Installation, Operation and Maintenance manual 803 C – 05/10 B

Date: October 2005

Supersedes: 803 C – 04/06 A

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McQuay is participating in the Eurovent Certification Programme.

Product are as listed in the Eurovent Directory of Certified Products
and on the web site www.eurovent-certification.com
803 C – 05/10 B – pag. 2/30
Introduction
General description
McQuay PFS “B” chillers are completely assembled and factory tested before shipment.
Each unit with 1 circuit has one compressor connected to one evaporator and one condenser. The units with
2 circuits are equipped with 2 compressors operating in parallel on a single evaporator and condenser.
The chillers use refrigerant R-134a to reduce the size and weight of the package compared to negative
pressure refrigerants, and since R-134a operates at a positive pressure over the entire operation range, no
purge system is required.
The controls are pre-wired, adjusted and tested. Only normal field connections such as piping, electrical and
interlocks, etc. are required, thereby simplifying installation and increasing reliability.
Most necessary equipment protection and operating controls are factory installed in the control panel.
The manual contents are applicable to all models of PFS “B” series unless specifically referenced otherwise.

Application
Units must be initially started at the job site by a factory trained McQuay service technician. Failure to follow
this startup procedure can affect the equipment warranty.
The standard limited warranty on this equipment covers parts that prove defective in material or
workmanship. Warranty does not cover materials that are subject to natural consumption.
Cooling towers used with McQuay PFS “B” chillers have to be selected according to 24°C ÷ 32°C as
maximum condenser inlet water temperature values.

Installation
Storage
If the chillers have to be stored prior to installation, the following warnings have to be observed.
Store the chillers inside, at ambient temperatures lower than 50°C.
Keep the chillers far from heat sources.
Do not expose the chillers to direct sun light.

Receiving and handling

The unit should be inspected immediately after receipt for possible damage.
The chillers are shipped ex-factory and all claims for handling and shipping damage are the responsibility of
the consignee.
Neoprene vibration pads are shipped loose. Check that these items have been delivered with the unit.
Extreme care must be used when rigging the equipment to prevent damage to the control panels or
refrigerant piping.
The unit can be lifted by fastening the rigging hooks to the four corners of the unit where the rigging eyes are
located. Spreader bars must be used between the rigging lines to prevent damage to the control panels,
piping and motor terminal boxes.

Figure 1 - Main components

Expansion valve Refrigerant level sensors

803 C – 05/10 B – pag. 3/30

 Note
For unit water connections and wiring, refer to dimensional drawing and wiring diagram.
Location and mounting
The unit must be mounted on a level concrete or steel base and must be located to provide service
clearance (3200 mm) at one end of the unit for possible removal of evaporator tubes and/or condenser
tubes. Evaporator and condenser tubes are rolled into the tube sheets to permit replacement if necessary.
Clearance at all other points, including the top, is 1 meter.
Make sure that the floor or structural support is adequate to support the full operating weight of the complete
unit.

Vibration pads
The shipped-loose neoprene vibration pads should be located under the corners of the unit (unless the job
specifications state otherwise). They are installed to be flush with the sides and outside edge of the feet. For
vibration-dampings installation, refer to dimensional drawing of the unit. If no screws are used for fixing the
unit to the floor, install anti-slip rubber between the floor and the vibration-dampings.

Before to deliver the units, refrigerant and oil valves are closed, to insulate the two fluids during the
transport. The valves have to be kept closed till start-up, that has to be performed by McQuay
technicians.

Water Piping

Evaporator and condenser water piping

All evaporators and condensers come standard with groove-type nozzles for Victaulic couplings (also
suitable for welding), or optional flange connections. The installing contractor must provide matching
mechanical connections of the size and type required.

Important Notes on Welding

If welding is to be performed on the mechanical or flange connections:
1. Remove the solid-state temperature sensor and thermostat bulbs from the wells to prevent damage
to those components.
2. Properly ground the unit or severe damage to the MicroTech II unit controller can occur.
Water pressure gauge connection taps and gauges could be provided in the field piping at the inlet and
outlet connections of both vessels for measuring the water pressure drops. The pressure drops and flow
rates for the various evaporators and condensers are job specific and the original job documentation can be
consulted for this information. Refer to the nameplate on the vessel shell for identification.
Be sure that water inlet and outlet connections match certified drawings and stenciled nozzle markings. The
condenser is connected with the coolest water entering at the bottom to maximize subcooling.
Note: When common piping is used for both heating and cooling modes, care must be taken to
provide that water flowing through the evaporator cannot exceed the maximum value which can
cause the relief valve to discharge refrigerant or damage controls.

The piping must be supported to eliminate weight and strain on the fittings and connections. Piping must
also be adequately insulated. A cleanable water strainer must be installed in both water inlet lines.
Sufficient shutoff valves must be installed to permit draining the water from the evaporator or condenser
without draining the complete system.

CAUTION
To avoid tubes damages on heat exchangers tubes, cleanable water strainer must be installed in
both water inlet lines. Filter mesh size has to be 1mm.

803 C – 05/10 B – pag. 4/30

Flow Switch
A water flow switch must be mounted in the evaporator inlet water line to signal the presence of adequate
water flow to the vessel before the unit can start. It also serves to shut down the unit in the event that water
flow is interrupted to guard against evaporator freeze-up, but the flow switch operation cannot be used as
unit control.
A flow switch is available as option. It is a "paddle" type switch and adaptable to any pipe size from 1 inch to
8 inches.
Installation should be as shown in figure 2.
Figure 2, flow switch mounting
Flow direction marked
on switch

I in. (25mm) NPT flow

switch connection

Tee

Electrical connections must be made to 5 and 23 terminals of M1 terminal board for the evaporator, to 5 and
8 terminals for the condenser. Flow switch contact quality must be suitable for 24 VAC, low current (16ma).
Flow switch wire must be in separate conduit from any high voltage conductors (115 VAC and higher).

CAUTION
Freeze notice: neither the evaporator nor the condenser is self-draining;
both must be blown out to help avoid damage from freezing.
The piping should also include thermometers at the inlet and outlet connections and air vents at the high
points.
The water heads can be interchanged (end for end) so that the water connections can be made at either end
of the unit. If this is done, new head gaskets must be used and control sensors relocated.
In cases where the water pump noise can be objectionable, vibration isolation sections are recommended at
both the inlet and outlet of the pump. In most cases, it will not be necessary to provide vibration eliminator
sections in the condenser inlet and outlet water lines. But they can be required where noise and vibration are
critical.

