Installation Manual WSC, WME and WMC-B Centrifugal Chillers Reassembly of Knockdown Shipments

Installation Manual WSC, WME and WMC-B Centrifugal Chillers Reassembly of Knockdown Shipments

Installation Manual

WSC, WME and WMC-B Centrifugal Chillers

Reassembly of Knockdown Shipments

COMPRESSOR

EVAPORATOR

SUPPORT

OIL PUMP

STARTER

UNIT

CONTROLLER

CONDENSER

IM 1128-1

Group: Chiller

Part Number: 331375601

Effective: April 2012

Supersedes: February 2012

REV: 01

2

Table of Contents

WSC Chiller Introduction ............................................................................... 3

Type I Reassembly ............................................................................................ 5

Type II Reassembly ........................................................................................ 14

Unit Photographs ................................................................................................................. 26

Type III Reassembly ....................................................................................... 28

Field Insulation Guide ................................................................................... 29

Dimensions and Weights ................................................................................ 31

Type I ................................................................................................................................... 31

Type II ................................................................................................................................. 33

Shipping Lists ................................................................................................. 38

WMC-B Introduction ..................................................................................... 42

Type IV Disassembly-Reassembly....................................................................................... 43

Type V Disassembly-Reassembly ........................................................................................ 43

WME Introduction ......................................................................................... 51

Type I Reassembly .......................................................................................... 52

Type II Reassembly ........................................................................................ 53

Type III Reassembly ....................................................................................... 56

Knockdown Dimensions ...................................................................................................... 57

Piping Removal ................................................................................................................... 58

Compressor Removal and Re-Attachment ........................................................................... 63

Compressor Removal and Re-Attachment ........................................................................... 64

Recognize Safety Symbols, Words, and Labels

The following label is used in this manual to indicate immediate or potential hazards. It is the responsibility of the owner and installer to read and comply with all safety information and instructions accompanying these symbols. Improper installation, operation and maintenance can void the warranty.

!

DANGER

Dangers indicate a hazardous situation which will result in death or serious injury if not avoided.

!

WARNING

Warnings indicate potentially hazardous situations, which can result in property damage, severe personal injury, or death if not avoided.

!

CAUTION

Cautions indicate potentially hazardous situations, which can result in personal injury or equipment damage if not avoided.

©2012 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: Magnitude, MicroTech E, from

McQuay International, Victaulic from Victaulic Company

Field Installation Procedure IM 1128-1

IM 1128-1

WSC Chiller Introduction

It is estimated that fifty percent of retrofit applications require partial or complete disassembly of the chiller. Daikin McQuay offers three solutions to the disassembly and reassembly effort on Model

WSC, single compressor centrifugal chillers.

TYPE I: The compressor is removed and put on a skid. All associated wiring and piping possible will remain on the vessel stack. The remaining loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5-psi helium holding charge.

3. The compressor will not be insulated at the factory. An insulation kit will be shipped with the unit.

4. The starter will ship loose. Bracket and cable kit to be included for unit-mounted starters and/or cableway for mini-cabinet starters.

5. The evaporator will be insulated at the factory.

6. Refrigerant will not be shipped with the unit and must be secured locally and furnished and installed by the installer.

7. Lubricant will be shipped in containers from the factory for field installation.

8. All field piping connections will be Victaulic

, O-ring face seal or copper brazing.

9. All free piping ends will be capped.

10. Touch-up paint will be included.

11. The unit will undergo the rigorous, full Daikin McQuay test program at the factory.

12. Contact local McQuay Factory Service for pricing and scheduling of required installation supervision.

TYPE II: The compressor with its terminal box is removed and placed on a skid. The condenser, evaporator, oil pump, oil cooler and tube sheet supports will remain connected only by their attachment bolts, ready for field disassembly and reassembly in the building. All wiring and piping that interconnects the components will be removed. The loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels have a 5-psi helium holding charge.

3. The compressor will not be insulated at the factory. An insulation kit will be shipped with the unit and will also include a container of adhesive.

4. Only the evaporator shell will be factory insulated. Loose insulation will be shipped for the suction line and remaining surface areas.

5. The starter will ship loose.

6. Refrigerant will not be shipped with the unit and must be secured locally and furnished and installed by the installer.

7. Lubricant will be shipped in containers from the factory for field installation.

8. All field piping connections will be Victaulic, flanged, O-ring face seal or copper brazing.

9. Bracket and cable kit will be included for all unit-mounted starters and/or cableway for minicabinet starters.

10. All free piping ends will be capped.

11. Touch-up paint and stick-on wire ties will be included.

12. A bolted bracket instead of a weld will mount the oil pump.

13. The discharge piping assembly will have a bolted flange connection (instead of welded) at the condenser. This assembly will ship loose.

14. Piping that remains attached to a component will be supported if it is not rigid.

15. The chiller will not be run-tested at the factory but the compressor, oil pump assembly and heat exchangers will be tested as sub-assemblies.

Field Installation Procedure 3

16. The control panels are shipped separately but have all sensors wired in, labeled and tied up.

Matching labels will exist at the sensor connection on the unit.

17. Contact local McQuay Factory Service for pricing and scheduling of required installation supervision.

TYPE III: The unit ships fully assembled and is field ready to knockdown. Included are the vessel bolt-on connection brackets, the discharge stack bolt-on flanges at the condenser and the bolt-on oil pump assembly.

1. The unit is shipped fully charged with refrigerant and lubricant.

2. The unit will be factory insulated and painted.

3. All electrical and sensor wiring will be fastened as usual.

4. The starter will ship per order instructions.

5. Touch up paint and stick-on wire ties will be included.

6. This unit will be fully tested at the factory.

7. Labels will be provided with the instructions to mark piping, electrical wiring and sensor wiring.

NOTE: If disassembly involves breaking any refrigerant connection, the refrigerant charge must be pumped down and isolated in the condenser.

4

Typical WSC Centrifugal Chiller

Field Installation Procedure IM 1128-1

Type I Reassembly

Description

TYPE I: The compressor with its terminal box is removed and placed on a skid as a separate package.

The suction piping is removed and shipped loose. All other piping will be disconnected from the compressor and remain attached to the vessel stack, where possible. Wiring and sensors to the compressor will be disconnected, rolled up and tied to the control panels. The remaining loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5-psi helium holding charge.

3. The compressor will not be insulated at the factory. An insulation kit will be shipped with the unit and will also include a container of adhesive.

4. The unit vessel stack will be insulated at the factory.

5. This unit will be tested with a full refrigerant charge at the factory and the charge will be removed after testing.

6. Refrigerant will not be shipped with the unit and must be secured locally and furnished and installed by the installer.

7. Bracket and cable kit will be included for all unit-mounted starters and/or cableway for minicabinet starters.

8. All free piping ends will be capped.

9. Touch-up paint and stick-on wire ties will be included.

10. Lubricant will be shipped in containers from the factory.

11. The starter will ship loose.

12. All field piping connections will be Victaulic, flanged, O-ring face seal or copper brazing.

13. The unit control panel and compressor control panel will be attached to the unit with loose sensor wires tied up behind the panel.

Reassembly Steps

NOTE: Additional instructions may be shown on the assembly drawings.

1. Mount the compressor on the stack. Be careful to avoid damaging lines already mounted on the unit.

Mounting bolts, washers and nuts are shipped loose. Leave the mounting bolts loose until the suction and discharge lines are installed and aligned.

During assembly, bolts holding block-off plates (motor cooling connection, for example), are used for

reassembly of the component. See Figure 1 or Figure 2 for the location and description of the block-

offs.

2. Do not remove block-offs until ready to install piping. The compressor and vessels have a Schrader valve on their block-off plates to be used for relieving the helium holding charge.

!

WARNING

Remove compressor and vessel holding charge through the Schrader valve in the block-off plates before attempting to loosen any fittings on them. Failure to do so can cause severe bodily injury.

3. Install the suction and discharge piping (see Figure 3). Before tightening the Victaulic couplings,

position the suction and discharge piping so that the compressor can be aligned to give the best fit-up.

When this is achieved, secure the compressor mounting bolts and proceed with installing the Victaulic couplings using a light coating of Victaulic lubrication.

IM 1128-1 Field Installation Procedure 5

6

4. Install the liquid injection line (see Figure 4). The liquid injection line is attached to the condenser

and has shipping straps securing it to the evaporator and condenser. It, and the compressor, each have a block-off. Note that any given injection line may be configured somewhat differently than shown on the drawing.

5. Install the motor cooling line (see Figure 5) using the same procedure as the liquid injection line.

6. Install the motor drain line (see Figure 6) using the same procedure as the liquid injection line.

7. Piping for the optional hot gas bypass is shipped mounted on the unit except for models WSC100,

WSC113 and WSC126 with vessel stacks sizes E36C30, E36C36, E42C36, E42C42, E48C42 and

E48C48. These units have the piping assembly shipped loose for field mounting. See Figure 7.

8. Install the compressor lubrication lines. There are four lines as shown in Figure 8:

a. Thrust pump return, injects lubricant from the compressor thrust pump (thrust bearing) into the lubricant supply line. b. Oil drain, drains lubricant from the compressor to the sump. c. Vent line, vents refrigerant from the sump back to the compressor suction. d. Oil supply, supplies lubricant from the pump in the sump to the compressor.

There is a variety of fitting types employed on the oil lines. Reconnect the compression fittings, bolt on the flanges using new gaskets furnished, and re-sweat the sweat connections.

9. Install the four-way solenoid on the compressor suction housing.

10. Install compressor wiring using Figure 9 (including notes) as a guide. Figure 9 shows connections for

both Type I and Type II arrangements. Only the connections listed below are required to be made for

Type I. The wire end that has been disconnected, and its attachment point on the compressor, will each have a label attached (VC for the vane close switch, for example) for matching purposes. a. Guardistor

, G1 (and G2 on some units), terminal box located on side of motor housing. b. Compressor heaters, CP1 (and CP2 on some units), located on the bottom of the compressor. c. Vane load/unload solenoids, SA and SB, located on the four-way solenoid assembly. d. Vane close switch, VC, located on compressor next to the discharge housing. e. Vane open switch, VO, located on suction end of compressor. f. High pressure switch, HPS, located on compressor discharge nozzle.

11. If the unit has been ordered with a starter or VFD as unit mounted, brackets for mounting it and interconnection cables to the compressor motor will be included as ship loose items. Control wiring as

shown in Figure 9 and Figure 13 (field wiring diagram), will also be required. The field wiring

diagram located on the control panel door should also be consulted as it will be current. If the unit has a free standing starter, use normal field procedures for mounting and wiring.

Normal procedure of leak testing, triple evacuation, and charging with refrigerant and lubricant must be followed prior to the start up procedure.

12. Insulate the compressor motor, suction line, and other miscellaneous areas with the included insulation

and adhesive after leak testing. See Field Insulation Guide on page 29.

This completes the reassembly procedure.

Field Installation Procedure IM 1128-1

Figure 1, WSC 063 - 087 Compressor Connections

LIQUID

INJECTION

FROM COND. BTM.

OIL LINE VENT

FROM TOP FRONT

OF OIL PUMP

OIL THRUST RETURN

TO OIL LINE TEE

MOTOR COOLING

REFRIGERANT

FROM COND. BTM

MOTOR COOLING

FROM COND. BTM.

4-WAY SOLENOID VALVE

LEFT VIEW

(20" MTR.HSG.)

OIL DRAIN

TO TOP BACK

OF OIL PUMP

MOTOR DRAIN

TO EVAP BOTTOM

MOTOR DRAIN

15" MTR. HSG.

ATTACH TAG TO ONE

TERMINAL INSIDE BOX

OIL SUPPLY

FROM OIL COOLER

MOTOR DRAIN

TO EVAP BOTTOM

R331311301C0100

RIGHT VIEW

Notes:

1. New O-rings and gaskets are in a plastic bag.

2. Compressor is charged with 5-psi of helium.

OIL OUT TO SA AND SB

SOLENOID VALVES AND

OIL PRESSURE TRANSDUCER

IM 1128-1 Field Installation Procedure 7

Figure 2, WSC 100-126 Compressor Connections

OIL OUT TO SA AND SB

SOLENOID VALVES AND

OIL PRESSURE TRANSDUCER

OIL SUPPLY

TO OIL COOLER

UNSWEAT LINE AND

SHUT VALVE

OIL VENT

FROM TOP FRT.

OF OIL PUMP

OIL THRUST

RETURN TO

OIL LINE TEE

MOTOR COOLING

FROM CONDENSER

BOTTOM

MOTOR COOLING

FROM COND.

BOTTOM

4 WAY SOLENOID VALVE

DISCHARGE

BLOCKOFF

OIL DRAIN

TO TOP BACK

OF OIL PUMP

REF. DRAIN

TO EVAP.

BOTTOM

LEFT VIEW

(22" MTR. HSG.)

REF.DRAIN

TO EVAP.

BOTTOM

REF. DRAIN

TO EVAP.

BOTTOM

MOTOR DRAIN

TO EVAP.

BOTTOM

20" MTR. HSG.

MOTOR DRAIN

TO EVAP.

