Product Manual

PM STARTER-3
Group: Chiller Date: October 2000 Supersedes: PM-STARTER-2 iihjRTERSTARTER

Starters and Variable Frequency Drives For Centrifugal Chillers

2000 McQuay International

Table of Contents
Introduction.............................................................................................. 3 Low Voltage Starters (200 through 600 volts)........................................... 4
General Specifications............................................................................................................4 Types ........................................................................................................................................4 Standard Components............................................................................................................5 Options.....................................................................................................................................6 McQuay Starter Model Codes ..............................................................................................7 General Arrangement..............................................................................................................8 Selection Procedure ................................................................................................................9 Specifications ........................................................................................................................11 Illustrations............................................................................................................................11 Dimensions ............................................................................................................................13

Medium & High Voltage Starters (2300 to 6900 Volts)........................... 16

Starter Types..........................................................................................................................16 Standard Components..........................................................................................................17 Options...................................................................................................................................18 McQuay Starter Model Codes ............................................................................................19 Selection Procedure ..............................................................................................................19 Specification ..........................................................................................................................19 Dimensions ............................................................................................................................20

Variable Frequency Drives....................................................................... 23

General....................................................................................................................................23 Standard Components..........................................................................................................23 Options...................................................................................................................................25 General Arrangement............................................................................................................25 VFD Dimensions ...................................................................................................................26

Power Factor Correction ........................................................................ 27

Our facility is ISO Certified

Initial Issue October 1998 "McQuay "is registered trademarks of McQuay International 1996 McQuay International "Illustrations and data represent the McQuay International products at the time of publication and we reserve the right to make changes in design and construction at anytime without notice"

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Introduction
McQuay offers a wide selection of conventional motor starting equipment as well as Variable Frequency Drives (VFD) that are starters with the additional capability of regulating compressor motor speed. Starters For low voltage (200 through 600 volts) there are wye-delta closed transition, autotransformer and solid state starters. Medium voltage (2300 through 6900 volts) starters are across-the-line full voltage, autotransformer reduced voltage, and primary reactor reduced voltage starters. Starters can be mounted and wired on the unit for most chiller sizes or they can be free-standing with wiring between the chiller and starter provided by the installer. A line-up of medium voltage starters can also be accommodated. A wide range of options is available for individual job requirements. Motor starters can be furnished by the customer provided they meet McQuay Starter Specifications and are approved by McQuay. Variable Frequency Drives While known and specified for their ability to control compressor motor speed for efficiency enhancement, VFDs also perform starting and motor protection functions. They are available for only 3/60/460-480 service. VFDs are available only from McQuay and when purchased as part of the original chiller purchase.

Basic Electrical Terms

Locked rotor amps (LRA): The amount of current that a specific motor will draw at start-up when full voltage is applied across the line. LRA may be 6 to 8 times FLA or possibly higher in some cases. Inrush current: The amount of current that a specific motor and starter combination will draw during startup. Normal inrush current will be substantially less than LRA for all starter types except for across-theline starters. Full load amps (FLA): The maximum amps the motor is designed for. Rated load amps (RLA): Actual amperage that the motor draws for a specific application. Centrifugal compressor motors operate at a RLA significantly below their maximum full load amps. RLA is used to determine electrical component sizing. Starting torque: Minimum torque required to begin the motors rotation. Interrupting capacity: The maximum fault current that a circuit breaker or fused disconnect can successfully interrupt. As the rating increases, the construction becomes heavier duty. For disconnect switches with fuses, the rating is based on 0 to 600 volts. For circuit breakers, the voltage and amperage relationship is considered with interrupting capacity decreasing as voltage increases. Withstand rating: There is a period of time that the short circuit current passes to the shorted circuit before the protection device can open. This time can be as long as 0.020 seconds (one cycle). The withstand rating of a starter is the maximum short circuit current that it can pass safely without emitting sparks or debris. Bypass contactor: Contactors that bypass auto-transformers, reactors or SCRs and allow full power to reach the motor. Phase amps: The current draw inside the delta connection of a wye-delta motor winding, and is equal to 0.577 x RLA of the motor for a specific load. Open transition: Reduced voltage starter characteristic when the motor is temporarily disconnected from power at the time the starter changes from the starting mode to the final operating mode. A second smaller inrush spike will occur. McQuay does not recommend use of this type of starter. Closed transition: Reduced voltage starter characteristic when the motor is NOT temporarily disconnected from the line during the transition from starting mode to operating mode. The electrical load is transferred to resistors during the transition phase and a second inrush spike is suppressed.

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Low Voltage Starters (200 through 600 volts)

General Specifications
Agency Approvals
All controllers are continuous duty AC magnetic type constructed in accordance with National Electric Manufacturers Associations (NEMA) Standard for Industrial Controls and Systems (ICS). The low voltage starters comply with the requirements of the Canadian Standard Association (CSA) and a CSA label is offered as an option. Underwriters Laboratory (UL) certification for Standard 508 is included and a UL label is provided with low voltage starters.. Starters can be modified to meet most federal, state and local codes.

Contactor Duty
Contactors are capable of carrying the specified current on a continuous basis and also handle locked rotor amps on a temporary basis without damage.

Storage and Operating Environment

Starters can be stored at temperatures from -40F to 140F (-40C to 60C). Operating range is from 32F to 104F (0C to 40C) with a maximum relative humidity of 95%.

