McQuay AGR 080AS Manual

Installation, Operation and Maintenance Manual IOMM ACR/AGR-1Group: ChillerPart Number: 074644201Effective: March 2000Supersedes: IOMM ACR/AGR© 1997 M

10 IOMM ACR/AGR-1Table 5, Flow Switch Minimum Flow RatesNOMINAL PIPE SIZEINCHES (mm)MINIMUM REQUIRED FLOW TOACTIVATE SWITCH - gpm (L/s)1 (25.4) 6.00

100 IOMM ACR/AGR-1EvaporatorThe remote evaporator on AGR-AM units and CDE evaporators are the direct expansion, shell-and-tube type with refrigerant f

IOMM ACR/AGR-1 1012. Add the charge to the system through the suction shutoff valve or through the Schrader fitting onthe tube entering the evaporator

102 IOMM ACR/AGR-1AGR Troubleshooting ChartPROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS1. Main Switch. 1. Close Switch.2. Fuse Blown. Circuit

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IOMM ACR/AGR-1 11Table 6, Ethylene Glycol FactorsFreeze Point%E.G.°F °CCapacity Power Flow Pressure Drop10 26 -3 0.991 0.996 1.013 1.07020 18 -8 0.982

12 IOMM ACR/AGR-1Figure 7, Pressure Drop CurveNOMINAL MAXIMUM MINIMUMPD Flow PD Flow PD FlowCDESizeAGRUnitSizeft of Water gpm lps ft of Water gpm lps

IOMM ACR/AGR-1 13Refrigerant PipingIntroductionProper refrigerant piping can represent the difference between a reliable, trouble free system andmonth

14 IOMM ACR/AGR-1Add b and c above to obtain the total equivalent feet. Use ASHRAE Table 3 (for R22) or Table 4 (forR134a). Suction line selections

IOMM ACR/AGR-1 15Underground Refrigerant LinesMcQuay does not recommend the installation of suction lines underground. If job conditions requirethat

16 IOMM ACR/AGR-1totaling 10 x 3.05 psi (or 10 x 2.2) and still satisfy the objective of delivering solid liquid to theexpansion valve.In calculating

IOMM ACR/AGR-1 17Physical DataAGR-AMTable 10, AGR 070AM - 085AMAGR MODEL NUMBERPHYSICAL DATASTANDARD EFFICIENCY070AM 075AM 080AM 085AMBASIC DATA Ckt.1

18 IOMM ACR/AGR-1Table 11, AGR 090AM - 100AMPHYSICAL DATA AGR MODEL NUMBERSTANDARD EFFICIENCY 090AM 095AM 100AMBASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.

IOMM ACR/AGR-1 19Table 12, ACR 060AS - 070ASPHYSICAL DATA ACR MODEL NUMBERSTANDARD EFFICIENCY 060AS 065AS 070ASBASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.

2 IOMM ACR/AGR-1Table of ContentsIntroduction...3Inspection ...

20 IOMM ACR/AGR-1Table 13, ACR 075A - 090APHYSICAL DATA ACR MODEL NUMBERSTANDARD EFFICIENCY 075AS 080AS 090ASBASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1

IOMM ACR/AGR-1 21Table 14, ACR 100A - 120APHYSICAL DATA ACR MODEL NUMBERSTANDARD EFFICIENCY 100AS 110AS 120ASBASIC DATA Ckt.1 Ckt.2 Ckt.1 Ckt.2 Ckt.1

22 IOMM ACR/AGR-1Electrical DataField WiringPower WiringCAUTIONInternal power wiring to the compressors for single and multiple point option arediffer

IOMM ACR/AGR-1 23AGR-AM DataACR DataTable 15, 60 Hz, Single Point Power Electrical DataPOWER SUPPLYField Wire Conduit HubACR-ASCond.UnitModelAGR-AMCh

24 IOMM ACR/AGR-1Table 16, 60 Hz, Compressor & Condenser Fan Motor Amp Draw Rated LoadAmpsLocked Rotor AmpsCompressors CompressorsAcross-The-Line

IOMM ACR/AGR-1 25Table 17, 60 Hz Single Point Power, Field Wiring DataWiring to StandardPower BlockWiring to OptionalNon-Fused Disconnect SwitchACR-A

26 IOMM ACR/AGR-1Electrical NotesNotes for “Electrical Data Single Point” Power:1. Unit wire size ampacity (MCA) is equal to 125% of the largest comp