BOTTOM

R331311301D0200

LIQUID INJECTION

FROM COND. BOTTOM

BOTTOM VIEW

Notes:

1. New O-rings and gaskets are in a plastic bag.

2. Compressor is charged with 5-psi of helium.

RIGHT VIEW

8 Field Installation Procedure IM 1128-1

Figure 3, Suction and Discharge Piping

TYPES I & II

INSTALL SUCTION

PIPING

TYPES I & II

VICTAULIC

BLOCKOFF PLATE

TYPES II & III

UNITS RECEIVE

SLIP-ON ASME

FLANGES

TYPE II

BOLT-ON

BLOCKOFF PLATE

TYPES I & II

EVAPORATOR AND CONDENSER ARE EVACUATED

AND CHARGED WITH 30 PSI OF HELIUM.

R331311308C0100

IM 1128-1 Field Installation Procedure 9

Figure 4, Liquid Injection Lines

MECHANICAL

BREAK POINT

TYPE I

BLOCKOFF

MECHANICAL

BREAK POINT

TYPE I

BLOCKOFF

LIQUID INJECTION LINES

(NOT ALL VARIATIONS SHOWN)

R331311303C0100

NOTE:

The liquid injection line (above) and the motor cooling line (below) are attached to the condenser and have shipping straps securing them to the evaporator and condenser. The lines and the compressor, each have blockoff plates, resulting in extra bolts.

Figure 5, Motor Cooling Lines

TORQUE TO

58 FT/LBS

MECHANICAL

BREAK POINT

TYPE I

BLOCKOFF

MECHANICAL

BREAK POINT

TYPE I

BLOCKOFF

10

R331311304C0100

MOTOR COOLING LINES

(NOT ALL VARIATIONS SHOWN)

Field Installation Procedure IM 1128-1

Figure 6, Motor Drain Line

MECHANICAL

BREAK POINT

MOTOR HOUSING

DRAIN LINE

MOTOR DRAIN LINE

(NOT ALL VARIATIONS SHOWN)

20" MOTOR REF. DRAIN

CONNECTION

(REAR VIEW)

15" MOTOR REF. DRAIN

CONNECTION

(REAR VIEW)

R331311305C0100

IM 1128-1 Field Installation Procedure 11

12

Figure 7, Optional Hot Gas Bypass Piping

TYPE I UNITS

INSTALL HOT GAS PIPING ON WSC MODELS

100, 113, & 126 WITH STACK SIZES

E36C30, E36C36, E42C36, E42C42,

E48C42, E48C48

TYPE II UNITS

INSTALL HOT GAS PIPING

Figure 8, Oil and Water Lines

BLOCKOFF

HOT GAS

BYPASS

LINE

SHUT OFF

VALVE

CONNECTION TO

DISCHARGE NOZZLE

MECHANICAL

BREAK POINTS

FLOW

HOT GAS

BYPASS

PILOT

LINE

NOTE: THIS LINE IS NOT ALWAYS

PRESENT. SOME UNITS HAVE

ELECTRONIC VALVES.

FLOW

MECHANICAL

BREAK POINT

MECHANICAL

BREAK POINT

EXPANSION

VALVE

EVAPOR

ATOR

BOTTOM

MECHANICAL

BREAK POINT

R331311307C0100

FLOW

TYPES I & II

INSTALL TOP PORTION

OF THRUST RETURN LINE

TYPES I AND II

INSTALL

OIL DRAIN

TYPES I AND II

INSTALL

OIL VENT

TYPES I & II

INSTALL TOP PORTION

OF LINE

OIL SUPPLY

RESWEAT LINE

ABOVE REDUCER

TYPES I & II

RESWEAT LINE

ABOVE TEE

TYPE II

INSTALL WATER LINES

Field Installation Procedure

R331311302C0200

IM 1128-1

Figure 9, Electrical and Sensors, Compressor Control Box and Connections

05

E5

OIL PUMP

HEATERS

08

1

3 2

07

E4

E6

OPH

TO STARTER {

G2

155

N7

2nd TERMINAL BOX

USED ON SELECTED

MOTORS.

GUARDISTOR

(ON COMPRESSOR)

CONNECT LEAD 155

TO TERMINAL IF 2nd

BOX IS NOT USED.

155

155

154

N7

G1

CP1

E7

E9

COMPRESSOR

HEATERS

JUNCTION BOX ON COMPRESSOR

MOUNTING BRACKET NEAR THE

SUCTION PIPE.

NUMBER OF HEATERS MAY VARY

DUE TO COMPRESSOR SIZE.

JUNCTION BOX NOT ON ALL UNITS.

CP2

}

SECOND HEATER CABLE FROM COMPR.

ON WSC063-087 ONLY.

(ON VFD)

VFD

10 LEADS

CCB POWER

OC

138

137

OIL COOLER

SOLENOID

4 LEADS

(ON SUPPLY

WATER LINE)

(ON DISCHARGE

NOZZLE)

HIGH

PRESSURE

SWITCH

HPS

104

103

102

101

VFD SPEED

SIGNAL

VANE

UNLOAD

142

141

SA

(ON COMPR.

FRONT)

140

139

SB VANE

LOAD

VANE CONTROL

SOLENOIDS

132

131

VC

(ON COMPR. NEXT

TO DISCHARGE)

VANE

CLOSE

SWITCH

R331311501C0100

135

136

LI

LIQ. INJ.

SOLENOID

(ON LIQUID

INJ. LINE)

Note:

1. Reference compressor controller schematic for detailed wiring connections.

133

134

HG

HOT GAS

SOLENOID

OPTION

(ON HOT

GAS LINE)

146

145

VO

VANE

OPEN

(ON COMPR.

FRONT)

SWITCH

(ON VFD ONLY)

IM 1128-1 Field Installation Procedure 13

14

Type II Reassembly

Description

TYPE II: The compressor with its terminal box is removed and shipped on a skid. The condenser, evaporator, oil sump, oil cooler and tube sheet support plates will remain connected only by their attachment bolts, ready for field disassembly on site and subsequent reassembly in the building. All wiring and piping that interconnects the components will have been removed and will require reinstallation. The loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5-psi helium holding charge.

3. The compressor will not be insulated at the factory. An insulation kit will be shipped with the unit and will also include a container of adhesive.

4. Only the evaporator shell will be factory insulated. Loose insulation will be shipped for the remaining surface areas.

5. The starter will ship loose.

6. The refrigerant will be field supplied.

7. All field piping connections will be Victaulic, flanged, O-ring face seal or copper brazing.

8. Bracket and cable kit will be included for all unit-mounted starters and/or cableway for mini-cabs.

9. All free piping ends will be capped.

10. Touch-up paint and stick-on wire ties will be included.

11. A bolted bracket instead of a weld will mount the oil pump.

12. The discharge piping assembly will have a bolted flange connection (instead of welded) at the condenser. This assembly will ship loose.

13. Piping that remains attached to a component will be supported if it is not rigid.

14. The chiller will not be run-tested at the factory but the compressor, oil pump assembly and heat exchangers will be tested as sub-assemblies.

15. The control panels are shipped separately but have all sensors wired in, labeled and tied up.

Matching labels will exist at the sensor connection to the unit.

Reassembly Steps

NOTE: Additional instructions may be shown on the assembly drawings.

The Type II arrangement is shipped with the evaporator, condenser, tube sheet support plate, oil cooler and oil sump bolted together. This provides structural support during transit and also allows several options for disassembly.

Figure 10, Component Disassembly

TWO ANGLE PLATES,

ONE WELDED TO EVAP.

ONE WELDED TO COND.

THEN BOLTED TOGETHER.

EVAPORATOR

TUBE SHEET

BOLTED

CONDENSER

TUBE SHEET

In most cases for narrow entry, the condenser will be separated by unbolting it from the evaporator angle bracket and from the tube sheet support plate. This leaves the evaporator and the support plate that has the mounting foot extended under where the condenser used to be. Therefore, the evaporator is usually unbolted from the two support plates, which can then be easily handled by themselves.

TUBE SHEET

SUPPORT

PLATE

WELDED

BOLTED

Field Installation Procedure IM 1128-1

!

WARNING

Remove compressor and vessel holding charge through the Schrader valve in the block-off plates before attempting to loosen any fittings on them. Failure to do so can cause severe bodily injury.

1. Disassemble the unit to the extent required by the site conditions. Rig the components to their final location and reassemble them using the fasteners that came with the unit.

2. The compressor and its suction and discharge piping should be installed on the stack before any other lines are attached. Mount the compressor on the stack. Mounting bolts, washers and nuts are shipped loose. Leave the mounting bolts loose until the suction and discharge lines are in place and aligned.

Install the suction and discharge piping. Before tightening the Victaulic couplings, position the suction and discharge piping so that the compressor can be aligned to give the best fit-up. When this is achieved, secure the compressor mounting bolts and proceed with installing the Victaulics using a light

coating of Victaulic lubricant. See Figure 3.

3.

Install the liquid line using Figure 11 as a guide. Commonly used arrangements are illustrated. The

bottom two arrangements illustrate lines with electronic valves used on some size units. Due to the variety of vessel combinations available, variation on specific units will occur.

4.

Install the motor cooling line using Figure 5 as a guide.

5.

Install the liquid injection line (see Figure 4). Note that any given injection line may be configured

somewhat differently than shown on the drawing.

6. If the oil cooler and oil sump have been removed on the job site, reinstall them using the fasteners that

came on the unit. See Figure 12 for piping between the cooler and sump and the cooling water piping.

See Figure 8 for the balance of the four oil lines connected to the compressor. There are a variety of

fitting types employed on the oil lines. Reconnect the compression fittings, bolt on the flanges using new gaskets/O-rings furnished, and re-sweat the sweat connections.

Due to the wide variety of model arrangements, some or all of the oil piping may be shipped loose.

When possible, the cooler and sump will be shipped mounted to their back plate with as much piping remaining as possible.

7. Install the four-way solenoid valve assembly on the compressor suction housing.

8. Install the two control panels; the compressor panel is mounted adjacent to the oil sump and the unit panel is on top of the evaporator. Wire and sensor leads have been disconnected at their terminus and labeled. They remain connected at the panels and rolled up. Their destinations have matching labels, which simplifies the installation. Compressor panel sensor labels are prefixed with CS, unit panel labels with US. Use the following drawings as a guide for installing wiring and sensors:

Compressor panel detail ........................................Figure 18

Unit panel wiring and connections ........................Figure 15

Unit panel detail .....................................................Figure 19

Unit panel sensor locations ....................................Figure 16 and Figure 17

Flow switch wiring detail ......................................Figure 20

9. If the unit has been ordered with a starter or VFD as unit mounted, brackets for mounting it and interconnection cables to the compressor motor will be included as ship loose items. Control wiring as

shown in Figure 9 will also be required. If the unit has a free-standing starter, use normal field

procedures for mounting and wiring.

Normal procedure of leak testing, triple evacuation, and charging with refrigerant and lubricant must be followed prior to the start up procedure.

IM 1128-1 Field Installation Procedure 15

10. Insulate the compressor, suction line, and other miscellaneous areas with the included insulation and

glue after leak testing. See Field Insulation Guide on page 29.

This completes the reassembly procedure.

Figure 11, Liquid Line Installation

SHOWN IS E36/C36 STACK

WITH 20-INCH MOTOR

EVAP. BLOCKOFF

EVAPORATOR

CONNECTION

TO TOP OF

EVAPORATOR

(VIEW 'B')

MECHANICAL

BREAK POINT

LIQUID LINE

MECHANICAL

BREAK POINT

CONDENSER

SHUTOFF VALVE

CONNECTION

SEE VIEW B

PILOT LINE

FLOW

MECHANICAL

BREAK POINT

EVAPORATOR

CONNECTION

RESWEAT PILOT LINE

ABOVE THE SHUTOFF

VALVE

LIQUID LINE

PLUG

LIQUID

LINES

CONDENSER

SHUTOFF

VALVE

TOP OF

EVAPORATOR

PILOT LINE

SHUT OFF

VALVE

TYPE II

KNOCKDOWN

ONLY

TO TOP OF

EVAPORATOR

(VIEW 'B')

LIQUID LINES

(NOT ALL

VARIATIONS

SHOWN)

CONDENSER

SHUTOFF VALVE

CONNECTION

FLOW

MECHANICAL

BREAK POINT

PILOT LINE

RESWEAT PILOT LINE

ABOVE THE SHUTOFF

VALVE

FROM PILOT

TX VALVE

FLOW

FLOW

VIEW B

R331311306C0100

NOTE: The bottom two liquid lines show the typical arrangement with electronic expansion valves. Liquid flow can be in different directions depending on the valve size.

16 Field Installation Procedure IM 1128-1

Figure 12, 16 Inch Oil Sump / Oil Cooler Assembly

PLUG

OIL DRAIN LINE

PLUG

OIL VENT LINE

FLOW

EQ

U

PR

AL

IZ

ES

AT

IO

SU

N

R

E

THRUST RETURN

OIL LINE

OIL SUPPLY TO

VALVE ON COMP.