Enclosure and Cable Penetrations

Unless stated otherwise, the starter enclosures for low voltage starters are NEMA 1 with gaskets. Standard construction for free standing starters allows main power to enter the top of the starter and load side connections through the bottom, lower sides, or back near the floor. As an option, the normal low voltage freestanding starter depth can be increased to 28" deep to allow space for a bottom power inlet or a top side power connection. Medium and high voltage cabinets are 30 deep and allow various wiring configurations without extended depth. Cabinet dimensions can also change to accommodate disconnect switches, power factor correction capacitors and other devices. Adequate separation of high and low voltage sections and proper mechanical and electrical interlocks are provided to meet all safety and operating codes.

Motors
Type Semi-hermetic, squirrel cage induction, 3-phase, 50/60 Hertz, 2 pole, single speed. Speed, 3550 rpm at nominal shaft horsepower at 60 Hertz, 2960 rpm at 50 Hertz. Continuous duty at minimum of 15 years with a maximum number of starts expected of 15,000 and a minimum delay between starts of 20 minutes. Leads Low voltage; 600 volts and below, will have six leads and are suitable for use with wye-delta, across-theline, auto-transformer, or solid state starters.

Types
Three types of reduced inrush low voltage starters are offered; wye-delta closed transition, autotransformer, and solid state starters. The objective of these starters is to reduce the starting inrush current while allowing the motor to generate enough torque to start. Reduced voltage starters also allow a soft start which means that the motor gradually accelerates to normal operating speed. The centrifugal chiller capacity control starts the compressor unloaded to minimize current and torque requirements.

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Wye-Delta Closed Transition

This starter (sometimes called star-delta) is the most popular type for centrifugal chiller applications. It reduces inrush current by first connecting the three motor windings in a wye configuration to reduce the maximum inrush current to 33.3% of locked rotor amps and producing 33.3% of normal starting torque. After a brief delay, the electrical load is momentarily transferred to resistors while the motor windings are changed to the delta configuration. The resistors minimize the second inrush current when the delta configuration becomes active. Open transition starters (without the resistors) are not recommended. These starters are excellent for centrifugal compressors because of the wye-deltas low inrush current, low starting torque and low initial cost.

Autotransformer
This starter type uses a transformer per phase with 50%, 65%, and 80% taps. The taps determine the initial voltage and resulting inrush amps that will reach the motor. For centrifugal compressors, the 65% tap is used allowing 42% of normal inrush current and produces 42% of starting torque. The 50% tap will usually not produce enough starting torque and the 80% tap allows unnecessary inrush (64% of LRA). After a designated time period, a bypass contactor closes allowing normal current to flow to the motor and bypasses the transformers.

Solid State Starters

Solid state starters are another excellent type of starter for centrifugal compressors. This starter uses solid state switching devices called SCRs (Silicon Controlled Rectifiers) that control the flow of current to the motor during start up. The SCRs control the amount of voltage that reaches the motor which in turn controls the motors acceleration and current inrush. Eventually, full voltage is applied and a bypass contactor is energized. The contactor bypasses the SCRs and allows full current to the motor. The compressor size and motor characteristics determine Setpoints. Starting torque requirements necessitate approximately three times the rated load amps of the compressor motor. Solid state starters are generally used in applications where it is desirable to provide precise control of motor starting characteristics. The inrush current may possibly, but not necessarily, be reduced below wye-delta starters.

Standard Components
The following components are standard on all types of low voltage starters:

Main Control Relays

Starters are equipped with redundant motor control relays with coils in parallel and contacts in series to interlock the starter with the chiller. These two relays constitute the only means of energizing the motor contractors. No other devices (manual or automatic) with the capability of energizing the starter can be used. The starter is controlled by the unit microprocessor.

Motor Protection and Overloads

Starter includes devices to provide monitoring and protection functions. These controls include: Solid state overload (overcurrent) protection Phase unbalance protection Phase reversal and phase loss protection Under and over voltage protection Adjustable overload to closely match motor performance

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Three current transformers to measure motor current and a fourth current transformer for input to the chiller microprocessor.

Control Voltage Transformer

The starter is provided with a 3KVA control transformer with both secondary and primary fuses to supply control power to the chiller.

Surge Capacitors
In wye-delta and autotransformer applications, surge capacitors are provided as standard in low voltage starters or motor terminal box to protect the compressor motor from voltage spikes. Surge capacitors are not used with solid state starters.

Terminals
Solderless mechanical connectors to handle wire sizes indicated by the NEC.

Options
A variety of options are available for low voltage starters and are dependent on the chiller mounting method. The options are listed below and their availability is shown in Table 1.

Auxiliary Relay
Two normally open and two normally closed contacts.

Motor Metering Devices

Analog ammeters and voltmeters with 3-phase selector switches.

Deluxe Motor Metering System

The deluxe motor metering system is the IQDP-4130 which includes digital readouts of 3-phase amps, 3-phase volts, watt-hours, watts, volt-amps, VAR-hours, power factor, and frequency, all in a single device.

Lightning Arrestors Ground Fault Protection Relay Pilot Lights NEMA Modifications
The standard enclosure is NEMA 1 with additional gasketing. NEMA 3R -- Rain resistant construction NEMA 4 -- Rain tight construction NEMA 12 -- Dust tight construction

Notes: 1. 2. 3. The UL label, and CSA certification are available for NEMA 1 only. If UL/CSA is required for NEMA 3R, 4, 12, contact factory. Motor terminal mounted starters for WSC063, WSC079, WSC087, WDC063, WDC079 and WDC087 are only available with NEMA 1 enclosures.

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Lug Size Options

A wide range of lug sizes for field power wire connections are available and are shown on the starter certified drawings.