Cooling tower
If cooling tower is used, a balancing valve is recommended. Some form of temperature control is also
required if cooling tower water should be very cold. Unit microprocessor includes the control for cooling tower
fans. Therefore it is suggested to make the relevant wiring connections.

Water treatment
Before every start-up, clean and flush the cooling water circuit. Make sure tower blowdown or bleed-off is
operating. It should be recognized that atmospheric air contains many contaminants that increase the need
for proper water treatment. The use of untreated water can result in corrosion, erosion, sliming, scaling or
algae formation. McQuay Italia S.p.A. assumes no responsibility for the results of untreated or improperly
treated water.

803 C – 05/10 B – pag. 5/30

Glycol solution
CAUTION
Use exclusively glycol for industrial applications. Do not use antifreeze for automotive applications
(this kind of antifreeze contains inhibitors that cause the evaporator tubes plating). Type and
managing of the glycol have to be according to rules in force.

Temperature and water flow limits

Operating Range

60

50
Condenser leaving temperature - °C

40

30

20

10

0
-10 -5 0 5 10 15 20
Evaporator leaving tem perature - °C

Note: the use of glycol is necessary for evaporator leaving water temperature below +3°C.

Flow rates below the minimum values shown in the evaporator and condenser pressure drop curves, may
cause freeze-up problems, scaling and poor control. Flow rates above the maximum values shown in the
evaporator and condenser pressure drop curves will result in unacceptable pressure drops, excessive
erosion and tube vibrations potential cause of tubes failure.

Evaporator freeze protection

1. If the unit will not operate during the winter, drain and flush the evaporator and chilled water piping with
glycol. Drain and vent connections are provided on the evaporator.
2. Insulate the water pipes, especially the chilled water side.
Note: freeze damages are not considered warranty failures. McQuay Italia S.p.A. declines any liability.

803 C – 05/10 B – pag. 6/30

Condenser protection and design considerations
When the unit is not operating, the condenser temperature and the liquid refrigerant line can go down the
room temperature if the cooling fluid comes from lake, river or bed water and the water valves have a blow-
by. This problem occurs when cold water circulates inside the condenser and the unit is off waiting to be
loaded. Under these conditions:
1. Shut-off the condenser water pump when the compressor is off.
2. Verify the liquid line solenoid valve is operating properly.

Chilled water temperature sensor

The PFS water-cooled chiller is equipped with a microprocessor. Be careful when working around the unit to
avoid damaging cables and sensors. Check the cables before running the unit. Avoid rubbing the cables on
the frame or other components. Verify the cables are firmly anchored. If the temperature sensor is removed
from the well for servicing, do not wipe off the heat conducting compound supplied in the well and place the
sensor correctly.

Safety valves
Each system will be equipped with a safety valve on condenser and evaporator in order to release the
refrigerant charge in case of faulty operation. Most codes require that relief valves be vented to the outside,
and this is a desirable practice for all installations.
CAUTION
To prevent injuries for R134a inhalation, avoid releasing the refrigerant in the atmosphere or inside.
The relief valves have to be vented to the outside, according to the rules in force in the country of the
installation. The installer is responsible for sizing the bleeder pipes and connecting the relief valves
to them.

Electrical connections
Wire size must be in accordance with the nameplate data and the rules in force.
McQuay Italia S.p.A. assumes no responsibility for the results of improperly electrical connections.

CAUTION
Connections to terminals must be made with copper lugs and copper wire.
Qualified and licensed electricians must perform wiring. Shock hazard exists.

Power wiring to compressors must be in proper phase sequence. For this reason, phase monitor is supplied
as standard.

Voltage unbalance
Extreme voltage unbalance in a three-phase system is the cause of increase in motor temperature. The
voltage unbalance between phases must not exceed 2%, according to the following calculation.
unbalance % = (Vx-Vm) x 100
Vm
Vx= phase with the maximum unbalance
Vm= avarage voltage

803 C – 05/10 B – pag. 7/30

i.e. the three phases are 383V, 386V e 392V, the average is:
383+386+392 = 387V,
3
therefore unbalance % is:
(392-387)x100 = 1,29% less then the maximum allowed (2%)
387

Control circuit
McQuay PFS unit’s circuit control is supplied with 110 Vac power.
Move the ON/OFF switch controller (Q0) to the “off” position every time unit operation is not required.
Inside the controller are installed connecting terminals for the water flow lock. See the wiring diagram to
operate the correct connection on the field. The purpose of the water flow interlocked switch is avoiding the
compressor operation till the evaporator and condenser pumps are able to grant the correct water flow. The
flow switch or the differential pressure switch is an accessory supplied by McQuay Italia upon request
however necessary to be installed on the unit.
It is recommended to let the microprocessor controlling the pumps for a better plant system.
In case of external control on the pumps use the following procedure.
Evaporator water pump:
• start-up the pump 2 minutes before turn on the unit;
• switch off the pump 5 minutes after turn off the unit.
Condenser water pump:
• start the pump 30 seconds before turn on the unit;
• switch on the pump 1 minute after the last compressor is off.
When the unit is not operating the condenser pump must be always off.

Circuit control test

All PFS units are factory tested. Both the control and power circuits are carefully inspected before delivering.

Operation

Operator responsibilities
It is important that the operator become familiar with the equipment and the system before attempting to
operate the chiller. In addition to reading this manual, the operator should study the operation manual for the
controller and the wiring diagram furnished with the unit before starting, operating, or shutting it down.
During the initial startup of the chiller the McQuay technician will be available to answer any questions and
instruct in the proper operating procedures.
It is recommended that the operator maintain an operating log for each individual chiller unit. In addition, a
separate maintenance log should be kept of the periodic maintenance and servicing activities.
This McQuay chiller represents a substantial investment and deserves the attention and care normally given
to keep this equipment in good working order. If the operator encounters abnormal or unusual operating
conditions, it is recommended that a McQuay service technician be consulted.

