Professional Documents
Culture Documents
IMM WGZ-2
Group: Chiller
Part Number: 331374401
Effective: October 2005
Supercedes: IOMM WGZ-1
Table of Contents
Introduction........................................3
General Description............................... 3
Nomenclature ........................................ 3
Inspection .............................................. 3
Installation..........................................4
Vibration Isolators ................................. 6
Water Piping.....................................10
Flow Switch......................................... 13
Glycol Solutions .................................. 13
Condenser Water Piping...................... 14
Minimum Flow Rates .......................... 15
Water Pressure Drop............................ 16
Dimensional Data.............................23
Physical Data....................................27
AW Water-Cooled................................ 27
AA Remote Condenser ........................ 30
Operating Limits.................................. 31
Components......................................... 32
Wiring ...............................................33
Unit Configuration ..........................34
Electrical Data..................................35
System Maintenance........................ 48
General ................................................ 48
Electrical Terminals............................. 49
Compressor Lubrication...................... 49
Sight glass and Moisture Indicator...... 49
Crankcase Heaters ............................... 50
Optional Controls ................................ 50
Phase/Voltage Monitor (Optional) ...... 50
Hot Gas Bypass (Optional) ................. 51
IMM WGZ-2
Introduction
General Description
McQuay Type WGZ water chillers are designed for indoor installations and are available with
water-cooled condensers (Model AW), or arranged for use with remote air-cooled or
evaporative condensers (Model AA). Each water-cooled unit is completely assembled and
factory wired before evacuation, charging and testing. They consist of hermetic scroll
compressors, brazed-plate evaporator, water-cooled condenser (WGZ-AW), and complete
refrigerant piping.
Units manufactured for use with remote condensers (Models WGZ-AA) have all refrigerant
specialties factory-mounted and connection points for refrigerant discharge and liquid lines.
Liquid line components that are included are manual liquid line shutoff valves, charging
valves, filter-driers, liquid line solenoid valves, sight glass/moisture indicators, and thermal
expansion valves.
Other features include compressor crankcase heaters, and a MicroTech II microprocessor
controller.
The electrical control center includes all equipment protection and operating controls
necessary for dependable automatic operation.
The compressors are not fused as standard, but can be protected by optional circuit breakers or
fuses, or can rely on a field-installed, fused disconnect switch for protection.
Nomenclature
W G Z 100 - A W
Water-Cooled
Global
Scroll Compressor
W = Water-Cooled Condenser
A = Unit Less Condenser
Design Vintage
Nominal Capacity (Tons)
Inspection
When the equipment is received, all items should be carefully checked against the bill of
lading to be sure of a complete shipment. All units must be carefully inspected for damage
upon arrival. All shipping damage must be reported to the carrier and a claim must be filed
with the carrier. The unit serial plate should be checked before unloading the unit to be sure
that it agrees with the power supply available. Physical damage to unit after acceptance is not
the responsibility of McQuay.
Note: Unit shipping and operating weights are given in the physical data tables
beginning on page 27.
IMM WGZ-2
Installation
Note: Installation and maintenance are to be performed only by qualified personnel
who are familiar with local codes and regulations, and experienced with this type of
equipment.
WARNING
Avoid contact with sharp edges. Personal injury can result.
Handling
Every model WGZ-AW water chiller with water-cooled condensers is shipped with a full
refrigerant charge. For shipment, the charge is contained in the condenser and is isolated by
the condenser liquid shutoff valve and the compressor discharge valve common to a pair of
compressors.
A holding charge is supplied in remote condenser models, WGZ-AA. The operating charge
must be field supplied and charged.
WARNING
If the unit has been damaged, allowing the refrigerant to escape, there can be
danger of suffocation in the area since the refrigerant will displace the air. Be
sure to review Environmental Protection Agency (EPA) requirements if damage
occurred. Avoid exposing an open flame to the refrigerant.
(2) 2
Lifting
Holes
Removable
Lifting
Bar
IMM WGZ-2
Never put the weight of the unit against the control box.
In moving, always apply pressure to the base on the skids only and not to the piping or other
components. A long bar will help move the unit easily. Avoid dropping the unit at the end of
the roll.
If the unit must be hoisted, lift the unit from the removable lifting arms factory-bolted to each
end of the unit adjacent to the tube sheet by attaching cables or chains to the end of the arms.
A spreader bar must be used to protect the piping, control panel and other areas of the chiller
(see Figure 1). The arms should be removed and discarded after use.
Do not attach slings to piping or equipment. Do not attempt to lift the unit by lifting points
mounted on the compressors. They are for lifting only the compressor should one need to be
removed from the unit. Move unit in the upright horizontal position at all times. Set unit
down gently when lowering from the truck or rollers.
Table 1, Lifting Loads
Package Units (lbs.
Model
WGZ 030
WGZ 035
WGZ 040
WGZ 045
WGZ 050
WGZ 055
WGZ 060
WGZ 070
WGZ 080
WGZ 090
WGZ 100
WGZ 110
WGZ 120
L1
L2
L3
L4
564
572
584
596
604
646
800
863
900
908
916
931
937
616
626
641
658
668
719
892
966
1009
1021
1031
1046
1050
655
672
695
717
739
761
855
890
961
1019
1059
1067
1077
715
736
764
792
817
846
953
996
1077
1145
1191
1196
1211
Shipping
Weight
2551
2606
2684
2763
2828
2973
3500
3716
3947
4094
4197
4240
4275
L1
469
473
477
486
487
526
620
673
702
700
696
706
706
Location
WGZ chillers are designed for indoor application and must be located in an area where the
surrounding ambient temperature is 40F (4C) or above. A good rule of thumb is to place
units where ambient temperatures are at least 5F (3C) above the leaving water temperature.
Because of the electrical control devices, the units should not be exposed to the weather. A
plastic cover over the control box is supplied as temporary protection during shipment. A
reasonably level and sufficiently strong floor is required for the water chiller. If necessary,
additional structural members should be provided to transfer the weight of the unit to the
nearest beams.
Note: Unit shipping and operating weights are given in Table 1 and in the physical
data tables beginning on page 27.
IMM WGZ-2
On units equipped with a water-cooled condenser (Type WGZ-AW) clearance should also be
provided for cleaning or removal of condenser tubes on one end of the unit. The clearance for
cleaning depends on the type of apparatus used, but can be as much as the length of the
condenser (10 feet, 3050 mm). Tube replacement requires the tube length of 10 feet (3050
mm) plus one to two feet of workspace. This space can often be provided through a doorway
or other aperture.
Allow a minimum of 4-foot clearance in front of the control panel.
Vibration Isolators
It is recommended that isolators be used on all upper level installations or in areas where
vibration transmission is a consideration.
Figure 2, Isolator Locations
4
LB
RB
Water
Connections
LF
FRF
Neoprene-In-Shear Mountings
Spring-Flex Mountings
Unit
Size
Opr. Wt.
Lbs. (kg)
030
2692
(1219)
589
(267)
648
(294)
692
(314)
762
(345)
RP-3
Gray
035
2760
(1250)
599
(271)
661
(299)
713
(323)
787
(356)
RP-3
Gray
040
2866
(1298)
616
(279)
682
(309)
744
(337)
824
(373)
RP-3
Gray
RP-3
Gray
RP-3
Gray
RP-3
Gray
CP-1
Gray
CP-1
Gray
CP-1
Gray
CP-1
Gray
045
2966
(1344)
632
(286)
702
(318)
773
(350)
860
(389)
RP-3
Gray
RP-3
Gray
RP-3
Gray
RP-3
Gray
CP-1
Gray
CP-1
Gray
CP-1
Gray
CP-1
Gray
050
3058
(1385)
644
(292)
718
(325)
802
(363)
894
(405)
RP-3
Gray
RP-3
Gray
RP-3
Gray
RP-3
Gray
CP-1
Gray
CP-1
Gray
CP-1
Gray
CP-1
Gray
055
3213
(1455)
688
(312)
772
(350)
826
(374)
927
(420)
RP-3
Gray
RP-3
Gray
RP-3
Gray
RP-3
Gray
CP-1
Gray
CP-1
Gray
CP-1
Gray
CP-1
Gray
060
3809
(1725)
853
(386)
959
(435)
940
(426)
1057
(479)
RP-4
Black
RP-4
Black
RP-4
Black
RP-4
Black
CP-1
White
CP-1
White
CP-1 CP-1
White White
IMM WGZ-2
Neoprene-In-Shear Mountings
Spring-Flex Mountings
Unit
Size
Opr. Wt.
Lbs. (kg)
070
4025
(1823)
916
(415)
1033
(468)
975
(442)
1100
(498)
RP-4
Black
RP-4
Black
RP-4
Black
RP-4
Black
CP-1
White
CP-1
White
080
4289
(1943)
958
(434)
1082
(490)
1056
(478)
1193
(540)
RP-4
Black
RP-4
Black
RP-4
Black
RP-4
Black
090
4484
(2031)
974
(441)
1103
(500)
1129
(511)
1278
(579)
RP-4
Black
RP-4
Black
RP-4
Black
RP-4
Black
100
4627
(2096)
989
(448)
1121
(508)
1170
(534)
1337
(606)
RP-4
Black
RP-4
Black
RP-4
Black
RP-4
Black
110
4670
(2120)
1010
(459)
1140
(518)
1178
(535)
1342
(609)
RP-4
Black
RP-4
Black
RP-4
Black
RP-4
Black
120
4705
(2136)
1015
(461)
1145
(520)
1195
(543)
1350
(613)
RP-4
Black
RP-4
Black
RP-4
Black
RP-4
Black
Unit
Size
Opr. Wt.
Lbs. (kg)
030
2162
(979)
468
(212)
502
(227)
575
(260)
616
(279)
035
2204
(998)
472
(214)
507
(230)
590
(267)
634
(287)
040
2257
(1022)
477
(216)
514
(233)
609
(276)
657
(297)
045
2329
(1055)
487
(220)
526
(238)
633
(287)
684
(310)
050
2370
(1074)
488
(221)
528
(239)
650
(295)
704
(319)
055
2505
(1135)
526
(238)
578
(262)
668
(303)
734
(332)
060
2771
(1255)
619
(280)
674
(305)
707
(320)
770
(349)
RP-3 RP-3
Green Green
RP-3
Gray
070
2942
(1333)
672
(304)
736
(333)
732
(332)
801
(363)
RP-3 RP-3
Green Green
RP-3
Gray
080
3154
(1429)
702
(318)
771
(349)
801
(363)
880
(399)
RP-3
Green
RP-3
Gray
RP-3
Gray
CP-1
Gray
090
3271
(1482)
700
(317)
771
(349)
857
(388)
944
(427)
RP-3
Green
RP-3
Gray
RP-3
Gray
CP-1
Gray
100
3346
(1516)
697
(316)
773
(350)
890
(403)
987
(447)
RP-3
Green
RP-3
Gray
RP-3
Gray
CP-1
Gray
110
3375
(1532)
707
(320)
783
(355)
895
(406)
990
(449)
RP-3
Green
RP-3
Gray
RP-3
Gray
RP-3
Gray
120
3405
(1546)
707
320)
783
(355)
910
(413)
1005
(456)
RP-3
Green
RP-3
Gray
RP-3
Gray
RP-3
Gray
CP-1 CP-1
White White
IMM WGZ-2
Neoprene-In-Shear Mountings
1
Spring-Flex Mountings
1
Spring
Color
CP-1
Red
CP-1
Purple
CP-1
Orange
CP-1
Green
CP-1
Gray
CP-1
White
CP-2
Green
Max. Load
Each
Lbs. (kg)
Defl.
