Installation, Operating and Maintenance Manual IOMM PEHPFH

Group: Chiller
Part Number: 736015417
Effective: February 1999
Supersedes: IM 306-4
IM 307-5

Single/Dual Compressor Centrifugal Chillers

PEH/PHH 050, 063, 079, 087, 100, 126
PFH/PJH 050, 063, 079, 087, 126

© 1997 McQuay International

 Table of Contents

Introduction ....................................................................................................................3

General Description..................................................................................................................................3
Application................................................................................................................................................3

Installation.......................................................................................................................4

Receiving and Handling ...........................................................................................................................4

Location and Mounting............................................................................................................................5
Water Piping..............................................................................................................................................6
Oil Cooler Piping .....................................................................................................................................8
Refrigerant Vent Piping............................................................................................................................9
Electrical.................................................................................................................................................11
Power Wiring..........................................................................................................................................11
Control Wiring........................................................................................................................................12
Prestart System Checklist.......................................................................................................................14

Operation.......................................................................................................................15

Operator Responsibilities.......................................................................................................................15
Nomenclature .........................................................................................................................................15
MicroTech Control Panel.......................................................................................................................16
Capacity Control System........................................................................................................................16
Lubrication System.................................................................................................................................19
Hot Gas Bypass.......................................................................................................................................20

Maintenance..................................................................................................................21

Pressure/Temperature Chart...................................................................................................................21
Routine Maintenance..............................................................................................................................21
Annual Shutdown ...................................................................................................................................24
Annual Startup........................................................................................................................................25
Repair of System.....................................................................................................................................25

Maintenance Schedule.................................................................................................28

Service Programs .........................................................................................................30

McQuay" is a registered trademark of McQuay International


1997 McQuay International
"Illustrations cover the general appearance of McQuay International products at the time of publication and we reserve the right to make
changes in design and construction at anytime without notice"

2 Centrifugal Chillers IOMM PEH/PFH

Introduction

General Description
The McQuay Model PE Centrifugal Water Chillers are complete, self-contained, automatically
controlled fluid chilling units. Each unit is completely assembled and factory tested before shipment.
In the PEH series, each unit contains one compressor connected to a condenser and evaporator. A
sister model, the PHH Heat Recovery Chiller is similar to the PEH models except for the substitution
of a split condenser (two water circuits) for heat recovery applications. The PHH models are equipped
with a hot-gas bypass system for operation at light cooling loads. This hot gas system is standard on
PHH units and optional for PEH models.
The PFH series are equipped with two compressors operating in parallel on a single evaporator and
condenser. Model PJH series are the equivalent double bundle heat recovery units.
The chillers use refrigerant R-134a to reduce the size and weight of the package compared to negative
pressure refrigerants and since R-134a operates at a positive pressure over the entire operation range,
no purge system is required.
The controls are pre-wired, adjusted and tested. Only normal field connections such as piping,
electrical and pump interlocks, etc. are required thereby simplifying installation and increasing
reliability. All necessary safety and operating controls are factory installed in the control panel.
The basic sizes of units are the PEH/PHH/PFH/PJH 048, 050, 063, 076, 079, 087, 100 and 126.
They provide a capacity range from 80 tons to 2500 tons. In this manual all references to the PEH
models will equally apply to other models unless specifically referenced otherwise.

Application
The operation and maintenance procedures presented in this manual apply to the standard PEH family
of chillers. Reference to the Installation Manual, IM 306 for these units should be made for details
pertaining to receiving and handling, installation, piping and wiring, and preparation for initial startup.
All McQuay centrifugal chillers are factory tested prior to shipment and must be initially started at the
job site by a factory trained McQuay service technician. Failure to follow this startup procedure
may affect the equipment warranty.
The standard warranty on this equipment covers parts which prove defective in material or
workmanship. Specific details of this warranty can be found in the warranty statement furnished with
the equipment and also found at the end of this manual.
Cooling towers used with McQuay model PE centrifugal chillers are normally selected for maximum
condenser inlet water temperatures between 75°F and 90°F (24°C and 32°C). Lower entering water
temperatures are desirable from the standpoint of energy reduction but a minimum does exist. For
recommendations for optimum entering water temperature and cooling tower fan control, consult
McQuay Product Manual PM PEH/PFH, Applications Section.

IOMM PEH/PFH Centrifugal Chillers 3

Installation

Receiving and Handling

The unit should be inspected immediately after receipt for possible damage.
All McQuay centrifugal water chillers are shipped FOB factory and all claims for handling and
shipping damage are the responsibility of the consignee.
Insulation corners from the evaporator's rigging hole locations is shipped loose and should be glued in
place after the unit is finally placed. Neoprene vibration pads are also shipped loose. Check to be sure
that these items are delivered with the unit.
Leave the shipping skid in place until the unit is in its final position. This will aid in handling the
equipment.
Extreme care should be used when rigging the equipment to prevent damage to the control center, or
refrigerant piping. See certified dimension sheets for the center of gravity of the unit.
The unit can be lifted by fastening the rigging hooks to the four corners of the unit where the rigging
eyes are located (see Figure 1). Spreader bars should be used between the rigging lines to prevent
damage to the control center and motor terminal boxes on PFH dual compressor units.

Figure 1, Unit Components

Control Panel

Evaporator
Relief Valve

Evaporator

Expansion Valve Condenser Dual

Relief Valves
Condenser

Liquid Line
Shutoff Valve

4 Centrifugal Chillers IOMM PEH/PFH

 Figure 2, Major Component Location

Lubricant to Lub Control

Box for Unloader Oil Sump,
Vent Line from Oil Sump Pump, Heater

Oil Pressure Regulator Discharge

Check Valve
Lubrication
Suction Control Box
Shutoff Valve Motor
(Duals Only) Cooling Inlet

Motor
Terminal Box
Rigging
Eyes Rigging
Eyes
Evaporator
Outlet

Evaporator
Inlet (Note)
Motor Cooling
Condenser Outlet Filter-Drier
Condenser
Outlet
(2) Dual
Relief Values
Lubricant Outlet
Condenser to Cooler
Inlet

Mounting Holes
(2) Each Corner

Note
The PFH126 Dual Compressor Chiller shown has the evaporator inlet in the bottom.
All other single and dual compressor units have the evaporator inlet on top.

Location and Mounting

The unit should be mounted on a level concrete or steel base and should be located so as to provide
service clearance at one end of the unit for possible removal of evaporator tubes and/or condenser
tubes. Clearances required are 18 feet (5.5 meters) for units with 16 foot (4.9 meters) long shells, 16
feet (4.9 meters) for units with 14-foot (4.3 meters) long shells, 14 feet (4.3 meters) for units with
12-foot (3.7 meters) long shells, and 10 feet (3 meters) for units with 8-foot (2.4 meters) long shells.
Evaporator/condenser tubes are rolled into the tube sheets to permit replacement if necessary.
Clearance at all other points, including the top, is 3 feet (1 meter).
The shipped loose neoprene vibration pads should be located under the corners of the unit (unless the
job specifications state otherwise).