IOMM ACR/AGR-1 27Electrical LegendFigure 8, Electrical Legend

28 IOMM ACR/AGR-1Wiring DiagramsFigure 9, AGR-AM, Typical Field Wiring with MicroTech Controller

IOMM ACR/AGR-1 29Figure 10, AGR-AM, Typical Field Wiring Diagram with UNT Controller

IOMM ACR/AGR-1 3IntroductionIMPORTANT INFORMATIONThis Product Manual contains information on three different McQuay product lines.• Model AGR-AM Th

30 IOMM ACR/AGR-1Figure 11, ACR-A, Field Wiring Diagram (No Capacity Control)

IOMM ACR/AGR-1 31Figure 12, ACR-A, Field Wiring Diagram (Capacity Control Staging)

32 IOMM ACR/AGR-1Figure 13, AGR-AM, MicroTech Controller Schematic

IOMM ACR/AGR-1 33Figure 14, AGR-AM, Unit Control Schematic (MicroTech)

34 IOMM ACR/AGR-1Figure 15, AGR-AM, Staging Schematic (MicroTech)

IOMM ACR/AGR-1 35Dimensional DataFigure 16, Dimensions AGR 070AM and ACR 060AS -075ASACR AGR OVERALL COMPRESSOR # 1 (SUCTION #1) COMPRESSOR # 2 (SUCTI

36 IOMM ACR/AGR-1Figure 17, AGR 075AM - 100AM and ACR 080AS - 120ASCOMPRESSOR # 1 (SUCTION #1)inches (mm)COMPRESSOR # 2 (SUCTION #2)inches (mm)ACRMODE

IOMM ACR/AGR-1 37CDE EvaporatorFigure 18, CDE 1004-1 - 1204-1WATER CONNECTIONinch (mm)REFRIGERANT CONNECTIONinch (mm)CDEMODELNUMBERC L P T M NCDE-120

38 IOMM ACR/AGR-1StartupPre Start-upThe system components must be inspected to ensure that nothing has become loose or damagedduring shipping or insta

IOMM ACR/AGR-1 39Extended1. Front seat both condenser liquid line service valves.2. Put both circuit switches in Pumpdown and Stop position.3. Afte

4 IOMM ACR/AGR-1InstallationNote: Installation is to be performed by qualified personnel who are familiar with local codesand regulations.WARNINGSharp

40 IOMM ACR/AGR-1Electrical Check OutCAUTIONElectrical power must be applied to the compressor crankcase heaters 24 hoursbefore starting unit.1. Open

IOMM ACR/AGR-1 41OperationHot Gas Bypass (Optional)This option allows the system to operate at low loads without the ON-OFF cycling of the compressor.

42 IOMM ACR/AGR-1System AdjustmentTo maintain peak performance at full load operation, the system superheat and liquid subcooling mayrequire adjustmen

IOMM ACR/AGR-1 43DX EvaporatorThe evaporator is of the direct expansion type with removable internally finned tubes. The coppertubes are individually

44 IOMM ACR/AGR-1Standard Controller Setpoints (optional Zone Terminal required tochange values)VALUESTEMPLATENAMEFACTORY SETPOINT RANGEOA/AI3 Lim SP

IOMM ACR/AGR-1 45UNT Controller, AGR-AMThe ACR Condensing Unit does not come factory equipped with a staging control. The control isfield supplied an

46 IOMM ACR/AGR-1Unit Set Points and CalibrationThe control software is installed and tested by the factory before shipping. No periodic calibration

IOMM ACR/AGR-1 47Chilled Water Flow SwitchThe chilled water flow switch is connected to field wiring terminals #142 and #143 on TB-7. When thechilled

48 IOMM ACR/AGR-1Digital InputsNote: All Digital Inputs are 24Vac supplied by transformer T2 in the control panel. Do not useinputs from another powe

IOMM ACR/AGR-1 49As the OAT increases above the Outdoor Air Low Limit (OALL), the Actual Leaving Water Setpoint isdecreased from its Leaving High Limi

IOMM ACR/AGR-1 5LocationUnit PlacementAGR-AM and ACR units are for outdoor applications and can be mounted on a roof or ground level.Set units on a so

50 IOMM ACR/AGR-1Figure 21, Zone Temperature ResetLWRBLWSPZTLL ZTHLZTRB(ZTLL=ZTHL - ZTRB)As the Zone Temperature increases above the Zone Temperature

IOMM ACR/AGR-1 51Table 22, Dip Switch ConfigurationRemote Reset / Demand LimitGlobal UNT Dipswitch SettingsSwitch 1 2 3 4 5 6On (10V) X X X X XSW2Of

