McQuay ACZ 055A Installation Manual

Installation, Operation and Maintenance ManualIOMM ACZ/AGZGroup: ChillerPart Number: 074644101Effective: July 1998Supersedes: New© 1997 McQuay Interna

10 IOMM ACZ/AGZGlycol SolutionsThe system glycol capacity, glycol solution flow rate in GPM, and pressure drop through the coolermay be calculated usi

100 IOMM ACZ/AGZUnit MaintenanceGeneralOn initial start-up and periodically during operation, it will be necessary to perform certain routineservice c

IOMM ACZ/AGZ 101drier. Subcooling should be checked at full load with 70°F (21.1°C) outdoor air temperature and allfans running.An element inside the

102 IOMM ACZ/AGZServiceCAUTION1. Service on this equipment is to be performed by qualified refrigeration personnel familiar withequipment operation, m

IOMM ACZ/AGZ 103EvaporatorThe remote evaporator on AGZ-AM units and CDE evaporators are the direct expansion, shell-and-tube type with refrigerant flo

104 IOMM ACZ/AGZ2. Add the charge to the system through the suction shutoff valve or through the Schrader fitting onthe tube entering the evaporator b

IOMM ACZ/AGZ 105Troubleshooting ChartPROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPSCompressor will not1. Main Switch. 1. Close Switch.Run2. Fuse Bl

13600 Industrial Park Boulevard, P.O. Box 1551, Minneapolis, MN 55440 USA (612) 553-5330

IOMM ACZ/AGZ 11Table 6, Capacity and Power DeratesChilled Water Fouling FactorDelta-T 0.00025 (0.044) 0.00075 (0.132) 0.00175 (0.308)ALTITUDE °F °C Ca

12 IOMM ACZ/AGZFigure 7, Pressure Drop CurveAGZ 030AM - 040AMCDE 1004-1AGZ 045AM - 050AMCDE 1204-3CDE AGZ-AM NOMINAL MAXIMUM MINIMUMUnit Unit Pressure

IOMM ACZ/AGZ 13Refrigerant PipingIntroductionProper refrigerant piping can represent the difference between a reliable, trouble free system andmonths

14 IOMM ACZ/AGZd. If a vertical riser exists including the trap at the coil, determine the minimum tons for thecircuit.Add b and c above to obtain the

IOMM ACZ/AGZ 15With the minimum tons known, a smaller line size should be selected from ASHRAE Chapter 2,Table 13 or 14 capable of entraining oil at t

Installation, Operation and Maintenance ManualIOMM ACZ/AGZGroup: ChillerPart Number: 074644101Effective: July 1998Supersedes: New© 1997 McQuay Interna

IOMM ACZ/AGZ 17side to the condenser side of the circuit. The relief can be sized for a pressure differential from 80 to180 psi, but not more than 18

18 IOMM ACZ/AGZTable 7, Liquid Line ComponentsNom.R-22 Sporlan Part Number Shown - (Equivalents Are Acceptable)Unit System Tons Filter Solenoid Sight

IOMM ACZ/AGZ 19Physical DataAGZ-AMTable 8, AGZ 030AM - 050AMPHYSICAL DATA AGZ-AM MODEL NUMBERSTANDARD EFFICIENCY 030AM 035AM 040AM 045AM 050AMCAPACITY

2 IOMM ACZ/AGZTable of ContentsIntroduction ...3Inspection...3Instal

20 IOMM ACZ/AGZACZ Condensing UnitsTable 9, ACZ 030A - 040APHYSICAL DATA ACZ MODEL NUMBERSTANDARD EFFICIENCY 030A 035A 040AUNIT CAPACITY @ ARI Condit

IOMM ACZ/AGZ 21Table 10, ACZ 045A - 055APHYSICAL DATA ACZ MODEL NUMBERSTANDARD EFFICIENCY 045AS 050AS 055ASBASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1 Ck

22 IOMM ACZ/AGZElectrical DataField WiringPower WiringCAUTIONInternal power wiring to the compressors for single and multiple point option are differe

IOMM ACZ/AGZ 23Electrical Data AGZ-AMElectrical Data ACZTable 11, AGZ-030AM - 050AM, ACZ 030A - 055A, 60 Hz, Single Point Power Electrical DataMini

24 IOMM ACZ/AGZTable 12, AGZ-AM, ACZ A, 60 Hz, Compressor & Condenser Fan Motor Amp DrawRated Load Amps Locked Rotor AmpsACZ AGZ-AM Compressors No