803 C – 05/10 B – pag. 8/30

Nomenclature
P F S “B” 249 . 2 134

P Water cooled

F Flooded

S Screw compressor

“B” Release

103÷296 Unit size

1 N° of compressors
2

134 Refrigerant HFC 134a

803 C – 05/10 B – pag. 9/30

Unit Description
Unit is equipped with Fr4 series single screw compressor and it includes a flooded shell-and-tube evaporator
with the refrigerant out the high efficiency tubes and the water inside them, a shell-and-tube type condenser
operating with the refrigerant out the high efficiency tubes and the cooling water inside them.
The single semi-hermetic screw compressor uses the suction gas coming from the evaporator to chill the
motor and to allow an excellent operation of the unit in all working load conditions.
Besides the standard lubrication of the moving parts, the oil injection lubrication system allows the sealing of
the screw granting the gas compression.
The refrigerant circuit also installs a rolling valve with a mechanical pilot system that runs the refrigerant
levels inside the heat exchangers still controlling the PUMP-DOWN operation.
All the reported components are managed by an innovative microprocessor control system able to monitor
all operating parameters optimising the process.
A self-diagnostic system helps the operator to detect the alarm and the failure cause.

Refrigerant Cycle Description

The low temperature refrigerant gas coming from the evaporator to the compressor cools the electric motor.
Later it is compressed and during this phase the refrigerant is mixed up to the oil coming from the separator.
The high-pressure oil refrigerant mixture is conveyed inside the oil separator of centrifugal high efficiency
type. Oil sediment to the end plate separator due to the pressure difference is again conveyed to the
compressor while the refrigerant separated from the oil is delivered to the condenser.
Inside the condenser the liquid refrigerant is equally distributed on all tube bundle surface. Crossing the heat
exchanger’s tubes, the refrigerant desuperheats starting to condense. Desuperheating and condensing heat
is taken off from condensing water consequently increasing the temperature.
Liquid condensed at saturation temperature crosses the subcooling section still yielding heat, which
increases the cycle efficiency. The subcooled liquid crosses the rolling gear that by a pressure drop starts an
expansion process flashing a part of the refrigerant.
The result is a low pressure and temperature liquid and gas mixture heat sensible that is conveyed to the
evaporator.
The liquid-gas refrigerant after being equally distributed along the tube bundle, exchanges the heat with the
water to be chilled reducing the temperature until the complete evaporation.
At gas condition the refrigerant leaves the evaporator to be again aspired by the compressor starting a new
cycle.

Evaporator
The evaporator is flooded shell-and-tube with the refrigerant out the tubes and the water inside them.
Normally no maintenance and service operation is required. When it is necessary to replace a tube it is easy
to remove the old one.

Condenser
The condenser is shell-and-tube with the refrigerant out the tubes and the water inside them. The condenser
tubes are externally finned and expanded on the tube plate. All units have an integrated subcooling in the
condenser also equipped with a safety valve. If required it is possible to remove and replace the tubes.

Expansion valve
The expansion valve is directly controlled by a refrigerant level sensor placed on the condenser. The system
controls the refrigerant liquid level, to grant an adequate operation of the expansion valve, completely
flooding the integrated sub-cooling section of the shell-and-tube condenser.
A solenoid valve controlled by the microprocessor is installed on the expansion valve body. It allows the
automatic control of pump-down function and the valve opening during the shutdown period.
The adequate positioning of liquid sensor and an appropriate refrigerant charge (factory executed) allow an
efficient and reliable unit operation.
Clear refrigerant sight glasses are located on the condenser and evaporator shells to verify immediately the
adequate charge.

803 C – 05/10 B – pag. 10/30

Refrigerant level sensor
The level sensor includes a floating element checking the refrigerant level inside the condenser and
controlling the expansion valve indirectly monitoring the refrigerant flow.
A regulating valve, installed on the sensor flange, allows to level stabilizing. This valve is factory set during
the test and normally does not require any further adjustment on the field unless on particularly unstable
plant where an additional regulation must be operated from qualified personnel only.

Compressors
The compressor is controlled by a special motor, installed on the end of the main driving shaft. It consists of
two screwed cast iron element: the main one includes all moving parts as the main rotor and the two
satellites, the second element includes the three-phases 2-poles electric motor.
The gas flows through the electric motor, cooling the windings before entering the suction ports. Sensors
inside the windings motor constantly monitor the temperature preventing from dangerous overheating. A
terminal box including the connectors for thermistors and power lines is located up to the motor casing.
The compressor moving elements executing the compression include 3 rotating parts, there are neither
reciprocating nor eccentric motions inside the compressor. Basic elements are the main rotor and two
exactly opposed gate rotors tightly meshing each other. A specially shaped synthetic material placed
between the main rotor and the satellites executes tightness seal during the compression. The main shaft
fixing both the motor and the main rotor is supported by 3 ball bearings. This system is balanced both
statically and dynamically before the assembly. Two large closing flanges are also installed on the
compressor sides for an easy access to the satellites, rotor, shaft and bearings without influencing the
assembly tolerances.

Compression process
With the single-screw compressor the refrigerant suction, compression and discharge process is operated
by a continue flow for each satellite. During this operation the volume is progressively reduced compressing
the refrigerant. After the compression, the gas is discharged through the ports properly designed. See figure
3 for suction, compression and discharge cycle.

803 C – 05/10 B – pag. 11/30

 1. and 2. Suction 1.
Main rotor flutes 'a','b'and 'c'are in
communication at one end with the suction
chamber via the bevelled rotor end face, and A
are sealed at the other end by the teeth of star
rotor A. As the main rotor turns, the effective
length of the flutes increases with a Suction
corresponding increase in the volume open to Gas
c
the suction chamber: Diagram 1 clearly b
shows this process. As flute ' a'assumes the a
position of flutes '
b'and 'c'its volume
increases, inducing suction vapour to enter B
the flute.

