MC Quay

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THE NEW FRAME 4 COMPRESSOR service & application
McQuay International
10.06.03 /
Overview
McQuay have carried out an extensive analysis of the

possible green alternatives refrigerants R410A, R407C, R404A, R134a
This has shown that whilst R407C should be retained

for piston and scroll compressors and R134a for screw units
McQuay has designed a screw compressor -- the Frame

4 which is optimized for R134a
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Design Philosophy
R134a is a lower pressure, higher volume refrigerant than R22 and

even more so when compared with R410a - so the swept volume must be increased at minimal cost.
The simplest way to achieve this is to use a larger diameter rotor and gates.
Oil injection has been used to COP at high condensing pressures.
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Design Philosophy--contd.
R134a almost always benefits from the use of an economizer but to

to simplify the compressor design this will be external to the compressor.
As the economizer will be external, the motor has also been simplified and is gas cooled rather than refrigerant cooled like the Frame 2. In line with normal J & E Hall practice the compressor has infinitely variable capacity control down to 25%. This provides an additional selling feature against competitors with step control.
From day one it will be available with an electronic soft-start.
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Screw chiller frame 4 compressor
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Rotor & Bearing Design
Three bearings for reliability and low vibration Simple gas-cooled motor
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Rotor Access
Large aperture for easy access

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Star-gate Assembly
Simple bearing cap assembly gives good location and easy removal
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Star-gate
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Capacity Slide Assembly
Spring-loaded slide for auto-return Porting designed for R134A Symmetrical unloading for balanced bearing loads
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Capacity Slide
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Main Feature Benefits
High efficiency -- COP >3.2 @ ARI air-cooled
Reliability -- oil injected, large clearances, 3 bearings Low vibration --- < 0.07mm/s ( 50% of FR2) Infinitely variable capacity control -- With optional feedback. Ease of maintenance Competitive price -- Lower cost/ton than FR2 Lower in-rush current -- Star/Delta or soft-start
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
Suction side
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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ALS Fr4
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PFS Fr4
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PFS Fr4
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PFS Fr4
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PFS Fr4
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PFS Fr4
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PFS Fr4
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PFS Fr4
PFS Fr4 - R134a water pressure control system Prestart: The Pico controller verify the condenser entering water temperature and the evaporator living water temperature. Thus values will be automatically converted by it self by the internal pressure/temperature table. If the ratio of thus calculated pressure is bigger than 1.6 the controller will start the compressors following the standard starting procedure. If the ratio is lower than 1.6 the controller will start the compressors following the "cold start" starting procedure.
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PFS Fr4
"Cold start" starting: The Pico controller, when the compressor start, send a signal to the electronic expansion valve (2 valves working together for "Dual" units) for 20% of full opening status. During this situation, the main Driver function is disabled, so the Pico controller it self, instead to follow the target suction superheat, will check the refrigerant pressure ratio (absolute condensing pressure/absolute evaporating pressure) opening or closing the "EXV" and trying to maintain it between 2.1 and 2.3. If this ratio go below 2.1, the controller sends to the valve a signal for close. If the ratio go above 2.3, the signal that the controller send to the valve is for opening. With a ratio value between the mentioned numbers the controller will send no signals to the EXV (dead band) so that it will say fixed. During the WPC status, suction super heat and liquid sub cooling reach very high values but, in this case, these must be ignored. As the evaporator and condenser water goes closer to the project conditions, the suction super heat value decrease continuously. The "cold start" starting is closed when the suction super heat value reach 2K. At this point the controller gives back to the Driver the EXV control, and it will drive the valve to achieve a suction super heat around 0.5K. During the "cold start" starting is possible that append the following anomalous conditions:
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PFS Fr4
1. Low suction pressure: If the electronic expansion valve closes to much, in order to guarantee the minimum pressure ratio, is possible that the suction pressure goes below the freezing value. In this case the controller will unload the compressor/compressors up to the pressure value reach at list 0C (calculated). If this situation should not happen, after 120 sec. The controller will switch off one compressor under low pressure alarm . If also after this operation the pressure will remain below 0C (calculated), after additional 120 sec. The controller will switch off the second compressor (If existing). The time delay is less than 40 sec. When the calculated saturated evap. Pressure is lower equal than -10C. 2. High delivery pressure: the excessive liquid refrigerant storage in the condenser shell, due to the cold start starting mode, could excessively reduce the heat transfer surface of the heat exchanger. In this condition the condensing pressure could increase above the maximum allowable value. At this point the Pico controller will unload the compressors following the standard "stage hold - stage down" logic. 3. High delivery super heat: the increasing suction super heat, due to the suction pressure reduction already described, will provoke a rise of the delivery super heat. If during the WPC the delivery temperature should achieve the maximum allowable value (setted to 85C as default), the Pico controller will go ahead with the standard "liquid injection oil cooling" procedure, energising the liquid injection solenoid coil by an output signal from the "OD06" digital output. If the temperature should rise again, the Pico controller will stop the compressor when the temperature will achieve 95C under alarm. If the temperature start to go down, The Pico controller will stop the "liquid injection oil cooling" procedure when the temperature will achieve the mentioned set point less the differential value (10C).
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PFS Fr4
During "Running" condition: Is possible that, in running condition, the condenser entering water temperature excessively reduce due to (for instance) an anomalous control of the cooling tower. In this case the pressure ratio could go down below the minimum set point (2.0). The Pico controller will react with the WPC logic as above described.
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PFS Fr4
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PFS Fr4
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PFS Fr4
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PFS Fr4 Vintage A