IOMM PEH/PFH Centrifugal Chillers 5

 Units are shipped with refrigerant and oil valves closed to isolate these fluids for
shipment. Valves must remain closed until start-up by McQuay technician.

Water Piping
Water Pumps
Make sure that the floor or structural support is adequate to support the full operating weight of the
complete unit.
Rubber Shearflex pads, or "Isomode," are supplied with the unit for use under each corner of the base
members. The unit must be level.
It will not be necessary to bolt the unit to the mounting slab or framework; but should this be
desirable, 1 1/8" (28.5 mm) mounting holes are provided in the unit support at the four corners and
under the compressor base on the side-mounted compressor units.

Note
Avoid the use of 3600/3000 rpm (two-pole motor) pump motors.

It is not uncommon to find these pumps operate with objectionable noise and vibration.
It is also possible to build up a frequency beat due to the slight difference in the operating rpm of the
pump motor and the McQuay centrifugal motor. McQuay encourages the use of 1750/1460 rpm or
four-pole pump motors whenever possible.

Evaporator and Condenser Water Piping

All PEH and PFH evaporators and condensers come equipped with groove-type nozzles for Victaulic
couplings (also suitable for welding) or flange connections. The installing contractor must provide
matching mechanical connections of the sizes given in the system dimension and capacity tables.

Important Notes on Welding

1. If welding is to be performed on the mechanical or flange connections, the solid-state temperature
sensor and thermostat bulbs must be removed from the wells to prevent damage to those
components.
2. The unit must be properly grounded or severe damage to the MicroTech Controller may occur.
Small water pressure test valves or pipe plugs are provided at both the inlets and outlets of the vessel
heads. The test valves permit the water flow pressure drops to be checked. The pressure drops and
flow rates for the various evaporators and condensers are shown in McQuay Product Manual PM
PEH/PFH. Refer to the nameplate on the vessel shell for identification.
Evaporator inlet and outlet water connections have been reversed over time with design changes in the
vessel. Be sure that water inlet and outlet connections match certified drawings and stenciled nozzle
markings. The condenser is connected with the coolest water entering at the bottom to maximize
subcooling.

Note
When common piping is used in connection with a heating system, care should be
taken to insure that water flowing through the evaporator cannot exceed 110°F
which can cause the relief valve to discharge refrigerant or damage controls.

The piping should be supported to reduce the weight and strain on the fittings and connections. Piping
should also be adequately insulated. A cleanable 20-mesh water strainer should be installed at both

6 Centrifugal Chillers IOMM PEH/PFH

 inlets. Sufficient shutoff valves should be installed to permit draining the water from the evaporator
or condenser without draining the complete system.

Flow Switch
A water flow switch must be mounted in either the entering or leaving water line to insure that there
will be adequate water flow to the evaporator before the unit can start. This will safeguard against
slugging the compressors on start-up. It also serves to shut down the unit in the event that water flow
is interrupted to guard against evaporator freeze-up.
A flow switch is available from McQuay under Part Number 017503300. It is a "paddle" type switch
and adaptable to any pipe size from 25mm to 203mm.
Consult the manufacturer's data for the minimum flow rates required to close the switch. Installation
should be as shown in Figure 3.

Figure 3, Flow Switch Mounting

Flow direction marked
on switch

25mm (1") NPT flow

switch connection

Tee

32mm (1 1/4") pipe dia. min. 32mm (1 1/4") pipe dia. min.
after switch after switch

Electrical connections in the unit control center should be made at terminals 62 and 63. The normally
open contacts of the flow switch should be wired between these two terminals. Flow switch contact
quality must be suitable for 24 VAC, low current (16ma). Flow switch wire must be in separate
conduit from any high voltage conductors (115 VAC and higher).

CAUTION
Freeze Notice: Neither the evaporator nor the condenser is self-draining;
both must be blown out.

The piping should also include thermometers at the inlet and outlet connections and air vents at the
high points.
The water heads can be interchanged (end for end) so that the water connections can be made at either
end of the unit. If this is done, new head gaskets must be used.
In cases where the water pump noise may be objectionable, rubber isolation sections are recommended
at both the inlet and outlet of the pump. In most cases, it will not be necessary to provide vibration
eliminator sections in the condenser inlet and outlet water lines; but where noise and vibration are
critical (for example, where a pipe chase goes through walls adjoining living quarters in an apartment
building), they may be required.
Where a cooling tower is used to supply condenser water, a flow balancing valve is required. Some
form of water flow modulation may also be required if tower water becomes too cold.

IOMM PEH/PFH Centrifugal Chillers 7

 Oil Cooler Piping
Figure 4, Oil Cooler Water Piping Across Chilled Water Pump

Figure 5, Oil Cooler with City Water or Other Supply

PEH-048/050 and PFH-048/050 units are equipped with internal self-contained refrigerant-cooled oil
coolers and require no field piping for the coolers.
PEH 063, 079, 087, 100 and 126 single compressor units have a factory mounted water-cooled oil
cooler, and a temperature controlled water regulating valve with the cooling water piping extended to
the condenser tube sheet. Accessories must be installed as shown Figure 4. The solenoid stop valve
can be factory installed as an option.
PFH 063, 079, 087, and 126 dual compressor units are equipped as above but the solenoid valves are
factory installed at each cooler as standard. The water piping for the two oil coolers cooling is factory
piped to a common connection at the tube sheet.
Field water piping to the inlet and outlet connections must be installed according to good piping
practices and should include stop valves to isolate the cooler for servicing. A 1" minimum cleanable
filter (40 mesh maximum), a solenoid stop valve wired in accordance with the field connection control
diagram (also available as a factory installed option,), and drain valve or plug should also be field
installed. The water supply for the oil cooler may be either from the chilled water circuit (preferred
and recommended) or from an independent source such as city water (see Figure 5).

8 Centrifugal Chillers IOMM PEH/PFH

 The use of condenser water for oil cooling is not recommended. When using chilled water it is
important that the water pressure drop through the oil cooler be less than the drop across the
evaporator or insufficient oil cooler flow will result. This is normally no problem except on single
pass evaporators in which case the oil cooler water should be piped across the chilled water pump to
provide the maximum possible head and flow.
The water flow through the oil cooler will be adjusted by the regulating valve so that the temperature
of oil supplied to the compressor bearings (leaving the oil cooler) is between 80°F (27°C) and 110°F
(43°C).
When supplied with city water, the oil piping should discharge through a trap into an open drain to
prevent draining the cooler by siphoning. The discharged city water may also be used for cooling
tower makeup by discharging it into the tower sump above the highest possible water level.

Refrigerant Vent Piping

As a safety precaution, each system is equipped with pressure relief valves located on the condenser,
evaporator, and oil sump vessel for the purpose of relieving excessive refrigerant pressure to the
atmosphere. Most codes require that relief valves be vented to the outside, and this is desirable
installation practice for all installations.

