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Installation, and Maintenance Manual IMM WGZC
Group: Chiller
Part Number: 331975201
Effective: February 2010
Supercedes: April 2009
Water-Cooled Scroll Compressor Chillers
WGZ 030CW to WGZ 200CW, Packaged Water-Cooled Chiller
WGZ 030CA to WGZ 200CA, Chiller with Remote Condenser
30 to 200 Tons, 105 to 700 kW
60 Hz, R-410A
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2 WGZ 030C through 200C IMM WGZC
Table of Contents
Introduction ....................................... 3Nomenclature ........................................ 3
Installation ......................................... 4Vibration Isolators................................. 6
Limitations of Operation ................ 11
Water Piping .................................... 12Flow Switch ........................................ 15Glycol Solutions.................................. 15Condenser Water Piping...................... 17
Pressure Drops................................. 17
Refrigerant Piping........................... 20Unit with Remote Condenser .............. 20Factory-Mounted Condenser............... 25
Dimensions ....................................... 26
Packaged Chillers................................ 26Chillers with Remote Condenser......... 29
Physical Data.................................... 32Packaged Chillers................................ 32Chillers with Remote Condenser......... 35Operating Limits ................................. 36Components ........................................ 37
Wiring............................................... 38
Unit Configuration .......................... 39
Electrical Data ................................. 40
Electrical Notes ................................... 53Field Wiring Diagram ......................... 55Control Panel Layout .......................... 57Motor Protection Module.................... 57
Start-Up and Shutdown..................58Pre Start-up.......................................... 58Start-up................................................ 58Weekend or Temporary Shutdown...... 59Start-up after Temporary Shutdown.... 59Extended Shutdown ............................ 59Start-up after Extended Shutdown ...... 60
System Maintenance .......................61General................................................ 61Electrical Terminals............................. 62Compressor Lubrication...................... 62Sightglass and Moisture Indicator....... 62Crankcase Heaters............................... 63Optional Controls................................ 63Phase/Voltage Monitor (Optional) ...... 63Hot Gas Bypass (Optional) ................. 64
Maintenance Schedule....................65
System Service.................................66Troubleshooting Chart ........................ 68
Warranty Statement .......................69
Manufactured in an ISO Certified facility
Cover Picture: WGZ 200C, Nominal 200 ton chiller
2009 McQuay International. Illustrations and data cover the McQuay International product at the time of publication and we reserve the right to
make changes in design and construction at anytime without notice. The following are trademarks or registered trademarks of their respective
companies: BACnet from ASHRAE; LONMARK, LonTalk, LONWORKS, and the LONMARK logo are managed, granted and used by LONMARK
International under a license granted by Echelon Corporation; Compliant Scroll from Copeland Corporation; ElectroFin from AST ElectroFin Inc.;
Modbus from Schneider Electric; FanTrol, MicroTech II, Open Choices, and SpeedTrol from McQuay International
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IMM WGZC WGZ 030C through 200C 3
Introduction
General Description
McQuay Type WGZ water chillers are designed for indoor installations and are available with
water-cooled condensers (Model WGZ-CW), or arranged for use with remote, air-cooled or
evaporative condensers (Model WGZ-CA). Each water-cooled unit is completely assembled andfactory wired before evacuation, charging and testing. They consist of hermetic scroll
compressors, brazed-plate evaporators on Models WGZ 030 to 130( shell-and-tube on Models
WGZ 150 to 200), water-cooled condenser (WGZ-CW), and complete refrigerant piping.
Units manufactured for use with remote condensers (Models WGZ-CA) 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 expansion valves.
Other features include compressor crankcase heaters, and a MicroTech IImicroprocessor
controller.
The electrical control center includes all equipment protection and operating controls necessaryfor 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 - C W
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 lifting weights are given in the physical data tables beginning on page 5.Corner operating weights are given on page 7
Water-Cooled
Global
Scroll Compressor Nominal Capacity (Tons)
W = Water-Cooled Condenser
A = Unit Less Condenser
Design Vintage
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4 WGZ 030C through 200C IMM WGZC
Installation
Note: Installation and maintenance are to be performed only by qualified personnelwho are familiar with local codes and regulations, and experienced with this type ofequipment.
! WARNING
Avoid contact with sharp edges. Personal injury can result
Handling
Every model WGZ-CW 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 of nitrogen/helium is supplied in remote condenser models, WGZ-CA and
must be removed prior to charging with refrigerant. The operating charge must be field
supplied and charged.
Moving the Unit The packaged unit skid option is strongly recommended for ease ofhandling and to help prevent damage if a crane is not available for rigging at site.Properly
designed field supplied skids or dollies are acceptable. Do not push unit along a floor without
them. The condenserless models (AGZ-CA) are manufactured with a base suitable for movingwith rollers.
Figure 1, Lifting the Unit
! WARNING
If the unit has been damaged, allowing the refrigerant to escape, there can be danger of suffocation in the area since refrigerant will displace the air. Be sure to review Environmental Protection Agency (EPA) requirements if damage occu
Avoid exposing an open flame to the refrigerant
331926901 REV. 0A
WGZ150-200CUNIT SHOWN
SPREADER BARS MUSTBE USED FOR STABILITY
DURING LIFTING OFALL SIZE UNITS
RemovableLiftingBar
(2) 2
LiftingHoles
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IMM WGZC WGZ 030C through 200C 5
All moving and handling of packaged units (illustrated above) must be performed with skids
or dollies under the unit and they should not be removed until the unit is in the final location.
Never put the weight of the unit against the control box.
All moving and handling of packaged units (illustrated above) must be performed with skids
or dollies under the unit and they should not be removed until the unit is in the final location.
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 othercomponents. 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 notattempt 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
WGZ-CW Package Units (lbs.) WGZ CA Less Condenser Units (lbs)ModelWGZ-C L1 L2 L3 L4
ShippingWeight
L1 L2 L3 L4ShippingWeight
WGZ 030 606 633 599 573 2410 415 430 374 361 1580
WGZ 035 632 646 616 603 2496 442 445 392 390 1670
WGZ 040 639 659 630 611 2539 443 451 399 392 1685
WGZ 045 639 667 639 612 2558 444 460 407 393 1704
WGZ 050 655 689 664 631 2639 451 468 416 400 1735
WGZ 055 655 698 673 632 2658 451 476 425 402 1754
WGZ 060 655 712 688 633 2688 451 484 433 404 1771
WGZ 070 929 874 942 1001 3746 649 595 556 606 2406
WGZ 080 1066 927 1001 1151 4145 765 635 598 720 2717
WGZ 090 1076 849 1059 1343 4327 806 653 623 770 2851
WGZ 100 1059 781 1118 1515 4474 829 681 657 801 2968
WGZ 115 1054 802 1146 1506 4508 830 710 689 805 3035
WGZ 130 1055 828 1181 1505 4568 831 737 716 807 3091
WGZ 150 1684 1516 1602 1780 6581 1204 1142 1184 1249 4779
WGZ 175 1814 1528 1637 1943 6921 1245 1149 1198 1299 4891
WGZ200 1829 1550 1677 1979 7036 1265 1178 1235 1326 5004
See Figure 2on the following page for location of lifting points.
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 toplace 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.
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Control Panel
WaterConnections
4
1
3
2
LB
LF
RB
FRF
Space Requirements for Connections and Servicing
The chilled water and condenser water (on units with a water-cooled condenser) piping
enters and leaves the unit from the right side when looking at the control panel. Left-hand
condenser connections are an option. A clearance of at least 3 feet (1219 mm), or more if
codes require, should be provided beyond this piping and on all other sides and ends of
the unit for general servicing or for changing the compressors, if it ever becomes
necessary.
On units equipped with a water-cooled condenser (Type WGZ-CW) 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 opening.
Allow a minimum of 4-foot clearance in front of the control panel.
Placing the UnitThe small amount of vibration normally encountered with the water chiller makes this
unit particularly desirable for basement or ground floor installations where the unit can be
mounted directly to the floor. The floor construction should be such that the unit will not
affect the building structure, or transmit noise and vibration into the structure. NOTE:Springs are Model CP1E, one spring per housing.
Vibration IsolatorsIt is recommended that isolators be used on all upper level installations or in areas where
vibration transmission is a consideration.
Figure 2, Isolator Locations
Transfer the unit as indicated
under Moving the Unit. In all
cases, set the unit in place and
level with a spirit level. When
spring-type isolators are
required, install springs runningunder the main unit supports.
The unit should be set initially
on shims or blocks at the listed
spring free height. When all piping, wiring, flushing, charging, etc., is completed, the
springs are adjusted upward to loosen the blocks or shims that are then removed.
A rubber anti-skid pad should be used under isolators if hold-down bolts are not used.
Installation of spring isolators requires flexible piping connections and at least three feet of
flexible electrical conduit to avoid straining piping and transmitting vibration and noise.
