Daikin McQuay. Centrifugal Chiller Dual Compressor WDC, TDC, HDC 100. Replacement Parts List No Revision F 11/2016

Transcription

1 Replacement Parts List Revision F /206 Daikin McQuay Centrifugal Chiller Dual Compressor WDC, TDC, HDC 00 To find your Daikin Applied parts distributor, call or visit

2 Contents Parts List Revision History... 3 Electrical Legend... 4 Nomenclature Nameplate Locations and Part s... 5 Unit Dataplate, Model - Unit, Style - Unit, Serial - Unit... 6 Model - Complete Control Box- MicroTech 200 Mounting of Unit Control Panels... 2 Front Panel & Inside of Micro Control Door Assembly... 3 Interior Panel Sensors... 6 Cables & Lube Box Tubing Mounting of Lube Boxes... 9 Lube Box Assembly- Oil Pump Control Box- MicroTech II Unit Control Box Mounting Components Unit Control Box Detail - Until 5/ Unit Control Box Detail- 5/05 to 6/ Unit Control Box Detail- 6/ and Later Compressor Control Box Mounting Components Compressor Control Box Detail- Until 6/ Compressor Control Box Detail- 6/ and Later Cables and Sensors Differential Pressure Switch Hot Gas Bypass Liquid Line Exp & Ball Valve, Sight Glass, King Valve, Flanges, Gaskets, O'Rings, Sensor Well, Tubing Expansion Valve Detail Condenser & Evaporator Valves Insulation Condenser Nomenclature Flanges, Heads, Gaskets, Tubes Evaporator Nomenclature Liquid Line Flange, Heads, Gaskets, Tubes Compressor Nomenclature Way SA/SB Solenoid Valve & Tubing Motor Drain Line, Motor Cooling Line, Liquid Injection 6 Foot Units Foot Units Suction and Discharge Lines; Suct Victaulics, Pipes, Seals, Dischg Nozzle, Flanges, Ck Valve 6 Foot Units Foot Units Final Section Assembly Front End Inlet Section; Vanes, Piston, Cone, Seals Main Gear Train Low & Medium Voltage Units (200V- 6600V)... 7 High Voltage Units (0000V- 000V) Motor End Low Speed Bearing, Cover, Rotor/Shaft, O'Rings, Gaskets Impeller, Gear End Low Speed Bearing, Low Speed Thrust Bearing & Cover, Diffuser, Low Speed (Bull) Gear, Oil Deflectors, High Speed Shaft Seal, O'Rings, Pins High Speed Assembly; Pinion, Thrust Pump, High Speed Bearings, Seals Gears- High Speed (Pinion) & Low Speed (Bull) O'Ring Kits " Motor Section " Motor Section " High Voltage Motor Section Discharge Flange/O'Ring, External Flanges, Valves, Fittings and Blockoffs " Motor Terminal Box " Motor Terminal Box " High Voltage Motor Terminal Box Oil Oil Pump Critical Parts List... CPL RPL / Page 2

3 Parts List Revision History Revision Date Description 06/04 New A 2/04 Page 25 - Added compressor Control Box dated 9/04 and later. Page 27 - Replaced table with one that has information 9/04 and later added. B 9/05 Page 23 - Added to heading "Until 5/05' Page 24 - Added to heading 'Until 5/05*' and note Page 25 - New page added Unit Control Box Detail 5/05 and Later' Note from page 25 and on the pages are re-numbered. Page 30 - Note 5 was added. Bub 220: Added another sensor well pn Bub. 55; Added another sensor well pn Page 34 - Added footnote 7. Page 36 - Added footnote 2. Page 40 - Footnote # changed Page 4 - Added footnotes 3 & 4. Page 47 - Tube table 6ft for code 'L' changed from to & 20ft changed from to Page 48 - Pn for Bub #350 2-pass return head changed from to Page 50-48' gasket pn changed from to Page 50 - Pn for Bub #350 2-pass return head changed from to Page 55-48' gasket pn changed from to Page 58 - Bub's 42, 404 & 405 had the reference to footnote # removed. Page 74 - Bub 49 Lee plug-added 'Until 7/04' to description, Bub 49Plug Expansion 7/04 & Later pn added. Page 79 - Bub changd to Page 83 - Bub to Page 87 & 88- Replaced page Page 94 - Replaced page Page 02 - Bub 332 pn changed from to Page 06 - Bub 6 - Pn changed from to C 5/09 Page 94- Remove "Maximum Net Operating Pressure= 00-0 Net PSI". D 9/09 Page 48- Change Tube Table Code N p/n to and p/n to Page 53- Change Tube Table Code F p/n to and p/n to Change Code Q p/n to and p/n to E 04/202 Major update of document, including: Corrections and additions to Unit, Condenser and Evaporator Nomenclature. Control Box- MTII: Expanded information for Operator Interface Panel. Added drawing and components for "Unit Control Box- 6/ and later." Added drawing and components for "Compressor Control Box- 6/ and later." Removed Condenser & Evaporator Head part numbers, added note to contact McQuayParts. Added several drawings, components & footnotes for High Voltage Units (0000V-000V). Removed some Suction and Discharge piping components. Plus various other changes, corrections and clarifications. F /206 Page 22: Corrected descriptions for Ref. 5 OITS Cables. Added Power Cord w/ac Adapter. Pages 24, 25 & 27: Updated description for BACnet to MS/TP, was RS232. Page 55: Corrected description for Evaporator Gaskets. Page 90: Added Footnote 2 to Ref. 60 Motor Assemblies. Page 08: Corrected quantity for Ref. #04 O-Ring, was. Page 2: Corrected p/n for Ref. 6 Valve, was ; & Ref. 7 Cover, was Page CPL: Added new page for Critical Parts List. Daikin Applied, 3600 Industrial Park Blvd., P.O. Box 55, Minneapolis, MN (763) RPL / Page 3