Note
Remove plastic shipping plugs (if installed) from the inside of the valves prior to
making pipe connections. Whenever vent piping is installed, the lines should be
run in accordance with local code requirements; where local codes do not apply,
ANSI/ASHRAE Standard 15-1994 code recommendations should be followed.

The condenser design incorporates two relief valves (one set) with a three-way shutoff valve
separating the two valves (see Figure 6). One valve remains/in the system at all times and the second
valve acts as a standby.
If one relief valve of the two-valve set fails, the shutoff valve may be used to isolate the faulty relief
valve, while the other valve provides pressure protection.

Figure 6, Condenser Relief Valve Set,

Relief Valve # 1 Relief Valve # 2

Stem In: # 1 Open 3-Way Valve

Stem Out: # 2 Open
Always Front or Back Seat

When piping the vent line to a dual valve set, it may be sized for one relief valve and piped to both
valves. On large capacity condenser designs, two separate sets of dual relief valves are used. The vent
line must be sized to the total of two valves but piped to all four.

IOMM PEH/PFH Centrifugal Chillers 9

 Relief Valves
Relief valve connection sizes and quantity
Relief Valve
are shown to the right. Relief valves must Evaporator Code Connection Number
be piped to the outside of the building in E1608 Thru E2616 1” FPT 1
accordance with ANSI/ASHRAE 15. Twin E3016 Thru E4216 1” FPT 2
relief valves mounted on a transfer valve are E4820 Thru E4824 1” FPT 2
used on the condenser so that one relief Condenser Code
valve can be shut off and removed leaving C1608 thru C3016 1” FPT 2
the other in operation. Where 4 valves are C3616 Thru C4216 1” FPT 4
C4820 Thru C4824 1” FPT 4
shown, they consist of two valves mounted
on two transfer valves. Only two relief
valves of the four are active at any time.
Vent piping is sized for only one valve of the set since only one can be in operation at a time. In no
case would a combination of evaporator and condenser sizes require more refrigerant than the
pumpdown capacity of the condenser. Condenser pumpdown capacities are based upon
ANSI/ASHRAE Standard 15 recommendations of 90% full at 90°F (32°C).

Relief Valve Pipe Sizing

Relief valve pipe sizing is based on the discharge capacity for the given evaporator or condenser and
the length of piping to be run. Discharge capacity for HFC-134a vessels is calculated as follows:
C = 0.133 xDxL
Where: C=Minimum discharge capacity, lbs of air/min
D=Vessel diameter, in.
L=Vessel length, ft.
Example: E3016 Evaporator, HFC-134a Refrigerant, 75 equivalent feet of piping
C = 0.133 x 30 x16 = 63.8 Lbs of air / min

From the table below, 75 feet of piping for 63.8 lb. of air/min. at 180 psig valve setting requires a 2"
diameter pipe.

Discharge Capacity, lbs of Air/Min

EQUIVALENT DIAMETER STANDARD WALL IRON PIPE
LENGTH OF 1” (25mm) 1.25” (32mm) 1.5” (38mm) 2” (50mm) 2.5” (64mm) 3” (76mm)
DISCHARGE RELIEF VALVE PRESSURE SETTNG
PIPING, FT. (m) 180 225 180 225 180 225 180 225 180 225 180 225
50 (15.2) 21.4 26.8 42.8 53.6 62.7 78.4 117.0 146.3 182.2 227.7 315.4 393.7
75 (22.9) 17.5 21.9 35.0 43.8 51.5 64.4 95.4 119.3 150.5 188.1 257.4 321.8
100 (30.5) 15.2 19.1 30.2 27.8 44.3 55.4 82.6 103.3 129.6 162.0 222.5 278.1
150 (45.7) 12.4 15.6 24.7 30.9 36.0 45.0 67.3 84.2 105.1 131.9 182.2 227.7
200 (61.0) 10.6 13.6 21.4 26.8 31.4 39.3 58.4 73.1 91.1 113.9 157.7 197.1
300 (91.4) 8.8 11.1 17.5 21.9 25.5 32.0 47.6 59.6 75.6 94.5 128.5 160.7
Note: Standard relief valve settings; R-134a, evaporator=180 psig, condenser=225 psig

Note: Per ASHRAE Standard 15, the pipe size may not be less than the relief device, meaning a
minimum 1" diameter pipe is required. The discharge from more than one relief valve may be run into
a common header, the area of which shall not be less than the sum of the areas of the connected pipes.
For further details, refer to ASHRAE Standard 15. The common header can be calculated by the
formula:
0 .5
D C o m m o n =  D 2 + D 2 .. . . D n2 
1 2

10 Centrifugal Chillers IOMM PEH/PFH

 Electrical
Wiring, fuse and wire size must be in accordance with information located in the electrical data.
Standard NEMA motor starters require modification to meet McQuay specifications. Refer to
electrical data supplied with the unit or McQuay Product Manual PM PEH/PFH.
Important: The voltage to these units should be within the limitation of +10%, and the voltage
unbalance between phases must not exceed 3%. Since a 3 1/2% voltage unbalance will cause an
approximate 25% increase in motor temperature, it is most important that the unbalance between
phases be kept at a minimum.

Power Wiring
CAUTION
Qualified and licensed electricians must perform wiring. Shock hazard exists.

Power wiring to compressors must be in proper phase sequence. Motor rotation is set up for
clockwise rotation facing lead end with phase sequence of 1-2-3. Care should be taken that proper
phase sequence is carried through the starter to compressor. With the phase sequence of 1-2-3 and L1
connected to T1 and T6, L2 connected to T2 and T4, and L3 connected to T3 and T5, rotation is
proper. See diagram in terminal box cover.
Proper phase sequence will be determined by the McQuay start-up technician.

CAUTION
Connections to terminals must be made with copper lugs and copper wire.

Care should be taken when attaching leads to compressor terminals.

Note
Do not make final connections to motor terminals until wiring has been checked and
approved by a McQuay technician.

Under no circumstances should a compressor be brought up to speed unless proper sequence and
rotation have been established. Serious damage may result if compressor starts in wrong direction.
It is the installing contractor's responsibility to insulate the compressor motor terminals when the unit
voltage is 600 volts or greater. This is to be done after the McQuay start-up technician has checked
for proper phase sequence and motor rotation.
Following this verification by the McQuay technician, the contractor should apply the following
furnished items.
Materials required:
1. Locktite brand safety solvent (12 oz. package available as McQuay part number 350A263H72)
2. 3M Co. Scotchfil brand electrical insulation putty (available in a 60-inch roll as McQuay part
number 350A263H81)
3. 3M Co. Scotchkote brand electrical coating (available in a 15 oz. can with brush as McQuay Part
Number 350A263H16)
4. Vinyl plastic electrical tape
The above items are also available at most electrical supply outlets.