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IMM WGZC WGZ 030C through 200C 7
Table 2, WGZ-CW Packaged, Mounting Weights & Vibration Mounting Location
Unit Mounting Weights, Lbs (kg) Spring-Flex Mountings R-I-S Mountings
Size M1 M2 M3 M4 M1 M2 M3 M4 M1 M2 M3 M4
ID-900 ID-900 ID-900 ID-900 RP-3 RP-3 RP-3 RP-3030 625 653 618 591
Green Green Green Green Gray Gray Gray Gray
ID-900 ID-900 ID-900 ID-900 RP-3 RP-3 RP-3 RP-3035 651 665 635 621
Green Green Green Green Gray Gray Gray Gray
ID-900 ID-900 ID-900 ID-900 RP-3 RP-3 RP-3 RP-3040 662 683 653 633
Green Green Green Green Gray Gray Gray Gray
ID-900 ID-900 ID-900 ID-900 RP-3 RP-3 RP-3 RP-3045 662 691 662 634
Green Green Green Green Gray Gray Gray Gray
ID-900 ID-900 ID-900 ID-900 RP-3 RP-3 RP-3 RP-3050 683 718 692 659
Green Green Green Green Gray Gray Gray Gray
ID-900 ID-900 ID-900 ID-900 RP-3 RP-3 RP-3 RP-3055 683 727 702 659
Green Green Green Green Gray Gray Gray Gray
ID-900 ID-900 ID-900 ID-900 RP-3 RP-3 RP-3 RP-3060 682 742 717 660
Green Green Green Green Gray Gray Gray Gray
ID-1350 ID-1350 ID-1350 ID-1350 RP-4 RP-4 RP-4 RP-4070 964 907 978 1038Purple Purple Purple Purple Brown Brown Brown Brown
ID-1350 ID-1350 ID-1350 ID-1350 RP-4 RP-4 RP-4 RP-4080 1106 962 1039 1195
Purple Purple Purple Purple Brown Brown Brown Brown
ID-1800 ID-1800 ID-1800 ID-1800 RP-4 RP-4 RP-4 RP-4090 1121 884 1103 1399
Green Green Green Green Brown Brown Brown Brown
ID-1800 ID-1800 ID-1800 ID-2400 RP-4 RP-4 RP-4 RP-4100 1108 817 1169 1585
Green Green Green Gray Brick Red Brick Red Brick Red Brick Red
ID-1800 ID-1800 ID-1800 ID-2400 RP-4 RP-4 RP-4 RP-4115 1102 839 1198 1574
Green Green Green Gray Brick Red Brick Red Brick Red Brick Red
ID-1800 ID-1800 ID-1800 ID-2400 RP-4 RP-4 RP-4 RP-4130 1102 865 1234 1572
Green Green Green Gray Brick Red Brick Red Brick Red Brick Red
ID-2400 ID-2400 ID-2400 ID-2400 RP-4 RP-4 RP-4 RP-4150 1886 1690 1794 1993
Gray Gray Gray Gray Brick Red Brick Red Brick Red Brick Red
ID-2400 ID-2400 ID-2400 ID-2400 RP-4 RP-4 RP-4 RP-4170 2033 1710 1835 2178
Gray Gray Gray Gray Brick Red Brick Red Brick Red Brick Red
ID-2400 ID-2400 ID-2400 ID-2400 RP-4 RP-4 RP-4 RP-4200 2047 1730 1877 2215
Gray Gray Gray Gray Brick Red Brick Red- Brick Red Brick Red WR
NOTES:
1. ID 900 has one spring per housing.
2. ID 1350, ID 1800, ID 2400 have two springs per housing.
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Table 3, WGZ-CA, Remote Condenser, Mounting Weights & Vibration Mounting Location
Unit Mounting Weights, Lbs Spring-Flex Mountings R-I-S Mountings
Size M1 M2 M3 M4 M5 M6 M1 M2 M3 M4 M5 M6 M1 M2 M3 M4 M5
ID-900 ID-900 ID-510 ID-510 RP-3 RP-3 RP-3 RP-3030 476 501 322 307 N/A N/A
Green Green Black BlackN/A N/A
Lime Lime Lime LimeN/A
ID-900 ID-900 ID-510 ID-510 RP-3 RP-3 RP-3 RP-3035 511 516 337 334 N/A N/A
Green Green Black Black
N/A N/A
Lime
Lime
Lime
Lime
N/A
ID-900 ID-900 ID-510 ID-510 RP-3 RP-3 RP-3 RP-3040 511 525 344 335 N/A N/A
Green Green Black BlackN/A N/A
Lime Lime Lime LimeN/A
ID-900 ID-900 ID-510 ID-510 RP-3 RP-3 RP-3 RP-3045 512 538 353 336 N/A N/A
Green Green Black BlackN/A N/A
Lime Lime Lime LimeN/A
ID-900 ID-900 ID-510 ID-510 RP-3 RP-3 RP-3 RP-3050 520 549 362 342 N/A N/A
Green Green Black BlackN/A N/A
Lime Lime Lime LimeN/A
ID-900 ID-900 ID-510 ID-510 RP-3 RP-3 RP-3 RP-3055 519 561 371 343 N/A N/A
Green Green Black BlackN/A N/A
Lime Lime Lime LimeN/A
ID-900 ID-900 ID-510 ID-510 RP-3 RP-3 RP-3 RP-3060 519 574 380 344 N/A N/A
Green Green Black BlackN/A N/A
Lime Lime Lime LimeN/A
ID-900 ID-900 ID-675 ID-900 RP3 RP3 RP3 RP3
070 738 651 509 577 N/A N/A Green Green Purple Green N/A N/A Gray Gray Gray Gray N/A
ID-900 ID-900 ID-675 ID-900 RP-3 RP-3 RP-3 RP-3080 884 675 532 697 N/A N/A
Green Green Purple GreenN/A N/A
Gray Gray Gray GrayN/A
ID-1020 ID-1020 ID-680 ID-1020 RP-3 RP-3 RP-3 RP-3090 937 690 552 749 N/A N/A
Black Black Red BlackN/A N/A
Gray Gray Gray GrayN/A
ID-1020 ID-1020 ID-680 ID-1020 RP-3 RP-3 RP-3 RP-3100 963 724 585 778 N/A N/A
Black Black Red BlackN/A N/A
Gray Gray Gray GrayN/A
ID-1020 ID-1020 ID-680 ID-1020 RP-3 RP-3 RP-3 RP-3115 957. 764 621 778 N/A N/A
Black Black Red BlackN/A N/A
Gray Gray Gray GrayN/A
ID-1020 ID-1020 ID-680 ID-1020 RP-3 RP-3 RP-3 RP-3130 956 804 655 779 N/A N/A
Black Black Red BlackN/A N/A
Gray Gray Gray GrayN/A
ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 RP-4 RP-4 RP-4 RP-4 RP-4 150 821 793 763 931 968 1003Black Black Black Black Black Black Brown Brown Brown Brown Brown B
ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 RP-4 RP-4 RP-4 RP-4 RP-4 170 863 812 750 919 986 1047
Black Black Black Black Black Black Brown Brown Brown Brown Brown B
ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 RP-4 RP-4 RP-4 RP-4 RP-4 200 875 831 784 947 1000 1057
Black Black Black Black Black Black Brown Brown Brown Brown Brown B
NOTES:
1. ID 510, ID 675 and ID 900 have one spring per housing.
2. ID 680 and ID 1020 have two springs per housing.
Table 4, WGZ-CW, Packaged, Isolator Kit Numbers
Model Number 030-060 070-080 090 100-130 150-200Spring-Flex 332320501 332320502 332320503 332320504 332320505
R-I-S 332325501 332325502 332325502 332325503 332325503
Table 5, WGZ-CA, Remote Condenser, Isolator Kit Numbers
Model Number 030-060 070-080 090-115 130 150-200
Spring-Flex 332320506 332320507 332320508 332320509 332320510
R-I-S 332325504 332325501 332325501 332325501 332325505
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Figure 3, Spring Flex Mounting. Two-Spring
Figure 4, Neoprene-in-Shear Mounting, RP-3
DRAWING NUMBER 3319880
2.50
1.75 (R)
.25
MOUNTING MOLDED INDURULENE. WEATHERRESISTANT (WR)
3.38
4.13
5.50
.5 DIA.2 HOLES
1/2-13 TAP
LOCATING PIN TOBE INSTALLED HERE
ALL
DIMENSIONS ARE IN DECIMAL INCHES
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Table 6, Spring Flex Mounting, One-Spring
Table 7, Neoprene-in-Shear, RP-4
NOTES:
MOUNT MATERIAL TO BE DURULENE RUBBER.1.
MOLDED STEEL AND ELASTOMER MOUNT FOR.OUTDOOR SERVICE CONDITIONS.
. RP-4 MOUNT VERSION WITH STUD IN PLACE.
ALL DIMENSIONS ARE IN DECIMAL INCHES
DRAWING NUMBER 3314814
1.13 .25APPROX.
1.63
.38
DURULENEMATERIAL
RAISED GRIP RIBS
3.00
3.75
5.00
6.25
3.87
.56 TYP.
4.63
R.28TYP.
R.250 TYP.
R.750 TYP.RECESSEDGRIP RIBS
.500-13NC-2B
R4
R4
VM&C
VM&C
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Limitations of Operation
1. Maximum allowable condenser water pressure is 232 psig (1599 kPa).
2. Maximum condenser LWT is 115F (46.1C).
3. Maximum design saturated discharge temperature (SDT) is 140F (60C). SDT=Condensingtemperature + discharge line loss.
4. Maximum condenser leaving water temperature is 115F (41.6C).
5. Maximum allowable water temperature to evaporator when not operating is 100F (37.8C).
Maximum entering water temperature for operating cycle is 90F (32.2C) (during system
changeover from heating to cooling cycle).
6. Minimum design leaving water temperature from the evaporator without anti-freeze protection is
40F (4.4C).
7. Contact your McQuay representative for operation with tower condenser water entering the chiller
below 60F (15.6C).
8. The maximum altitude for air-cooled condensers is 8,000 feet.9. Consult factory for ambient operation below 0F (-17.8C) for air-cooled applications.
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Water Piping
Vessel Drains at Start-upCondensers are drained of water in the factory and are shipped with the 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.
GeneralDue 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 anystrain 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 atthe lowest points in the system.
5. Some means of maintaining adequate system water pressure (e.g., expansion tank or regulatingvalve).
6. Temperature and pressure indicators located within 3 feet (0.9 meters) of the inlet and outlet ofthe vessels to aid in unit servicing.
7. A strainer or some means of removing foreign matter from the water before it enters the pump isrecommended. 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 NoteA cleanable 40-mesh strainer must also be placed in the water line just prior to the inletof the evaporator on Models WGZ 030 to 130. A 20-mesh is satisfactory on Models WGZ150 to 200. This will aid in preventing foreign material from entering and decreasing theperformance of the evaporator.
8. If the unit is used as a replacement chiller on a previously existing piping system, the systemshould 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 propyleneglycol 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.
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IMM WGZC WGZ 030C through 200C 13
Note: A water flow switch or pressure differential switch must be mounted in theevaporator outlet water line to signal that there is water flow before the unit will start.
Table 8, Typical Field Evaporator Water Piping, WGZ 030 to 130AirVent
FlowSwitch
VibrationEliminators
Drain
Outlet
Inlet
PIsolationValves
Strainer
NOTE: Water piping must be supported independently from the unit.
