10 (254)

Tube Length, in., (mm) 120 (3048) 120 (3048) 120 (3048) 120 (3048) 120 (3048) 120 (3048)

Design W.P.PSIG, (kPa):

Refrigerant Side 500 (3447) 500 (3447) 500 (3447) 500 (3447) 500 (3447) 500 (3447)

Water Side 232 (1599) 232 (1599) 232 (1599) 232 (1599) 232 (1599) 232 (1599)

Pump-Out Capacity, lb., (kg) (3) 245.8 (111.7) 245.8 (111.7) 228.2 (103.7) 228.2 (103.7) 205.4 (93.4) 205.4 (93.4)

Conn.In & Out, in, (mm) Victaulic 4 (102) 4 (102) 4 (102) 4 (102) 4 (102) 4 (102)

Relief Valve, Flare In., (mm) (15.9) (15.9) (15.9) (15.9) (15.9) (15.9)

Purge Valve, Flare In., (mm) (12.7) (12.7) (12.7) (12.7) (12.7) (12.7)

Vent & Drain, in. (mm) NPT (6.4) (6.4) (6.4) (6.4) (6.4) (6.4)

Liquid Subcooling Integral Integral Integral Integral Integral Integral

EVAPORATOR, BRAZED-PLATENumber 1 1 1 1 1 1


Water Volume, gallons, (l) 1.9 (7.1) 2.2 (8.3) 2.4 (9.1) 2.9 (11.0) 3.4 (12.8) 3.7 (14.0)

Refrig. Side D.W.P. Psig, (kPa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102)

Water Side D.W.P,. psig, (kPa) 653 (4500) 653 (4500) 653 (4500) 653 (4500) 653 (4500) 653 (4500)

Conn. In & Out, in. (mm) Victaulic 2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65)

Relief Valve, Flare in., (mm) (15.9) (15.9) (15.9) (15.9) (15.9) (15.9)

Vent & Drain Field Field Field Field Field Field

UNIT DIMENSIONS

Length In., (mm) 136.0 (3455) 136.0 (3455) 136.0 (3455) 136.0 (3455) 136.0 (3455) 136.0 (3455)

Width In., (mm) 32.8 (832) 32.8 (832) 32.8 (832) 32.8 (832) 32.8 (832) 32.8 (832)

Height In., (mm) 63.4 (1609) 63.4 (1609) 63.4 (1609) 63.4 (1609) 63.4 (1609) 63.4 (1609)

UNIT WEIGHTS

Operating Weight, lb., (kg) 2486 (1128) 2572 (1167) 2631 (1193) 2650 (1202) 2752 (1248) 2771 (1257)

Shipping Weight, lb., (kg) 2410 (1093) 2496 (1132) 2539 (1152) 2558 (1160) 2639 (1197) 2658 (1206)

Cir # 1,Opn. Charge, lb.,(kg) R410a 45 (20.5) 45 (20.5) 47 (21.4) 47 (21.4) 47 (21.4) 50 (22.7)

Cir # 2,Opn. Charge, lb.,(kg) R410a 45 (20.5) 45 (20.5) 47 (21.4) 47 (21.4) 47 (21.4) 50 (22.7)

Notes:

1. Certified in accordance with ARI Standard 550/590-2003.2. 90% Full R-410a at 90F (32C) per unit.


33/72


Table 17, WGZ060CW - WGZ100CW

WGZ UNIT SIZE 60 70 80 90 100

Unit capacity @ ARI tons, (kW) (1) 60.5 (212.8) 70.8 (249.0) 78.3 (275.4) 88.0 (309.5) 97.8 (344.0)

No. Circuits 2 2 2 2 2

COMPRESSORS

Nominal Tons 15 15 15/20 15/20 20 20 20 26 26 26

Number per Circuit4 2 2 2 2 2 2 2 2 2 2


Staging, 4 Stages, Circuit #1 in Lead 25 / 50 / 75 / 100 22 / 50 / 72 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100

Staging, 4 Stages, Circuit #2 in Lead 25 / 50 / 75 / 100 22 / 50 / 72 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100

Oil Charge, per compressor oz. (l) 110 (3.3)110 (3.3)158 (4.7)

110 (3.3)158 (4.7)