2.
Upon further rotation of the main rotor , the
flutes which have been open to the suction
chamber engage with the teeth of the other
A
star rotor. This coincides with each flute being
progressively sealed by the main rotor. Once
the flute volume is closed off from the suction
chamber, the suction stage of the
c
compression cycle is complete. b
a

3.
3. Compression
As the main rotor turns, the volume of gas
trapped within the flute is reduced as the
length of the flute shortens and compression
occurs.
c

b
a

4.
4. Discharge
As the star rotor tooth approaches the end of Discharge
a flute, the pressure of the trapped vapour Gas
reaches a maximum value occurring when the
leading edge of the flute begins to overlap the
triangular shaped discharge port.
Compression immediately ceases as the gas A
is delivered into the discharge manifold. The
star rotor tooth continues to scavenge the flute
b
until the flute volume is reduced to zero. This
compression process is repeated for each a
flute/star tooth in turn.
While the compression process described
above is occurring in the upper half of the
compressor, there is an identical process B
taking place simultaneously in the lower half
using star B, thus each main rotor flute is used
twice per rotor revolution (one by one tooth in
each star). The compression process may be
likened to an assembly of six double-acting
cylinders (the main rotor flutes) in which the
star rotor teeth move as pistons (always in the
same direction).

Figure 3, Compression Process

803 C – 05/10 B – pag. 12/30

Capacity control
The compressors are provided with infinitely variable capacity control as standard. This system allows unit
load to be equal to plant demand. Stepless capacity control is permitted by a pair of sliding valves, fitted in
the compressor, one for each half of the symmetrical compression process. Each slide valve is housed in a
semicircular slot in the wall of the annular ring which encloses the main rotor. As the slide valve travels
axially from the full load position it uncovers a port, which vents part of the gas trapped in the main rotor flute
back to suction, before compression can begin. When the flute has passed beyond the port, compression
commences with a reduced volume of gas. However, a simple bypass arrangement without any further
refinement would produce an undesirable fall in the effective volume ratio which in turn causes under
compression and inefficient part load operation. To overcome this problem, the slide valve is shaped so that
it delays the opening of the discharge port at the same time as the bypass slot is created.

B A

Oil Supply Oil Vent

NC NC

Piston Slide
Spring

Figure 4, Capacity Control Mechanism

803 C – 05/10 B – pag. 13/30

 B A

Oil Supply Mandata

Energised De-energised dell’olio
Compressor Unloading
(Open) (Closed)

Unload

Oil Pressure + Spring Force > Suction/Discharge Differential Pressure = Slide and Piston Move Towards Unload

B A
Oil Supply Oil Vent

De-energised Energised
(Closed) (Open) Compressor Loading

Load

Suction/Discharge Differential Pressure > Spring Force = Slide and Piston Move Towards Load
CAPACITY CONTROL ACTION SOLENOID VALVE SOLENOID VALVE
A B

Load compressor
Oil is vented from the capacity control cylinder. The action of the suction/
discharge differential pressure on the slide/piston assembly overcomes the Energised (open) De-energised (close)
force of the unloading spring and moves the slide valve towards the
maximum load position.

Unload compressor
High pressure oil is admitted to the capacity control cylinder. Oil pressure
supplements the force of the spring acting on the unload side of the piston.
The combined force is sufficient to overcome the action of the De-energised (close) Energised (open)
suction/discharge differential pressure and move the slide valve towards the
minimum load position.

Hold slide valve position

The slide valve is hydraulically locked at the desired load position. De-energised (close)

1
Start-up Start Compressor Starts Compressor
Requested (Loading Inhibited) Permitted to Load

Compressor Stopped 60 Seconds 60 Seconds

Time
Solenoid valve B Solenoid Valve B Solenoid valve B Energised (Open)
Energised (Open) De-energised Until Compressor Required to Load
(Closed)

Figure 5, Continuously variable Capacity Control

803 C – 05/10 B – pag. 14/30

Oil System control
Each screw compressor is connected to a tank (oil separator) separating and collecting the oil from
discharge gas.
The discharge gas pressure pushes the oil into the compressor where, after passing through a high capacity
filter, is conveyed to the main injection port for compressor seal and lubrication of all moving parts.
During the compression, the oil joints the discharge gas before being conveyed again into the oil separator
and re-start the cycle.
The oil flow is granted by the pressure difference created between the condenser and the evaporator. This
difference depends on the cooling water and evaporator water temperatures. During the start-up it is vital to
establish rapidly the appropriate temperature difference, by checking the right cooling water temperature.
In order to get the right pressure difference, McQuay PFS B units install regulating valve on the condenser
outlet. That valve, monitored by an analogical signal released by the microprocessor installed in the electrical
panel, is modulated depending on the unit compression ratio. The head of cooling water pump at zero flow
rate should not exceed the maximum working pressure of condenser and plant water side.
After the oil filter, a pressure transducer is installed on the compressor always monitoring the oil pressure
and forwarding the values to the microprocessor. Oil pressure control prevents the compressor from any
possible operating anomalies.
On the oil piping is also installed a flow switch deactivating the compressor in case of oil leak in the cooling
system.
Units already include the correct oil charge. Once the system is started, it is not necessary to fill additional
oil, unless repairing or when a big quantity of oil have been removed from the system.
WARNING
It is dangerous for the unit to execute a wrong maintenance on the lubricating system, including to
over charge of oil or to use oil or oil filter different from the original ones. This operation must be
performed only by qualified personnel. Please contact your local McQuay Service Centre.

Lubricating oils
Besides lubricating the bearing and other moving parts, the oil has the equally important task of granting the
seal during the compression, improving the efficiency. The amount of oil injected is therefore well in excess
than required for lubrication alone.
Lubricating oil approved for use with McQuay screw compressor is Mobil Artic 68 or ICI Emkarate RL68H.

Liquid injection
Within the nominal operating range (7°C leaving evaporator water temperature, 35°C leaving condenser
water temperature) McQuay PFS B units do not require any device for cooling the discharge gas or the oil.
When the operating conditions exceed the standard values (leaving condenser water temperature higher
than 40°C), the compressor requires the oil cooling kit defined as “liquid injection”.
That system, standard supplied on all PFS B units’ heat pump and heat recovery versions, is directly
monitored by the microprocessor installed on the unit depending on the oil temperature inside the separator.
Figure 6 shows the liquid injection circuit.
At normal operating condition and when the compressor is off, the solenoid valve (A), that controls the liquid
injection, should be also off. If the oil temperature exceeds the set point value settled in the microprocessor,
the system energises the solenoid valve (A) that injects the liquid refrigerant inside the dedicated port. The
oil temperature gradually decreases down to the set point minus the control differential when the
microprocessor de-energises the solenoid valve (A). The liquid injection may activate during plant starting
and/or during unloading conditions.