OIL

COOLER

FLOW

OIL

SUPPLY

FL

O

W

WATER

RETURN

FLOW

WATER

SUPPLY

DUE TO DIFFERENT PIPE ROUTINGS

SOME OR ALL PIPING SHOWN MAY

BE SHIPPED LOOSE

Notes:

1. Piping arrangements will vary according to specific model.

2. Oil sump is shipped without oil on Type I and Type II knockdown units.

3. Type III knockdown units are shipped with oil.

FLOW

WATER SUPPLY

FLOW

WATER RETURN

R331311302C0100

IM 1128-1 Field Installation Procedure 17

Figure 13, Typical Field Connection Diagram, WSC Unit

* COOLING

TOWER

FOURTH

STAGE

STARTER

GND

POWER

* NOTE 7

A

H

O

* NOTE 10

NEUTRAL

C4

MICROTECH CONTROL

BOX TERMINALS

(115V) (24V)

PE

85

54

86

80

74

86

86

70

55

* COOLING

TOWER

THIRD

STAGE

STARTER

A

H

O

* NOTE 10

C3

79

73

* COOLING

TOWER

SECOND

STAGE

STARTER

H

O

* NOTE 10

C2

A

78

77

76

75

EP2

O

H

A C

EP1

O

H

A C

* COOLING

TOWER

FIRST

STAGE

STARTER

A

H

* NOTE 10

O

C1

T3-S

EF

CF

CP2

O

H

A C

COMMON

POWER

81

82(NO)

83(NC)

84

A

ALARM RELAY

(NOTE 4)

COOLING TOWER

BYPASS VALVE

COOLING TOWER VFD

1-10 VDC

1-10 VDC

52

71

71

53

CP1

O

H

A

C

18

L1 L2 L3

GND

CP1

CP2

COMPRESSOR

MOTOR

STARTER

(NOTE 1)

23(5A)

24(5)

25

1

2

11

12

22

3

4

6

MICROTECH

COMPRESSOR CONTROL

BOX TERMINALS

CTB1

NOTE 2

115 VAC

23

24

25

PE

L1

L2

3

4

11

1

2

11

12

22

-LOAD-

NOTE 2

LESS

THAN

30V

OR

24VAC

STARTER LOAD SIDE TERMINBALS

VFD

U V W

T1 T6 T2 T4 T3 T5

COMPRESSOR TERMINALS

STARTER LOAD SIDE TERMINBALS

WYE-DELTA

T1 T2 T3

T4 T5 T6

T1 T2 T3 T4 T5 T6

COMPRESSOR TERMINALS

STARTER LOAD SIDE TERMINBALS

SOLID STATE

T1 T2 T3

T1 T6 T2 T4 T3 T5

COMPRESSOR TERMINALS

STARTER LOAD SIDE TERMINBALS

MEDIUM AND HIGH VOLTAGE

T1 T2 T3

T1 T2 T3

COMPRESSOR TERMINALS

- FOR DC VOLTAGE AND 4-20 MA

CONNECTIONS (SEE NOTE 3)

- FOR DETAILS OF CONTROL REFER

TO UNIT CONTROL SCHEMATIC

330342103

- COMPRESSOR CONTROL

SCHEMATIC 330342203

- LEGEND: 330343003

* FIELD SUPPLIED ITEM

NOTE 12

330387901-0A

Field Installation Procedure IM 1128-1

Figure 14, Compressor Control Panel Electrical and Sensor Connections

05

E5

OIL PUMP

HEATERS

08

1

3 2

07

E4

E6

OPH

TO STARTER {

G2

155

N7

2nd TERMINAL BOX

USED ON SELECTED

MOTORS.

GUARDISTOR

(ON COMPRESSOR)

CONNECT LEAD 155

TO TERMINAL IF 2nd

BOX IS NOT USED.

155

155

154

N7

G1

CP1

E7

E9

COMPRESSOR

HEATERS

JUNCTION BOX ON COMPRESSOR

MOUNTING BRACKET NEAR THE

SUCTION PIPE.

NUMBER OF HEATERS MAY VARY

DUE TO COMPRESSOR SIZE.

JUNCTION BOX NOT ON ALL UNITS.

CP2

}

SECOND HEATER CABLE FROM COMPR.

ON WSC063-087 ONLY.

(ON VFD)

VFD

10 LEADS

CCB POWER

138

137

4 LEADS

(ON SUPPLY

WATER LINE)

OC

OIL COOLER

SOLENOID

(ON DISCHARGE

NOZZLE)

HIGH

PRESSURE

SWITCH

HPS

104

103

102

101

VFD SPEED

SIGNAL

VANE

UNLOAD

SA

(ON COMPR.

FRONT)

140

139

SB

VANE

LOAD

VANE CONTROL

SOLENOIDS

132

131

VC

(ON COMPR. NEXT

TO DISCHARGE)

VANE

CLOSE

SWITCH

R331311501C0100

135

136

LI

LIQ. INJ.

SOLENOID

(ON LIQUID

INJ. LINE)

133

134

HG

Note:

Refer to the compressor controller schematic for detailed wiring connections.

HOT GAS

SOLENOID

OPTION

(ON HOT

GAS LINE)

146

145

VO

VANE

OPEN

(ON COMPR.

FRONT)

SWITCH

(ON VFD ONLY)

IM 1128-1 Field Installation Procedure 19

Figure 15, Unit Controller Electrical and Sensor Connections

REFERENCE THE UNIT CONTROLLER SCHEMATIC

FOR DETAILED WIRING CONNECTIONS

TYPE II KNOCKDOWN ONLY

}

WATER PUMPS

(FIELD INSTALLED)

}

TOWER STAGING

(FIELD INSTALLED)

}

ALARMS

(FIELD INSTALLED)

}

POWER

(FIELD INSTALLED)

UNIT CONTROL BOX

CONNECT THESE LEADS

TO THE COMPRESSOR

CONTROL BOX

UNIT CONTROLLER

FLOW SWITCH

COMMUNICATION

UC POWER

FS POWER pLAN

ENTERING EVAP. WATER TEMP.

ENTERING COND. WATER TEMP.

LEAVING COND. WATER TEMP.

LIQUID LINE TEMP.

(OPTIONAL)

(OPTIONAL)

ENTERING HEAT RECOVERY

LEAVING HEAT RECOVERY

US02

US03

US04

US05

US09

US10

OPERATOR

INTERFACE

PANEL

7 LEADS

OIP

EF BLACK

CF BLACK

EF WHITE

CF WHITE

EF & CF BROWN

EF & CF BLUE

MASS FLOW

SENSOR OPTION

UNIT COMP 1 COMP 2

CIRCUIT BKR.

ON-(IN)

OFF-(OUT)

PUMP/TOWER

UTB1

J6

J5

J4

J3

J1

AIR C ON DITIONIN G

J11

EXPANSION MEMORY

MICROTECH II TM

PRINTER CARD

J2 J3

J12

SERIAL CARD

J4

J13 J14 J15

J21

J16

J22

J17

J23

J18

J5

CONTROLLER pCO2

J20

J19

J6 J7 J8

EVAPORATOR

FLOW SWITCH

150

149

C.

N.O.

EF

152

151

C. N.O.

CF

CONDENSER

FLOW SWITCH

}

}

COND. GPM SENSOR

(FIELD OPTION)

EVAP. GPM SENSOR

(FIELD OPTION)

}

TOWER BYPASS/TOWER VFD

(FIELD OPTION)

}

WATER RESET/REMOTE START-STOP/

MODE/DEMAND LIMIT

(FIELD OPTION)

R331311502C0100

20 Field Installation Procedure IM 1128-1

Figure 16, Unit Electrical and Sensor Locations

CS07

CS06

SEE DETAIL B

CS01

SEE DETAIL A

CS08

FIELD

OPTION

SEE DETAIL D

US02

SEE

DETAIL D

CS10

US10

&

US04

SEE DETAIL D

US09 & US03

SEE DETAIL D

EVAPORATOR

CS04

SEE DETAIL E

US05

REAR VIEW SHOWN WITH PILOT OPERATED EXPANSION VALVE

SEE DETAIL C

CS09

EVAPORATOR

FRONT VIEW AT COMPRESSOR

CS02

SEE DETAIL F

CS05

CS03

SEE DETAIL E

US05

WITH ELECTRONIC EXPANSION VALVE

R3313115

Note: See Figure 17 for reference detail drawings.

LEGEND

STANDARD TEMPERATURE SENSOR

STANDARD PRESSURE TRANSDUCER

OPTIONAL TEMPERATURE SENSOR

IM 1128-1 Field Installation Procedure 21

Figure 17, Unit Sensor Location Details

CS01

DETAIL "A"

VALVE CORE

MUST BE IN

CONNECTION.

CS09

US02 US03 US04 CS10

US09 US10

DETAIL "C" DETAIL "D"

DETAIL "E"

US05

HIGH PRESSURE SWITCH

DO NOT USE A VALVE

CORE WITH THIS DEVICE

CS06

DISCHARGE PRESSURE

TRANSDUCER

USE A VALVE CORE

W/ THIS DEVICE

CS05

ONE

PLACE

ONLY

CS05

DETAIL "F”

SUCTION NOZZLE END

OF COMPRESSOR

HIGH PRESSURE SWITCH

DO NOT USE A VALVE

CORE WITH THIS DEVICE

CS06

DISCHARGE PRESSURE

TRANSDUCER

USE A VALVE CORE

W/ THIS DEVICE

UNIT CONTROL SENSORS

SENSOR

NUMBER

DESCRIPTION

US02

US03

US04

US05

US09

US10

EVAP. ENTERING WATER TEMP.

COND. ENTERING WATER TEMP.

COND. LEAVING WATER TEMP.

LIQUID LINE TEMPERATURE

ENT. HEAT RECOVERY TEMP.

LVG. HEAT RECOVERY TEMP.

COMPRESSOR CONTROL SENSORS

SENSOR

NUMBER

DESCRIPTION

CS01

CS02

CS03

CS04

CS05

CS06

CS07

CS08

CS09

CS10

OIL SUMP PRESSURE

OIL FEED GAUGE PRESSURE

EVAP. REFRIGERANT PRESSURE

OIL SUMP TEMPERATURE

COMP SUCTION TEMPERATURE

COND. REFRIGERANT PRESSURE

COMP. DISCHARGE TEMP.

% COMPRESSOR AMPS (STARTER)

OIL FEED TEMPERATURE

EVAP. LEAVING WATER TEMP.

STANDARD UNIT W/O HOT GAS

DETAIL 'B'

SENSOR/H.P. SWITCH LOCATION

UNIT WITH HOT GAS

R331311503C0200

22 Field Installation Procedure IM 1128-1

Figure 18, Compressor Control Box

IM 1128-1 Field Installation Procedure 23

Figure 19, Unit Control Box

24 Field Installation Procedure IM 1128-1

Figure 20, Flow Switch Wiring

IM 1128-1 Field Installation Procedure 25

26

Unit Photographs

Figure 21, WSC 087, Photo

Figure 22, WSC 100, Photo

Field Installation Procedure IM 1128-1

Figure 23, WSC 126, Photo

IM 1128-1 Field Installation Procedure 27

Type III Reassembly

Description

TYPE III: The unit ships fully assembled and is field ready to knockdown. Included are the vessel bolt-on connection brackets, the discharge stack bolt-on flanges at the condenser and the bolt-on oil pump assembly.

1. The unit is shipped fully charged with refrigerant and lubricant.

2. The unit will be factory insulated and painted.

3. All electrical and sensor wiring will be fastened as usual.

4. The starter will ship per order instructions.

5. Touch up paint and stick on wire ties will be included.

6. This unit will be fully tested at the factory.

7. Labels will be provided with the instructions to mark piping, electrical wiring and sensor wiring.

Reassembly Steps

Type III units offer a variety of disassembly opportunities. In some cases the condenser and tube support plate are removed to meet narrow entrance requirements. Sometimes the compressor and unit control panel are removed for low height situations. Other possibilities exist.

Therefore it is difficult to prescribe step-by-step procedures. Various sections of this manual can be used where applicable, bearing in mind that the unit is fully charged with refrigerant and lubricant.

28 Field Installation Procedure IM 1128-1

Field Insulation Guide

Figure 24, Insulation Requirements

IM 1128-1 Field Installation Procedure 29

30 Field Installation Procedure IM 1128-1

Dimensions and Weights

Type I

The following table gives the dimensions and weight of the chiller with the compressor and starter/VFD removed and the dimensions and weight of the shipped-loose compressor.

Table 1, Type I, Dimensions & Weights

079

079

079

079

079

079

079

079

079

063

063

063

063

063

063

063

063

063

063

063

063

Unit Size Vessel Code

Unit Width

Chiller w/o Comp.

