McQuay AGR 100AS Unit installation

McQuay AGR 100AS Unit installation
Installation, Operation and Maintenance Manual
IOMM AGR-1
Group: Chiller
Part Number: 330145704
Effective: August 2001
Supersedes: IOMM AGR
Air-Cooled Reciprocating Chiller
AGR 070AS through 100AS
60 Hertz, English and Metric
Global Chiller Line
Table of Contents
Introduction ....................................... 3
General Description..................................... 3
Inspection .................................................... 3
Installation ......................................... 4
Handling ...................................................... 4
Location....................................................... 5
Service Access and Clearances .................... 5
Vibration Isolators ....................................... 7
Water Piping ................................................ 8
Flow Switch................................................. 9
Water Connections....................................... 9
Refrigerant Charge ...................................... 9
Glycol Solutions ........................................ 10
Evaporator Water Flow/Pressure Drop ...... 12
Physical Data ................................... 13
Electrical Data ................................. 15
Field Wiring............................................... 15
Dimensional Data ............................ 36
Crankcase Heaters...................................... 42
Water Cooler.............................................. 42
UNT Controller Operation ............. 43
General Description ................................... 43
Optional Sensors........................................ 43
Controller Inputs /Outputs ......................... 45
Additional UNT Controller Features ......... 49
Alarms........................................................ 51
ZONE TERMINAL (optional)................... 52
Zone Terminal Glossary............................. 55
UNT Controller Troubleshooting Chart..... 57
MicroTech Controller Installation
and Operation.................................. 58
General Description ................................... 58
Optional Sensor Packages.......................... 58
Installation ................................................. 58
Sequence of Operation............................... 66
Start-Up and Shutdown.............................. 68
Keypad / Display ....................................... 69
Menu Descriptions..................................... 72
Trouble Analysis for the AGR MicroTech
Controller................................................... 83
Test Procedures.......................................... 86
AGR Unit Start-Up.......................... 38
Unit Maintenance ............................ 93
Start-Up ..................................................... 39
Shutdown................................................... 39
Preventative Maintenance Schedule .......... 94
AGR Unit Operation....................... 40
Sequence of Operation .............................. 40
Hot Gas Bypass (Optional)........................ 41
Filter Driers ............................................... 41
System Adjustment .................................... 42
Liquid Sightglass and Moisture Indicator.. 42
Refrigerant Charging ................................. 42
Thermostatic Expansion Valve .................. 42
Superheat and Subcooling ......................... 42
Unit Service...................................... 95
Liquid Line Solenoid Valve ....................... 95
Evaporator ................................................. 96
Refrigerant Charging.................................. 96
AGR Troubleshooting Chart ...................... 98
Notes ................................................. 99
Our Facility is ISO Certified
"McQuay" is a registered trademark of McQuay International

2001 McQuay International
"Illustrations and data cover McQuay International products at the time of publication and we reserve the right to
make changes in design and construction at anytime without notice."
2
AGR 070A through 100A
IOMM AGR-1
Introduction
General Description
McQuay Air-Cooled Global water chillers are complete, self-contained automatic refrigerating units.
Every unit is completely assembled, factory wired, charged, and tested. Each unit consists of twin
Air-Cooled condensers with integral subcooler sections, two reciprocating compressors, replaceable
tube dual circuit shell-and-tube evaporator, and complete refrigerant piping. Liquid line components
include manual liquid line shutoff valves, sight-glass/moisture indicators, solenoid valves, and double
diaphragm hydraulic element thermal expansion valves. Other features include compressor crankcase
heaters, an evaporator heater for chilled water freeze protection, limited recycling pumpdown during
“on” or “off” periods, compressor lead-lag switch to alternate the compressor starting sequence, and
sequenced starting of compressors.
The electrical control center includes all safety and operating controls necessary for dependable
automatic operation. Condenser fan motors are fused in all three phases and started by their own
three-pole contactors. Compressors are not fused but may be protected by optional circuit breakers.
Inspection
Check all items carefully against the bill of lading. Inspect all units for damage upon arrival. Report
shipping damage and file a claim with the carrier. Check the unit name plate before unloading,
making certain it agrees with the power supply available. McQuay is not responsible for physical
damage after unit leaves the factory.
Note: Unit shipping and operating weights are available in the Physical Data tables
beginning on page 13.
IOMM AGR-1
AGR 070A through 100A
3
Installation
Note: Installation is to be performed by qualified personnel who are familiar with local codes
and regulations.
WARNING
Sharp edges and coil surfaces are a potential hazard. Avoid contact with them.
Handling
Be careful to avoid rough handling of the unit. Do not push or pull the unit from anything other than
the base. Block the pushing vehicle away from the unit to prevent damage to the sheet metal cabinet
and end frame (see Figure 1).
To lift the unit, 2 1/2" (64mm) diameter lifting holes are provided in the base of the unit. Arrange
spreader bars and cables to prevent damage to the condenser coils or cabinet (see Figure 2).
Figure 1, Suggested Pushing Arrangement
Blocking is required
across full width
Figure 2, Suggested Lifting Arrangement
Spreader Bars
recommended
(use caution)
Number of fans may vary
from this diagram. The
lifting method will remain
the same
These rigging holes
must be used.
4
AGR 070A through 100A
IOMM AGR-1
Location
Unit Placement
AGR units are for outdoor applications and can be mounted on a roof or ground level. Set units on a
solid and level foundation. For roof mounted applications, install the unit on a steel channel or Ibeam frame to support the unit above the roof. For ground level applications, install the unit on a
substantial base that will not settle. A one piece concrete slab with footings extended below the frost
line is recommended. Be sure the foundation is level (within 1/2” [13mm] over its length and width).
The foundation must support the operating weights listed in the Physical Data tables beginning on
page 13.
On ground level applications protect fins against vandalism using the optional coil guards or by
erecting a screen fence. The fence must allow free flow of air to the condenser coil for proper unit
operation.
Clearances
The flow of air to and from the condenser coil must not be limited. Restricting air flow or allowing
air recirculation will result in a decrease in unit performance and efficiency. There must be no
obstruction above the unit that would deflect discharge air downward where it could be recirculated
back to the inlet of the condenser coil. The condenser fans are propeller type and will not operate
with ductwork on the fan outlet.
Install the unit with enough side clearance for air entrance to the coil and for servicing. Provide
service access to the evaporator, compressors, electrical control panel and piping components as
shown in Figure 3.
Do not allow debris to accumulate near the unit. Air movement may draw debris into the condenser
coil causing air starvation. Give special consideration to low ambient operation where snow can
accumulate. Keep condenser coils and fan discharge free of snow or other obstructions to permit
adequate airflow.
Sound Isolation
The ultra-low sound levels of the AGR chiller is suitable for most applications. When additional
sound reduction is necessary, locate the unit away from sound sensitive areas. Avoid locations
beneath windows or between structures where normal operating sounds may be objectionable.
Reduce structurally transmitted sound by isolating water lines, electrical conduit and the unit itself.
Use wall sleeves and rubber isolated piping hangers to reduce transmission of water or pump noise
into occupied spaces. Use flexible electrical conduit to isolate sound through electrical conduit.
Spring isolators are effective in reducing the low amplitude sound generated by reciprocating
compressors and for unit isolation in sound sensitive areas.
Service Access and Clearances
Each end of the unit must be accessible after installation for periodic service. Compressors, filterdriers, and manual liquid line shutoff valves are accessible. The high pressure control is located in the
control panel when using the Global UNT controller, and on the compressor when using the
MicroTech controller. Low pressure, and motor protector controls are on the compressor. Most other
operational, safety and starting controls are located in the unit control box.
The condenser fan and motors can be removed from the top of the unit.
IOMM AGR-1
AGR 070A through 100A
5
Figure 3, Clearance Requirements
AIR
DISCHARGE
AIR
DISCHARGE
AIR FLOW
AIR FLOW
AIR FLOW
10 FT.
The recommended minimum side clearance between two units is 10 feet (3048mm).
Distance less than 10 feet (3048mm) can result in air recirculation.
AIR
DISCHARGE
AIR FLOW
AIR FLOW
The unit must not be installed in a pit or enclosure that is deeper
Or taller than the height of the unit unless extra space is provided,
(consult factory) the minimum clearance on each side of the unit is
8 feet (2438mm) when installed in a pit.
AIR
DISCHARGE
AIR FLOW
AIR FLOW
8 FT.
The minimum clearance to a side wall or building taller than the
Unit height is 6 feet (1828mm) provided no solid wall above 6 feet
(1830mm) tall is closer than 8 feet (2438mm) to the opposite
Side of the unit. (consult factory for special situations.)
6
AGR 070A through 100A
Do not block the flow of air to
and from the condenser coil.
Restricting airflow or allowing
air recirculation will result in a
decrease in unit performance
and efficiency because
discharge pressures are
increased. There must be no
obstruction above the unit that
would deflect discharge air
downward where it could be
recirculated back to the inlet of
the condenser coil. The
condenser fans are propeller
type and will not operate with
ductwork on the fan outlet.
Install the unit with enough side
clearance for air entrance to the
coil and for servicing. Provide
service access to the evaporator,
compressors, electrical control
panel and piping components.
Do not allow debris to
accumulate near the unit. Air
movement may draw debris into
the condenser coil causing coil
starvation. Give special
consideration to low ambient
operation where snow can
accumulate. Keep condenser
coils and fan discharge free of
snow or other obstructions to
permit adequate airflow for
proper unit operation.
IOMM AGR-1
Vibration Isolators
Vibration isolators are recommended for all roof mounted installations or wherever vibration
transmission is a consideration.
See Dimensional Data for dimensions required to secure each isolator to the mounting surface.
The spring flex isolators are white type CP2-32, McQuay kit number 350014821, includes four spring
isolators assemblies.
Figure 4, Isolator Locations (4 and 6 fan units)
Spring Isolator
Table 1, Isolator Loads at each Mounting Location with Aluminum Fins
Unit
Size
070
075
080
085
090
095
100
Control Box Left
lb
kg
1071
486
1491
676
1542
699
1561
708
1675
760
1678
761
1678
761
Control Box Right
lb
kg
1193
541
1633
741
1745
792
1822
826
1850
839
1853
841
1853
841
Opposite End Left
lb
kg
952
432
1137
516
1151
522
1171
531
1264
573
1266
574
1266
574
Opposite End Right
lb
kg
1060
481
1245
565
1302
591
1367
620
1396
633
1398
634
1398
634
Table 2, Isolator Loads at each Mounting Location with Copper Fins
Unit
Size
070
075
080
085
090
095
100
IOMM AGR-1
Control Box Left
lb
kg
1279
580
1828
829
1877
851
1889
857
2012
913
2015
914
2015
914
Control Box Right
lb
kg
1424
646
2002
908
2123
963
2206
1001
2222
1008
2225
1009
2225
1009
Opposite End Left
lb
kg
1137
516
1394
632
1400
635
1417
643
1518
689
1520
689
1520
689
AGR 070A through 100A
Opposite End Right
lb
kg
1266
574
1526
692
1584
719
1654
750
1677
761
1679
762
1679
762
7
Water Piping
Local authorities can supply the installer with the proper building and safety codes required for safe
and proper installation.
Install piping with minimum bends and changes in elevation to minimize pressure drop. Consider the
following when installing water piping:
1.
Vibration eliminators to reduce vibration and noise transmission to the building.
2.
Shutoff valves to isolate the unit from the piping system during unit servicing.
3.
Manual or automatic air vent valves at the high points of the system. Install drains at the lowest
points in the system.
4.
A means of maintaining adequate system water pressure (expansion tank or regulating valve).
5.
Temperature and pressure indicators located at the unit to aid in unit servicing.
6.
A strainer or other means of removing foreign matter from the water before it enters the pump.
Place the strainer far enough upstream to prevent cavitation at the pump inlet (consult pump
manufacturer for recommendations). The use of a strainer will prolong pump life and keep
system performance up.
7.
Place a strainer in the water line just before the inlet of the evaporator. This will help prevent
foreign material from entering and decreasing the performance of the evaporator.
CAUTION
If separate disconnect is used for the 115V supply to the evaporator heating cable, mark the
disconnect clearly to ensure disconnect is not accidentally shut off during cold seasons.
8.
The shell-and-tube evaporator has a thermostat and heating cable to prevent freeze-up down to 20°F (-29°C). It is suggested that the heating cable be wired to a separate 110V supply circuit.
As shipped from the factory, the heating cable is wired to the control circuit. All water piping to
the unit must also be protected to prevent freezing.
9.
If the unit is used as a replacement chiller on a previously existing piping system, flush the
system thoroughly before unit installation. Regular water analysis and chemical water treatment
for the evaporator loop is recommended immediately at equipment start-up.
10. The total water volume in the system should be sufficient to prevent frequent “on-off” cycling.
Turnover rate should not be less than 15 minutes for normal variable cooling loads. Turnover
rate for process cooling or a constant load, should not be less than 6 minutes.
11. When glycol is added to the water system for freeze protection, the refrigerant suction pressure
will be lower, cooling performance less, and water side pressure drop greater. If the percentage
of glycol is high, or if propylene is used instead of ethylene glycol, the added pressure drop and
loss of performance could be substantial. Reset the freezestat and low leaving water alarm
temperatures. The freezestat is factory set to default at 36°F (2.2°C). Reset the freezestat setting
to approximately 4 to 5 degrees F (2.3 to 2.8 degrees C) below the leaving chilled water setpoint
temperature. See the section titled “Glycol Solutions” for additional information concerning
glycol.
12. Perform a preliminary leak check before insulating the piping and filling the system.
13. Piping insulation should include a vapor barrier to prevent condensation and possible damage to
the building structure.
8
AGR 070A through 100A
IOMM AGR-1
Figure 5, Typical field evaporator water piping
Flow Switch
Mount a water flow switch in either the entering or leaving (recommended) water line to shut down
the unit when water flow is interrupted.
A flow switch is available from McQuay (part number 0017503300). It is a “paddle” type switch and
adaptable to any pipe size from 3” (76mm) to 8” (203mm) nominal. Certain minimum flow rates are
required to close the switch and are listed in Table 3. Installation should be as shown in Figure 6.
Connect the normally open contacts of the flow switch in the unit control center at terminals 5 and 6.
There is also a set of normally closed contacts on the switch that can be used for an indicator light or
an alarm to indicate when a “no flow” condition exists. Freeze protect any flow switch that is
installed outdoors.