803 C – 05/10 B – pag. 15/30

 Iniezione di liquido
Oil injection

Discharge
Line
To Oil Separator

Figure 6, Liquid injection for oil cooling

Oil recovery system

Each compressor includes a system to recover the oil accumulated inside the evaporator during the normal
operation.
This system consists of a jet pump able to collect continuously all the oil from the evaporator preventing from
the accumulation due to the low speed refrigerant gas.
The high-pressure discharge gas feeds the jet pump that creates a depression, which allows the suction of
the oil refrigerant mixture from the evaporator into the compressor to re-establish the oil level inside the
lubrication system.
On the oil recovery piping a sight glass allows to check the oil-gas mixture flow to the compressor. If flow is
insufficient or if the unit continuously stops for “Low Oil Level” alarm, verify the correct operation of the
corresponding circuit.
Verify:
1) Opening of oil recovery system shutoff valves
2) Correct functioning of solenoid valve installed on the Jet Pump feed.

Heating elements
The compressor and the oil separator are supplied with resistances for heating the compressor and the oil
inside the separator, to prevent the migration and the condensation of the refrigerant during shutdown unit.
The auxiliary circuit should be energised for at least 12 hours prior to start up compressor. The compressor
and oil temperatures should be sufficiently high before starting the system lowering at the minimum problems
of lubrication and liquid blows. The microprocessor monitors directly the oil temperature and inhibits the
compressor starting if the oil temperature is not at least 5°C higher than the evaporating saturation
temperature. In that condition the compressor status will be: “Off: Oil Heating”. For granting the good
operation of the heating resistances, regularly verify their power input.

803 C – 05/10 B – pag. 16/30

MicroTech II C+ controller
The unit controller has been designed to perform, step by step, compressors starting, load modulation,
compressor protection, shout-down sequencing for no load.
MicroTech II C+ controller can be used to modify unit set points and check control parameters. For
optimizing unit running, it is recommended to gain a good experience in the system.

Figure 7, MicroTech II C+ panel

Control section - main features:

• Full routine operation at condition of:
High thermal load
High evaporator entering water temperature (start-up)
Critical heat exchange
• Display of evaporator entering/leaving water temperature
• Display of condensing/evaporating temperature and pressure
• Modulation of leaving cooled water temperature. Temperature tolerance ± 0,2°C
• Display of starts number and running hours for each compressor
• Display of safety devices status
• Equalization of starts number and running hours for the compressors
• Optimized management of compressors load
• Cooling tower’s fans management according to condensing pressure
• Automatic re-start in case of power failure
• Demand limit
• Soft Load
• AOT reset (optional)
• Current limit (optional)

Safety for each refrigerant circuit

High pressure (pressure switch)
Compressor overload (optional)
High discharge temperature for the compressor
Star / Delta transition failed
High differential oil pressure
No oil flow

System security
Phase monitor
Freeze protection

803 C – 05/10 B – pag. 17/30

Low pressure (pressure switch)
Evaporator flow switch

Regulation type
Proportional + integral + derivative modulation on input probe the evaporator water (T = ± 0,2°C)

MicroTech II C+ terminal
MicroTech II C+ terminal has following features:
• 4-lines by 20-characters liquid crystals display back lighted
• Remotable key-pad (connection by RJ11 jack)
• “Clear language display
• Key-pad consisting of 15 keys
• Multilanguage
• No volatile memory for data storage
• General faults alarm led
• 4-levels password access to modify the set values
• Service report displaying running hours and general conditions

Compressors rotation
McQuay PFS B water cooled units automatically alternate the starting sequence of compressors for
balancing starts number and running hours.
On “automatic mode”, the compressor with the lower number of starts is activated as first. If both
compressors are running, in case of need, the first one to be stopped is the one with the highest working
hours.

High condensing pressure control

The microprocessor is supplied with a transducer for monitoring the condensation pressure. Although the
main task of high pressure transducer is to maintain the correct condensing pressure control (monitoring the
cooling towers when connected), the transducer also send a signal to the microprocessor to stop the
compressor when the discharge pressure is over the maximum limit. When the unit is off due to high
condensation pressure, the microprocessor should be manually reset.

Mechanical high pressure safety switch

The high pressure safety switch is a single pole switch that opens when the pressure exceeds the limit.
When the switch opens, the control relay is disconnected and the compressor shutdown.
The pressure switch is installed on the oil separator.
For reset the pressure switch, push the blue button and reset the alarm on the microprocessor.

Compressor motor protection

The compressors are protected against the motor over temperature by thermistors installed on each motor
winding. The three thermistors, mounted in series, are connected to a device reported on the wiring diagram
as MP1 and MP2. The alarm “compressor thermal relay” is resetable manually on the keyboard.
Repeated use of this protection, during the normal operation, may indicate a potential compressor motor
problem or a suction overheating due to low refrigerant charge. The overload relays (optional) are manually
resetable and both the relays and the microprocessor must be reset.

Phase monitor
The phase monitor provides protection against phase loss and phase reversal. Whenever any of these
conditions occurs, a contact opens disabling the start-up or disconnecting the system.

803 C – 05/10 B – pag. 18/30

 WARNING
The phase reversal may seriously damage the compressor.

When energising the unit, the phase monitor relay closes and the microprocessor enables the compressors
for operation. If the output relay does not close, the microprocessor releases the alarm “Phase Monitor”. In
that case perform the following tests:
1. Using an external phase tester, verify that R/S/T phases sequence is correct. A correct rotation is
required for compressor operation. If phases sequence correction is required, turn off the unit and invert
two phases on the main power supply line.
2. Turn on the unit. The phase monitor relay should now close.
3. If the alarm is still on, verify with a voltmeter the phase’s presence.

