Single/Dual Compressor Centrifugal Chillers: PEH/PHH 050,063,079,087, 100, 126 PFH/PJH 050,063,079,087, 126
Single/Dual Compressor Centrifugal Chillers: PEH/PHH 050,063,079,087, 100, 126 PFH/PJH 050,063,079,087, 126
Application
The operation and maintenance procedures presented in this manual apply to the standard PEH family
of chillers. Reference to the Installation Manual, IM 306 for these units should be made for details
pertaining to receiving and handling, installation. piping and wiring, and preparation for initial startup.
All McQuay centrifugal chillers are factory tested prior to shipment and must be initially started at
the job site by a factory trained McQuayService technician. Failure to follow this startup procedure
may affect the equipment warranty.
The standard warranty on this equipment covers parts which prove defective in material or
workmanship. Specific details of this warranty can be found in the warranty statement furnished with
the equipment and also found at the end of this manual.
Cooling towers used with McQuay model PE centrifugal chillers are normally selected for maximum
condenser inlet water temperatures between 75°F and 90°F (24°C and 32°C). Lower entering water
temperatures are desirable from the standpoint of energy reduction but a minimum does exist. For
recommendations for optimum entering water temperature and cooling tower fan control, consult
McQuay Catalog 955. Applications Section.
2 IM 307-5
Operation
Operator Responsibilities
It is important that the operator become familiar with the equipment and the system before attempting to
operate the chiller. In addition to reading this manual the operator should study installation and
operation bulletin IM6 16 and the control diagram furnished with the unit so that he understands the
starting, operating and shutdown sequences as well as the safety shutdown modes.
During the initial startup of the chiller the McQuay technician will be available to answer any
questions and instruct in the proper operating procedures.
It is recommended that the operator maintain an operating log for each individual chiller unit. A
suggested log sheet is shown on page 19 of this manual.
In addition, a separate maintenance log should be kept of the periodic maintenance and servicing
activities.
This McQuay centrifugal chiller represents a substantial investment and deserves the attention
and care normally given to keep this equipment in good working order. If the operator should encoun-
ter abnormal or unusual operating conditions, it is recommended that a McQuayService technician be
consulted.
McQuay International conducts training for McQuay centrifugal operators at its factory Training
Center several times a year. These sessions are structured to provide basic classroom instruction and
include hands-on operating and troubleshooting exercises. For further information, contact your
McQuay representative.
Nomenclature
Each centrifugal chiller is assigned a set of identifying numbers which are used to describe the unit
features and to identify each individual unit. These number groups are stamped on each unit name-
plate.
All inquiries pertaining to operating and servicing of this unit should include all identification
numbers.
Each of the major individual components also have nameplates to provide certain necessary
information to the installer and the operator.
Compressors are designated as model CE. For example a model CEO50 compressor is used on a
model PEHO5O chiller unit. The compressor nameplate identifies the compressor model, style and serial
number and includes the electrical characteristics of the compressor motor. The CEO50 compressor
nameplate also shows the oil pump electrical characteristics.
The condenser and evaporator vessels have nameplates stamped with the maximum working
pressure of the vessel, the National Board Number, and the vessel style number. It should be noted
that the vessel relief valve maximum settings coincides with the maximum refrigerant side vessel
working pressure.
IM 307-5 3
MicroTech Control Panel
The MicroTech unit controller is a microprocessor based control panel designed to initiate the step-by-
step start functions of its host centrifugal compressor unit, monitor and regulate the compressors
capacity, protect it, and sequence the compressor shutdown on lack of load or in response to a preset
time. On dual compressor units, each compressor has its own controller. They are interconnected to
provide lead-lag and load-balance functions.
The full information on the features, installation, operation and problem analysis of the McQuay
microprocessor control for Centrifugal chillers, see Installation and Operation Manual IM 616 and
Operators Manual OM125. The MicroTech panel provides a wide range of control options and data
reporting and recording capability. Familiarity with the control system is important for optimum unit
operation.