NOTE: Differential pressure switches are not recommended for outdoor installation.
Table 3, Flow Switch Minimum Flow
NOMINAL PIPE SIZE
INCHES (MM)
3
4
5
6
(76.20
(101.6)
(127.0)
(152.4)
Figure 6, Flow Switch Installation
MINIMUM REQUIRED
FLOW TO
ACTIVATE SWITCH GPM (L/S)
30.00 (1.90)
39.70 (2.50)
58.70 (3.70)
79.20 (5.00)
Flow direction marked
on switch
1" (25mm) NPT flow
switch connection
Tee
Water Connections
Bring water piping to the evaporator through the side, between the vertical supports.
Refrigerant Charge
All units are designed for use with R-22 and other refrigerants. See nameplate for specific refrigerant
used. Units are shipped with an operating charge and ready for operation. The operating charge
(using R-22) for each unit is shown in the Physical Data tables beginning on page 13.
IOMM AGR-1
AGR 070A through 100A
9
Figure 7, Refrigerant Piping (Some Components Are Optional)
Glycol Solutions
The system glycol capacity, glycol solution flow rate in GPM, and pressure drop through the cooler
may be calculated using the following formulas and data from Table 4 or Table 5.
Note: The procedure
does not specify the
type of glycol. Use
the derate factors
found in Table 4 for
corrections when
using ethylene glycol
and those in Table 5
for propylene glycol.
1.
Capacity -- Find the reduced capacity by multiplying the chiller’s capacity with water by the
capacity correction factor.
2.
Flow -- To determine evaporator gpm (or Delta-T) knowing Delta-T (or gpm) and capacity:
24 × capacity ( glycol )
Glycol GPM =
× FlowCorrection (from table)
Delta − T
For Metric Applications -- To determine evaporator L/s (or Delta-T) knowing Delta-T (or L/s)
and kW:
kW
Glycol L/s =
× FlowCorrection (from table)
4.18 × Delta − T
3.
Pressure drop -- To determine pressure drop through the evaporator, when using glycol, enter
the water pressure drop curve on page 12 at the water flow rate. Multiply the water pressure drop
by PD correction factor from Table 4 or Table 5 to obtain corrected glycol pressure drop.
4.
To determine the unit's power consumption when using glycol, multiply the water system kW by
factor kW.
Test coolant with a clean, accurate glycol solution hydrometer (similar to that found in service
stations) to determine the freezing point. Obtain percent glycol from the freezing point table below.
On glycol applications it is normally recommended by the supplier that a minimum of 25% solution
by weight be used for protection against corrosion.
10
AGR 070A through 100A
IOMM AGR-1
CAUTION
Do not use an automotive grade antifreeze. Industrial grade glycols must be used.
Automotive antifreeze contains inhibitors which will cause plating on the copper tubes within
the chiller evaporator. The type and handling of glycol used must be consistent with local
codes.
Table 4, Ethylene Glycol
%
E.G.
10
20
30
40
50
Freeze Point
°F
°C
26
-3
18
-8
7
-14
-7
-22
-28
-33
Cap.
kW
Flow
PD
0.991
0.982
0.972
0.961
0.946
0.996
0.992
0.986
0.976
0.966
1.013
1.040
1.074
1.121
1.178
1.070
1.129
1.181
1.263
1.308
Cap.
kW
Flow
PD
0.987
0.975
0.962
0.946
0.929
0.992
0.985
0.978
0.971
0.965
1.010
1.028
1.050
1.078
1.116
1.068
1.147
1.248
1.366
1.481
Table 5, Propylene Glycol
%
P.G.
10
20
30
40
50
Freeze Point
°F
°C
26
-3
19
-7
9
-13
-5
-21
-27
-33
Table 6, Capacity and Power Derates
ALTITUDE
IOMM AGR-1
Chilled Water
Delta-T
Fouling Factor
0.0001 (0.0176)
0.00025 (0.044)
0.00075 (0.132)
0.00175 (0.308)
°F
°C
Cap.
Power
Cap.
Power
Cap.
Power
Cap.
Power
6
3.3
0.992
0.995
0.985
0.993
0.962
0.986
0.919
0.972
8
4.4
0.995
0.997
0.988
0.995
0.965
0.988
0.922
0.974
SEA
10
5.6
1.000
1.000
0.993
0.998
0.970
0.991
0.927
0.977
LEVEL
12
6.7
1.005
1.002
0.998
1.000
0.975
0.993
0.932
0.979
14
6.8
1.010
1.005
1.003
1.003
0.980
0.996
0.936
0.982
16
8.9
1.014
1.007
1.007
1.005
0.984
0.998
0.940
0.984
6
3.3
0.978
1.005
0.971
1.003
0.949
0.996
0.906
0.982
0.984
8
4.4
0.982
1.007
0.975
1.005
0.953
0.998
0.910
2000 feet
10
5.6
0.986
1.009
0.979
1.007
0.956
1.000
0.914
0.986
(610 m)
12
6.7
0.992
1.011
0.985
1.009
0.962
1.002
0.919
0.988
14
6.8
0.997
1.014
0.990
1.012
0.967
1.005
0.924
0.991
16
8.9
1.000
1.016
0.993
1.014
0.970
1.007
0.927
0.993
6
3.3
0.966
1.016
0.959
1.014
0.937
1.007
0.895
0.993
0.995
8
4.4
0.969
1.018
0.962
1.016
0.940
1.009
0.898
4000 feet
10
5.6
0.973
1.021
0.966
1.019
0.944
1.012
0.902
0.998
(1220 m)
12
6.7
0.978
1.025
0.971
1.023
0.949
1.016
0.906
1.002
14
6.8
0.982
1.027
0.975
1.025
0.953
1.018
0.910
1.004
16
8.9
0.986
1.028
0.979
1.026
0.956
1.019
0.914
1.005
6
3.3
0.953
1.025
0.946
1.023
0.924
1.016
0.883
1.002
1.005
8
4.4
0.955
1.028
0.948
1.026
0.926
1.019
0.885
6000 feet
10
5.6
0.959
1.031
0.952
1.029
0.930
1.022
0.889
1.008
(1830 m)
12
6.7
0.963
1.034
0.956
1.032
0.934
1.024
0.893
1.011
14
6.8
0.968
1.036
0.961
1.034
0.939
1.026
0.897
1.013
16
8.9
0.972
1.037
0.965
1.035
0.943
1.027
0.901
1.014
AGR 070A through 100A
11
Evaporator Water Flow/Pressure Drop
Evaporator flow rate must fall between the minimum and maximum values shown in the evaporator
pressure drop table on page 12. Varying chilled water flow through the evaporator while the
compressor(s) are operating is not recommended.
Figure 8, Pressure Drop Curve
090 - 100
070
075 - 085
NOMINAL
MAXIMUM
MINIMUM
PD
Flow
PD
Flow
PD
Flow
(ft) of Water
(gpm)
(lps)
(ft) of Water
(gpm)
(lps)
(ft) of Water
(gpm)
(lps)
070AS
11.2
162
10.22
28.1
270
17.03
4.8
101
6.39
075AS
8.9
172
10.85
22.5
287
18.09
3.8
108
6.78
080AS
10.3
187
11.80
25.9
312
19.66
4.4
117
7.37
085AS
11.8
202
12.74
29.7
337
21.24
5.0
126
7.97
090AS
10.5
208
13.12
26.3
347
21.87
4.5
130
8.20
095AS
12.0
224
14.13
30.0
373
23.55
5.2
140
8.83
100AS
13.4
238
15.02
33.6
397
25.02
5.7
149
9.38
Minimum and maximum flows are established to ensure the Delta-T for each unit size falls within the 6 - 16°F range for proper
unit control. Contact factory for unit operation outside of minimum and maximum flows shown.
Unit
Size
12
AGR 070A through 100A
IOMM AGR-1
Physical Data
Table 7, AGR 070AS – AGR 085AS
AGR MODEL NUMBER
PHYSICAL DATA
STANDARD EFFICIENCY
070AS
075AS
080AS
BASIC DATA
Ckt.1
Ckt.2
Ckt.1
Ckt.2
Ckt.1
Ckt.2
Unit Capacity @ ARI Conditions (1), Tons (kW)
67.5 (237.6)
70.1 (246.7)
77.9 (273.9)
Number Of Refrigerant Circuits
2
2
2
Unit Operating Charge, R-22, lbs. (kg)
60 (27.2) 84 (38.1) 84 (38.1) 86 (39.9) 86 (39.9) 86 (39.9)
Unit Operating Charge, R-134a, , lbs. (kg)
63 (28.6) 88 (40.0) 88 (40.0) 90 (41.9) 90 (41.9) 90 (41.9)
Cabinet Dimensions, LxWxH, In.
94.0 x 88.2 x 96.2
136.4 x 88.2 x 96.2
136.4 x 88.2 x 96.2
Cabinet Dimensions, LxWxH, (mm)
2388 x 2241 x 2444
3463 x 2241 x 2444
3463 x 2241 x 2444
Unit Operating Weight, Lbs. (kg)
4276
(5506)
5506
(2497)
5740
(2604)
Unit Shipping Weight, Lbs. (kg)
4169
(5359)
5359
(2431)
5593
(2537)
Add'l Weight If Copper Finned Coils, Lbs. (kg)
830
(375)
1245
(565)
1245
(565)
COMPRESSORS
Type
Semi-Hermetic
Semi-Hermetic
Semi-Hermetic
Nominal Horsepower
35
40
40
40
40
50
Number Of Cylinders Per Compressor
6
6
6
6
6
8
Oil Charge Per Compressor, oz.
140
255
255
255
255
255
Oil Charge Per Compressor, (g)
(3969)
(7229)
(7229)
(7229)
(7229)
(7229)
CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT
Standard Staging - Circuit #1 in Lead
0-16-33-49-67
0-17-33-50-67
0-15-42-58-73
-83-100
-83-100
-86-100
Standard Staging - Circuit #2 in Lead
0-17-33-51-67
0-17-33-50-67
0-27-42-56-71
-84-100
-83-100
-85-100
CONDENSERS - HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING
Coil Face Area, sq. ft.
58
58
87
87
87
87
Coil Face Area, (m2)
(5.4)
(5.4)
(8.1)
(8.1)
(8.1)
(8.1)
Finned Height x Finned Length, In.
100x 83.5 100x 83.5 100x125.3 100x125.3 100x125.3 100x125.3
2032 x
2032 x
2540 x
2540 x
2540 x
2540 x
Finned Height x Finned Length, (mm)
2121
2121
3183
3183
3183
3183
Fins Per Inch x Rows Deep
16 x 3
16 x 3
16 x 3
16 x 3
16 x 3
16 x 3
Pumpdown capacity @ 90% lbs. (kg)
108 (49)
108 (49)
162 (73)
162 (73)
162 (73)
162 (73)
Maximum Relief Valve Pressure Setting, psig (kPa)
450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103)
CONDENSER FANS – DIRECT DRIVE PROPELLER TYPE
Number Of Fans - Fan Diameter, In. (mm)
4 - 28 (712)
6 - 28 (712)
6 - 28 (712)
Number Of Motors - HP (kW)
4 - 2.0 (1.5)
6 - 2.0 (1.5)
6 - 2.0 (1.5)
Fan And Motor RPM, 60Hz
1140
1140
1140
60 Hz Fan Tip Speed, fpm (m/Sec)
8357 (35.4)
8357 (35.4)
8357 (35.4)
60 Hz Total Unit Airflow, cfm (m3/sec)
40800 (19.3)
61200 (28.9)
61200 (28.9)
DIRECT EXPANSION EVAPORATOR - BAFFLED SHELL AND THRU-TUBE
Diameter, in. - Length, ft.
12.75- 4
12.75 - 5.5
12.75 - 5.5
Diameter, (mm) – Length, (mm)
324 - 1220
324 - 1676
324 - 1676
Water Volume, gallons, (l)
12.8 (48.5)
17.6 (66.6)
17.6 (66.6)
Maximum Water Pressure, psig (kPa)
175 (1207)
175 (1207)
175 (1207)
Maximum Refrigerant Working Pressure, psig (kPa)
225 (1552)
225 (1552)
225 (1552)
Water Inlet / Outlet Victaulic Connections, In. (mm)
5 (141.3)
5 (141.3)
5 (141.3)
Drain - NPT int, In. (mm)
.375 (9.5)
.375 (9.5)
.375 (9.5)
Vent - NPT int, In. (mm)
.375 (9.5)
.375 (9.5)
.375 (9.5)
NOTE: Nominal capacity based on 95°F ambient air and 54°F/44°F water range.
IOMM AGR-1
AGR 070A through 100A
085AS
Ckt.1
Ckt.2
84.7 (298.1)
2
86 (39.9) 86 (39.9)
90 (41.9) 90 (41.9)
136.4 x 88.2 x 96.2
3463 x 2241 x 2444
5921
(2686)
5774
(2619)
1245
(565)
Semi-Hermetic
50
50
8
8
255
255
(7229)
(7229)
0-25-50-63-75
-88-100
0-25-50-63-75
-88-100
87
87
(8.1)
(8.1)
100x125.3 100x125.3
2540 x
2540 x
3183
3183
16 x 3
16 x 3
162 (73)
162 (73)
450 (3103) 450 (3103)
6 - 28 (712)
6 - 2.0 (1.5)
1140
8357 (35.4)
61200 (28.9)
12.75 - 5.5
324 - 1676
17.6 (66.6)
175 (1207)
225 (1552)
5 (141.3)
.375 (9.5)
.375 (9.5)
13
Table 8, AGR 090A – AGR 100A
PHYSICAL DATA
AGR MODEL NUMBER
STANDARD EFFICIENCY
090AS
095AS
100AS
BASIC DATA
Ckt.1
Ckt.2
Ckt.1
Ckt.2
Ckt.1
Ckt.2
Unit Capacity @ ARI Conditions (1), Tons (kW)
86.5 (304.1)
93.4 (328.4)
99.3 (349.1)
Number Of Refrigerant Circuits
2
2
2
Unit Operating Charge, R-22, lb.
90
90
90
90
92
92
Unit Operating Charge, R-22, (kg)
(40.8)
(40.8)
(40.8)
(40.8)
(41.7)
(41.7)
Cabinet Dimensions, LxWxH, In.