158 (4.7)158(4.7)

230(6.8)

230 (6.8)

CONDENSER

Number 1 1 1 1 1

No. Refrigerant Circuits 2 2 2 2 2

Diameter, in. (mm) 10 (254) 14 (356) 14 (356) 14 (356) 14 (356)

Tube Length, in. (mm) 120 (3048) 120 (3048) 120 (3048) 120 (3048) 120 (3048)

Design W.P., psig (kPa):

Refrigerant Side 500 (3447) 500 (3447) 500 (3447) 500 (3447) 500 (3447)

Water Side 232 (1599) 232 (1599) 232 (1599) 232 (1599) 232 (1599)

No. of Passes 2 2 2 2 2

Pump-Out Capacity lb., (kg) (3) 205.4 (93.4) 415.1 (188.7) 397.5 (180.7) 371.1 (168.7) 344.7 (156.7)

Conn. In & Out, in., (mm) Victaulic 4 (102) 4 (102) 4 (102) 4 (102) 4 (102)

Relief Valve, Flare in., (mm) (15.9) (15.9) (15.9) (15.9) (15.9)

Purge Valve, Flare in. (mm) (12.7) (12.7) (12.7) (12.7) (12.7)

Vent & Drain, in. (mm) NPT (6.4) (6.4) (6.4) (6.4) (6.4)

Liquid Subcooling Integral Integral Integral Integral Integral

EVAPORATOR, BRAZED-PLATE

Number 1 1 1 1 1


Water Volume, gallons (l) 4.2 (15.9) 6.4 (24.3) 6.6 (24.9) 7.5 (28.4) 8.0 (30.2)Refrigerant Side D.W.P., psig, (kPa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102)

Water Side D.W.P., psig, (kPa) 653 (4500) 653 (4500) 653 (4500) 653 (4500) 653 (4500)

Conn. In & Out, in. (mm) Victaulic 2.5 (65) 3 (76) 3 (76) 3 (76) 3 (76)


Vent & Drain Field Field Field Field Field

UNIT DIMENSIONS

Length, in. (mm) 136.0 (3455) 143.3 (3639) 149.6 (3799) 149.4 (3795) 149.4 (3795)

Width, in. (mm) 32.8 (832) 35.0 (889) 35.0 (889) 35.0 (889) 35.0 (889)

Height, in. (mm) 63.4 (1609) 65.5 (1664) 65.5 (1664) 65.5 (1664) 65.5 (1664)

UNIT WEIGHTS

Operating Wt, lb., (kg) 2801 (1271) 3887 (1763) 4302 (1951) 4507 (2044) 4678 (2122)

Shipping Wt, lb. (kg) 2688 (1219) 3746 (1699) 4145 (1880) 4327 (1963) 4474 (2029)

Cir # 1,Opn. Charge, lb, (kg) R410a 50 (22.7) 74 (34.1) 80 (36.4) 80 (36.4) 90 (40.9)

Cir # 2,Opn. Charge, lb.,(kg) R410a 50 (22.7) 74 (34.1) 80 (36.4) 80 (36.4) 90 (40.9)

Notes:

1. Certified in accordance with ARI Standard 550/590-2003.-2. Units WGZ030 to 130 have two parallel compressors per circuit. Units WGZ150 to 200 have three parallel compressors per circuit.3. 90% Full R-410a at 90F (32C) per unit.


34/72


Table 18, WGZ115CW - WGZ200CW

WGZ UNIT SIZE 115 130 150 170 200

Unit capacity @ ARI. tons, (kW) (1) 112.9 (397.1) 125.4 (441.0) 146.6 (515.6) 169.3 (595.4) 188.1 (661.5)


COMPRESSORS

Nominal Tons 26/30 26/30 30 30 26 26 26 30 30 30

Number Per Circuit 2 2 2 2 3 3 3 3 3 3


Staging, 4 Stages, Circuit #1 in Lead 22 / 50 / 72 / 100 25 / 50 / 75 / 10017 / 33 / 50 / 67

/ 83 / 10015 / 33 / 48 / 67 /

81 / 10017 / 33 / 50 / 67 /

83 / 100

Staging, 4 Stages, Circuit #2 in Lead 22 / 50 / 72 / 100 25 / 50 / 75 / 10017 / 33 / 50 / 67