Figure 5, Typical Field Evaporator Water Piping, WGZ 150 to 200
Vent
Drain
GateValve
WaterStrainer
VibrationEliminatorValved
PressureGauge
In
OutProtect All Field Piping
Against Freezing
Flow
VibrationEliminator
FlowSwitch
BalancingValve
GateValve
Flow
Liquid
Suction
NOTE: Inlet and outlet connections may be reversed on some units. Check unit
dimension drawing.
System Water VolumeIt is important to have adequate water volume in the system to provide an opportunity for the chiller
to sense a load change, adjust to the change, and then stabilize. As the expected load change
becomes more rapid, a greater water volume is needed. The system water volume is the total
amount of water in the evaporator, air handling equipment, and associated piping. If the water
volume is too low, operational problems can occur including rapid compressor cycling, rapid
loading and unloading of compressors, erratic refrigerant flow in the chiller, improper motor
cooling, shortened equipment life and other undesirable occurrences.
For normal comfort cooling applications where the cooling load changes relatively slowly, a
minimum system volume of two to three minutes times the flow rate (GPM) is recommended. For
example, if the design chiller flow rate is 120 gpm, we recommend a system volume of 240 to 360
gallons.
For process applications where the cooling load can change rapidly, additional system water
volume is needed. A process example would be the quenching of hot metal objects. The load would
be very stable until the hot metal is dipped into the water tank. Then, the load would increase
drastically.
Since there are many other factors that can influence performance, systems can successfully operate
below these suggestions. However, as the water volume decreases below these guidelines, the
possibility of problems increases.
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Suction
Circuit #1SuctionCircuit #2
LiquidCircuit #2
LiquidCircuit #1
Leaving ChilledWater Sensor
Variable Chilled Water FlowReducing chilled water flow in proportion to load can reduce total system power consumption.
Certain restrictions apply to the amount and rate of flow change. The rate of flow change should
be a maximum of 10 percent of the change, per minute. Do not reduce flow lower than the part
load minimum flows listed on page 17.
Chilled Water PipingThe system water piping must be flushed thoroughly prior to making connections to the unit
evaporator. It is required that a 40-mesh strainer be installed in the return water line before the
inlet to the chiller. Lay out the water piping so the chilled water circulating pump discharges into
the evaporator inlet.
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 beginning on page 18. 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 forthe 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.
Figure 6 Thermostat Well Location, WGZ 030 - 130
The chilled water sensor is factory installed in the leaving water
connection on the evaporator. Care should be taken not to damage
the sensor cable or lead wires when working around the unit. It isalso advisable to check the lead wire before running the unit to be
sure that it is firmly anchored and not rubbing on the frame or any
other component. If the sensor is ever removed from the well for
servicing, care must be taken to not wipe off the heat-conducting
compound supplied in the well.
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IMM WGZC WGZ 030C through 200C 15
! CAUTION
The thermostat bulb should not be exposed to water temperatures above 125F (51.7C)since this will damage it.
Flow SwitchA water flow switch must be mounted in the leaving evaporator and condenser water lines 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.
Factory-mounted and wired evaporator and condenser flow switches are available as an option
If the optional factory flow switch is not supplied, 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 flow rates are required to open the switch and are listed
in Table 9. Wire from switch terminals Y and R to panel terminals 33 and 43 (chilled water) and
41 and 53 (condenser water). 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 thepipe diameter without any valves, elbows, or other flow restricting elements.
! CAUTION
Make sure the arrow on the side of the switch is pointed in the direction of flow. The flowswitch is designed to handle the control voltage and should be connected according to thewiring diagram
Table 9, Paddle-Type Flow Switch Flow Rates
inch 1 1/4 1 1/2 2 2 1/2 3 4 5 6 8Pipe SizeNOTES (x) mm 32 (2) 38 (2) 51 63 (3) 76 102 (4) 127 (4) 153 (4) 204 (5)
gpm 5.8 7.5 13.7 18.0 27.5 65.0 125.0 190.0 205.0Flow
Lpm 1.3 1.7 3.1 4.1 6.2 14.8 28.4 43.2 46.6
gpm 3.7 5.0 9.5 12.5 19.0 50.0 101.0 158.0 170.0
Min.
Adjst. NoFlow Lpm 0.8 1.1 2.2 2.8 4.3 11.4 22.9 35.9 38.6
gpm 13.3 19.2 29.0 34.5 53.0 128.0 245.0 375.0 415.0Flow
Lpm 3.0 4.4 6.6 7.8 12.0 29.1 55.6 85.2 94.3
gpm 12.5 18.0 27.0 32.0 50.0 122.0 235.0 360.0 400.0
Max.
Adjst. No
Flow Lpm 2.8 4.1 6.1 7.3 11.4 27.7 53.4 81.8 90.8
NOTES:
1. A segmented 3-inch paddle (1, 2, and 3 inches) is furnished mounted, plus a 6-inch paddle loose.
2. Flow rates for a 2-inch paddle trimmed to fit the pipe.
3. Flow rates for a 3-inch paddle trimmed to fit the pipe.
4. Flow rates for a 3-inch paddle.
5. Flow rates for a 6-inch paddle.
Glycol Solutions
Chiller capacity, flow rate, evaporator pressure drop, and power input for glycol solutions can becalculated using the following formulas and reference to Table 10for ethylene and Table 11for
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:
TablesFromGCorrectionFlowxT
CapacityGlycolxGPMGlycol
24
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16 WGZ 030C through 200C IMM WGZC
For Metric Applications -- Determine evaporator lps (or T) knowing T (or lps)
and kW:
TablesfromGCorrectionFlowxTx
kWLpsGlycol
18.4
3. Pressure Drop, To determine glycol pressure drop through the cooler, enter the waterpressure drop graph on page 17at 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 10 or Table 11. 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 intemperature, its characteristics have a tendency to mirror those of water.
Therefore, for selection purposes, there is no derate in capacity for glycol in thecondenser.
Table 10, Ethylene Glycol
Freezing PointPercentGlycol F C
C (Capacity) K (Power) G (Flow)P (Pressure
Drop)
10 26 -3 0.991 0.996 1.013 1.070
20 18 -8 0.982 0.992 1.040 1.129
30 7 -14 0.972 0.986 1.074 1.181
40 -7 -22 0.961 0.976 1.121 1.263
50 -28 -33 0.946 0.966 1.178 1.308
Table 11, Propylene Glycol
Freezing PointPercent
Glycol F C C (Capacity) K (Power) G (Flow)
P (Pressure
Drop)
10 26 -3 0.987 0.992 1.010 1.068
20 19 -7 0.975 0.985 1.028 1.147
30 9 -13 0.962 0.978 1.050 1.248
40 -5 -21 0.946 0.971 1.078 1.366
50 -27 -33 0.929 0.965 1.116 1.481
! CAUTION
Do not use automotive antifreeze. Industrial glycols must be used. Automotive antifreezecontains inhibitors that causes plating on copper tubes. The type and handling of glycol usedmust be consistent with local codes.
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IMM WGZC WGZ 030C through 200C 17
Circuit #1Outlet
Condenser
Temperature
ControlValve
CondenserWater
Circuit #2Outlet
Circuit #1Inlet
Circuit #2Inlet
Condenser Water PipingArrange the condenser water so the water enters the bottom connection of the condenser.
The condenser water will discharge from the top connection. Failing to arrange the
condenser water as stated above will negatively affect the capacity and efficiency.
Install pressure gauges in the inlet and outlet water lines to the condenser. Pressure drop
through the condenser should be measured to determine flow on the pressure drop/flowcurves on beginning on page 17Error! Bookmark not defined.. Vibration eliminators
are recommended in both the supply and return water lines. Install a 20-mesh strainer in
the inlet piping to the condenser.
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 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 7 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 7, Recirculating Discharge Pressure Control System
Pressure Drops
The evaporator flow rates and pressure drops shown on the following page (Figure 8) are for full load
design purposes. The maximum flow rate and pressure drop are based on a 6-degree temperature drop.
Avoid higher flow rates with resulting lower temperature drops to prevent potential control problems
resulting from very small control bands and limited start up/shut off temperature changes.
The minimum flow and pressure drop is based on a full load evaporator temperature drop of 16-degrees.
Condenser pressure drops are shown on the page following evaporator drops.
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Figure 8, Evaporator Pressure Drop, WGZ 030C WGZ 200C
Minimum Flow & PD Nominal Flow & PD Maximum Flow & PD
Inch-Pound S.I. Inch-Pound S.I. Inch-Pound S.I.WGZ-C
Model
Ref
#GPM Ft. L/S kPa GPM Ft. L/S kPa GPM Ft. L/S kPa
WGZ030C A 45 4.7 2.8 14.1 72 11 4.5 32.9 120 27.6 7.6 82.4WGZ035C B 51.9 4.9 3.3 14.6 83 11.4 5.2 34 138.3 28.5 8.7 85.4
WGZ040C C 61.1 5.1 3.9 15.2 97.8 11.8 6.2 35.4 163 29.7 10.3 88.8
WGZ045C D 68.2 5.2 4.3 15.5 109.1 12.1 6.9 36.1 181.8 30.2 11.5 90.4
WGZ050C E 76.7 5.8 4.8 17.2 122.6 13.4 7.7 40.1 204.4 33.6 12.9 100.6
WGZ055C F 84.6 6.1 5.3 18.1 135.4 14.1 8.5 42.2 225.6 35.4 14.2 105.9
WGZ060C G 90.8 6.6 5.7 19.7 145.2 15.6 9.2 46.5 242 39.2 15.3 117.1
WGZ070C H 106.3 3.7 6.7 10.9 170 8.6 10.7 25.6 283.4 21.2 17.9 63.3WGZ080C I 117.5 4.3 7.4 12.8 187.9 10 11.9 29.9 313.2 25 19.8 74.9
WGZ090C J 132.1 4.5 8.3 13.3 211.3 10.5 13.3 31.3 352.1 26.1 22.2 78.1
WGZ100C K 146.6 4.9 9.3 14.6 234.6 11.4 14.8 34.1 391.1 28.7 24.7 85.8
WGZ115C L 169.3 4.5 10.7 13.5 270.9 10.5 17.1 31.4 451.5 26.4 28.5 78.9
WGZ130C M 188.1 4.2 11.9 12.6 301 9.8 19 29.5 501.6 24.7 31.6 73.9
WGZ150C N 219.9 5.5 13.9 351.8 12.8 22.2 38.3 586.4 32.0 37
WGZ170C O 254 7.9 16 406.3 18.5 25.6 55.3 677.2 46.4 42.7
WGZ200C P 282.2 9.5 17.8 451.4 22 28.5 65.8 752.4 55.1 47.5
Notes: Minimum, nominal, and maximum flows are at a 16 F, 10 F, and 6 F chilled water temperature range respectively atARI tons.