Figure 1. MicroTech Control Panel
Vane Operation
The hydraulic system for the inlet guide vane capacity control operation consists of a 4-way normally
open solenoid valve located in the oil management control panel. Oil under pressure from the oil filter is
directed by the 4-way valve to either or both sides of the piston depending on whether the control
signal is to load, unload, or hold.
To open the vanes (or load the compressor) solenoid SA is de-energized and solenoid SB is
energized, allowing oil flow from port SA to one side of the piston then drain through port SB.
To close the vanes (unload compressor) valve SB is de-energized and valve SA is energized to
move the piston and vanes toward the unload position.
4 IM 307-5
When both solenoid valves SA and SB are de-energized, full oil pressure is directed to both sides
of the piston through ports SA and SB, thus the vanes are held in that position. Refer to figures 3 and 4
for solenoid action. Note that both solenoids cannot be energized simultaneously.
Metering Values
The speed at which the capacity control vanes are opened or closed can be adjusted to suit system
operating requirements. Adjustable needle valves in the oil drain lines are used to control the rate of
bleed-off and consequently the “vane speed”. These needle valves are part of the 4-way solenoid valve
assembly located in the compressor lube box (Figure 2).
The valves are normally factory set so the vanes will move from fully closed to fully opened in
approximately 3 minutes and from fully open to fully closed in 1 minute (except CEI 26). The speed
should be slow enough to prevent over-controlling and hunting.
IM 307-5 5
Oil System
The oil system for the PEH family of units provides lubrication and heat removal for compressor
bearings and internal parts. In addition, the system provides oil under pressure to hydraulically operate
the unloading piston for positioning the inlet guide vanes for capacity control. PFH dual compressor
chillers have completely independent lubrication systems for each compressor.
Proper operation of the hydraulic system and bearing lubrication system can be assured only if
recommended oil is used, recommended oils are shown in Table 1. Each unit is factory charged with the
correct amount of the recommended oil. Under normal operation, no additional should be needed. Oil
should be visible in the oil sump sight glass at all times.
The oil pump for the CE038/050 compressor is completely self-contained within the compressor
housing. The assembly includes the pump, pump motor, oil heater and oil separator. The oil is pumped
through the oil discharge line to the oil filter in the compressor casting and then to the internal refriger-
ant-cooled oil cooler.
The other compressor sizes-CE063. through CE1 26-utilize a separate oil pump contained in the oil
reservoir. This assembly includes pump, motor, heater and oil separator system. Oil is pumped through
the external oil cooler and then to the oil filter located inside the compressor housing. Standard PEH/
PHH 063- I26 units utilize a water-cooled oil cooler although an optional refrigerant-cooled oil cooler is
available. All dual compressor PFH/PJH chillers are equipped with refrigerant-cooled oil coolers as
standard.
The oil coolers maintain the proper oil temperature under normal operating conditions. The coolant
flow control valve should maintain 9O”F- 100°F (32”C-38°C). Lubrication protection for coast down in
the event of a power failure is accomplished by a spring loaded piston in models CEO50 through 100.
When the oil pump is started, the piston is forced back by the oil pressure, compressing the spring and
filling the piston cavity with oil. When the pump stops. the spring pressure on the piston forces the oil
out to the bearings.
In model CEI 26 the compressor coast down lubrication is supplied from a gravity feed oil reservoir.
A typical flow diagram is shown in figure 5.
Lubricant Designation Mobil Artic EAL 22: Mobil Artic EAL 46;
ICI Emkarate RL22N (1) ICI Emkarate RL32H@
McQuay Part Number
55 Gal. Drum 735030430, Rev 47 735030432, Rev 47
5 Gal. Drum 735030431, Rev 47 735030433, Rev 47
1 Gal. Can 735030434. Rev 47 735030435, Rev 47
Compressor Oil Label 070200105, Rev OB 070200106, Rev OB
1. ICI RL22S and 22H are not approved, only RL22N is acceptable
2. ICI RL32S Ester lubricant is not approved, only RL32H is acceptable
3. Approved Oil from two suppliers can be mixed.
IM 307-5 7
Figure 5. Typical Oil Flow Diagram
COMPRESSOR
7
. FILTER
I 1
OIL
COOLEf
BYPASS RELIEF
i , VALVE
OUT
[Link] WATER
IN
HEATER
8 IM 307-5
Maintenance
Routine Maintenance
Lubrication (See Caution)
After the system is once placed into operation, no other additional oil is required except in the event
that repair work becomes necessary to the oil pump or unless a large amount of oil is lost from the
system due to a leak.