In. (mm)
450
(204)
600
(272)
750
(340)
900
(408)
1100
(498)
1300
(589)
1800
(815)
1.22
(30.9
1.17
(29.7)
1.06
(26.9)
1.02
(25.9)
0.83
(21.0)
0.74
(18.7)
1.02
(25.9)
Dimensions
In. (mm)
C
7.5
(190.5)
7.5
(190.5)
7.5
(190.5)
7.5
(190.5)
7.5
(190.5)
7.5
(190.5)
10.2
(259.1)
6.0
(152.4)
6.0
(152.4)
6.0
(152.4)
6.0
(152.4)
6.0
(152.4)
6.0
(152.4)
9.0
(228.6)
4.7
(119.4)
4.7
(119.4)
4.7
(119.4)
4.7
(119.4)
4.7
(119.4)
4.7
(119.4)
7.7
(195.6)
Housing
Spring
Part Number Part Number
2.7
(68.6)
2.7
(68.6)
2.7
(68.6)
2.7
(68.6)
2.7
(68.6)
2.7
(68.6)
2.7
(68.6)
5.5
(139.7)
5.5
(139.7)
5.5
(139.7)
5.5
(139.7)
5.5
(139.7)
5.5
(139.7)
5.75
(146.0)
226102B-00
226115A-00
226102B-00
226116A-00
226102B-00
226117A-00
226102B-00
226118A-00
226102B-00
226119A-00
226102B-00
226120A-00
NOTE: CP-1 housing contains one spring. CP-2 housing contains two identical springs.
RP-3
Green
RP-3
Gray
R-4
Black
Max. Load
Defl.
Each
In. (mm)
Lbs. (kg)
750
(339)
1100
(498)
1500
(679)
0.25
(6.4)
0.25
(6.4)
0.25
(6.4)
A
2.5
(63.5)
2.5
(63.5)
3.75
(95.3)
Dimensions
In. (mm)
D (1)
E
0.5
4.1
0.56
(12.7) (104.1) (14.2)
0.5
4.1
0.56
(12.7) (104.1) (14.2)
0.5
5.0
0.56
(12.7) (127.0) (14.2)
0.25
(6.4)
0.25
(6.4)
0.25
(6.4)
McQuay
Part Number
1.75
5.5
3.4
216397A-03
(44.4) (165) (85.7)
1.75
5.5
3.4
216397A-05
(44.4) (165) (85.7)
1.6
6.5
4.6
216398A-04
(41.1) (165.1) (116.8)
IMM WGZ-2
IMM WGZ-2
Figure 6, Neoprene-in-Shear, R4
Water Piping
Vessel Drains at Start-up
Condensers are drained of water in the factory and are shipped with condenser drain plugs in
the heads removed and stored in a bag in the control panel. Be sure to replace plugs prior to
filling the vessel with fluid.
General
Due to the variety of piping practices, it is advisable to follow the recommendations of local
authorities for code compliance. They can supply the installer with the proper building and
safety codes required for a safe and proper installation.
Basically, the piping should be designed with a minimum number of bends and changes in
elevation to keep system cost down and performance up. Other piping design considerations
include:
1. All piping should be installed and supported to prevent the chiller connections from
bearing any strain or weight of the system piping.
2. Vibration eliminators to reduce vibration and noise transmission to the building.
3. Shutoff valves to isolate the unit from the piping system during unit servicing.
4. Manual or automatic air vent valves at the high points of the system. Drains should be
placed at the lowest points in the system.
5. Some means of maintaining adequate system water pressure (e.g., expansion tank or
regulating valve).
6. Temperature and pressure indicators located within 3 feet (0.9 meters) of the inlet and
outlet of the vessels to aid in unit servicing.
7. A strainer or some means of removing foreign matter from the water before it enters the
pump is recommended. It should be placed far enough upstream to prevent cavitation at
the pump inlet (consult pump manufacturer for recommendations). The use of a strainer
will prolong pump life and thus maintain system performance.
Important Note
A cleanable 40-mesh strainer must also be placed in the water line just prior to the
inlet of the evaporator. This will aid in preventing foreign material from entering and
decreasing the performance of the evaporator.
8. If the unit is used as a replacement chiller on a previously existing piping system, the
system should be thoroughly flushed prior to unit installation. Regular water analysis and
chemical water treatment on the evaporator and condenser is recommended immediately
upon equipment start-up.
9. In the event glycol is added to the water system, as an afterthought for freeze protection,
recognize that the refrigerant suction pressure will be lower, cooling performance less, and
water side pressure drop will be higher. If the percentage of glycol is large, or if
propylene glycol is used instead of ethylene glycol, the added pressure drop and loss of
performance could be substantial. Reset the freezestat and low leaving water alarm
temperatures. The freezestat is factory set to default at 36F (2.2C). Reset the freezestat
setting to approximately 4 to 5F (2.3 to 2.8C) below the leaving chilled water setpoint
temperature. See the section titled Glycol Solutions for additional information
concerning the use of glycol.
10. A preliminary leak check of the water piping should be made before filling the system.
10
IMM WGZ-2
Note: A water flow switch or pressure differential switch must be mounted in the
evaporator outlet water line to signal that there is water flow before the unit will start.
Isolation
Valves
Vibration
Eliminators
Outlet
Flow
Switch
Drain
IMM WGZ-2
11
The return water line must be piped to the evaporator inlet connection and the supply water
line must be piped to the evaporator outlet connection. If the evaporator water is piped in the
reverse direction, a substantial decrease in capacity and efficiency of the unit will be
experienced.
A flow switch must be installed in the horizontal piping of the supply (evaporator outlet) water
line to prove water flow before starting the unit.
Drain connections should be provided at all low points in the system to permit complete
drainage of the system. Air vents should be located at the high points in the system to purge
air out of the system. The evaporators are not equipped with vent or drain connections and
provision must be made in the entering and leaving chilled water piping for venting and
draining.
Pressure gauges should be installed in the inlet and outlet water lines to the evaporator.
Pressure drop through the evaporator should be measured to determine water flow from the
flow/pressure drop curves on page 16. Vibration eliminators are recommended in both the
supply and return water lines.
Chilled water piping should be insulated to reduce heat loss and prevent condensation.
Complete unit and system leak tests should be performed prior to insulating the water piping.
Insulation with a vapor barrier would be the recommended type of insulation. If the vessel is
insulated, the vent and drain connections must extend beyond the proposed insulation
thickness for accessibility.
Chillers not run in the winter should have their water systems thoroughly drained if subject to
sub-freezing temperatures. If the chiller operates year-round, or if the system is not drained
for the winter, the chilled water piping exposed to sub-freezing ambient temperatures should
be protected against freezing by wrapping the lines with a heater cable. In addition, an
adequate percentage of glycol should be added to the system to further protect the system
during low ambient temperature periods. It should be noted that water piping that has been
left drained is subject to more corrosion than if filled with water. Use of a Vapor Corrosion
Inhibitor (VCI) or some other protection should be considered.
CAUTION
The thermostat bulb should not be exposed to water temperatures above 125F
(51.7C) since this will damage it.
12
IMM WGZ-2
Flow Switch
A water flow switch must be mounted in the leaving evaporator and condenser water line to
prove adequate water flow 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 01750330. It is a paddle type
switch and adaptable to any pipe size from 1 in. (25 mm) to 6 in. (152 mm) nominal. Certain
minimum flow rates are required to close the switch and are listed in Table 5. Electrical
connections in the unit control center should be made at terminals 33 and 43 (chilled water)
and 41 and 53 (condenser water). The normally open contacts of the flow switch should be
wired between these two terminals. There is also a set of normally closed contacts on the
switch that could be used for an indicator light or an alarm to indicate when a no flow
condition exists.
1. Apply pipe sealing compound to only the threads of the switch and screw unit into 1 in.
(25 mm) reducing tee. The flow arrow must be pointed in the correct direction.
2. Piping should provide a straight length before and after the flow switch of at least five
times the pipe diameter without any valves, elbows, or other flow restricting elements.
3. Trim flow switch paddle if needed to fit the pipe diameter. Make sure paddle does not
hang up in pipe.
CAUTION
Make sure the arrow on the side of the switch is pointed in the direction of flow.
The flow switch is designed to handle the control voltage and should be
connected according to the wiring diagram (see wiring diagram inside control
box door). Incorrect installation will cause improper operation and possible
evaporator damage.
Table 5, Flow Switch Flow Rates
inch
mm
gpm
Lpm
gpm
Lpm
gpm
Lpm
gpm
Lpm
Pipe Size
Minimum
Adjustment
Maximum
Adjustment
Flow
No
Flow
Flow
No
Flow
2
51
13.7
51.8
9.4
35.6
56.4
214.0
47.4
179.0
2 1/2
63
17.9
67.8
12.1
45.8
71.3
270.0
59.2
224.0
3
76
24.2
91.6
16.4
62.1
89.0
337.0
72.5
274.0
4
102
35.3
134.0
27.0
102.0
118.0
446.0
105.0
397.0
5
(125)
48.6
184.0
37.4
142.0
178.0
674.0
160.0
606.0
6
(150)
60.3
228.0
46.8
177.0
245.0
927.0
225.0
852.0
Glycol Solutions
When using a glycol solution, the chiller capacity, flow rate, evaporator pressure drop, and
chiller power input can be calculated using the following formulas and reference to Table 6 for
ethylene glycol and Table 7 for propylene glycol.
1. Capacity, Capacity is reduced compared to that with plain water. To find the reduced
value, multiply the chillers capacity when using water by the capacity correction factor C
to find the chillers capacity when using glycol.
2. Flow, To determine evaporator gpm (or T) knowing T (or gpm) and capacity:
Glycol GPM =
IMM WGZ-2
24 x Glycol Capacity
x Flow Correction G From Tables
T
13
For Metric Applications -- Determine evaporator lps (or T) knowing T (or lps) and
kW:
Glycol Lps =
kW
x Flow Correction G from Tables
4.18 x T
3. Pressure Drop, To determine glycol pressure drop through the cooler, enter the water
pressure drop graph on page 15 at the actual glycol flow. Multiply the water pressure drop
found there by P to obtain corrected glycol pressure drop.
4. Power, To determine glycol system kW, multiply the water system kW by factor K.
Test coolant with a clean, accurate, glycol solution hydrometer (similar to that found in service
stations) to determine the freezing point. Obtain percent glycol from the freezing point found
in Table 6 or Table 7. On glycol applications the supplier normally recommends that a
minimum of 25% solution by weight be used for protection against corrosion or the use of
additional inhibitors.
Note: The effect of glycol in the condenser is negligible. As glycol increases in
temperature, its characteristics have a tendency to mirror those of water. Therefore,
for selection purposes, there is no derate in capacity for glycol in the condenser.
