Operation and Maintenance Data ne IM 307-4 January 1995, Form Ho, S06A 160HOT-A Single Compressor Centrifugal Chillers PEH/PHH 050, 063, 079, 087, 100, 126 {21006 MechnyItrnaonaTABLE OF CONTENTS INTRODUCTION Genoral Description Application OPERATION ‘Operator lesponsibiltios Nomenclature Microtech Control Panel Capacity Control System Vane Operation Metering Valves Vane Speed Adjustment 4, il System Hot Gas Bypass System PEHO7® Chiller PEH126 Chiller PHH068 Chiller MAINTENANCE Routine Mainienance Lubrication ‘Changing Oil Filter Reftigerant Cycle Electrical System Cleaning and Preserving. 8 Seasonal Servicing 8 ‘Annual Shutdown 89 Annual Start-up a Repair of System 8 Pumping Down 9 Pressure Testing 9 Leak Testing O Evacuation 940 Refrigeration Charging, 10 Pressure Relief Valve Replacement 10 Equipment Warranty 10 Evaporator, Condenser Flow Limits 40, 11 Refrigerant Charts it MAINTENANCE SCHEDULE 12, 19 CENTRIFUGAL OPERATING LOGS Microtech Control Panel 1“ Non-MicroTech Control Panel 5 SERVICE PROGRAMS 6 WARRANTY 16 INTRODUCTION GENERAL DESCRIPTION ‘Tho McQuay Model PEH Centrifugal Water Chilers are com- plete, selt-contained, automatically controlled water chiling units. Each unit is completely assembled and factory tested prior to shipment. Inthe PEH series, each unit contains one compressor con- nected to a condenser and evaporator. A sistor model called the PHH Heat Recovery Chiller is similar to the PEH models ‘except for the addition of a second split condenser for heat recovery applications. The PHH models are equipped with a hot ges bypass system for operation at light cooling loads. This hot gas system is standard on PHH units and optional for PEH models The standard chillers use refrigerant 194a, to reduce the size and weight of the package and since they operate at ‘a positive pressure over the entire operation range, no purge system is required, The controls are completely prewired, adjusted and tested. (Only normal field connections such as piping, electrical and ‘pump interlocks, ete. are required thereby simplifying installa- tion and increasing reliability, All necessary safety and ‘operating controls are factory installed in the control panel "The six basic sizes of units are the PEHOSO, 083, 079,087, 4100 and 126 and provide a capacity range from 80 tons to 1200 tons. The PEHO5O is also applied with modified impellers land are designed as PEHO46 or PEHO48, In this manual al references to the PEH models will equally apply to PHH models unless specifically referenced otherwise APPLICATION ‘The operation and maintenance procedures presented in this manual apply to the slandard model PEH chillers and the ‘model PHH heat recovery chillers. Reference to the Installa- tion Manual, IM 306, and the Mlcrafech Operation Manual, 1M 403, for these units should be made for details pertaining toreceiving and handling, installation, piping and wiring, and preparation for intial startup All McQuay centrifugal chillers are factory tested prior to shipment and must be intially started by a factory trained McQuayService technician, Failure to follow this startup pro cedure may alfect the equipment waranty The standard warranty on this equipment covers parts which prove defective in material or workmanship. Specific 1020 | 120 toa ts tae [ss ss1 | os N00 | iss joer 2 ws | a2 fez | e tose | ize tone we ta7 | ss ssa | o9 tts | iss ora 4 sr | ae S05 | ee toae | ia 2002 momo |e sry [xo tie | wo done & io | ae S20 |e tia0 | 126 dose 2 mele oor [ie tao |e 2120 8 ie | as sox | os rier [i anne 2% 20 | er sao | toe tase | tae 217s w 107 | 5 S78 | 9 i208 | io a2 2 aa |e 50 | 106 MWe at 2 212 | 8 gor | 9 tae | ise baat 2 mo |e ore | 108 ie 28a v4 226 | oe Gan | 9 tae | io bea ae | 7 702 | 110 1s 208 te 241 | 56 G2 | 96 tae? | ioe ase 2 1 | mo |i is bos ie 287 | 5 Gro | 90 tooo | ioe aera a oat | mee [ie is hes 2% 73 | 708 | x00 jai2 | m0 2ar7 % se |e ea | ite 1s eae m eo |e fas | ice jase | ae 2a m2 | a2 [ie 1822508 2 S06 | ex faa | toe ton | ia boo 70 | aaa | 120 16 3651 2 324 | es a9 | toe tay | ae Bara 2 ss |e ow fiz ie ans 2s 32 | ea 23 | toe toa | ia 2ra2 ator |e 2 [ie tes 2704 50360] 70 asa | io seet_} 150 Zar TABLE 6, HFC-134a THFC-1aan TEMPERATURE PRESSURE CHART. 