If oil must be added with the system under pressure, use a hand pump with its discharge line
connected to the service valve at the bottom of the oil pump. (The CEO50 compressor with its internal
oil pump is equipped with an oil service valve on the compressor. The synthetic oils used with R-l 34a
are hydrophilic and care should be exercised to avoid exposure to moisture.
Caution
Improper servicing of the lubrication system, including the addition of excessive or incorrect oil,
substitute quality oil filter, or mishandling of the equipment under pressure is hazardous. Only autho-
rized and trained service personnel should attempt this service. For qualified assistance, contact your
local McQuay Service technician.
Refrigerant Cycle
Maintenance of the refrigerant cycle consists of maintaining a log of the operating conditions, and
assuring the unit has the proper oil and refrigerant charge. (See the maintenance schedule and the
appropriate operating log at the end of this bulletin)
At every inspection, the oil, suction and discharge pressures should be noted and recorded, as
well as condenser and chiller water temperatures.
10 IM 307-5
The suction line temperature at the compressor should be taken at least once a month. Subtracting
from this, the saturated temperature equivalent of the suction pressure will give the superheat. Extreme
changes in superheat over a period of time will indicate losses of refrigerant or possible deterioration of
the expansion valves. Proper superheat setting is 1 l/2 to 2 degrees Fahrenheit (1 degree Celsius) at full
load. Such a small temperature difference can be hard to measure accurately. Another method is to
measure the compressor discharge superheat, the difference between the actual discharge temperature
and the saturated discharge temperature. The superheat should be between 14 and 16 degrees Fahren-
heit (8 to 9 degrees Celsius) at full load. The liquid injection should be deactivated (remove relay #10)
when taking the discharge temperature. The superheat will increase linearly to 55 degrees Fahrenheit
(30 degrees Celsius) at 10% load. The Series 200 MicroTech Control can display all superheat and
subcooling temperatures.
Figure 8. Typical Refrigerant Flow Diagram
LIQUID
FILTER
DRIER
CHII-LED
rT NOTE 2
&T
w
T EXPANSION‘?4 LVE
p/ CONDENSER
OUT
CONDENSED WATER
I
IN
Electrical System
Maintenance of the electrical system involves the general requirement of keeping contacts clean and
connections tight and checking on specific items as follows:
1. The compressor current draw should be checked and compared to nameplate RLA value. Normally
the actual current will be lower since the nameplate rating represents full load operation. Also check
all pump and fan motor amperages and compare with nameplate ratings.
IM 307-5 11
2. Inspection should verify that the oil heaters are operative. The heaters are insert cartridge type and
can be checked by ammeter reading. They should be energized whenever power is available to the
control circuit and when the compressor is inoperative). When the compressor starts the heaters
are de-energized.
3. At least once a quarter, all safety controls except compressor overloads should be made to operate
and their operating points checked. Any control may shift its operating point as it ages, and this
must be detected so the controls can be adjusted or replaced. Pump interlocks and flow switches
should be checked to be sure they interrupt the control circuit when tripped.
4. The contactors in the motor starter should be inspected and cleaned quarterly. Tighten all terminal
connections.
5. The compressor motor resistance to ground should be checked and logged semi-annually. This log
will track insulation deterioration. A reading of 5 megohms or less indicates possible insulation
failure and should be further checked.
6. The centrifugal compressor must rotate in the direction indicated by the arrow on the casting near
the rotation sightglass. If the operator has any reason to suspect that the power system connec-
tions may have been altered, (phases reversed) the compressor should be jogged to check rotation.