Unit Height Unit Weight

E2009 / C1809 57.1 (1450.6) 61.6 (1564.4)

E2209 / C2009 57.1 (1450.6) 64.0 (1624.8)

E2209 / C2209 57.1 (1450.6) 64.0 (1624.8)

E2609 / C2209 57.1 (1450.6) 67.5 (1715.0)

E2609 / C2609 57.1 (1450.6) 73.1 (1857.8)

E3009 / C2609 56.8 (1441.7) 75.7 (1922.0)

E2012 / C1812 57.1 (1450.6) 61.6 (1564.4)

E2212 / C2012 57.1 (1450.6) 64.0 (1624.8)

E2212 / C2212 57.1 (1450.6) 64.0 (1624.8)

E2612 / C2212 57.1 (1450.6) 67.5 (1715.0)

E2612 / C2612 57.1 (1450.6) 73.1 (1857.8)

E3012 / C2612 56.8 (1441.7) 75.7 (1922.0)

5212 (2366)

5919 (2687)

6216 (2882)

7048 (3200)

7784 (3534)

9692 (4400)

6084 (2762)

6982 (3170)

7357 (3340)

8377 (3803)

9294 (4219)

10703 (4859)

E2209 / C2209 50.2 (1274.6) 62.3 (1581.7)

E2609 / C2209 52.7 (1338.3) 63.9 (1622.8)

E2609 / C2609 52.7 (1338.3) 69.5 (1765.6)

E3009 / C2609 57.1 (1449.8) 74.0 (1878.6)

E3009 / C3009 59.0 (1499.4) 79.4 (2016.8)

E3609 / C3009 74.7 (1896.1) 78.8 (2001.0)

E2212 / C2212 50.2 (1274.6) 62.3 (1581.7)

E2612 / C2212 52.7 (1338.3) 63.9 (1622.8)

E2612 / C2612 52.7 (1338.3) 69.5 (1765.6)

079

079

E3012 / C2612 57.1 (1449.8) 74.0 (1878.6)

E3012 / C3012 59.0 (1499.4) 79.4 (2016.8)

079 E3612 / C3012 74.7 (1896.1) 78.8 (2001.0)

Continued on next page.

6940 (3151)

7780 (3532)

8516 (3866)

9692 (4400)

10876 (4938)

12713 (5772)

8081 (3669)

9109 (4135)

10026 (4552

11435 (5191)

12919 (5865)

15140 (6874)

Width

44.0 (1118.6)

44.0 (1118.6)

44.0 (1118.6)

44.0 (1118.6)

44.0 (1118.6)

44.0 (1118.6)

44.0 (1118.6)

44.0 (1118.6)

44.0 (1118.6)

44.0 (1118.6)

44.0 (1118.6)

44.0 (1118.6)

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

Compressor

Height

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

Weight

2000 (908)

2000 (908)

2000 (908)

2000 (908))

2000 (908)

2000 (908)

2000 (908)

2000 (908))

2000 (908)

2000 (908)

2000 (908)

2000 (908)

3200 (1452)

3200 (1452)

3200 (1452)

3200 (1452)

3200 (1452)

3200 (1452)

3200 (1452)

3200 (1452)

3200 (1452)

3200 (1452)

3200 (1452)

3200 (1452)

IM 1128-1 Field Installation Procedure 31

Type 1, Dimensions & Weights, Continued

Unit

Size

Vessel Code

Unit Width

Chiller w/o Comp.

Unit Height Unit Weight

087 E2609 / C2209 52.7 (1338.3) 65.2 (1656.3)

087 E2609 / C2609 52.7 (1338.3) 70.8 (1799.1)

087 E3009 / C2609 57.1 (1449.8) 68.8 (1746.5)

7780 (3532)

8516 (3866)

9692 (4400)

087 E3009 I C3009 59.5 (1510.5) 78.7 (1998.0) 10876 (4938)

087 E3609 / C3009 74.7 (1896.1) 78.8 (2001.0) 12713 (5772)

087 E2612 / C2212 52.7 (1338.3) 65.2 (1656.3) 9109 (4135)

087 E2612 / C2612 52.7 (1338.3) 70.8 (1799.1) 10029 (4553)

087 E3012 / C2612 57.1 (1449.8) 68.8 (1746.5) 11435 (5191)

087 E3012 / C3012 59.5 (1510.5) 78.7 (1998.0) 12918 (5865)

087 E3612 / C3012 74.7 (1896.1) 78.8 (2001.0) 15139 (6873)

087 E3612 / C3612 80.7 (2049.3) 89.2 (2264.4) 17384 (7892)

Width

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

43.6 (1108.2)

Compressor

Height

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

25.1 (638.3)

100 E3012 / C3012 67.4 (1712.2) 76.5 (1943.1) 13397 (6082)

100 E3612 / C3012 77.2 (1961.6) 77.6 (1971.5) 15587 (7076)

100 E3612 / C3612 83.2 (2114.0) 77.6 (1971.5) 17826 (8093)

100 E4212 / C3612 86.2 (2190.5) 76.4 (1940.8) 20487 (9301)

100 E4212 / C4212 92.2 (2342.9) 86.7 (2202.7) 23298 (10577)

100 E4812 / C4212 98.2 (2495.3) 90.6 (2300.2) 26024 (11815)

113 E3012 / C3012 67.4 (1712.2) 76.5 (1943.1) 13397 (6082)

113 E3612 / C3012 77.2 (1961.6) 77.6 (1971.5) 15578 (7072)

113 E3612 / C3612 83.2 (2114.0) 77.6 (1971.5) 17826 (8093)

113 E4212 / C3612 86.2 (2190.5) 76.4 (1940.8) 20457 (9287)

113 E4212 / C4212 92.2 (2342.9) 86.7 (2202.7) 23298 (10577)

113 E4812 / C4212 98.2 (2495.3) 90.6 (2300.2) 26024 (11815)

113 E4812 / C4812 104.2 (2647.7) 90.6 (2300.2) 29016 (13173)

44.0 (1117.9)

44.0 (1117.9)

44.0 (1117.9)

44.0 (1117.9)

44.0 (1117.9)

44.0 (1117.9)

44.0 (1117.9)

44.0 (1117.9)

44.0 (1117.9)

44.0 (1117.9)

44.0 (1117.9)

44.0 (1117.9)

44.0 (1117.9)

31.5 (800.1)

31.5 (800.1)

31.5 (800.1)

31.5 (800.1)

31.5 (800.1)

31.5 (800.1)

31.5 (800.1)

31.5 (800.1)

31.5 (800.1)

31.5 (800.1)

31.5 (800.1)

31.5 (800.1)

31.5 (800.1)

126 E3612 / C3012 77.2 (1961.6) 77.6 (1971.5) 15680 (7119)

126 E3612 / C3612 83.2 (2114.0) 77.6 (1971.5) 17826 (8093)

126 E4212 / C3612 86.2 (2190.5) 76.4 (1940.8) 20457 (9287)

44.0 (1117.9)

44.0 (1117.9)

44.0 (1117.9)

31.5 (800.1)

31.5 (800.1)

31.5 (800.1)

6000 (2724)

6000 (2724)

6000 (2724)

126 E4212 / C4212 92.2 (2342.9) 86.7 (2202.7) 23298 (10577)

126 E4812 / C4212 98.2 (2495.3) 90.6 (2300.2) 26024 (11815)

44.0 (1117.9)

44.0 (1117.9)

31.5 (800.1)

31.5 (800.1)

6000 (2724)

6000 (2724)

126 E4812 / C4812 104.2 (2647.7) 90.6 (2300.2) 29016 (13173) 44.0 (1117.9) 31.5 (800.1) 6000 (2724)

Notes:

1. The overall vessel length can vary depending on the specified tube length and pass arrangement. Consult the Daikin McQuay certified submittal drawings, or unit dimensions in Catalog WSCWDC-4 for specific vessel lengths.

2. Allow plus / minus 1 inch (24.5mm) for factory manufacturing tolerance.

3. All dimensions are shown in inches (mm). All weights are shown in lbs (kg).

6000 (2724)

6000 (2724)

6000 (2724)

6000 (2724)

6000 (2724)

6000 (2724)

6000 (2724)

6000 (2724)

6000 (2724)

6000 (2724)

6000 (2724)

6000 (2724)

6000 (2724)

Weight

3200 (1452)

3200 (1452)

3200 (1452)

3200 (1452)

3200 (1452)

3200 (1452)

3200 (1452)

3200 (1452)

3200 (1452)

3200 (1452)

3200 (1452)

32 Field Installation Procedure IM 1128-1

Type II

The following tables give the dimensions and weights of the various components as shipped.

063

063

063

063

063

063

063

063

063

063

063

063

079

079

079

079

079

079

079

079

079

079

079

079

E2009 / C1809

E2209 / C2009

E2209 / C2209

E2609 / C2209

E2609 / C2609

E3009 / C2609

E2012 / C1812

E2212 / C2012

E2212 / C2212

E2612 / C2212

E2612 / C2612

E3012 / C2612

E2209 / C2209

E2609 / C2209

E2609 / C2609

E3009 / C2609

E3009 / C3009

E3609 / C3009

E2212 / C2212

E2612 / C2212

E2612 / C2612

E3012 / C2612

E3012 / C3012

E3612 / C3012

30.5

(775.2)

30.5

(775.2)

30.5

(775.2)

36.0

(914.9)

41.4

(1052.3)

41.9

(1063.5)

30.5

(775.2)

30.5

(775.2)

30.5

(775.2)

36.0

(914.9)

41.4

(1052.3)

41.9

(1063.5)

31.8

(806.5)

30.5

(774.2)

30.5

(774.2)

30.5

(774.2)

36.0

(914.9)

36.0

(914.9)

31.8

(806.5)

30.5

(774.2)

30.5

(774.2)

30.5

(774.2)

36.0

(914.9)

36.0

(914.9)

Table continued on next page.

Table,2 Type II Dimensions & Weights

Unit

Size

Vessel Code

Cond.

Width

Cond.

Height

Front &

Back

Support

Width

33.1

(841.0)

35.9

(911.4)

39.3

(997.0)

39.3

(997.0)

45.8

(1162.1)

45.8

(1162.1)

33.1

(841.0)

35.9

(911.4)

39.3

(997.0)

39.3

(997.0)

45.8

(1162.1)

45.8

(1162.1)

36.8

(933.5)

36.8

(933.5)

36.8

(933.5)

36.8

(933.5)

42.3

(1073.2)

42.3

(1073.2)

36.8

(933.5)

36.8

(933.5)

36.8

(933.5)

36.8

(933.5)

42.3

(1073.2)

42.3

(1073.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

8.0 (203.2)

Front &

Back

Support

Height

22.9

(580.9)

22.9

(580.9)

22.1

(561.8)

22.1

(561.8)

27.7

(704.6)

27.0

(685.5)

22.9

(580.9)

22.9

(580.9)

22.1

(561.8)

22.1

(561.8)

27.7

(704.6)

27.0

(685.5)

20.6

(522.0)

20.6

(522.0)

26.2

(665.0)

25.4

(645.2)

30.9

(783.8)

25.5

(648.7)

20.6

(522.0)

20.6

(522.0)

26.2

(665.0)

25.4

(645.2)

30.9

(783.8)

25.5

(648.7)

Evaporator

Width

Evaporator

Height

Compressor

Width

Compressor

Height

31.5

(799.8)

33.2

(842.3)

33.2

(842.3)

37.3

(948.4)

37.3

(948.4)

43.7

(1109.7)

31.5

(799.8)

33.2

(842.3)

33.2

(842.3)

37.3

(948.4)

37.3

(948.4)

43.7

(1109.7)

28.8

(731.3)

35.4

(899.9)

35.4

(899.9)

35.9

(912.6)

35.9

(912.6)

37.3

(948.4)

28.8

(731.3)

35.4

(899.9)

35.4

(899.9)

35.9

(912.6)

35.9

(912.6)

37.3

(948.4)

32.8

(834.1)

36.7

(933.2)

36.7

(933.2)

40.1

(1017.8)

42.6

(1081.0)

48.1

(1222.2)

32.8

(834.1)

36.7

(933.2)

36.7

(933.2)

40.1

(1017.8)

42.6

(1081.0)

48.1

(1222.2)

34.6

(877.8)

34.6

(877.8)

34.6

(877.8)

39.2

(996.7)

39.2

(996.7)

42.6

(1081.0)

34.6

(877.8)

34.6

(877.8)

34.6

(877.8)

39.2

(996.7)

39.2

(996.7)

42.6

(1081.0)

43.6

(1108.2)

43.6

(1108.2)

43.6

(1108.2)

43.6

(1108.2)

43.6

(1108.2)

43.6

(1108.2)

43.6

(1108.2)

43.6

(1108.2)

43.6

(1108.2)

43.6

(1108.2)

43.6

(1108.2)

43.6

(1108.2)

44.0

(1118.6)

44.0

(1118.6)

44.0

(1118.6)

44.0

(1118.6)

44.0

(1118.6)

44.0

(1118.6)

44.0

(1118.6)

44.0

(1118.6)

44.0

(1118.6)

44.0

(1118.6)

44.0

(1118.6)

44.0

(1118.6)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

IM 1128-1 Field Installation Procedure 33

34

Type II Dimensions & Weights, Continued

Unit

Size

Vessel Code

Cond.

Width

Cond.