7F pea [-F _psia | -F psia | +r pai@ a a a 2 ye | 43 az | os 1000 | 120 toes wo 120 | 6 asa | 0 ion | 190 tor we toa [8 477 | se tant | ia 20s wo tea [oe Goo | ot Heo | ioe Fas m a1 [mm Ha [io t409 | iso bee 2 2a |r vo |i teu [ise 300 a a [as aoe | He tens | ise be? m a1 | 7 gaa [ie tee0 | ise bee 330 | @ a7 |i iret | too 200 ‘@ 370 |e G00 | iz trea | tee Sore 0 Less Lie tana [ioe sree IM 207 / Page 11MAINTENANCE SCHEDULE FIGURE 8, MAINTENANCE INTERVAL, MONTHLY ‘QUARTERLY ANNUALLY AS REQ’D BY PERFORMANCE ‘SEMI-ANNUALLY 1. COMPRESSOR ‘A. Performance Evaluation (Log Cont. & Analy)” ° 5. Mole + Meg, Wings (600 Note on page 18) | x + Amp Balance thin 105) x * Teiminal Check ight conn, porsian caso) I x + Motor Cooling (check amperes) © Lubeton System +O Lines Temperatures ° + Wiator(Relegerant Ceolent Temperature o + Ol Cooter Sino (wa) x +O} Cooler Solenoid Opraton x + Ot Anais x * Ol Appoarance (dear clr, quantity) o +01 Fite Change x 3 Vane Operaton + Compressor Loads ‘Oporto Manual Switch x Recor Motor Amps x + compress Unonds ‘Operate Manus! Sitch x Record Motor Amp x + Vanes Wl Hold (lace manual sitchin “oly ‘Obeoryo Walt Temp & Facord Amps x E infernal Compressor Choo x i, conTROLS ‘A Operating Cont: ‘+ Chook LAT Setings and Operation + Chak Vane Conte Sting and Gperaon + Vey Motor Load Lint Conta * Very Load Balance Operation + chesk Oi Pump Contactor Protacive Gon: + Test Operation o: ‘lm Relay Pum lnerocks Hot and Cold OF Temperature Switches Guaritor and Sugwouard Relays High and Low Prossure Swiches High Suction Temparature Swichoe igh Oienarge Temperature Swteh Low Pressure Oveita Sach (1 Pump Pressur Dioranal Switch (1 Pump Satety Timer (1 Pump Time Delay Switch ‘ystem Mont: Timer Vane Czsed Switch 1, CONDENSER [A Perormance Evstion ° Test Water Gua |e C. Clean Condoneor Taba i ~b. Edsjeurent TestTube Wall Theknoss x E, Seasondl Proteton x (0 — Pertormod by in-house personnel X— Perormed by MeQusySenies personne Page 12 IM 307FIGURE 8. MAINTENANCE INTERVAL (Continued) ‘MONTHLY ‘QUARTERLY ‘SEMI-ANNUALLY ANNUALLY AS REQ’D BY PERFORMANCE ‘A. Petormance Evaluation (Log Cont. & Analy)" Test Wate Guay .Ciean Evaporator Tubes as aquired) 1. Eddyeurnt TestTube Wall Thickness (a requeg) E, Seasonal Protectan 'V. EXPANSION VALVES ‘A Perirmance Evaluation (Supsreat Cont} Vi. COMPRESSOR-CHILLER UNIT ‘A Perirmanco Evaluation Leak Test + Compressor Fitngs and Termint + Piping Ftings +O Pump Joins and Ftings + Vessel Rot Valves ©. Vain tolatlon Test 1. General Appearance: + Insition Vil, STARTERS) ‘A. Examine Contactors (hardware and epeaon) 8, Vorly Overload Seting and Tp . Test Elsticl Connections ‘3 Pump Down Contre (erly operat ‘Vn, OPTIONAL CONTROLS ‘A Hot Gas Gypase Cantos verty operation Liquid injection Controls vetly operon) ‘Pump Down Conrel (ery epartn ey: © = Peeiomed by inhouse personnal X = Pecormed by McQuaySence prsonnat NOTE: Some centrfugals use power factory correction capacitors and some use a surge capacitor. The surge capacitor may ’e installed out of sight in the compressor motor terminal box. In all cases, capacitors must be disconnected from the circuit to obtain a useful Meggor reading. Fallure to do so will produce a low reading. In handling electrical com- ponents, only fully qualified electrical techniclans should attempt service, IM 907 1 Page 13McQUAY CENTRIFUGAL OPERATING LOGS FIGURE 9. MICROTECH CONTROL PANEL (commu “dua syaq umoa anus: Bey e1ges10, x5 Ber axqeua sho (6)aun yen) duos wea dn ves 3 Bonne war aby eer wes Suis 75TH Sno BaD ‘HFG ENUEFEHTO HO. We SET BIE ie 1567 paz eg SET ES HON, au én due ur dury Buuuibea "HUT BEOT HOS ibis diy s1OWoH ‘ma dary ows may day > is say ewe Las Bones sey "14s deg Guneary ‘YO Sauna wun Tay) pu0 BUREST Teun Gury enue Tea BIOS HTT uN day owe {Nor Guy = a —f Suypeawn enssera mor "yO Buqwuny s Hon, awu| — NOWIGNoD WH) NOLLIGNOD. Sival ONULV3d0 laiva| ONLLVuado. oan ‘Ga "PLC 10H a ‘ad ‘dena, ywess61y0u (ora ‘ave Jesuopu0g Guo “ON Ives. toys “916M pomD BuIAED (vossaxduioo 2e3) “Tu sossasdwoo, on oo a SLINN ‘TANVd ‘TOHLNOO HO3LOWOIN ‘507 ONILVHSdO Page 14// IM S07FIGURE 10. NON-MICROTECH CONTROL PANEL WSiSKS “XTHINOW CUOWOIEOUWLIYE DA aly ‘SNOLIONGO NDISAG GVOT Ting IM 307 / Page 15SERVICE PROGRAMS Its important that an air conditioning system receive ade- uate maintenance ifthe full equipment life and full system benefits