83 / 10019 / 33 / 52 / 67

86 /10017 / 33 / 50 / 67 /

83 / 100

Oil Charge, per compressor oz. (l)230 (6.8 )/213 (6.3)

230 (6.8 )/213 (6.3)

213 (6.3) 230 (6.8) 230 (6.8) 213 (6.3) 213 (6.3)

CONDENSER

Number 1 1 1 1 1


Diameter, in. (mm) 14 (356) 14 (356) 16 (406.4) 16 (406.4) 16 (406.4)

Tube Length, in. (mm) 120 (3048) 120 (3048) 144 (3658) 144 (3658) 144 (3658)

Design W.P., psig (kPa):

Refrigerant Side 500 (3447) 500 (3447) 500 (3447) 500 (3447) 500 (3447)

Water Side 232 (1599) 232 (1599) 232 (1599) 232 (1599) 232 (1599)

Pump-Out Capacity lb., (kg) (3) 344.7 (156.7) 344.7 (156.7) 572.3 (260.1) 508.9 (231.3) 508.9 (231.3)

Water Conn In & Out, in., (mm) (4) 4 (102) 4 (102) 5 (127) 5 (127) 5 (127)


Purge Valve, Flare in. (mm) (12.7) (12.7) (12.7) (12.7) (12.7)

Vent & Drain, in. (mm) FPT 6.4) 6.4) 6.4) 6.4) 6.4)

Liquid Subcooling Integral Integral Integral Integral Integral

EVAPORATOR, BRAZED-PLATE SHELL-AND-TUBE

Number 1 1 1 1 1

No. Refrigerant Circuits 2 2 2 2 2Water Volume, gallons (l) 8.5 (32.1) 10.5 (39.7) 57.6 (218.0) 56.9 (215.4) 56.9 (215.4)

Refrigerant Side D.W.P., psig, (kPa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102)


Water Conn.In & Out, in. (mm) Victaulic 3 (76) 3 (76) 8 (203) 8 (203) 8 (203)

Relief Valve, Flare in., (mm) (15.9) (15.9)

Drain & Vent size, in. (mm) Field Field (12.7) (12.7) (12.7)

UNIT DIMENSIONS

Length, in. (mm) 149.4 (3795) 149.4 (3795) 170.2 (4322) 170.2 (4322) 170.2 (4322)

Width, in. (mm) 35.0 (889) 35.0 (889) 36.5 (927) 36.5 (927) 36.5 (927)

Height, in. (mm) 65.5 (1664) 65.5 (1664) 77.7 (1973) 77.7 (1973) 77.7 (1973)

UNIT WEIGHTS

Operating Wt, lb., (kg) 4712 (2137) 4772 (2165) 7370 (3343) 7758 (3519) 7873 (3571)Shipping Wt, lb. (kg) 4508 (2045) 4568 (2072) 6581 (2985) 6921 (3139) 7036 (3192)

Cir #1, Op. Charge, lb., (kg) R-410a 100 (45.5) 100 (45.5) 150 (68.2) 150 (68.2) 150 (68.2)

Cir #2, Op. Charge, lb., (kg) R-410a 100 (45.5) 100 (45.5) 150 (68.2) 150 (68.2) 150 (68.2)

Notes:

1. Certified in accordance with ARI Standard 550/590-2003.2. Units WGZ030 to 130 have two parallel compressors per circuit, units WGZ150 to 200 have three parallel compressors per circuit.3. 90% Full R-410a at 90F (32C) per unit.


35/72


Chillers with Remote CondenserTable 19, WGZ030CA - WGZ055CAWGZ UNIT SIZE 30 35 40 45 50 55

Tons, (kW), 44F LWT, 125F SDT 26.6 (93.5) 30.5 (107.3) 35.2 (123.8) 39.8 (139.9) 45.8 (161.0) 50.3 (176.8)

No. Circuits 2 2 2 2 2 2

COMPRESSORS

Nominal Tons 7.5 7.5 9 9 10 10 12 12 13 13 13 15

Number per Circuit 2 2 2 2 2 2 2 2 2 2 2 2



Oil Charge, per comp. oz, (l) 85 (2.5) 110 (3.3) 110 (3.3) 110 (3.3) 110 (3.3) 110 (3.3)