Height

Front &

Back

Support

Width

Front &

Back

Support

Height

087 E2609 / C2209 30.5 (775.2) 36.8 (933.5) 8.0 (203.2) 20.6 (522.0)

Evaporator

Width

Evaporator

Height

Compressor

Width

Compressor

Height

087

087

087

087

087

087

087

087

087

100

100

100

100

100

100

113

113

113

113

113

113

113

E2609 / C2609

E3009 / C2609

E2612 / C2612

E3012 / C2612

36.0 (914.9) 41.8 (1060.5) 8.0 (203.2) 26.2 (665.0)

36.0 (914.9) 41.8 (1060.5) 8.0 (203.2) 25.4 (645.2)

E3009 / C3009 41.9 (1063.5) 45.8 (1162.1) 8.0 (203.2) 30.9 (783.8)

E3609 / C3009 41.9 (1063.5) 45.8 (1162.1) 8.0 (203.2) 25.5 (648.7)

36.0 (914.9) 41.8 (1060.5) 8.0 (203.2) 26.2 (665.0)

36.0 (914.9) 41.8 (1060.5) 8.0 (203.2) 25.4 (645.2)

E3012 / C3012 41.9 (1063.5) 45.8 (1162.1) 8.0 (203.2) 30.9 (783.8)

E3612 / C3012 41.9 (1063.5) 45.8 (1162.1) 8.0 (203.2) 25.5 (648.7)

E3612 / C3612 46.2 (1173.2) 51.8 (1314.5) 8.0 (203.2) 35.9 (912.1)

E3012 / C3012 41.0 (1041.9) 46.2 (1172.7) 8.0 (203.2) 28.6 (725.4)

E3612 / C3012 41.0 (1041.9) 46.2 (1172.7) 8.0 (203.2) 24.4 (619.5)

E3612 / C3612 45.3 (1151.4) 52.1 (1322.3) 8.0 (203.2) 24.4 (619.5)

E4212 / C3612 45.3 (1151.4) 52.1 (1322.3) 8.0 (203.2) 18.6 (473.5)

E4212 / C4212 49.6 (1260.1) 57.6 (1462.0) 8.0 (203.2) 21.4 (543.3)

E4812 / C4212 49.6 (1260.1) 57.6 (1462.0) 8.0 (203.2) 19.6 (498.9)

E3012 / C3012 41.0 (1041.9) 46.2 (1172.7) 8.0 (203.2) 28.6 (725.4)

E3612 / C3012 41.0 (1041.9) 46.2 (1172.7) 8.0 (203.2) 24.4 (619.5)

E3612 / C3612 45.3 (1151.4) 52.1 (1322.3) 8.0 (203.2) 24.4 (619.5)

E4212 / C3612 45.3 (1151.4) 52.1 (1322.3) 8.0 (203.2) 18.6 (473.5)

E4212 / C4212 49.6 (1260.1) 57.6 (1462.0) 8.0 (203.2) 21.4 (543.3)

E4812 / C4212 49.6 (1260.1) 57.6 (1462.0) 8.0 (203.2) 19.6 (498.9)

E4812 / C4812 53.9 (1369.1) 63.5 (1612.9) 8.0 (203.2) 19.6 (498.9)

39.2

(996.7)

39.2

(996.7)

42.6

(1081.3)

42.6

(1081.3)

48.1

(1222.2)

39.2

(996.7)

42.6

(1081.3)

42.6

(1081.3)

48.1

(1222.2)

48.1

(1222.2)

48.4

(1229.6)

52.1

(1324.1)

52.1

(1324.1)

54.4

(1382.5)

54.4

(1382.5)

60.1

(1527.0)

48.4

(1229.6)

52.1

(1324.1)

52.1

(1324.1)

54.4

(1382.5)

54.4

(1382.5)

60.1

(1527.0)

60.1

(1527.0)

35.9

(912.6)

35.9

(912.6)

37.3

(948.4)

37.3

(948.4)

43.7

(1109.7)

35.9

(912.6)

37.3

(948.4)

37.3

(948.4)

43.7

(1109.7)

43.7

(1109.7)

38.4

(974.6)

44.1

(1120.6)

44.1

(1120.6)

51.5

(1307.6)

51.5

(1307.6)

57.1

(1449.6)

38.4

(974.6)

44.1

(1120.6)

44.1

(1120.6)

51.5

(1307.6)

51.5

(1307.6)

57.1

(1449.6)

57.1

(1449.6)

43.6

(1108.2)

43.6

(1108.2)

43.6

(1108.2)

43.6

(1108.2)

43.6

(1108.2)

43.6

(1108.2)

43.6

(1108.2)

43.6

(1108.2)

43.6

(1108.2)

43.6

(1108.2)

44.0

(1117.9)

44.0

(1117.9)

44.0

(1117.9)

44.0

(1117.9)

44.0

(1117.9)

44.0

(1117.9)

44.0

(1117.9)

44.0

(1117.9)

44.0

(1117.9)

44.0

(1117.9)

44.0

(1117.9)

44.0

(1117.9)

44.0

(1117.9)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

25.1

(638.3)

31.5

(800.1)

31.5

(800.1)

31.5

(800.1)

31.5

(800.1)

31.5

(800.1)

31.5

(800.1)

31.5

(800.1)

31.5

(800.1)

31.5

(800.1)

31.5

(800.1)

31.5

(800.1)

31.5

(800.1)

31.5

(800.1)

Table continued on next page.

Field Installation Procedure IM 1128-1

Type II Dimensions & Weights, Continued

Unit

Size

Vessel Code

Cond.

Width

Cond.

Height

Front &

Back

Support

Width

Front &

Back

Support

Height

Evaporator

Width

Evaporator

Height

Compressor

Width

Compressor

Height

126 E3612 / C3012 41.0 (1041.9) 46.2 (1172.7) 8.0 (203.2) 24.4 (619.5)

126 E3612 / C3612 45.3 (1151.4) 52.1 (1322.3) 8.0 (203.2) 24.4 (619.5)

126 E4212 / C3612 45.3 (1151.4) 52.1 (1322.3) 8.0 (203.2) 18.6 (473.5)

126 E4212 / C4212 49.6 (1260.1) 57.6 (1462.0) 8.0 (203.2) 21.4 (543.3)

126 E4812 / C4212 49.6 (1260.1) 57.6 (1462.0) 8.0 (203.2) 19.6 (498.9)

126 E4812 / C4812 53.9 (1369.1) 63.5 (1612.9) 8.0 (203.2) 19.6 (498.9)

52.1

(1324.1)

52.1

(1324.1)

54.4

(1382.5)

54.4

(1382.5)

60.1

(1527.0)

60.1

(1527.0)

44.1

(1120.6)

44.1

(1120.6)

51.5

(1307.6)

51.5

(1307.6)

57.1

(1449.6)

57.1

(1449.6)

44.0

(1117.9)

44.0

(1117.9)

44.0

(1117.9)

44.0

(1117.9)

44.0

(1117.9)

44.0

(1117.9)

Notes:

1. The overall vessel length can vary depending on the specified tube length and pass arrangement. Consult the Daikin McQuay certified submittal drawings, or unit dimensions in Catalog WSCWDC-4 for specific vessel lengths.

2. Allow plus / minus 1 inch (24.5mm) for factory manufacturing tolerance.

3. All dimensions are shown in inches (mm). All weights are shown in lbs (kg).

31.5

(800.1)

31.5

(800.1)

31.5

(800.1)

31.5

(800.1)

31.5

(800.1)

31.5

(800.1)

IM 1128-1 Field Installation Procedure 35

Type II Dimensions & Weights, Continued

Unit

Size

Vessel Code

Oil Pump

Width

Oil Pump

Height

Condenser

Weight

063 E2009 / C1809

063 E2209 / C2009

063 E2209 / C2209

063 E2609 / C2209

063 E2609 / C2609

063 E3009 / C2609

063 E2012 / C1812

063 E2212 / C2012

063 E2212 / C2212

063 E2612 / C2212

063 E2612 / C2612

063 E3012 / C2612

079 E2209 / C2209

079 E2609 / C2209

079 E2609 / C2609

079 E3009 / C2609

079 E3009 / C3009

079 E3609 / C3009

079 E2212 / C2212

079 E2612 / C2212

079 E2612 / C2612

079 E3012 / C2612

079 E3012 / C3012

079 E3612 / C3012

087 E2609 / C2209

087 E2609 / C2609

087 E3009 / C2609

087 E3009 / C3009

087 E3609 / C3009

087 E2612 / C2212

087 E2612 / C2612

087 E3012 / C2612

087 E3012 / C3012

087 E3612 / C3012

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

087 E3612 / C3612 19.8 (501.9)

Table continued on next page.

18.8 (476.5)

18.8 (476.5)

18.8 (476.5)

18.8 (476.5)

18.8 (476.5)

19.8 (501.9)

18.8 (476.5)

18.8 (476.5)

18.8 (476.5)

18.8 (476.5)

18.8 (476.5)

19.8 (501.9)

20.8 (528.1)

20.8 (528.1)

20.8 (528.1)

20.8 (528.1)

20.8 (528.1)

20.8 (528.1)

20.8 (528.1)

20.8 (528.1)

20.8 (528.1)

20.8 (528.1)

20.8 (528.1)

20.8 (528.1)

2511 (1137)

2511 (1137)

3210 (1454)

3210 (1454)

4356 (1973)

4356 (1973)

3031 (1373)

3031 (1373)

3900 (1767)

3900 (1767)

5333 (2416)

5333 (2416)

1835 (831)

2230 (1010)

2511 (1137)

2511 (1137)

3210 (1454)

3210 (1454)

2183 (989)

2677 (1213)

3031 (1373)

3031 (1373)

3900 (1767)

3900 (1767)

2511 (1137)

3210 (1454)

3210 (1454)

4356 (1973)

4356 (1973)

3031 (1373)

3900 (1767)

3900 (1767)

5333 (2416)

5333 (2416)

7508 (3401)

29.1 (739.6)

29.1 (739.6)

29.1 (739.6)

29.1 (739.6)

29.1 (739.6)

26.7 (678.9)

29.1 (739.6)

29.1 (739.6)

29.1 (739.6)

29.1 (739.6)

29.1 (739.6)

26.7 (678.9)

30.6 (778.0)

30.6 (778.0)

30.6 (778.0)

30.6 (778.0)

30.6 (778.0)

30.6 (778.0)

30.6 (778.0)

30.6 (778.0)

30.6 (778.0)

30.6 (778.0)

30.6 (778.0)

30.6 (778.0)

26.7 (678.9)

26.7 (678.9)

26.7 (678.9)

26.7 (678.9)

26.7 (678.9)

26.7 (678.9)

26.7 (678.9)

26.7 (678.9)

26.7 (678.9)

26.7 (678.9)

26.7 (678.9)

2708 (1227)

3381 (1532)

3381 (1532)

4397 (1992)

4397 (1992)

5882 (2665)

3071 (1391)

3880 (1758)

3880 (1758)

5075 (2299)

5075 (2299)

6840 (3099)

3381 (1532)

3381 (1532)

4397 (1992)

4397 (1992)

5882 (2665)

3880 (1758)

3880 (1758)

5075 (2299)

5075 (2299)

6840 (3099)

6840 (3099)

Evaporator

Weight

2543 (1152)

2708 (1227)

2708 (1227)

3381 (1532)

3381 (1532)

4397 (1992)

2862 (1296)

3071 (1391)

3071 (1391)

3880 (1758)

3880 (1758)

5075 (2299)

11340 (5144)

12180 (5525)

12916 (5859)

14092 (6392)

15276 (6929)

17113 (7762)

12481 (5661)

13509 (6128)

14426 (6544)

15835 (7183)

17319 (7856)

19539 (8863)

12180 (5525)

12916 (5859)

14092 (6392)

15276 (6929)

17113 (7762)

13509 (6128)

14426 (6544)

15835 (7183)

17318 (7855)

19539 (8863)

21784 (9881)

Unit Shipping

Weight

9612 (4360)

10319 (4681)

10616 (4815)

11448 (5193)

12184 (5527)

14092 (6392)

10484 (4756)

11382 (5163)

11757 (5333)

12777 (5796)

13694 (6203)

15103 (6851)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

Compressor

Weight

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

3200 (1440)

36 Field Installation Procedure IM 1128-1

Type II Dimensions & Weights, Continued

Unit

Size

Vessel Code

100 E3012 / C3012

100 E3612 / C3012

100 E3612 / C3612

100 E4212 / C3612

100 E4212 / C4212

100 E4812 / C4212

113 E3012 / C3012

113 E3612 / C3012

113 E3612 / C3612

113 E4212 / C3612

113 E4212 / C4212

113 E4812 / C4212

113 E4812 / C4812

126 E3612 / C3012

126 E3612 / C3612

126 E4212 / C3612

126 E4212 / C4212

126 E4812 / C4212

126 E4812 / C4812

Notes:

Oil Pump

Width

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

19.8 (501.9)

Oil Pump

Height

34.8 (884.4)

34.8 (884.4)

34.8 (884.4)

34.8 (884.4)

34.8 (884.4)

34.8 (884.4)

34.8 (884.4)

34.8 (884.4)

34.8 (884.4)

34.8 (884.4)

34.8 (884.4)

34.8 (884.4)

34.8 (884.4)

34.8 (884.4)

34.8 (884.4)

34.8 (884.4)

34.8 (884.4)

34.8 (884.4)

34.8 (884.4)

Condenser

Weight

5333 (2416)

5333 (2416)

7508 (3401)

7508 (3401)

10267 (4651)

10267 (4651)

5333 (2416)

5333 (2416)

7508 (3401)

7508 (3401)

10267 (4651)

10267 (4651)

13077 (5924)

5333 (2416)

7508 (3401)

7508 (3401)

10267 (4651)

10267 (4651)

13077 (5924)

Evaporator

Weight

5075 (2299)

6840 (3099)

6840 (3099)

8922 (4042)

8922 (4042)

11125 (5040)

5075 (2299)

6840 (3099)

6840 (3099)

8922 (4042)

8922 (4042)

11125 (5040)

11125 (5040)

6840 (3099)

6840 (3099)

8922 (4042)

8922 (4042)

11125 (5040)

11125 (5040)

Compressor

Weight

6000 (2700)

6000 (2700)

6000 (2700)

6000 (2700)

6000 (2700)

6000 (2700)

6000 (2700)

6000 (2700)

6000 (2700)

6000 (2700)

6000 (2700)

6000 (2700)

6000 (2700)

6000 (2700)

6000 (2700)

6000 (2700)

6000 (2700)

6000 (2700)

6000 (2700)

Unit Shipping

Weight

20597 (9343)

22778 (10332)

25026 (11352)

27657 (13545)

30498 (13834)

33224 (15070)

20597 (9343)

22778 (10332)

25026 (11352)

27657 (13545)

30498 (13834)

33224 (15070)

36216 (16427)

22880 (10378)

25128 (11398)

27657 (12545)

30498 (13834)

33224 (15070)

36216 (16427)

1. The overall vessel length can vary depending on the specified tube length and pass arrangement. Consult the Daikin McQuay certified submittal drawings, or unit dimensions in Catalog WSCWDC-4 for specific vessel lengths.