PlantVisorTM
TM
The units can be monitored locally or via modem by PlantVisor supervision program that runs on PC under
Windows 2000-XP.
TM
PlantVisor is the best solution:
• To centralize all the information in one local or remote PC
• To check all the parameters of the connected units
• To be kept updated about the alarms by modems or printers
• Data record for temperature, pressure and humidity
• Printouts of alarms, parameters and graphs
• To control several plants located in different geographical areas from a central station

TM
PlantVisor allows:
• Display and modification of the microprocessors parameters
• Protection of the main parameters by multiple password levels
• Record of data and graphics
• Display, print-out and record of the alarms

803 C – 05/10 B – pag. 19/30

Maintenance
Pressure / Temperature

Pressare / Temperature for HFC-134a

°C Bar °C Bar °C Bar °C Bar

-14 0,71 12 3,43 38 8,63 64 17,47

-12 0,85 14 3,73 40 9,17 66 18,34

-10 1,01 16 4,04 42 9,72 68 19,24

-8 1,17 18 4,37 44 10,30 70 20,17

-6 1,34 20 4,72 46 10,90 72 21,13

-4 1,53 22 5,08 48 11,53 74 22,13

-2 1,72 24 5,46 50 12,18 76 23,16

0 1,93 26 5,85 52 13,85 78 24,23

2 2,15 28 6,27 54 13,56 80 25,33

4 2,38 30 6,70 56 14,28 82 26,48

6 2,62 32 7,15 58 15,04 84 27,66

8 2,88 34 7,63 60 15,82 86 28,88

10 3,15 36 8,12 62 16,63 88 30,14

Ordinary maintenance

Check on condenser performance

It is important to program periodic cleaning of copper piping to prevent from performance failure. This check
can be done verifying on the microprocessor that the difference between the condensing temperature and
the condenser leaving water temperature does not exceed 5°C. In case of value deviation it is recommended
to clean the condenser.

Expansion valve and level control

PFS B units are equipped with an expansion valve directly controlled by a level sensor installed on the
condenser. This system should not normally require maintenance, being factory set during the final test. The
expansion valve is energised under the control by a solenoid valve, managed by the microprocessor. That
valve executes the evaporator pump down during unit shutdown. In case of unit shut down at low pressure
condition, check the solenoid valve operation. A regulating valve factory set is installed on the level
controller. However for plants particularly unbalanced could be required an adjustment. Valve closing
increases the expansion valve response time up the complete closing, making the level control slower while
the valve opening speeds up this operation. It is recommended not to vary the valve position unless strictly
required.

Refrigerant circuit
The refrigerant circuit maintenance consists of recording all operating conditions and ensures the correct oil
and refrigerant quantity. (See maintenance program and the operating data at the end of this bulletin).
During each inspection, the following data should be recorded: oil pressure, suction pressure, discharge
pressure, condenser water temperature, evaporator water temperature. Changes in sub-cooling and/or
discharge superheating could be due to low refrigerant charge. The right discharge superheating value at full
load should be included between 8°C and 15°C with R134a refrigerant, while the sub-cooling included
between 3,5°C and 6,0°C (at full load).

803 C – 05/10 B – pag. 20/30

 COMPRESSOR COMPRESSOR

EVAPORATOR

WATER
OUTLET
CONDENSER
WATER
INLET

Figure 8, Typical refrigerant circuit

F12 – 22 LP LOW PRESSURE SWITCH

F13 – 23 HP HIGH PRESSURE SWITCH
OLS1 – 2 OIL LEVEL READOUT
Y1 LIQUID SOLENOID VALVE
Y3 – 4 OIL INJECTION SOLENOID VALVE
Y17 – 27 JET PUMP SOLENOID VALVE
YC CONDENSING CONTROL VALVE
WH1 HIGH PRESSURE TRANSDUCER (0÷30 bar)
WL1 LOW PRESSURE TRANSDUCER (-0,5÷7 bar)
WD1 – 2 DISCHARGE SENSOR
WOC CONDENSER LEAVING WATER TEMPERATURE SENSOR
WIC CONDENSER ENTERING WATER TEMPERATURE SENSOR
WOE EVAPORATOR LEAVING WATER TEMPERATURE SENSOR
WIE EVAPORATOR ENTERING WATER TEMPERATURE SENSOR

Refrigerant charge
PFS B units are designed to operate with R134a refrigerant. DO NOT USE any other refrigerant other than
R134a.

WARNING
Ensure the correct water flow inside the evaporator and condenser while adding or removing the refrigerant
to prevent from tubes freezing.
Freezing damages invalidates the warranty conditions.

803 C – 05/10 B – pag. 21/30

Qualified personnel using correct material must perform refrigerant removing and drain operation.
Inappropriate maintenance could lead to refrigerant or pressure loss. Do not discharge the refrigerant or the
lubricant oil into the environment. Always use a proper recovery system.

WARNING
DO NOT OVERCHARGE THE SYSTEM
Excessive refrigerant charge increases the gas level in the evaporator contributing to the oil migration into
the evaporator, which may trigger alarm for lack of oil into the compressor.

All units are shipped factory charged with a full operating charge of refrigerant. However if a unit must be
recharged at the jobsite following are recommendations to apply. PSF B units are more sensitive to
overcharging therefore it is preferable a slightly undercharge of refrigerant. The optimum charge allows the
unit to run with a correct refrigerant flow at all operating conditions.

Check on refrigerant charge

To verify if the unit is operating with the correct refrigerant charge the following checks must be executed.
1. Run the unit at maximum operating load.
2. Check the evaporator leaving water temperature to be between 6÷8°C.
3. Check the condenser entering water temperature to be between 25 and 32°C.
4. Under the above mentioned conditions verify the following items.
a) The discharge superheating to be between 8 and 15°C
b) The sub-cooling to be between 4 and 6°C
c) The difference between leaving water temperature and evaporating temperature to be in
0,5÷4°C range.
d) The difference between condensing temperature and condenser leaving water
temperature to be in 0,2÷3°C range.
e) The evaporator refrigerant level slightly laps last tubes row by checking the sight glass
installed on each evaporator for a visual inspection.
f) The condenser refrigerant level to be included between the condensing and the sub-
cooling sections by checking the sight glass installed on each condenser for a visual
inspection.
5. Verify the sight glass on the liquid piping to be fully charged.
If one of the above parameters exceeds the limits, unit may require an additional refrigerant charge.

Note: As the unit changes the load, the sub-cooling will vary, but should become stable shortly; however it
should never go below 3°C. The sub-cooling will vary somewhat with evaporator and condenser leaving
water temperatures.