EVAPORATOR, BRAZED PLATE


Water Volume, gallons, (l) 1.9 (7.1) 2.2 (8.3) 2.4 (9.1) 2.9 (11.0) 3.4 (12.8) 3.7 (14.0)

Refrig. Side D.W.P. Psig, (kPa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102)

Water Side D.W.P. Psig, (kPa) 653 (4500) 653 (4500) 653 (4500) 653 (4500) 653 (4500) 653 (4500)

Inlet & Outlet, in., (mm) (1) 2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65)

Relief Valve, Flare in., (mm) (15.9) (15.9) (15.9) (15.9) (15.9) (15.9)

Drain & Vent Field Field Field Field Field Field

UNIT DIMENSIONS

Length In., (mm) 137.0 (3480) 137.0 (3480) 137.0 (3480) 137.0 (3480) 137.0 (3480) 137.0 (3480)

Width In., (mm) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864)

Height In., (mm) 60.0 (1524) 60.0 (1524) 60.0 (1524) 60.0 (1524) 60.0 (1524) 60.0 (1524)

UNIT WEIGHTS

Operating Weight, lb., (kg) 1606 (728) 1698 (770) 1715 (778) 1738 (788) 1773 (804) 1795 (814)

Shipping Weight, lb., (kg) 1580 (717) 1670 (758) 1685 (764) 1704 (773) 1735 (787) 1754 (796)

Table 20, WGZ060CA - WGZ100CAWGZ UNIT SIZE 60 70 80 90 100

Tons, (kW) 44F LWT, 125F SDT 53.9 (189.5) 61.3 (215.7) 68.6 (242.0) 77.7 (273.3) 86.6 (304.5)


COMPRESSORS

Nominal Tons 15 15 15/20 15/20 20 20 20 26 26 26Number Per Circuit 2 2 2 2 2 2 2 2 2 2

Staging, Circuit #1 in Lead 25 / 50 / 75 / 100 22 / 50 / 72 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100

Staging, Circuit #2 in Lead 25 / 50 / 75 / 100 22 / 50 / 72 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100

Oil Charge, per compressor oz. (l) 110 (3.3) 110 (3.3) 158 (4.7) 158 (4.7) 230 230 (6.8)

EVAPORATOR, BRAZED PLATE


Water Volume, gallons (l) 4.2 (15.9) 6.4 (24.3) 6.6 (24.9) 7.5 (28.4) 8.0 (30.2)

Refrigerant Side D.W.P., psig, (kPa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102)


Inlet & Outlet, in. (mm) (2) 2.5 (63) 3 (76) 3 (76) 3 (76) 3 (76)


Drain & Vent Field Field Field Field Field

UNIT DIMENSIONS

Length, in. (mm) 137.0 (3480) 137.0 (3480) 137.0 (3480) 137.0 (3480) 137.0 (3480)Width, in. (mm) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864)

Height, in. (mm) 60.0 (1524) 60.0 (1524) 60.0 (1524) 60.0 (1524) 60.0 (1524)

UNIT WEIGHTS


Shipping Wt, lb. (kg) 1771 (803) 2406 (1091) 2717 (1232) 2851 (1293) 2968 (1346)

Notes:1. Condenser and field piping not included.


36/72


Table 21, WGZ115CA WGZ200CA

WGZ UNIT SIZE 115 130 150 170 200

Tons, (kW)44F LWT, 125F SDT 100.1 (352.2) 111.4 (391.7) 129.9 (456.8) 150.2 (528.3) 170.6 (599.8)


COMPRESSORS

Nominal Tons 26/30 26/30 30 30 26 26 26 30 30 30

Number Per Circuit 2 2 2 2 3 3 3 3 3 3

Staging, Circuit #1 in Lead 22 / 50 / 72 / 100 25 / 50 / 75 / 100 17 / 33 / 50 / 67 /83 / 100

15 / 33 / 48 / 67 /81 / 100

17 / 33 / 50 / 67 /83 / 100

Staging, Circuit #2 in Lead 22 / 50 / 72 / 100 25 / 50 / 75 / 10017 / 33 / 50 / 67 /