2. The oil pump width is the dimension from front to back. The height is from the bottom of the sump to the top of the piping connections. Transporting the oil pump is usually not an issue when compared to the vessels.

3. Allow plus / minus 1 inch (24.5mm) for manufacturing tolerance.

4. All dimensions are shown in inches (mm).

5. All weights are shown in lbs. (kg).

IM 1128-1 Field Installation Procedure 37

Shipping Lists

38

Table 3, Type I WSC Knockdown Shipping List

LABEL DESCRIPTION

LOOSE

PARTS

QTY.

FROM - TO

COPPER PIPE ASSY’S

HOT GAS

HOT GAS BYPASS

(OPTION)

1 DISCH. NOZZLE TO EVAP. BTM.

LIQUID

INJECTION

MOTOR

COOLING

MOTOR

DRAIN

MOTOR

DRAIN

OIL DRAIN

LIQUID INJECTION

MOTOR COOLING

MOTOR DRAIN (LARGE)

MOTOR DRAIN (SMALL)

OIL PUMP DRAIN

N/A

N/A

N/A

N/A

1

COND. BOTTOM TO COMPR.

COND. TO MOTOR

COMPRESSOR TO EVAP

BOTTOM

COMP. TO LARGE MOTOR

DRAIN

COMP. TO OIL PUMP

OIL VENT OIL PUMP VENT 1 COMP. TO OIL PUMP

OIL RETURN OIL RETURN TUBE (THRUST) 1

COMP. TO OIL PUMP TEE

(NEAR COOLER)

OIL SUPPLY OIL SUPPLY TUBE 1 COMP. TO OIL COOLER BTM.

STEEL PIPE ASSY'S

1 COMP. TO EVAP. SUCTION LINE

DISCHARGE NOZZLE AND

CHECK VALVE

1 EA COMP. TO DISCHARGE PIPE

073244408

001358000

TOUCH UP SPRAY PAINT

CANS

WIRE TIES

070183501 WIRE TIE STICK-ON MOUNTS

Daikin McQuay LONMARK

LABEL BAG

LITERATURE AND SCHEMATIC

IN MANILLA ENVELOPE

STARTER SHROUD

STARTER BRACKETS

TERMINAL SHROUD

ISOLATOR PADS

OPERATOR INTERFACE

PANEL

LCD SUPPORT ARM

POWER CABLES

CONTROL BOX WATER

HOSES

COMPRESSOR 4 WAY VALVE

ASSY

1

1

2

1

6

1

1

3 OR 6

2

1

MISCELLANEOUS

6

50

25

1

REF. DWG.

R331311307

R331311303

R331311304

R331311305

R331311305

R331311302

R331311302

R331311302

R331311302

R331311308

R331311308

FACTORY

NOTES

LEAVE OR

REMOVE PER

DWG.

BLOCK-OFF

AND SECURE

BLOCK-OFF

AND SECURE

BLOCK-OFF

AND SECURE

BLOCK-OFF

AND SECURE

REMOVE AND

CRATE

REMOVE AND

CRATE

REMOVE PART

OF LINE AND

CRATE

REMOVE PART

OF LINE AND

CRATE

REMOVE AND

CRATE

LEAVE OR

REMOVE PER

DWG.

IF PRESENT

IF UNIT

MOUNTED

IF PRESENT

IF UNIT

MOUNTED

Field Installation Procedure IM 1128-1

LABEL DESCRIPTION

COMPRESSOR INSULATION

KIT

O-RINGS AND GASKETS IN

PLASTIC BAG

735030433 OIL CONTAINERS (5 GAL. EA.)

000986000 INSULATION GLUE (1 GAL.)

074646106 PRESSTITE THERMAL MASTIC

070217402 V-740 THERMAL COMPOUND

KNOCKDOWN REFERENCE

DWG. PACKET

LOOSE

PARTS

QTY.

1

1

COMPRESSOR W/ SKID

STARTER W/ SKID

WSC UNIT STACK

FROM - TO

X

1

2

2

1

MAJOR COMPONENTS

1

1

1

Table 4, Type II WSC Knockdown Shipping List

LABEL

HOT GAS

DESCRIPTION

HOT GAS BYPASS

(OPTION)

LOOSE

PARTS

QTY.

FROM - TO

COPPER PIPE ASSY'S

1 DISCH. NOZZLE TO EVAP. BTM.

LIQUID

INJECTION

LIQUID INJECTION 1 COND. BOTTOM TO COMPR.

LIQUID LINE 1 COND. BTM. TO EVAP. BTM LIQUID LINE

MOTOR

COOLING

MOTOR

DRAIN

MOTOR

DRAIN

OIL DRAIN

OIL VENT

MOTOR COOLING

MOTOR DRAIN (LARGE)

MOTOR DRAIN (SMALL)

OIL PUMP DRAIN

OIL PUMP VENT

OIL RETURN OIL RETURN TUBE (THRUST)

1

N/A

N/A

1

1

1

COND. TO MOTOR

COMPRESSOR TO EVAP

BOTTOM

COMP. TO LARGE MOTOR

DRAIN

COMP. TO OIL PUMP

COMP. TO OIL PUMP

COMP. TO OIL PUMP TEE

(NEAR COOLER)

OIL SUPPLY

PILOT LINE

PILOT LINE

WATER

RETURN

WATER

SUPPLY

OIL SUPPLY TUBE

PILOT - 1/4" FLEX TUBE

PILOT VALVE LINE

WATER RETURN

WATER SUPPLY

1

1

1

1

1

COMP. TO OIL COOLER BTM.

LIQ. LINE TO TOP OF EVAP.

COND. BTM. TO EXP. VALVE

OIL COOLER TO FIELD

CONNECTION

OIL COOLER TO FIELD

CONNECTION

REF. DWG.

REF. DWG.

R331311307

R331311303

R331311306

R331311304

R331311305

R331311305

R331311302

R331311302

R331311302

R331311302

R331311306

R331311306

R331311302

R331311302

FACTORY

NOTES

SEE BOM FOR

QUANTITY

NOTES

REMOVE AND

CRATE

REMOVE PART

OF LINE &

CRATE

REMOVE AND

CRATE

REMOVE PART

OF LINE &

CRATE

BLOCK-OFF

AND SECURE

BLOCK-OFF

AND SECURE

REMOVE AND

CRATE

REMOVE AND

CRATE

REMOVE PART

OF LINE AND

CRATE

REMOVE PART

OF LINE AND

CRATE

REMOVE AND

CRATE

REMOVE AND

CRATE

REMOVE AND

CRATE

REMOVE AND

CRATE

IM 1128-1 Field Installation Procedure 39

40

LABEL DESCRIPTION

SUCTION LINE

DISCHARGE LINE

DISCHARGE NOZZLE

LOOSE

PARTS

QTY.

FROM - TO

1

1

STEEL PIPE ASSY'S

COMPRESSOR TO

EVAPORATOR

COMPRESSOR TO

CONDENSER

1 IN DISCHARGE LINE

CHECK VALVE 1 IN DISCHARGE LINE

LABEL DESCRIPTION

LOOSE

PARTS

QTY.

FROM - TO

PART NO.

073244408

001358000

TOUCH- UP SPRAY PAINT

CANS

WIRE TIES

070183501 WIRE TIE STICK-ON MOUNTS

Daikin McQuay LONMARK

LABEL BAG

LITERATURE AND SCHEMATIC

IN MANILLA ENVELOPE

STARTER SHROUD

STARTER BRACKETS

TERMINAL SHROUD

ISOLATOR PADS

OPERATOR INTERFACE

PANEL

LCD SUPPORT ARM

POWER CABLES

CONTROL BOX WATER

HOSES

COMPRESSOR 4 WAY VALVE

ASSY

COMPRESSOR INSULATION

KIT

SHEET INSULATION (HEADS,

BRACKETS ETC.)

O-RINGS AND GASKETS IN

PLASTIC BAG

735030433 OIL CONTAINERS (5 GAL. EA.)

3 OR 6

2

1

1

X SQ. FT.

1

X

000986000 INSULATION GLUE (1 GAL.) 1

074646106 PRESSTITE THERMAL MASTIC 2

070217402 V-740 THERMAL COMPOUND

KNOCKDOWN REFERENCE

DWG. PACKET

2

1

Continued on the next page.

2

1

6

1

1

1

1

MISCELLANEOUS

12

100

50

1

Field Installation Procedure

REF. DWG.

FACTORY

NOTES

R331311308

R331311308

R331311308

R331311308

REF. DWG.

REMOVE AND

CRATE

REMOVE AND

CRATE

REMOVE AND

CRATE

REMOVE AND

CRATE

NOTES

IF PRESENT

IF UNIT

MOUNTED

IF PRESENT

IF UNIT

MOUNTED

SEE BOM FOR

QUANTITY

SEE BOM FOR

QUANTITY

IM 1128-1

LABEL DESCRIPTION

COMPRESSOR

STARTER

COMPRESSOR CONTROL BOX

UNIT CONTROL BOX

WSC UNIT STACK

LOOSE

PARTS

QTY.

FROM - TO

MAJOR COMPONENTS

1

1

1

1

1

Table 5, Type III WSC Knockdown Shipping List

LABEL DESCRIPTION

PART NO.

073244408

001358000

TOUCH-UP SPRAY PAINT

CANS

WIRE TIES

070183501 WIRE TIE STICK-ON MOUNTS

McQUAY LONMARK LABEL

BAG

LITERATURE AND SCHEMATIC

IN MANILLA ENVELOPE

LOOSE

PARTS

QTY.

FROM - TO

MISCELLANEOUS

6

50

25

1

1

STARTER BRACKETS 2

ISOLATOR PADS

OPERATOR INTERFACE

PANEL

LCD SUPPORT ARM

POWER CABLES

CONTROL BOX WATER

HOSES

KNOCKDOWN REFERENCE

DWG. PACKET

331311601 ELEC. AND PIPING LABELS

STARTER

WSC UNIT

6

1

1

3 OR 6

2

1

1

1

1

MAJOR COMPONENTS

IM 1128-1 Field Installation Procedure

REF. DWG.

FACTORY

NOTES

REF. DWG. NOTES

IF UNIT

MOUNTED &

SHIPPED

LOOSE

IF UNIT

MOUNTED

IF UNIT

MOUNTED

IF SHIPPED

LOOSE

41

WMC-B Introduction

It is estimated that fifty percent of retrofit applications require partial or complete disassembly of the chiller. Daikin McQuay offers two solutions to the disassembly and reassembly effort on WMC chillers.

WMC chillers are relatively easy to disassembly due to the small compressor size and the absence of a lubrication system with its attendant components and piping.

TYPE IV Knockdown: The compressor(s), control panel, compressor power panel(s) are removed at the factory and put on skids. The stripped vessel stack is shipped as a single piece. Discharge and suction piping, liquid line and the compressor cooling line(s) are removed and crated. All associated wiring and piping possible will remain on the vessel stack.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5-psi helium holding charge.

3. The suction line(s) is not insulated at the factory. An insulation kit will be shipped with the unit.

4. The evaporator will be insulated at the factory.

5. Refrigerant will not be shipped with the unit and must be secured locally and furnished and installed by the installer.

6. All field piping connections will be flanged or copper brazing.

7. All free piping ends will be capped.

8. Touch-up paint will be included.

9. The unit will undergo the rigorous, full McQuay test program at the factory.

10. Contact local McQuay Factory Service for pricing and scheduling of required installation supervision.

TYPE V Knockdown: The unit ships fully assembled, tested and is ready for field knockdown. This option allows components to be removed as required at the site. The unit dimension drawing gives sufficient dimensions to determine what should be removed. Approximate reduction in unit size for

Type IV knockdown is shown below

Table 6, Dimension Reduction

WMC Model

145/150

250/290

400

Compressor(s)

-7” ht.

-7” ht.

-12” ht.

Remove

Compressor(s)

& Panels

Panels Only

-19” ht.

-20” ht.

0

0

-18” ht. 0

Separate

Vessels

30 ” max. width

39 ” max. width

45 ” max. width

1. The unit is shipped fully charged with refrigerant. Pump down or remove refrigerant before breaking any refrigerant connection.