StandBy Compressor By HP Prevent 11.0 bar Tranducer HP Warning Tranducer HP alarm Tranducer LP alarm 11.5 bar 12.0 bar 2.5 bar
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PFS Fr4 Vintage B

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PFS Fr4 Vintage C

Cooling Tower Control (as per ALS fan control) 3 way valve control WP start control New I/O: all probes enabled on both master and slave pCO card
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WHS Fr4
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WHS Fr4
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WHS Fr4
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WHS Fr4
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Frame 4 Opening to the World

Frame 4 Screw chillers are managed by CAREL pCOTM controllers pCOTM boards are connected in network using the pLANTM link
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You can skip between different boards simply by pressing on status & info keys Settings have to be inserted / verified for each board. Settings are divided in three classes, under different passwords: USER, MANUFACTURER and CAREL
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User parameters PSW 003
Set parameters

Summer temperature setpoint limits:

05.0 C 17.0 C
Low High
Summer setpoint Winter setpoint
07.0 C 45.0 C
Regulation temperature:
OUTLET
Summer Winter 3.0 C 45.0 C
Type
Outlet regulation force off
Temperature Band Modulation Band

Neutral zone
03.0 C
02.0 C
Time between main pump/fan and Compressor start Delay on switching the main Pump off Digital input remote On / Off Digital input remote Summer / Winter Supervisory remote On / Off Supervisory remote Winter / Summer Insert another user psw
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030s 180s Yes No No No 0003

63

Manufacturer parameters PSW 033

Unit config. water/air chiller 00 Probes enable: B1, B2, B4, B7, B8 (MSTR) Probes enable: -, -, B4, B7, B8 (SLAVE) High pressure probe config. 4mA 20mA 0.0 bar 30.0 bar 0.0 bar 30.0 bar
Time to reach min. power Minimum compr. power-off time Time to reach max power Min time betw. Same comp. Strts Enable particular manag. of stg1 Time Sol./S1
Standby config. Compressor Relay 6 OFF Relay 7 OFF Decrement config. Compressor Relay 6 OFF Relay 7 ON Increment config. Compressor Relay 6 ON Relay 7 OFF
120s 120s 100s 600s No 3s
Low pressure probe config.