For assistance. call McQuayService.
Seasonal Servicing
Prior to shutdown periods and before starting up again, the following service procedures should be
completed.
Annual Shutdown
1. Where the chiller may be subject to freezing temperatures, the condenser and chiller water piping
should be disconnected and drained of all water. Dry air blown through the condenser will aid in
forcing all water out. Removal of condenser heads is also recommended. The condenser and
evaporator are not self-draining. Water permitted to remain in the piping and vessels will rupture
these parts if subjected to freezing temperature.
Forced circulation of antifreeze through the water circuits is the only sure method of avoiding
trouble.
2. Take measures to prevent the shutoff valve in the water supply line from being accidentally turned
on.
12 IM 307-5
3. If a cooling tower is used and if the water pump will be exposed to freezing temperatures, be sure to
remove the pump drain plug and leave it out so any water that may accumulate will drain away.
4. Open the compressor disconnect switch, and remove the Fusetrons. If the transformer is used for
control voltage, the disconnect must remain on to provide power to the oil heater. Set the manual
stop/auto switch (SWI) to the stop position. To insure against the possibility of an accidental start,
remove the fault relay from the left side of the MicroTech panel (see IM 616).
5. Check for corrosion and clean and paint rusted surfaces.
6. Clean and flush water tower for all units operating on a water tower. Make sure tower “blowdown”
or bleed-off is operating. Set up and use a good maintenance program to prevent “liming up” of
both tower and condenser. It should be recognized that atmospheric air contains many contami-
nants which increase the need for proper water treatment. The use of untreated water may result in
corrosion, erosion, sliming, scaling or algae formation. It is recommended that the service of a
reliable water treatment company be used. McQuay International assumes no responsibility for the
results of untreated or improperly treated water.
7. Remove condenser heads at least once a year to inspect the condenser tubes and clean if required.
Annual Startup
A dangerous condition can exist if power is applied to a faulty compressor motor starter which has been
burned out. This condition can exist without the knowledge of the person starting the equipment.
This is a good time to check all the motor winding resistance to ground. Semi-annual checking and
recording of this resistance will provide a record of any deterioration of the winding insulation. All new
units have well over 100 megohms resistance between any motor terminal and ground.
Whenever great discrepancies in readings occur or uniform readings of less than 5 megohms are
obtained, the motor cover should be removed for inspection of the winding prior to starting the unit.
Uniform readings of less than 5 megohms indicate motor failure is imminent and motor should be
replaced or repaired. Repair before failure occurs can save a great deal of time and labor expended in
the cleanup of a system after motor burnout.
1. The control circuit should be energized at all times. If the control circuit has been off and oil is cool,
energize oil heaters and allow 24 hours for heater to remove refrigerant from the oil before starting.
2. Check and tighten all electrical connections.
3. Replace the drain plug in cooling tower pump if it was removed at shutdown time the previous
season.
4. Install Fusetrons in main disconnect switch (if removed).
5. Reconnect water lines and turn on supply water. Flush out condenser and check for leaks.
6. Refer to Manual IM 6 16 before energizing the compressor circuit.
I M 307-5 13
Repair of System
Pumping Down
If it becomes necessary to pump the system down. extreme care should be used to avoid damage to the
evaporator from freezing. Always make sure that full water flow is maintained through the chiller and
condenser while pumping down. To pump the system down, close all liquid line valves. With all liquid
line valves closed and water flowing, start the compressor. Set the MicroTech panel to the manual load
(see IM 6 16). The vanes must be open while pumping down to avoid a surge or other damaging
condition. Pump the unit down until the MicroTech cuts out at approximately 20 psig. It is possible
that the unit might experience a mild surge condition prior to cutout. If this should occur, immediately
shut off the compressor. Use a portable condensing unit to complete the pump down, condense the
refrigerant, and pump it into the condenser or pumpout vessel.