IOMM ACZ/AGZ 25Electrical NotesNotes for “Electrical Data Single Point” Power:1. Unit wire size ampacity (MCA) is equal to 125% of the largest compres

26 IOMM ACZ/AGZElectrical LegendFigure 9, Electrical Legend

IOMM ACZ/AGZ 27Wiring DiagramsFigure 10, AGZ-AM, Typical Field Wiring with Global UNT ControllerUNITMAINTERMINALBLOCKDISCONNECT(BYOTHERS)3PHASEPOWERSU

28 IOMM ACZ/AGZFigure 11, AGZ-AM, Typical Field Wiring Diagram with MicroTech ControllerUNITMAINTERMINALBLOCKDISCONNECT(BYOTHERS)3PHASEPOWERSUPPLYGND

IOMM ACZ/AGZ 29Figure 12, AGZ-AM, Single-point Connection with FanTrol

IOMM ACZ/AGZ 3IntroductionIMPORTANT INFORMATIONThis Installation and Operating Manual contains information on three differentMcQuay product lines• Mod

30 IOMM ACZ/AGZFigure 13, AGZ-AM, Single-point Connection with SpeedTrol

IOMM ACZ/AGZ 31Figure 14, AGZ-AM, Unit Control Schematic (UNT)

32 IOMM ACZ/AGZFigure 15, AGZ-AM, Staging Schematic (UNT)

IOMM ACZ/AGZ 33Figure 16, AGZ-AM, MicroTech Controller Schematic

34 IOMM ACZ/AGZFigure 17, AGZ-AM, Unit Control Schematic (MicroTech)

IOMM ACZ/AGZ 35Figure 18, AGZ-AM, Staging Schematic (MicroTech)

36 IOMM ACZ/AGZFigure 19, ACZ Field Connection Diagram (No Capacity Control)

IOMM ACZ/AGZ 37Figure 20, ACZ Field Wiring Diagram (Capacity Control Staging)

38 IOMM ACZ/AGZDimensional DataAGZ-AMACZFigure 21, Dimensions AGZ 030AM - 050AM and ACZ 030A - 055AACZ AGZ DIMENSIONS CENTER OF GRAVITY UNIT WEIGHTS A

IOMM ACZ/AGZ 39CDEFigure 22, CDE 1004-1 - 1204-3CDE WATER CONNECTION REFRIGERANT CONNECTIONMODEL INCHES (mm) INCHES (mm)NUMBER C L P T M NCDE-1004-1 3

4 IOMM ACZ/AGZInstallationNote: Installation is to be performed by qualified personnel who are familiar with localcodes and regulations.WARNINGSharp e

40 IOMM ACZ/AGZStartupPre Start-upThe system components must be inspected to ensure that nothing has became loose or damagedduring shipping or install

IOMM ACZ/AGZ 41Extended1. Front seat both condenser liquid line service valves.2. Put both circuit switches in Pumpdown and Stop position.3. After the

42 IOMM ACZ/AGZRefrigerant ChargingLiquid line subcooling at the liquid shut-off valve should be between 15 and 20 degrees F at fullload. If the unit

IOMM ACZ/AGZ 43Electrical Check OutCAUTIONElectrical power must be applied to the compressor crankcase heaters 24 hours beforestarting unit.1. Open al

44 IOMM ACZ/AGZOperationSequence of OperationStartingWith control power on, 115Vac power is applied through F1 to the compressor crankcase heatersand

IOMM ACZ/AGZ 45Software Description (Global UNT Interface Kit required to read orchange variables)VariableNameDescription Default Value RangeLPSS Low

46 IOMM ACZ/AGZ Filter DriersEach refrigerant circuit is furnished with a full flow filter drier or an optional replaceable core typefilter-drier. Th

IOMM ACZ/AGZ 47The suction superheat for the suction leaving the evaporator is set at the factory for 8° to 12°F atfull load. To have full rated uni

48 IOMM ACZ/AGZGlobal UNT Controller, AGZ-AMThis section provides installation, setup and troubleshooting information for the Global UNTcontroller.All

IOMM ACZ/AGZ 49Unit Set Points and CalibrationThe control software is installed and tested by the factory before shipping. No periodic calibrationof

IOMM ACZ/AGZ 5LocationUnit PlacementAGZ-AM and ACZ units are for outdoor applications and can be mounted on a roof or ground level.Set units on a soli

50 IOMM ACZ/AGZChilled Water Flow SwitchThe chilled water flow switch is connected to field wiring terminals #142 and #143 on TB-7. Whenthe chilled w

IOMM ACZ/AGZ 51Digital InputsNote: All Digital Inputs are 24Vac supplied by transformer T2 in the control panel. Do notuse inputs from another power