900 1000
CBD K
LJIA
EFG
H
0
6
12
18
24
27
30
9
21
15
60
90
40 50 60 70 80 90 100 200 300 400 500 600
PresureDrop(ftofwater)
Flow Rate (GPM)
700 800
O
P
N
M
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IMM WGZC WGZ 030C through 200C 19
Figure 9, Condenser Pressure Drop, WGZ 030C WGZ 200C
Minimum Flow & PD Nominal Flow & PD Maximum Flow & PD
Inch-Pound SI Inch-Pound SI Inch-Pound SIUnit ModelRef
#GPM Ft. L/S kPa GPM Ft. L/S kPa GPM Ft. L/S kPa
WGZ030C A 56.1 2.4 3.5 7.2 89.7 6.3 5.7 18.8 149.5 17.4 9.4 52.0
WGZ035C B 64.9 3.4 4.1 10.2 103.8 8.6 6.5 25.7 173.0 23.9 10.9 71.4
WGZ040C C 76.3 2.7 4.8 8.1 122.1 6.9 7.7 20.6 203.5 19.3 12.8 57.7
WGZ045C D 85.3 3.6 5.4 10.8 136.5 9.2 8.6 27.5 227.5 25.7 14.4 76.8
WGZ050C E 96.4 2.9 6.1 8.7 154.2 7.5 9.7 22.4 257.0 20.7 16.2 61.9
WGZ055C F 105.8 3.8 6.7 11.4 169.2 9.7 10.7 29.0 282.0 26.8 17.8 80.1
WGZ060C G 113.4 4.5 7.2 13.5 181.5 11.6 11.5 34.7 302.5 32.3 19.1 96.5
WGZ070C H 132.8 4.1 8.4 12.3 212.4 10.4 13.4 31.1 354.0 29.0 22.3 86.7
WGZ080C I 146.8 3.7 9.3 11.1 234.9 9.5 14.8 28.4 391.5 26.5 24.7 79.2
WGZ090C J 165.0 3.4 10.4 10.2 264 8.8 16.7 26.3 440.0 24.5 27.8 73.2WGZ100C K 183.4 3.4 11.6 10.2 293.4 8.8 18.5 26.3 489.0 24.4 30.9 72.9
WGZ115C L 211.7 4.8 13.4 14.3 338.7 12.3 21.4 36.8 564.5 34.1 35.6 101.9
WGZ130C M 235.1 6.1 14.8 18.2 376.2 15.5 23.7 46.3 627.0 43.1 39.6 128.8
WGZ150C N 274.9 6.2 17.3 18.5 439.8 15.8 27.7 47.2 733.0 43.8 46.2 130.9
WGZ170C O 317.4 5.5 20.0 16.4 507.9 14.0 32.0 41.8 846.5 38.9 53.4 116.3
WGZ200C P 352.7 7.4 22.3 22.1 564.3 18.8 35.6 56.2 940.5 52.3 59.3 156.3
P
ressureDrop(ftofwater)
Flow Rate (GPM)
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Refrigerant Piping
Unit with Remote CondenserGeneral
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.
NOTE:Do not install any refrigerant piping underground.
The discharge gas valves, liquid line solenoids, filter-driers, moisture indicators, and
expansion valves are all factory mounted as standard equipment with the water chiller.
For remote condenser application (WGZ-CA) such as air-cooled or evaporative
condenser, the chillers are shipped with a nitrogen/helium holding charge. The unit is
evacuated in the factory to 500 microns before charging with the nitrogen.
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
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. Internalgases can increase the internal pressure and cause a life-threatening explosion. Open thesystem 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.
When the field piping has been leak tested, evacuated, and is ready to charge, the unit
valves can be opened and the system is ready to pressure test, evacuate and charge the
entire system together at one time.
After the equipment is properly installed, leak tested, and evacuated, it can be charged
with R-410A, 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 air-cooled condenser used and volume of the refrigerant piping.NOTE:On WGZ-CA 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.
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IMM WGZC WGZ 030C through 200C 21
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 and 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. Install a relief device in the hot
gas piping at the condenser coil as shown in and Figure 11. Install a discharge check valve in
the discharge line, in a horizontal run, close to the condenser.
Recommended Line SizingThe following tables provide recommended line sizing for the field piping. Final design
should be based on ASHRAE design standards.
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Table 12, Equivalent Feet for Fittings
Fitting Type 7/8 1 1/8 1 3/8 1 5/8 2 1/8 2 5/8 3 1/8
Elbows
90Standard 2.0 2.6 3.3 4.0 5.0 6.0 7.5
90Long Radius 1.4 1.7 2.3 2.6 3.3 4.1 5.0
90Street 3.2 4.1 5.6 6.3 8.2 10 12
45Standard 0.9 1.3 1.7 2.1 2.6 3.2 4.045Street 1.5 2.1 3.0 3.4 4.5 5.2 6.4
180Bend 3.2 4.1 5.6 6.3 8.2 10 12
Tees
Full Size 1.4 1.7 2.3 2.6 3.3 4.1 5.0
Reducing 2.0 2.6 3.3 4.0 5.0 6.0 7.5
Valves
Globe Valve, Open 22 29 38 43 55 69 84
Gate Valve, Open 0.9 1.0 1.5 1.8 2.3 2.8 3.2
Angle Valve, Open 9.0 12 15 18 24 29 35
Table 13, Maximum Line Size for Oil Carry Up a Discharge Riser, R-410A
Unit Size WGZ030
WGZ035
WGZ040
WGZ045
WGZ050
WGZ055
WGZ060
WGZ070
WGZ080
WGZ090
Line
Size (in.)1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8
Unit SizeWGZ
100
WGZ
115
WGZ
130
WGZ
150
WGZ
170
WGZ
200
Line
Size (in.)2 5/8 3 1/8 3 1/8 2 5/8 3 1/8 3 1/8
Table 14, Recommended Liquid Line Size, R-410A
Recommended Liquid Line Size (in.)
Up to Up to Up to Up to Up to
Unit Model
WGZ-CB
Connection
Size at Unit(in.) 50 Equiv. Ft 75 Equiv. Ft 100 Equiv. Ft 125 Equiv. Ft 150 Equiv. Ft
WGZ 030 7/8" 7/8 " 7/8 " 7/8 " 7/8 " 7/8 "
WGZ 035 7/8" 7/8 " 7/8 " 7/8 " 7/8 " 1 1/8 "
WGZ 040 7/8" 7/8 " 7/8 " 7/8 " 1 1/8 " 1 1/8 "
WGZ 045 7/8" 7/8 " 7/8 " 7/8 " 1 1/8 " 1 1/8 "
WGZ 050 7/8" 7/8 " 7/8 " 7/8 " 1 1/8 " 1 1/8 "
WGZ 055 7/8" 7/8 " 7/8 " 1 1/8 1 1/8 " 1 1/8 "
WGZ 060 7/8" 7/8 7/8 " 1 1/8 " 1 1/8 " 1 1/8 "
WGZ 070 1 1/8 1 1/8 1 1/8 " 1 1/8 " 1 1/8 " 1 1/8
WGZ 080 1 1/8 1 1/8 " 1 1/8 " 1 1/8 1 1/8 1 1/8
WGZ 090 1 1/8 1 1/8 " 1 1/8 " 1 1/8 1 1/8 1 1/8
WGZ 100 1 1/8 1 1/8 " 1 1/8 " 1 1/8 1 1/8 1 1/8WGZ 115 1 1/8 1 1/8 " 1 1/8 " 1 1/8 1 3/8 1 3/8
WGZ 130 1 1/8 1 1/8 " 1 3/8 1 1/8 1 3/8 1 3/8
WGZ 150 1 3/8 1 3/8 1 1/8 " 1 3/8 1 3/8 1 3/8
WGZ 170 1 3/8 1 3/8 1 1/8 " 1 3/8 1 3/8 1 3/8
WGZ-200 1 3/8 1 3/8 1 1/8 " 1 3/8 1 3/8 1 3/8
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Table 15, Recommended Horizontal or Downflow Discharge Line Size, R-410A
Recommended Discharge Line Sizes
Up to Up to Up to Up to Up toUnit Model
AGZ-CB
Connection
Size
At Unit 50 Equiv. Ft 75 Equiv. Ft 100 Equiv. Ft 125 Equiv. Ft 150 Equiv. Ft
WGZ 030 1 3/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"
WGZ 035 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8"
WGZ 040 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8"WGZ 045 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8"
WGZ 050 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8"
WGZ 055 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8"
WGZ 060 1 3/8" 1 3/8" 1 5/8 1 5/8 1 5/8 1 5/8
WGZ 070 1 3/8" 1 3/8" 1 5/8 1 5/8 1 5/8 1 5/8
WGZ 080 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8
WGZ 090 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8
WGZ 100 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8
WGZ 115 1 5/8 1 5/8 1 5/8 2 1/8" 2 1/8" 2 1/8"
WGZ 130 1 5/8 1 5/8 2 1/8" 2 1/8" 2 1/8" 2 1/8"
WGZ 150 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8"
WGZ 170 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8"
WGZ 200 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 5/8"
Typical Arrangements
Figure 10 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 thecompressor 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 11 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.
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24 WGZ 030C through 200C IMM WGZC
Condenser
Relief Valve
Check Valve
Purge Valve
Discharge Line
Loop
Receiver
ReceiverBypass
ToEvap.