IOMM PEH/PFH Centrifugal Chillers 11

 Application procedure:
1. Disconnect and lock out the power source to the compressor motor.
2. Using the safety solvent, clean the motor terminals, motor barrel adjacent to the terminals, lead
lugs, and electrical cables within the terminal 4OX to remove all dirt, grime, moisture and oil.
3. Wrap the terminal with Scotchfil filling in all irregularities. The final result should be smooth and
cylindrical.
4. Doing one terminal at a time, brush the Scotchkote on the motor barrel to a distance of up to '/2"
around the terminal and, on the wrapped terminal, the rubber insulation next to the terminal and
the lug and cable for approximately 10". Wrap additional Scotchfil insulation over the
Scotchkote.
5. Tape the entire wrapped length with electrical tape to form a protective jacket.
6. Finally, brush on one more coat of Scotchkote to provide an extra moisture barrier.

Unit Mounted Starter Power Wiring

Some units are supplied with a factory wired and mounted star-delta starter equipped with ambient
compensated quick trip overloads. Wiring, fuse and wire size must be in accordance with information
located in the electrical data supplied with the unit or the electrical data pertaining to your unit.
Important: See reference above to maximum voltage unbalance limitation of 3%.
The transition timer in the starter is factory set to disconnect the star winding connection and connect
the delta winding, when the motor comes up to speed and before any speed reduction occurs.

Control Wiring
The control circuit on the McQuay PEH/PFH packaged chiller is designed for 115 volts. Power
should be supplied from a separate circuit and fused at 20 amps inductive load. If the unit is supplied
with a factory mounted starter then the control circuit power supply may be provided through a
transformer located in the starter.
The disconnect switch should be tagged to prevent current interruption. Switch is to remain on at all
times in order to keep oil heaters operative and prevent refrigerant from diluting in oil.
The control center off-on switch should be turned to the "off" position at any time compressor
operation is not desired.
In the event control voltage is supplied by a transformer, the transformer should be rated at 2 KVA,
with an inrush rating of 12 KVA minimum at 80% power factor and 95% secondary voltage. For
control wire sizing, refer to N.E.C. Articles 215 and 310. In the absence of complete information to
permit calculations, the voltage drop should be physically measured. Again, the disconnect switch
should be marked to prevent control circuit from being de-energized. Water flow interlock terminals
are provided on the control center terminal strip. See field connection diagram in the Electrical Data
Section or in the cover of control center for proper connections.
The purpose of the water flow interlocks is to prevent compressor operation until such time as both
the evaporator water and condenser water pumps are running. If flow or pressure differential switches
are not furnished factory installed and wired, they must be furnished and installed by others before the
unit can be started.

WARNING
On older style units severe damage to the compressor can result if the anti-recycle
timer is turned to the "off" position and the flow switches operate intermittently.

12 Centrifugal Chillers IOMM PEH/PFH

 Operation of the chilled water pump may be to cycle the pump with the compressor, operate
continuously, or start automatically by a remote source. The cooling tower pump must cycle with the
machine. The holding coil of the cooling tower pump motor starter must be rated at 115 volts, 60 Hz
with a maximum volt-amperage rating of 100. If the voltage-amperage rating is exceeded, a control
relay is required.
All interlock contacts must be rated for no less than 10 inductive amps. The alarm circuit provided in
the control center utilizes 115 volts AC. The alarm used should not draw more than 10 volt amperes.
See IM 616 and OM 125 for MicroTech control details.

Testing Control Circuit

McQuay will test the circuits upon completion of power and control wiring during unit's initial start-
up.

Surge Capacitors
All units (except those supplied with solid state starters) are supplied with surge capacitors to protect
compressor motors from electrical damage resulting from high voltage spikes. The capacitors may or
may not be wired depending upon whether or not the starter was furnished by McQuay or whether or
not it was factory mounted. Surge capacitors should be enclosed, either inside the starter (on terminal
box mounted starters) or in the compressor motor terminal box, and should be connected on the motor
terminals with leads less than 18 inches (460 mm).

IOMM PEH/PFH Centrifugal Chillers 13

 Prestart System Checklist
Yes No N/A
Chilled Water
Piping complete ...................................................................................................................... o o o
Water system filled, vented..................................................................................................... o o o
Pumps installed, (rotation checked), strainers cleaned ......................................................... o o o
Controls (3-way, face and bypass dampers, bypass valves, etc.) operable............................ o o o
Water system operated and flow balanced to meet unit design requirements ...................... o o o
Condenser Water
Cooling tower flushed, filled and vented .............................................................................. o o o
Pumps installed, (rotation checked), strainers cleaned ........................................................ o o o
Controls (3-way, bypass valves, etc.) operable ..................................................................... o o o
Water system operated and flow balanced to meet unit requirements ................................. o o o
Electrical
115 volt service completed, but not connected to control panel ......................................... o o o
Power leads connected to starter; load leads run to compressor ready for
connection when service engineer is on hand for start-up ................................................. o o o
(Do not connect starter or compressor terminals)
All interlock wiring complete between control panel and complies with specifications ... o o o
Starter complies with specifications ..................................................................................... o o o
*Oil cooler solenoid wired to control panel as shown on wiring diagram
Pump starter and interlock wired ...................................................................................... o o o
Cooling tower fans and controls wired ................................................................................ o o o
Wiring complies with National Electrical Code and local codes ........................................ o o o
Condenser pump starting relay (CWR) installed and wired ................................................ o o o
Miscellaneous
Oil cooler water piping complete (units with water cooled oil coolers only) .................... o o o
Relief valve piping complete ................................................................................................. o o o
Thermometer wells, thermometers, gauges, control wells, controls, etc., installed ........... o o o
Minimum system load of 25% of machine capacity available for testing
and adjusting controls.......................................................................................................... o o o

Note
This checklist must be completed and sent to the local McQuay service location two
weeks prior to start-up.

14 Centrifugal Chillers IOMM PEH/PFH

Operation

Operator Responsibilities
It is important that the operator become familiar with the equipment and the system before attempting
to operate the chiller. In addition to reading this manual the operator should study installation and
operation bulletin IM616 and OM 125 and the control diagram furnished with the unit so that he
understands the starting, operating and shutdown sequences as well as the safety shutdown modes.
During the initial startup of the chiller the McQuay technician will be available to answer any
questions and instruct in the proper operating procedures.
It is recommended that the operator maintain an operating log for each individual chiller unit. In
addition, a separate maintenance log should be kept of the periodic maintenance and servicing
activities.
This McQuay centrifugal chiller represents a substantial investment and deserves the attention and care
normally given to keep this equipment in good working order. If the operator should encounter
abnormal or unusual operating conditions, it is recommended that a McQuay service technician be
consulted.
McQuay International conducts training for McQuay centrifugal operators at its factory Training
Center several times a year. These sessions are structured to provide basic classroom instruction and
include hands-on operating and troubleshooting exercises. For further information, contact your
McQuay representative.