Table 6, Ethylene Glycol
Percent
Glycol
10
20
30
40
50
Freezing Point
F
C
26
-3
18
-8
7
-14
-7
-22
-28
-33
C (Capacity)
K (Power)
G (Flow)
0.991
0.982
0.972
0.961
0.946
0.996
0.992
0.986
0.976
0.966
1.013
1.040
1.074
1.121
1.178
C (Capacity)
K (Power)
G (Flow)
0.987
0.975
0.962
0.946
0.929
0.992
0.985
0.978
0.971
0.965
1.010
1.028
1.050
1.078
1.116
P (Pressure
Drop)
1.070
1.129
1.181
1.263
1.308
Freezing Point
F
C
26
-3
19
-7
9
-13
-5
-21
-27
-33
P (Pressure
Drop)
1.068
1.147
1.248
1.366
1.481
CAUTION
Do not use automotive antifreeze. Industrial glycols must be used. Automotive
antifreeze contains inhibitors that causes plating on copper tubes. The type and
handling of glycol used must be consistent with local codes.
14
IMM WGZ-2
Water-cooled condensers can be piped for use with cooling towers, well water, or heat
recovery applications. Cooling tower applications should be made with consideration of
freeze protection and scaling problems. Contact the cooling tower manufacturer for
equipment characteristics and limitations for the specific application.
Head pressure control must be provided if the entering condenser water can fall below 60F.
The WGZ condenser has two refrigerant circuits with a common condenser water circuit. This
arrangement makes head pressure control with discharge pressure actuated control valves
difficult.
If for some reason the tower water temperature cannot be maintained at a 60F minimum, or
when pond, lake, or well water that can fall below 60F (15C) is used as the condensing
medium, special discharge pressure control must be used. A water recirculating system with
recirculating pump as shown in Figure 9 is recommended. This system also has the advantage
of maintaining tube velocity to help prevent tube fouling. The pump should cycle with the
chiller.
Figure 9, Recirculating Discharge Pressure Control System
Circuit #1
Inlet
Circuit #2
Inlet
Temperature
Control
Valve
Condenser
Circuit #1
Outlet
Condenser
Water
Circuit #2
Outlet
IMM WGZ-2
WGZ Model
030
035
040
045
050
055
060
070
080
090
100
110
120
Minimum Part
Load Flow
30
34
38
43
47
53
58
67
74
83
91
102
113
15
2.5
3.2
12.6
18.9
25.2
31.5
37.9
44.2
40
120
30
90
WGZ 050
20
WGZ 040
WGZ 080
60
WGZ 060
10
9
30
27
24
21
18
15
WGZ 030
12
WGZ 070
WGZ 035
WGZ 055
WGZ 090
WGZ 045
1
3
30
40
50
60 70 80 90 100
200
300
400
500 600
700
Minimum Flow
Inch-Pound
S.I.
GPM
Ft.
L/S
kPa
Nominal Flow
Inch-Pound
S.I.
GPM
Ft.
L/S
kPa
Maximum Flow
Inch-Pound
S.I.
GPM
Ft.
L/S
kPa
56.9
62.8
72.2
79.6
87.5
97.7
107.3
122.4
140.4
154.4
168.7
191.2
211.0
94.8
104.7
120.3
132.6
145.8
162.9
178.8
204.0
234.0
257.4
281.1
318.6
351.6
158.0
174.5
200.5
221.0
243.0
271.5
298.0
340.0
390.0
429.0
468.5
531.0
586.0
2.66
3.25
2.83
3.43
3.02
3.77
3.38
3.45
3.92
3.95
3.55
4.56
5.56
3.59
3.96
4.55
5.02
5.52
6.17
6.77
7.72
8.86
9.74
10.64
12.06
13.31
7.96
9.71
8.45
10.26
9.02
11.26
10.11
10.31
11.72
11.81
10.62
13.64
16.61
7.40
9.02
7.85
9.54
8.38
10.46
9.39
9.58
10.89
10.97
9.87
12.68
15.44
5.98
6.61
7.59
8.37
9.20
10.28
11.28
12.87
14.76
16.24
17.73
20.10
22.18
22.11
26.97
23.46
28.51
25.05
31.27
28.07
28.64
32.56
32.80
29.50
37.89
46.15
20.55
25.07
21.80
26.49
23.28
29.06
26.09
26.62
30.26
30.48
27.41
35.21
42.89
9.97
11.01
12.65
13.94
15.33
17.13
18.80
21.45
24.61
27.07
29.56
33.50
36.97
61.43
74.93
65.17
79.18
69.58
86.85
77.97
79.56
90.45
91.11
81.94
105.26
128.19
Note: Minimum, nominal, and maximum flows are at a 16F, 10F, and 6F chilled water temperature range respectively and at ARI tons. See previous page.
16
IMM WGZ-2
Figure 11, Condenser Water Pressure Drop, WGZ 030AW through 120AW
Flow Rate (L/s)
1.9
2.5
3.2
12.6
18.9
25.2
31.5
37.9
44.2
70
210
60
180
50
150
WGZ 080
WGZ 050, 055
40
WGZ 090
120
90
20
60
10
30
27
24
21
18
15
12
WGZ 070
WGZ 060
6
30
40
50
60
70 80 90 100
200
300
400
500 600
700
Flow Rate
Nominal Flow
Pressure Drop
Flow Rate
Maximum Flow
Pressure Drop
Flow Rate
Pressure Drop
gpm
L/s
ft.
kPa
gpm
L/s
ft.
kPa
gpm
L/s
ft.
kPa
030
56.9
3.59
2.66
7.96
94.8
5.98
7.40
22.11
158.0
9.97
20.55
61.43
035
62.8
3.96
3.25
9.71
104.7
6.61
9.02
26.97
174.5
11.01
25.07
74.93
040
72.2
4.55
2.83
8.45
120.3
7.59
7.85
23.46
200.5
12.65
21.80
65.17
045
79.6
5.02
3.43
10.26
132.6
8.37
9.54
28.51
221.0
13.94
26.49
79.18
050
87.5
5.52
3.02
9.02
145.8
9.20
8.38
25.05
243.0
15.33
23.28
69.58
055
97.7
6.17
3.77
11.26
162.9
10.28
10.46
31.27
271.5
17.13
29.06
86.85
060
107.3
6.77
3.38
10.11
178.8
11.28
9.39
28.07
298.0
18.80
26.09
77.97
070
122.4
7.72
3.45
10.31
204.0
12.87
9.58
28.64
340.0
21.45
26.62
79.56
080
140.4
8.86
3.92
11.72
234.0
14.76
10.89
32.56
390.0
24.61
30.26
90.45
090
154.4
9.74
3.95
11.81
257.4
16.24
10.97
32.80
429.0
27.07
30.48
91.11
100
168.7
10.64
3.55
10.62
281.1
17.73
9.87
29.50
468.5
29.56
27.41
81.94
110
191.2
12.06
4.56
13.64
318.6
20.10
12.68
37.89
531.0
33.50
35.21
105.26
120
211.0
13.31
5.56
16.61
351.6
22.18
15.44
46.15
586.0
36.97
42.89
128.19
IMM WGZ-2
17
Refrigerant Piping
Unit with Remote Condenser
General
Refrigerant piping, to and from the unit, should be sized and installed according to the latest
ASHRAE Handbook. It is important that the unit piping be properly supported with sound
and vibration isolation between tubing and hanger, and that the discharge lines be looped at
the condenser and trapped at the compressor to prevent refrigerant and oil from draining into
the compressors. Looping the discharge line also provides greater line flexibility.
The discharge gas valves, liquid line solenoids, filter-driers, moisture indicators, and
thermostatic expansion valves are all factory mounted as standard equipment with the water
chiller.
For remote condenser application (WGZ-AA) such as air-cooled or evaporative condenser, the
chillers are shipped with an R-22 holding charge. Some special order units may have R-407c
refrigerant. The unit is evacuated in the factory to 500 microns before charging with a holding
charge of R-22 (407c) refrigerant. The unit is leak tested after charging and before shipment.
The liquid line has a shutoff valve upstream from the liquid line solenoid valve and a copper
tube cap to be brazed on this line after test to seal this line for shipment.
The discharge line has a ball valve installed between the compressor and the discharge stub
tube with a copper tube cap brazed on the line after test to seal it for shipment.
The discharge gas valves, liquid line solenoids, filter-driers, moisture indicators, and
thermostatic expansion valves are all factory-mounted as standard equipment with the water
chiller.
DANGER
Do not apply heat, such as a brazing torch, to a sealed unit, vessel, or component. Internal
gases can increase the internal pressure and cause a life-threatening explosion. Open the
system when heating. The short line between a valve and brazed end cap can be drilled to
vent it. Note that the valve may leak and the entire unit charge may be open to the cap.
It is important that the unit be kept tightly closed until the remote condenser is installed, piped
to the unit and the high side evacuated. NOTE: it is possible to maintain a positive refrigerant
pressure in the unit when a small leak is present. Therefore, add refrigerant to the unit to
achieve sufficient pressure to allow a good leak test and carefully leak test the unit. Correct
any leaks found.
When the field piping has been leak tested, evacuated, and is ready to charge, the unit valves
can be opened and the system charged.
Alternate method: an alternate method is to open up the unit to the field piping and to
pressure test, evacuate and charge the entire system together at one time. Many people feel
that this is a more straight-forward approach.
Refrigerant piping, to and from the unit, should be sized and installed according to the latest
ASHRAE Handbook. It is important that the unit piping be properly supported with sound
and vibration isolation between tubing and hanger, and that the discharge lines be looped at
18
IMM WGZ-2
the condenser and trapped at the compressor to prevent refrigerant and oil from draining into
the compressors. Looping the discharge line also provides greater line flexibility.
NOTE: Do not run refrigerant piping underground.
After the equipment is properly installed, leak tested, and evacuated, it can be charged with
R-22, and run at design load conditions. Add charge until the liquid line sight glass is clear,
with no bubbles flowing to the expansion valve. Total operating charge will depend on the aircooled condenser used and volume of the refrigerant piping.
NOTE: On WGZ-AA units (units with remote condensers), the installer is required to record
the refrigerant charge by stamping the total charge and the charge per circuit on the serial plate
in the appropriate blocks provided for this purpose.
The following discussion is intended for use as a general guide to the piping of air-cooled
condensers.
Discharge lines must be designed to handle oil properly and to protect the compressor from
damage that can result from condensing liquid refrigerant in the line during shutdown. Total
friction loss for discharge lines of 3 to 6 psi (20.7 to 41.4 kPa) is considered good design.
Careful consideration must be given for sizing each section of piping to insure that gas
velocities are sufficient at all operating conditions to carry oil. If the velocity in a vertical
discharge riser is too low, considerable oil can collect in the riser and the horizontal header,
causing the compressor to lose its oil and result in damage due to lack of lubrication. When
the compressor load is increased, the oil that had collected during reduced loads can be carried
as a slug through the system and back to the compressor, where a sudden increase of oil
concentration can cause liquid slugging and damage to the compressor.
Any horizontal run of discharge piping should be pitched away from the compressor
approximately 1/8 inch (6.4 mm) per foot (meter) or more. This is necessary to move, by
gravity, any oil lying in the header. Oil pockets must be avoided because oil needed in the
compressor would collect at such points and the compressor crankcase can become starved.
It is recommended that any discharge lines coming into a horizontal discharge header rise
above the centerline of the discharge header. This is necessary to prevent any oil or condensed
liquid from draining to the compressor heads when the compressor is not running.
In designing liquid lines, it is important that the liquid reach the expansion valve without flash
gas since this gas will reduce the capacity of the valve. Because flashing can be caused by a
pressure drop in the liquid line, the pressure losses due to friction and changes in static head
should be kept to a minimum.
A check valve must be installed in the liquid line in all applications where the ambient
temperature can drop below the equipment room temperature. This prevents liquid migration
to the condenser, helps maintain a supply of refrigerant in the liquid line for initial start-up,
and keeps liquid line pressure high enough on off cycle to keep the expansion valve closed.