2. The unit will be factory insulated and painted.

3. All electrical and sensor wiring will be fastened as usual.

4. Touch up paint and stick-on wire ties will be included.

5. This unit will be fully tested at the factory.

6. Labels will be provided with the instructions to mark piping, electrical wiring and sensor wiring.

!

WARNING

Prior to un-sweating any connection in the field, verify that there is no pressure or charge in lines. Failure to do so can result in property damage, severe personal injury, or death.

42 Field Installation Procedure IM 1128-1

Type IV Disassembly-Reassembly

Disassembly

Type IV Knockdown units are shipped disassembled except for the vessel stack and are shipped less refrigerant, If the stack size or weight dictates further disassembly, the vessels can be separated by disconnecting any interconnecting wiring and tubing and then unbolting them. The vessels and compressors have a helium holding charge that must be released prior to attempting to open any connection.

Reassembly

1. Reassemble the vessel stack, if disassembled, and reconnect any wiring and tubing.

2. Mount the compressor(s) on the stack. Be careful to avoid damaging lines already mounted on the unit.

Mounting bolts, washers and nuts are shipped loose. Leave the mounting bolts loose until the suction and discharge lines are installed and aligned.

During assembly, bolts holding block off plates (suction connection, for example), are used for reassembly

of the component. See Figure 25 for the location and description of the block offs.

3. Do not remove block offs until ready to install piping. The compressor and vessels have a Schrader valve on their block off plates to be used for relieving the helium holding charge.

!

WARNING

Remove compressor, piping or vessel holding charge through the Schrader valve in the block off plates before attempting to loosen any fittings on them. Failure to do so can cause severe bodily injury.

4. Install the suction and discharge line(s). See Figure 30. Tighten bolts after the entire line has been

installed and aligned. Insulate the suction line with the insulation and glue provided.

5.

Install the liquid line and motor cooling lines. See

Figure 31

and

Figure 32

.

6. Install control panel and compressor power panels by bolting to the horizontal support members.

7. If the unit has single-point power, connect the power leads from the terminal box under the control panel to each power panel line side connection.

8. Connect any loose wiring.

9. Pressure (leak) test, evacuate, and charge with field supplied R-134a using standard refrigeration practice.

Type V Disassembly-Reassembly

Type V units are designed for a wide range of disassembly and the degree of knockdown varies. Use instructions and drawings from Type IV Disassembly-Reassembly instructions above. Observe the following recommendations.

1. The chiller is shipped with the full refrigerant charge that must be pumped down into the condenser or removed before breaking any refrigerant connection. Before attempting any disassembly, assume the condenser isolation valves may have leaked and that any component of the chiller may be pressurized with refrigerant. Exert the proper precautions with this caveat in mind.

2. Check that power has been removed from the unit. Before disconnecting any wire, it is prudent to label its function and connection point to facilitate reconnection.

3. The refrigerant charge must be removed from the unit if the vessels are to be separated.

4. Some insulation repair and touch-up painting may be required.

5. See Type IV instructions for reassembly of components.

IM 1128-1 Field Installation Procedure 43

Table 7, Component Weight

WMC-B

Model

145S

145D

150D

250D

290D

400D

Compressor

282

262

262

282

282

282

Power Panel

(Front End

Box)

375

310

310

375

375

375

Control

Panel

125

125

125

125

125

125

Evaporator

Model

E2209

E2209

E2212

E2609

E2612

E3012

Weight

2490

2490

2857

3259

3812

5075

NOTES:

1. All weights in pounds.

2. “S” models have one compressor; “D” models have two compressors.

Table 8, Component Dimensions

Condenser

Model Weight

C2009

C2009

C2012

C2209

C2212

C2612

2142

2142

2615

2392

2942

3900

WMC-B

Model

145S

145D

150D

250D

290D

400D

Depth x Width x Height

Compressor

Power Panel

(Front End

Box)

Control

Panel

Model

Evaporator

Length x Width x Height

Condenser

Model

Stack

32 x 22 x 18 17 x 40 x 67 9 x 19 x 33 2209 135 x 28 x 29 2009 128 x 36 x 33 135 x 36 x 60

32 x 18 x 18 17 x 40 x 67 9 x 19 x 33 2209 135 x 28 x 29 2009 128 x 36 x 33 135 x 36 x 60

32 x 18 x 18 17 x 40 x 67 9 x 19 x 33 2212 170 x 28 x 29 2012 164 x 36 x 33 170 x 36 x 60

32 x 22 x 18 17 x 40 x 67 9 x 19 x 33 2609 130 x 32 x 33 2209 135 x 38 x 33 135 x 38 x 63

32 x 22 x 18 17 x 40 x 67 9 x 19 x 33 2612 165 x 32 x 33 2212 170 x 38 x 33 170 x 38 x 63

32 x 22 x 18 17 x 40 x 67 9 x 19 x 33 3012 169 x 36 x 36 2612 165 x44 x 36 169 x 44 x 72

NOTES:

1. All dimensions in inches.

2. Dimensions include protuberances such as mounting brackets and disconnect handles.

44 Field Installation Procedure IM 1128-1

Figure 25, Type IV, Compressor Block Offs

Figure 26, Type IV, Parts in Crates, WMC 145S (Single Compressor),

IM 1128-1 Field Installation Procedure 45

Figure 27, Type IV, Parts in Crates, (Dual Compressor)

NOTES:

1. See previous page for WMC 145S crate

2. Crate 2 will have two sets of suction and discharge lines..

46 Field Installation Procedure IM 1128-1

Figure 28, Type IV, Bare Vessel Stack

Figure 29, Part Load Bypass Valve (PLBV)

Evaporator

This part stays with discharge line

Flange

Connection

PLBV

The drawing shows the PLBV piping for one circuit.

This part stays on evaporator

Condenser

IM 1128-1 Field Installation Procedure

Liquid line connection

47

Figure 30, Type IV, Suction and Discharge Line Removal

Suction Line (2)

Discharge Line (2)

Figure 31, Type IV, Motor Cooling Line Removal

48 Field Installation Procedure IM 1128-1

Figure 32, Type IV, Liquid Line Removal

Figure 33, Type V, Liquid line Removal

IM 1128-1 Field Installation Procedure 49

Figure 34, Type V, Vessel Separation

50 Field Installation Procedure IM 1128-1

WME Introduction

It is estimated that fifty percent of retrofit applications require partial or complete disassembly of the chiller. Daikin McQuay offers three solutions to the disassembly and reassembly effort on Model

WME, magnetic bearing compressor chillers.

TYPE I ... Type I provides a moderate amount of disassembly. The compressor, suction and discharge piping, and compressor VFD power panel are removed and put on a skid. The touchscreen and mounting arm will ship in a separate container. All associated wiring and piping will remain attached if possible. The remaining loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5 psi helium holding charge.

3. The compressor will not be insulated at the factory. An insulation kit will be shipped with the unit.

4. The compressor and VFD power panel will ship loose.

5. The control panel will ship separately and have all sensors wired in, labeled and tied up. Matching label will exist on the sensor locations.

6. The vessel stack will be insulated at the factory.

7. Suction piping insulation and glue will be shipped with the unit for field installation.

8. Refrigerant will not be shipped with the unit and must be furnished and installed by the installer.

9. All field-piping connections will be grooved mechanical couplings, O-ring face seal or copper brazing.

10. Touch-up paint and stick-on wire ties will be included.

11. The unit will undergo the rigorous, full McQuay run-test program at the factory.

12. Contact local McQuay Factory Service for price quotation and scheduling.

TYPE II ... Type II provides a total knockdown of the unit. The compressor and VFD power panel are removed and put on a skid. The touchscreen and mounting arm will ship in a separate container. The condenser, evaporator, and tube sheet supports will remain connected only by the attachment bolts for easy disassembly at the job site. All wiring and piping that interconnects the components will be removed. The remaining loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5 psi helium holding charge.

3. The compressor will not be insulated at the factory. An insulation kit will be shipped with the unit.

4. Only the evaporator shell will be factory insulated. Loose insulation and glue will be shipped for the remaining surface areas.

5. The compressor and VFD power panel will ship loose.

6. Refrigerant will be field supplied and installed.

7. All field-piping connections will be grooved mechanical couplings, O-ring face seal or copper brazing.

8. Touch-up paint and stick-on wire ties will be included.

9. The discharge piping and suction elbow will be shipped loose in a separate crate.

10. The unit will undergo the rigorous, full Daikin McQuay run-test program at the factory.

11. Contact local McQuay Factory Service for price quotation and scheduling.

Type III ... The units are shipped fully assembled, factory charged, run-tested, insulated and painted; ready for disassembly at the job site. Included are the vessel bolt-on connection brackets, discharge line bolt-on flanges at the condenser. Touch-up paint and stick-on wire ties will be included. Site disassembly and reassembly must be supervised by McQuay startup personnel. Contact local McQuay

Factory Service for price quotation and scheduling.

IM 1128-1 Field Installation Procedure 51

Type I Reassembly

TYPE I ... Type I provides a moderate amount of disassembly. The compressor, suction and discharge piping, and compressor VFD power panel are removed and put on a skid. The touchscreen and mounting arm will ship in a separate container. All associated wiring and piping will remain attached if possible. The remaining loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5 psi helium holding charge.

3. The compressor will not be insulated at the factory. An insulation kit will be shipped with the unit.

4. The compressor and VFD power panel will ship loose.

5. The control panel will ship separately and have all sensors wired in, labeled and tied up. Matching label will exist on the sensor locations.

6. The vessel stack will be insulated at the factory.

7. Suction piping insulation and glue will be shipped with the unit for field installation.

8. Refrigerant will not be shipped with the unit and must be furnished and installed by the installer.

9. All field-piping connections will be grooved mechanical couplings, O-ring face seal or copper brazing.

10. Touch-up paint and stick-on wire ties will be included.

11. The unit will undergo the rigorous, full Daikin McQuay run-test program at the factory.

12. Contact local McQuay Factory Service for price quotation and scheduling.

Reassembly Steps

NOTE: Additional instructions may be shown on the assembly drawings.

1. Mount the compressor on the stack. Be careful to avoid damaging lines already mounted on the unit. Mounting bolts, washers and nuts are shipped loose. Leave the mounting bolts loose until the suction and discharge lines are installed and aligned.

During assembly, bolts holding block-off plates (motor cooling connection, for example), are used

for reassembly of the component. See Figure 1 or Figure 2 for the location and description of the

block-offs.

2. Do not remove block-offs until ready to install piping. The compressor and vessels have a Schrader valve on their block-off plates to be used for relieving the helium holding charge.

!

WARNING

Remove compressor and vessel holding charge through the Schrader valve in the block-off plates before attempting to loosen any fittings on them. Failure to do so can cause severe bodily injury.

3. Install the suction and discharge piping (see Figure 3). Before tightening the Victaulic couplings,

position the suction and discharge piping so that the compressor can be aligned to give the best fitup. When this is achieved, secure the compressor mounting bolts and proceed with installing the

Victaulics using a light coating of Victaulic lubrication.

4. Install the liquid injection line The liquid injection line is attached to the condenser and has shipping straps securing it to the evaporator and condenser. It, and the compressor, each have a block-off.

5. Install the motor cooling line using the same procedure as the liquid injection line.

6. Install the motor drain line (see Figure 6) using the same procedure as the liquid injection line.

52 Field Installation Procedure IM 1128-1

7. Install compressor wiring. The wire end that has been disconnected, and its attachment point on the compressor, will each have a label attached (VC for the vane close switch, for example) for matching purposes.

Guardistor

, G1 (and G2 on some units), terminal box located on side of motor housing.

Vane load/unload solenoids, SA and SB, located on the four-way solenoid assembly.

Vane close switch, VC, located on compressor next to the discharge housing.

Vane open switch, VO, located on suction end of compressor.

High pressure switch, HPS, located on compressor discharge nozzle.

8. Mount the VFD power panel on the brackets in the front of the unit and interconnect to the compressor motor using the cables provided. Control wiring will also be required. The field wiring diagram located on the control panel door should also be consulted.

9. Normal procedure of leak testing, triple evacuation, and charging with refrigerant and lubricant must be followed prior to the start up procedure.

10. After leak testing, insulate the compressor motor, suction line, and other miscellaneous areas with the included insulation and adhesive. The following components should be insulated:

Evaporator Evaporator water heads

Motor cooling lines Suction elbow

Expansion valve

VFD cooling line

Stator cooling line Evaporator tube sheets

This completes the reassembly procedure.

Type II Reassembly

TYPE II ... Type II provides a total knockdown of the unit. The compressor and VFD power panel are removed and put on a skid. The touchscreen and mounting arm will ship in a separate container.

The condenser, evaporator, and tube sheet supports will remain connected only by the attachment bolts for easy disassembly at the job site. All wiring and piping that interconnects the components will be removed. The remaining loose parts will be packaged in a separate crate.

1. Block-offs will cover all openings on the compressor and vessels.

2. The compressor and vessels will receive a 5 psi helium holding charge.

3. A compressor insulation kit will be shipped with the unit.

4. Only the evaporator shell will be factory insulated. Loose insulation and glue will be shipped for the remaining surface areas.