Nomenclature
Each centrifugal chiller is assigned a set of identifying numbers that are used to describe the unit
features and to identify each individual unit. These number groups are stamped on each unit
nameplate.
All inquiries pertaining to operating and servicing of this unit should include all identification
numbers.
Each of the major individual components also have nameplates to provide certain necessary
information to the installer and the operator.
Compressors are designated as model CE. For example a model CE050 compressor is used on a
model PEH050 chiller unit. The compressor nameplate identifies the compressor model, style and
serial number and includes the electrical characteristics of the compressor motor. The CE050
compressor nameplate also shows the oil pump electrical characteristics.
The condenser and evaporator vessels have nameplates stamped with the maximum working pressure
of the vessel, the National Board Number, and the vessel style number. It should be noted that the
vessel relief valve maximum settings coincides with the maximum refrigerant side vessel working
pressure.

IOMM PEH/PFH Centrifugal Chillers 15

 MicroTech Control Panel
The MicroTech unit controller is a microprocessor based control panel designed to initiate the step-by-
step start functions of its host centrifugal compressor unit, monitor and regulate the compressors
capacity, protect it, and sequence the compressor shutdown on lack of load or in response to a preset
time. On dual compressor units, each compressor has its own controller. They are interconnected to
provide lead-lag and load-balance functions.
The full information on the features, installation, operation and problem analysis of the McQuay
microprocessor control for Centrifugal chillers, see Installation and Operation Manual IM 616 and
Operators Manual OM125. The MicroTech panel provides a wide range of control options and data
reporting and recording capability. Familiarity with the control system is important for optimum unit
operation.

Figure 7, MicroTech Control Panel

Capacity Control System

The movement of the inlet vanes, opening or closing to permit the correct quantity of refrigerant to
enter the impeller, controls the compressor capacity. The vane movement occurs in response to oil
flow from the SA or SB solenoid valves which, in turn, respond to a control module signal. This oil
flow activates a piston to rotate the vanes.

Vane Operation
The hydraulic system for the inlet guide vane capacity control operation consists of a 4-way normally
open solenoid valve located in the oil management control panel. Oil under pressure from the oil
filter is directed by the 4-way valve to either or both sides of the piston depending on whether the
control signal is to load, unload, or hold.
To open the vanes (or load the compressor) solenoid SA is de-energized and solenoid SB is energized,
allowing oil flow from port SA to one side of the piston then drain through port SB.
To close the vanes (unload compressor) valve SB is de-energized and valve SA is energized to move
the piston and vanes toward the unload position.
When both solenoid valves SA and SB are de-energized, full oil pressure is directed to both sides of
the piston through ports SA and SB, thus the vanes are held in that position. Refer to Figure 9 and
Figure 10 for solenoid action. Note that both solenoids cannot be energized simultaneously.

16 Centrifugal Chillers IOMM PEH/PFH

 Metering Valves
The speed at which the capacity control vanes are opened or closed can be adjusted to suit system
operating requirements. Adjustable needle valves in the oil drain lines are used to control the rate of
bleed-off and consequently the “vane speed”. These needle valves are part of the 4-way solenoid valve
assembly located in the compressor lube box (Figure 8).
The valves are normally factory set so the vanes will move from fully closed to fully opened in
approximately 3 minutes and from fully open to fully closed in 1 minute (except CE126). The speed
should be slow enough to prevent over-controlling and hunting.

Vane Speed Adjustment

The vane speed at which the capacity control vanes open or close is controlled by the rate of oil bleed-
off from the vane actuating position. This bleed-off rate is adjustable by positioning the needle valves
on SA and SB solenoid valves located in the lube box.
Screwdriver openings in the left side of the lube box permit access. The upper opening accesses the
SB needle valve for adjusting the vane OPENING speed for loading the compressor (refer to Figure
8). Turn this screw clockwise to decrease the vane opening and counterclockwise to increase the
opening speed.
The lower opening accesses the SA needle valve for adjusting the CLOSING speed for unloading the
compressor. The same adjustment applies . . . clockwise to decrease closing, counterclockwise to
increase vane closing.
The vane speed is factory set and varies by compressor size:
Compressor Model Opening Time Closing Time
CE048 - CE050 2 - 2 1/2 min. 3/4 - 1 min.
CE063 - CE100 3 - 5 min. 1 - 2 min
CE126 5 - 8 min. 1 - 2 min.

Figure 8, Lube Box

IOMM PEH/PFH Centrifugal Chillers 17

 Figure 9, Vane Control Solenoid Operation

Figure 10, Vane Control Solenoid Operation, Continued

18 Centrifugal Chillers IOMM PEH/PFH

 Lubrication System
The lubrication system for the PEH family of units provides lubrication and heat removal for
compressor bearings and internal parts. In addition, the system provides oil under pressure to
hydraulically operate the unloading piston for positioning the inlet guide vanes for capacity control.
PFH dual compressor chillers have completely independent lubrication systems for each compressor.
Proper operation of the hydraulic system and bearing lubrication system can be assured only if
recommended oil is used, recommended oils are shown in Table 1. Each unit is factory charged with
the correct amount of the recommended oil. Under normal operation, no additional should be needed.
Oil should be visible in the oil sump sight glass at all times.
The oil pump for the CE048/050 compressor is completely self-contained within the compressor
housing. The assembly includes the pump, pump motor, oil heater and oil separator. The oil is
pumped through the oil discharge line to the oil filter in the compressor casting and then to the internal
refrigerant-cooled oil cooler.
The other compressor sizes-CE063, through CE126-utilize a separate oil pump contained in the oil
reservoir. This assembly includes pump, motor, heater and oil separator system. Oil is pumped
through the external oil cooler and then to the oil filter located inside the compressor housing.
PEH/PHH/PFH/PJH 063-126 units, single or dual compressor, utilize a water-cooled oil cooler.
The oil coolers maintain the proper oil temperature under normal operating conditions. The coolant
flow control valve should maintain 90°F-100°F (32°C-38°C). Lubrication protection for coast down
in the event of a power failure is accomplished by a spring loaded piston in models CE050 through
100. When the oil pump is started, the piston is forced back by the oil pressure, compressing the spring
and filling the piston cavity with oil. When the pump stops, the spring pressure on the piston forces the
oil out to the bearings.
In model CE126 the compressor coast down lubrication is supplied from a gravity feed oil reservoir.
A typical flow diagram is shown in Figure 11.

Table 1, Approved Polyolester Oils For R-134a Units

Compressor Models CE048/050, 063, 076/079, 087 CE100, 126
Lubricant Designation Mobil Artic EAL 22; Mobil Artic EAL 46;
ICI Emkarate RL22N (1)
ICI Emkarate RL32H(2)

McQuay Part Number

55 Gal. Drum 735030430, Rev 47 735030432, Rev 47
5 Gal. Drum 735030431, Rev 47 735030433, Rev 47
1 Gal. Can 735030434, Rev 47 735030435, Rev 47

Compressor Oil Label 070200105, Rev OB 070200106, Rev OB

1. ICI RL22S and 22H are not approved, only RL22N is acceptable.
2. ICI RL32S Ester lubricant is not approved, only RL32H is acceptable.
3. Approved oil from two suppliers can be mixed.
4. Mobile Artic EAL 22 CC is not approved, only Mobile Artic EAL 22.