PreferredSubcoolerHook-up
Relief Valve(Vent to Outdoorsor to Condenser Sideof Liquid LineCheck Valve)
Pitch
CheckValve
Subcooler
Condenser
Relief Valve
Check Valve
Purge Valve
Relief Valve(Vent to Outdoorsor to Condenser Sideof Liquid LineCheck Valve)
Pitch
CheckValve
Discharge Line
Receiver
ReceiverBypass
ToEvap.
PreferredSubcoolerHook-up
CheckValve
Subcooler
Figure 10, Condenser Above Compressor and Optional Receiver Installation
Figure 11, Condenser and Compressor on Same Level, Optional Receiver
Installation
The receiver shown is optional and not used on many installations. It is bypassed during
normal operation.
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IMM WGZC WGZ 030C through 200C 25
Factory-Mounted CondenserUnits 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 tocirculate 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.
Relief Valve Piping
The ANSI/ASHRAE Standard 15, Safety Standard for Refrigeration Systems, specifies
that pressure relief valves on vessels containing Group 1 refrigerant (R-410a) shall
discharge to the atmosphere at a location not less than 15 feet (4.6 meters) above the
adjoining ground level and not less than 20 feet (6.1 meters) from any window,
ventilation opening or exit in any building. The piping must be provided with a rain capat the outside terminating point and with a drain at the low point on the vent piping to
prevent water buildup on the atmospheric side of the relief valve. Also, a flexible pipe
section should be installed in the line to eliminate any piping stress on the relief valve(s).
The size of the discharge pipe from the pressure relief valve should not be less than the
size of the pressure relief outlet. When two or more vessels are piped together, the
common header and piping to the atmosphere should not be less than the sum of the area
of each of the lines connected to the header.
NOTE: Fittings should be provided to permit vent piping to be easilydisconnected for inspection or replacement of the relief valve.
Figure 12, Relief Valve Piping
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26 WGZ 030C through 200C IMM WGZC
Dimensions
Packaged Chillers
Figure 13, WGZ 030CW through WGZ 060CW
CHILLER WATER CONNECTIONSIZE (NOM) VICTAULIC
CONDENSER WATER
CONNECTION SIZE(NOM) VICTAULIC
CENTER OF GRAVITYWGZ MODELNUMBER
IN (MM) A IN (MM) X Y Z
WGZ030C 2.5 (64) 107.4 (2728) 4 (102) 59.2 22.4 14.1
WGZ035C 2.5 (64) 108.4 (2753) 4 (102) 59.9 22.8 14.2
WGZ040C 2.5 (64) 109.8 (2789) 4 (102) 59.6 22.8 14.2
WGZ045C 2.5 (64) 111.5 (2832 4 (102) 59.2 22.9 14.2
WGZ050C 2.5 (64) 113.3 (2878) 4 (102) 59.0 23.3 14.2
WGZ055C 2.5 (64) 115.0 (2921) 4 (102) 58.7 23.4 14.2
WGZ060C 2.5 (64) 116.7 (2965) 4 (102) 58.0 23.6 14.3
CONDENSER
INLET
121.13075
9.7246
134.63419
3.8
REF.98 " X "
" Y "
3.9100
.875 DIA MOUNTING HOLES (4)
INLET
OUTLET
OUTLET
RELIEF VALVES
MICROTECH II USER INTERFACE
VENT
DRAIN
CIRCUIT 1CIRCUIT 2
30.1763
32.8832
" Z "
" Y "
23.5597
2.051
20.0508
29.0737
13.3338
32.0813
8.0204
14.0354
29.2742
44.91139
12.4314
63.41609
40.01016
EVAPORATOR
REMOVABLEDISC. HANDLE
REMOVE BRKT.FOR SHIPPING
ONLYPOWER
CONNECTIONS
CONTROLCONNECTION
.88 KNOCKOUTSON OPPOSITE SIDE
.88 KNOCKOUTS
"A"
CONTROL BOX
WATERCONNECTIONS
L1 / M1 L2 / M2
L3 / M3L4 / M4
WGZ030C-060CPac kaged Unit
331929701
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IMM WGZC WGZ 030C through 200C 27
Figure 14, WGZ 070CW through WGZ 130CW
MAXIMUM OVERALL
DIMENSIONSIN (MM) CENTER OF GRAVITYWGZ MODELNUMBER
L W H
CHILLERWATER
CONNECTIONIN(MM)
VICTAULIC
SIZE (NOM)
A
CONDENSERWATER
CONNECTIONIN(MM)
VICTAULIC
SIZE (NOM)
T
X Y Z
WGZ070C143.3(3639)
35.0(889)
65.5(1664)
3 (76)114.9(2918)
4 (102)8.0
(203)62.4 28.6 15.0
WGZ080C149.6(3799)
35.0(889)
65.5(1664)
3 (76)115.3(2930)
4 (102)14.3(363)
64.8 29.3 15.1
WGZ090C149.4(3795)
35.0(889)
65.5(1664)
3 (76)117.1(2975)
4 (102)14.1(359)
67.7 29.6 16.1
WGZ100C149.4
(3795)
35.0
(889)
65.5
(1664)
3 (76)118.0
(2997)
4 (102)14.1
(359)
69.7 29.9 17.1
WGZ115C149.4(3795)
35.0(889)
65.5(1664)
3 (76)121.6(3088)
4 (102)14.1(359)
68.8 30.2 17.1
WGZ130C149.4(3795)
35.0(889)
65.5(1664)
3 (76)124.7(3167)
4 (102)14.1(359)
67.8 30.4 17.1
CONDENSER
121.13075"T"
14.2361
"L"
"A"
" X "
4.0102
.875 DIA MOUNTING HOLES (4)
INLET
INLET
OUTLET
OUTLET
EVAPORATOR
RELIEF VALVES
MICROTECH II USER INTERFACE
VENT
DRAIN
CIRCUIT 2 CIRCUIT 1
29.0737
13.0330
32.3821
"W"
" Y "
" Z "
23.5597
2.051
10.0253
17.9454
32.8834
57.6
1462
14.5369
20.0508
"H"
32.0813
40.01016
40.21021
REMOVABLEDISC. HANDLE REMOVE BRKT.
FOR SHIPPINGONLY
POWERCONNECTIONS
CONTROLCONNECTION
.88 KNOCKOUTSON OPPOSITE SIDE
.88 KNOCKOUTS
CONTROL BOX
WATERCONNECTIONS
L1 / M1 L2 / M2
L3 / M3L4 / M4
WGZ070-130CWPackaged Chiller
331929801
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28 WGZ 030C through 200C IMM WGZC
Figure 15, WGZ 150CW through WGZ 200CW
CHILLER WATERCONNECTION SIZE(NOM) VICTAULIC
CONDENSER WATERCONNECTION SIZE(NOM) VICTAULIC
CENTER OF GRAVITYWGZ MODELNUMBER
IN (MM) IN (MM) X Y Z
WGZ150C 8 (203) 5 (127) 68.7 38.6 14.9
WGZ170C 8 (203) 5 (127) 66.3 38.3 15.0
WGZ200C 8 (203) 5 (127) 66.6 38.7 15.1
CONDENSER
EVAPORATOROUTLET
10.9276
145.13685
14.2361
170.24322
" X "
" Y "
4.0
102
INLET
OUTLET
EVAPORATORINLET
RELIEF VALVES
MICROTECH II USER INTERFACE
VENT
VENT
DRAINDRAIN
29.0737
13.3337
33.8859
36.5
T.B.D.927
77.71973
" Z "
23.5597
2.051
15.5394
17.0432
9.6243
18.3464
36.9
EVAP
INLET/OUTLET
938
32.0813
5.0127
40.01016
41.21046
.875 DIA MOUNTING HOLES (4)
.88 KNOCKOUT
REMOVABLEDISC HANDLE
REMOVE BRKT.FOR SHIPPING
ONLY
CONTROLCONNECTION
.88 KNOCKOUTSON OPPOSITE SIDE
POWERCONNECTIONS
23.5596
77.21961
1.334
CIRCUIT 1CIRCUIT 2
WGZ150CW-200CWPackaged Chiller
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IMM WGZC WGZ 030C through 200C 29
Chillers with Remote Condenser
Figure 16, WGZ 030CA through WGZ 060CA
CHILLER WATER CONNECTIONSIZE (NOM) VICTAULIC
CONDENSER WATER
CONNECTION SIZE(NOM) VICTAULIC
CENTER OF GRAVITYWGZ MODEL
NUMBER
IN (MM) A IN (MM) X Y Z
WGZ030CA 2.5 (64) 21.6 (550) 4 (102) 67.3 22.8 13.3
WGZ035CA 2.5 (64) 20.6 (523) 4 (102) 68.3 23.8 13.4
WGZ040CA 2.5 (64) 19.2 (488) 4 (102) 67.9 23.9 13.5
WGZ045CA 2.5 (64) 17.5 (444) 4 (102) 67.3 24.0 13.5
WGZ050CA 2.5 (64) 15.8 (400) 4 (102) 67.2 24.5 13.5
WGZ055CA 2.5 (64) 14.0 (356) 4 (102) 66.6 24.6 13.5
WGZ060CA 2.5 (64) 12.3 (312) 4 (102) 66.1 24.7 13.6
WGZ030-060CAREMOTE CONDENSER UNIT
331929711
" X "
" Y "
137.03480
12.3312
6.0152
20.2512
MICROTECH II USER INTERFACE
CIRCUIT 1CIRCUIT 2
1.38 DISCHARGECONNECTIONS
.88 LIQUIDCONNECTIONS
30.3770
" Z "
23.5597
2.051
30.0762
2.051
20.0508
34.0864
40.01016
6.0152
6.0151
16.5419
60.01524
EVAPORATOR
REMOVABLEDISC. HANDLE REMOVE BRKT.
FOR SHIPPING
ONLY
POWERCONNECTIONS
CONTROLCONNECTION
.88 KNOCKOUTSON OPPOSITE SIDE
.88 KNOCKOUTS
ISOLATOR HOLES (4)
OUTLET
INLET
LIQUIDCONNECTIONS
EVAP. ANDDISCHARGECONNECTIONS
25.9657
41.51054
" A "
27.4696
38.2971 87.9
223498.82509
11.4289
10.4263
OUTLET
INLET
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30 WGZ 030C through 200C IMM WGZC
Figure 17, WGZ 070CA through WGZ 130CA
CHILLER WATERCONNECTION SIZE
(NOM) VICTAULIC
COND.
