McQuay AGR 100AS Installation Manual

Installation, Operation and Maintenance ManualIOMM AGR-1Group: ChillerPart Number: 330145704Effective: August 2001Supersedes: IOMM AGRAir-Cooled Recip

10 AGR 070A through 100A IOMM AGR-1Figure 7, Refrigerant Piping (Some Components Are Optional)Glycol SolutionsThe system glycol capacity, glycol solut

Post Office Box 2510, Staunton, Virginia 24402 USA • (800) 432-1342 • www.mcquay.com

IOMM AGR-1 AGR 070A through 100A 11CAUTIONDo not use an automotive grade antifreeze. Industrial grade glycols must be used.Automotive antifreeze cont

12 AGR 070A through 100A IOMM AGR-1Evaporator Water Flow/Pressure DropEvaporator flow rate must fall between the minimum and maximum values shown in t

IOMM AGR-1 AGR 070A through 100A 13Physical DataTable 7, AGR 070AS – AGR 085ASAGR MODEL NUMBERPHYSICAL DATASTANDARD EFFICIENCY070AS 075AS 080AS 085ASB

14 AGR 070A through 100A IOMM AGR-1Table 8, AGR 090A – AGR 100APHYSICAL DATA AGR MODEL NUMBERSTANDARD EFFICIENCY 090AS 095AS 100ASBASIC DATA Ckt.1 Ckt

IOMM AGR-1 AGR 070A through 100A 15Electrical DataField WiringCAUTIONInternal power wiring to the compressors for single and multiple point option are

16 AGR 070A through 100A IOMM AGR-1Table 9, 60 Hz, Single Point Power Electrical DataPOWER SUPPLYField Wire Conduit HubAGRUnitSizeVoltsMinimumCircuitA

IOMM AGR-1 AGR 070A through 100A 17 Table 10, 60 Hz, Compressor and Condenser Fan Motor Amp Draw Rated Load Amps Locked Rotor AmpsCompressors Compress

18 AGR 070A through 100A IOMM AGR-1Table 11, 60 Hz Single Point Power, Field Wiring DataWiring to Standard Wiring to OptionalPower Block Non-Fused Dis

IOMM AGR-1 AGR 070A through 100A 19 Notes for “Electrical Data Single Point” Power:1. Unit wire size ampacity (MCA) is equal to 125% of the largest c

2 AGR 070A through 100A IOMM AGR-1Table of ContentsIntroduction... 3General Description...

20 AGR 070A through 100A IOMM AGR-1Figure 9, Typical Field Wiring with Global UNT Controller

IOMM AGR-1 AGR 070A through 100A 21Figure 10, Typical Field Wiring Diagram with MicroTech Controller

22 AGR 070A through 100A IOMM AGR-1Figure 11, Standard Single-Point Connection with FanTrol

IOMM AGR-1 AGR 070A through 100A 23Figure 12, Standard Single-Point Connection with Optional SpeedTrol

24 AGR 070A through 100A IOMM AGR-1Figure 13, Unit Control Schematic (2 compressor UNT)

IOMM AGR-1 AGR 070A through 100A 25Figure 14, Staging Schematic (2 compressor 4-stage UNT)

26 AGR 070A through 100A IOMM AGR-1Figure 15, Staging Schematic (2 compressor 6-stage UNT)

IOMM AGR-1 AGR 070A through 100A 27Figure 16, MicroTech Controller Schematic

28 AGR 070A through 100A IOMM AGR-1Figure 17, Unit Control Schematic (MicroTech)

IOMM AGR-1 AGR 070A through 100A 29Figure 18, Staging Schematic (4-stage MicroTech)

IOMM AGR-1 AGR 070A through 100A 3IntroductionGeneral DescriptionMcQuay Air-Cooled Global water chillers are complete, self-contained automatic refrig

30 AGR 070A through 100A IOMM AGR-1Figure 19, Staging Schematic (6-stage MicroTech)

IOMM AGR-1 AGR 070A through 100A 31Figure 20, Unit Control Schematic (2 compressor MicroTech)

32 AGR 070A through 100A IOMM AGR-1Figure 21, UNT Instrument LayoutSee legend on page 34.

IOMM AGR-1 AGR 070A through 100A 33Figure 22, MicroTech Instrument LayoutSee legend on page 34.