IOMM PEH/PFH Centrifugal Chillers 19

 Figure 11, Typical Oil Flow Diagram

1. Does not apply to CE 048,050 compressors

2. Refrigerant - cooled oil coolers use high pressure refrigerant expanded THROUGH a temperature control valve.
3. Connections not necessarily in correct relative location

Hot Gas Bypass

The PHH and PJH heat recovery chillers are equipped as standard with a hot gas bypass system used to
feed discharge gas directly into the evaporator when the system load falls below a predetermined
minimum compressor capacity. PEH and PFH units can be so equipped as an option when operation
below the minimum 10% compressor capacity is desired.
Light load conditions are signaled by measurement of a set percentage of RLA amps by the MicroTech
control panel. When the RLA drops to the setpoint the hot gas bypass solenoid is energized making
hot gas bypass available for use. This introduction of hot gas provides a stable refrigerant flow and
keeps the chiller from short cycling under light load conditions. It also prevents surge during heat
recovery operation.
The factory setpoint for bringing on hot gas bypass is 40% of RLA. See IM 616.

20 Centrifugal Chillers IOMM PEH/PFH

Maintenance

Pressure/Temperature Chart
HFC-134a Temperature Pressure Chart

°F PSIG °F PSIG °F PSIG °F PSIG

6 9.7 46 41.1 86 97.0 126 187.3

8 10.8 48 43.2 88 100.6 128 192.9
10 12.0 50 45.4 90 104.3 130 198.7
12 13.2 52 47.7 92 108.1 132 204.5
14 14.4 54 50.0 94 112.0 134 210.5
16 15.7 56 52.4 96 115.9 136 216.6
18 17.1 58 54.9 98 120.0 138 222.8
20 18.4 60 57.4 100 124.1 140 229.2
22 19.9 62 60.0 102 128.4 142 235.6
24 21.3 64 62.7 104 132.7 144 242.2
26 22.9 66 65.4 106 137.2 146 249.0
28 24.5 68 68.2 108 141.7 148 255.8
30 26.1 70 71.1 110 146.3 150 262.8
32 27.8 72 74.0 112 151.1 152 270.0
34 29.5 74 77.1 114 155.9 154 277.3
36 31.3 76 80.2 116 160.9 156 284.7
38 33.1 78 83.4 118 166.0 158 292.2
40 35.0 80 86.7 120 171.1 160 299.9
42 37.0 82 90.0 122 176.4 162 307.8
44 39.0 84 93.5 124 181.8 164 315.8

Routine Maintenance
Lubrication (See Caution)
After the system is once placed into operation, no other additional oil is required except in the event
that repair work becomes necessary to the oil pump or unless a large amount of oil is lost from the
system due to a leak.
If oil must be added with the system under pressure, use a hand pump with its discharge line connected
to the service valve at the bottom of the oil pump. (The CE050 compressor with its internal oil pump
is equipped with an oil service valve on the compressor.) The POE oils used with R-134a are
hygoscopic and care should be exercised to avoid exposure to moisture (air).

Changing Oil Filters (See Caution)

McQuay chillers are at positive pressure at all times and do not leak contaminated moist air into the
refrigerant circuit eliminating the need for annual oil changes. An annual laboratory oil check is
recommended to check overall compressor condition.
CE050 Compressors - If the unit is equipped with a suction line service valve (dual compressor units
are so equipped as standard), close this valve and close the valve on the motor cooling liquid line to
isolate the compressor. Remove the refrigerant from the compressor using approved procedures.

IOMM PEH/PFH Centrifugal Chillers 21

 Remove the filter cover and the old filter and install the new filter, open end first. Replace the cover
using a new gasket. Reopen the suction and liquid line valves.
If the unit is not equipped with a suction line service valve, the unit will have to be pumped down in
order to remove the pressure in the compressor before removing the cover and changing the filter.
Refer to later section for pumpdown procedure.
CE063 and Larger Compressors - The oil filter in each of these machines can be changed by simply
isolating the filter cavities. Close the oil discharge line service valve at the oil pump (at the filter on
CE126). Remove the filter cover; some foaming may occur but the check valve should limit leakage
from other compressor cavities. Remove the filter, replace with new element and replace filter cover
using new gasket. Reopen the valve in pump discharge line and purge air from the oil filter cavity.
When machine is operated again, the oil level should be checked to determine if oil needs to be added
to maintain the proper operating level.

CAUTION
Improper servicing of the lubrication system,
including the addition of excessive or incorrect oil, substitute quality oil filter,
or mishandling of the equipment under pressure is hazardous.
Only authorized and trained service personnel should attempt this service.
For qualified assistance, contact your local McQuay service location.

Refrigerant Cycle
Maintenance of the refrigerant cycle consists of maintaining a log of the operating conditions, and
assuring the unit has the proper oil and refrigerant charge. (See the maintenance schedule and the
appropriate operating log at the end of this bulletin).
At every inspection, the oil, suction and discharge pressures should be noted and recorded, as well as
condenser and chiller water temperatures.
The suction line temperature at the compressor should be taken at least once a month. Subtracting
from this, the saturated temperature equivalent of the suction pressure will give the superheat.
Extreme changes in subcooling and/or superheat over a period of time will indicate losses of
refrigerant or possible deterioration of the expansion valves. Proper superheat setting is 0 to 1 degree
F (0.5 degree C) at full load. Such a small temperature difference can be hard to measure accurately.
Another method is to measure the compressor discharge superheat, the difference between the actual
discharge temperature and the saturated discharge temperature. The discharge superheat should be
between 14 and 16 degrees F (8 to 9 degrees C) at full load with R-134a refrigerant. The liquid
injection should be deactivated (remove relay #10) when taking the discharge temperature. The
superheat will increase linearly to 55 degrees F (30 degrees C) at 10% load. The Series 200
MicroTech Control can display all superheat and subcooling temperatures.

22 Centrifugal Chillers IOMM PEH/PFH

 Figure 8. Typical Refrigerant Flow Diagram

1. Connection not necessarily in correct relative location.

2. Filter on dual compressor units only.
3. Liquid injection does not apply to CE 048, 050, compressors.
4. The evaporator chilled water connections are correct for PFH 126 dual compressor units only. All other models have the
chilled water inlet in the top connection.

Electrical System
Maintenance of the electrical system involves the general requirement of keeping contacts clean and
connections tight and checking on specific items as follows:
1. The compressor current draw should be checked and compared to nameplate RLA value.
Normally the actual current will be lower since the nameplate rating represents full load
operation. Also check all pump and fan motor amperages and compare with nameplate ratings.
2. Inspection should verify that the oil heaters are operative. The heaters are insert cartridge type and
can be checked by ammeter reading. They should be energized whenever power is available to the
control circuit and when the compressor is inoperative). When the compressor starts the heaters
are de-energized.
3. At least once a quarter, all safety controls except compressor overloads should be made to operate
and their operating points checked. Any control may shift its operating point as it ages, and this
must be detected so the controls can be adjusted or replaced. Pump interlocks and flow switches
should be checked to be sure they interrupt the control circuit when tripped.
4. The contactors in the motor starter should be inspected and cleaned quarterly. Tighten all terminal
connections.
5. The compressor motor resistance to ground should be checked and logged semi-annually. This
log will track insulation deterioration. A reading of 50 megohms or less indicates a possible
insulation defect or moisture and should be further checked.