A refrigerant leak could be such small to have little effect on the circuit or could be such severe to cause the
unit to shut down for operation of safety protections.
Procedure to charge a moderately uncharged PFS B unit.
1. Connect the refrigerant tank to the service-filling valve located on the evaporator.
2. Open the refrigerant cylinder and charge the unit weighing the gas – or – charge the unit during the
compressor/s operation until the evaporating pressure allows the compressors running at full load.
3. With compressors running at 100%, add the refrigerant checking the evaporator gas level does not
exceed the last tubes row.

803 C – 05/10 B – pag. 22/30

 WARNING
If during the unit operation there is an excessive formation of foam inside the evaporator, check the oil
recovery system. An excessive oil dilution into the evaporator could be determined by a too rich refrigerant
charge.

Electrical System
Maintenance of the electrical system involves the general requirement of keeping contacts clean and
connections tight and checking on specific items as follows:
The compressor current draw should be checked and compared to nameplate value. Normally, the actual
current will be lower, since the nameplate rating represents full load operation.
Inspection must verify that the oil heaters are operative. The heaters can be checked by ammeter
reading. They should be energised whenever power is available to the control circuit and the compressor
is inoperative. When the compressor runs, the heaters are de-energised.
At least once a quarter, all equipment protection controls except compressor overloads and high
pressure switches should be made to operate and their operating points checked. A control can shift its
operating point as it ages, and this must be detected so the controls can be adjusted or replaced. Pump
interlocks and flow switches should be checked to be sure they interrupt the control circuit when tripped.
Thermal relays and high pressure switches have to be checked separately at the test bench.
Absorbed current for electrical heaters in the compressor is about 4,1 A, while it is about 1,4 A for the oil
separator.
The contactors in the motor starter should be inspected and cleaned quarterly. Tighten all terminal
connections.
The compressor motor resistance to ground should be checked and logged semi-annually. This log will
track insulation deterioration. A reading of 50 MΩ or less indicates a possible insulation defect or
moisture and must be further checked.

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

Cleaning and Preserving

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

Seasonal Servicing
Prior to shutdown periods and before starting up again, the following service procedures must be completed.
Annual Shutdown
Where the chiller can be subject to freezing temperatures, the condenser and chiller must be drained of
all water. Dry air blown through the condenser will aid in forcing all water out. Removal of condenser
heads is also recommended. The condenser and evaporator are not self-draining and tubes must be
blown out. Water permitted to remain in the piping and vessels can rupture these parts if subjected to
freezing temperature.
Forced circulation of antifreeze through the water circuits is one method of avoiding freeze up.

803 C – 05/10 B – pag. 23/30

2. Take measures to prevent the shutoff valve in the water supply line from being accidentally turned on.
If a cooling tower is used, and if the water pump will be exposed to freezing temperatures, be sure to
remove the pump drain plug and leave it out so any water that can accumulate will drain away.
Open the compressor disconnect switch, and remove the fuses. Set the manual I/O switch to the O
position.
Check for corrosion and clean and paint rusted surfaces.
Clean and flush water tower for all units operating on a water tower. Make sure tower blowdown or
bleed-off is operating. Set up and use a good maintenance program to prevent “liming up” of both tower
and condenser. It should be recognized that atmospheric air contains many contaminants that increase
the need for proper water treatment. The use of untreated water can result in corrosion, erosion, sliming,
scaling or algae formation. It is recommended that the service of a reliable water treatment company be
used.
Remove condenser heads at least once a year to inspect the condenser tubes and clean if required.

WARNING
McQuay International assumes no responsibility for the results of untreated or improperly treated
water.

Annual Startup
This is a good time to check all the motor winding resistance to ground. Semi-annual checking and recording
of this resistance will provide a record of any deterioration of the winding insulation. All new units have well
over 100 MΩ resistance between any motor terminal and ground.
1. The control circuit must be energised at all times, except during service. If the control circuit has been off
and oil is cool, energise oil heaters and allow 24 hours for heater to remove refrigerant from the oil
before starting.
2. Check and tighten all electrical connections.
3. Replace the drain plug in the cooling tower pump if it was removed at shutdown time the previous
season.
4. Install fuses in main disconnect switch (if removed).
5. Reconnect water lines and turn on supply water. Flush condenser and check for leaks.

Repair of System

Pumping Down
If it becomes necessary to pump the system down, extreme care must be used to avoid damage to the
evaporator from freezing. Always make sure that full water flow is maintained through the chiller and
condenser while pumping down. To pump the system down, close all liquid line valves. With all liquid line
valves closed and water flowing, start the compressor. Pump the unit down until the MicroTech II controller
cuts out. Use a portable condensing unit to complete the pump down, condense the refrigerant, and pump it
into the condenser.
A pressure regulating valve must always be used on the drum being used to build the system pressure.
Also, do not exceed the test pressure given above. When the test pressure is reached disconnect the gas
cylinder.

Pressure Testing
No pressure testing is necessary unless some damage was incurred during shipment. Damage can be
determined upon a visual inspection of the exterior piping, checking that no breakage occurred or fittings
loosened. Service gauges should show a positive pressure. If no pressure is evident on the gauges, a leak

803 C – 05/10 B – pag. 24/30

may have occurred, discharging the entire refrigerant charge. In this case, the unit must be leak tested to
determine the location of the leak.

Leak Testing
In the case of loss of the entire refrigerant charge, the unit must be checked for leaks prior to charging the
complete system. This can be done by charging enough refrigerant into the system to build the pressure up
to approximately 70 kPa and adding sufficient dry nitrogen to bring the pressure up to a maximum of 850
kPa. Leak test with an electronic leak detector. Halide leak detectors do not function with R-134a. Water flow
through the vessels must be maintained anytime refrigerant is added or removed from the system.

WARNING
Do not use oxygen or a mixture of R-22 and air to build up pressure
as an explosion can occur causing serious personal injury.
To build up pressure, pressure regulating valve must be used. If pressure test is requested, disconnect the
refrigerant cylinder before performing the test.
If any leaks are found in welded or brazed joints, or it is necessary to replace a gasket, relieve the test
pressure in the system before proceeding. Brazing is required for copper joints.
After making any necessary repair, the system must be evacuated as described in the following section.