4 Electrical Legend Sch. Sym. Description Location M, 2M Contactor Starter S, 2S Energizing Contactor Starter ADI Analog/Digital Input Board MicroTech 200 Control Box AOX Analog Output Board MicroTech 200 Control Box CAP Capacitor Lube Box (MicroTech 200) or Compressor Control Box (MicroTech II) CB Circuit Breaker MicroTech 200 or MicroTech II Unit Control Box CF Condenser Flow Switch Tube Sheet Support- MicroTech II Units CHW Evaporator Flow Switch Tube Sheet Support- MicroTech 200 Units CR Relay MicroTech II Compressor Control Box CS0- CS0 Sensors- Compressor Controller Throughout Unit- MicroTech II (see MicroTech II section for sensor placement) CTB, CTB2 Terminal Block Compressor Controller- MicroTech II Units CW Condenser Flow Switch Tube Sheet Support- MicroTech 200 Units DIST/ISO Dist. & Isolation Board MicroTech II Unit Controller EF Evaporator Flow Switch Tube Sheet Support- MicroTech II Units FVC Flux Vector Control VFD Panel (Code 29-= V) HP High Pressure Switch MicroTech 200 Panel HR Relay MicroTech II Compressor Controller KDI Keypad/Display MicroTech 200 Panel LR Relay MicroTech II Compressor Controller MCB Main Control Board MicroTech 200 Panel MCR Motor Control Relay Starter Panel OBA Output Board MicroTech 200 Panel OIM Operator Interface Module VFD Panel (Code 29-= V) OITS Operator Interface Touch Screen MicroTech II Units OL Oil Pump Overload Lube Box (MicroTech 200) or Compressor Control Panel (MicroTech II) OP Oil Pump Contactor Lube Box (MicroTech 200) or Compressor Control Panel (MicroTech II) pc02 Main Controller MicroTech II Unit Controller PHP High Pressure Transducer Discharge Nozzle plan LAN Cable Connects MicroTech II Controllers RES Transition Resistor Starter RMI Remote Meter Interface VFD (Code 29-= V) S00- S22 Sensor- MicroTech 200 Throughout the Unit (see MicroTech 200 section for sensor placement) SA/SB 4- Way Vane Speed Solenoid Compressor Gear Housing SC Signal Converter MicroTech 200 Control Box or MicroTech II Compressor Control Box T, T2, T3 Main Control Transformer Starter T2 24V Control Transformer MicroTech 200 Control Box T3 8V Control Transformer MicroTech 200 Control Box TR Timing Relay Starter TRP Transition Resistance Protector Starter TSW Toggle Switch- Templifier MicroTech 200 Control Box (TDC only) US02- US0 Sensor- Unit Controller Throughout Unit- MicroTech II (see MicroTech II section for sensor placement) UTB Unit Control Terminal Block MicroTech II Unit Control Box VC Vane Close Switch Lube Box- MicroTech 200 Unit VR Voltage Relay Lube Box- MicroTech 200 Unit RPL / Page 4

5 Nomenclature Nameplate Locations and Part s Unit Dataplate pn: Unit Dataplate pn: End View- MicroTech 200 Units (6 ft. Unit Shown) End View- MicroTech II Units (6 ft. Unit Shown) Compressor Dataplate pn: Compressor Dataplate pn: Evaporator Dataplate pn: (until 8/03) pn: (8/03 & later) Condenser Dataplate pn: (until 8/03) pn: (8/03 & later) Front View (20 ft. Unit Shown) RPL / Page 5

6 Nomenclature Unit Dataplate Model - Unit WDC 00 L Unit Model WDC= Water- Cooled Dual Compressor Centrifugal Chiller HDC= Water- Cooled Dual Compressor Centrifugal Chiller with Heat Recovery Condenser TDC= Templifier, Dual Compressor Centrifugal Impeller type L, M Impeller Size 00= 0.0" Diameter Style - Unit E Always "E" 6- Digit G.O. G.O. Item Serial - Unit STN U Plant Identification Abbreviation STN = Staunton U= Unit Year of Manufacture 00= = = = = = 2005 etc. Serial (build sequence) Month of Manufacture 0= January 07= July 02= February 08= August 03= March 09= September 04= April 0= October 05= May = November 06= June 2= December RPL / Page 6

7 . Model Type WDC= Water Cooled Centrifugal Chiller- Dual Compressor HDC= Water Cooled Heat Recovery Chiller- Dual Compressor TDC= Centrifugal Templifier- Dual Compressor 2. Compressor Size/Impeller Type 00 (0.0" impeller) 00L, 00M 3. Gear Ratio Code (speed code) AV, AW, A2, AY, AZ, BA, BB, BC, BD, BE, BF, BG, BH, BJ, BK, BL, BM, BN, BP, BQ, BR, BS, BT, BU 4. Motor Horsepower/Voltage first 2 digits= horsepower, third digit= voltage Digits & 2 60 Hz. Codes 6= 600HP 62= 600HP 72= 725HP 73= 725HP 84= 840HP 85= 850HP K0= 000HP N0= 990HP N= 090HP N2= 90HP N3= 300HP P6= 830HP P7= 000HP P8= 250HP R5= 500HP Digits & 2 50 Hz. Codes 52= 500HP 53= 500HP 59= 600HP 62= 600 HP 7= 700HP 73= 700HP 83= 830HP 85= 830HP 9= 95HP N0= 990HP N= 090HP N2= 90HP M= 085HP P6= 830HP P7= 000HP P8= 250HP R5= 500HP Digit 3 60 Hz. Codes N= 200V B= 208V P= 220V V= 230V 4= 400V A= 440V R= 460V S= 480V D= 575V Q= 46V M= 2400V C= 3300V L= 460V 3= 2300V T= 4600V 2= 6600V Digit 3 50 Hz. Codes E= 220V Y= 346V F= 380V G= 400V K= 45V H= 440V Z= 500V J= 3300V 6= 3000V 8= 6000V 9= 6600V 5= 0000V 6= 000V 5. Refrigerant Contamination Protection Y= None 6. Sound Control L= Liquid Injection 7. Compressor Revision Level A= Rev. Level A B= Rev. Level B Nomenclature Model - Complete WDC 00L BK 85R Y L B E426 4E 2LA B CC Y A C426 3LYY Code: LAYYY D4 370 CCYY YY A A RC 2LEYSA 25YY2YYY 083 H H2 B Code: B Y S Y A A 800 U B C Y Y Y Y Y Code: Evaporator Description E366= Standard Evaporator, 36" Diameter/6' Long E426= Standard Evaporator, 42" Diameter/6' Long E4220= Standard Evaporator, 42" Diameter/20' Long E486= Standard Evaporator, 48" Diameter/6' Long E4820= Standard Evaporator, 48" Diameter/20' Long 9. Evaporator Tube Description first digit= Tube Count/ second digit= Tube type Tube Count 36" diameter: = 6 2= 676 3= 750 4= 770 5= 82 6= " diameter: = 94 2= 04 3= 076 4= 053 5= 03 6= 47 48" diameter: = 237 2= 322 3= 452 4= 405 5= 504 6= 55 Tube Type E= Turbo EFP.025 Wall; F= Turbo EFP.028 Wall; Q= Turbo EFP.035 Wall 0. Evaporator Head Description first digit= of Water Passes:, 2, 3 second digit= Inlet Nozzle Location: L= Left R= Right third digit= Nozzle Type: A= Victaulic (std.); B= Flanged; C= Marine Box- Victaulic; E= Marine Box- Flanged RPL / Page 7