IOMM PEH/PFH Centrifugal Chillers 23

 WARNING
Never Megger a motor while in a vacuum. Severe damage can result.

6. The centrifugal compressor must rotate in the direction indicated by the arrow on the casting near
the rotation sightglass. If the operator has any reason to suspect that the power system
connections may have been altered, (phases reversed) the compressor should be jogged to check
rotation. For assistance, call the McQuay service location.

Cleaning and Preserving

A common cause of service calls and equipment malfunction is dirt. This can be prevented with
normal maintenance. The system components most subject to dirt are:
1. Permanent or cleanable filters in the air handling equipment must be washed in accordance with
the manufacturer’s instructions; throwaway filters should be replaced. The frequency of this
service will vary with each installation.
2. Remove and clean strainers in chilled water system, oil cooler line and condenser water system at
every inspection.

Seasonal Servicing
Prior to shutdown periods and before starting up again, the following service procedures should be
completed.

Annual Shutdown
1. Where the chiller may be subject to freezing temperatures, the condenser and chiller water piping
should be disconnected and drained of all water. Dry air blown through the condenser will aid in
forcing all water out. Removal of condenser heads is also recommended. The condenser and
evaporator are not self-draining. Water permitted to remain in the piping and vessels will rupture
these parts if subjected to freezing temperature.
Forced circulation of antifreeze through the water circuits is a sure method of avoiding
freeze up.
2. Take measures to prevent the shutoff valve in the water supply line from being accidentally turned
on.
3. If a cooling tower is used and if the water pump will be exposed to freezing temperatures, be sure
to remove the pump drain plug and leave it out so any water that may accumulate will drain away.
4. Open the compressor disconnect switch, and remove the Fusetrons. If the transformer is used
for control voltage, the disconnect must remain on to provide power to the oil heater. Set
the manual stop/auto switch (SWI) to the stop position. To insure against the possibility of an
accidental start, remove the fault relay from the left side of the MicroTech panel (see IM 616).
5. Check for corrosion and clean and paint rusted surfaces.
6. Clean and flush water tower for all units operating on a water tower. Make sure tower
“blowdown” or bleed-off is operating. Set up and use a good maintenance program to prevent
“liming up” of both tower and condenser. It should be recognized that atmospheric air contains
many contaminants that increase the need for proper water treatment. The use of untreated water
may result in corrosion, erosion, sliming, scaling or algae formation. It is recommended that the
service of a reliable water treatment company be used. McQuay International assumes no
responsibility for the results of untreated or improperly treated water.
7. Remove condenser heads at least once a year to inspect the condenser tubes and clean if required.

24 Centrifugal Chillers IOMM PEH/PFH

 Annual Startup
A dangerous condition can exist if power is applied to a faulty compressor motor starter that has been
burned out. This condition can exist without the knowledge of the person starting the equipment.
This is a good time to check all the motor winding resistance to ground. Semi-annual checking and
recording of this resistance will provide a record of any deterioration of the winding insulation. All
new units have well over 100 megohms resistance between any motor terminal and ground.
Whenever great discrepancies in readings occur or uniform readings of less than 50 megohms are
obtained, the motor cover should be removed for inspection of the winding prior to starting the unit.
Uniform readings of less than 5 megohms indicate motor failure is imminent and motor should be
replaced or repaired. Repair before failure occurs can save a great deal of time and labor expended in
the cleanup of a system after motor burnout.
1. The control circuit should be energized at all times. If the control circuit has been off and oil is
cool, energize oil heaters and allow 24 hours for heater to remove refrigerant from the oil before
starting.
2. Check and tighten all electrical connections.
3. Replace the drain plug in cooling tower pump if it was removed at shutdown time the previous
season.
4. Install Fusetrons in main disconnect switch (if removed).
5. Reconnect water lines and turn on supply water. Flush out condenser and check for leaks.
6. Refer to Manual IM 616 before energizing the compressor circuit.

Repair of System
Pressure Relief Valve Replacement
Current condenser designs use two relief valves (1 set) separated by a three way shutoff valve. This
valve allows either relief valve to be shut off, but at no time can both be shut off. In the event one of
the relief valves are leaking in the two valve set, these procedures should be followed:

• If the valve closest to the valve stem is leaking, back seat the three-way valve all the way, closing
the port to the leaking pressure relief valve. Remove and replace the faulty relief valve. The
three-way shutoff valve should remain either fully back seated or fully forward to normal
operation. If the relief valve farthest from the valve stem is leaking, front seat the three-way valve
and replace the relief valve as stated above.
• The refrigerant in the evaporator must be pumped down to the condenser to replace its relief
valve.

Pumping Down
If it becomes necessary to pump the system down, extreme care should be used to avoid damage to the
evaporator from freezing. Always make sure that full water flow is maintained through the chiller and
condenser while pumping down. To pump the system down, close all liquid line valves. With all
liquid line valves closed and water flowing, start the compressor. Set the MicroTech panel to the
manual load (see IM 616). The vanes must be open while pumping down to avoid a surge or other
damaging condition. Pump the unit down until the MicroTech cuts out at approximately 20 psig. It is
possible that the unit might experience a mild surge condition prior to cutout. If this should occur,
immediately shut off the compressor. Use a portable condensing unit to complete the pump down,
condense the refrigerant, and pump it into the condenser or pumpout vessel using approved
procedures.

IOMM PEH/PFH Centrifugal Chillers 25

 A pressure regulating valve should always be used on the drum being used to build the system
pressure. Also, do not exceed the test pressure given above. When the test pressure is reached
disconnect the gas cylinder.

Pressure Testing
No pressure testing is necessary unless some damage was incurred during shipment. Damage may be
determined upon a visual inspection of the exterior piping assuring no breakage occurred or fittings
loosened. Service gauges should show a positive pressure. If no pressure is evident on the gauges, a
leak may have occurred discharging the entire refrigerant charge. In this case, the unit should be leak
tested to determine the location of the leak.

Leak Testing
In the case of loss of the entire refrigerant charge, the unit should be checked for leaks prior to
charging the complete system. This can be done by charging enough refrigerant into the system to
build the pressure up to approximately 10 psig (69 kPa) and adding sufficient dry nitrogen to bring the
pressure up to a maximum of 125 psig (860 kPa) and then leak test with an electronic leak detector.
Halide leak detectors do not function with R-134a. Water flow through the vessels should be
maintained anytime refrigerant is added or removed from the system.

CAUTION
Do not use oxygen or a mixture of R-22 and air to build up pressure as a serious
explosion can result.