On systems as described above, a relief valve or relief-type check valve, must be used in the
liquid line as shown in piping systems (shown in Figure 12 and Figure 13). Its purpose is to
relieve dangerous hydraulic pressures that could be created as cool liquid refrigerant trapped
in the line between the check valve and the expansion or shutoff valve warms up. A relief
device is also recommended in the hot gas piping at the condenser coil as shown in Figure 12
and Figure 13.
Install a discharge check valve in the discharge line, in a horizontal run, close to the
condenser.
IMM WGZ-2
19
Typical Arrangements
Figure 12 illustrates a typical piping arrangement involving a remote air-cooled condenser
located at a higher elevation than the compressor and receiver. This arrangement is commonly
encountered when the air-cooled condenser is on a roof and the compressor and receiver are
on grade level or in a basement equipment room.
Notice, in both illustrations, that the hot gas line is looped at the bottom and top of the vertical
run. This is done to prevent oil and condensed refrigerant from flowing back into the
compressor and causing damage. The highest point in the discharge line should always be
above the highest point in the condenser coil. It is advisable to include a purging vent at this
point to extract non-condensables from the system.
Figure 13 illustrates another very common application where the air-cooled condenser is
located on essentially the same level as the compressor and receiver. The discharge line
piping in this case is not too critical. The principal problem encountered with this
arrangement is that there is frequently insufficient vertical distance to allow free drainage of
liquid refrigerant from the condenser coil to the receiver.
The receiver is used when it is desired to have refrigerant storage capacity, in addition to the
pumpdown capability of the condenser.
20
IMM WGZ-2
Pitch
Condenser
Discharge Line
Subcooler
Preferred
Subcooler
Relief Valve
Hook-up
(Vent to Outdoors
or to Condenser Side
of Liquid Line
Check Valve)
To
Evap.
Loop
Receiver
Bypass
Check
Valve
Receiver
Purge Valve
Discharge Line
Pitch
Condenser
Check
Valve
Subcooler
Relief Valve
(Vent to Outdoors
or to Condenser Side
of Liquid Line
Check Valve)
Preferred
Subcooler
Hook-up
To
Evap.
Receiver
Bypass
Check
Valve
Receiver
The receiver shown is optional and not used on many installations. It is bypassed during
normal operation.
IMM WGZ-2
21
Factory-Mounted Condenser
Units with the standard water-cooled, factory-mounted condenser are provided with complete
refrigerant piping and full operating refrigerant charge at the factory.
There is a remote possibility on water-cooled units utilizing low temperature pond or river
water as a condensing medium, and if the water valves leak, that the condenser and liquid line
refrigerant temperature could drop below the equipment room temperature on the off cycle.
This problem only arises during periods when cold water continues to circulate through the
condenser and the unit remains off due to satisfied cooling load.
If this condition occurs:
1. Cycle the condenser pump off with the unit.
2. Check the liquid line solenoid valve for proper operation.
22
IMM WGZ-2
Dimensional Data
WGZ-AW Water-Cooled
Figure 15, WGZ 030AW through WGZ 055AW
38
965
Door Swing
36
915
Recommended
for Servicing
4.5
114
Evaporator
52.4
1331
20
508
27.8
707
14
8 354
204
12.3
311
13.25
337
1.5
38
29
711
1.5
38
Z
L
A
Evaporator
Control Connection
Inlet
Outlet
Outlet
Inlet
Condenser
WGZ
Model
Number
030
035
040
045
050
055
Relief Valves
(1) Each End
121.4
3085
Maximum Overall
Dimensions
in (mm)
L
134.1
(3406)
134.1
(3406)
134.1
(3406)
134.1
(3406)
134.1
(3406)
134.1
(3406)
Power Connections
(2) .875" (22 mm)
W
32
(813)
32
(813)
32
(813)
32
(813)
32
(813)
32
(813)
H
63.5
(1613)
63.5
(1613)
63.5
(1613)
63.5
(1613)
63.5
(1613)
63.5
(1613)
Chilled Water
Connection
in. (mm)
Victaulic
Size
3
(76)
3
(76)
3
(76)
3
(76)
3
(76)
3
(76)
A
114.3
(2903)
115.2
(2926)
116.5
(2959)
117.8
(2992)
119.1
(3025)
121.0
(3073)
Condenser
Water
Connections
in. (mm)
Victaulic
Size
4
(102)
4
(102)
4
(102)
4
(102)
4
(102)
4
(102)
Center of Gravity
T
3.0
(76.2)
3.0
(76.2)
3.0
(76.2)
3.0
(76.2)
3.0
(76.2)
3.0
(76.2)
X
62.9
(1596)
63.3
(1607)
63.7
(1618)
64.1
(1627)
64.6
(1640)
63.6
(1614)
Y
26.8
(680)
26.9
(682)
26.9
(682)
27.1
(688)
27.1
(688)
27.3
(693)
Z
13.4
(340)
13.4
(340)
13.4
(340)
13.4
(340)
13.4
(340)
13.3
(338)
IMM WGZ-2
23
36
915
Recommended
for Servicing
4.5
114
Evaporator
58.1
1476
H
20
508
33.5
852
Y
18
9.8 458
248
15
382
Z
13.25
337
1.5
38
737
1.5
38
L
A
Control Connection
Evaporator
Outlet
Power Connections
(2) .875" (22 mm)
Outlet
Condenser
Inlet
(4) .875" (22 mm)
Diameter Mounting Holes
X
121.1
3075
WGZ
Model
Number
060
070
080
090
100
110
120
Maximum Overall
Dimensions
in (mm)
L
144.2
(3663)
148.2
(3764)
148.2
(3764)
149
(3785)
149
(3785)
149
(3785)
149
(3785)
Relief Valves
(1) Each End
W
32
(813)
32
(813)
32
(813)
32
(813)
32
(813)
32
(813)
32
(813)
H
66
(1676)
66
(1676)
66
(1676)
66
(1676)
66
(1676)
66
(1676)
66
(1676)
Chiller Water
Connection
in. (mm)
Victaulic
Size
A
3
117.3
(76)
(2980)
3
119.5
(76)
(3036)
3
122.6
(76)
(3114)
3
126.6
(76)
(3216)
3
128.9
(76)
(3274)
3
128.9
(76)
(3274)
3
128.9
(76)
(3274)
7.7
196
Condenser Water
Connections
in. (mm)
Victaulic
Size
5
(127)
5
(127)
5
(127)
5
(127)
5
(127)
5
(127)
5
(127)
Center of Gravity
T
10.3
(263)
14.4
(367)
14.4
(367)
15.3
(388)
15.3
(388)
15.4
(390)
15.4
(390)
X
61.0
(1549)
60
(1525)
61.1
(1553)
62.7
(1591)
63.6
(1614)
63.3
(1608)
61.2
(1555)
Y
30.5
(775)
31.6
(804)
32.8
(834)
33.2
(843)
33.0
(839)
33.6
(854)
34.2
(870)
Z
13.4
(340)
13.4
(340)
13.4
(340)
13.4
(340)
13.4
(340)
13.4
(340)
13.4
(340)
NOTES
1. Allow a minimum of three feet (one meter) service clearance on all four sides of the unit. Allow sufficient space at one end for
tube cleaning or replacement.
24
IMM WGZ-2
2.
Allow two additional inches in width for the optional disconnect switch handle.
36
915
Recommended
for Servicing
4.5
114
52.4
1331
H
20
508
27.8
24.1 707
613
13.8
350
12.5
318
1.5
38
1.5
38
29
737
Z
L
A
Control Connection
Evaporator
Inlet
Outlet
B
D
Power Connections
(2) - .875 (22 mm)
C
F
"E" Liquid System #2
121.4
3085
Maximum Overall
Dimensions
In. (mm)
WGZ
Model
030
035
040
045
050
055
L
125.4
(3186)
125.4
(3186)
125.4
(3186)
125.4
(3186)
125.4
(3186)
125.4
(3186)
W
32
(813)
32
(813)
32
(813)
32
(813)
32
(813)
32
(813)
H
63.5
(1613)
63.5
(1613)
63.5
(1613)
63.5
(1613)
63.5
(1613)
63.5
(1613)
Evaporator
Connection
In. (mm)
Victaulic
Size
3
(76)
3
(76)
3
(76)
3
(76)
3
(76)
3
(76)
A
114.3
(2903)
115.2
(2926)
116.5
(2959)
117.8
(2992)
119.1
(3025)
121.0
(3073
System #2
Connection Size
Center of Gravity
Y
31.0
(788)
31.2
(792)
31.3
(796)
31.5
(801
31.7
(804)
31.8
(809)
Z
14.0
(356)
14.0
(356)
14.0
(356)
13.9
(354)
13.9
(354
13.8
(351)
IMM WGZ-2
25
36
915
Recommended
for Servicing
4.5
114
Evaporator
58.1
1476
H
20
508
33.5
852
Y
18
9.8 458
248
15
382
Z
13.25
337
1.5
38
737
1.5
38
L
A
Control Connection
Evaporator
Outlet
Power Connections
(2) .875" (22 mm)
Outlet
Condenser
Inlet
(4) .875" (22 mm)
Diameter Mounting Holes
X
121.1
3075
WGZ
Model
Number
060
070
080
090
100
110
120
Maximum Overall
Dimensions
in (mm)
L
144.2
(3663)
148.2
(3764)
148.2
(3764)
149
(3785)
149
(3785)
149
(3785)
149
(3785)
Relief Valves
(1) Each End
W
32
(813)
32
(813)
32
(813)
32
(813)
32
(813)
32
(813)
32
(813)
H
66
(1676)
66
(1676)
66
(1676)
66
(1676)
66
(1676)
66
(1676)
66
(1676)
Chiller Water
Connection
in. (mm)
Victaulic
Size
A
3
117.3
(76)
(2980)
3
119.5
(76)
(3036)
3
122.6
(76)
(3114)
3
126.6
(76)
(3216)
3
128.9
(76)
(3274)
3
128.9
(76)
(3274)
3
128.9
(76)
(3274)
7.7
196
Condenser Water
Connections
in. (mm) Victaulic
Size
5
(127)
5
(127)
5
(127)
5
(127)
5
(127)
5
(127)
5
(127)
Center of Gravity
T
10.3
(263)
14.4
(367)
14.4
(367)
15.3
(388)
15.3
(388)
15.4
(390)
15.4
(390)
X
61.0
(1549)
60
(1525)
61.1
(1553)
62.7
(1591)
63.6
(1614)
63.3
(1608)
61.2
(1555)
Y
30.5
(775)
31.6
(804)
32.8
(834)
33.2
(843)
33.0
(839)
33.6
(854)
34.2
(870)
Z
13.4
(340)
13.4
(340)
13.4
(340)
13.4
(340)
13.4
(340)
13.4
(340)
13.4
(340)
Notes:
1. Allow a minimum of 3 ft (1 meter) service clearance on all 4 sides of the unit. Allow sufficient space on one end for condenser tube
cleaning and replacement. Allow 4 ft clearance in front of the control panel.