8 . Evaporator Design Pressures first digit= Refrigerant Side Pressure: B= 80 PSIG; C= 200 PSIG; D= 225 PSIG second digit= Waterside Pressure: = 50 PSIG ASME; 2= 250 PSIG ASME; 3= 350 PSIG ASME; 4= 50 PSIG Non-ASME; 5= 300 PSIG Non-ASME 2. Evaporator Leaving Water Temperature Code is listed in tenths of F (example 0450= 45.0 F) 3. Evaporator Tube Sheet & Head Material first digit= Tube Sheet Material: C= Carbon Steel (std.); N= Monel Clad; S= Stainless Steel Clad; T= Titanium Clad Steel second digit= Head Material: C= Carbon Steel (std.); E= Epoxy Coated 4. Evaporator Tube Cleaning System Y= None B= WSA Brushes 5. Evaporator Model Revision A= Revision A 6. Condenser Description C366= Standard Condenser, 36" Diameter/6' Long C426= Standard Condenser, 42" Diameter/6' Long C4220= Standard Condenser, 42" Diameter/20' Long C486= Standard Condenser, 42" Diameter/6' Long C4820= Standard Condenser, 48" Diameter/20' Long S486= Split-Head Condenser, 42" Diameter/6' Long S4820= Split-Head Condenser, 48" Diameter/20' Long 7. Tower Condenser Tube Description/Heat Recovery (Split Head Condenser Only) Tube Description first & third digit= Tube Count/ second & fourth digit= Tube type Tube Count 36" diameter: = 929 2= 07 3= 03 4= 46 5= 70 42" diameter: = 34 2= 469 3= 554 4= 593 5= 640 6= " diameter: = 858 2= 954 3= = = 25 6= 23 7= 286 Tube Type L= Turbo CSL.025 Wall; N= Turbo CSL.028 Wall; P= Turbo CSL.035 Wall If there is no Heat Recovery Condenser digits 3 & 4= Y 8. Tower Condenser Head Description/Heat Recovery (Split Head Condenser Only) Head Description first & fourth digit= of Water Passes:, 2, 3 second & fifth digit= Inlet Nozzle Location: L= Left R= Right third digit= Nozzle Type: A= Victaulic (std.); B= Flanged; D= Marine Box- Victaulic; F= Marine Box- Flanged sixth digit= Nozzle Type: A= Victaulic (std.); B= Flanged If there is no Heat Recovery Condenser digits 4, 5 & 6= Y 9. Condenser Design Pressures first digit= Refrigerant Side Pressure: C= 200 PSIG; D= 225 PSIG; E= 250 PSIG; F= 275 PSIG; G= 300 PSIG second digit= Waterside Pressure: = 50 PSIG ASME; 2= 250 PSIG ASME; 3= 350 PSIG ASME; 4= 50 PSIG Non-ASME (std.); 5= 300 PSIG None-ASME 20. Maximum Condenser Leaving Water Temperature Code is listed in tenths of F (example 370= 37.0 F) 2. Condenser Tube Sheet & Head Material first & third digit= Tube Sheet Material: C= Carbon Steel (std.); N= Monel Clad; S= Stainless Steel Clad; T= Titanium Clad Steel second & fourth digit= Head Material: C= Carbon Steel (std.); E= Epoxy Coated If there is no Heat Recovery Condenser digits 3 & 4= Y 22. Condenser Tube Cleaning System YY= None Tower Cond./None HR Cond. YB= None Tower Cond./WSA Brushes HR Cond. BY= WSA Brushes Tower/None HR Cond. BB= WSA Brushes Tower/WSA Brushes HR Cond. 23. Condenser Model Revision A= Revision A Nomenclature Model - Complete Continued RPL / Page 8

9 24. Pressure Vessel Code A= ASME (standard); B= Belgian; D= TUV (German); E= TUV (Austrian); J= Australian; K= Swiss; P= Chinese 25. Refrigerant Type 34= Refrigerant 34a 26. Refrigerant Weight Total weight divided by 0 rounded to next whole number (example: 352/0= 35) 27. Main Expansion Valve/ Pilot Valve first digit= Main Expansion Valve: R= 00 ton; S= 700 ton second digit= Pilot Valve: C= 0 ton; F= 0 ton (TDC) 28. Controller Options MicroTech 200 first digit= Control Type: M= MicroTech second digit= Sensor Functions: A= Outdoor Air (OA) Thermistor S20; B= OA and HR; H= Heat Recovery (HR) Thermistors S2/S22 third digit= Language: E= English Language/English Units; M= English Language/Metric Units; J= Japanese; C= Chinese fourth digit= Instruments: M= Modem; Y= None fifth digit= Special Functions: A= Analog Outputs; B= Analog Outputs & Signal Converter; S= Signal Converter sixth digit= Enclosure: A= NEMA ; B= NEMA 4; C= NEMA 2 MicroTech II first digit= Control Type: 2= MicroTech II second digit= Size: L= Large; H= Heat Recovery third digit= Language: E= English Language fourth digit= Instruments: M= Modem; Y= None fifth digit= Communications: B= BACnet; E= BACnet w/ethernet; L= LonWorks; M= MODBUS; P= Serial Port w/modem; S= Serial Port (RS232) sixth digit= Enclosure: A= NEMA 29. Starter Options first digit= Starter Type: 2= Wye-Delta Closed; 3= Across-The-Line; 4= Auto Transformer; 5= Primary Reactor; 6= Solid State V= Variable Frequency Drive second digit= Enclosure: 5= 90" X 36" X 2" free standing; 7= Medium/High Voltage 90" X 36" X 36" free standing; 9= Med/High Voltage 90" X 36" X 36" free standing; A= 90" High for Field Mounting w/brackets & Cables; L= VFD free standing third digit= Meters: Y= None fourth digit= Disconnect: Y= None fifth digit= Surge Protection Capacitor: 2= Surge Capacitor mounted in Compressor Motor Terminal Box; S= Surge Capacitor mounted in Starter Box; Y= None sixth digit= Phase Loss/Rotation Protection: Y= None seventh digit= Ground Fault Protection: Y= None G= Ground Fault Protection eighth digit= Load Balance: Y= None F= Load Balance 30. Rated Load Amps Actual RLA 3. Hot Gas Bypass H= Hot Gas Bypass (standard on HDC & TDC) Y= None Nomenclature Model - Complete Continued 32. Insulation first digit= Condenser & Evaporator Shell Insulation: H= ¾" Closed Cell Foam Insulation on Evaporator Shell, Suction Piping, Compressor Inlet, Motor Barrel + High Humidity 2= Closed Cell Foam Insulation on Condenser Shell Only 3= -½" Closed Cell Foam Insulation on Evap. Shell, ¾" Insulation on Suction Piping, Comp. Inlet, Motor Barrel + High Humidity 5= Code H + Code 2 6= Sound Insulation on Condenser & Discharge Line 7= Sound Insulation on Discharge Line Only D= Daikin Specifications M= Code H + Code 7 N= Code 3 + Code 7 S= Code H + Code 6 T= Code 3 + Code 6 Y= None second digit= Condenser & Evaporator Head Insulation: Y= None; = Return Heads Only; 2= Return & Connection Heads RPL / Page 9