136.4 x 88.2 x 96.2
136.4 x 88.2 x 96.2
136.4 x 88.2 x 96.2
Cabinet Dimensions, LxWxH, (mm)
3463 x 2241 x 2444
3463 x 2241 x 2444
3463 x 2241 x 2444
Unit Operating Weight, Lbs. (kg)
6184
(2805)
6194
(2810)
6194
(2810)
Unit Shipping Weight, Lbs. (kg)
6008
(2725)
6018
(2730)
6018
(2730)
Add'l Weight If Copper Finned Coils, Lbs. (kg)
1245
(565)
1245
(565)
1245
(565)
COMPRESSORS
Type
Semi-Hermetic
Semi-Hermetic
Semi-Hermetic
Nominal Horsepower
50
50
50
60
60
60
Number Of Cylinders Per Compressor
8
8
8
8
8
8
Oil Charge Per Compressor, Oz.
255
255
255
255
255
255
Oil Charge Per Compressor, (g)
(7229)
(7229)
(7229)
(7229)
(7229)
(7229)
CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT
Standard Staging - Circuit #1 in Lead
0-25-50-63-750-23-50-61-75
0-25-50-63-75
88-100
88-100
88-100
Standard Staging - Circuit #2 in Lead
0-25-50-63-750-27-50-61-750-25-50-63-7588-100
88-100
88-100
CONDENSERS - HIGH EFFICIENCY FIN AND TUBE TYPE WITH INTEGRAL SUBCOOLING
Coil Face Area, Sq. Ft.
87
87
87
87
87
87
Coil Face Area, (M2)
(8.1)
(8.1)
(8.1)
(8.1)
(8.1)
(8.1)
Finned Height x Finned Length, In.
100x125.3 100x125.3 100x125.3 100x125.3 100x125.3 100x125.3
Finned Height x Finned Length, (mm)
2540 x
2540 x
2540 x
2540 x
2540 x
2540 x
3183
3183
3183
3183
3183
3183
Fins Per Inch x Rows Deep
16 x 3
16 x 3
16 x 3
16 x 3
16 x 3
16 x 3
Maximum Relief Valve Pressure Setting, psig (kPa)
450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103) 450 (3103)
CONDENSER FANS - DIRECT DRIVE PROPELLER TYPE
Number Of Fans - Fan Diameter, In. (mm)
6 - 28 (712)
6 - 28 (712)
6 - 28 (712)
Number Of Motors - HP (kW)
6 - 2.0 (1.5)
6 - 2.0 (1.5)
6 - 2.0 (1.5)
Fan And Motor RPM, 60Hz
1140
1140
1140
60 Hz Fan Tip Speed, FPM (M/Sec)
8357 (35.4)
8357 (35.4)
8357 (35.4)
60 Hz Total Unit Airflow, CFM (M3/sec)
61200 (28.9)
61200 (28.9)
61200 (28.9)
DIRECT EXPANSION EVAPORATOR - BAFFLED SHELL AND THRU-TUBE
Diameter, in. - Length, Ft.
14 - 5.5
14 - 5.5
14 - 5.5
Diameter, (mm) - Length, (mm)
356 - 1676
356 - 1676
356 - 1676
Water Volume, Gallons, (L)
21.2
(80.3)
21.2
(80.3)
21.2
(80.3)
Maximum Water Pressure, psig (kPa)
175 (1207)
175 (1207)
175 (1207)
Maximum Refrigerant Working Pressure, psig (kPa)
225 (1552)
225 (1552)
225 (1552)
Water Inlet / Outlet Victaulic Connections, In. (mm)
5 (141.3)
5 (141.3)
5 (141.3)
Drain - NPT int, In. (mm)
.375 (9.5)
.375 (9.5)
.375 (9.5)
Vent - NPT int, In. (mm)
.375 (9.5)
.375 (9.5)
.375 (9.5)
NOTE:
1.
Nominal capacity based on 95°F ambient air and 54°F/44°F water range.
14
AGR 070A through 100A
IOMM AGR-1
Electrical Data
Field Wiring
CAUTION
Internal power wiring to the compressors for single and multiple point option are different.
Field wiring must be installed according to unit wiring diagram.
Wiring must comply with all applicable codes and ordinances. Warranty is void if wiring is not in
accordance with specifications. Copper wire is required for all power lead terminations at the unit.
Aluminum or copper can be used for all other wiring.
Standard AGR units have internal power wiring for single point power connection. A single large
power terminal block is provided and wiring within the unit is sized in accordance with the National
Electrical Code. A single field supplied fused disconnect is required. The control transformer with
fuses is factory installed.
If the evaporator heater is on a separate disconnect switch from the main unit power supply, the unit
may be shut down without defeating the freeze protection (115V, 420W heat tape) provided by the
cooler heater.
IOMM AGR-1
AGR 070A through 100A
15
Table 9, 60 Hz, Single Point Power Electrical Data
POWER SUPPLY
Field Wire
Conduit Hub
Minimum
Circuit
Ampacity
(MCA)
Quantity
Wire
Gauge
Quantity
Nominal
Size
Max. Fuse
or
HACR Breaker
Size
070AS
070AM
208
230
380
460
575
322
300
190
153
114
3
3
3
3
3
400
350
3/0
2/0
#2
1
1
1
1
1
2.50
2.50
2.00
1.50
1.25
450
400
250
200
150
075AS
075AM
208
230
380
460
575
351
329
220
163
126
3
3
3
3
3
500
400
4/0
2/0
#1
1
1
1
1
1
3.00
2.50
2.00
1.50
1.50
450
450
300
225
150
080AS
080AM
208
230
380
460
575
384
373
240
187
151
6
3
3
3
3
3/0
500
250
3/0
2/0
2
1
1
1
1
2.00
3.00
2.50
2.00
1.50
500
500
300
250
200
085AS
085AM
208
230
380
460
575
411
408
256
206
171
6
6
3
3
3
4/0
4/0
300
4/0
3/0
2
2
1
1
1
2.00
2.00
2.50
2.00
2.00
500
500
350
250
225
090AS
090AM
208
230
380
460
575
411
408
256
206
171
6
6
3
3
3
4/0
4/0
300
4/0
3/0
2
2
1
1
1
2.00
2.00
2.50
2.00
2.00
500
500
350
250
225
095AS
095AM
208
230
380
460
575
461
458
269
220
176
6
6
3
3
3
250
4/0
300
4/0
3/0
2
2
1
1
1
2.00
2.00
2.50
2.00
2.00
600
600
350
300
225
100AS
100AM
208
230
380
460
575
501
498
279
231
180
6
6
3
3
3
250
250
300
250
3/0
2
2
1
1
1
2.00
2.00
2.50
2.00
2.00
700
700
350
300
250
AGR
Unit
Size
Volts
All Electrical Data notes are on page 19.
16
AGR 070A through 100A
IOMM AGR-1
Table 10, 60 Hz, Compressor and Condenser Fan Motor Amp Draw
AGR
Unit
Size
Volts
Rated Load Amps
Compressors
Fan
Motors
(Each)
No. Of
Fan
Motors
Fan
Motors
(Each)
Locked Rotor Amps
Compressors
Across-The-Line
Part Winding (1)
No. 1
No. 2
No. 1
No. 2
No.
1
No.
2
070AS
070AM
208
230
380
460
575
122
112
65
60
42
135
127
87
63
48
7.8
7.2
4.1
3.6
3.0
4
4
4
4
4
30.5
27.6
20.0
13.8
11.0
N.A.
N.A.
365
315
245
N.A.
N.A.
365
315
245
400
340
N/A
195
152
463
340
N/A
195
152
075AS
075AM
208
230
380
460
575
135
127
87
63
48
135
127
87
63
48
7.8
7.2
4.1
3.6
3.0
6
6
6
6
6
30.5
27.6
20.0
13.8
11.0
N.A.
N.A.
365
315
245
N.A.
N.A.
365
315
245
463
340
N/A
195
152
463
340
N/A
195
152
080AS
080AM
208
230
380
460
575
135
127
87
63
48
162
162
103
82
68
7.8
7.2
4.1
3.6
3.0
6
6
6
6
6
30.5
27.6
20.0
13.8
11.0
N.A.
N.A.
365
315
245
N.A.
N.A.
740
510
405
463
340
N/A
195
152
654
654
N/A
330
262
085AS
085AM
208
230
380
460
575
162
162
103
82
68
162
162
103
82
68
7.8
7.2
4.1
3.6
3.0
6
6
6
6
6
30.5
27.6
20.0
13.8
11.0
N.A.
N.A.
740
510
405
N.A.
N.A.
740
510
405
654
654
N/A
330
262
654
654
N/A
330
262
090AS
090AM
208
230
380
460
575
162
162
103
82
68
162
162
103
82
68
7.8
7.2
4.1
3.6
3.0
6
6
6
6
6
30.5
27.6
20.0
13.8
11.0
N.A.
N.A.
740
510
405
N.A.
N.A.
740
510
405
654
654
N/A
330
262
654
654
N/A
330
262
095AS
095AM
208
230
380
460
575
162
162
103
82
68
202
202
113
93
72
7.8
7.2
4.1
3.6
3.0
6
6
6
6
6
30.5
27.6
20.0
13.8
11.0
N.A.
N.A.
740
510
405
N.A.
N.A.
740
510
405
654
654
N/A
330
262
654
654
N/A
330
262
100AS
100AM
208
230
380
460
575
202
202
113
93
72
202
202
113
93
72
7.8
7.2
4.1
3.6
3.0
6
6
6
6
6
30.5
27.6
20.0
13.8
11.0
N.A.
N.A.
740
510
405
N.A.
N.A.
740
510
405
654
654
N/A
330
262
654
654
N/A
330
262
All Electrical Data notes are on page 19.
IOMM AGR-1
AGR 070A through 100A
17
Table 11, 60 Hz Single Point Power, Field Wiring Data
Wiring to Standard
Power Block
AGR
Unit
Size
Volts
Wiring to Optional
Non-Fused Disconnect Switch
Terminal
Amps
Connector Wire Range
(Copper Wire Only)
Terminal
Amps
Connector Wire Range
(Copper Wire Only)
070AS
070AM
208
230
380
460
575
335
335
335
335
335
# 4 - 400 MCM
# 4 - 400 MCM
# 4 - 400 MCM
# 4 - 400 MCM
# 4 - 400 MCM
400
400
250
250
150
250 - 500 MCM
250 - 500 MCM
#4 - 350 MCM
#4 - 350 MCM
#2 - 3/0
075AS
075AM
208
230
380
460
575
840
335
335
335
335
(2 qty.) 1/0 - 600 MCM
# 4 - 400 MCM
# 4 - 400 MCM
# 4 - 400 MCM
# 4 - 400 MCM
400
400
250
250
150
250 - 500 MCM
250 - 500 MCM
#4 - 350 MCM
#4 - 350 MCM
#2 - 3/0
080AS
080AM
208
230
380
460
575
840
840
335
335
335
(2 qty.) 1/0 - 600 MCM
(2 qty.) 1/0 - 600 MCM
# 4 - 400 MCM
# 4 - 400 MCM
# 4 - 400 MCM
400
400
250
250
250
250 - 500 MCM
250 - 500 MCM
#4 - 350 MCM
#4 - 350 MCM
#4 - 350 MCM
085AS
085AM
208
230
380
460
575
840
840
335
335
335
(2 qty.) 1/0 - 600 MCM
(2 qty.) 1/0 - 600 MCM
# 4 - 400 MCM
# 4 - 400 MCM
# 4 - 400 MCM
600
600
400
250
250
(2 qty.) 250 - 500 MCM
(2 qty.) 250 - 500 MCM
250 - 500 MCM
#4 - 350 MCM
#4 - 350 MCM
090AS
090AM
208
230
380
460
575
840
840
335
335
335
(2 qty.) 1/0 - 600 MCM
(2 qty.) 1/0 - 600 MCM
# 4 - 400 MCM
# 4 - 400 MCM
# 4 - 400 MCM
600
600
400
250
250
(2 qty.) 250 - 500 MCM
(2 qty.) 250 - 500 MCM
250 - 500 MCM
#4 - 350 MCM
#4 - 350 MCM
095AS
095AM
208
230
380
460
575
840
840
335
335
335
(2 qty.) 1/0 - 600 MCM
(2 qty.) 1/0 - 600 MCM
# 4 - 400 MCM
# 4 - 400 MCM
# 4 - 400 MCM
600
600
400
250
250
(2 qty.) 250 - 500 MCM
(2 qty.) 250 - 500 MCM
250 - 500 MCM
#4 - 350 MCM
#4 - 350 MCM
100AS
100AM
208
230
380
460
575
840
840
335
335
335
(2 qty.) 1/0 - 600 MCM
(2 qty.) 1/0 - 600 MCM
# 4 - 400 MCM
# 4 - 400 MCM
# 4 - 400 MCM
600
600
400
250
250
(2 qty.) 250 - 500 MCM
(2 qty.) 250 - 500 MCM
250 - 500 MCM
#4 - 350 MCM
#4 - 350 MCM
All Electrical Data notes are on page 19.
18
AGR 070A through 100A
IOMM AGR-1
Notes for “Electrical Data Single Point” Power:
1.
Unit wire size ampacity (MCA) is equal to 125% of the largest compressor-motor RLA plus
100% of RLA of all other loads in the circuit including the control transformer.
2.
If the control transformer option is furnished, a separate 115v power is not required.
3.
If a separate 115V power supply is used for the control circuit, then the wire sizing amps is 10
amps for all unit sizes.
4.
Recommended power lead wire sizes for 3 conductors per conduit are based on 100% conductor
ampacity in accordance with NEC. Nominal voltage drop has been included. It is recommended
that power leads be kept short. All terminal block connections must be made with copper (type
THW) wire.
5.
“Recommended Fuse Sizes or HACR breaker size” is selected at approximately 150% to 175%
of the largest compressor RLA, plus 100% of all other loads in the circuit.
6.
“Maximum Fuse or HACR breaker size” is selected based on 225% of the largest compressor
RLA, plus 100% of all other loads in the circuit.
7.
The recommended power lead wire sizes are based on an ambient temperature of 86°F (30°C).
Ampacity correction factors must be applied for other ambient temperatures. Refer to the
National Electrical Code Handbook.
8.
Must be electrically grounded according to national and local electrical codes.
9.
The MCA may vary slightly due to motor options such as SpeedTrol, TEFC.
Voltage Limitations:
Within ± 10 percent of unit nameplate rating.
Notes for “Compressor and Condenser Fan Amp Draw”:
1.
Compressor RLA values are for wiring sizing purposes only and may be higher than nominal
operating current draw at rated capacity.