A pressure regulating valve should always be used on the drum used to build up the system pressure.
Also, do not exceed the test pressure given above. When the test pressure is reached, disconnect the
gas cylinder.
If any leaks are found in welded or brazed joints or it is necessary to replace a gasket, relieve the test
pressure in the system before proceeding. For copper joints, brazing is required.
After making any necessary repair, the system should be evacuated as described in the section
following.

Evacuation
After it has been determined that there are no refrigerant leaks the system should be evacuated using a
vacuum pump with a capacity that will reduce the vacuum to at least 1000 microns of mercury.
A mercury manometer, electronic or other type of micron gauge should be connected at the farthest
point from the vacuum pump. For readings below 1000 microns, an electronic or other micron gauge
should be used.
The triple evacuation method is recommended and is particularly helpful if the vacuum pump is unable
to obtain the desired 1 millimeter of vacuum. The system is first evacuated to approximately 29
inches of mercury. Dry nitrogen is then added to the system to bring the pressure up to zero pounds.
Then the system is once again evacuated to approximately 29 inches of mercury. This is repeated three
times. The first pulldown will remove about 90% of the noncondensables, the second about 90% of
that remaining from the first pulldown and, after the third, only 1/10-1% noncondensables will
remain.

26 Centrifugal Chillers IOMM PEH/PFH

 Charging the System
PEH and PFH water chillers are leak tested at the factory and shipped with the correct charge of
refrigerant as indicated on the unit nameplate. In the event the refrigerant charge was lost due to
shipping damage, the system should be charged as follows after first repairing the leaks and evacuating
the system.
a. Connect the refrigerant drum to the gauge port on the liquid line shutoff valve and purge the
charging line between the refrigerant cylinder and the valve. Then open the valve to the mid-
position.
b. Turn on both the cooling tower water pump and chilled water pump and allow water to circulate
through the condenser and the chiller. (It will be necessary to manually close the condenser pump
starter.)
c. If the system is under a vacuum, stand the refrigerant drum with the connection up and open the
drum and break the vacuum with refrigerant gas to a saturated pressure above freezing.
d. With a system gas pressure higher than the equivalent of a freezing temperature, invert the
charging cylinder and elevate the drum above the condenser. With the drum in this position,
valves open, water pumps operating, liquid refrigerant will flow into the condenser.
Approximately 75% of the total requirement estimated for the unit can be charged in this manner.
e. After 75% of the required charge has entered the condenser, reconnect the refrigerant drum and
charging line to the service valve on the bottom of the evaporator. Again purge the connecting
line, stand the drum with the connection up, and place the service valve in the open position.
IMPORTANT: At this point the charging position should be interrupted and prestart checks made
before attempting to complete refrigerant charge. The compressor must not be started at this time.
(Preliminary check must first be completed.)
Operation and maintenance manuals pertaining to the individual PEH or PFH unit are available from
your local McQuay representative.

Caution
It is of utmost importance that all local, national, and international regulations
concerning the handling and emission of refrigerants are observed.

IOMM PEH/PFH Centrifugal Chillers 27

Maintenance Schedule

I. Compressor
A. Performance Evaluation (Log & Analysis) * O
B. Motor
• Meg. Windings X
• Ampere Balance (within 10%) X
• Terminal Check (tight conn., porcelain clean) X
• Motor Cooling (check temperature) X
C. Lubrication System
• Oil Lines Temperatures O
• Water (Refrigerant) Coolant Temperature O
• Oil Cooler Strainer (water) X
• Oil Cooler Solenoid Operation X
• Oil Analysis X
• Oil Appearance (clear color, quantity) O
• Oil Filter Change X
• Oil change if indicated by oil analysis X
D. Vane Operation
• Compressor Loads:
Operate Manual Switch X
Record Motor Amps X
• Compressor Unloads:
Operate manual Switch X
Record Motor Amps X
• Vanes Will Hold (place manual switch in "hold")
Observe Water Temp and Record Amps X
E. Internal Compressor Check X
II. Controls
A. Operating Controls
• Check Settings and Operation X
• Check Vane Control Setting and Operation X
• Verify Motor Load Limit Control X
• Verify Load Balance Operation X
• Check Oil Pump Contactor X
B. Protective Controls
• Test Operation of:
Alarm Relay X
Pump Interlocks X
Hot and Cold Oil Temperature Cutouts X
Guardistor and Surgeguard Relays X
High and Low Pressure Cutouts X
High Suction Temperature Cutout X
High Discharge Temperature Cutout X
Low Pressure Override Switch X
Oil Pump Pressure Differential Cutout X
Oil Pump Safety Timer X
Oil Pump Time Delay X
Vane Closed Switch X
Key: O = Performed by in-house personnel X = Performed by McQuay Service personnel

28 Centrifugal Chillers IOMM PEH/PFH

 Maintenance Schedule, Cont.

III. Condenser
A. Performance Evaluation O
B. Test Water Quality X
C. Clean Condenser Tubes X
D. Eddycurrent Test - Tube Wall Thickness X
E. Seasonal Protection X
IV. Evaporator
A. Performance Evaluation (Log Conditions And Analysis O
B. Test Water Quality X
C. Clean Evaporator Tubes (as required) X
D. Eddycurrent Test - Tube Wall thickness (as required) X
E. Seasonal Protection X
V. Expansion Valves
A. Performance Evaluation (Superheat Control) X
VI. Compressor - Chiller Unit
A. Performance Evaluation O
B. Leak Test:
• Compressor Fittings and Terminal X
• Piping Fittings X
• Oil Pump Joints and Fittings X
• Vessel Relief Valves X
C. Vibration Isolation Test X
D. General Appearance:
• Paint X
• Insulation X
VII. Starter(s)
A. Examine Contactors (hardware and operation) X
B. Verify Overload Setting and Trip X
C. Test Electrical Connections X
VIII. Optional Controls
A. Hot Gas Bypass (verify operation) X
B. Liquid Injections Controls (verify operation) X
Key: O = Performed by in-house personnel X = Performed by McQuay Service personnel

Note
Some compressors use power factory correction capacitors and all have a surge
capacitor (excepting units with solid state starters). The surge capacitor may be
installed out of sight in the compressor motor terminal box. In all cases, capacitors
must be disconnected from the circuit to obtain a useful Megger reading. Failure to
do so will produce a low reading. In handling electrical components, only fully
qualified technicians should attempt service.

IOMM PEH/PFH Centrifugal Chillers 29

Service Programs
It is important that an air conditioning system receive adequate maintenance if the full equipment life
and full system benefits are to be realized.
Maintenance should be an ongoing program from the time the system is initially started. A full
inspection should be made after 3 to 4 weeks of normal operation on a new installation and on a
regular basis thereafter.
McQuay offers a variety of maintenance services through the local McQuay service office, its
worldwide service organization, and can tailor these services to suit the needs of the building owner.
Most popular among these services is the McQuay Comprehensive Maintenance Contract.
For further information concerning the many services available, contact your local McQuay service
office.

30 Centrifugal Chillers IOMM PEH/PFH

Post Office Box 2510, Staunton, Virginia 24402-2510 (540) 248-0711