10 33. Water Pressure Differential Switch E= Evaporator C= Condenser B= Both Evaporator & Condenser Y= None 34. Paint = Standard Painting 35. Packaging = Standard Wood Skid; 2= Open Export Crate; 3= Totally Enclosed Export Crate; 4= Shipping Bag w/wood Skid 5= Shipping Bag Only; 6= Shipping Bag w/ Totally Enclosed Export Crate; 7= Shipping Bag w/open Export Crate; Y= None 36. Refrigerant Tag A= Full Factory Charge B= Holding Charge 37. Miscellaneous Y= None X= Special (specials not covered in the normal code string) 38. Oil Cooler S= Water Cooled w/factory Solenoid (standard) 39. Rebate Y= None R= Rebate 40. Testing = Standard Factory Performance Test 2, 9, A, B, C, D, E, F, G, H, J, Q, S= Various Witness Tests 3, 4, 5, 6, 7, 8, K, L, M, N, P, R, T= Various Certified Performance Tests Y= None 4. Approval Listing A= ARI Approval U= UL C= Canadian UL V= ARI + UL D= Canadian ARI + UL Y= None 42. Latest Unit Model Revision A= Revision A 43. Tons Actual Tons 44. Startup Y= Export- No Startup U= Domestic Startup 7= Canadian Startup 45. Labor Warranty Y= Export Order, no labor warranty B= Domestic Order, st year labor warranty 7= Canadian Order, st year labor warranty 46. Extended Warranties Y= None C= Extended year parts; D= Extended year parts + Labor; E= Extended 2 year parts; F= Extended 2 year parts + Labor; G= Extended 3 year parts; H= Extended 3 year parts + Labor; J= Extended 4 year parts; K= Extended 4 year parts + Labor; (L thru S apply to Compressor/Drive Train Only) L= Extended year parts; M= Extended year parts + Labor; N= Extended 2 year parts; O= Extended 2 year parts + Labor; P= Extended 3 year parts; Q= Extended 3 year parts + Labor; R= Extended 4 year parts; S= Extended 4 year parts + Labor; 47. Always Y 48. Always Y Nomenclature Model - Complete Continued RPL / Page 0

11 Nomenclature Model - Complete Continued 49. Always Y 50. Motor A= A.O. Smith C= YYZ M= Ram R= Reliance 5. Refrigerant Warranty 0 thru 5= actual number of years 52. Delayed Warranty Start Y= None 53. Miscellaneous Y= Standard C= Compressor Kit only B= BOM only M=Stock Modification R= Retrofit Compressor Kit only 54. Coolant Rating W= Water on Evaporator and Condenser G= Non-water on Evaporator, Condenser, or both 55. Always YYYY 56. Always YYYY 57. Always YYYY RPL / Page

12 Control Box- MicroTech 200 Mounting of Unit Control Panels Ref. Description Part Qty. 20 Control Box Screw.37 x Nut Washer- Plain.375 ZPS Washer- Lock.375 ZPS Shelf 36"/42" Evaporator Shelf 48" Evaporator Bracket- Control Box See following pages for component detail. RPL / Page 2

13 Control Box- MicroTech 200 Front Panel & Inside of Micro Control Door Assembly Inside of Micro Door Ass'y Ref. Description Part Qty. 42 Toggle Switch- Contrast Control Membrane Switch- Control English Language Japanese Language Chinese Language KDI Control Cover- KDI Board Hinge- Painted Latch- Door Lock Door- Power Door- Control N/S Cover- Sensor N/S= Not Shown on Diagram. RPL / Page 3

14 Control Box- MicroTech 200 Interior Panel Diagram Modem Detail See detail above Micro Door Ass'y (see previous page) RPL / Page 4

15 Control Box- MicroTech 200 Interior Panel Components Ref. Description Specification Part Qty. 02 Main Controller- MicroTech M ADI Board until 3/ ADI Board 3/03 and later Mount- ADI Board Cord Set- PCB Interface Ribbon Cable 50C 8/24 OB Ribbon Cable 50C 3" Clip, Flat- Cable Terminal Block AD AD Transformer- Control.03 KVA 24/8V Terminal Block 9 Pole Row Cover- Terminal Block Bracket- Terminal Block Insulation- Fishpaper Board- Signal Converter SC Spacer- Signal Converter Toggle Switch (TDC Templifier Only) TSW Output Board 24 SM Board- Guardistor Circuit Breaker 3A P Transformer 50 VA 20/24V Terminal Block Unit & Field Varistor 30 VRMS Ferrules- Dual Wires 8 mm Mount- Circuit Board Socket, Relay- High Pressure Relay- High Pressure HP Relay- Output Board AOX Board 4 Channel Mount- AOX Board Cord Set 9" 28AWG Bracket- Magnetic Latch Magnetic Latch Fastener- Magnetic Latch Gasket.2 X Bushing- Snap In 2.00" Bushing- Snap In.50" Plug- Terminal Housing 4 Pin Female Plug- Terminal Housing 6 Pin Female Terminal- Socket 24-8 AWG Modem 4.4 BAUD Cord Set- Modem Gasket.25 X Bracket- Modem Mounting Bracket- Vertical, Modem Controller needs to be programmed.the Unit serial number is required to properly program the controller. RPL / Page 5