2.
If unit is equipped with SpeedTrol condenser fan motors, the first motor on each refrigerant
circuit is a single phase, 1hp motor, with a FLA of 2.8 amps at 460 volts, 5.6 amps at 208, 230,
and 575 volts.
3.
Compressor LRA for reduced inrush start are for the first winding of part-winding start only.
4.
If the unit is equipped with SpeedTrol motors, the first motor is a single phase, 1 hp motor, with a
LRA of 7.3 amps at 460 volts, 14.5 amps at 208, 230, and 575 volts.
Notes for “Field Wiring Data”:
IOMM AGR-1
1.
The standard unit requires a single disconnect to supply electrical power to the unit. Power
supply must either be fused or use an HACR type circuit breaker.
2.
Multiple point power connection for field wiring is available as an option. Two power terminal
blocks are supplied in the unit, one for each system in the unit. Each power terminal block
supplies both compressor and fan motor power for each system. If the control transformer option
is furnished, it is connected to the system #1 power terminal block.
3.
All field wiring to unit power block or optional non-fused disconnect switch must be copper.
4.
All field wire size values given in table apply to 75°C rated wire per NEC. Following NEC
guidelines for other wire ratings such as 90°C.
AGR 070A through 100A
19
Figure 9, Typical Field Wiring with Global UNT Controller
20
AGR 070A through 100A
IOMM AGR-1
Figure 10, Typical Field Wiring Diagram with MicroTech Controller
IOMM AGR-1
AGR 070A through 100A
21
Figure 11, Standard Single-Point Connection with FanTrol
22
AGR 070A through 100A
IOMM AGR-1
Figure 12, Standard Single-Point Connection with Optional SpeedTrol
IOMM AGR-1
AGR 070A through 100A
23
Figure 13, Unit Control Schematic (2 compressor UNT)
24
AGR 070A through 100A
IOMM AGR-1
Figure 14, Staging Schematic (2 compressor 4-stage UNT)
IOMM AGR-1
AGR 070A through 100A
25
Figure 15, Staging Schematic (2 compressor 6-stage UNT)
26
AGR 070A through 100A
IOMM AGR-1
Figure 16, MicroTech Controller Schematic
IOMM AGR-1
AGR 070A through 100A
27
Figure 17, Unit Control Schematic (MicroTech)
28
AGR 070A through 100A
IOMM AGR-1
Figure 18, Staging Schematic (4-stage MicroTech)
IOMM AGR-1
AGR 070A through 100A
29
Figure 19, Staging Schematic (6-stage MicroTech)
30
AGR 070A through 100A
IOMM AGR-1
Figure 20, Unit Control Schematic (2 compressor MicroTech)
IOMM AGR-1
AGR 070A through 100A
31
Figure 21, UNT Instrument Layout
See legend on page 34.
32
AGR 070A through 100A
IOMM AGR-1
Figure 22, MicroTech Instrument Layout
See legend on page 34.
IOMM AGR-1
AGR 070A through 100A
33
Figure 23, AGR Power Side Component Layout
See legend on page 34.
Figure 24, Component Layout Legend
34
AGR 070A through 100A
IOMM AGR-1
Figure 25, MicroTech Sensor Layout
IOMM AGR-1
AGR 070A through 100A
35
Dimensional Data
Figure 26, Dimensions AGR 070AS
4” (107mm) (AGR055-060)
5” (127mm) (AGR065-070)
VICTAULIC CONNECTIONS
FURNISHED WITH GROOVES
FOR VICTAULIC COUPLINGS
BY OTHERS
C
OUTLET
D
INLET
NOTE:
1. ALL DIMENSIONS IN INCHES (mm)
2. ALL UNITS HAVE (2) INDEPENDENT
REFRIGERANT CIRCUITS
EVAPORATOR
2 REFRIGERANT CIRCUITS
COIL HEADERS
AT THIS END
OF UNIT
CONTROL BOX
AT THIS END
OF UNIT
COMPRESSOR # 2
COMPRESSOR # 1
POWER ENTRY
LOCATION
THIS SIDE ONLY
(A KNOCKOUT IS LOCATED
6” (152mm) BELOW THIS
OPENING FOR MULTIPLE
POWER SUPPLY)
AIR DISCHARGE
AIR DISCHARGE
OPTIONAL
COIL GUARDS
A
B
E
CONTROL
CENTER
6.50
(165.1)
33.38
(847.3)
POWER CENTER
31.50
(800.1)
Z
F
5.50
(139.7)
2.00
(50.8)
13.12
(333.2)
88.12
(2238.2)
15.12
(384.0)
AGR
MODEL
Number
070AS
36
A
B
96.2
(2444)
91.7
(2329)
78.88
(2003.6)
80.88
(2054.4)
23.9
(607)
E
F
4.3
(108)
16.0
(406)
Y
2.00
(50.8)
2.5” (63mm) DIAMETER
LIFTING HOLES (4)
(2) PER SIDE AS SHOWN
94.00
(2387.6)
Unit Dimensions
inch (mm)
C
D
60.0
(1525)
UNIT ISOLATOR/
MOUNTING HOLE
LOCATIONS (4)
(2) PER SIDE AS SHOWN
X
CONTROL WIRING
ENTRY KNOCKOUTS
FOR 1/2” (13mm)
CONDUIT, AT BACK
OF CONTROL BOX
ON CONTROL SIDE
Center of Gravity
inch (mm)
X
Y
Z
45.0
(1143)
41.8
(1062)
AGR 070A through 100A
38.8
(986)
TYPICAL SPACING FOR 1.0 (25.4)
DIAMETER ISOLATOR/MOUNTING
HOLE LOCATIONS (4)
Weights
lb. (kg)
Operating
Shipping
4755
(2154)
4650
(2106)
Additional Weight
for Units with Copper
Fin Coils lb (kg)
830
(375)
IOMM AGR-1
Figure 27, Dimensions AGR 075AS through 100AS
5” (127mm) (AGR075-100)
VICTAULIC CONNECTIONS
FURNISHED WITH GROOVES
FOR VICTAULIC COUPLINGS
BY OTHERS
C
NOTE:
1. ALL DIMENSIONS IN INCUES (mm)
2. ALL UNITS HAVE (2) INDEPENDENT
REFRIGERANT CIRCUITS
D
OUTLET
INLET
EVAPORATOR
2 REFRIGERANT CIRCUITS
CONTROL BOX
AT THIS END
OF UNIT
COIL HEADERS
AT THIS END
OF UNIT
COMPRESSOR # 1
POWER ENTRY
LOCATION
THIS SIDE ONLY
(A KNOCKOUT IS LOCATED
6” (152mm) BELOW THIS
OPENING FOR MULTIPLE
POWER SUPPLY)
AIR DISCHARGE
AIR DISCHARGE
OPTIONAL
COIL GUARDS
A
B
CONTROL
CENTER
COMPRESSOR # 2
6.50
(165.1)
33.36
(847.3)
POWER CENTER
E
31.50
(800.1)
Z
F
5.50
(139.7)
CONTROL WIRING
ENTRY KNOCKOUTS
FOR 1/2” (13mm)
CONDUIT AT BACK
OF CONTROL BOX
ON CONTROL SIDE
AGR
MODEL
Number
075AS
080AS
085AS
090AS
095AS
100AS
IOMM AGR-1
2.00
(50.8)
13.12
(333.2)
88.12
(2238.2)
A
B
96.2
(2444)
96.2
(2444)
96.2
(2444)
96.2
(2444)
96.2
(2444)
96.2
(2444)
91.7
(2329)
91.7
(2329)
91.7
(2329)
91.7
(2329)
91.7
(2329)
91.7
(2329)
15.12
(384.0)
X
123.23
(3130.0)
121.23
(3079.2)
45.2
(1148)
45.2
(1148)
45.2
(1148)
45.2
(1148)
45.2
(1148)
45.2
(1148)
E
F
4.4
(112)
4.4
(112)
4.4
(112)
3.8
(96)
3.8
(96)
3.8
(96)
17.5
(444)
17.5
(444)
17.5
(444)
17.5
(444)
17.5
(444)
17.5
(444)
Center of Gravity
inch (mm)
X
Y
Z
60.4
(1534)
60.4
(1534)
60.4
(1534)
60.4
(1534)
60.4
(1534)
60.4
(1534)
Y
2.00
(50.8)
2.5” (63mm) DIAMETER
LIFTING HOLES (4)
(2) PER SIDE AS SHOWN
136.35
(3463.3)
Unit Dimensions
inch (mm)
C
D
99.2
(2520)
99.2
(2520)
99.2
(2520)
99.2
(2520)
99.2
(2520)
99.2
(2520)
UNIT ISOLATOR/
MOUNTING HOLE
LOCATIONS (4)
(2) PER SIDE AS
SHOWN
42.2
(1072)
41.5
(1054)
40.8
(1036)
42.0
(1067)
42.0
(1067)
42.0
(1067)
AGR 070A through 100A
37.3
(947)
36.9
(937)
36.2
(919)
36.8
(935)
35.4
(899)
35.4
(899)
TYPICAL SPACING FOR 1.0 (25.4)
DIAMETER ISOLATOR/MOUNTING
HOLE LOCATIONS (4)
Weights
lb. (kg)
Operating
Shipping
5506
(2500)
5740
(2605)
5920
(2685)
6185
(2805)
6195
(2810)
6195
(2810)
5360
(2428)
5595
(2540)
5775
(2620)
6010
(2725)
6020
(2730)
6020
(2730)
Additional Weight
for Units with Copper
Fin Coils lb (kg)
1245
(565)
1245
(565)
1245
(565)
1245
(565)
1245
(565)
1245
(565)
37
AGR Unit Start-Up
Pre start-up
The chiller must be inspected to ensure no components became loose or damaged during shipping or
installation or during extended shut down periods.
Water piping checkout
1.
Check the pump operation and vent all air from the system.
2.
Circulate evaporator water checking for proper system pressure and pressure drop across the
chiller barrel. Compare the pressure drop to the Evaporator water pressure drop curve.
3.
Clean all water strainers before placing the chiller into service.
Refrigerant piping checkout
1.
Check all exposed brazed joints for evidence of leaks. Joints may have been damaged during
shipping or when the unit was installed.
2.
Check that all refrigerant valves are either opened or closed as required.
3.
Check all valve stem packing for leaks. Replace all refrigerant valve caps and tighten.
4.
Check all refrigerant lines to ensure they will not vibrate against each other or against other
chiller components.
5.
Check all flare connections and all refrigerant threaded connectors.
6.
Look for any signs of refrigerant leaks around the condenser coils and for damage during
shipping or installation.
7.
Leak detector is applied externally to refrigerant joints at the factory. Do not confuse this residue
with an oil leak.
8.
Connect refrigerant service gauges to each refrigerant circuit before starting unit.
Electrical Check Out
NOTE: Electrical power must be applied to the compressor crankcase heaters 24 hours before
starting unit.
1.
Open all electrical disconnects and check all power wiring connections. Start at the power block
and check all connections through all components to and including the compressor terminals.
These should be checked again after 3 months of operations and at least yearly thereafter.
2.
Check all control wiring by pulling on the wire at the spade connections and tighten all screw
connections. Check plug-in relays for proper seating and to insure retaining clips are installed.
3.
Put System Switch (S1) to the Emergency Stop position.
4.
Put both circuit #1 & #2 switches to the Pumpdown and Stop position.
5.
Apply power to the unit. The panel Alarm Light will stay on until S1 is closed. Ignore the Alarm
Light for the check out period. You may wish to disconnect the optional Alarm Bell.
6.
Check at the power block or disconnect for the proper voltage and proper voltage between
phases.
7.
Check for 120Vac at the optional control transformer and at TB-2 terminal #1 and the neutral
block (NB).
8.
Check between TB-2 terminal #7 and NB for 120Vac supply for transformer #2.
9.
Check between TB-2 terminal #2 and NB for 120Vac control voltage. This supplies the
compressor crank case heaters.
10. Check between TB-3 terminal #17 and #27 for 24Vac control voltage.
11. Check on the Global UNT controller between terminals marked 24Vac and common for 24Vac
control voltage. Green light on Global UNT controller should be flashing.
38
AGR 070A through 100A
IOMM AGR-1
Start-Up
There should be adequate building load (25% of unit capacity minimum) to properly check the
operation of the chiller refrigerant circuits.
Be prepared to record all operating parameters required by the “Compressorized Equipment Warranty
Form”. Return this information within 10 working days to McQuay International as instructed on the
form to obtain full warranty benefits.
1.
Verify chilled water flow.
2.
Verify remote start / stop or time clock has requested the chiller to start.
3.
Set the chilled water setpoint to required temperature. (The system water temperature must be
greater than the total of the leaving water temperature setpoint plus 1/2 the control band before
the Global UNT controller will stage on cooling.)
4.
Set the control band to 4°F as a starting point.
5.
Put both circuit switches to the AUTO position.
6.
Put switch S1 to AUTO position.
7.
There will be a delay of 2 minutes after closing S1. The time delay is due to the compressor
inherent motor protection. This may allow more than one compressor to start after this time
period. This should only occur on initial start-up or when power to the chiller has been turned off
and back on. The panel Alarm Light will turn off.
8.
After operating for a period of time and unit has become stable, check the following:
Compressor oil level.
Refrigerant sight glass for flashing.
Rotation of condenser fans.
Shutdown
Temporary
1.
Put both circuit switches to Pumpdown and Stop.
2.
After compressors have stopped, put System Switch (S1) to Emergency Stop.
3.
Turn off chilled water pump. Chilled water pump to operate during pumpdown.
To start the chiller after a temporary shutdown follow the start up instructions.
Extended
1.
Front seat both condenser liquid line service valves.
2.
Put both circuit switches in Pumpdown and Stop position.
3.
After the compressors have stopped, put System Switch (S1) in Emergency Stop position.
4.
Front seat both refrigerant circuit discharge valves.
5.
If chilled water system is not drained, maintain power to the evaporator heater to prevent
freezing. Maintain heat tracing on the chilled water lines.
6.
Drain evaporator and water piping to prevent freezing.
7.
If electrical power is on to unit, the compressor crankcase heaters will keep the liquid refrigerant
out of the compressor oil. This will minimize start up time when putting the unit back into
service. The evaporator heater will be able to function.
8.
If electrical power is off, make provisions to power the evaporator heater (if chilled water system
is not drained). Tag all opened electrical disconnect switches to warm against startup before the
refrigerant valves are in the correct operating position. When starting the unit, electrical power
must be on for 24 hours before starting the chiller.