52 IOMM ACZ/AGZAs the OAT increases above the Outdoor Air Low Limit (OALL), the Actual Leaving WaterSetpoint is decreased from its Leaving High Limit

IOMM ACZ/AGZ 53Zone Temperature (optional Zone Temperature Sensor )When selected, a Zone Temperature Sensor is connected to TB-7 terminals #134 and #1

54 IOMM ACZ/AGZUnoccupied ModeWhen the remote start / stop input is opened, the unoccupied mode is initiated. The chiller willmaintain a higher leavi

IOMM ACZ/AGZ 55Freezestat ControlOn startup the Global UNT controller will check the evaporator pressure after the SLPT(starting lowpressure time) tim

56 IOMM ACZ/AGZFreezestat reset on the control panel. There is a five minute time delay after depressing the resetbutton.The chiller must have the ma

IOMM ACZ/AGZ 57Figure 26, Zone TerminalMONITORADJUSTTIME SCHEDULEPASSWORD ENTERCompressor 1Compressor 2Stage 3Stage 4Solenoid #1Frzstat#1AlmF

58 IOMM ACZ/AGZDISPLAYS, SYMBOLS, KEYS, AND BUTTONSThe Zone Terminal simultaneously displays three set points or sensed values. In addition, flashing

IOMM ACZ/AGZ 59CONNECTING THE ZONE TERMINALYou can unit mount the ZT, or use it as a portable tool for convenient access to any chillerinformation.McQ

6 IOMM ACZ/AGZFigure 3, Clearance Requirements

60 IOMM ACZ/AGZAdjustable PointsThe following McQuay Global Scroll Chiller points are adjustable by the Zone Terminal.Table 21, Adjustable PointsTEMPL

IOMM ACZ/AGZ 61Cir #2 Starts - Counts the number of starts for circuit #2. Note: If power is lost to thecontroller, this data is lost and will start

62 IOMM ACZ/AGZGlobal UNT Controller Troubleshooting ChartPROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONSCompressor will notrun1. Main switch, circuit brea

IOMM ACZ/AGZ 63MicroTech Controller, AGZ-AMAll operational descriptions are based on the MicroTech controller software versions AGZ2E01A.Operating cha

64 IOMM ACZ/AGZRemote 4-20 milliamp signalsSignals for leaving water reset or demand limit are provided by the installing contractor andconnected to t

IOMM ACZ/AGZ 65Field WiringInterconnecting wiring for the control panel may consist of the following:• 115Vac power wiring• Chilled water pump relay•

66 IOMM ACZ/AGZDigital OutputsThe digital output board has normally open solid-state relays with an on-board replaceable 5 ampfuse. The status of all

IOMM ACZ/AGZ 67Controller Inputs /OutputsAnalog InputsAnalog inputs are used to read the various temperatures and pressures on the chiller as well as

68 IOMM ACZ/AGZTable 24, Relay Board OutputsDigital OutputNumberOutputDescription0 Alarm Circuit1 Chilled Water Pump Relay2 Liquid Line Solenoid Circ

IOMM ACZ/AGZ 69The remote 4-20mA input must be 4mA or less and the leaving water temperature will be controlledto the calculated setpoint. When the r

IOMM ACZ/AGZ 7Vibration IsolatorsVibration isolators are recommended for all roof mounted installations or wherever vibrationtransmission is a conside

70 IOMM ACZ/AGZManual OperationManual operating modes are available to simplify setup and troubleshooting of the unit. Any of thefollowing manual mod

IOMM ACZ/AGZ 71Pumpdown ControlThe AGZ units have a one time pump down. If two compressors are operating on a refrigerantcircuit and the chiller is c

72 IOMM ACZ/AGZCircuit Alarm ConditionsThe “Circuit Alarm Conditions” are those alarms which only affect one circuit and can stop thecompressors of th

IOMM ACZ/AGZ 73If an alarm condition exists which prevents normal operation of both refrigerant circuits, the chillerwill be disabled and the display

74 IOMM ACZ/AGZStart-Up and ShutdownPre-Start CheckoutConfiguration default set points are entered at the factory and all values must be checked and r

IOMM ACZ/AGZ 75rises above the LPCutIn value, a compressor on the lead circuit will start. Refer to the unit stagingschematic to determine which LED

76 IOMM ACZ/AGZMenu Structure (general description)The information stored in the MicroTech controller can be accessed through the keypad using a tree-

IOMM ACZ/AGZ 77minutes so the password only needs to be entered once per session. After 5 minutes of inactivity, thepassword access time will expire