16 Control Box- MicroTech 200 Sensors Sensor layout applies to either control box. Unit has two identical sets of sensors HDC only HP Detail Ref. Description Part Qty.* 500 Low Pressure Transducer High Pressure Transducer Sensor- 20 foot Sensor- 50 foot High Pressure Cable Assy (HP) N/S Boot- Transducer Protection N/S Cable- Pressure Transducer, 0 ft N/S Cable- Pressure Transducer, 5 ft N/S High Pressure Switch- 90 PSI * Quantities are for ONE control box. Each control box has a set of the sensors illustrated above. N/S= Not Shown on Diagram. Quantity for HDC units is (Sensors S2 & S22 are added into the additional nozzles). Sensor Application Sensor Application Sensor Application S00 Evap. Leaving Water Temp. S0 Evap. Entering Water Temp. S02 Compr. Suction Temp. S08 Cond. Liquid Line Temp. S09 Cond. Entering Water Temp. S0 Cond. Leaving Water Temp. S2 Compr. Discharge Temp. S3 Oil Feed Temp. S4 Oil Sump Temp. S5 Oil Vent Low Press. Transducer S6 Evap. Refrigerant Low Press. Transducer S7 Cond. Refrigerant HP Transducer S8 Oil Feed Gauge High Press. Transducer S20 Outdoor Air S2 Entering Heat Recovery Temp. (HDC) S22 Leaving Heat Recovery Temp. (HDC) RPL / Page 6

17 Control Box- MicroTech 200 Cables & Lube Box Tubing Diagram Lube Box Tubing Detail 758 Lube Box Tubing Detail 757 RPL / Page 7

18 Control Box- MicroTech 200 Cables & Lube Box Tubing Components Ref. Description Part Qty. 405 Cable- Hot Gas Bypass Cable- Evaporator DPS Cable- Condenser DPS Box- Electrical Cover- Electrical Box Screw Cable- To Lube Box # Cable- To Compressor Heater # Cable- To Oil Pump # Cable- To Oil Cooling Solenoid # Cable- To Motor Cooling Solenoid # Cable- Liquid Injection # Cable- To Lube Box # Cable- To Compressor Heater # Cable- To Oil Pump # Cable- To Oil Cooling Solenoid # Cable- To Motor Cooling Solenoid # Cable- Liquid Injection # Tube Assembly Tube Assembly Tube Cable- 22" Motor Terminal Box Cable- Guardistor RPL / Page 8

19 Control Box- MicroTech 200 Mounting of Lube Boxes Ref. Description Part Qty. 74 Lube Box Screw- Hex Nut- Hex Washer- Lock.25 ZPS Bracket- Lube Box See following pages for component detail. RPL / Page 9

20 Control Box- MicroTech 200 Lube Box Assembly- Oil Pump Diagram RPL / Page 20

21 Control Box- MicroTech 200 Lube Box Assembly- Oil Pump Diagram Ref. Sch. Description Part Qty. Sym. Complete Lube Box Assembly Box- Lube Cover VC Switch- Vane Close Washer SASB Valve- 4 Way Solenoid Connector Coupling.25F Tee Union- Brass.25F Channel- Terminal Block Clamp- Terminal Block Terminal Block- End Terminal Block- Sec Strap- Capacitor OL Overload CAP Capacitor 370V Heater- Overload Fitting- Conduit OP Contactor 4P Jumper Line Assy Line Assy Line Assy Line Assy Terminal # RPL / Page 2

22 Control Box- MicroTech II Unit Control Box Mounting Components NOTE: Original design Operator Interface Panel shown. Mounting hardware is the same for all panels. Ref. Description Specification Part Qty. 5 Operator Interface Panel (OITS), Original until 5/05* Cable, 7-wire single, Original until 5/05* Connector Only, Original until 5/05* Operator Interface Panel w/cables, 2 Beige 5/05 & later* Operator Interface Panel w/vga & Serial cables, 5 Beige 5/05 & later* Operator Interface Panel w/ VGA & Serial cables, 5 Black 5/05 & later* Cable, 2V DC Power w/4 Pin Molex & 2 Plugs all 5/05 & later* Cable, Serial all 5/05 & later* Cable Kit (includes VGA & Serial cables) all 5/05 & later* Power Cord w/ac Adapter all 5/05 & later* Support Arm Assy, Beige (includes swivel pin, washers, & nut) Support Arm Assy, Black (includes swivel pin, washers, & nut) Block- Mount Shelf Screw Washer- Plain Washer- Lock Spring Washer- Lock Washer- Nylon Nut Screw * For units built /05 to 5/05, check unit to verify which panel is installed. Original panel had single cable, later panels have 3 cables. RPL / Page 22

23 Control Box- MicroTech II Unit Control Box Detail - Until 5/05 Diagrams Modem Detail (Code 28= 2LEYPA) Unit Control Detail 7 8 RPL / Page 23