Extended Warranty On Parts Only, or Parts & labor Main Disconnect (with Padlockable Handle)
Non-fused Fused, 600 volt fuse clips only, fuses by others Circuit breaker

Power Factor Correction Capacitors

The McQuay chiller selection program prints out the unit power factor and will also calculate capacitor size for power factor correction. Table 1, Starter Option Availability
Option Ammeter Voltmeter IQ-DP-4130 Lightning Arrestors Ground Fault Protection Indicating Lights 4-Pole Auxiliary Relay Power Factor Correction Capacitors NEMA 3R NEMA 4 NEMA 12 California Code Non-Fused Disconnect Fused Disconnect Circuit Breaker Extended Warranty Motor Terminal Mount 063, 079, 087 Only X X X X X Free Standing or Unit Mount X X X X X X X X X X X X X X X X

X X X X

McQuay Starter Model Codes

The McQuay starter codes adapt the Cutler Hammer codes for order entry and drawing identification as follows:

WSR 089 A 5A
Starter Size

Type: Wye-Delta=089 Auto Trans=060 Solid State=031

A=Free Standing E=Motor Terminal Mount

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General Arrangement
Low voltage starters can be supplied in several different mounting arrangements depending on the chiller size and starter type. See Table 2 for availability. Motor Terminal Mounted: The starter is mounted on the chiller unit with the back of the starter against the motor terminal box and wired directly from the starter to the motor. This arrangement is available only on WSC/WDC 063, 079, or 087 units. See cover photograph. Unit Mounted: The starter is factory mounted on the side of the chiller unit and connected to the motor with conduit and cable. Available on models WSC/WDC 048/050. Free standing: Floor mounted separate from the chiller unit and field wired to the compressor motor. This is available on all units and is the only starter arrangement available for WDC 100 and 126. Brackets and cable: Starters for WSC 100 and 126 units may be shipped separately from the chiller unit and furnished with mounting brackets and interconnecting cables for field mounting and connection by others. This option must be clearly specified when chillers are ordered since brackets are welded onto the evaporator during its construction.

Table 2, Starter Mounting Arrangements

Size WSC/WDC 050 WSC/WDC 063 WSC/WDC 079 WSC/WDC 087 WSC 100, 126 WDC 100, 126
NOTE: 888 amp maximum

Motor Terminal Mount (72 in. High) NOTE (1) X X X

Unit Mount (72 in. High) X

Free Standing (90 in. High) X X X X X X

Brackets & Cables (90 in. High)

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Selection Procedure
Use the following procedure to select the proper starter size: Step 1. Refer to the McQuay MS-85 selection program to obtain the compressor RLA. Find the LRADelta (LRAD), from the rating side of the MS85 program, by clicking on the "Order Data" button in the upper right corner. The value can also be found in the Motor Data Table in the centrifugal product manual. Step 2. Determine the starter type required and check the mounting arrangement from Table 2. Step 3. Select the starter size from Table 3 that is above the maximum rated load amps (RLA). If the initial starter size has a maximum LRAD that is greater than the LRAD of the motor, the initial selection is acceptable. If the motor LRAD is greater than the starter LRAD, use the next larger starter. The starter must meet RLA and LRAD requirements. Table 3, Starter Size Selections
Wye-Delta Starter Size 3A 3D 4A 4D 5A 5D 6A 6D 7A Max RLA 156 207 233 365 467 623 935 1212 1400 240/ 480V LRAD 859 1385 1880 2728 3637 4018 5785 7794 8660 600V LRAD 859 909 1880 2196 3117 3291 4625 7274 8417 Main Lug Rating 5kA 10kA 10kA 18ka 18kA 18kA 18kA 18kA 30kA Auto-Transformer Starter Siz e 3A 3D 4A 4D 5A 5D 6A 6D 7A Max. RLA 90 120 135 211 270 361 540 760 810 240/ 480V LRAD 496 496 1080 1575 2100 2320 4000 4560 5000 600V LRAD 496 496 1080 1268 1800 1900 3240 4560 4860 Solid State Starter Size 13 18 24 30 36 42 65 85 Max. RLA 135 180 240 304 360 420 650 850

Notes:
1. The A designation represents a NEMA rated all-purpose starter that is applicable to any motor application. These starters have a lower maximum RLA and LRA rating to be suitable for unknown applications. Some owners and designers desire only NEMA rated starters. The D designation represents a definite purpose starter (such as a centrifugal chiller motor) where the duty and application is known. The D starters meet the National Electric Code but are not specifically covered by NEMA standards. It is common for definite purpose starters to be used with centrifugal starters. Main lug rating is main lugs only short circuit rating.

2.

3.

Step 4. Select the disconnect/breaker option (if required) from Table 6 Step 5. With the size and type known, find overall starter dimensions from the table below. Detailed dimension drawings are in the Dimension Section beginning on page 13. Table 4, Starter Dimensions
Type Wye-Delta, Free-Standing, Size 3A to 6A Solid State, Free-Standing, Size 13 to 85 Motor Terminal Mount Height, in. 90 90 72 Width, in. 36 36 36 Depth, in. 21 21 15

Low Voltage Disconnect and Circuit Breaker Options

Non-fused disconnect A molded case switch without an automatic trip, includes a through-the-door handle which can be used to break all power to the starter and chiller. Fusible disconnect switch (less fuses) A fused disconnect switch is identical to the non-fused disconnect except that a fuse block is added. It is industry practice for the installer to supply the fuses. Fuses are NOT included. The interrupting capacity for 200 to 600 volts is 100,000 amps. Refer to the chart below for fuse sizes.
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Table 5, Fuse Sizes