34 AGR 070A through 100A IOMM AGR-1Figure 23, AGR Power Side Component LayoutSee legend on page 34.Figure 24, Component Layout Legend

IOMM AGR-1 AGR 070A through 100A 35Figure 25, MicroTech Sensor Layout

36 AGR 070A through 100A IOMM AGR-1Dimensional DataFigure 26, Dimensions AGR 070AS4” (107mm) (AGR055-060)5” (127mm) (AGR065-070)VICTAULIC CONNECTIONSF

IOMM AGR-1 AGR 070A through 100A 37Figure 27, Dimensions AGR 075AS through 100AS5” (127mm) (AGR075-100)VICTAULIC CONNECTIONSFURNISHED WITH GROOVESFOR

38 AGR 070A through 100A IOMM AGR-1AGR Unit Start-UpPre start-upThe chiller must be inspected to ensure no components became loose or damaged during s

IOMM AGR-1 AGR 070A through 100A 39Start-UpThere should be adequate building load (25% of unit capacity minimum) to properly check theoperation of the

4 AGR 070A through 100A IOMM AGR-1InstallationNote: Installation is to be performed by qualified personnel who are familiar with local codesand regula

40 AGR 070A through 100A IOMM AGR-1AGR Unit OperationSequence of OperationStartingWith control power on, 115Vac power is applied through F1 to the com

IOMM AGR-1 AGR 070A through 100A 41Software Description (Global UNT Interface Kit required to read orchange variables)VariableNameDescription Default

42 AGR 070A through 100A IOMM AGR-1System AdjustmentTo maintain peak performance at full load operation, the system superheat and liquid subcooling ma

IOMM AGR-1 AGR 070A through 100A 43UNT Controller OperationThis section provides setup and troubleshooting information for the Global UNT controller.A

44 AGR 070A through 100A IOMM AGR-1The “setpoint” control knob adjusts the leaving water setpoint. The “Control Band” knob adjusts thecontroller temp

IOMM AGR-1 AGR 070A through 100A 45Chilled Water Flow SwitchThe chilled water flow switch is connected to field wiring terminals #142 and #143 on TB-7

46 AGR 070A through 100A IOMM AGR-1Digital InputsNote: All Digital Inputs are 24 VAC supplied by transformer T2 in the control panel. Do notuse input

IOMM AGR-1 AGR 070A through 100A 47Figure 28, Outside Air ResetLWRBLWSPOALL OAHLOARB(OALL=OAHL - OARB) As the OAT increases above the Outdoor Air Low

48 AGR 070A through 100A IOMM AGR-1When Return Water Reset is chosen, a Fail Smart Logic option is also available. This option works asfollows. If t

IOMM AGR-1 AGR 070A through 100A 49Additional UNT Controller FeaturesRemote Stop/StartWhen the remote stop/start switch is open, the controller will b

IOMM AGR-1 AGR 070A through 100A 5LocationUnit PlacementAGR units are for outdoor applications and can be mounted on a roof or ground level. Set unit

50 AGR 070A through 100A IOMM AGR-1energized, the operating compressor on that refrigerant circuit will operate until the low pressureswitch opens and

IOMM AGR-1 AGR 070A through 100A 51Head Pressure ControlThere are two or three condenser fans per refrigerant circuit. These fans are cycled on and o

52 AGR 070A through 100A IOMM AGR-1ZONE TERMINAL (optional)The Zone Terminal (ZT) is a hand-held or unit mounted device that monitors and adjusts your

IOMM AGR-1 AGR 070A through 100A 53You can simultaneously monitor the chiller in three ways:• Monitor up to three settings/sensed values. A maximum

54 AGR 070A through 100A IOMM AGR-11. With the ZT on a flat surface, press the white tab with your index finger Figure 32.2. Pull the front cover of

IOMM AGR-1 AGR 070A through 100A 55MAKING ZONE TERMINAL ADJUSTMENTSAdjusting Control Settings1. You can adjust only a flashing number with the ZT. I