To start the chiller after an extended shutdown, follow the pre startup and startup instructions.
IOMM AGR-1
AGR 070A through 100A
39
AGR Unit Operation
Sequence of Operation
Starting
With control power on, 115Vac power is applied through F1 to the compressor crankcase heaters and
control transformer T2. T2 supplies 24Vac to the Global UNT controller. The green light on the
Global UNT controller will begin to flash. The panel Alarm Light will illuminate. Put the System
Switch S1 into the AUTO position. This applies power to the control circuit and a digital input to the
Global UNT controller. Control power is applied through the MHP’s to the compressor inherent
motor protectors. After approximately a two (2) minute time delay, the MP’s are energized and the
panel Alarm Light will turn off. If this is a first start, depress the Freezestat Reset Button for 1
second. There is a default time delay of 5 minutes on the Freezestat reset.
Start the chiller water pump and put the chiller into the run mode by closing the remote start / stop
input or time clock input. After the flow switch has made, the Global UNT controller will begin to
ramp up if the chilled water temperature is above the leaving water setpoint dial plus 1/2 the control
band dial. Internal timing functions will vary the stage up time.
The refrigerant circuit starting is switched between circuits every ten (10) starts. This maintains equal
starts on the first compressor of each refrigerant circuit. Refrigerant circuit #1 is assumed as the
starting circuit for the following.
When the first stage of cooling is required, relay BO1 will be energized and if the evaporator pressure
is above the LPSS (low pressure starting setpoint), relay BO7 will be energized starting Compressor
#1 and energizing the liquid line solenoid valve (SV1) through control relay CCR1.
As additional cooling is required, relay BO2 will be energized and if the evaporator pressure is above
the LPSS (low pressure starting setpoint), relay BO8 will be energized starting Compressor #2 and
energizing the liquid line solenoid valve (SV2) through control relay CCR2.
As additional cooling is required, relays BO3 and BO4 will load compressors #1 and #2 respectively.
On six stage units, B05 and B06 will add additional load on the compressors.
The reverse will occur as the cooling requirements are reduced. Relays BO4 and BO3 will activate
unloading compressors #2 and #1. Relay BO2 will open closing the #2 refrigerant liquid line
solenoid valve. Compressor #2 will continue to operate until the LPLL (low pressure low limit) is
reached or the PDTD (pumpdown delay time period) timer times out. Relay BO8 will open stopping
compressor #2. Relay BO1 will open closing the #1 refrigerant liquid line solenoid valve.
Compressor #1 will continue to operate until the LPLL is reached or the PDTD timer times out.
Relay BO7 will open stopping compressor #1. The compressors will cycle on if the evaporator
pressure exceeds the LPSS setpoint. The Global Reciprocating Chiller has recycling pumpdown.
Standard Controller Setpoints (optional Zone Terminal required to
change values)
TEMPLATE
NAME
OA/AI3 Lim SP
OA/AI3 Reset SP
LvgWtr Rband SP
Unoccpd Lvg SP
OA Lockout SP
Lvg Low Lim SP
SoftSta Capcty
SoftStart Time
40
VALUES
FACTORY SETPOINT
80°F
-40°F
0°F
70°F
-10°F
20°F
50%
2 min
AGR 070A through 100A
RANGE
0 to 100°F
-100 to 100°F
0 to 15°F
40 to 90°F
-20 to 65°F
20 to 40°F
0 to 100%
0 to 20 minutes
IOMM AGR-1
Software Description (Global UNT Interface Kit required to read or
change variables)
Variable
Name
LPSS
SLPT
Description
Default Value
Range
Low Pressure Starting Setpoint
Starting Low Pressure Time
10 psi
260 sec
MLPS
Minimum Low Pressure Setpoint
5 psi
LPSD
LPFS
LPHL
LPLL
FSTP
PDTD
Low Pressure Starting Differential
Low Pressure Freezestat setpoint
Low Pressure High Limit
Low Pressure Low Limit
Freezestat Time Period
Pumpdown Delay Time Period
5 psi
54 psi
57 psi
55 psi
60 sec
60 sec
5 to 15 psi
90 to 300 seconds
Calculated (LPSS-LPSD)
5 psi
3 to 10 psi
30 to 55 psi
40 to 60 psi
40 to 55 psi
60 seconds fixed
60 seconds fixed
Hot Gas Bypass (Optional)
This option allows the system to operate at low loads without the ON-OFF cycling of the compressor.
When the hot gas bypass option is used it is required to be on both refrigerant circuits because of the
lead / lag feature of the Global UNT controller.
This option allows passage of discharge gas into the evaporator inlet (between the TX valve and the
evaporator) which generates a false load to supplement the actual chilled water load.
Note: The hot gas bypass valve cannot generate a 100% false load.
The valve that is supplied can provide a load of approximately 10 tons. The system load added to the
ten tons of the hot gas bypass valve has to exceed the compressor capacity for stage 1 compressor
operating unloaded for stable system operation. This requires some system load. When using hot gas
bypass, the optional six stage capacity staging unit is recommended.
A solenoid valve in the hot gas bypass lines is wired in parallel with both circuit’s liquid line solenoid
valves SV1 and SV2. The hot gas bypass is available whenever a refrigerant circuit is operating. The
hot gas valve is regulating by the evaporator pressure and the remote adjustable bulb. The pressure
regulating valve is factory set to begin opening at 58 psig (32°F for R-22). This setting can be
changed by adjusting the remote adjustable bulb. Remove the cap on the remote bulb and raise the
pressure by turning the adjustment screw clockwise. Lower the pressure by turning the adjusting
screw counterclockwise. This changes the pressure that the hot gas bypass valve will start to open.
Do not force the adjusting screw as this can damage the adjusting assembly.
NOTE: The hot gas line may become hot enough to cause injury. Be careful during valve
checkout.
NOTE: The remote adjusting bulb must be installed on the outside of the suction line
insulation. The bulb has to have a stable ambient air temperature for proper operation.
Placing the bulb in contact with the evaporator refrigerant line will limit the operation of the
hot gas bypass valve.
Filter Driers
Each refrigerant circuit is furnished with a full flow filter drier or an optional replaceable core type
filter-drier. The core assembly of the replaceable core drier consists of a filter core held tightly in the
shell in a manner that allows full flow without bypass.
Pressure drop across the filter drier at full load conditions must not exceed 10 psig. If pressure drop
is more than 10 psig, then replace the filter drier.
NOTE: Pump out refrigerant before removing end flange for replacement of core(s).
A condenser liquid line service valve is provided for isolating the charge in the condenser, but also
serves as the point from which the liquid line can be pumped out. With the line free of liquid, the
filter-drier core(s) can be easily replaced.
IOMM AGR-1
AGR 070A through 100A
41
System Adjustment
To maintain peak performance at full load operation, the system superheat and liquid subcooling may
require adjustment. Read the following subsections closely to determine if adjustment is required.
Liquid Sightglass and Moisture Indicator
The moisture indicator color is an indication of the dryness of the system and is extremely important
when the system has been serviced. Immediately after the system has been opened for service, the
element may indicate a wet condition. It is recommended that the unit operate for about 12 hours to
allow the system to reach equilibrium before deciding if the system requires a change of drier cores.
Bubbles in the sightglass to expansion valve at constant full load conditions indicates a shortage of
refrigerant, a plugged filter-drier, or a restriction in the liquid line. However, it is not unusual to see
bubbles in the sightglass during changing load conditions.
Refrigerant Charging
Liquid line subcooling at the liquid shut-off valve should be between 15° and 20°F at full load. If the
unit is at steady full load operation and bubbles appear in the sightglass, check liquid subcooling.
Thermostatic Expansion Valve
The expansion valve performs one specific function. It keeps the evaporator supplied with the proper
amount of refrigerant to satisfy the load conditions.
The sensing bulb of the expansion valve is installed in the closest straight run of suction line from the
evaporator. The bulb is held on by clamps around the suction line and is insulated to reduce the effect
of surrounding ambient temperatures. In case the bulb must be removed, simply slit the insulation on
each side of the bulb, remove the clamps and then remove the capillary tubing that runs along the
suction line from the valve.
The power element is removable from the valve body without removing the valve from the line.
Superheat and Subcooling
For optimum operation, set the evaporator superheat for 8 to 12°F (4.4 to 6.6°C) and condenser
subcooling (at the liquid shutoff valves) to 15°F to 20°F (8.3°C to 11.11°C).
CAUTION Before adjusting superheat, check that unit charge is correct and liquid line sightglass is
full with no bubbles.
The suction superheat for the suction leaving the evaporator is set at the factory for 8° to 12°F at full
load. To have full rated unit performance the superheat must be about 8°F at 95°F outdoor ambient.
Crankcase Heaters
The reciprocating compressors are equipped with compressor crankcase heaters located at the oil
sump level. The function of the heater is to keep the temperature in the crankcase high enough to
prevent refrigerant from migrating to the crankcase and condensing in the oil during off-cycle.
Power must be supplied to the heaters 24 hours before starting the compressors.
Water Cooler
The water cooler is of the direct expansion type with removable internally finned tubes. The copper
tubes are individually rolled into heavy duty steel tube sheets and sealed by a steel refrigerant head.
The water connection nozzles which enter and leave the shell are on the same side of the unit. No
special attention is required for the cooler except that clean, filtered water should be supplied.
42
AGR 070A through 100A
IOMM AGR-1
UNT Controller Operation
This section provides setup and troubleshooting information for the Global UNT controller.
All operational descriptions are based on the Global UNT software SURE4-2A. Operational
characteristics may vary with other versions of software.
General Description
The Global UNT is a microprocessor based leaving water controller designed for multiple stage
operation.
The Global UNT’s operation is based on an adjustable setpoint and control band. Controller software
is available for different reset options, refrigerants and metric units. Optional equipment includes a
Zone Terminal that can be installed in the unit or remotely. The Zone Terminal provides a user
interface to all reset options and adjusts specific setpoints. Downloading of software or changing
selected operating parameters requires the Global UNT Interface Kit.
Optional Sensors
•
Return water temperature sensor
•
Zone temperature sensor
Sensors and Transducers
Sensors and transducers are mounted and connected to the Global UNT controller with sensor cable.
The evaporator pressure transducers depress the Schrader fittings and can be replaced without
pumping the unit down. The pressure transducers are connected to the Global UNT controller analog
inputs with IDC connectors (Insulation Displacement Connectors). The low pressure transducers
have a blue dot. The leaving water sensor is in a thermal well for easy replacement without draining
the water system. As standard, an outside air sensor is provided on the back of the control box.
When other reset options are selected, the outside air sensor is not provided as only one (1) type of
reset is available.
Control Wiring
Low voltage control wiring is installed, labeled and tested by the factory before shipment.
External Voltage Inputs
The signal for remote reset option (2 to 10 Vdc) or demand limit (0 to 10 Vdc) is provided by the
installing contractor. Connect to TB -7 terminals #134 (+) and #135 (-) as indicated by the unit
wiring diagram. A 4 to 20mA signal conditioned by a 500 ohm resistor can provide the 2 to 10 Vdc
input for the remote reset option. Polarity of the external DC signal must match the controller
polarity.
Interlock Wiring
All interlock wiring to field devices (such as a flow switch or time clock) is provided by the installing
contractor. All interlocking wiring must be connected to the Global UNT 24Vac power supply.
External power supplies connected to the Global UNT controller can damage the controller. See unit
wiring diagram.
Unit Set Points and Calibration
The control software is installed and tested by the factory before shipping. No periodic calibration of
the controller is necessary. All control and safety set points must be checked by the installing
contractor and adjusted as necessary before starting the unit.
IOMM AGR-1
AGR 070A through 100A
43
The “setpoint” control knob adjusts the leaving water setpoint. The “Control Band” knob adjusts the
controller temperature control band. To set, divide the chilled water temperature range by the number
of capacity steps and add 0.5°F for the minimum setting.
Example:
Evaporator water temperature range = 10°F from 54°F to 44°F
Capacity steps = 6
Control band = 10÷6 = 1.66 +0.5 = 2.2°F minimum
Optional Sensors
Optional sensor kits, available from the factory, can be installed in the field. The optional sensor kits
have the same characteristics as the leaving water sensor.
Field Wiring
Interconnecting wiring for the control panel may consist of the following:
•
115 VAC power wiring
•
Analog input signals
•
Digital input signals
•
Digital output signals
•
Communications to a personal computer
Power Wiring
The installing contractor provides the unit voltage power source, disconnect, fuses and necessary
wiring for these circuits. All wiring must conform to the National Electrical Code and applicable
local building codes. If the evaporator heater power source (120 Vac) is supplied from a separate
external supply, remove wires 540 and 545 as indicated on the unit wiring diagram.
Power Supplies
There are several internal power supplies used by the controller and related circuitry. The regulated 5
Vdc power is supplied by RSP1 and provides power to pressure transducers. Do not use this power
supply to operate external devices. A 24 Vac power supply is available for the alarm bell option.
Wire according to the unit wiring diagram.
Analog input signals
All sensors and transducers required for normal chiller operation are installed and wired at the factory.
All optional analog input signal wiring is provided by the installing contractor must be twisted,
shielded pair (Belden #8760 or equal). The optional demand limit and remote reset signals are 0 to
10 VDC signals. The controlling range of the remote reset signal is from 2 Vdc to 10 Vdc.
Digital input signals
Remote contacts for all digital inputs into the Global UNT controller must be dry contacts suitable for
the 24 Vac control signals from the control panel. Do not connect 120 Vac power to the digital inputs
or 24 Vac from an external power source.
Remote Stop/Start
If remote stop/start control is selected, remove the jumper between terminals #140 and #141 on TB-7
and install the input between these terminals. When the remote stop/start switch is open, the
controller will be in the unoccupied mode.
44
AGR 070A through 100A
IOMM AGR-1
Chilled Water Flow Switch
The chilled water flow switch is connected to field wiring terminals #142 and #143 on TB-7. When
the chilled water pump is enabled, the Global UNT controller checks for proof-of-flow through the
flow switch digital input.
Digital Outputs
The digital outputs are controlled by the Global UNT controller. The outputs are double pole double
throw plug-in type relays, with a 24Vac holding coil and 120Vac - 7.0 amp rated contacts. These
relays are field replaceable. Only one contact is used per relay. The contact that is used can be
normally open or normal closed and is dependent on the relay function.