WATERCONN. SIZE
VICTAULIC
REFRIGERANTPIPING
CONNECTION SIZE
CENTER OF GRAVITY(IN.)
WGZMODEL
NUMBER
IN (MM) A IN (MM) B DISC. C LIQ.
T
LEFTOVERHANG
X Y Z
WGZ070C 3 (76) 14.1 (359) 4 (102) 1.38 OD 1.13 OD N/A 71.5 29.3 14.9
WGZ080C 3 (76) 13.7 (348) 4 (102) 1.62 OD 1.13 OD 6.3 (161) 74.9 30.1 15.0
WGZ090C 3 (76) 11.9 (303) 4 (102) 1.62 OD 1.13 OD 6.6 (167) 75.7 30.4 15.1
WGZ100C 3 (76) 11.0 (280) 4 (102) 1.62 OD 1.13 OD 6.6 (167) 75.2 30.6 15.2
WGZ115C 3 (76) 7.5 (190) 4 (102) 1.62 OD 1.13 OD 6.6 (167) 73.8 30.8 15.2
WGZ130C 3 (76) 4.4 (111) 4 (102) 1.62 OD 1.13 OD 6.6 (167) 72.6 30.9 15.3
" T "
" Y "
" X "
137.03480
12.3312
6.0152
23.2588
MICROTECH II USER INTERFACECIRCUIT 1CIRCUIT 2
DISCHARGE CONNECTIONS "B"
LIQUID CONNECTIONS "C"
32.3821
23.5597
2.051
30.0762
2.051" Z "
20.0508
34.0864
40.01016
6.0152
60.01524
4.0
101
15.5394
EVAPORATOR
REMOVABLEDISC. HANDLE
REMOVE BRKFOR SHIPPIN
ONLYPOWER
CONNECTIONS
CONTROLCONNECTION
.88 KNOCKOUTSON OPPOSITE SIDE
.88 KNOCKOUTS
ISOLATOR HOLES (4)
OUTLET
INLET
LIQUID
CONNECTIONS
EVAP. ANDDISCHARGECONNECTIONS
52.01322
18.5469
27.3694
"A "
13.3338
12.4.253166.35
38.2971
89.22266
98.82509
OUTLET
INLET
WGZ070-130CAUnit less condenser
331929811
1.533
5.2413
1.533
2.051
30.0
762
2.051
%%c.75
ISOLATOR HOLES IN THEBOTTOM OF THE BASE
19
CONTROL BOX
CIRCUIT 1CIRCUIT 2
L1 L2
L3L4
M1 M2
M3M4
EVAP WATERCONNECTIONS
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IMM WGZC WGZ 030C through 200C 31
Figure 18, WGZ 150CA through WGZ 200CA
CHILLER WATERCONNECTION SIZE
(NOM) VICTAULIC
CENTER OF GRAVITYWGZ MODELNUMBER
IN (MM) X Y Z
WGZ150C 8 (203) 79.1 43.2 15.3
WGZ170C 8 (203) 80.1 43.6 15.4
WGZ200C 8 (203) 79.7 44.0 15.4
" Y "
" X "
154.03912
2.051
MICROTECH IIUSER INTERFACE
CIRCUIT 1CIRCUIT 2
WGZ150-200CAREMOTE CONDENSER UNIT
331929911
2.051
30.0762
2.051
" Z "
5.0127
12.0
305
35.5902
3.076
75.01905
12.0305
34.0864
40.01016
4.0101
5.0127
REMOVABLEDISC. HANDLE
REMOVE BRKT.FOR SHIPPING
ONLY
CONTROLCONNECTION
.88 KNOCKOUTSON OPPOSITE SIDE
.88 KNOCKOUTSISOLATOR HOLES (6)
POWERCONNECTIONS
(QTY 3)
LIQUIDCONNECTIONS
106.52705
33.9862
42.11069 119.3
3030
34.2867
24.9631
74.71898
17.4443
6.0152
23.2588
OUTLETINLET
1.62 O.D. DISCHARGECONNECTIONS
1.38 O.D. LIQUIDCONNECTIONS
CIRCUIT 1 CIRCUIT 2
2.360 7.9
200
14.5368
13.4340
3.690
EVAPORATORINLET/OUTLET
DISCHARGECIRCUIT 1 DISCHARGE
CIRCUIT 2
21.0533
30.0762
2.051
2.051
21.0533
58.01473
54.01372
.75
ISOLATOR HOLES IN THEBOTTOM OF THE BASE
19
CONTROL BOX
CIRCUIT 1CIRCUIT 2
L1 L2
L3L4
M1 M3
M4M6
M2
M5
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32 WGZ 030C through 200C IMM WGZC
Physical Data
Packaged Chillers
Table 16, WGZ 030CW WGZ 055CW
WGZ UNIT SIZE 30 35 40 45 50 55
Unit capacity @ ARI tons, (kW) 30.0 (105.5) 34.6 (121.7) 40.7 (143.1) 45.5 (160.0) 51.4 (180.8) 56.4 (198.4)
No. Circuits 2 2 2 2 2 2
COMPRESSORS
Nominal Tons 7.5 7.5 9 9 10 10 12 12 13 13 13 15
Number Per Circuit 2 2 2 2 2 2 2 2 2 2 2 2
CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT
Staging, Circuit #1 in Lead 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 23 / 50 / 73 / 100
Staging, Circuit #2 in Lead 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 27 / 50 / 77 / 100
Oil Charge per Compressor oz., (l) 85 (2.5) 110 (3.3) 110 (3.3) 110 (3.3) 110 (3.3) 110 (3.3)
CONDENSER
Number 1 1 1 1 1 1
No. Refrigerant Circuits 2 2 2 2 2 2
Diameter, in., (mm) 10 (254) 10 (254) 10 (254) 10 (254) 10 (254) 10 (254)
Tube Length, in., (mm) 120 (3048) 120 (3048) 120 (3048) 120 (3048) 120 (3048) 120 (3048)
Design W.P.PSIG, (kPa):
Refrigerant Side 500 (3447) 500 (3447) 500 (3447) 500 (3447) 500 (3447) 500 (3447)
Water Side 232 (1599) 232 (1599) 232 (1599) 232 (1599) 232 (1599) 232 (1599)
Pump-Out Capacity, lb., (kg) (3) 245.8 (111.7) 245.8 (111.7) 228.2 (103.7) 228.2 (103.7) 205.4 (93.4) 205.4 (93.4)
Conn.In & Out, in, (mm) Victaulic 4 (102) 4 (102) 4 (102) 4 (102) 4 (102) 4 (102)
Relief Valve, Flare In., (mm) (15.9) (15.9) (15.9) (15.9) (15.9) (15.9)
Purge Valve, Flare In., (mm) (12.7) (12.7) (12.7) (12.7) (12.7) (12.7)
Vent & Drain, in. (mm) NPT (6.4) (6.4) (6.4) (6.4) (6.4) (6.4)
Liquid Subcooling Integral Integral Integral Integral Integral Integral
EVAPORATOR, BRAZED-PLATENumber 1 1 1 1 1 1
No. Refrigerant Circuits 2 2 2 2 2 2
Water Volume, gallons, (l) 1.9 (7.1) 2.2 (8.3) 2.4 (9.1) 2.9 (11.0) 3.4 (12.8) 3.7 (14.0)
Refrig. Side D.W.P. Psig, (kPa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102)
Water Side D.W.P,. psig, (kPa) 653 (4500) 653 (4500) 653 (4500) 653 (4500) 653 (4500) 653 (4500)
Conn. In & Out, in. (mm) Victaulic 2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65)
Relief Valve, Flare in., (mm) (15.9) (15.9) (15.9) (15.9) (15.9) (15.9)
Vent & Drain Field Field Field Field Field Field
UNIT DIMENSIONS
Length In., (mm) 136.0 (3455) 136.0 (3455) 136.0 (3455) 136.0 (3455) 136.0 (3455) 136.0 (3455)
Width In., (mm) 32.8 (832) 32.8 (832) 32.8 (832) 32.8 (832) 32.8 (832) 32.8 (832)
Height In., (mm) 63.4 (1609) 63.4 (1609) 63.4 (1609) 63.4 (1609) 63.4 (1609) 63.4 (1609)
UNIT WEIGHTS
Operating Weight, lb., (kg) 2486 (1128) 2572 (1167) 2631 (1193) 2650 (1202) 2752 (1248) 2771 (1257)
Shipping Weight, lb., (kg) 2410 (1093) 2496 (1132) 2539 (1152) 2558 (1160) 2639 (1197) 2658 (1206)
Cir # 1,Opn. Charge, lb.,(kg) R410a 45 (20.5) 45 (20.5) 47 (21.4) 47 (21.4) 47 (21.4) 50 (22.7)
Cir # 2,Opn. Charge, lb.,(kg) R410a 45 (20.5) 45 (20.5) 47 (21.4) 47 (21.4) 47 (21.4) 50 (22.7)
Notes:
1. Certified in accordance with ARI Standard 550/590-2003.2. 90% Full R-410a at 90F (32C) per unit.
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IMM WGZC WGZ 030C through 200C 33
Table 17, WGZ060CW - WGZ100CW
WGZ UNIT SIZE 60 70 80 90 100
Unit capacity @ ARI tons, (kW) (1) 60.5 (212.8) 70.8 (249.0) 78.3 (275.4) 88.0 (309.5) 97.8 (344.0)
No. Circuits 2 2 2 2 2
COMPRESSORS
Nominal Tons 15 15 15/20 15/20 20 20 20 26 26 26
Number per Circuit4 2 2 2 2 2 2 2 2 2 2
CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT
Staging, 4 Stages, Circuit #1 in Lead 25 / 50 / 75 / 100 22 / 50 / 72 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100
Staging, 4 Stages, Circuit #2 in Lead 25 / 50 / 75 / 100 22 / 50 / 72 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100
Oil Charge, per compressor oz. (l) 110 (3.3)110 (3.3)158 (4.7)
110 (3.3)158 (4.7)
158 (4.7)158(4.7)
230(6.8)
230 (6.8)
CONDENSER
Number 1 1 1 1 1
No. Refrigerant Circuits 2 2 2 2 2
Diameter, in. (mm) 10 (254) 14 (356) 14 (356) 14 (356) 14 (356)
Tube Length, in. (mm) 120 (3048) 120 (3048) 120 (3048) 120 (3048) 120 (3048)
Design W.P., psig (kPa):
Refrigerant Side 500 (3447) 500 (3447) 500 (3447) 500 (3447) 500 (3447)
Water Side 232 (1599) 232 (1599) 232 (1599) 232 (1599) 232 (1599)
No. of Passes 2 2 2 2 2
Pump-Out Capacity lb., (kg) (3) 205.4 (93.4) 415.1 (188.7) 397.5 (180.7) 371.1 (168.7) 344.7 (156.7)
Conn. In & Out, in., (mm) Victaulic 4 (102) 4 (102) 4 (102) 4 (102) 4 (102)
Relief Valve, Flare in., (mm) (15.9) (15.9) (15.9) (15.9) (15.9)
Purge Valve, Flare in. (mm) (12.7) (12.7) (12.7) (12.7) (12.7)
Vent & Drain, in. (mm) NPT (6.4) (6.4) (6.4) (6.4) (6.4)
Liquid Subcooling Integral Integral Integral Integral Integral
EVAPORATOR, BRAZED-PLATE
Number 1 1 1 1 1
No. Refrigerant Circuits 2 2 2 2 2
Water Volume, gallons (l) 4.2 (15.9) 6.4 (24.3) 6.6 (24.9) 7.5 (28.4) 8.0 (30.2)Refrigerant Side D.W.P., psig, (kPa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102)
Water Side D.W.P., psig, (kPa) 653 (4500) 653 (4500) 653 (4500) 653 (4500) 653 (4500)
Conn. In & Out, in. (mm) Victaulic 2.5 (65) 3 (76) 3 (76) 3 (76) 3 (76)
Relief Valve, Flare in., (mm) (15.9) (15.9) (15.9) (15.9) (15.9)
Vent & Drain Field Field Field Field Field
UNIT DIMENSIONS
Length, in. (mm) 136.0 (3455) 143.3 (3639) 149.6 (3799) 149.4 (3795) 149.4 (3795)
Width, in. (mm) 32.8 (832) 35.0 (889) 35.0 (889) 35.0 (889) 35.0 (889)
Height, in. (mm) 63.4 (1609) 65.5 (1664) 65.5 (1664) 65.5 (1664) 65.5 (1664)
UNIT WEIGHTS
Operating Wt, lb., (kg) 2801 (1271) 3887 (1763) 4302 (1951) 4507 (2044) 4678 (2122)
Shipping Wt, lb. (kg) 2688 (1219) 3746 (1699) 4145 (1880) 4327 (1963) 4474 (2029)
Cir # 1,Opn. Charge, lb, (kg) R410a 50 (22.7) 74 (34.1) 80 (36.4) 80 (36.4) 90 (40.9)
Cir # 2,Opn. Charge, lb.,(kg) R410a 50 (22.7) 74 (34.1) 80 (36.4) 80 (36.4) 90 (40.9)
Notes:
1. Certified in accordance with ARI Standard 550/590-2003.-2. Units WGZ030 to 130 have two parallel compressors per circuit. Units WGZ150 to 200 have three parallel compressors per circuit.3. 90% Full R-410a at 90F (32C) per unit.
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34 WGZ 030C through 200C IMM WGZC
Table 18, WGZ115CW - WGZ200CW
WGZ UNIT SIZE 115 130 150 170 200
Unit capacity @ ARI. tons, (kW) (1) 112.9 (397.1) 125.4 (441.0) 146.6 (515.6) 169.3 (595.4) 188.1 (661.5)
No. Circuits 2 2 2 2 2
COMPRESSORS
Nominal Tons 26/30 26/30 30 30 26 26 26 30 30 30
Number Per Circuit 2 2 2 2 3 3 3 3 3 3
CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT
Staging, 4 Stages, Circuit #1 in Lead 22 / 50 / 72 / 100 25 / 50 / 75 / 10017 / 33 / 50 / 67
/ 83 / 10015 / 33 / 48 / 67 /
81 / 10017 / 33 / 50 / 67 /
83 / 100
Staging, 4 Stages, Circuit #2 in Lead 22 / 50 / 72 / 100 25 / 50 / 75 / 10017 / 33 / 50 / 67
83 / 10019 / 33 / 52 / 67
86 /10017 / 33 / 50 / 67 /
83 / 100
Oil Charge, per compressor oz. (l)230 (6.8 )/213 (6.3)
230 (6.8 )/213 (6.3)
213 (6.3) 230 (6.8) 230 (6.8) 213 (6.3) 213 (6.3)
CONDENSER
Number 1 1 1 1 1
No. Refrigerant Circuits 2 2 2 2 2
Diameter, in. (mm) 14 (356) 14 (356) 16 (406.4) 16 (406.4) 16 (406.4)
Tube Length, in. (mm) 120 (3048) 120 (3048) 144 (3658) 144 (3658) 144 (3658)
Design W.P., psig (kPa):
Refrigerant Side 500 (3447) 500 (3447) 500 (3447) 500 (3447) 500 (3447)
Water Side 232 (1599) 232 (1599) 232 (1599) 232 (1599) 232 (1599)
Pump-Out Capacity lb., (kg) (3) 344.7 (156.7) 344.7 (156.7) 572.3 (260.1) 508.9 (231.3) 508.9 (231.3)
Water Conn In & Out, in., (mm) (4) 4 (102) 4 (102) 5 (127) 5 (127) 5 (127)
Relief Valve, Flare in., (mm) (15.9) (15.9) (15.9) (15.9) (15.9)
Purge Valve, Flare in. (mm) (12.7) (12.7) (12.7) (12.7) (12.7)
Vent & Drain, in. (mm) FPT 6.4) 6.4) 6.4) 6.4) 6.4)
Liquid Subcooling Integral Integral Integral Integral Integral
EVAPORATOR, BRAZED-PLATE SHELL-AND-TUBE
Number 1 1 1 1 1
No. Refrigerant Circuits 2 2 2 2 2Water Volume, gallons (l) 8.5 (32.1) 10.5 (39.7) 57.6 (218.0) 56.9 (215.4) 56.9 (215.4)
Refrigerant Side D.W.P., psig, (kPa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102)
Water Side D.W.P., psig, (kPa) 653 (4500) 653 (4500) 150 (1034) 150 (1034) 150 (1034)
Water Conn.In & Out, in. (mm) Victaulic 3 (76) 3 (76) 8 (203) 8 (203) 8 (203)
Relief Valve, Flare in., (mm) (15.9) (15.9)
Drain & Vent size, in. (mm) Field Field (12.7) (12.7) (12.7)
UNIT DIMENSIONS
Length, in. (mm) 149.4 (3795) 149.4 (3795) 170.2 (4322) 170.2 (4322) 170.2 (4322)
Width, in. (mm) 35.0 (889) 35.0 (889) 36.5 (927) 36.5 (927) 36.5 (927)
Height, in. (mm) 65.5 (1664) 65.5 (1664) 77.7 (1973) 77.7 (1973) 77.7 (1973)
UNIT WEIGHTS
Operating Wt, lb., (kg) 4712 (2137) 4772 (2165) 7370 (3343) 7758 (3519) 7873 (3571)Shipping Wt, lb. (kg) 4508 (2045) 4568 (2072) 6581 (2985) 6921 (3139) 7036 (3192)
Cir #1, Op. Charge, lb., (kg) R-410a 100 (45.5) 100 (45.5) 150 (68.2) 150 (68.2) 150 (68.2)
Cir #2, Op. Charge, lb., (kg) R-410a 100 (45.5) 100 (45.5) 150 (68.2) 150 (68.2) 150 (68.2)
Notes:
1. Certified in accordance with ARI Standard 550/590-2003.2. Units WGZ030 to 130 have two parallel compressors per circuit, units WGZ150 to 200 have three parallel compressors per circuit.3. 90% Full R-410a at 90F (32C) per unit.