5. The compressor and VFD power panel will ship loose.

6. Refrigerant will be field supplied and installed.

7. All field-piping connections will be grooved mechanical couplings, O-ring face seal or copper brazing.

8. Touch-up paint and stick-on wire ties will be included.

9. The discharge piping and suction elbow will be shipped loose in a separate crate.

10. The unit will undergo the rigorous, full Daikin McQuay run-test program at the factory.

11. Contact local McQuay Factory Service for price quotation and scheduling.

IM 1128-1 Field Installation Procedure 53

54

Reassembly Steps

NOTE: Additional instructions may be shown on the assembly drawings.

The Type II arrangement is shipped with the evaporator, condenser, tube and sheet support plate bolted together. This provides structural support during transit and also allows several options for disassembly.

Figure 35, Component Disassembly

TWO ANGLE PLATES,

ONE WELDED TO EVAP.

ONE WELDED TO COND.

THEN BOLTED TOGETHER.

EVAPORATOR

TUBE SHEET

BOLTED

TUBE SHEET

SUPPORT

PLATE

WELDED

CONDENSER

TUBE SHEET

BOLTED

In most cases for narrow entry, the condenser will be separated by unbolting it from the evaporator angle bracket and from the tube sheet support plate. This leaves the evaporator and the support plate that has the mounting foot extended under where the condenser used to be. Therefore, the evaporator is usually unbolted from the two support plates, which can then be more easily handled by themselves.

!

WARNING

Remove compressor and vessel holding charge through the Schrader valve in the block-off plates before attempting to loosen any fittings on them. Failure to do so can cause severe bodily injury.

11. Disassemble the unit to the extent required by the site conditions. Rig the components to their final location and reassemble them using the fasteners that came with the unit.

12. The compressor and its suction and discharge piping should be installed on the stack before any other lines are attached. Mount the compressor on the stack. Mounting bolts, washers and nuts are shipped loose. Leave the mounting bolts loose until the suction and discharge lines are in place and aligned.

Install the suction and discharge piping. Before tightening the grooved mechanical couplings, position the suction and discharge piping so that the compressor can be aligned to give the best fit-up. When this is achieved, secure the compressor mounting bolts and proceed with installing the grooved mechanical

using a light coating of lubricant. See Figure 3.

13. Install the liquid line using Figure 11 as a guide. Due to the variety of vessel combinations available,

variation on specific units will occur.

14. Install the motor cooling line using Figure 5 as a guide.

15. Install the liquid injection line (see Figure 4). Note that any given injection line may be configured

somewhat differently than shown on the drawing.

16. Install the four-way solenoid valve assembly on the compressor suction housing.

17. Install the control panel; the unit panel is on top of the condenser. Wire and sensor leads have been disconnected at their terminus and labeled. They remain connected at the panel and rolled up. Their destinations have matching labels, which simplifies the installation. :

Compressor panel detail ........................................ Figure 18

Unit panel wiring and connections ........................ Figure 15

Field Installation Procedure IM 1128-1

Unit panel detail .....................................................Figure 19

Unit panel sensor locations ....................................Figure 16 and Figure 17

Flow switch wiring detail ......................................Figure 20

18. The VFD as unit mounted on the condenser with brackets for mounting it and interconnection cables to

the compressor motor. Control wiring as shown in Figure 9 will also be required.

Normal procedure of leak testing, triple evacuation, and charging with refrigerant and lubricant must be followed prior to the start up procedure.

19. Insulate the compressor, suction line, and other miscellaneous areas with the included insulation and

glue after leak testing. See Field Insulation Guide on page 29.

This completes the reassembly procedure.

IM 1128-1 Field Installation Procedure 55

Type III Reassembly

Description

TYPE III: The unit ships fully assembled and charged and is field ready to knockdown as required after refrigerant is pumped down or removed. Included are the vessel bolt-on connection brackets and the discharge stack bolt-on flanges at the condenser.

1. The unit is shipped fully charged with refrigerant.

2. The unit will be factory insulated and painted.

3. All electrical and sensor wiring will be fastened as usual.

4. The VFD will be installed.

5. Touch up paint and stick on wire ties will be included.

6. This unit will be fully tested at the factory.

7. Labels will be provided with the instructions to mark piping, electrical wiring and sensor wiring.

Reassembly Steps

Type III units offer a variety of disassembly opportunities. In some cases the condenser and tube support plate are removed to meet narrow entrance requirements. The compressor and VFD power panel may be removed for low height situations. Other possibilities exist.

Therefore it is difficult to prescribe step-by-step procedures. Various sections of this manual can be used where applicable, bearing in mind that the unit is fully charged with refrigerant.

!

DANGER

Prior to un-sweating any connection in the field, verify there is no pressure or charge in the component or lines. Failure to do so can cause severe injury or dearth.

!

CAUTION

Avoid applying excessive heat to valve seats when brazing or removing lines. Use cooling on valve components. Failure to do so will cause valve damage.

!

CAUTION

Cover any opening to prevent foreign objects from entering. Failure to do so can cause equipment damage.

Table 9, Major Component Dimensions and Weights

Chiller

WME 500

WME 700

Component

E3012 Evaporator

E3612 Evaporator

C2612 Condenser

C3012 Condenser

Compressor

M2 VFD Power Panel

M3 VFD Power Panel

Control Panel

E3612 Evaporator

C3012 Condenser

C3612 Condenser

Compressor

M4 VFD Power Panel

Control Panel

Dimensions L x W x H in.

169 x 43 x 38

171 x 48 x 44

165 x 36 x43

mm

4292 x 1081 x 955

4329 x 1222 x 1120

4181 x 915 x 1080

169 x 42 x 46

35 x 45 x 20

41 x 21 x 61

54 x 24 x 60

17 x 7 x 17

171 x 48 x 44

169 x 42 x 46

173 x 48 x 52

35 x 46 x 28

54 x 24 x 60

17 x 7 x 17

4292 x 1065 x 1170

889 x 1143 x 508

1035 x 533 x 1545

1370 x 610 x 1523

432 x 178 x 432

4329 x 1222 x 1120

4292 x 1065 x 1170

4394 x 1219 x 1321

889 x 1168 x 711

1370 x 610 x 1523

432 x 178 x 432

lbs

5075

6840

3900

Dry Weight kg

2299

3099

1767

5333

750

1850

2750

75

6840

5333

7508

770

2750

75

2416

340

804

1197

33

3099

2416

3401

350

1197

33

56 Field Installation Procedure IM 1128-1

Knockdown Dimensions

Figure 36, WME 0500 Chiller Height with Components Removed

A B

C

Vessel Size/ Motor Code

>>

E3012

C2612

M2 in (mm)

WME 500

E3012

C2612

M3 in (mm)

E3612

C3012

M2 in (mm)

E3612

C3012

M3 in (mm)

WME 700

E3612

C3012

M4 in (mm)

E3612

C3612

M4 in (mm)

A To Top of Compressor Brackets

Panels, Raceway, Compressor, Discharge

Line , Suction Elbow Removed (Note 2)

B To Top of Discharge Flange

Panels, Raceway, Compressor Removed

C To Top of Compressor

Panels, Raceway, Removed

Total Unit height, No Components Removed

62.0

(1575)

68.4

(1737)

85.5

(2171)

95.3

(2421)

62.0

(1575)

68.4

(1737)

85.5

(2171)

94.8

(2408)

69.8

(1773)

76.2

(1935)

91.3

(2319)

99.3

(2522)

69.8

(1773)

76.2

(1935)

91.3

(2319)

98.8

(2510)

69.8

(17730

81.0

(2058)

92.5

(2350)

98.8

(2510)

75.6

(1920)

86.7

(2203)

98.3

(2497)

104.8

(2662)

NOTES:

1. See specific unit dimension drawing for balance of dimensions.

2. The compressor mounting bracket is higher than the top of the evaporator tube sheet. This knockdown arrangement is the lowest unit height without separating the vessels.

IM 1128-1 Field Installation Procedure 57

Piping Removal

Figure 37, Refrigerant Piping to Compressor

Liquid

Injection

Supply

Discharge

Line and

Check

Valve

Stator

Cooling

Supply

Stator

Cooling

Return

58 Field Installation Procedure IM 1128-1

Figure 38, Refrigerant Piping from Condenser

VFD Cooling

Supply,

Connected to

VFD Panel

Rotor

Cooling

Supply

Stator

Cooling

Supply

King

Valve

Expansion Valve with Liquid

Injection Supply

Line Behind

IM 1128-1 Field Installation Procedure 59

Figure 39, Refrigerant Connections at Compressor

Stator

Cooling

Supply

Rotor

Cooling

Return

Figure 40, Electric Connections at Compressor

Rotor Cooling

Supply

60

Power

300Vdc

Low

Voltage and

Logic

Ethernet

Field Installation Procedure

Compressor

Wire Harness

IM 1128-1

Figure 41, Liquid Injection Piping

Figure 42, Stator Cooling Piping

IM 1128-1 Field Installation Procedure 61

Figure 43, Rotor Cooling Lines

Figure 44, VFD Cooling Piping

62 Field Installation Procedure IM 1128-1

Compressor Removal and Re-Attachment

Figure 45, Compressor Removal/Re-Attachment, View #1

Figure 46, Compressor Removal/Re-Attachment, View #2

IM 1128-1 Field Installation Procedure 63

64

Compressor Removal and Re-Attachment

Removal Preparation

1. Close the king valve at condenser liquid line outlet.

2. Close all other related shut-off valves.

3. Pump the refrigerant charge down into the condenser.

4. Ensure that the charge has been removed from the compressor and evaporator and that the discharge check valve is holding the charge in the condenser.

5.

Loosen and remove bolts on either side of the compressor discharge nozzle (see Figure 46, flag #1).

Compressor Removal

1.

Loosen and remove bolts on either side of the cast suction elbow (see Figure 45, flag #2).

2. Remove rotor cooling return line on the underside of the compressor motor housing along with both

rotor cooling supply lines per Figure 43 noted as "mechanical break points”, and Figure 39,

3.

Remove (2) DIN connectors from the solenoid coils (see flag #3 on Figure 41 and Figure 42).

4.

Remove rotor stepping valve control wire (see flag #4 on Figure 43).The wire ties will have to be cut

away during this process.

5.

The following wires coming from the VFD will need to be removed (Figure 40):

- 300v dc power supply ( yellow cable )

- 25 pin "D" shell connector

- power leads on the top of the motor housing

- Ethernet cable coming from the unit control box

6. Remove the wireway box assembly from the compressor to the back of the VFD.

7.

Loosen the (4) bolts from the compressor's bottom mounting feet see Figure 45, flag #5). Do not

loosen or remove bolts securing the compressor brackets as height is pre-set from the factory.

8. Mount a 1/2-13 swivel lifting eye to the front tapped lifting hole on the compressor motor housing. (see

Figure 45, flag #6). The compressor weight is 1000 lbs.

Compressor Re-Attachment

The following gaskets and “O” rings required for compressor reassembly are shipped loose:

Table 10, WME 500 Type III Knockdown “O” Rings and Gaskets

Part No. Quantity Description Unit Location

070194992

350233017

070199039

1

1

1

“O” Ring

“O” Ring

Gasket

Between suction nozzle and compressor inlet connection

Between suction nozzle and evaporator outlet flange

Between compressor discharge nozzle and upper discharge pipe flange(Note 1)

Between the compressor volute and the discharge nozzle. 735073620 1 “O” Ring

Notes:

1. There are four identical gaskets for the discharge pipe, all are not used.

2. Blank-off plates not shown but may be required for extended aperture opening. The discharge nozzle is the short section of pipe with fittings between the compressor volute and the discharge pipe.

1. Set the suction elbow back on top of the evaporator and install the screws loosely at the evaporator flange, being sure to inspect the O-rings for damage and replace if needed.

2. Set compressor on mounting brackets and install the (4) mounting bolts loosely. Install the gasket at check valve and insert bolts through the spool piece.

Field Installation Procedure IM 1128-1

3. Install (12) bolts at elbow to compressor and torque to 25 ft-lbs; do not over-tighten.

4. Install (18) bolts at evaporator flange to the suction line and torque to 62 ft-lbs; do not over-tighten.

5. Torque the (8) bolts to the spool piece at the check valve to 205 ft-lbs.

6. Re-install the wireway between the compressor and the VFD.

7. Re-attach all associated power wiring & Ethernet cable.

8. Evacuate the evaporator and VFD cooling lines to 300 microns for one hour.

9. Open all valves.

10. Perform refrigerant leak check to ensure all connections and fittings are securely fastened.

IM 1128-1 Field Installation Procedure 65

66 Field Installation Procedure IM 1128-1

McQuay International Training and Development

Now that you have made an investment in modern, efficient Daikin McQuay equipment, its care should be a high priority. For training information on all Daikin McQuay HVAC products, please visit us at www.daikinmcquay.com and click on training, or call 540-248-9646 to speak to the Training

Department.

Warranty

All Daikin McQuay equipment is sold pursuant to McQuay International standard terms and conditions of sale, including Limited Product Warranty. Consult your local Daikin McQuay Representative for warranty details. To find your local Daikin McQuay Representative, go to www.daikinmcquay.com.

This document contains the most current product information as of this printing. For the most up-todate product information, please go to www.daikinmcquay.com.

2012 McQuay International • (800) 432-1342 • www.daikinmcquay.com

IM 1128-1 (4/12)

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