Fuse Class 220 A, Class J 400A, Class J 600A, Class J 800A, Class L 1220A, Class L 2000A, Class L Fuse Range (amps) 110A 225A 450A 601A 1000A 1350A to to to to to to 200A 400A 600A 899A 1200A 2000A RLA Range (amps) 81A to 160A 161A to 322A 323A to 480A 481A to 640A 641A to 960A 961A to 1289A Centerline Dim. Hole to Hole (in) 4.375 5.25 6.00 6.25 6.25 (1), 9.375 (2) 6.25 (1), 9.375 (2) Mounting Pattern 2 2 2 2 4 4 bolt bolt bolt bolt bolt bolt

Notes: 1. Inside hole to inside hole 2. Outside hole to outside hole

Thermal-magnetic Circuit Breakers Thermal-magnetic circuit breakers are available with standard, high and ultra high interrupting capacity. Highest interrupting capacity circuit breakers, Tri-Pac The Tri-Pac is a combination fuse and breaker unit that offers the highest interrupting capacity. The interrupting capacity for 200 to 600 volts is 200,000 amps. Available only on free-standing starters. Table 6, Ratings and Interrupting Capacity (kA) for Circuit Breakers, Wye-Delta, Solid State, and Autotransformer Starters
Max RLA Non-Fusible Disconnect Fram e K-SW K-SW K-SW K-SW NDK RDK RDK Rating 200 400 600 800 1200 1600 2000 Fusible Disconnect (Free-standing Only) Fuse Fram Fuse Rating Clas e Clip s K-SW K-SW K-SW K-SW NDK RDK RDK 200 400 600 800 1200 1600 2000 200 400 600 800 1200 2000 2000 J J J L L L L Standard Interrupting Circuit Breaker Fram e JD KD LD MDL ND RD RD Rating 250 400 600 800 1200 1600 2000 Interrupting Capacity(kA) 240 V 480 V 600 V 65 25 18 65 35 25 65 35 25 65 50 25 65 50 25 125 65 50 125 65 50

156 296 444 606 888 1185 1481

Max RLA 156 296 444 606 888 1185 1481

Fram e

High Interrupting Circuit Breaker Interrupting Capacity (kA) Rating 240 V 480 V 600 V HJD 250 100 65 25 HKD 400 100 65 35 HLD 600 100 65 35 HMDL 800 100 65 35 HND 1200 100 65 35 RD 1600 125 65 50 RD 2000 125 65 50 Tri-Pac Circuit Breaker (Freestanding Only)

Ultra-High Interrupting Circuit Breaker Interrupting Capacity (kA) Frame Rating 240 V 480 V 600 V JDC 250 200 100 35 KDC 400 200 100 50 LDC 600 200 100 50 NDC 800 200 100 50 NDC 1200 200 100 50 RDC 1600 200 100 65 RDC 2000 200 100 65

Max RLA 296 606 1185

Frame LA NB PB

Rating 400 800 1600

240 V 200 200 200

480 V 200 200 200

600 V 200 200 200

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Specifications
Detailed specifications for customers wishing to specify and purchase their own starters are contained in McQuay Drawing (Specification) 359A999. Contact your local McQuay representative for a current copy.

Illustrations
Figure 1, Wye-Delta Closed Transition Starter

Surge Capacitor

Incoming Power

Optional Metering

Overload Current Transformer Motor Terminals

Main Contactors I Q 500 Resistor Contactor

Control Transformer

Transition Resistors
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Motor Control Relays (MCR)

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Figure 2, Solid State Starter w/ Disconnect

Incoming Terminals

Motor Terminal

Silicon Controlled Rectifiers (SCR)

Motor Control Signal

Motor Control Relays (MCR)

Control Transformer

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Dimensions
Figure 3, Free-Standing, Wye-Delta, 36 Inch Wide

NOTES:
1. 2. Enclosure height A = 90 in. Enclosures are designed for incoming line cables at top, outgoing load cables at bottom. Other wiring practices may result in cable routing difficulties. Use standard incoming lugs table for all combination and non-combination units.

3.

Max RLA 156 207 233 365 518 623 888 1212

Incoming Lugs Main Lugs Only No. Size 1 #6-350 1 #6-350 1 #6-350 2 #4-500 2 #4-500 3 #2-600 3 #2-600 4 250-600

Outgoing Lugs (Note 1) No. 1 1 1 1 1 2 2 2 Size #6 - 2/0 #6 - 4/0 #6 - 4/0 #6 - 300 #1/0 - 500 #1/0 - 500 #1/0 - 500 #2-600

Note 1: Outgoing lug size applies to all Wye-Delta starters

Fused & Non-Fused Disconnect Switch Terminals Max Fuse Type Incoming Lugs RLA Type 156 200A K-SW J (1) #6-250 (1) 750 or 296 400A K-SW J (2) 1/0-300 444 600A K-SW J (2) #2-600 606 800A K-SW L (4) 3/0-750 888 1200A NDK MCS L (4) 4/0-500

Series-C Circuit Breaker Standard, High, or Ultra-High Interrupting Capacity Circuit Breaker Option Terminal Information Max. RLA Frame Incoming Lugs 156 J (1) #4-350 296 K (2) 2/0-250 or (1) 2/0-500 365 L (1) 4/0-600 444 L (2) 250-350 606 M (2) #1-500 623 M (3) 3/0-400 888 N (4) 4/0-500

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Figure 4, Free Standing, Solid State, Sizes 13 - 85, 36 Inch Wide NOTES: 1. Enclosures are designed for incoming line cables at top, outgoing load cables at bottom. Other wiring practices may result in cable routing difficulties. Use standard incoming lugs table for all combination and non-combination units.