External Alarm Annunciator Circuitry
An audible alarm can be connected to the Alarm Output terminals #19 and #28 of TB-3 of the control
panel and is highly recommended to make certain the operator is alerted to any alarm condition. This
output can also be used to alert a building automation system by paralleling a 24Vac control relay
with the alarm light. This circuit is a 24Vac 1.8 amp maximum load output. The alarm output will be
activated when an alarm condition occurs. Refer to the unit schematic.
Note: The alarm signal is not active during a power failure and will not provide a “Loss of
Power” alarm.
PC Connection
The Global UNT controller can be connected to an IBM or IBM compatible computer for setpoint
changes and downloading of different software’s. A Global UNT Interface Kit is available from your
local McQuay Sales Representative.
Software Identification
Control software is factory installed and tested in each panel prior to shipment. The software is
identified by a program code which is printed on the a small label attached to the controller.
Controller Inputs /Outputs
Analog Inputs
Analog inputs are used to read the various temperatures and pressures on the chiller as well as any
customer supplied reset signals. The regulated 5 VDC power supply provides correct operating
voltage for the pressure transducers. This 5VDC supply cannot be used for other inputs.
Table 12, Analog Inputs
Input
AI-1
AI-2
AI-3
AI-4
AI-5
AI-6
IOMM AGR-1
Description
Leaving Chilled Water Temp
Circuit #1 Evap Pressure
Optional Reset input
Leaving Water Temp Setpoint Dial
Circuit #2 Evap Pressure
Control Band Setpoint Dial
Location
Leaving ChW nozzle
Circuit #1 Suction Line
TB-7 #134 and #135
Control Panel
Circuit #2 Suction Line
Control Panel
AGR 070A through 100A
Range
0 to 120°F(0 - 49°C)
0 to 150 psi (0 - 1034kPa)
0/2 to 10VDC / temp sensor
10 to 60°F ( -12 to 15°C)
0 to 150 psi (0 - 1034kPa)
0 to 10° F (-17 to -12°C)
45
Digital Inputs
Note: All Digital Inputs are 24 VAC supplied by transformer T2 in the control panel. Do not
use inputs from another power supply external to the unit. This can cause failure of the
Global UNT controller.
Table 13, Digital Inputs
Input
BI-1
BI-2
Description
Time Clock
Auto / Pumpdown and Stop Switch Circuit #1
Location
Field Installed to TB-7 #140 & #141
Control Panel
Closed
Run
Run
BI-3
Auto / Pumpdown and Stop Switch Circuit #2
Control Panel
Run
BI-4
Chilled Water Flow Switch
Field Installed to TB-7 #142 & #143
Run
Open
Stop
Pumpdown
Stop
Pumpdown
Stop
Stop
Relay Outputs
All of the relay outputs are controlled by the Global UNT controller. The relays are double pole
double throw relays with contacts rated for 120VAC - 7.0 amp and a 24 VAC holding coil. Refer to
the unit staging schematic.
Table 14, Relay Board Outputs
Relay Output
Number
1
2
3
4
5
6
7
8
Output
Description
Circuit #1 Liquid Line Solenoid Valve
Circuit #2 Liquid Line Solenoid Valve
Compressor #1 Unloader #1
Compressor #2 Unloader #1
Compressor #1 Unloader #2 (6-stage)
Compressor #2 Unloader #2 (6-stage)
Low Pressure Relay Circuit #1
Low Pressure Relay Circuit #2
Reset Options
The Global UNT controller is capable of one reset option. The reset option should be selected at the
time of purchase. Outside Air is the standard option and a Zone Terminal is necessary to activate this
option or any other reset option. Other reset options are available and requires a software download.
Field modifications can be accomplished with the Global UNT Interface Kit.
Outside Air Reset
When selected, a Outdoor Air Temperature (OAT) sensor is connected to TB-7 terminals #134 and
#135. Four variables are used to setup the reset ramp that calculates the Actual Leaving Water
Setpoint. These are: Leaving Water Setpoint (AI-4), Reset Band selected with a Zone Terminal,
Outdoor Air High Limit (OAHL), and Outdoor Air Reset Band (OARB).
46
AGR 070A through 100A
IOMM AGR-1
Figure 28, Outside Air Reset
LWRB
LWSP
OALL
OAHL
OARB
(OALL=OAHL - OARB)
As the OAT increases above the Outdoor Air Low Limit (OALL), the Actual Leaving Water Setpoint
is decreased from its Leaving High Limit (Leaving Water Setpoint plus Leaving Reset Band) to the
Leaving Water Setpoint. When OAT reaches the OAHL, the Actual Leaving Water Setpoint equals
the Leaving Water Setpoint (AI4). If the OAT sensor is missing or unreliable, no reset occurs and the
Actual Leaving Water Setpoint equals the Leaving Water Setpoint. If the Leaving Water Sensor (AI1)
becomes unreliable, the compressor command is forced to 0%.
Return Water Reset (optional Return Water Sensor is required)
When selected, a Return Water Temperature (RWT) sensor is connected to TB-7 terminals #134 and
#135. Four variables are used to setup the reset ramp that calculates the Actual Leaving Water
Setpoint. These are: Leaving Water Setpoint (AI-4), Reset Band selected with a Zone Terminal,
Return Water High Limit (RWHL), and Return Water Reset Band (RWRB).
Figure 29, Return Water Reset
LWRB
LWSP
RWLL
(RWLL=RWHL - RWRB)
RWHL
RWRB
As the RWT increases above the Return Water Low Limit (RWLL), the controller decreases the
Actual Leaving Water Setpoint from its Leaving High Limit (Leaving Water Setpoint plus Leaving
Reset Band) to the Leaving Water Setpoint. When RWT reaches the RWHL, the Actual Leaving
Water Setpoint equals the Leaving Water Setpoint (AI-4). If the RWT sensor is missing or unreliable,
no reset occurs and the Actual Leaving Water Setpoint equals the Leaving Water Setpoint. If the
Leaving Water Sensor (AI-1) becomes unreliable, the compressor command is forced to 0%.
IOMM AGR-1
AGR 070A through 100A
47
When Return Water Reset is chosen, a Fail Smart Logic option is also available. This option works as
follows. If the Leaving Water Sensor (AI-1) becomes unreliable, the controller switches from
Leaving Water control to Return Water control. Actual Return Water Setpoint equals Leaving Water
Setpoint (AI-4) plus an adjustable Leaving Water Setpoint Offset. This value takes into account the
temperature differential between Leaving and Return water temperatures, which is typically about
10oF. If both the Leaving and Return water sensors are unreliable, the compressor is forced to 0%.
Zone Temperature (optional Zone Temperature Sensor )
When selected, a Zone Temperature Sensor is connected to TB-7 terminals #134 and #135. Four
variables are used to setup the reset ramp that calculates the Actual Leaving Water Setpoint. These
are: Leaving Water Dial Setpoint (AI-4), Reset Band SP selected with the Zone Terminal, Zone
Temperature High Limit (ZTHL), and Zone Temperature Reset Band (ZTRB).
Figure 30, Zone Temperature Reset
LWRB
LWSP
ZTLL
(ZTLL=ZTHL - ZTRB)
ZTHL
ZTRB
As the Zone Temperature increases above the Zone Temperature Low Limit (ZTLL), the controller
decreases the Actual Leaving Water Setpoint from its Leaving High Limit (Leaving Water Setpoint
plus Leaving Reset Band) to the Leaving Water Setpoint. When the Zone Temperature reaches the
ZTHL, the Actual Leaving Water Setpoint equals the Leaving Water Setpoint (AI-4). If the Zone
Temperature sensor is missing or unreliable, no reset occurs and the Actual Leaving Water Setpoint
equals the Leaving Water Setpoint. If the Leaving Water Sensor (AI-1) becomes unreliable, the
compressor command is forced to 0%.
The Zone Terminal is required to activate and change the reset values.
Remote Reset (2 to 10VDC input)
When selected, a 2 to 10 Vdc signal is connected to TB-7 terminals #134 and #135. This input can be
achieved by using a 4-20mA signal and conditioning it with a 500 ohm resistor. This input resets the
leaving water temperature to a higher value based on the reset input signal magnitude. At a 2 Vdc
(4mA) chiller signal input, the controller uses the Setpoint Dial setting. At a 10 Vdc (20mA) signal
input, the controller adds the reset value to the Dial Setpoint for the controlling temperature. Between
2 Vdc and 10 Vdc, a proportional value is added to the Dial Setpoint for the controlling temperature.
The leaving water temperature can be reset upwards an additional 15oF. The Zone Terminal is
required to change the reset values.
Demand Limit (0 to 10VDC input)
When selected, a 0 to 10 Vdc signal is connected to TB-7 terminals #134 and #135. This input limits
the cooling capacity (0 to 100%). At 0 Vdc signal input, the controller does not limit compressor
staging. At 10 Vdc signal input, the chiller would be off. Between 0 Vdc and 10 Vdc, a proportional
percentage capacity is available.
48
AGR 070A through 100A
IOMM AGR-1
Additional UNT Controller Features
Remote Stop/Start
When the remote stop/start switch is open, the controller will be in the unoccupied mode. The unit
will be enabled when the remote start / stop switch is closed and will control at the leaving water
temperature setpoint.
Unoccupied Mode
When the remote start / stop input is opened, the unoccupied mode is initiated. The chiller will
maintain a higher leaving water temperature setpoint (default 70°F) if the chilled water circulation is
maintained. The unoccupied leaving water setpoint can be changed from the Zone Terminal.
Soft Start
Soft loading limits the number of available stages when the unit is started to prevent excessive power
consumption and possible overshoot of the leaving water temperature set point. Soft loading is in
effect whenever the unit is started from an “off” cycle. When stage up starts, the controller starts a
countdown timer to indicate how long the unit has been in the cool stage mode. The number of stages
allowed during soft loading is determined by the Soft Start Capacity. The duration of the soft load
sequence is determined by the Soft Start Timer. If the Soft Start Timer is set to zero, no soft loading
will take place. The Zone Terminal is required to change the Soft Start values.
Compressor Staging
The AGR Reciprocating chiller has two refrigerant circuits and each circuit has one reciprocating
compressor. When the first stage of cooling is required, the #1 refrigerant circuit will start. This
circuit will be the first to start for the next ten starts. The Global UNT controller will then select the
#2 refrigerant circuit to start first for the next ten starts. This cycle will continue and balance the
number of starts between the refrigerant circuits. This is an automatic lead / lag control.
There are four or six stages of cooling capacity on the Global Reciprocating chiller unit. The first
stage of cooling will start the compressor of the lead refrigerant circuit. The second stage of cooling
will start the compressor of the lag refrigerant circuit. Cooling stage three will always be compressor
unloader head changing to loaded condition on the lead circuit. Cooling stage four will always be
loading of the lag refrigerant circuit.
Stage down is the reverse of the above paragraph.
Table 15, System Staging and Unit Capacity
Unit Model
Comp #1 Leading
Stage 1
Stage 2
Stage 3
Stage 4
Stage 5
Stage 6
Comp #2 Leading
Stage 1
Stage 2
Stage 3
Stage 4
Stage 5
Stage 6
Comp #1
%Load
6 Cyl.
AGR 070 - 075
Comp #2
% Load
6 Cly
Unit
Cap.
Comp #1
%Load
6 Cyl.
AGR080
Comp #1
%Load
8 Cyl.
Unit
Cap.
AGR 085 - 100
Comp #1
Comp #1
%Load
%Load
8 Cyl.
8 Cyl.
Unit
Cap.
33
33
67
67
100
100
0
33
33
67
67
100
17
33
50
67
83
100
33
33
67
100
100
100
0
50
50
50
75
100
15
42
58
73
86
100
50
50
75
75
100
100
0
50
50
75
75
100
25
50
63
75
88
100
0
33
33
67
67
100
33
33
67
67
100
100
17
33
50
67
83
100
33
33
67
100
100
100
0
50
50
50
75
100
27
42
56
71
85
100
0
50
50
75
75
100
50
50
75
75
100
100
25
50
63
75
88
100
Pumpdown Control
The AGR units have a limited recycling pump down. The pump down is activated when a circuit’s
liquid line solenoid valve is de-energized. After the circuit’s liquid line solenoid valve is deIOMM AGR-1
AGR 070A through 100A
49
energized, the operating compressor on that refrigerant circuit will operate until the low pressure
switch opens and stops that compressor. The compressor will cycle on if the evaporator pressure
exceeds the low pressure cut-in value. After a two hour time delay, the compressor will start again to
pump down the circuit (limited recycling pumpdown). After a two hour time delay, the compressor
will start if the Global UNT controller calls for cooling.
The Pumpdown and Stop switch will open its respective circuit’s digital input to the Global UNT
controller. This will open the associate circuit’s output and open the circuit’s solenoid valve. If a
compressor is operating on that circuit, the compressor will operate until the low pressure switch
stops the compressor. If a compressor is not running, the switch does not activate a pumpdown for
that circuit but will not allow the circuit to stage on and operate.
Certain alarm conditions will not permit chiller pumpdown. These alarm conditions are:
•
High Condenser Pressure
•
Bad Evap Pressure Sensor
•
Compressor Motor Protect
•
Freezestat Alarm
•
Oil Pressure
•
Phase Voltage Monitor (optional)
•
Ground Fault (optional)
Freezestat Control
On startup the Global UNT controller will check the evaporator pressure after the SLPT(starting low
pressure time) timer times out. If the evaporator pressure is greater than the LPHL (low pressure high
limit) value, the Global UNT controller will continue to stage up as additional cooling is required. If
the evaporator pressure is less than the LPHL, the Global UNT controller will de-energize BO7 or
BO8 (depends on circuit starting) which will stop the compressor. This is a Freezestat alarm (alarm
will indicate on the optional Zone Terminal) and will require the resetting by depressing the
FREEZESTAT RESET on the control panel. The circuit will not go through a pumpdown.
If the chiller has been operating and the evaporator pressure in either circuit is less than the LPFS
(low pressure Freezestat setpoint) the Global UNT controller starts the FSTP (Freezestat time period).
If the evaporator pressure is below the LPHL after the FSTP times out, BO7 or BO8 (depends on
evaporator circuit with the low pressure) will be de-energized stopping the operating compressor(s)
and closing that refrigerant circuit’s liquid line solenoid valve. This is a Freezestat alarm (alarm will
indicate on the optional Zone Terminal) and will require the resetting by depressing the
FREEZESTAT RESET on the control panel. There is a five-minute time delay after the freezestat
reset switch has been depressed. The circuit will not go through a pumpdown upon alarm.