are to be realized. Maintenance should be an ongoing program from the time ‘tho systom is intially started, fl inspection should be made after 8 to 4 weeks of normal operation on a new installation and on a regular basis thereafter. McQuay offers a variety of maintonance services through McQuayServie, its nationwide service organization, and can tallor these services to suit the neods of the building owner. Most popular among these services is the ‘McQuayService Comprehensive Maintenance Plan wherein ‘McQuay International assumes full responsibilty for your alr Conditioning equipment. Included are regular routine inspec- tions and emergency service by factory trained technicians. All parts, labor, materials, and refrigerant are included ina McQuayService Comprehensive Maintenance Contract, For further information concerning the many services available, contact your local McQuayService representative PRODUCT WARRANTY McQuay International, hereinatter referred to as the “Com pany” warrants that i will provide, at the Company's option, ‘ther fre replacement parts or free repair of component parts inthe event any product manufactured by the Company and Used in the United States proves defective in material or ‘workmanship within twolve (12) months from initial startup or eighteen (18) months from the date shipped by the Company, \whichaver comes fits. For adcitional consideration, the Com pany warrants that for four (4) years following the intial war- ranty period it will provide, at the Company's option, {ree replacement parts for the motor-comprossor, or, ree replace ment for any intagral component of the motor-compressor Which proves defective in material or workmanship. For an Additional consideration, the Company warrants that for nine (9) years following the initial warranty period it will provide free replacement of the heat exchanger in gas-fired or olMired furnaces which proves defective In material and workman ship, (Extonded warranties for motor-compressors and heat ‘exchangers aro not applicable unless separately purchased.) “To obtain assistance under this parts warranty, extended rmotor-compressor warranty, or extended heat exchangor war- ranty, simply contact the selling agency. To obtain informa- tion orto gain factory help, contact McQuay International, War- ranty Claims Department, P.O. Box 1551, Minneapolis, MN £55440, telephone (612) 553-5390, ‘This warranty constitutes the buyer's sole remedy. tis given in lieu of all other warranties. There is no implied warranty of merchantability or fitness for a particular pur- pose. In no event and under no circumstances shall the McQuay De ervations! 12600 sil Prk Be, PO, Box 1551, Mlnnassl, MN S5¢40 (612 859-6990 Company be liable for incidentiat or consequential damages, whether the theory be breach of this or any other warranty, negligence or strict tort This parts warraniy and the optional extended warranties extend only to the original user. Of course, abuse, misuse, €f alteration of the product in any manner voids the Com: pany’s warranty obligation. Neither the parts or oxtended war- Fanty obligates the Company to pay any labor or service costs for removing or replacing paris, or any shipping charges. Rofrigerants fluids, ols, and expendable items such as fiters fre not covered by this warranty ‘The extended wareanties apply ony to integral components ‘of the motor-compressor or heal exchanger, not to retigerant Controls, electrical controls, or mechanical controls, or to fallutes caused by failure of thoso controls. ‘Attached to this warranty is @ requirement for equipment ‘containing motor-compressors andlor furnaces to report start Up information. The registration form accompanying the pro- duct must be completed and returned to the Company within ten (10) days of original equipment start-up If that is not done, the date of shipment shal be presumed to be the date of stat- Up and the warranty shall expire twelve (12) months from that date. 'No person (including any agent, salesman, dealer or distributor) has authority to expand the Company's obligation beyond the tarms ofthis express warranty, or to state that the performance of the product is other than that published by the Company. ® Prints on royce paper containing a ast 10% post-consumer eccld mateal