83 / 10019 / 33 / 52 / 67 /

86 / 10017 / 33 / 50 / 67 /

83 / 100

Oil Charge, per compressor oz. (l)230 (6.8 )213 (6.3)

213 (6.3) 230 (6.8) 230 (6.8) 213 (6.3) 213 (6.3)

EVAPORATOR, BRAZED PLATE------------------------------------------------ SHELL-AND-TUBE


Water Volume, gallons (l) 8.5 (32.1) 10.5 (39.7) 57.6 (218.0) 56.9 (215.4) 56.9 (215.4)

Refrigerant Side D.W.P., psig, 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102)


Water Connections:

In & Out, in. (mm), victaulic 3 (76) 3 (76) 8 (203) 8 (203) 8 (203)


Drain & Vent Field Field (12.7) (12.7) (12.7)

UNIT DIMENSIONS

Length, in. (mm) 137.0 (3480) 137.0 (3480) 154.0 (3912) 154.0 (3912) 154.0 (3912)

Width, in. (mm) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864)

Height, in. (mm) 60.0 (1524) 60.0 (1524) 75.0 (1905) 75.0 (1905) 75.0 (1905)

UNIT WEIGHTS


Shipping Wt, lb. (kg) 3035 (1377) 3091 (1402) 4779 (2168) 4891 (2219) 5004 (2270)

Notes:1. Condenser and field piping not included

Operating Limits

Equipment room temperature limits, operating or standby: 32F to 104F (0C to 40C) Maximum allowable condenser water pressure is 232 psig (1599 kPa).

Maximum design saturated discharge temperature is 140F (60C).

Maximum allowable water temperature to evaporator in a non-operating cycle is 100F (37.8C).

Maximum entering water temperature for operating cycle is 90F (32.2C) (during system changeover

from heating to cooling cycle).

Minimum leaving water temperature from the evaporator without freeze protection is 40F (4.4C).

Minimum entering tower condenser water temperature is 60F (15.6C).

Maximum condenser leaving water temperature is 115F (46.1C)

For remote air-cooled condensers, the temperature difference between the saturated discharge temperature

and the outside air temperature (TD) must be between 15 and 35 degrees F and the saturated dischargetemperature cannot exceed 135F.


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Components

Figure 19, Compressor Locations

4 2 3 1

Circuit 2 Circuit 1Control Panel

EvaporatorEvaporator andCondenserConnections

NOTE: Models WGZ 150 to 200 add a #5 compressor to circuit #1 and a #6 compressor to

circuit #2.

Table 22, Major Components

System #1 System #2 Expansion ValveWGZ-C

Unit

SizeComp. #1 Comp. #3 Comp. #2 Comp. #4

Evap.

Vessel

Size

Cond.

Vessel

Size System #1 System #2

30 ZP90KCE ZP90KCE ZP90KCE ZP90KCE ACH130-90DQ C1010-47 OZE-20-GA-BP15 OZE-20-GA-BP15


40 ZP120KCE ZP120KCE ZP120KCE ZP120KCE ACH130118DQ C1010-57 OZE-20-GA-BP15 OZE-20-GA-BP15











150 (3) ZP295KCE (3) ZP295KCE EV34191111/9NS C1612-156 SEHI100-30-S SEHI100-30-S




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WGZ 030C through 200C IMM WGZC

Wiring

Field Wiring, Power

The WGZ C vintage chillers are supplied standard with compressor contactors and power terminal block,

designed for multi-point power supply to the unit, no compressor circuit breakers. Available options are:

Single-point connection to power block with compressor circuit breakers

Single-point connection to disconnect switch with compressor circuit breakersHigh short circuit current rating with single-point disconnect switch

Multi-point connection to disconnect switch, no compressor circuit breakers

A factory installed control circuit transformer is standard. Optionally, a field-installed control power source

can be wired to the unit.

Wiring and conduit selections must comply with the National Electrical Code and/or local requirements.

An open fuse indicates a short, ground, or overload. Before replacing a fuse or restarting a compressor, the

trouble must be found and corrected. Tables in the Electrical Data section (page 40) give specific

information on recommended wire sizes.

Unit power inlet wiring must enter the control box through the right

I&M Manual_WGZ-1

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