24 Control Box- MicroTech II Unit Control Box Detail - Until 5/05* Components Ref. Sch. Description Specification Part Qty. Sym. Enclosure- No Emergency Cut-Off Switch until 2/ Enclosure- w/emergency Cut-Off Switch 2/03 & later Bracket- Switches UTB Terminal Block w/rail pc02 Controller- with Display Large CB Circuit Breaker 5 Amp SP Switch 25V Serial Gateway RS 232 Code 28, digit 5= P, S MODBUS Code 28, digit 5= M LonWorks Code 28, digit 5= L BACnet MS/TP Code 28, digit 5= B BACnet w/ethernet Code 28, digit 5= E Board- Distribution & Isolation with connectors Connector Large Controller Switch- Emergency Cut-Off Bracket- Modem Code 28= 2LEYPA Bracket- Modem Code 28= 2LEYPA Circuit Board- Modem Code 28= 2LEYPA Bracket Code 28= 2LEYPA Cord Set- Modem Code 28= 2LEYPA Cord Set- BACnet Code 28= 2LEYPA Serial Gateway- RS232 Code 28= 2LEYPA N/S Connector- Service N/S= Not Shown on diagram. Controller must be programmed before shipping. Unit serial number and software code (located on controller label) are required when ordering to insure proper software installation. * This control box was used with the original design opeartor interface panel (which is connected to the control box with one seven-wire cable). A new design flat screen operator interface panel can be retrofitted for use with this control box using retrofit kit p/n RPL / Page 24

25 Control Box- MicroTech II Unit Control Box Detail- 5/05 to 6/ Ref. Sch. Description Specification Part Qty. Sym. 2 Bracket- Switches UTB Terminal Block w/rail pc02 Controller- with Display CB Circuit Breaker 5 Amp SP Switch 25V Serial Gateway RS 232 Code 28, digit 5= P, S MODBUS Code 28, digit 5= M LonWorks Code 28, digit 5= L BACnet MS/TP Code 28, digit 5= B BACnet w/ethernet Code 28, digit 5= E Relay 24V Connector Holder- Relay Switch- Emergency Cut-Off UCM Board- Universal Communications PC Assy- Single Board PC N/S Connector- Service N/S= Not Shown on diagram. Controller must be programmed before shipping. Unit serial number and software code (located on controller label) are required when ordering to insure proper software installation. RPL / Page 25

26 Control Box- MicroTech II Unit Control Box Detail- 6/ and Later Components PC Controller RPL / Page 26

27 Control Box- MicroTech II Unit Control Box Detail- 6/ and Later Components Ref. Sch. Description Specification Part Qty. Sym. 2 Bracket- Switches UTB Terminal Block w/rail pc02 Controller- with Display CB Circuit Breaker 5 Amp SP Switch 25V Serial Gateway RS232 Code 28, digit 5= P,S MODBUS Code 28, digit 5= M LonWorks Code 28, digit 5= L BACnet MS/TP Code 28, digit 5= B BACnet w/ethernet Code 28, digit 5= E Relay 24V Connector Kit Holder- Relay Switch- Emergency Cut-Off UCM Board- Universal Communications PC Assy- Single Board PC Driver- Liquid Line Electronic Expansion Valve Transformer- Isolation 5VA N/S Connector- Service N/S= Not Shown on diagram. Controller must be programmed before shipping. Unit serial number and software code (located on controller label) are required when ordering to insure proper software installation. RPL / Page 27

28 Control Box- MicroTech II Compressor Control Box Mounting Components 6' Units before / ' Units before /02 Ref. Description Spec Part Qty. 742 Screw Nut Washer- Lock.25 ZPS Bracket Compressor Control Box 20' Units 6' Units /02 and later Compressor Control Box Compressor Control Box A A ' or 20' Units /02 & Later Ref # Description Specification Part # Qty. 742 Screw x Nut Washer- Lock.375 ZPS Washer Washer.438 thick RPL / Page 28

29 Control Box- MicroTech II Compressor Control Box Detail- Until 6/ Diagram RPL / Page 29

30 Control Box- MicroTech II Compressor Control Box Detail- Until 6/ Components Ref. Sch. Description Specification Part Qty. Sym. pc02 Controller T2/T3/T4 Transformer 20V- 24V 00VA 9/04 & later until 9/ OP Contactor- Oil Pump 4P 33A 24VAC Coil 9/04 & later until 9/ OL Overload- Oil Pump 48DA8AA Heater- Oil Pump Overload CTB Terminal Block w/rail CAP Capacitor- 60 Hz. Units 35 MFD 370V CAP Capacitor- 50 Hz. Units 60 MFD 370V CB Circuit Breaker 6A 9/04 & later until 9/ LR/CR/HR Relay 24VAC 0A 9/04 & later until 9/ Holder- Relays 9/04 & later until 9/ Springs- Relay Hold Down Standoff- Nylon Post SC Signal Converter Board Guardistor Board CTB2 Terminal Block Board- Transducer 3 Transducers Cover 9/04 & later until 9/ Bushing.5 9/04 & later until 9/ Bushing Barrier- Electrical Connector Kit- Transducer Connector Kit- Controller Controller must be programmed before shipping. Unit serial number and software code (located on controller label) are required when ordering to insure proper software installation. RPL / Page 30

31 Control Box- MicroTech II Compressor Control Box Detail- 6/ and Later Components TD OL CB LR CR HR 2 T2 T3 T4 CAP Compressor Controller RPL / Page 3

32 Control Box- MicroTech II Compressor Control Box Detail- 6/ and Later Components Ref. Sch. Description Specification Part Qty. Sym. pc02 Controller T2/T3/T4 Transformer 20V- 24V 00VA OP Contactor- Oil Pump 4P 33A 24VAC Coil OL Overload- Oil Pump 48DA8AA Heater- Oil Pump Overload CTB Terminal Block w/rail CAP Capacitor- 60 Hz. Units 35 MFD 370V CAP Capacitor- 50 Hz. Units 60 MFD 370V CB Circuit Breaker 6A LR/CR/HR Relay 24VAC 0A Holder- Relays Standoff- Nylon Post SC Signal Converter Board Guardistor Board CTB2 Terminal Block Board- Transducer 3 Transducers Cover Bushing Bushing Connector Kit- Transducer Connector Kit- Controller Barrier- Electrical Gasket- Neoprene.25 x ft. 37 Standoff Relay, Time Delay Surge Suppressor Controller must be programmed before shipping. Unit serial number and software code (located on controller label) are required when ordering to insure proper software installation. RPL / Page 32