2. Allow two additional inches in width for optional disconnect switch.
26
IMM WGZ-2
Physical Data
AW Water-Cooled
Table 9, WGZ 030AW WGZ 055AW
WGZ UNIT SIZE
030
035
IMM WGZ-2
040
045
050
055
40.1 (141)
44.2 (155)
48.6 (171)
54.3 (191)
10
10
2
2
25 / 50 / 75
140 (4.1)
13
10
2
2
28 / 50 / 78
140 (4.1)
13
13
2
2
25 / 50 / 75
140 (4.1)
13
15
2
2
27 / 50 / 77
140 (4.1)
1
2
10 (254)
120 (3048)
1
2
10 (254)
120 (3048)
1
2
10 (254)
120 (3048)
1
2
10 (254)
120 (3048)
450 (3102)
232 (1599)
2
260 (117.9)
450 (3102)
232 (1599)
2
253 (114.8)
450 (3102)
232 (1599)
2
240 (108.9)
450 (3102)
232 (1599)
2
234 (106.1)
4 (102)
(12.7)
(12.7)
(12.7)
Integral
4 (102)
(12.7)
(12.7)
(12.7)
Integral
4 (102)
(12.7)
(12.7)
(12.7)
Integral
4 (102)
(12.7)
(12.7)
(12.7)
Integral
1
2
5 (18.9)
450 (3102)
363 (2503)
1
2
5.7 (21.4)
450 (3102)
363 (2503)
1
2
6.3 (23.9)
450 (3102)
363 (2503)
1
2
7.2 (27.3)
450 (3102)
363 (2503)
3 (76)
Field
3 (76)
Field
3 (76)
Field
3 (76)
Field
134.1 (3406)
32 (813)
63.5 (1613)
134.1 (3406)
32 (813)
63.5 (1613)
134.1 (3406)
32 (813)
63.5 (1613)
134.1 (3406)
32 (813)
63.5 (1613)
2864 (1299)
2772 (1257)
47 (21.3)
47 (21.3)
2966 (1345)
2853 (1294)
46 (20.8)
46 (20.8)
3058 (1387)
2918 (1324)
44 (20.0)
44 (20.0)
3213 (1457)
3063 (1389)
45 (20.2)
45 (20.2)
27
28
080
090
100
78.0 (274)
84.4 (297)
93.7 (330)
20
20
2
2
25 / 50 / 75
148 (4.3)
20
25
25
25
2
2
2
2
27 / 50 / 77
25 / 50 / 75
148 (4.3) 200 (5.9) 200 (5.9 200 (5.9
1
2
14 (356)
120 (3048)
1
2
14 (356)
120 (3048)
1
2
14 (356)
120 (3048)
450 (3102)
232 (1599)
2
450 (3102)
232 (1599)
2
450 (3102)
232 (1599)
2
449 (203.7)
429 (194.6)
409 (185.5)
5 (127)
(12.7)
(12.7)
(12.7)
Integral
5 (127)
(12.7)
(12.7)
(12.7)
Integral
5 (127)
(12.7)
(12.7)
(12.7)
Integral
1
2
10.8 (40.7)
1
2
12.8 (48.3)
1
2
13.9 (52.5)
450 (3102)
450 (3102)
450 (3102)
363 (2503)
363 (2503)
363 (2503)
3 (76)
Field
3 (76)
Field
3 (76)
Field
146.7 (3726)
32 (813)
66 (1676)
149 (3784)
32 (813)
66 (1676)
149 (3784)
32 (813)
66 (1676)
4289 (1945)
4037 (1831)
82 (37.0)
82 (37.0)
4478 (2031)
4178 (1895)
76 (34.3)
76 (34.3)
4627 (2099)
4287 (1945)
76 (34.3)
76 (34.3)
IMM WGZ-2
IMM WGZ-2
29
AA Remote Condenser
Table 12, WGZ-030AA - WGZ-055AA
WGZ UNIT SIZE
Cap @ 44F LWT , 125F SDT
tons, (kW)
No. Circuits
COMPRESSORS
Nominal Tons
Number (Note 1)
Unloading Steps, %
Oil Charge, per compressor oz, (l)
Discharge Valve In., (mm)
EVAPORATOR
No. Refrigerant Circuits
Water Volume, gallons, (l)
Refrig. Side D.W.P. Psig, (kPa)
Water Side D.W.P. Psig, (kPa)
Water Connections, Victaulic:
Inlet & Outlet, in., (mm) (1)
Drain & Vent
030
035
040
045
050
055
29 (103)
31.6 (112)
36.6 (130)
40.7 (144)
44.7 (158)
49.8 (177)
7.5
9
2
2
27 / 50 / 77
140 (4.1)
9
9
2
2
25 / 50 / 75
140 (4.1)
10
10
2
2
25 / 50 / 75
140 (4.1)
13
10
2
2
28 / 50 / 78
140 (4.1)
13
13
2
2
25 / 50 / 75
140 (4.1)
1.125 (28)
1.125 (28)
1.125 (28)
1.125 (28)
1.125 (28)
13
15
2
2
27 / 50 / 77
140 (4.1)
1.125 (28)
1.375 (35)
2
3.9 (14.7)
450 (3102)
363 (2503)
2
4.3 (16.4)
450 (3102)
363 (2503)
2
5 (18.9)
450 (3102)
363 (2503)
2
5.7 (21.4)
450 (3102)
363 (2503)
2
6.3 (23.9)
450 (3102)
363 (2503)
2
7.2 (27.3)
450 (3102)
363 (2503)
3 (76)
Field
3 (76)
Field
3 (76)
Field
3 (76)
Field
3 (76)
Field
3 (76)
Field
122.4 (3109)
32 (813)
63.5 (1613)
122.4 (3109)
32 (813)
63.5 (1613)
122.4 (3109)
32 (813)
63.5 (1613)
122.4 (3109)
32 (813)
63.5 (1613)
122.4 (3109)
32 (813)
63.5 (1613)
123.4 (3134)
32 (813)
63.5 (1613)
2169 (983)
2248 (1018)
2211 (1002)
2285 (1035)
2263 (1025)
2331 (1056)
2335 (1058)
2392 (1084)
2376 (1076)
2424 (1098)
2510 (1137)
2558 (1159)
6.0 (2.7)
6.1 (2.8)
6.4 (2.9)
6.6 (3)
7.0 (3.2)
9.7 (4.4)
UNIT DIMENSIONS
Length In., (mm)
Width In., (mm)
Height In., (mm)
UNIT WEIGHTS
Operating Weight, lb., (kg)
Shipping Weight, lb., (kg)
Holding Charge, lb., (kg) R-22
Per Circuit
30
IMM WGZ-2
Operating Limits
IMM WGZ-2
31
Components
Figure 19, Compressor Locations
Circuit 2
Evaporator
Circuit 1
Evaporator and
Condenser
Connections
Control Panel
32
Comp. #3
Comp. #2
Comp. #4
Evap.
Vessel
Size
System #1
Comp. #1
System #2
Cond.
Vessel
Size
Expansion Valve
System #1
System #2
030
ZR90K3
ZR90K3
ZR11M3
ZR11M3
AC250-70DQ
C1010-046
OVE-20-CP100
OVE-20-CP100
035
ZR11M3
ZR11M3
ZR11M3
ZR11M3
AC250-78DQ
C1010-046
OVE-20-CP100
OVE-20-CP100
040
ZR12M3
ZR12M3
ZR12M3
ZR12M3
AC250-90DQ
C1010-058
OVE-20-CP100
OVE-20-CP100
045
ZR12M3
ZR12M3
ZR16M3
ZR16M3
AC250-102DQ
C1010-058
OVE-30-CP100
OVE-30-CP100
050
ZR16M3
ZR16M3
ZR16M3
ZR16M3
AC250-114DQ
C1010-070
OVE-30-CP100
OVE-30-CP100
055
ZR16M3
ZR16M3
ZR19M3
ZR19M3
AC250-130DQ
C1010-070
OVE-30-CP100
Y929-VCP100
060
ZR19M3
ZR19M3
ZR19M3
ZR19M3
AC250-146DQ
C1410-078
Y929-VCP100
Y929-VCP100
070
ZR19M3
ZR19M3
ZR250KC
ZR250KC
AC250-166DQ
C1410-090
OVE-40-CP100
OVE-40-CP100
080
ZR250KC
ZR250KC
ZR250KC
ZR250KC
AC250-194DQ
C1410-098
OVE-40-CP100
OVE-40-CP100
090
ZR250KC
ZR250KC
ZR300KC
ZR300KC
AC250-230DQ
C1410-110
OVE-55-CP100
OVE-55-CP100
100
ZR300KC
ZR300KC
ZR300KC
ZR300KC
AC250-250DQ
C1410-122
OVE-55-CP100
OVE-55-CP100
110
ZR300KC
ZR300KC
ZR380KC
ZR380KC
AC250-250DQ
C1410-122
OVE-55-CP100
OVE-70-CP100
120
ZR380KC
ZR380KC
ZR380KC
ZR380KC
AC250-250DQ
C1410-122
OVE-70-CP100
OVE-70-CP100
IMM WGZ-2
Wiring
Field Wiring, Power
The WGZ A vintage chillers are built standard with compressor contractors and power
terminal block, designed for single power supply to the unit. Optional power connections
include a non-fused disconnect switch mounted in the control box or multi-point power
connection.
A factory installed control circuit transformer is standard. Optionally, a field-installed control
power source can be wired to the unit.
Circuit breakers for backup compressor short circuit protection are standard on all units.
Wiring and conduit selections must comply with the National Electrical Code and/or local
requirements.
An open fuse indicates a short, ground, or overload. Before replacing a fuse or restarting a
compressor, the trouble must be found and corrected. Tables in the Electrical Data section
(page 35) give specific information on recommended wire sizes.
Unit power inlet wiring must enter the control box (right side) through a patch plate provided
for field terminating conduit. (Refer to control panel dimension drawings for general location
of power inlet and components.)
NOTE: Use only copper conductors in main terminal block. Terminations are sized for
copper only.
IMM WGZ-2
33
Unit Configuration
The chiller unit has two refrigerant circuits, two tandem scroll compressors (total of four), a
single two-circuited brazed plate evaporator, a single two-circuited water-cooled condenser,
interconnecting refrigerant piping and a control panel with associated sensors and transducers.
Figure 20, Schematic Piping Diagram (One of Two Circuits)
T
P1
Evaporator
Chilled
Water
LWT
Comp
#1
Comp
#2
CV
Condenser
Water
Condenser
T
S
S
F-D
Legend:
T
Temperature Sensor
P
T
Pressure Transducer
P1
LWT
Relief Valve
S
T
CV
Schrader Fitting
Charging Valve
S
Solenoid Valve
F-D
34
Filter-Drier
Angle Valve
Ball Valve
IMM WGZ-2
Electrical Data
Table 16, Compressor Amp Draw, WGZ 030 - WGZ 120
WGZ
Unit
Size
030
035
040
045
050
055
060
070
080
090
100
110
120
Voltage
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
Freq.