Starting Timers
The Global UNT controller has a starting timer which delays checking the evaporator pressure for
260 seconds. After the timer times out, the evaporator pressure is checked. If the pressure is above
the LPHL (low pressure high limit, (default 57psi)) value, the controller stages up on leaving water
temperature requirements. If the evaporator pressure is below the LPHL, then the controller will stop
that circuit and indicate a freezestat alarm on the (optional) Zone Terminal.
50
AGR 070A through 100A
IOMM AGR-1
Head Pressure Control
There are two or three condenser fans per refrigerant circuit. These fans are cycled on and off
according to the circuit’s condenser pressure. Fan #1 of a refrigerant circuit will start when the
compressor of that refrigerant circuit has started. This fan will not cycle off until the circuit is
stopped. The second fan on a refrigerant circuit will cycle on and off according to its head pressure
controller (PC12 or PC22). The third fan on a refrigerant circuit is controlled by an ambient
temperature control.
Optional Head Pressure Control (SpeedTrol)
The first condenser fan on each circuit can have the SpeedTrol option. The fan rpm’s is varied to
maintain a minimum condenser head pressure for stable operation at low ambient temperatures. Wind
baffles may be required in addition to the SpeedTrol option for low ambient operation if the unit is
positioned where winds can blow directly into the coils.
Alarms
Circuit Alarm Conditions
The “Circuit Alarm Conditions” are those alarms which only affect one circuit and can stop the
compressors of that circuit. These alarms are:
•
Compressor Motor Protection
•
High Condenser Pressure
•
Freezestat Protection
The Alarm Light on the control panel will illuminate if either circuit has a high head pressure
occurrence or a compressor motor protection occurrence. Freeze protection would be indicated on
the optional Zone Terminal. If a circuit is off and the panel alarm light is not on, try depressing the
Freezestat reset on the control panel. There is a five minute time delay after depressing the reset
button.
The chiller must have the manual reset system alarm conditions cleared before normal operation can
resume. If the alarm that occurred is an auto-clearing alarm, once the condition has corrected, the
chiller will resume normal operation provided the anti-cycle timers have cleared and sufficient load
exists.
System Alarm Conditions
The “System Alarm Conditions” are those alarms that are common to both refrigeration circuits and
require all compressors to be temporarily shut off or locked out, whichever applies.
System alarm conditions are:
•
Loss of Water Flow
•
Phase Voltage Monitor PVM (Optional)
•
Ground Fault Protection GFP (Optional)
The Alarm Light on the control panel will illuminate if either the PVM or GFP has a fault occurrence.
Loss of water flow is indicated on the optional Zone Terminal.
The chiller must have the manual reset system alarm conditions cleared before normal operation can
resume. If the alarm which occurred is an auto-clearing alarm, once the condition has corrected, the
chiller will resume normal operation provided the anti-cycle timers have cleared and sufficient load
exists.
IOMM AGR-1
AGR 070A through 100A
51
ZONE TERMINAL (optional)
The Zone Terminal (ZT) is a hand-held or unit mounted device that monitors and adjusts your
McQuay Global Reciprocating Chiller information.
A standard telephone-style jack directly connects the ZT to the McQuay Global UNT controller.
Features
•
Portability
•
Simultaneous monitoring of three different settings or values
•
Easy operation with only seven buttons
•
Flashing numbers to show which items are ZT adjustable
•
Flashing symbols to notify you of alarm conditions
Capabilities
With the ZT, you can:
•
Quickly identify a chiller alarm and its location
•
Monitor and adjust up to 18 different settings
Figure 31, Zone Terminal
Display Item List
Display Indicator Dot
Warning Signal
McQuay AGZ/AGR Global Chiller
INSERT 10
Display
Button 1
2
3
Mode
Selector
Button
Mode
Selector
Panel
ON
Lvg Water Temp
Evap Pres #1
Evap Pres #2
OA/AI3 Input
OA/AI3 HiLimSP
OA/AI3 ResetSP
Lvg Water SP
LvgWtr RBnd SP
Contrl Band SP
Actual Lvg SP
Unoccpd Lvg SP
OA Lockout SP
Display Area 11
% Unit Load
Lvg Low Lim SP
SoftSta Capcty
SoftStart Time
Cir #1 Starts
Cir #2 Starts
Display Area 31
Display Area 21
Operating Mode Indicator
MONITOR
ADJUST
TIME SCHEDULE
PASSWORD
On/Off Status
OFF
Occupied
Flow Failure
OA Lockout
Cir#2Lead=On
Pmp/Stp #1=0
Pmp/Stp #2=0
Solenoid #1
Solenoid #2
Frzstat#1Alm
Frzstat#2Alm
MinLowPres#1
MinLowPres#2
Compressor 1
Compressor 2
Stage 3
Stage 4
Stage 5 Opt.
Stage 6 Opt.
ALARM
Alarm Light
Up/Down Arrow Keys
ENTER
Door
AGZ-AGR
OPERATING MODES
Two operating modes are included: Monitor and Adjust.
Monitor Mode
As soon as the ZT is connected, it completes a self-check, and starts up in the Monitor Mode.
Monitor Mode lets you view up to three of chiller settings/sensed values at a time.
To allow you to monitor your system, a clear plastic Insert (factory made and installed) relates the
ZT’s output to your McQuay Global UNT controller.
52
AGR 070A through 100A
IOMM AGR-1
You can simultaneously monitor the chiller in three ways:
•
Monitor up to three settings/sensed values. A maximum of six items are accessible in each of the
three displays.
•
Read the symbols to the right of the display numbers to learn the on/off status of various inputs,
outputs, or modes (| = On status; m = Off status). This provides continuous monitoring of 18
different status (on/off).
•
Monitor alarm status–a flashing red alarm light and any flashing symbol ( |, m, s) visually notifies
you when your chiller has an alarm condition.
Adjust Mode
In Adjust Mode, the ZT displays information in each of the three numerical displays. Typically, the
displays are set up so that the relationship between the values can be viewed simultaneously. For
example:
Display 1 = Lvg Water Temp
Display 2 = Lvg Water SP
Display 3 = % Unit Load
This operating mode allows you to adjust any flashing setpoints. Setpoints adjusted by the ZT remain
in effect until you change them.
DISPLAYS, SYMBOLS, KEYS, AND BUTTONS
The Zone Terminal simultaneously displays three set points or sensed values. In addition, flashing
symbols indicate when items are in a state of alarm. The keys, buttons, displays, and symbols are
explained below.
Table 16, Displays, Symbols, Keys, Buttons
DISPLAYS, SYMBOLS,
KEYS, BUTTONS
Display Button
1, 2, 3
Enter Key
Flashing Numbers
Flashing
s, m, ( | )
Mode Selector Button
On/Off Status Symbols( | )
for On/a circle (m) for Off
Red Alarm Light
DESCRIPTION
Select the value you want to monitor or adjust.
Use to commit your changes. Adjustments are
not processed unless you press Enter.
Appear in Display 1, 2, or 3 to indicate
numbers you can adjust. Numbers that do not
flash are monitor only numbers.
Shows an item is in alarm.
Press this button to select Operating Modes:
Monitor, Adjust, Password, Time Scheduling.
A green Mode Indicator light moves through
the modes.
Observe On/Off conditions of a point in the
HVAC controller with these symbols. A bar (| )
for On, a circle (m) for Off. These are always
monitor only items. If the symbol flashes, item
is in alarm.
Flashes anytime a problem exists regardless
of which Operating Mode you have entered.
Up (↑) or Down (↓) Arrow
Keys
Use these keys to adjust a flashing number.
l
Appears in the displays, and corresponds to
the item you are monitoring or adjusting.
INSTALLING THE PLASTIC LABELS
Note: The insert is normally factory-installed. These steps are required only if the insert is
not already installed.
To use the ZT, you'll need the plastic label which is included with your ZT.
Insert
The clear plastic Insert is a custom-made label unique to your chiller. Use this Insert when
monitoring or adjusting specific items of your system:
IOMM AGR-1
AGR 070A through 100A
53
1.
With the ZT on a flat surface, press the white tab with your index finger Figure 32.
2.
Pull the front cover of the ZT away from the back and slide the Insert into position.
3.
Press the ZT together. With the Insert in place and the ZT connected, the l in top position of each
display lines up with the first word.
Figure 32, Installing the Insert
CONNECTING THE ZONE TERMINAL
You can unit mount the ZT, or use it as a portable tool for convenient access to any chiller
information.
McQuay Global Reciprocating Controller Connection
A standard telephone-style jack connects the ZT to a McQuay Chiller Controller directly.
Figure 33, Connecting ZT to a Global UNT Controller Using 6 to 8 Pin Cable
1 2 3 4 5 6 7 8
OF
F
+15VDC
AS-UNT330-1
6 Pin
Connection
A NA LO G INPUTS
1 2 3 4 5 6
BINA RY IN
1 2 3 4
BINARY OUTPUT
1 2 3 4 5 6
C OM
7
8
T O
PW R
ZO N E
STAT
IN
A NA LOG INPUTS
BINARY COM
C O MMO N
ANALO G INPUTS
24V
AC
24V A C TO LO A DS
BINARY IN
BINARY OUTPUTS
8 Pin
Connection
Connect ZT
here.
ALARM STATUS
The ZT indicates an alarm as follows :
•
The warning signal (s) flashes to the right of the Display Indicator dot ( l ) if the system operating
values are in alarm.
•
The On/Off Status bar ( | ) or circle (m) flashes when an On/Off status is in alarm.
•
The red alarm light to the right of the Mode Selector Panel flashes when any of the above items
are in alarm.
Alarms cannot be cleared with the ZT. The problem must be corrected by maintenance or repair of
the affected item.
54
AGR 070A through 100A
IOMM AGR-1
MAKING ZONE TERMINAL ADJUSTMENTS
Adjusting Control Settings
1. You can adjust only a flashing number with the ZT. If the number does not flash, that item is a
monitor only item. Adjust Control Settings in Display 1, 2, or 3 as follows:
2.
Press the Mode Selector Button until the green Mode Indicator Light moves next to the word
Adjust.
3.
Press either Display Button 1, 2, or 3 to locate adjustable items, which are indicated by flashing
numbers.
If you continue pressing the display buttons, the dot ( | ) in each display changes positions and the
corresponding number appears.
4.
Press the Up () or Down () Arrow key until you reach the number you want to enter. If you
hold down the Up () or Down () Arrow keys, you can speed through the numbers more
quickly.
Press Enter. After you press Enter, the numbers stop flashing for a few seconds. This pause tells
you the ZT has processed your adjustment.
5.
Press any of the Display Buttons to make other adjustments, and repeat Steps 2 and 3.
Adjustable Points
The following McQuay Global Reciprocating Chiller points are adjustable by the Zone Terminal.
Table 17, Adjustable Points
TEMPLATE
NAME
OA/AI3 HiLim SP
OA/AI3 Reset SP
LvgWtr Rband SP
Unoccpd Lvg SP
OA Lockout SP
Lvg Low Lim SP
SoftSta Capcty
SoftStart Time
VALUES
FACTORY SETPOINT
80°F
-40°F
0°F
70°F
-10°F
20°F
50%
2 min
RANGE
0 to 100°F
-100 to 100°F
0 to 15°F
40 to 90°F
-20 to 65°F
20 to 40°F
0 to 100%
0 to 20 minutes
Zone Terminal Glossary
Lvg Water Temp - Shows the temperature of the water leaving the evaporator.
Evap Pres #1 - Shows the evaporator pressure for refrigerant circuit #1.
Evap Pres #2 - Shows the evaporator pressure for refrigerant circuit #2.
OA/AI3 Input - Reset input signal (Outdoor Air Temp. is standard), non-adjustable
OA/AI3 HiLimSP - Used in algorithm for Outside Air Reset. Adjusts Outdoor Air High Limit
(OAHL)(default is 80°F).
OA/AI3 Reset SP - Used in algorithm for Outside Air Reset. Adjusts Outdoor Air Reset Band
(OARB)(default is -40°F; therefore outdoor air reset is 40-80°F).
Lvg Water SP - Shows the dial adjustment setpoint. Non-adjustable from ZT.
LvgWtr Rbnd SP - Can be adjusted through the ZT, 0° - 15°F (default is 0°F). Used in algorithm for
Outside Air Reset. (For an example of 10°F reset; 45°F Leaving Water Setpoint reset up to
55°F).
Contrl Band SP - Indicates what the Control Band Knob is set at. Non-adjustable from ZT.
Actual Lvg SP - Shows the actual setpoint, including any reset that is occurring.
Unoccpd Lvg SP - Adjustable from 40°F - 90°F (default is 70°F). The setpoint is activated by a
timeclock in unoccupied mode.
OA Lockout SP - Adjustable from -20°F to 65°F (default is -10°F). Shuts the unit off when the
Outside Air reaches the setpoint. (Differential = 5°F).
% Unit Load - Indicates the % of the unit load.
IOMM AGR-1
AGR 070A through 100A
55
Lvg Low Lim SP - Adjustable from 20°F - 40°F (default is 20°F). This safety that will shut the
chiller off based on the leaving water temperature going below this setpoint.
SoftSta Capcty - Adjusts the ramping of steps from 0% - 100% (default is 50%).
SoftStart Time - Adjustable ramping time from 0 - 20 minutes (default is 2 minutes).
Cir #1 Starts - Counts the number of starts for circuit #1.
Cir #2 Starts - Counts the number of starts for circuit #2. Note: If power is lost to the controller, this
data is lost and will start counting over. When power is applied and kept on, the controller will
allow 10 starts for circuit #1 as the lead circuit, then will switch to circuit #2 for the next 10
starts, etc (Automatic Lead/Lag).
Occupied - |= On, 0 = Off
Flow Failure - |= Alarm, 0 = Normal
OA Lockout - Indicates whether your in OA lockout (see OA Lockout SP). No alarm.
Cir#2Lead=On - Indicates which circuit is in the lead e.g., ½= On, 0 = Off indicates that circuit #2 is
in the lead.
Pmp/Stp #1=0 - |= Auto, circuit #1 allowed to run if cooling capacity is needed, 0 = Pump down
circut #1 and stop.
Pmp/Stp #2=0 - |= Auto, circuit #2 allowed to run if cooling capacity is needed, 0 = Pump down
circut #2 and stop.