2.

Siz e 13 18 24 30 36 42 65 85 99

Max RLA 135 180 240 304 360 420 650 850 1000

Outgoing Lugs No. 2 2 2 2 2 2 4 4 4 Size #4-500 2/0-300 2/0-300 2/0-300 4/0-500 4/0-500 4/0-500 4/0-500 4/0-500

Main Lugs Only Max RLA 156 207 233 365 518 623 888 1000 No. 1 1 1 2 2 3 3 4 Incoming Lugs 350 350 350 500 500 600 600 600

Fused & Non-Fused Disconnect Switch Terminals Max Fuse Incoming Type RLA Type Lugs 156 200A K-SW J (1) #6-250 (1) 750 or 296 400A K-SW J (2) 1/0-300 444 600A K-SW J (2) #2-600 606 800A K-SW L (4) 3/0-750 888 1200A NDK MCS L (4) 4/0-500 1000 1600A RDK MCS L (4) 1-600 Series-C Circuit Breaker: Standard, High, or Ultra-High Interrupting Capacity Circuit Breaker Option Terminal Information Max. RLA Frame Incoming Lugs 156 J (1) #4-350 296 K (2) 2/0-250 or (1) 2/0-500 365 L (1) 4/0-600 444 L (2) 250-350 606 M (2) #1-500 623 M (3) 3/0-400 888 N (4) 4/0-500 1000 R (4) 1-600

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Figure 5, Motor Terminal Mounted, WSC/WDC 063, 079, 087 and Unit Mounted WSC/WDC 048-050

Notes:
1. 2. Enclosures for top entry only. See chiller unit drawings for location of the starter on the unit.

Max RLA 156 207 233 365 518 623 888

Incoming Lugs Main Lugs Only No. 1 1 1 2 2 3 3 Size #6-350 #6-350 #6-350 #4-500 #4-500 #2-600 #2-600

Outgoing Lugs (Note 1) No. 1 1 1 1 1 2 2 Size #6 - 2/0 #6 - 4/0 #6 - 4/0 #6 - 300 #1/0 - 500 #1/0 - 500 #1/0 - 500

Fused & Non-Fused Disconnect Switch Terminals Max Fuse Incoming Type FLA Type Lugs 156 200A K-SW J (1) #6-250 (1) 750 or 296 400A K-SW J (2) 1/0-300 444 600A K-SW J (2) #2-600 606 800A K-SW L (4) 3/0-750 888 1200A NDK MCS L (4) 4/0-500

Series-C Circuit Breaker Standard, High, or Ultra-High Interrupting Capacity Circuit Breaker Option Terminal Information Max. RLA Frame Incoming Lugs 156 J (1) #4-350 296 K (2) 2/0-250 or (1) 2/0-500 365 L (1) 4/0-600 444 L (2) 250-350 606 M (2) #1-500 623 M (3) 3/0-400 888 N (4) 4/0-500

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Medium & High Voltage Starters (2300 to 6900 Volts)

Agency Approvals
All controllers are continuous duty AC magnetic type constructed in accordance with National Electric Manufacturers Associations (NEMA) Standard for Industrial Controls and Systems (ICS). Medium voltage starters are rated as NEMA Class E2. Medium voltage starters have UL and CSA labels available as an option. Starters can be modified to meet most federal, state and local codes.

Contactor Duty
Contactors are capable of carrying the specified current on a continuous basis and also handle locked rotor amps on a temporary basis without damage.

Storage and Operating Environment

Starters can be stored at temperatures from -40F to 140F (-40C to 60C). Operating range is from 32F to 104F (0C to 40C) with a maximum relative humidity of 95%.

Enclosure and Cable Penetrations

Unless stated otherwise, the starter enclosures for medium and high voltage starters are NEMA 1 with gaskets. Standard construction for free standing starters allows main power to enter the top of the starter and load side connections through the bottom, lower sides, or back near the floor. As an option, the normal low voltage freestanding starter depth can be increased to 28" deep to allow space for a bottom power inlet or a top side power connection. Medium and high voltage cabinets are 30 deep and allow various wiring configurations without extended depth. Cabinet dimensions can also change to accommodate disconnect switches, power factor correction capacitors and other devices. Adequate separation of high and low voltage sections and proper mechanical and electrical interlocks are provided to meet all safety and operating codes.

Motors
Semi-hermetic, squirrel cage induction, 3-phase, 50/60 Hertz, 2 pole, single speed, 3550 rpm at nominal shaft horsepower at 60 Hertz, 2960 rpm at 50 Hertz. Continuous dutyat minimum of 15 years with a maximum number of starts expected of 15,000 and a minimum delay between starts of 20 minutes.

Leads
Medium and high voltage; 2300 to 6900 volts, will have three leads and are suitable for across-the-line, auto-transformer, and primary reactor starters.

Starter Types
Medium and high voltage starter types are across-the-line, reduced voltage autotransformer, and reduced voltage primary reactor. They are designed as freestanding only.

Across-the-Line Starter
Across-the-line starters are very simple and consist of a primary contactor that allows locked rotor amps to reach the motor when energized. These starters are low cost, provide the highest starting torque, and can be used with any standard motor.