4mA 20mA
Enable double setpoint: Compressor config.:

Enable driver Yes N. of compressor Rotation comp.
No
2 Yes
Modulation Config.
Pulse period min. pulse D max pulse D min. pulse I max pulse I 2s 0.5s 0.5s 0.5s 0.5s
Type of unloads:
Time Star/line 0,15s Time Star Time Star/Delta.
Modulant
4,0s 0.05s
Enable start restriction
No
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Time force decr. For start cmprssr 08s Force solenoid with compr. OFF No Pump down config.
Enable Maximum time Yes 15s
Type INVERTER Fan number 1 Condensation

Setpoint 6.0 bar Diff. 4.0 bar
STEP
En pressure prevent Yes Sby compr. by HP Prevent 13.0 bar Transducer high pressure warning
setpoint diff. 14 bar 2,0 bar
Inverter config.
Max speed Min. speed Speed up time 10.0 V 04.0 V 01s
Step 1
Setpoint Diff. XX.0 bar X.0 bar
Discharge temp. Prevent

Setpoint Diff. 110C 10C 1.0C
Yes
Inverter config.
Point C Point D Point F Point B Point E 7.0 bar 8.0 bar 10 V 10.0 bar 10.0 bar
Freeze prevent 5.0C

diff.
Condensation Enable
Pressure
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Step 2
Setpoint Diff. XX.0 bar X.0 bar
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Manufacturer parameters PSW 033 Enable serious alarm Yes Valve open when compr. switces on 40% Driver Alarm Switch off driver 1 comp when battery error No Driver Alarm Switch off driver1 comp if LOP mode N Delay 00.0 min Evaporator flow alarm Yes (MASTER) Evaporator flow alarm No (SLAVE) Enable condenser flow alarm No Enable phase alarm Yes (MASTER) Enable phase alarm No (SLAVE) Evaporator flow alarms delays No Start-up delays 20s Run delay 05s Transducers high pressure alarm McQuay International
Setpoint Diff.
17.0 bar 03.0 bar 01.0 bar 00.5 bar
Transducers low pressure alarm

Setpoint Diff.
Low diff. Press. Alarm

Setpoint 04.0 bar Start-up delay 120s Running delay 060s
Low pressure alarm delays

Start-up delay Run delay 050s 20s 180s 090s 120s 010s
Oil differential alarm delays

Start-up delay Run delay
Oil level alarm delays

Start-up delay Run delay
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Antifreeze alarm
Setpoint Diff. 03.0 C 01.0 C
Electrovalve management Setpoint 85C Diff. 10C Antifreeze heater Setpoint 04.5 C Diff. 01.0 C
Circuit 1 config. EXV manufacturer Insert password 0000 Circuit 1 EXV Carel parameters Insert password 0000
Clock board 32K Enable Y Supervisor System Communication Speed 1200 (RS485/RS422) Identification No.: nn
Reset all parameters to default value No Insert another manufacturer psw 0033
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pCo I/O Layout
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What refrigerant is the Frame 4 compressor optimized for?

What refrigerant is the Frame 4 compressor optimized for?

What design changes were made to the motor and economizer?

What design changes were made to the motor and economizer?

Your Climate...

THE NEW FRAME 4 COMPRESSOR service & application

McQuay have carried out an extensive analysis of the

This has shown that whilst R407C should be retained

McQuay has designed a screw compressor -- the Frame

R134a is a lower pressure, higher volume refrigerant than R22 and

Oil injection has been used to COP at high condensing pressures.

R134a almost always benefits from the use of an economizer but to

From day one it will be available with an electronic soft-start.

Screw chiller frame 4 compressor

Rotor & Bearing Design

Large aperture for easy access

Capacity Slide Assembly

Main Feature Benefits

High efficiency -- COP >3.2 @ ARI air-cooled

PFS Fr4 Vintage A

PFS Fr4 Vintage B

PFS Fr4 Vintage C

Frame 4 Opening to the World

Frame 4 Opening to the World

Frame 4 Opening to the World

Summer temperature setpoint limits:

Summer setpoint Winter setpoint

Outlet regulation force off

Temperature Band Modulation Band

030s 180s Yes No No No 0003

Frame 4 Opening to the World

120s 120s 100s 600s No 3s

Low pressure probe config.

Enable double setpoint: Compressor config.:

Enable start restriction

Frame 4 Opening to the World

Type INVERTER Fan number 1 Condensation

Discharge temp. Prevent

Freeze prevent 5.0C

Frame 4 Opening to the World

17.0 bar 03.0 bar 01.0 bar 00.5 bar

Transducers low pressure alarm

Low diff. Press. Alarm

Low pressure alarm delays

Oil differential alarm delays

Oil level alarm delays

Frame 4 Opening to the World

Frame 4 Opening to the World

pCo I/O Layout

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