Pressure Testing
No pressure testing is necessary unless some damage was incurred. After repairs are made, pressure
test the system at a pressure that does not exceed the standby pressure in the condenser. (A test
pressure higher than condenser pressure would open the discharge check valve and allow flow of test
pressure into condenser). In cases where the entire refrigerant charge is lost. refer to the following
paragraphs. The evacuation procedure can be followed in both cases.
Leak Testing
In case of the loss of the entire refrigerant charge. the unit should be checked for leaks prior to charging
the complete system. This can be done by charging only enough refrigerant into the system to build
the pressure up to approximately 10 psig and adding sufficient dry nitrogen to bring the pressure up to
a maximum of 125 psig and then leak test with halide or electronic leak detector. Caution: Do not use
oxygen to build up pressure, as a serious explosion can result. A pressure regulating valve should
always be used on the drum being used to build the system pressure. Also, do not exceed the test
pressure given above. When the test pressure is reached disconnect the gas cylinder.
If any leaks are found in welded or silver soldered joints or if it necessary to replace a gasket.
relieve the test pressure in the system before proceeding. For copper joints, silver solder is recom-
mended.
After making any necessary repair, the system should be evacuated as described below.
Evacuation
After it has been determined that there are no refrigerant leaks, the system should be evacuated using a
vacuum pump with a capacity of approximately 3 [Link]./min. and that will reduce the vacuum to at least 1
millimeter( 1000 microns).
A mercury manometer, electronic or other type of micron gauge should be connected at the farthest
point from the vacuum pump. For readings below I millimeter, the electronic or other micron gauge
should be used.
The triple evacuation method is recommended and is particularly helpful if the vacuum pump is
unable to obtain the desired I millimeter of vacuum. The system is first evacuated to approximately 29
inches of mercury. Enough refrigerant vapor is then added to the system to bring the pressure up to
zero gauge pressure. Then the system is once again evacuated to approximately 29 inches of mercury.
This is repeated 3 times. The second pull down will remove about 90% of that remaining from the first
pull down and after the third, only 1/10 of 1 c% non-condensibles will remain.
14 IM 307-5
Refrigerant Charging
Since January 1993, all McQuay centrifugal chillers use R- 134a. R- 12, or R-500 refrigerants may have
been used prior to December 1992. Therefore it is recommended that the operator check the unit
nameplate to assure the correct refrigerant selection prior to charging or adding refrigerant.
An initial operating charge of R- 134a is made at the factory prior to shipment. In the event the
operator needs to add refrigerant after the unit is installed, certain precautions should be taken to
protect equipment components. Refrigerant charging lines must be kept dry, clean and free of non-
condensable gasses. Care should be taken on selecting the best charging point in the unit so as to
protect the unit from damage.
If the entire charge is lost or removed from the unit, recharging can be accomplished quickly and
safely by introducing the liquid refrigerant directly into the bottom of the evaporator with the expansion
valve manually opened. Both condenser water and chilled water must be flowing through the respec-
tive vessels to prevent localized freezing. Consult the chiller nameplate for the proper refrigerant
charge.
With a near-normal charge in the system, final charging can best be accomplished with the unit
running at full load. In this operating mode the unit should be charged until suction superheat is
between 1 l/2 to 2 degrees Fahrenheit (1 degree Celsius). or by the discharge superheat as explained
earlier. Adjusting the thermal expansion valve as necessary. Continue charging until 8 to 10 degrees
Fahrenheit (4.5 to 5.5 degrees Celsius) liquid subcooling is obtained leaving the condenser if the unit is
operating at full load. At less than full load, liquid subcooling will be proportionally less.
IM 307-5 15
Service Programs
It is important that an air conditioning system receive adequate maintenance if the full equipment life
and full system benefits are to be realized.
Maintenance should be an ongoing program from the time the system is initially started. A full
inspection should be made after 3 to 4 weeks of normal operation on a new installation and on a regular
basis thereafter.
McQuay offers a variety of maintenance services through McQuayService, its nationwide service
organization, and can tailor these services to suit the needs of the building owner. Most popular among
these services is the McQuayService Comprehensive Maintenance Contract.
For further information concerning the many services available, contact your local McQuayService
representative.
20 IM 307-5