(Hertz)
60
60
60
60
60
60
60
60
60
60
60
60
60
Standard
Rated Load Amps
Per Compressor
( 2 Compr./Circuit)
Circuit 1
Circuit 2
23.7
29.9
23.7
29.9
12.5
15.3
9.1
11.6
29.9
29.9
29.9
29.9
15.3
15.3
11.6
11.6
33.6
33.6
33.6
33.6
16.5
16.5
13.7
13.7
33.6
41.0
33.6
41.0
16.5
21.8
13.7
17.3
41.0
41.0
41.0
41.0
21.8
21.8
17.3
17.3
41.0
48.1
41.0
48.1
21.8
23.7
17.3
21.2
48.1
48.1
48.1
48.1
23.7
23.7
21.2
21.2
48.1
73.1
48.1
73.1
23.7
30.1
21.2
24.4
73.1
73.1
73.1
73.1
30.1
30.1
24.4
24.4
73.1
78.9
73.1
78.9
30.1
38.5
24.4
30.8
78.9
78.9
78.9
78.9
38.5
38.5
30.8
30.8
78.9
100
78.9
100
38.5
48.7
30.8
39.0
100
100
100
100
48.7
48.7
39.0
39.0
NOTES:
1. Compressor RLA values are for wire sizing purposes only and do not reflect normal operating current draw.
2. External Overloads only available on Units with Single Power Supply and Water Cooled Condensers
IMM WGZ-2
35
030
035
040
045
050
055
060
070
080
090
100
110
120
Voltage
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
Freq.
(Hertz)
60
60
60
60
60
60
60
60
60
60
60
60
60
106
97
49
39
112
102
51
41
126
116
58
48
137
125
61
51
146
133
65
54
161
145
72
60
173
156
78
65
209
189
91
74
241
218
102
82
256
232
113
91
269
245
122
99
308
279
141
113
343
309
156
126
54
54
29
21
68
68
35
27
76
76
38
31
76
76
38
31
93
93
50
39
93
93
50
39
109
109
54
48
109
109
54
48
165
165
68
55
165
165
68
55
178
178
87
70
178
178
87
70
225
225
110
88
68
68
35
27
68
68
35
27
76
76
38
31
93
93
50
39
93
93
50
39
109
109
54
48
109
109
54
48
165
165
68
55
165
165
68
55
178
178
87
70
178
178
87
70
225
225
110
88
225
225
110
88
NOTES:
1. Unit wire sizing amps are equal to 125% of the largest compressor-motor RLA plus 100% of RLA of all other loads in the
circuit including control transformer.
2. Single point power supply requires a single fused disconnect to supply electrical power to the unit.
3. Multiple point power supply requires two independent power circuits with separate fused disconnects. (Two compressor
circuits, control circuit will be wired to Circuit #1 from the factory)
36
IMM WGZ-2
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
030
035
040
045
050
055
060
070
080
090
100
110
120
Freq.
(Hertz)
60
60
60
60
60
60
60
60
60
60
60
60
60
NOTES:
1.
2.
"Recommended Fuse Size" are selected at approximately 175% of the largest compressor RLA, plus 100% of all other circuit load.
"Maximum Fuse Sizes" are selected at approximately 225% of the largest compressor RLA, plus 100% of all other loads.
IMM WGZ-2
37
030
035
040
045
050
055
060
070
080
090
100
110
120
38
Voltage
3-Phase
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
Freq.
(Hertz)
60
60
60
60
60
60
60
60
60
60
60
60
60
No. of
Power
Wires
Wire
Size
No. of
Power
Wires
Wire
Size
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
6
6
3
3
6
6
3
3
2 GA
2 GA
6 GA
8 GA
1 GA
1 GA
4 GA
8 GA
1/0
1/0
4 GA
6 GA
2/0
2/0
4 GA
4 GA
2/0
2/0
3 GA
4 GA
3/0
3/0
3 GA
4 GA
4/0
4/0
2 GA
3 GA
300 kcmil
300 kcmil
2 GA
3 GA
400 kcmil
400 kcmil
1 GA
2 GA
400 kcmil
400 kcmil
1/0
1 GA
500 kcmil
500 kcmil
2/0
1/0
250 kcmil
250 kcmil
3/0
1/0
300 kcmil
300 kcmil
4/0
2/0
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
2 GA
3 GA
8 GA
8 GA
2 GA
2 GA
6 GA
8 GA
1 GA
1 GA
6 GA
8 GA
1/0
1 GA
6 GA
6 GA
1/0
1/0
6 GA
6 GA
2/0
1/0
4 GA
6 GA
2/0
2/0
4 GA
6 GA
4/0
3/0
3 GA
4 GA
250 kcmil
4/0
2 GA
4 GA
300 kcmil
250 kcmil
2 GA
3 GA
300 kcmil
250 kcmil
1 GA
3 GA
350 kcmil
300 kcmil
1/0
2 GA
500 kcmil
350 kcmil
2/0
1 GA
Circuit #1
Circuit #2
No. Of
Wires
Wire
Size
No. Of
Wires
Wire
Size
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
6 GA
6 GA
10 GA
12 GA
4 GA
4 GA
10 GA
10 GA
4 GA
4 GA
8 GA
10 GA
4 GA
4 GA
8 GA
10 GA
3 GA
3 GA
8 GA
8 GA
3 GA
3 GA
8 GA
8 GA
2 GA
2 GA
6 GA
8 GA
2 GA
2 GA
6 GA
8 GA
2/0
2/0
4 GA
6 GA
2/0
2/0
4 GA
6 GA
3/0
3/0
3 GA
4 GA
3/0
3/0
3 GA
4 GA
4/0
4/0
2 GA
3 GA
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
4 GA
4 GA
10 GA
10 GA
4 GA
4 GA
10 GA
10 GA
4 GA
4 GA
8 GA
10 GA
3 GA
3 GA
8 GA
8 GA
3 GA
3 GA
8 GA
8 GA
2 GA
2 GA
6 GA
8 GA
2 GA
2 GA
6 GA
8 GA
2/0
2/0
4 GA
6 GA
2/0
2/0
4 GA
6 GA
3/0
3/0
3 GA
4 GA
3/0
3/0
3 GA
4 GA
4/0
4/0
2 GA
3 GA
4/0
4/0
2 GA
3 GA
IMM WGZ-2
Table 20, Single Point Connection Sizing, WGZ 030 - WGZ 120
WGZ
Size
030
035
040
045
050
055
060
070
080
090
100
110
120
Voltage
3-Phase
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
Freq.
(Hertz)
60
60
60
60
60
60
60
60
60
60
60
60
60
Disconnect Switch
Size (1)
Connection (3)
Size (2)
Connection (3)
175
175
175
175
175
175
175
175
175
175
175
175
335
335
175
175
335
335
175
175
335
335
175
175
335
335
175
175
335
335
175
175
760
760
335
335
760
760
335
335
760
760
335
335
760
760
335
335
760
760
335
335
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
6 GA - 400kcmil
6 GA - 400kcmil
14 GA - 2/0
14 GA - 2/0
6 GA - 400kcmil
6 GA - 400kcmil
14 GA - 2/0
14 GA - 2/0
6 GA - 400kcmil
6 GA - 400kcmil
14 GA - 2/0
14 GA - 2/0
6 GA - 400kcmil
6 GA - 400kcmil
14 GA - 2/0
14 GA - 2/0
6 GA - 400kcmil
6 GA - 400kcmil
14 GA - 2/0
14 GA - 2/0
(2) 2 GA - 500kcmil
(2) 2 GA - 500kcmil
6 GA - 400kcmil
6 GA - 400kcmil
(2) 2 GA - 500kcmil
(2) 2 GA - 500kcmil
6 GA - 400kcmil
6 GA - 400kcmil
(2) 2 GA - 500kcmil
(2) 2 GA - 500kcmil
6 GA - 400kcmil
6 GA - 400kcmil
(2) 2 GA - 500kcmil
(2) 2 GA - 500kcmil
6 GA - 400kcmil
6 GA - 400kcmil
(2) 2 GA - 500kcmil
(2) 2 GA - 500kcmil
6 GA - 400kcmil
6 GA - 400kcmil
125
125
125
125
250
250
125
125
250
250
125
125
250
250
125
125
250
250
125
125
250
250
125
125
250
250
125
125
400
400
125
125
400
400
250
125
400
400
250
250
400
400
250
250
600
600
250
250
600
600
250
250
3GA - 3/0
3GA - 3/0
3GA - 3/0
3GA - 3/0
6GA - 350 kcmil
6GA - 350 kcmil
3GA - 3/0
3GA - 3/0
6GA - 350 kcmil
6GA - 350 kcmil
3GA - 3/0
3GA - 3/0
6GA - 350 kcmil
6GA - 350 kcmil
3GA - 3/0
3GA - 3/0
6GA - 350 kcmil
6GA - 350 kcmil
3GA - 3/0
3GA - 3/0
6GA - 350 kcmil
6GA - 350 kcmil
3GA - 3/0
3GA - 3/0
6GA - 350 kcmil
6GA - 350 kcmil
3GA - 3/0
3GA - 3/0
(2) 3/0 - 500 kcmil
(2) 3/0 - 500 kcmil
3GA - 3/0
3GA - 3/0
(2) 3/0 - 500 kcmil
(2) 3/0 - 500 kcmil
6GA - 350 kcmil
3GA - 3/0
(2) 3/0 - 500 kcmil
(2) 3/0 - 500 kcmil
6GA - 350 kcmil
6GA - 350 kcmil
(2) 3/0 - 500 kcmil
(2) 3/0 - 500 kcmil
6GA - 350 kcmil
6GA - 350 kcmil
(2) 3/0 - 500 kcmil
(2) 3/0 - 500 kcmil
6GA - 350 kcmil
6GA - 350 kcmil
(2) 3/0 - 500 kcmil
(2) 3/0 - 500 kcmil
6GA - 350 kcmil
6GA - 350 kcmil
NOTES:
1. "Size" is the maximum amperage rating for the terminals or the main electrical device.
2. "Size" is the disconnect part number and not the amperage rating for the terminals or the main electrical device.
3. "Connection" is the range of wire sizes that the terminals on the electrical device will accept.
IMM WGZ-2
39
Table 21, Multiple Point Connection Sizing, WGZ 030 - WGZ 120
Multiple Point - Circuit #1
Multiple Point - Circuit #2
WGZ
Voltage Freq.
Unit
Power Block
Disconnect Switch
Power Block
Disconnect Switch
3-Phase (Hertz)
Size
Size (1) Connection (3) Size (2) Connection (3) Size (1) Connection (3) Size (2) Connection (3)
030
035
040
045
050
055
060
070
080
090
100
110
120
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
60
60
60
60
60
60
60
60
60
60
60
60
60
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
335
335
175
175
335
335
175
175
335
335
175
175
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
6 GA - 400kcmil
6 GA - 400kcmil
14 GA - 2/0
14 GA - 2/0
6 GA - 400kcmil
6 GA - 400kcmil
14 GA - 2/0
14 GA - 2/0
6 GA - 400kcmil
6 GA - 400kcmil
14 GA - 2/0
14 GA - 2/0
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
250
250
125
125
250
250
125
125
250
250
125
125
250
250
125
125
250
250
125
125
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
6 GA - 350kcmil
6 GA - 350kcmil
3 GA - 3/0
3 GA - 3/0
6 GA - 350kcmil
6 GA - 350kcmil
3 GA - 3/0
3 GA - 3/0
6 GA - 350kcmil
6 GA - 350kcmil
3 GA - 3/0
3 GA - 3/0
6 GA - 350kcmil
6 GA - 350kcmil
3 GA - 3/0
3 GA - 3/0
6 GA - 350kcmil
6 GA - 350kcmil
3 GA - 3/0
3 GA - 3/0
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
175
335
335
175
175
335
335
175
175
335
335
175
175
335
335
175
175
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
14 GA - 2/0
6 GA - 400kcmil
6 GA - 400kcmil
14 GA - 2/0
14 GA - 2/0
6 GA - 400kcmil
6 GA - 400kcmil
14 GA - 2/0
14 GA - 2/0
6 GA - 400kcmil
6 GA - 400kcmil
14 GA - 2/0
14 GA - 2/0
6 GA - 400kcmil
6 GA - 400kcmil
14 GA - 2/0
14 GA - 2/0
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
250
250
125
125
250
250
125
125
250
250
125
125
250
250
125
125
250
250
125
125
250
250
125
125
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
3 GA - 3/0
6 GA - 350kcmil
6 GA - 350kcmil
3 GA - 3/0
3 GA - 3/0
6 GA - 350kcmil
6 GA - 350kcmil
3 GA - 3/0
3 GA - 3/0
6 GA - 350kcmil
6 GA - 350kcmil
3 GA - 3/0
3 GA - 3/0
6 GA - 350kcmil
6 GA - 350kcmil
3 GA - 3/0
3 GA - 3/0
6 GA - 350kcmil
6 GA - 350kcmil
3 GA - 3/0
3 GA - 3/0
6 GA - 350kcmil
6 GA - 350kcmil
3 GA - 3/0
3 GA - 3/0
NOTES:
1.