56 AGR 070A through 100A IOMM AGR-1Lvg Low Lim SP - Adjustable from 20°F - 40°F (default is 20°F). This safety that will shut thechiller off based on

IOMM AGR-1 AGR 070A through 100A 57UNT Controller Troubleshooting ChartPROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONSCompressorWill Not Run1. Main switch

58 AGR 070A through 100A IOMM AGR-1MicroTech Controller Installation and OperationAll operational descriptions are based on the MicroTech controller s

IOMM AGR-1 AGR 070A through 100A 59Interlock wiringAll interlock wiring to field devices (such as flow switches and pump starters) is provided by thei

6 AGR 070A through 100A IOMM AGR-1Figure 3, Clearance RequirementsDo not block the flow of air toand from the condenser coil.Restricting airflow or al

60 AGR 070A through 100A IOMM AGR-1Power WiringThe installing contractor provides the unit voltage power source, disconnect, fuses and necessarywiring

IOMM AGR-1 AGR 070A through 100A 61External Alarm Annunciator CircuitryAn audible alarm can be connected to the Alarm Output terminals #19 and #28 of

62 AGR 070A through 100A IOMM AGR-1Digital InputsAll Digital Inputs are 24 Vac. At 7.5 Vac to 24 Vac the digital input contacts are considered closed

IOMM AGR-1 AGR 070A through 100A 634 - 20 mA (remote reset signal)When selecting “4-20mA” as the reset mode, the controller will reset the leaving wat

64 AGR 070A through 100A IOMM AGR-1Soft LoadingSoft loading limits the number of available stages when the unit is started to prevent excessive powerc

IOMM AGR-1 AGR 070A through 100A 65Head Pressure ControlThere are two or three condenser fans per refrigerant circuit. These fans are cycled on and o

66 AGR 070A through 100A IOMM AGR-1Circuit Alarm ConditionsThe “Circuit Alarm Conditions” are those alarms which only affect one circuit and can stop

IOMM AGR-1 AGR 070A through 100A 67Assuming none of the above “OFF” conditions are true, the controller will examine the internal timeclock schedule t

68 AGR 070A through 100A IOMM AGR-1Start-Up and ShutdownPre-Start CheckoutConfiguration default set points are entered at the factory and all values m

IOMM AGR-1 AGR 070A through 100A 69above the LPCutIn value, a compressor on the lead circuit will start. Refer to the unit stagingschematic to determ

IOMM AGR-1 AGR 070A through 100A 7Vibration IsolatorsVibration isolators are recommended for all roof mounted installations or wherever vibrationtrans

70 AGR 070A through 100A IOMM AGR-1Menu Structure (general description)The information stored in the MicroTech controller can be accessed through the

IOMM AGR-1 AGR 070A through 100A 71Keypad Key FunctionsThe MicroTech keypad consists of twelve pressure sensitive membrane switches (Figure 34). These

72 AGR 070A through 100A IOMM AGR-1Decr. - When changing the value of a menu item entry, pressing “DECR. -” shifts the menu itemdisplay line to the ne

IOMM AGR-1 AGR 070A through 100A 73Menu #6: Circuit 62 Pressures—The circuit #2 evaporator and condenser refrigerant pressurereadings are displayed un

74 AGR 070A through 100A IOMM AGR-1If the 4-20 milliamp reset option is enabled, the controller will reset the leaving chilled watertemperature to a h

IOMM AGR-1 AGR 070A through 100A 75Figure 35, Delta-T Setpoints for ChillersMenu #15: Softload Set Points—The controller can limit the number of avail

76 AGR 070A through 100A IOMM AGR-1Press the Next Item key. The display will show the current Day, Hour, Minute and Second. If thisinformation needs t

IOMM AGR-1 AGR 070A through 100A 77Table 22, MENU 1 Chiller StatusScreen DisplayOFF: Manual ModeOFF: System SwOFF: Remote CommOFF: Remote SwOFF: Time