52 IOMM ACR/AGR-1Pumpdown ControlThe AGR units have a one time pump down. The pump down is activated when a circuit’s liquid linesolenoid valve is de

IOMM ACR/AGR-1 53AlarmsCircuit Alarm ConditionsThe “Circuit Alarm Conditions” are those alarms that only affect one circuit and can stop thecompressor

54 IOMM ACR/AGR-1Figure 22, Zone TerminalMONITORADJUSTTIME SCHEDULEPASSWORD ENTERCompressor 1Compressor 2Stage 3Stage 4Solenoid #1Frzstat#1Al

IOMM ACR/AGR-1 55DISPLAYS, SYMBOLS, KEYS, AND BUTTONSThe Zone Terminal simultaneously displays three set points or sensed values. In addition, flashi

56 IOMM ACR/AGR-1CONNECTING THE ZONE TERMINALYou can unit mount the ZT, or use it as a portable tool for convenient access to any chillerinformation.M

IOMM ACR/AGR-1 57Adjustable PointsThe following McQuay Global Reciprocating Chiller points are adjustable by the Zone Terminal.Table 24, Adjustable Po

58 IOMM ACR/AGR-1Cir #2 Starts - Counts the number of starts for circuit #2. Note: If power is lost to the controller, thisdata is lost and will sta

IOMM ACR/AGR-1 59Global UNT Controller Troubleshooting ChartPROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONSCompressor will notrun1. Main switch, circuit b

6 IOMM ACR/AGR-1Figure 3, Clearance RequirementsDo not block the flow of air toand from the condenser coil.Restricting airflow or allowingair recircul

60 IOMM ACR/AGR-14. Controller stage timing.5. Defective TXV.6. Hot gas bypass not set properly.7. Low ambient operation.4. Check timing and rese

IOMM ACR/AGR-1 61MicroTech ControllerAll operational descriptions are based on the MicroTech controller software versions rcp2e02g.cod forEnglish and

62 IOMM ACR/AGR-1Interlock wiringThe installing contractor provides all interlock wiring to field devices (such as flow switches andpump starters). S

IOMM ACR/AGR-1 63Field WiringInterconnecting wiring for the control panel may consist of the following:• 115Vac power wiring• Chilled water pump rel

64 IOMM ACR/AGR-1Digital OutputsThe digital output board has normally open solid-state relays with an on-board replaceable 5 ampfuse. The status of a

IOMM ACR/AGR-1 65Controller Inputs /OutputsAnalog InputsAnalog inputs are used to read the various temperatures and pressures on the chiller as well a

66 IOMM ACR/AGR-1Table 27, Relay Board OutputsDigital OutputNumberOutputDescription0 Alarm Circuit1 Chilled Water Pump Relay2 Liquid Line Solenoid Ci

IOMM ACR/AGR-1 67The remote 4-20mA input must be 4mA or less and the leaving water temperature will be controlled tothe calculated setpoint. When the

68 IOMM ACR/AGR-1Manual OperationManual operating modes are available to simplify setup and troubleshooting of the unit. Any of thefollowing manual m

IOMM ACR/AGR-1 69The MicroTech controller alarms can either be of the manual reset type or the auto reset type. Criticalalarm conditions such as High

IOMM ACR/AGR-1 7Vibration IsolatorsVibration isolators are recommended for all roof mounted installations or wherever vibrationtransmission is a consi

70 IOMM ACR/AGR-1Sequence of OperationOff ConditionsWith power supplied to the unit, 115Vac power is applied through the control fuse F1 to thecompres

IOMM ACR/AGR-1 71Low Ambient StartIf the “LOW AMBIENT” option was selected and the out side air temperature is below 50°F, the lowambient start logic

72 IOMM ACR/AGR-1Start-Up and ShutdownPre-Start CheckoutConfiguration default set points are entered at the factory and all values must be checked and

IOMM ACR/AGR-1 73Move both pumpdown switches to the auto position. DH1-7 and DH2-15 will turn off. The controllerwill then activate one of the refri

74 IOMM ACR/AGR-1Menu Structure (General Description)The information stored in the MicroTech controller can be accessed through the keypad using a tre

IOMM ACR/AGR-1 75Keypad Key FunctionsThe MicroTech keypad consists of twelve pressure sensitive membrane switches (refer to Figure 25).These keys are

76 IOMM ACR/AGR-1Decr.When changing the value of a menu item entry, pressing “DECR. -” shifts the menu itemdisplay line to the next lower value or pr