Autotransformer Starter
The autotransformer starter operation was discussed in the low voltage starter section. As with low voltage starters, they are factory wired at the 65% tap for centrifugal compressors providing 42% starting torque and 45% inrush current. Once the starting sequence begins, the motor is not disconnected from the line that prevents a second inrush spike from occurring. A bypass contactor is provided for across-the-line operation after the start

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up cycle is completed. Autotransformer starters are a good choice because of their efficiency and flexibility.

Primary Reactor Starter

Primary reactor starters are a medium voltage starter that uses a reactor in series with the motor to reduce inrush current. These starters have a higher inrush current for the same starting torque as an autotransformer starter The starters are factory wired at the 65% tap which produces 42% starting torque and 65% inrush current. A bypass contactor is provided for across-the-line operation after the start up cycle is completed.

Standard Components
Across-the Line
Across-the-line starters contain the standard components listed below.

Reduced Voltage Primary Reactor

In addition to the standard components listed below, these starters also contain: Drawout magnetic, three-pole, vacuum break shorting assembly Three-phase starting reactor, factory set at the 65% tap

Reduced Voltage Auto-Transformer

In addition to the standard components listed below, these starters contain: Drawout magnetic, three-pole, vacuum break shorting contactor Drawout magnetic, two-pole, vacuum break starting contactor Open delta starting auto-transformer factory set at 65%

Main Control Relays Starters are equipped with redundant motor control relays with coils in parallel and contacts in series to interlock the starter with the chiller. These two relays constitute the only means of energizing the motor contractors. No other devices (manual or automatic) with the capability of energizing the starter can be used. The starter is controlled by the unit microprocessor. Motor Protection and Overloads The starter includes overload protection functions. These controls include: Solid state overload (overcurrent) protection Phase unbalance protection Phase reversal and phase loss protection. Adjustable overload to closely match motor performance Three current transformers to measure motor current and a fourth current transformer for input to the chiller microprocessor.

Undervoltage (UV) Relay The undervoltage relay is an adjustable three-phase protection system that is activated when the voltage falls below a predetermined safe value and is factory set at 85% of nominal. Control Voltage Transformer The starter is provided with a 3KVA control transformer with both secondary and primary fuses to supply control power to the chiller.

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Additional Standard Components Mechanical type solderless connectors to handle wire sizes indicated by the NEC. Three isolated vertical line contactors Three-pole, gang operated non-load break isolating switch Three vertically mounted current limiting power fuse blocks (fuses included) Magnetic three-pole, vacuum break contactor Single phase control circuit transformer Vertically mounted control circuit primary current limiting fuses Current transformers Load terminals Control circuit terminal blocks and secondary fuses Phase failure and reversal relay

Options
Motor Metering Devices
Analog ammeters and voltmeters with 3-phase selector switches..

Deluxe Motor Metering System

The deluxe motor metering system is the IQDP-4130 which includes digital readouts of 3-phase amps, 3phase volts, watt-hours, watts, volt-amps, VAR-hours, power factor, and frequency, all in a single device.

Protection Devices
Overvoltage relay. Lightning arrestors.

Ground Fault Protection Surge Capacitors Pilot Devices

Indicating lights, additional electrical interlocks and control relays.

NEMA Modifications
NEMA modifications for the NEMA 1-Gasketed standard enclosure include: NEMA 3R -- Rain resistant construction NEMA 12 -- Dust tight construction

Certifications and Approvals (Optional Adder)

UL certification for full voltage starters UL certification for reduced voltage starters CSA certification for full voltage starters CSA certification for reduced voltage starters

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Power Factor Correction Capacitors

See the Power Factor Correction section at the rear of this manual for selection information.

McQuay Starter Model Codes

The McQuay starter codes adapt the Cutler Hammer codes for order entry and drawing identification as follows:

WSR 202 M 04
Starter Type: Across-the-Line=202 Auto Trans=602 Primary Reactor=502 Size: 01 to 13 Voltage: M=2300V to 4800V H=5000V to 6900V

Selection Procedure
Select the correct size from Table 7 and options from the previous page. Table 7, Starter Size Selection
Size Max. RLA Size Max. RLA 01 18 08 107 02 27 09 125 03 32 10 148 04 46 11 172 05 55 12 204 06 65 13 255 07 88

Notes for medium voltage starters Full voltage enclosures are 90" tall, 36" wide and 30" deep. Reduced voltage enclosures are 90" tall, 72"wide and 30" deep. Add 10" to height if main horizontal bus is required. All starters are supplied with current limiting fuses and a non-load break isolation switch. Load-break fused disconnect is available as an option. Consult factory.

IMPORTANT --- ISOLATION SWITCH Medium voltage starters are constructed to allow components to slide out of the cabinet for servicing and repair. The non-load break isolation switch disconnects the power to electrical components within the starter for safety of service personnel. The standard enclosure is designed for the vacuum contactors to slide out. Contact the factory if optional roll out construction is desired. Medium voltage starters have a wide range of special options and application flexibility that is not available with low voltage starters. Contact the factory for special needs.

Specification
Detailed specification for customers wishing to specify and purchase their own starters are contained in McQuay Drawing (Specification) 359A999. Contact your local McQuay representative for a current copy.