78 AGR 070A through 100A IOMM AGR-1Table 28, MENU 7 Circ #1 Temp'sScreen DisplaySatur Evap=xxx°F (°C)1N/A **°F (°C)SuctLine = xxx.x°F (°C)Open °F

IOMM AGR-1 AGR 070A through 100A 79Table 34, MENU 13 Control ModeScreen Display Factory Setpoint Range1Manual Unit OffAutomaticManual StagingManual Un

8 AGR 070A through 100A IOMM AGR-1Water PipingLocal authorities can supply the installer with the proper building and safety codes required for safean

80 AGR 070A through 100A IOMM AGR-1Table 37, MENU 15 SoftLoad SptsScreen Display Factory Setpoint Range1 Time Left= xxmin2 SoftLoad= xx min 20 0 - 254

IOMM AGR-1 AGR 070A through 100A 81Table 43, MENU 20 ScheduleScreen Display Factory Setpoint Range1 Override= xx.xx hr 0.00 Hr 00:00 - 63.502 NMPSched

82 AGR 070A through 100A IOMM AGR-1Table 47, MENU 23 Misc SetupScreen Display Factory Setpoint RangeUnit Type= Air Cooled12 Units = English English En

IOMM AGR-1 AGR 070A through 100A 83Trouble Analysis for the AGR MicroTech ControllerMicroprocessor Control BoardThe Microprocessor Control Board (MCB)

84 AGR 070A through 100A IOMM AGR-11. The red (“Reset”) LED turns on and remains on for approximately 5 seconds. During this periodthe MCB performs a

IOMM AGR-1 AGR 070A through 100A 85Communication PortsThe MCB has two communication ports: port A and port B. Each port has six terminals and is set u

86 AGR 070A through 100A IOMM AGR-1Test ProceduresStatus LED DiagnosticsThe MCB status LED indications can aid in controller diagnostics. If the stat

IOMM AGR-1 AGR 070A through 100A 876. Reconnect the analog input ribbon cable. Cycle power to the controller and check the powerfuses.If both fuses

88 AGR 070A through 100A IOMM AGR-1Figure 38, MCB Power Supply TerminalsPOWER FUSES[BUSSMAN GDC-T2A]POWER IN[18-24 VCT]AC AC GND GNDAUX/OUT43219 8 7 6

IOMM AGR-1 AGR 070A through 100A 89Troubleshooting Analog InputsAn analog input, such as a temperature sensor, is connected to the ADI board. The ADI

IOMM AGR-1 AGR 070A through 100A 9Figure 5, Typical field evaporator water pipingFlow SwitchMount a water flow switch in either the entering or leavin

90 AGR 070A through 100A IOMM AGR-1Figure 39, Output Board Relay Socket12345LEDFuseTest Resistor330-680 Ohm*250V ~ 50/60 Hz*120V ~ 50/60 HzWARNINGElec

IOMM AGR-1 AGR 070A through 100A 912. Remove power from the controller by placing CB1 to the OFF position. Disconnect at least onewire from the powe

92 AGR 070A through 100A IOMM AGR-13. Remove power from the controller by opening CB1. Try to improve the connections in theAux/Out plug insulation

IOMM AGR-1 AGR 070A through 100A 93Unit MaintenanceGeneralOn initial start-up and periodically during operation, it will be necessary to perform certa

94 AGR 070A through 100A IOMM AGR-1clogged filter-drier or a restriction elsewhere in the liquid line See Table 54 for maximum allowablepressure drops

IOMM AGR-1 AGR 070A through 100A 95Unit ServiceCAUTION1. Service on this equipment is to be performed by qualified refrigeration personnel familiar w

96 AGR 070A through 100A IOMM AGR-1EvaporatorThe evaporator is the direct expansion, shell-and-tube type with refrigerant flowing through the tubesand

IOMM AGR-1 AGR 070A through 100A 973. The charge can be added at any load condition between 25-100% load per circuit but at least twofans should be op

98 AGR 070A through 100A IOMM AGR-1AGR Troubleshooting ChartPROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS1. Main Switch. 1. Close Switch.2. Fuse

IOMM AGR-1 AGR 070A through 100A 99Notes