"Size" is the maximum amperage rating for the terminals or the main electrical device.
2.
"Size" is the disconnect part number and not the amperage rating for the terminals or the main electrical device.
3.
"Connection" is the range of wire sizes that the terminals on the electrical device will accept.
40
IMM WGZ-2
UNIT MAIN
TERMINAL BLOCK
GND LUG
3 PHASE
TO COMPRESSOR(S)
AND FAN MOTORS
POWER
SUPPLY
FUSED CONTROL
CIRCUIT TRANSFORMER
OPTION
120 VAC
DISCONNECT
(BY OTHERS)
TB1-20
N
10A
FUSE
120VAC
CONTROL POWER
(BY OTHERS)
TB1
CONTROL
CIRCUIT
FUSE
1
2
120 VAC
11
N
CHW PUMP RELAY (BY OTHERS)
120 VAC 1.0 AMP MAX
14
CONTROLLER
120 VAC
TB3-90 J15-NO8
CDW PUMP RELAY (BY OTHERS)
120 VAC 1.0 AMP MAX
TB1-12
120 VAC
TB3-91 J16-NO9
TOWER FAN #1 COIL (BY OTHERS)
120 VAC 1.0 AMP MAX
TB1-12
120 VAC
TB3-92 J16-NO10
ALARM
BELL
OPTION
120 VAC
10
ALARM BELL RELAY
15
TIME
CLOCK
REMOTE STOP
SWITCH
(BY OTHERS)
AUTO
OFF
TB2
ON
40
53
MANUAL
AUTO
OFF
GND
IF REMOTE STOP
897 CONTROL IS USED,
REMOVE LEAD 897
FROM TERM. 40 TO 53.
ALARM BELL
RELAY
COM
42
NO
BELL
60
ON
43
2
ALARM BELL OPTION
55
MANUAL
CHW FLOW SWITCH
---MANDATORY(BY OTHERS)
33
44
41
54
4-20MA FOR
EVAP. WATER RESET
(BY OTHERS)
4-20MA FOR
DEMAND LIMIT
(BY OTHERS)
49
50
51
52
TB3
COOLING TOWER BYPASS
(BY OTHERS)
78
80
LESS
EVAPORATOR
ONLY
77
79
GND
0-10 VDC
N
0-10 VDC
N
24 VAC
62
65
N
24 VAC
63
65
24 VAC
67
70
24 VAC
68
IMM WGZ-2
70
41
Figure 22, WGZ 030AA 120AA Field Wiring Diagram (Remote Condenser)
DISCONNECT
(BY OTHERS)
UNIT MAIN
TERMINAL BLOCK
GND LUG
3 PHASE
POWER
SUPPLY
TO COMPRESSOR(S)
AND FAN MOTORS
FUSED CONTROL
CIRCUIT
TRANSFORMER
OPTION
120 VAC
DISCONNECT
(BY OTHERS)
FIELD
SUPPLIED
OPTION
TB1-20
N
10A
FUSE
120VAC
TB1
CONTROL
CIRCUIT
FUSE
(BY OTHERS)
CONTROL POWER
120 VAC
11
14
CHW PUMP RELAY
(BY OTHERS)
120 VAC 1.0 AMP MAX
ALARM BELL
OPTION
120 VAC
10
ALARM BELL RELAY
TIME
CLOCK
15
AUTO
OFF
TB2
REMOTE STOP
SWITCH
(BY OTHERS)
GND
ON
40
MANUAL
AUTO
897
53
IF REMOTE STOP
CONTROL IS USED,
REMOVE LEAD 897
FROM TERM. 40 TO 53.
ALARM BELL
RELAY
42
OFF
BELL
ICE MODE
SWITCH
(BY OTHERS)
60
ON
43
NO
55
MANUAL
CHW FLOW SWITCH
33
---MANDATORY(BY OTHERS)
COM
2
ALARM BELL OPTION
44
4-20MA FOR
CHW RESET
(BY OTHERS)
4-20MA FOR
DEMAND LIMIT
(BY OTHERS)
37
49
50
38
GND
51
52
TB3
78
77
GND
0-10 VDC
N
0-10 VDC
80
COOLING TOWER BYPASS
(BY OTHERS)
79
CONTROLLER
TB3-90
FAN MOTOR #1 COIL (BY OTHERS)
120 VAC 1.0 AMP MAX.
120 VAC
J15-NO8
TB1-12
N
120 VAC
TB3-91
J16-NO9
120 VAC
NOTE: CONDENSER
FAN MOTORS CAN ALSO
BE CONTROLLED BY
PRESSURE SWITCHES
ON THE CONDENSER.
TB3-92 J16-NO10
FAN MOTOR #3 COIL (BY OTHERS)
120 VAC 1.0 AMP MAX.
120 VAC
TB3-93 J16-NO11
120 VAC
TB3-94 J18-NO13
120 VAC
TB3-95 J22-NO16
120 VAC
TB3-96 J22-NO17
120 VAC
TB3-97 J22-NO18
FAN MOTOR #8 COIL (BY OTHERS)
120 VAC 1.0 AMP MAX.
42
IMM WGZ-2
Voltage Limitations:
1. Within 10 percent of nameplate rating
2. Voltage unbalance not to exceed 2% with a resultant current unbalance of 6 to 10 times
the voltage unbalance per NEMA MG-1, 1998 Standard. This is an important restriction
that must be adhered to.
Supplemental Overloads Option -Supplemental overloads option is used to reduce the required electrical service size and wire
sizing to the water cooled version of WGZ chillers. The overloads reduce the electrical
ratings for the compressor because water-cooled duty is less severe than air cooled duty. The
overload option is only available for models with water-cooled condensers (not WGZ-AA
models with air-cooled condensers) and having single point electrical power connections.
Refer to the electrical data on pages 35, 37, and 38 for the reduced electrical requirements
IMM WGZ-2
43
Terminal Strips
S1, PS1,
PS2
Switches
Space for
Optional Circuit
Breakers and
Multi-point
Connection
(4)
Compressor
Contactors
Disconnect
Switch
Grounding Lug
NOTES:
1. Additional space provided in the upper right section for extra components required for
optional multiple point power connection and optional circuit breakers.
2. Front door has opening on top for access to the MicroTech II controller for viewing
display and making keypad entries without opening the panel door.
44
IMM WGZ-2
Pre Start-up
1. The chilled-water system should be flushed and cleaned. Proper water treatment is
required to prevent corrosion and organic growth.
2. With main disconnect open, check all electrical connections in control panel and starter to
be sure they are tight and provide good electrical contact. Although connections are
tightened at the factory, they can loosen enough in shipment to cause a malfunction.
3. Check and inspect all water piping. Make sure flow direction is correct and piping is
made to correct connection on evaporator and condenser.
4. Open all water flow valves to the condenser and evaporator.
5. Flush the cooling tower and system piping to be sure the system is clean. Start evaporator
pump and manually start condenser pump and cooling tower. Check all piping for leaks.
Vent the air from the evaporator and condenser water circuit, as well as from the entire
water system. The cooler circuit should contain clean, treated, non-corrosive water.
6. Check to see that the evaporator water thermostat sensor is securely installed.
7. Making sure control stop switch S1 is open (off) and pumpdown switches PS1 and PS2
are on manual pumpdown, place the main power and control disconnect switches to
on. This will energize the crankcase heaters. Wait a minimum of 12 hours before
starting the unit.
8. Check compressor oil level. Prior to start-up, the oil level should cover at least one-third
of the oil sight glass located in the equalizing line between the compressors or on the
compressor.
9. Check water pressure drop across evaporator and condenser, and see that water flow is
correct (on pages 15 and 16) per the design flow rates.
10. Check the actual line voltage to the unit to make sure it is the same as called for on the
compressor nameplate, within + 10%, and that phase voltage unbalance does not exceed
3%. Verify that adequate power supply and capacity is available to handle load.
11. Make sure all wiring and fuses are of the proper size. Also make sure that all interlock
wiring is completed per McQuay diagrams.
12. Verify that all mechanical and electrical inspections by code authorities have been
completed.
13. Make sure all auxiliary load and control equipment is operative and that an adequate
cooling load is available for initial start-up.
Start-up
1. Open the compressor discharge shutoff valves until backseated. Always replace valve seal
caps.
2. Open the two manual liquid line shutoff valves.
3. Check to see that the unit circuit breakers are in the off position.
4. Check to see that the pumpdown switches, PS1 and PS2, are in the manual pumpdown
position and the control system switch S1 is in the off position.
5. Put the main power and control circuit disconnects to the on position.
IMM WGZ-2
45
6. Verify crankcase heaters have operated for at least 12 hours prior to start-up. Crankcase
should be warm to the touch.
7. Check that the MicroTech II controller is set to the desired chilled water temperature.
8. Start the system auxiliary equipment for the installation by turning on the time clock,
ambient thermostat and/or remote on/off switch and water pumps.
9. Check resets of all equipment protection controls.
10. Switch on the unit circuit breakers.
11. Set pumpdown switches PS1 and PS2 to auto for restart and normal operation.
12. Start the system by setting the system switch S1 to on.
13. After running the unit for a short time, check the oil level in each compressor crankcase,
rotation of condenser fans (if any), and check for flashing in the refrigerant sight glass.
14. After system performance has stabilized, it is necessary that the Compressorized
Equipment Warranty Form (Form No. 206036A) be completed to establish
commencement of the warranty period. Be sure to list the pressure drop across both
vessels. This form is shipped with the unit and after completion should be returned to the
McQuayService Department through your sales representative.
Extended Shutdown
1.
2.
3.
4.
5.
46
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47
System Maintenance
General
To provide smooth operation at peak capacity and to avoid damage to package components, a
program of periodic inspections should be set up and followed. The following items are
intended as a guide to be used during inspection and must be combined with sound
refrigeration and electrical practices to provide trouble-free performance.
The liquid line sight glass/moisture indicator on all circuits must be checked to be sure that the
glass is full and clear and that the moisture indicator indicates a dry condition. If the indicator
shows that a wet condition exists or if bubbles show in the glass, even with a full refrigerant
charge, the filter-drier element must be changed.
Water supplies in some areas can tend to foul the water-cooled condenser to the point where
cleaning is necessary. The fouled condenser will be indicated by an abnormally high
condenser approach temperature (saturated discharge temperature minus leaving condenser
water temperature) and can result in nuisance trip-outs. To clean the condenser, mechanical
cleaning or a chemical descaling solution should be used according to the manufacturers
directions.