Evacuation
After it has been determined that there are no refrigerant leaks, the system must be evacuated using a
vacuum pump with a capacity that will reduce the vacuum to at least 130Pa ≅1mmHg).
A mercury manometer, or an electronic or other type of micron gauge, must be connected at the farthest
point from the vacuum pump. For readings below 130Pa, an electronic or other micron gauge must be used.
The triple evacuation method is recommended and is particularly helpful if the vacuum pump is unable to
obtain the desired 130Pa of vacuum. The system is first evacuated to approximately 660Pa ≅5mmHg). Dry
nitrogen is then added to the system to bring the pressure up to zero.
Then the system is once again evacuated to approximately 230Pa ≅2mmHg). This is repeated three times.
The first pulldown will remove about 90% of the noncondensables, the second about 90% of that remaining
from the first pulldown and, after the third, only 0,2% noncondensables will remain.

Charging the System

PFS B water chillers are leak tested at the factory and shipped with the correct charge of refrigerant as
indicated on the unit nameplate. In the event the refrigerant charge was lost due to shipping damage, the
system should be charged as follows after first repairing the leaks and evacuating the system.
Connect the refrigerant drum to the gauge port on the liquid line shutoff valve and purge the charging
line between the refrigerant cylinder and the valve. Then open the valve to the mid-position.
2. Turn on both the cooling tower water pump and chilled water pump and allow water to circulate through
the condenser and the chiller. (It will be necessary to manually switch on the condenser pump.)
3. If the system is under a vacuum, stand the refrigerant drum with the connection up, and open the drum
and break the vacuum with refrigerant gas to a saturated pressure above freezing.
4. With a system gas pressure higher than the equivalent of a freezing temperature, invert the charging
cylinder and elevate the drum above the condenser. With the drum in this position, valves open, water
pumps operating, liquid refrigerant will flow into the condenser. Approximately 75% of the total
requirement estimated for the unit can be charged in this manner.
After 75% of the required charge has entered the condenser, reconnect the refrigerant drum and
charging line to the service valve on the bottom of the evaporator. Again purge the connecting line, stand
the drum with the connection up, and place the service valve in the open position.

803 C – 05/10 B – pag. 25/30

IMPORTANT: At this point, the charging procedure should be interrupted and prestart checks made before
attempting to complete refrigerant charge. The compressor must not be started at this time. (Preliminary
check must first be completed.)

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

803 C – 05/10 B – pag. 26/30

Maintenance Schedule

I. Compressor
A. Performance Evaluation (Log & Analysis) * O
B. Motor
• Meg. Windings X
• Ampere Balance (within 10%) X
• Terminal Check (tight connections, porcelain clean) X
C. Lubrication System
• Oil Lines Temperatures O
• Oil Solenoid Valve Operation X
• Oil Analysis X
• Oil Appearance (clear color, quantity) O
• Oil Filter Change X
• Oil change if indicated by oil analysis X
D. Unloading Operation
• Compressor Loads:
Record Motor Amps X
• Compressor Unloads:
Record Motor Amps X
E. Internal Compressor Check X
II. Controls
A. Operating Controls
• Check Settings and Operation X
• Check Unloading Setting and Operation X
• Verify Load Balance Operation X
B. Protective Controls
• Test Operation of:
Alarm Relay X
Pump Interlocks X
High and Low Pressure Cutouts X
High Discharge Temperature Cutout X
Oil Pump Pressure Differential Cutout X
III. Condenser
A. Performance Evaluation O
B. Test Water Quality X
C. Clean Condenser Tubes X
E. Seasonal Protection X
IV. Evaporator
A. Performance Evaluation (Log Conditions And Analysis) O
B. Test Water Quality X
C. Clean Evaporator Tubes (as required) X
E. Seasonal Protection X
V. Expansion Valves
A. Performance Evaluation X
Key: O = Performed by in-house personnel X = Performed by McQuay Service personnel

803 C – 05/10 B – pag. 27/30

Maintenance Schedule, Cont.

VI. Compressor - Chiller Unit

A. Performance Evaluation O
B. Leak Test:
• Compressor Fittings and Terminal X
• Piping Fittings X
• Oil Pump Joints and Fittings X
• Vessel Relief Valves X
C. Vibration Isolation Test X
D. General Appearance:
• Paint X
• Insulation X
VII. Starter
A. Examine Contactors (hardware and operation) X
B. Verify Overload Setting and Trip X
C. Test Electrical Connections X
VIII. Optional Controls
B. Liquid Injections Controls (verify operation) X
Key: O = Performed by in-house personnel X = Performed by McQuay Service personnel

NOTE
Some compressors use power factory correction capacitors. Capacitors must be disconnected from
the circuit to obtain a useful Megger reading. Failure to do so will produce a low reading. In handling
electrical components, only fully qualified technicians must attempt service.

803 C – 05/10 B – pag. 28/30

Prestart System Checklist
Chilled Water
Piping complete
Water system filled, vented
Pumps installed, (rotation checked), strainers cleaned
Controls (3-way, face and bypass dampers, bypass valves, etc.) operable
Water system operated and flow balanced to meet unit design requirements
Condenser Water
Cooling tower flushed, filled and vented
Pumps installed, (rotation checked), strainers cleaned
Controls (3-way, bypass valves, etc.) operable
Water system operated and flow balanced to meet unit requirements
Electrical
Power leads connected to the electrical panel
Pump starters and interlock wired
Cooling tower fans and controls wired
Wiring complies with local codes
Condenser pump starting relay installed and wired
Miscellaneous
Relief valve piping complete
Thermometer wells, thermometers, gauges, control wells, controls, etc., installed
Minimum system load of 25% of machine capacity available for testing and
adjusting controls

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

803 C – 05/10 B – pag. 29/30

 We reserve the right to make changes in design and construction at any time without notice, thus the cover picture is not binding.

McQuay partecipa al programma di McQuay is participating in the Eurovent

Certificazione Eurovent. Certification Programme
I prodotti interessati figurano nella Guida Product are as listed in the Eurovent
Eurovent dei Prodotti Certificati. Directory of Certified Products

McQuay Italia S.P.A.

S.S. Nettunense, km 12+300 – 00040 Cecchina (Roma) Italia – Tel. (06) 937311 – Fax (06) 9374014 – email: info@mcquayeurope.com
www.mcquayeurope.com

803 C – 05/10 B – pag. 30/30