78 IOMM ACZ/AGZKeypad Key FunctionsThe MicroTech keypad consists of twelve pressure sensitive membrane switches (refer to Figure 29).These keys are us

IOMM ACZ/AGZ 79Decr.When changing the value of a menu item entry, pressing “DECR. -” shifts the menu itemdisplay line to the next lower value or prev

8 IOMM ACZ/AGZWater PipingLocal authorities can supply the installer with the proper building and safety codes required for safeand proper installatio

80 IOMM ACZ/AGZMenu #6: Circuit 62 PressuresThe circuit #2 evaporator and condenser refrigerant pressurereadings are displayed under this menu. The c

IOMM ACZ/AGZ 81("MaxChWRst"). At 4mA or less, no reset will occur. At 20mA, the chilled water set point will bereset to a value equaling the

82 IOMM ACZ/AGZFigure 30, Delta-T Setpoints for ChillersMenu #15: Softload Set Points—The controller can limit the number of available stages when the

IOMM ACZ/AGZ 83will advance to the Year position on the display. Use the Incr, Decr, and Enter keys to set the correctYear.Press the Next Item key. Th

84 IOMM ACZ/AGZTable 26, MENU 1 Chiller StatusScreen Display1 OFF: Manual ModeOFF: System SwOFF: Remote CommOFF: Remote SwOFF: Time ClockOFF: AlarmOF

IOMM ACZ/AGZ 85Table 32, MENU 7 Circ #1 Temp'sScreen Display1 Satur Evap=xxx°F (°C)N/A **°F (°C)2 SuctLine = xxx.x°F (°C)Open °F (°C)Short °F (°C

86 IOMM ACZ/AGZTable 38, MENU 13 Control ModeScreen Display Factory Setpoint Range1 Manual Unit Off Manual Unit OffAutomaticManual Staging2 Manual Sta

IOMM ACZ/AGZ 87Table 41, MENU 15 SoftLoad SptsScreen Display Factory Setpoint Range1 Time Left= xxmin2 SoftLoad= xx min 20 0 - 2543 SoftLdMaxStg= x 4

88 IOMM ACZ/AGZTable 47, MENU 20 ScheduleScreen Display Factory Setpoint Range1 Override= xx.xx hr 0.00 Hr 00:00 - 63.502 NMPSchedule= N/A N/A3 Sun 00

IOMM ACZ/AGZ 89Table 51, MENU 23 Misc SetupScreen Display Factory Setpoint Range1 Unit Type= Air Cooled2 Units = English English English - Metric4 Spe

IOMM ACZ/AGZ 9Figure 5, Typical Evaporator Field Water PipingFlow SwitchMount a water flow switch in either the entering or leaving water line to shut

90 IOMM ACZ/AGZTrouble Analysis for the AGZ MicroTech ControllerMicroprocessor Control BoardThe Microprocessor Control Board (MCB) is shown in Figure

IOMM ACZ/AGZ 91Following is the normal start-up sequence that the three status LED’s should follow when power isapplied to the MCB:1. The red (“Reset”

92 IOMM ACZ/AGZFigure 32, Hex Switches1230456789ABCDEF1230456789ABCDEFHI (left) hex switch LO (right) hex switch* Hex switch setting 01 shownCommunica

IOMM ACZ/AGZ 93Test ProceduresStatus LED DiagnosticsThe MCB status LED indications can aid in controller diagnostics. If the status LEDs do not operat

94 IOMM ACZ/AGZ6. Reconnect the analog input ribbon cable. Cycle power to the controller and check the powerfuses.If both fuses are intact, go to step

IOMM ACZ/AGZ 95Figure 33, MCB Power Supply TerminalsPOWER FUSES[BUSSMAN GDC-T2A]POWER IN[18-24 VCT]AC AC GND GNDAUX/OUT43219 8 7 6 5 4 3 2 1Fuse F1Fus

96 IOMM ACZ/AGZTroubleshooting Analog InputsAn analog input, such as a temperature sensor, is connected to the ADI board. The analog input isthen cond

IOMM ACZ/AGZ 97Figure 34, Output Board Relay Socket12345LEDFuseTest Resistor330-680 Ohm*250V ~ 50/60 Hz*120V ~ 50/60 HzWARNINGElectric shock hazard. C

98 IOMM ACZ/AGZ2. Remove power from the controller by placing CB1 to the OFF position. Disconnect at least onewire from the power input terminals of t

IOMM ACZ/AGZ 993. Remove power from the controller by opening CB1. Try to improve the connections in theAux/Out plug insulation displacement terminals