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Dimensions
Figure 6, Free Standing, Full Voltage (see notes on page 23)

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Figure 7, Free Standing, Reduced Voltage Auto-Transformer and Primary Reactor (see notes on page 23)

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Detail Notes: A .75 diameter, typical of 4 holes. Mounting studs must extend a minimum of 2.50" above grade. HV conduit space, line and load for two high starters, upper starter cable should enter in rear half of conduit space and lower starter should enter in front half of conduit space (line connection w/o main bus). HV conduit space (line w/o main bus). HV conduit space (incoming line connection). LV conduit space. For two high starters control wiring for upper starter should enter in rear half of conduit space and lower starter control wiring should enter in front half of conduit space. Door dimensions to open doors 90 auxiliary compartment door. Not applicable for two high starters. HV conduit space, load. HV conduit space, line only. LV conduit space only. For top entry load terminals located 32.50" from bottom of enclosure. For bottom entry load term located 18.00" from bottom of enclosure. For top entry load terminals located 76.00"from bottom of enclosure. For bottom entry 61.00" from bottom of enclosure. For top entry load terminals located 53.00" from bottom of enclosure. For bottom entry load terminals located 40.50" from bottom of enclosure. For top entry load terminals located 62.50" from bottom of enclosure. For bottom entry load terminals located 48.00" from bottom of enclosure. Load terminals located on left hand side of enclosure. Load terminals located in reduced voltage enclosure on left hand side. Maximum sill height 6.00" and maximum sill extension 3.00" for removal of contactor w/o lifting device. Line terminal for top cable entry. Line terminal for bottom cable entry. Steel bottom w/removable lead plates. Tolerances -0.0" + .25" per structure. Conduits to extend a maximum of 2" into structure.

B1 B2 C

E F G H

H1

H2

H3

J J1 K

L M X Y Z

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Variable Frequency Drives

General
WSC and WDC single and dual compressor chillers can be equipped with Variable Frequency Drive (VFD). A VFD modulates the compressor speed in response to load and evaporator and condenser pressures as sensed by the microprocessor. Despite the small power penalty attributed to the VFD, the chiller can achieve outstanding part load efficiency. VFDs really prove their worth when there is reduced load combined with low compressor lift (lower condenser water temperatures) dominating the operating hours. The drives provide two important operating benefits. The traditional method of controlling centrifugal compressor capacity is by inlet guide vanes. Capacity can also be reduced by slowing down the compressor speed and reducing the impeller tip speed providing sufficient tip speed is retained to meet the chiller's discharge pressure requirements. This method is more efficient than guide vanes by themselves. In actual practice a combination of the two techniques is used. The microprocessor slows the compressor (to a fixed minimum of full load speed) as much as possible considering the need for speed to make the required compressor lift. Guide vanes take over to make up the difference. This methodology provides the optimum efficiency under any circumstances.

Standard Components
1) 2) 3) 4) Incoming and outgoing power terminals. Transformer to supply power to the control circuit, oil heaters, and oil pump. Redundant motor control relays with coils in series. The VFD is current rated at 2 kHz carrier frequency for all 2001000 HP drives. The drive is capable of running at 110% of nameplate current continuously and provides a minimum of 150% of this rated current for 5 seconds. The VFD will not generate damaging voltage pulses at the motor terminals when applied within 500 feet of each other. Both Drive and Motor comply with NEMA MG1 section 30.40.4.2 which specifies these limits at a maximum peak voltage of 1600 Volts and a minimum rise time of .1 microseconds. Units drawing 240 amps or less are air-cooled. All others are water-cooled. Factory mounted water-cooled VFDs are factory piped to chilled water inlet and outlet nozzles. Free-standing water-cooled units require chilled water supply and return piping for the VFD cooling. VFD has a liquid-cooled heat sink assembly enabling liquid cooling of the drive through a single inlet and outlet connection point, dissipating 25,000 BTUs/Hr for 600 HP, 16,000 BTUs/Hr for 350 HP and 20,000 BTUs/Hr for 450 HP. The cooling circuit maintains water temperature between 60F and 104F (15C to 40C). The VFD and options are cUL 508 listed. The drive and options are designed to comply with the applicable requirement of the latest standards of ANSI, NEMA, National Electric Code NEC, NEPU-70, IEEE 519-1992, FCC Part 15 Subpart J, CE 96. The VFD is functionally tested under motor load. During this load test the VFD is monitored for correct phase current, phase voltages, and motor speed. Correct Current Limit operation is verified by simulating a motor overload. Verification of proper factory presets by scrolling through all parameters is performed to ensure proper microprocessor settings. The computer port also verifies that the proper factory settings are loaded correctly in the drive.

5)

6)

7)

8)

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9)

The VFD has the following basic features: a) An electronic overload circuit designed to protect an A-C motor operated by the VFD output from extended overload operation on an inverse time basis. This Electronic overload is UL and NEC recognized as adequate motor protection. No additional hardware such as motor overload relays or motor thermostats are required.

b) An LED display that digitally indicates: Frequency output Voltage output Current output Motor RPM Input kW Elapsed Time Time Stamped Fault Indication DC Bus Volts a) The capability of riding though power dips up to 10 seconds without a controller trip depending on load and operating condition. In this extended ride through, the drive uses the energy generated by the rotating fan as a power source for all electronic circuits.

b) RS232 Port and Windows based software for Configuration, Control, and Monitoring. c) An isolated 0-20mA, 4-20mA or 0-4, 0-8, 0-10 volt analog speed input follower.

d) An isolated 0-10 V or 4-20 mA output signal proportional to speed or load. e) Standard I/O Expansion Interface Card with the following features: PI regulator for set point control Four Isolated 24 VDC programmable digital inputs An additional analog input for speed feedback to PI regulator One Frequency Input (0 to 200 Hz) for digital control of current limit Four programmable Isolated Digital Outputs (24 VDC rated) One Form A output relay rated at 250 VAC or 24 VDC Two NO/NC programmable output relays rated at 250 VAC or 24 VDC 1) The VFD includes the following protective circuits and features: Motor current exceeds 200% of drive continuous current rating. Output phase-to-phase short circuit condition. Total ground fault under any operating condition. High input line voltage. Low input line voltage. Loss of input or output phase. External fault. (This protective circuit shall permit wiring of remote N.C. safety contact to shut down the drive). Metal Oxide Varistors for surge suppression are provided at the VFD input terminals.