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IMM WGZC WGZ 030C through 200C 35
Chillers with Remote CondenserTable 19, WGZ030CA - WGZ055CAWGZ UNIT SIZE 30 35 40 45 50 55
Tons, (kW), 44F LWT, 125F SDT 26.6 (93.5) 30.5 (107.3) 35.2 (123.8) 39.8 (139.9) 45.8 (161.0) 50.3 (176.8)
No. Circuits 2 2 2 2 2 2
COMPRESSORS
Nominal Tons 7.5 7.5 9 9 10 10 12 12 13 13 13 15
Number per Circuit 2 2 2 2 2 2 2 2 2 2 2 2
Staging, Circuit #1 in Lead 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 23 / 50 / 73 / 10
Staging, Circuit #2 in Lead 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 27 / 50 / 77 / 10
Oil Charge, per comp. oz, (l) 85 (2.5) 110 (3.3) 110 (3.3) 110 (3.3) 110 (3.3) 110 (3.3)
EVAPORATOR, BRAZED PLATE
No. Refrigerant Circuits 2 2 2 2 2 2
Water Volume, gallons, (l) 1.9 (7.1) 2.2 (8.3) 2.4 (9.1) 2.9 (11.0) 3.4 (12.8) 3.7 (14.0)
Refrig. Side D.W.P. Psig, (kPa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102)
Water Side D.W.P. Psig, (kPa) 653 (4500) 653 (4500) 653 (4500) 653 (4500) 653 (4500) 653 (4500)
Inlet & Outlet, in., (mm) (1) 2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65)
Relief Valve, Flare in., (mm) (15.9) (15.9) (15.9) (15.9) (15.9) (15.9)
Drain & Vent Field Field Field Field Field Field
UNIT DIMENSIONS
Length In., (mm) 137.0 (3480) 137.0 (3480) 137.0 (3480) 137.0 (3480) 137.0 (3480) 137.0 (3480)
Width In., (mm) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864)
Height In., (mm) 60.0 (1524) 60.0 (1524) 60.0 (1524) 60.0 (1524) 60.0 (1524) 60.0 (1524)
UNIT WEIGHTS
Operating Weight, lb., (kg) 1606 (728) 1698 (770) 1715 (778) 1738 (788) 1773 (804) 1795 (814)
Shipping Weight, lb., (kg) 1580 (717) 1670 (758) 1685 (764) 1704 (773) 1735 (787) 1754 (796)
Table 20, WGZ060CA - WGZ100CAWGZ UNIT SIZE 60 70 80 90 100
Tons, (kW) 44F LWT, 125F SDT 53.9 (189.5) 61.3 (215.7) 68.6 (242.0) 77.7 (273.3) 86.6 (304.5)
No. Circuits 2 2 2 2 2
COMPRESSORS
Nominal Tons 15 15 15/20 15/20 20 20 20 26 26 26Number Per Circuit 2 2 2 2 2 2 2 2 2 2
Staging, Circuit #1 in Lead 25 / 50 / 75 / 100 22 / 50 / 72 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100
Staging, Circuit #2 in Lead 25 / 50 / 75 / 100 22 / 50 / 72 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100
Oil Charge, per compressor oz. (l) 110 (3.3) 110 (3.3) 158 (4.7) 158 (4.7) 230 230 (6.8)
EVAPORATOR, BRAZED PLATE
No. Refrigerant Circuits 2 2 2 2 2
Water Volume, gallons (l) 4.2 (15.9) 6.4 (24.3) 6.6 (24.9) 7.5 (28.4) 8.0 (30.2)
Refrigerant Side D.W.P., psig, (kPa) 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102)
Water Side D.W.P., psig, (kPa) 653 (4500) 653 (4500) 653 (4500) 653 (4500) 653 (4500)
Inlet & Outlet, in. (mm) (2) 2.5 (63) 3 (76) 3 (76) 3 (76) 3 (76)
Relief Valve, Flare in., (mm) (15.9) (15.9) (15.9) (15.9) (15.9)
Drain & Vent Field Field Field Field Field
UNIT DIMENSIONS
Length, in. (mm) 137.0 (3480) 137.0 (3480) 137.0 (3480) 137.0 (3480) 137.0 (3480)Width, in. (mm) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864)
Height, in. (mm) 60.0 (1524) 60.0 (1524) 60.0 (1524) 60.0 (1524) 60.0 (1524)
UNIT WEIGHTS
Operating Wt, lb., (kg) 1816 (824) 2474 (1122) 2787 (1264) 2928 (1328) 3050 (1383)
Shipping Wt, lb. (kg) 1771 (803) 2406 (1091) 2717 (1232) 2851 (1293) 2968 (1346)
Notes:1. Condenser and field piping not included.
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36 WGZ 030C through 200C IMM WGZC
Table 21, WGZ115CA WGZ200CA
WGZ UNIT SIZE 115 130 150 170 200
Tons, (kW)44F LWT, 125F SDT 100.1 (352.2) 111.4 (391.7) 129.9 (456.8) 150.2 (528.3) 170.6 (599.8)
No. Circuits 2 2 2 2 2
COMPRESSORS
Nominal Tons 26/30 26/30 30 30 26 26 26 30 30 30
Number Per Circuit 2 2 2 2 3 3 3 3 3 3
Staging, Circuit #1 in Lead 22 / 50 / 72 / 100 25 / 50 / 75 / 100 17 / 33 / 50 / 67 /83 / 100
15 / 33 / 48 / 67 /81 / 100
17 / 33 / 50 / 67 /83 / 100
Staging, Circuit #2 in Lead 22 / 50 / 72 / 100 25 / 50 / 75 / 10017 / 33 / 50 / 67 /
83 / 10019 / 33 / 52 / 67 /
86 / 10017 / 33 / 50 / 67 /
83 / 100
Oil Charge, per compressor oz. (l)230 (6.8 )213 (6.3)
213 (6.3) 230 (6.8) 230 (6.8) 213 (6.3) 213 (6.3)
EVAPORATOR, BRAZED PLATE------------------------------------------------ SHELL-AND-TUBE
No. Refrigerant Circuits 2 2 2 2 2
Water Volume, gallons (l) 8.5 (32.1) 10.5 (39.7) 57.6 (218.0) 56.9 (215.4) 56.9 (215.4)
Refrigerant Side D.W.P., psig, 450 (3102) 450 (3102) 450 (3102) 450 (3102) 450 (3102)
Water Side D.W.P., psig, (kPa) 653 (4500) 653 (4500) 150 (1034) 150 (1034) 150 (1034)
Water Connections:
In & Out, in. (mm), victaulic 3 (76) 3 (76) 8 (203) 8 (203) 8 (203)
Relief Valve, Flare in., (mm) (15.9) (15.9) (15.9) (15.9) (15.9)
Drain & Vent Field Field (12.7) (12.7) (12.7)
UNIT DIMENSIONS
Length, in. (mm) 137.0 (3480) 137.0 (3480) 154.0 (3912) 154.0 (3912) 154.0 (3912)
Width, in. (mm) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864)
Height, in. (mm) 60.0 (1524) 60.0 (1524) 75.0 (1905) 75.0 (1905) 75.0 (1905)
UNIT WEIGHTS
Operating Wt, lb., (kg) 3120 (1415) 3194 (1449) 5279 (2395) 5385 (2443) 5498 (2494)
Shipping Wt, lb. (kg) 3035 (1377) 3091 (1402) 4779 (2168) 4891 (2219) 5004 (2270)
Notes:1. Condenser and field piping not included
Operating Limits
Equipment room temperature limits, operating or standby: 32F to 104F (0C to 40C) Maximum allowable condenser water pressure is 232 psig (1599 kPa).
Maximum design saturated discharge temperature is 140F (60C).
Maximum allowable water temperature to evaporator in a non-operating cycle is 100F (37.8C).
Maximum entering water temperature for operating cycle is 90F (32.2C) (during system changeover
from heating to cooling cycle).
Minimum leaving water temperature from the evaporator without freeze protection is 40F (4.4C).
Minimum entering tower condenser water temperature is 60F (15.6C).
Maximum condenser leaving water temperature is 115F (46.1C)
For remote air-cooled condensers, the temperature difference between the saturated discharge temperature
and the outside air temperature (TD) must be between 15 and 35 degrees F and the saturated dischargetemperature cannot exceed 135F.
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IMM WGZC WGZ 030C through 200C 37
Components
Figure 19, Compressor Locations
4 2 3 1
Circuit 2 Circuit 1Control Panel
EvaporatorEvaporator andCondenserConnections
NOTE: Models WGZ 150 to 200 add a #5 compressor to circuit #1 and a #6 compressor to
circuit #2.
Table 22, Major Components
System #1 System #2 Expansion ValveWGZ-C
Unit
SizeComp. #1 Comp. #3 Comp. #2 Comp. #4
Evap.
Vessel
Size
Cond.
Vessel
Size System #1 System #2
30 ZP90KCE ZP90KCE ZP90KCE ZP90KCE ACH130-90DQ C1010-47 OZE-20-GA-BP15 OZE-20-GA-BP15
35 ZP103KCE ZP103KCE ZP103KCE ZP103KCE ACH130-102DQ C1010-47 OZE-20-GA-BP15 OZE-20-GA-BP15
40 ZP120KCE ZP120KCE ZP120KCE ZP120KCE ACH130118DQ C1010-57 OZE-20-GA-BP15 OZE-20-GA-BP15
45 ZP137KCE ZP137KCE ZP137KCE ZP137KCE ACH130-138DQ C1010-57 OZE-25-GA-BP15 OZE-25-GA-BP15
50 ZP154KCE ZP154KCE ZP154KCE ZP154KCE ACH130-158DQ C1010-70 OZE-25-GA-BP15 OZE-25-GA-BP15
55 ZP154KCE ZP154KCE ZP182KCE ZP182KCE ACH130-178DQ C1010-70 OZE-25-GA-BP15 OZE-35-GA-BP15
60 ZP182KCE ZP182KCE ZP182KCE ZP182KCE ACH130-198DQ C1010-70 OZE-35-GA-BP15 OZE-35-GA-BP15
70 ZP182KCE ZP235KCE ZP182KCE ZP235KCE ACH250-122DQ C1410-88 OZE-35-GA-BP15 OZE-35-GA-BP15
80 ZP235KCE ZP235KCE ZP235KCE ZP235KCE ACH350-126DQ C1410-98 OZE-50-GA-BP15 OZE-50-GA-BP15
90 ZP235KCE ZP235KCE ZP295KCE ZP295KCE ACH350-142DQ C1410-113 OZE-50-GA-BP15 OZE-50-GA-BP15
100 ZP295KCE ZP295KCE ZP295KCE ZP295KCE ACH350-152DQ C1410-128 OZE-50-GA-BP15 OZE-50-GA-BP15
115 ZP295KCE ZP385KCE ZP295KCE ZP385KCE ACH350-182DQ C1410-128 OZE-60-GA-BP15 OZE-60-GA-BP15
130 ZP385KCE ZP385KCE ZP385KCE ZP385KCE ACH350-210DQ C1410-128 OZE-60-GA-BP15 OZE-60-GA-BP15
150 (3) ZP295KCE (3) ZP295KCE EV34191111/9NS C1612-156 SEHI100-30-S SEHI100-30-S
170 (3) ZP295KCE (3) ZP385KCE EV34191212/7NS C1612-186 SEHI100-30-S SEHI100-30-S
200 (3) ZP385KCE (3) ZP385KCE EV34191212/7NS C1612-186 SEHI100-30-S SEHI100-30-S
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WGZ 030C through 200C IMM WGZC
Wiring
Field Wiring, Power
The WGZ C vintage chillers are supplied standard with compressor contactors and power terminal block,
designed for multi-point power supply to the unit, no compressor circuit breakers. Available options are:
Single-point connection to power block with compressor circuit breakers
Single-point connection to disconnect switch with compressor circuit breakersHigh short circuit current rating with single-point disconnect switch
Multi-point connection to disconnect switch, no compressor circuit breakers
A factory installed control circuit transformer is standard. Optionally, a field-installed control power source
can be wired to the unit.
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 40) give specific
information on recommended wire sizes.
Unit power inlet wiring must enter the control box through the right