33 Control Box- MicroTech II Cables Diagram HDC Only RPL / Page 33

34 Control Box- MicroTech II Sensors Diagram NOTE: Control Sensor (all sensors CSxx) layout applies to either control box. Unit has two identical sets of control sensors. There is only one set of unit sensors (all sensors USxx), and they are all shown in these diagrams HP & CS06 w/o Hot Gas Bypass HP & CS06 with Hot Gas Bypass Compressor Control Sensor Application Unit Control Sensor Application Sensor Application Sensor CS0 Oil Sump Pressure US02 CS02 Oil Feed Gauge Pressure US03 CS03 Evap. Refrigerant Pressure US04 CS04 Oil Sump Temperature US05 CS05 Compressor Suction Temp. US09 CS06 Cond. Refrigerant Pressure US0 CS07 Compressor Discharge Temp. CS08 % Compressor Amps (Starter) CS09 Oil Feed Temperature CS0 Evap. Leaving Water Temp. Application Evaporator Entering Water Temp. Condenser Entering Water Temp. Condenser Leaving Water Temp. Liquid Line Temp. Heat Recovery Entering Water Temp. Heat Recovery Leaving Water Temp. RPL / Page 34

35 Control Box- MicroTech II Cables and Sensors Components Ref. Sch. Description Specification Part Qty. Sym. 7 Cable- Operator Interface Panel Until 5/ Connector Only Conduit Fitting.375" ***** 80 Conduit Fitting.250" Valve Core Sensor Well- Oil Supply Tube Sensor Well 3 until 3/ Sensor Well 5 3/05 and later CS04 Sensor- Oil Sump Cable- CS04 Sensor Cable- Comp Heater Cable- Oil Pump Heater Cable- Solenoids Cable- Hot Gas Solenoid 6 ft. Units Cable- Hot Gas Solenoid 20 ft. Units Cable- Differential Pressure Switches until 5/ ** 5/04 & later CS05 Sensor 4 until 3/ Sensor 4 3/03 to 3/ Sensor, 5 ft. 3/05 and later Sensor, 25 ft. 3/2 and later Sensor *** 555 Cable- CS05 Sensor 3/03 & later Cable- Transducer HP Switch- High Pressure Cable- High Pressure Switch CS02/06 Transducer- High 40 PSI CS0/03 Transducer- Low 32 PSI plan Cable- plan between Unit & Compressor Controller **** 998 Cable- Power between Unit & Compressor Controller ****** N/S Boot- Transducer until 5/ N/S= Not Shown on diagram. ** There is one cable per DPS (see code 33). Each cable is 6 ft. of the above referenced p/n. *** Quantity is on WDC/TDC units, 3 on HDC units. **** There are two cables. Each made from 5 feet of the above listed p/n. ***** Quantity is 2 on WDC/TDC units, 4 on HDC units. ******There are two cables. Each made from 20 feet of the above listed p/n. Cable assembly includes 90 fitting p/n and Anti- Short bushing p/n CS07, CS08, CS09, CS0, US02, US03, US04, US05 [ US09 & US0 on HDC units only]. 3 Paste for sensor well is p/n This well was used with sensor p/n until 3/03. 4 The CS05 Sensor change resulted in a relocation of the sensor. After 3/03, the sensor is located in the inlet cone (as shown in the diagram). Before 3/03, the sensor was located in the suction elbow. 5 Beginning 3/05 the CS05 sensor was redesigned to use a well. The location remained the same. From 3/03 to 3/05 no well was used. 6 This cable was used with the original operator interface panel. The new flat screen panel used a VGA cable and a serial cable which comes with the panel. RPL / Page 35

36 Differential Pressure Switch Factory Mounted & Wired (Code 33= B, C or E) Switches, Wells, Power Cables, Fittings Wiring- MicroTech 200 Control 667A 667C 4 667B /A6: CHW- NO 57/A7: CH- NO 525/A25: CHW & CH- C Wiring- MicroTech II Control Well Detail (ref. 667) Until 5/ Ref. Description Part Qty.* 4 Cable- Evaporator DPS MicroTech 200 Control MicroTech II Control (until 5/04) ft. MicroTech II Control (5/04 and later) Cable- Condenser DPS MicroTech 200 Control MicroTech II Control (until 5/04) ft. MicroTech II Control (5/04 and later) Differential Press. Switch (until 5/04) Differential Press. Switch (5/04 and later) Elbow- 90 (until 5/04) Flare Nut (2 per tube) (until 5/04) Sensor Well (until 5/04) A Elbow (until 5/04) B Tube (until 5/04) C Nozzle (until 5/04) Well (5/04 and later) Bracket- Switch (until 5/04) Well N/S Fitting (5/04 and later) /250: EF- NO 52/252: CF- NO 49/249/5/25: EF & CF- C NOTES: The water pressure differential switch is an optional component. It is factory installed and wired when code 33= E (evaporator only), C (condenser only) or B (both condenser and evaporator). The switches used for either the MicroTech 200 or the MicroTech II control types are the same as are the wells. However the schematic designations are different. MicroTech 200 units designate the Evaporator & Condenser switches as CHW & CH, while the MicroTech II units designate the same switches as EF & CF. The only component part number difference of note are the power cables. *Quantities are based on the presence of both DPS (Code 33= B). If code 33= E or C part numbers 65 & 656 quantities are & 4 respectively, and only one cable (4 if C33= E or 42 if C33= C) is used. If only one DPS is used, the well (ref. # 667) has a quantity of (used on the vessel with the DPS) and (used on the vessel without the DPS). Differential Pressure Switch- None (Code 33= Y) Wells N/S= Not shown on diagram Ref. Description Part Qty. N/S Sensor Well (Evap & Cond in/out nozzles) RPL / Page 36

37 Hot Gas Bypass- 6 Foot Units Valves, Connectors, Tubing Diagrams & Components 254B 254A Pilot Valve Tee (see liquid line ref. # 254) 72F Regulator Valve to Pilot Valve Tee Detail 72E 70A 7A B 70C D C 732B 732A B 72A B 72C A A See Liquid Line Section D Ref. Description Specification Part Qty. 48 Screw.75 x B Elbow E36C36 Stack Elbow E42C42 & E48C48 Stack Pipe P044LBAAAA 75 Flange- Liquid Line Pipe Assy A Pipe Assy Coupling-.45 foot A Coupling-.33 foot A Tee Assy B Tee Flange- Evaporator Inlet Flange O'Ring- Flange Screw- Flange.62 x Weld Ring RPL / Page 37