Systems with remote air-cooled condensers require periodic cleaning of the finned surface of
the condenser coil.
Cleaning can be accomplished by using a cold water spray, brushing, vacuuming, or highpressure air. No tools should be used that could damage the coil tubes or fins.
The compressor oil level must be checked periodically to be sure that the level is at the center
of the oil sightglass located in the compressor's equalizing line or on the compressor itself.
Low oil level can cause inadequate lubrication and if oil must be added, use oils referred to in
the following Compressor Lubrication section.
A pressure tap has been provided on the liquid line downstream of the filter-drier and solenoid
valve but before the expansion valve. An accurate subcooled liquid pressure and temperature
can be taken here. The pressure read here could also provide an indication of excessive
pressure drop through the filter-drier and solenoid valve due to a clogging filter-drier. Note: A
normal pressure drop through the solenoid valve is approximately 3 psig (20.7 kPa) at full
load conditions.
CAUTION
Warranty may be affected if wiring is not in accordance with specifications. A
blown fuse or tripped protector indicates a short ground or overload. Before
replacing fuse or restarting compressor, the trouble must be found and
corrected. It is important to have a qualified control panel electrician service
this panel. Unqualified tampering with the controls can cause serious damage
to equipment and void the warranty.
48
IMM WGZ-2
DANGER
The panel is always energized to ground even when the system switch is off.
To de-energize the complete panel including crankcase heaters, pull the main
unit disconnect. Failure to do so can result in severe personal injury or death.
If motor or compressor damage is suspected, do not restart until qualified service personnel
have checked the unit.
Electrical Terminals
WARNING
To avoid injury from electric shock hazard, turn off all power and perform
lockout and tag-out of source before continuing with the following service.
Note that the unit might be powered from multiple sources.
All power electrical terminals should be re-tightened every six months, as they tend to loosen
due to normal heating and cooling of the wire.
Compressor Lubrication
The oil level should be watched carefully upon initial start-up and regularly thereafter.
All tandem compressors on WGZ units come equipped with one or two oil equalization lines
connecting the crankcase of each set of compressors in each refrigerant circuit. This allows
the oil to move from one compressor crankcase to the other during normal operation, and
balance between the two when the compressors are off. The oil sight glass is located in the
equalization line on one circuit of the WGZ 070 and both circuits of WGZ 080 through WGZ
100. All other models have the oil sight glass in the compressor body. In either case, the oil
level should be 1/4 to 1/3 of the glass.
At the present time, standard refrigerant mineral oils such as Suniso No. 3GS, Calumet R015,
and Texaco WF32 oils are approved by Copeland for use in these compressors.
Oil can be added to the Copeland compressor through the oil fill hole in the crankcase.
Special equipment is required to add oil and the work should be done by qualified
refrigeration technicians with the proper training and equipment.
Bubbling refrigerant in the sight glass may occur at other conditions and may indicate that the
system is short of refrigerant charge. Refrigerant gas flashing in the sight glass could also
indicate an excessive pressure drop in the line, possibly due to a clogged filter-drier or a
restriction elsewhere in the system. An element inside the sight glass indicates what moisture
condition corresponds to a given element color. If the sight glass does not indicate a dry
IMM WGZ-2
49
condition after about 12 hours of operation, the unit should be pumped down and the filterdriers changed.
If the system is suspected of being short of refrigerant, a qualified service technician with EPA
certification should be contacted to thoroughly check out the unit and add refrigerant if
necessary.
Crankcase Heaters
The compressors are equipped with crankcase heaters. The function of the heater is to keep
the temperature in the crankcase high enough to prevent refrigerant from migrating to the
crankcase and condensing in the oil during off-cycle. When a system is to be started up
initially, the power to the heaters should be turned on for at least 12 hours before the
compressors are started. The crankcase should be up to about 80F (26.7C) before the system
is started up, to minimize lubrication problems or liquid slugging of compressor on start-up.
If the crankcase is cool (below 80F) (26.7C) and the oil level in the sight glass is full to top,
allow more time for oil to warm before starting the compressor.
The crankcase heaters are on whenever power is supplied to the unit and the compressor is not
running.
Optional Controls
Phase/Voltage Monitor (Optional)
The phase/voltage monitor is a device that provides protection against three-phase electrical
motor loss due to power failure conditions, phase loss, and phase reversal. Whenever any of
these conditions occur, an input relay is deactivated, disconnecting power to the thermostatic
control circuit. The compressor do a rapid shutdown pump down.
The input relay remains deactivated until power line conditions return to an acceptable level.
Trip and reset delays have been provided to prevent nuisance tripping due to rapid power
fluctuations.
When three-phase power has been applied, the input relay should close and the run light
should come on. If the relay does not close, perform the following tests.
1. Check the voltages between L1-L2, L1-L3, and L2-L3. These voltages should be
approximately equal and within +10% of the rated three-phase line-to-line voltage.
2. If these voltages are extremely low or widely unbalanced, check the power system to
determine the cause of the problem.
3. If the voltages are good, turn off the power and inter-change any two of the supply power
leads at the disconnect switch.
This may be necessary, as the phase/voltage monitor is sensitive to phase reversal. Turn on the
power. The relay should now close after the appropriate delay.
Factory settings are as follows:
Voltage Setting, set at nameplate voltage.
Trip Delay Time, 2 seconds
Restart Delay Time, 60 seconds
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51
Maintenance Schedule
I. Compressor
A. Performance Evaluation (Log & Analysis) *
B. Motor
Meg. Windings
Ampere Balance (within 10%)
Terminal Check (tight connections, porcelain clean)
Motor Cooling (check temperature)
C. Lubrication System
Oil Level
Oil Appearance (clear color, quantity)
Oil change if indicated by oil analysis
II. Controls
A. Operating Controls
Check Settings and Operation
B. Protective Controls
Test Operation of:
Alarm Relay
Pump Interlocks
High and Low Pressure Cutouts
III. Condenser
B. Test Water Quality
C. Clean Condenser Tubes (or as required)
D. Eddycurrent Test - Tube Wall Thickness
E. Seasonal Protection
IV. Evaporator
B. Test Water Quality
C. Clean Evaporator Tubes (or as required)
D. Eddycurrent Test - Tube Wall thickness (or as required)
E. Seasonal Protection
V. Expansion Valves
A. Performance Evaluation (Superheat Control)
VI. Compressor - Chiller Unit
A. Performance Evaluation
B. Leak Test:
Compressor Fittings and Terminal
Piping Fittings
Vessel Relief Valves
C. Vibration Isolation Test
D. General Appearance:
Paint
Insulation
VII. Starter(s)
A. Examine Contactors (hardware and operation)
B. Verify Overload Setting and Trip
C. Test Electrical Connections
VIII. Optional Controls
A. Hot Gas Bypass (verify operation)
52
O
X
X
X
X
O
O
X
X
X
X
X
X
X
X
X
X
X
X
X
X
O
X
X
X
X
X
X
X
X
X
X
IMM WGZ-2
System Service
DANGER
Service on this equipment is to be performed only by qualified refrigeration
personnel. Causes for repeated tripping of equipment protection controls must
be investigated and corrected. Disconnect all power before doing any service
inside the unit or serious personal injury or death can occur.
NOTE: Anyone servicing this equipment must comply with the requirements set forth
by the EPA concerning refrigerant reclamation and venting.
Filter-Driers
To change the filter-drier, pump the unit down (with the compressor running) by closing the
manual liquid line shutoff valve(s). The unit will start pumping down until it reaches the lowpressure cutoff setting of 58 psi.
Close the discharge valve. Remove the refrigerant in the liquid line with a recovery unit to
EPA required pressure. Remove and replace the filter-drier(s). Evacuate the lines through the
liquid line manual shutoff valve(s) to remove noncondensables that may have entered during
filter replacement. A leak check is recommend before returning the unit to operation.
Unit Arrangement
Water-Cooled
Water-Cooled
Remote Condenser
Unit Size
030 - 060
070 - 120
All
Type Filter-Drier
Sealed/Brazed
2-core Replaceable
2-core Replaceable
IMM WGZ-2
53
To increase the superheat setting of the valve, remove the cap at the bottom of the valve to
expose the adjustment screw. Turn the screw clockwise (when viewed from the adjustment
screw end) to increase the superheat and counterclockwise to reduce superheat. Allow time
for system rebalance after each superheat adjustment.
The expansion valve, like the solenoid valve, should not normally require replacement, but if
it does, the unit must be pumped down by following the steps involved when changing a filterdrier.
If the problem can be traced to the power element only, it can be unscrewed from the valve
body without removing the valve, but only after pumping the unit down.
Figure 24, Thermostatic Expansion Valve
CAUTION
Adjustment of expansion valve should only be performed by a qualified service
technician. Failure to do so can result in improper unit operation.
Note: Superheat will vary with compressor unloading, but should be approximately as
follows: between 8F and 12F (4.4C and 6.7C) at full load; between 6F and 10F at part
load.
Water-cooled Condenser
The condenser is of the shell-and-tube type with water flowing through the tubes and
refrigerant in the shell. External finned copper tubes are rolled into steel tube sheets and to the
center dividing tube sheet. Integral subcoolers are incorporated on all units. All condensers
are equipped with 450 psig (3104 kPa) relief valves. Normal tube cleaning procedures can be
followed.
Evaporator
The evaporator is a sealed, brazed-stainless steel plate unit. Normally no service work is
required on the evaporator.
54
IMM WGZ-2
Troubleshooting Chart
PROBLEM
1.
2.
3.
Compressor Will
Not Run
Compressor
Noisy or Vibrating
3.
6.
7.
8.
No cooling required.
Liquid line solenoid will not open.
Motor electrical trouble.
6.
7.
8.
9.
Loose wiring.
9.
1.
1.
2.
2.
2.
3.
4.
5.
6.
3.
4.
5.
6.
7.
7.
1.
2.
3.
1.
2.
3.
4.
4.
5.
5.
1.
Excessive load.
1.
2.
1.
2.
3.
4.
2.
1.
2.
3.
4.
5.
6.
6.
7.
7.
8.
1.
2.
8.
1.
2.
3.
4.
3.
4.
4.
5.
2.
Low Discharge
Pressure
High Suction
Pressure
Low Suction
Pressure
1.
2.
3.
1.
High Discharge
Pressure
POSSIBLE CAUSES
Main switch, circuit breakers open.
Fuse blown.
4.
5.
3.
1.
5.
Little or No Oil
Pressure
IMM WGZ-2
55
PROBLEM
Compressor
Loses Oil
Motor Overload
Relays or Circuit
Breakers Open
Compressor
Thermal Switch
Open
Freeze Protection
Opens
1.
POSSIBLE CAUSES
Lack of refrigerant.
1.
2.
3.
2.
3.
1.
1.
2.
2.
5.
5.
6.
6.
1.
2.
1.
2.
3.
2.
1.
2.
3.
3.
4.
3.
4.
1.
Warranty Statement
Limited Warranty
Consult your local McQuay Representative for warranty details. Refer to Form 933-43285Y.
To find your local McQuay Representative, go to www.mcquay.com.
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57
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This document contains the most current product information as of this printing. For the most up-todate product information, please go to www.mcquay.com.
Post Office 2510, Staunton, Virginia 24402 USA (800) 432-1342 www.mcquay.com