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VFD Model Sizes

VFD Model VFD 019 VFD 025 VFD 047 VFD 060 VFD 072 VFD 090 VFD120 Max. Amps 170 240 414 500 643 890 1157 Power 3/60/460-480 3/60/460-480 3/60/460-480 3/60/460-480 3/60/460-480 3/60/460-480 3/60/460-480 Cooling Air Air Water Water Water Water Water

Options
Reactor
Used for control of line harmonics in some installations.

Incoming Line Termination (Chose one)

Terminal Block Non-Fused Disconnect with through-the-door handle Fused Disconnect with TD Fuses with through-the-door handle Standard Interrupting Circuit Breaker with through-the-door handle High Interrupting Circuit Breaker with through-the-door handle Ultra High Circuit Breaker with through-the-door handle

Volts/Amps Meter with 3-phase Switch Watt Transducer

General Arrangement
VFD Mounting
VFDs can be factory mounted on the same units and in the same location as conventional starters or can be free-standing as shown below.
Chiller Model WSC, WDC 050 087 WSC 100-126 WDC 100-126 Mounted at Factory (1) X Unit Mounted in Field Free-Standing (2) X X X

X (3)

Notes 1. Optional reactor is field mounted and wired to unit mounted VFD. 2. Optional reactor is factory mounted in the VFD enclosure. 3. Brackets and interconnecting cables shipped with unit

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VFD Line Harmonics

Despite their many benefits, care must be taken when applying VFDs due to the effect of line harmonics on the electric system. VFDs cause distortion of the AC line because they are nonlinear loads-that is, they don't draw sinusoidal current from the line. They draw their current from only the peaks of the AC line, thereby flattening the top of the voltage waveform. Some other nonlinear loads are electronic ballasts and uninterruptible power supplies. Line harmonics and their associated distortion may be critical to AC drive users for three reasons: 1. 2. 3. Current harmonics can cause additional heating to transformers, conductors, and switchgear. Voltage harmonics upset the smooth voltage sinusoidal waveform. High-frequency components of voltage distortion can interfere with signals transmitted on the AC line for some control systems.

The harmonics of concern are the 5th, 7th, 11th, and 13th. Even harmonics, harmonics divisible by three, and high magnitude harmonics are usually not a problem. Current Harmonics An increase in reactive impedance in front of the VFD helps reduce the harmonic currents. Reactive impedance can be added in the following ways: 1. 2. 3. Mount the drive far from the source transformer. Add line reactors Use an isolation transformer.

Voltage Harmonics Voltage distortion is caused by the flow of harmonic currents through a source impedance. A reduction in source impedance to the point of common coupling (PCC) will result in a reduction in voltage harmonnics. This may be done in the following ways: 1. 2. 3. 4. Keep the PCC as far from the drives (close to the power source) as possible. Increase the size (decrease the impedance) of the source tranformer. Increase the capacity (decrease the impedance) of the busway or cables from the source to the PCC. Make sure that added reactance is "downstream" (closer to the VFD than the source) from the PCC.

The IEEE 519-1991 Standard The Institute of Electrical and Electronics Engineers (IEEE) has developed a standard that defines acceptable limits of system current and voltage distortion. A simple form is available from McQuay that allows McQuay to determine compliance with IEEE 519-1991. Line reactors, isolation transformers, or phase-shifting transformers may be required on some installations.

VFD Dimensions
Dimensions for free-standing VFDs are available as Certified Drawings from the local McQuay sales office.

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Power Factor Correction

Many local codes and utility companies require power factor correction to improve the utilization of power. Voltage and current in alternating current systems travel through wires in a sine wave pattern developing positive charges and negative charges. The number of sine waves or cycles per second is called frequency. The most common frequencies are 50 Hz and 60 Hz (cycles per second). Induction devices such as electric motors and solenoid coils use energy to create magnetic fields to perform their tasks. This magnetizing energy does not perform usable work and will cause the current to lag the voltage, traveling in a slightly different sine wave. When electrical measurements are made, only the mean values for voltage and amperage are measured. These measurements do not indicate that the voltage and amperage have slipped. This slippage can be corrected by applying power factor capacitors. These capacitors have the reverse effect causing voltage to lag current. When capacitors are used with motors, the two devices offset each other allowing voltage and amperage to travel more consistently. It is good practice to select capacitors that will correct to a maximum of 95% of total correction. Capacitors are sized in terms of KVAR (1000 volt amp reactive). Readily available low voltage sizes are 2.5, 5.0, 7.5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 75 and 100 KVAR. For medium voltage applications, available sizes are 25, 50, 100, 150 and 200 KVAR. Contact the factory for larger sizes. Power factor correction capacitors should be connected to the load side of contactors except for solid state starters. If field supplied capacitors are used with solid state starters, they must be installed upstream of the starter. At least ten feet of wire is required between the capacitors and the starter. A separate isolation contactor must be supplied to disconnect the capacitors during starter ramp-up and ramp-down. When the capacitors for solid state starters are supplied by McQuay, the isolation contactor is furnished and ten feet of wire is coiled within the starter enclosure. Use two sets of capacitors for WDC dual compressor units. The McQuay chiller selection program prints out the unit power factor and will also calculate capacitor size for power factor correction.

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