38 Hot Gas Bypass- 6 Foot Units Valves, Connectors, Tubing Components, Continued Ref. Description Specification Part Qty. 70A Tube Assy E36C36 Stack Tube Assy E42C42 Stack Tube Assy E48C48 Stack B Tube Assy E36C36 Stack Tube Assy E42C42 & E48C48 Stacks C Tube Assy E36C36 Stack Tube Assy Tube Assy Elbow Expansion Valve until / Expansion Valve /03 & later Elbow Valve- Hot Gas Regulator A Tube- HGBP Regulator 2/02 & later A Tube- Hot Gas B Flare Nut C Tube- Hot Gas D Tube- Hot Gas E36C36 Stack Tube- Hot Gas E42C42 Stack Tube- Hot Gas E48C48 Stack E Tube- Hot Gas E36C36 Stack Tube- Hot Gas E42C42 Stack Tube- Hot Gas E48C48 Stack F Tube- Hot Gas E36C36 Stack Tube- Hot Gas E42C42 & E48C48 Stacks Tee Elbow Valve- Solenoid until / Valve- Solenoid /02 & later Ball Valve-.625 until / Ball Valve-.500 /02 & later Adapter Weld Ring Reducer Flange Screw- Flange.75 x Gasket- Flange Valve- Shut Off 3" A Screw- Shut Off Valve.62 x B Gasket- Shut Off Valve C Coupling- Half Union D Cap- Shut Off Valve TXV parts detail follows HGBP 20' unit section. 2 Until /02 tube was p/n Until /02 tube was p/n Until /02 tube was p/n Until /02 tube was p/n Until /02 tube was p/n This is a service kits which includees the Expansion Valve Assembly p/n (parts detail follows this section), and fitting p/n RPL / Page 38

39 Hot Gas Bypass- 6 Foot Units Valves, Connectors, Tubing Components, Continued Ref. Description Specification Part Qty. 736 Flange Gasket- Flange Screw- Flange.62 x Washer- Flange Adapter Fitting- Straight Fitting- Nut Fitting- Sleeve Fitting- Braze Ring RPL / Page 39

40 Hot Gas Bypass- 20 Foot Units Valves, Connectors, Tubing Diagrams & Components Ref. Description Specification Part Qty. 74 Pipe P044LBAAAA 75 Flange- Liquid Line Pipe E42C42 Stack Pipe E48C48 Stack Weld Ring Coupling Tube- Hot Gas E42C42 Stack Tube- Hot Gas E48C48 Stack Tube Elbow Expansion Valve until / Expansion Valve /03 & later Elbow TXV parts detail follows the next page. 2 This is a service kits which includees the Expansion Valve Assembly p/n (parts detail follows this section), and fitting p/n RPL / Page 40

41 Ref. Description Specification Part Qty. 70 Tube- Hot Gas Valve- Hot Gas Regulator Tube- Hot Gas E42C42 Stack Tube- Hot Gas E48C48 Stack Tee Elbow Valve- Solenoid Ball Valve until 0/ Ball Valve 0/03 to 4/ Ball Valve 4/0 & later Adapter Weld Ring Tube E42C42 Stack Tube E48C48 Stack Reducer Tube Tube E42C42 Stack Tube E48C48 Stack Flange Screw- Flange.75 x Valve- Shutoff 3" Cap- Shutoff Valve Flange Tube- Hot Gas E42C42 Stack Tube E48C48 Stack Coupling Tube E42C42 Stack Only N/S Tube, Copper x 2.50" E42C42 Stack Only N/S= Not shown on diagram Hot Gas Bypass- 20 Foot Units Valves, Connectors, Tubing Components, Continued RPL / Page 4

42 Hot Gas Bypass Expansion Valve Detail Original Expansion Valve (until 0/02) Ref. Description Part Qty. Valve Assy- 650 Ton Body Cap Spring Stop Stem Pin-.69 x O'Ring Washer Piston Seal Ring O'Ring Screw Pin-.88 x Fitting- Orifice Cap O'Ring Seal- Washer Washer- Plain Current Expansion Valve Ref. Description Part Qty. Valve Assy- 650 Ton Body Cap Spring Stop Stem Pin-.69 x O'Ring Retainer Washer Piston Seal Ring O'Ring Screw Pin-.88 x Fitting- Orifice Quad Ring Cap Screw Seal- Washer Washer- Plain RPL / Page 42

43 Liquid Line Expansion Valve, Ball Valve, Sight Glass, King Valve, Flanges, Gaskets, O'Rings, Pilot Valve Sensor Well, Tubing Diagram Pilot Valve Bulb Detail Pressure Connector 33 (ref. # 304) 308 Detail C 27A D 27E B RPL / Page 43

44 Liquid Line Expansion Valve, Ball Valve, Sight Glass, King Valve, Flanges, Gaskets, O'Rings, Pilot Valve Sensor Well, Tubing Components Ref. Description Specification Part Qty. 48 Screw.75 x ** 243 Cap- Flare Cap- Tube Valve- Shut Off.50P x.63f Cap- Shut Off Valve Elbow Tube Assy Adapter Flange- Liquid Line to King Valve Screw- Flange.75 x Tube- Connects to King Valve Flange Tube Assy- Liquid Line 6 foot units E36C36 Stack E42C42 Stack E48C48 Stack Tube Assy- Liquid Line 20 foot units E42C42 Stack E48C48 Stack Gasket- LL to King Valve Flange Coupling Pilot Expansion Valve Tee- Reducer A Tube- Pilot Valve 6 foot units Tube- Pilot Valve 20 foot units B Tube- Pilot Valve 3 6 foot units E36C36 Stack E42C42 Stack E48C48 Stack Tube- Pilot Valve 3, 4 20 foot units E42C42 Stack E48C48 Stack C Tube- Pilot Valve 3 6 foot units E36C36 Stack E42C42 Stack E48C48 Stack Tube- Pilot Valve 3, 4 20 foot units E42C42 Stack E48C48 Stack D Fitting- Nut 3 6 foot units only E Fitting- Sleeve 3 6 foot units only Strainer ** Varies. Tube ass'y contains one ()ea: schrader valve #070080, valve cap # , valve core # , sight glass saddle # (# before 0/04), & sight glass cap # ( before 0/04). 2 Not used after /02 on 6' units. 3 Pilot valve tubes used on 20 foot units have flare nuts that connect to the TXV. The tubes on 6 foot units connect with part #'s 27D & 27E. 4 On 20 foot units only, these two tubes are attached with four (4) each of: clamp p/n & screw p/n RPL / Page 44