IOMM ACR/AGR-1 77Menu #6: Circuit 62 PressuresThe circuit #2 evaporator and condenser refrigerant pressurereadings are displayed under this menu. The

78 IOMM ACR/AGR-1If the 4-20 milliamp reset option is enabled, the controller will reset the leaving chilled watertemperature to a higher value based

IOMM ACR/AGR-1 79Figure 26, Delta-T Setpoints for ChillersMenu #15: Softload Set Points—The controller can limit the number of available stages when t

8 IOMM ACR/AGR-1Table 3, AGR-AM Isolator Loads At Each Mounting Location With Copper Fins1 2 3 4 TOTAL UNITAGR-AMSizelb kg lb kg lb kg lb kg lb kg070

80 IOMM ACR/AGR-1Press the Next Item key. The display will show the current Day, Hour, Minute and Second. If thisinformation needs to be changed, foll

IOMM ACR/AGR-1 81Table 29, MENU 1 Chiller StatusScreen DisplayOFF: Manual ModeOFF: System SwOFF: Remote CommOFF: Remote SwOFF: Time ClockOFF: AlarmOF

82 IOMM ACR/AGR-1Table 35, MENU 7 Circ #1 Temp'sScreen DisplaySatur Evap=xxx°F (°C)1N/A **°F (°C)SuctLine = xxx.x°F (°C)Open °F (°C)2Short °F (°C

IOMM ACR/AGR-1 83Table 41, MENU 13 Control ModeScreen Display Factory Setpoint RangeManual Unit OffAutomaticManual Staging1 Manual Unit Off2 Manual St

84 IOMM ACR/AGR-1Table 44, MENU 15 SoftLoad SptsScreen Display Factory Setpoint Range1 Time Left= xxmin2 SoftLoad= xx min 20 0 - 2543 SoftLdMaxStg= x

IOMM ACR/AGR-1 85Table 50, MENU 20 ScheduleScreen Display Factory Setpoint Range1 Override= xx.xx hr 0.00 Hr 00:00 - 63.502 NMPSchedule= N/A N/A3 Sun

86 IOMM ACR/AGR-1Table 54, MENU 23 Misc SetupScreen Display Factory Setpoint Range1 Unit Type= Air Cooled - -2 Model AGZ 4 Stages - -3 # Compressors

IOMM ACR/AGR-1 87MicroTech Controller Trouble AnalysisMicroprocessor Control BoardThe Microprocessor Control Board (MCB) is shown in Figure 27. It con

88 IOMM ACR/AGR-1Following is the normal start-up sequence that the three status LED’s should follow when power isapplied to the MCB:1. The red (“Res

IOMM ACR/AGR-1 89Figure 28, Hex Switches1230456789ABCDEF1230456789ABCDEFHI (left) hex switch LO (right) hex switch* Hex switch setting 01 shownCommuni

IOMM ACR/AGR-1 99. If the unit is used as a replacement chiller on a previously existing piping system, flush thesystem thoroughly before unit instal

90 IOMM ACR/AGR-1Test ProceduresStatus LED DiagnosticsThe MCB status LED indications can aid in controller diagnostics. If the status LEDs do not oper

IOMM ACR/AGR-1 916. Reconnect the analog input ribbon cable. Cycle power to the controller and check the powerfuses.If both fuses are intact, go to s

92 IOMM ACR/AGR-1Figure 29, 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 F1F

IOMM ACR/AGR-1 93Troubleshooting Analog InputsAn analog input, such as a temperature sensor, is connected to the ADI board. The ADI board thenconditi

94 IOMM ACR/AGR-1Figure 30, Output Board Relay Socket12345LEDFuseTest Resistor330-680 Ohm*250V ~ 50/60 Hz*120V ~ 50/60 HzWARNINGElectric shock hazard.

IOMM ACR/AGR-1 952. Remove power from the controller by placing CB1 to the OFF position. Disconnect at least onewire from the power input terminals

96 IOMM ACR/AGR-13. Remove power from the controller by opening CB1. Try to improve the connections in theAux/Out plug insulation displacement termi

IOMM ACR/AGR-1 97Unit MaintenanceGeneralOn initial start-up and periodically during operation, it will be necessary to perform certain routineservice

98 IOMM ACR/AGR-115°F) and flashing is visible in the sightglass check the pressure drop across the filter-drier.Subcooling should be checked at full

IOMM ACR/AGR-1 99ServiceCAUTION1. Service on this equipment is to be performed by qualified refrigeration personnelfamiliar with equipment operation,