Solenoid #1 - On a call for cooling on circuit 1, the solenoid is energized and opened.
Solenoid #2 - On a call for cooling on circuit 2, the solenoid is energized and opened.
Frzstat#1Alm - If circuit #1 fails on freeze, the alarm light on the ZT will light. To clear the alarm,
the Freez-Stat Reset button (located on the Control Panel) must be pushed once to clear.
Frzstat#2Alm - If circuit #2 fails on freeze, the alarm light on the ZT will light. To clear the alarm,
the Freez-Stat Reset button (located on the Control Panel) must be pushed once to clear.
MinLowPres#1 - If circuit #1 falls below the Minimum Low Pressure Setpoint (default is 10 psig) Differential (default is 5 psig) the ZT alarm will light. Once it increases above the Minimum
Low Pressure Setpoint, the alarm will clear.
MinLowPres#2 - If circuit #2 falls below the Minimum Low Pressure Setpoint (default is 10 psig) Differential (default is 5 psig) the ZT alarm will light. Once it increases above the Minimum
Low Pressure Setpoint, the alarm will clear.
Compressor #1 - Compressor 1 is On or Off
Compressor #2 - Compressor 2 is On or Off
Stage 3 to 6 - Indicates how many additional unloading stages are on at the time.
56
AGR 070A through 100A
IOMM AGR-1
UNT Controller Troubleshooting Chart
PROBLEM
Compressor
Will Not Run
POSSIBLE CAUSES
CORRECTIVE ACTIONS
1.
2.
Main switch, circuit breakers open.
Fuse blown.
3.
4.
5.
Thermal overloads tripped or fuses blown.
Defective contactor or coil.
System shut down by safety devices.
4.
5.
6.
7.
8.
No cooling required.
Liquid line solenoid will not open.
Motor electrical trouble.
6.
7.
8.
9.
Loose wiring.
9.
1.
2.
Dirty condenser coils.
Fan not operating.
1.
2.
3.
4.
5.
6.
7.
High Ambient conditions.
High return water temperature.
Overcharge of refrigerant.
Non condensable.
Discharge valve partially closed.
3.
4.
5.
6.
7.
Low Discharge
Pressure
1.
2.
3.
4.
5.
6.
Fan contactor failed in closed position.
Fan pressure switch defective.
Low ambient temps.
Low on refrigerant charge.
Reduced chilled water flow.
No load and on hot gas bypass.
1.
2.
3.
4.
5.
6.
Repair or replace.
Replace pressure switch.
Install SpeedTrol Kit.
Add refrigerant.
Check flow and correct.
Adjust hot gas bypass to maintain a
higher evaporator pressure.
High Suction
Pressure
1.
2.
Excessive load (high return water temp).
Controller not staging up.
1.
2.
3.
4.
Compressor capacity reduced.
Can be associated with high condenser
pressure.
3.
4.
Check water flow, reduce load.
Check UNT controller. Replace if
defective.
Replace compressor.
Check reasons for high condenser
pressure.
Low Suction
Pressure
1.
2.
3.
4.
5.
6.
7.
Low refrigerant charge.
Defective expansion valve.
Dirty filter drier.
Reduced water flow.
Hot gas bypass valve not set properly.
Liquid line solenoid valve not opening.
UNT controller defective.
1.
2.
3.
4.
5.
6.
7.
8.
Gasket failure in evap head ring.
8.
Add refrigerant.
Check operation. Repair or replace.
Replace cores.
Increase water to design GPM.
Set valve for a higher pressure.
Repair or replace.
Check water sensor, set point dial,
control band dial. Calibrate, repair or
replace.
Replace gasket.
Compressor Oil Loss
1.
2.
3.
4.
Excessive refrigerant flood back.
Defective crankcase heater.
Low refrigerant change.
Hot gas bypass not set properly.
1.
2.
3.
4.
Check TXV. Repair or replace.
Replace heater.
Add refrigerant.
Increase hot gas flow.
Compressor
Overloads or Circuit
Breakers Open
1.
Low line voltage.
1.
2.
3.
4.
High compressor amps.
Loose power wiring.
High condenser pressures.
2.
3.
4.
Check incoming voltage. Report to
electrical supplier.
Determine cause and correct.
Tighten all connections.
Refer to High Condenser Pressure.
5.
Single phasing.
5.
Replace fuses or breaker.
1.
Compressor amps high.
1.
2.
Motor winding damaged.
2.
Refer to the above concerning high
compressor amps.
Check motor winding resistance.
Replace if defective.
1.
Pressure transducers defective.
1.
2.
3.
Low water flow.
Low loads / erratic water flow.
2.
3.
4.
5.
6.
7.
Controller stage timing.
Defective TXV.
Hot gas bypass not set properly.
Low ambient operation.
4.
5.
6.
7.
Compare output to actual refrigerant
pressures.
Check water GPM and correct.
Check pump operation, water strainer, air
handler control valves.
Check timing and reset as necessary.
Check and repair or replace.
Set hot gas bypass.
Install SpeedTrol, wind baffles.
1.
2.
3.
4.
5.
Chilled water flow erratic.
System load erratic.
Bad water sensor.
Reset function calibration.
Defective UNT controller.
1.
2.
3.
4.
5.
Check for reasons and correct.
Check water flow control valve operation.
Replace.
Re-calibrate
Replace
1.
2.
3.
High Discharge
Pressure
Compressor Internal
Motor Switch Open
Freeze Protection
Trips
Erratic Loading and
Unloading
IOMM AGR-1
AGR 070A through 100A
Close switch.
Check electrical circuits and motor
winding for shorts or grounds. Possible
overloading. Replace fuse or reset
breakers after fault is corrected.
Overloads are auto reset. Check unit
closely when operating again.
Repair or replace.
Determine type and cause of shutdown
and correct it before resetting safety.
None. Wait for load.
Repair or replace.
Check motor for opens, shorts circuit or
burnout.
Check all wire junctions. Tighten all
terminals.
Clean.
Check fan motor, contactor, contactor
coil, fan pressure switch. Repair or
replace defective part.
Check against design conditions.
Disable a compressor on each.
Remove excessive amount of charge.
Remove non condensable.
Back seat valve.
57
MicroTech Controller Installation and Operation
All operational descriptions are based on the MicroTech controller software versions AGR2E01A.
Operating characteristics and menu selections may vary with other versions of software. Contact
McQuay Technical Support for software update information.
General Description
The MicroTech control panel contains a model 250-6 microprocessor based controller which provides
all control functions. The operator can review and change operating parameters from the interface
keypad that consists of twelve input keys and a two line by sixteen character display. In addition to
providing all normal operating controls, the controller monitors all safety devices on the unit and will
shut the system down and alarm through a set of dedicated alarm contacts. Important operating
conditions at the time of the alarm are retained in the controller’s memory to aid in troubleshooting
and unit diagnostics. McQuay MicroTech Monitor software is available for remote adjustment and
monitoring of the chiller.
The system is protected by a simple password scheme that allows access by authorized personnel.
The operator must enter a valid password into the panel before any setpoints can be changed.
Optional Sensor Packages
•
•
Refrigerant Sensor Package
Suction line temperature, circuit #1
Suction line temperature, circuit #2
Liquid line temperature, circuit #1
Liquid line temperature, circuit #2
Unit amp package
Unit amperage - Percent total unit amperage including compressors and condenser fans.
Does not include externally powered equipment such as water pumps.
Installation
The MicroTech controller is shipped factory tested with default values for the type of refrigerant. All
control values must be entered for the specific application of the chiller.
Sensors and transducers
Sensors and transducers are mounted and connected to the analog / digital input (ADI) board with
shielded cable. The evaporator and condenser pressure transducers depress the Schrader fittings and
can be replaced without pumping the unit down. The pressure transducers are connected to the
MicroTech analog inputs with IDC connectors (Insulation Displacement Connectors). High pressure
transducers have a red dot and low pressure transducers have a blue dot. Water sensors are in thermal
wells for easy replacement without draining the water system. Optional refrigerant line temperature
sensors are in a copper sleeve brazed to the appropriated refrigerant line.
Control wiring
Low voltage control wiring is installed, labeled and tested by the factory before shipment.
Remote 4-20 milliamp signals
Signals for leaving water reset or demand limit are provided by the installing contractor and
connected to the terminal block as indicated by the unit wiring diagram. See Field Wiring diagram
for details.
58
AGR 070A through 100A
IOMM AGR-1
Interlock wiring
All interlock wiring to field devices (such as flow switches and pump starters) is provided by the
installing contractor. See unit wiring diagrams and field wiring diagram.
Unit set points and calibration
The control software is installed and tested by the factory before shipping. Calibration of the
controller is not necessary. All control and safety set points must be checked by the installing
contractor and adjusted as necessary before starting the unit. Controllers for McQuay chillers have
default set points. Refer to the menu items listed below.
•
Control mode
•
Leaving water temperature
•
Head pressure settings
•
Compressor staging
•
Soft loading
•
Holiday dates
•
Internal scheduling
•
Alarm functions
The default settings are suitable for most installations. The control mode is factory set for “Manual
Unit Off”. Check and set the control and safety settings for the application before starting the unit.
For more information on menu items, see the menu description section.
Modem kit
An optional modem kit allowing remote monitoring of the chiller from an off-site PC running
McQuay Monitor software is available from your local McQuay International sales representative.
The modem kit comes complete with modem, mounting bracket, wiring harness, and installation
instructions. The modem kit can be field installed or as an option at the factory. Modem wiring is
shown on the field wiring diagram.
Optional sensors
Optional sensor kits, available from the factory, can be installed in the field. Thermistors in the
optional sensor kit are the negative coefficient type and have the same characteristics as the entering
and leaving water evaporator sensors.
Field Wiring
Interconnecting wiring for the control panel may consist of the following:
IOMM AGR-1
•
115 VAC power wiring
•
Chilled water pump relay
•
Analog input signals
•
Digital input signals
•
Digital output signals
•
Network communications
•
Communications to a personal computer
•
Telephone line for remote modem access
AGR 070A through 100A
59
Power Wiring
The installing contractor provides the unit voltage power source, disconnect, fuses and necessary
wiring for these circuits. All wiring must conform to the National Electrical Code and applicable
local building codes. If the control power source (120Vac) or the evaporator heater power source
(120Vac) or both are supplied from a separate external supply, remove wires 540 and 545 as indicated
on the field wiring diagram.
Power Supplies
There are several internal power supplies used by the controller and related circuitry. The regulated
5 Vdc power is supplied by the controller and provides power to all analog inputs into the ADI board.
Do not use this power supply to operate external devices. A 24 Vac power supply is available for the
alarm bell option. Wire according to the field wiring diagram.
Analog Input Signals
All sensors and transducers required for normal chiller operation are installed and wired at the factory,
All optional analog signal wiring provided by the installing contractor must be twisted, shielded pair
(Belden #8760 or equal). The optional demand limit and leaving water reset signals are 4 to 20
milliamp DC signals. The resistive load that conditions the milliamp signal is a 249 ohm resistor
mounted on the ADI board at the factory.
Digital Input Signals
Remote contacts for all digital inputs into the MicroTech controller must be dry contacts suitable for
the 24 Vac control signals from the control panel. Do not connect 120 Vac power to the digital inputs.
Remote Stop/Start
If remote stop/start control is selected, remove the jumper between terminals #140 and #141 on TB-7.
When the remote stop/start switch is open, the controller will be in the “Off: Remote Sw” mode. The
unit will be enabled when the switch is closed.
Chilled Water Flow Switch
The chilled water flow switch is connected to field wiring terminals #142 and #143 on TB-7. When
the chilled water pump is enabled, the MicroTech controller checks for proof-of-flow through the
flow switch digital input.
Digital Outputs
The digital output board has normally open solid-state relays with an on-board replaceable 5 amp
fuse. The status of all outputs are shown by the individual output red LEDs.
Chilled Water Pump Relay
The optional chilled water pump relay is connected to terminal #10 and #9 on TB-2. When the unit is
enabled, the chilled water pump relay is energized. Be sure the relay coil is rated for a maximum load
of 1.8 amps at 120 Vac. There is a 5 amp fuse on the digital output board for this control circuit.
60
AGR 070A through 100A
IOMM AGR-1
External Alarm Annunciator Circuitry
An audible alarm can be connected to the Alarm Output terminals #19 and #28 of TB-3 of the control
panel and is highly recommended to make certain the operator is alerted to any alarm condition. This
output can also be used to alert a building automation system or other controls as required. This
circuit is a 24Vac 1.8 amp maximum load output but can be used as a dry contact or another voltage
by rewiring the circuit. Refer to the unit schematic.
The alarm output can be programmed to activate when an alarm or pre-alarm condition is detected.
The alarm signal is de-energized during normal operations. During a fault alarm condition the alarm
circuit will energize and the alarm status light will be on. During a pre-alarm condition the alarm
output and status light will pulse “on” for one-half second and “off” for four seconds.
Note: The alarm signal is not active during a power failure and will not provide a “Loss of
Power” alarm.
PC Connection
The MicroTech controller can be connected to an IBM or IBM compatible computer for local or
remote system monitoring. Communication network wiring uses low voltage shielded twisted pair
cable (Belden 8760 or equal). The network uses the RS232 communications standard with a
maximum cable length of 50 Feet. An RS232/485 adapter may be used to allow for cable runs to
5000 feet.
Telephone line
If remote access and monitoring of the unit is chosen, then a voice quality direct dial telephone line is
required. The line must be a dedicated line and used only for modem access. The phone line must be
terminated with a standard RJ-11 modular phone plug.
Software Identification
Control software is factory installed and tested in each panel before shipment. The software is
identified by a program code printed on a small label attached to the controller. The software version
may also be displayed on the keypad display by viewing the menu items in the Misc. Setup menu.
The software “version” is the last three digits of the software identification code.
Example of typical software identification: AGR2E01A
Controller Inputs /Outputs
Analog Inputs
Analog inputs are used to read the various temperatures and pressures on the chiller as well as any
customer supplied 4-20mA reset signals. The controller’s internal regulated 5 Vdc and 12 Vdc
supplies provide correct operating voltage for the sensors. See Table 18 for details.
Table 18, Analog Inputs
Input
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
IOMM AGR-1
LED
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Description
Leaving Chilled Water Temp
Circuit #1 Evap Pressure
Circuit #2 Evap Pressure
Circuit #1 Cond Pressure
Circuit #2 Cond Pressure
Voltage Ratio Signal
Chw Water Reset
Demand Limit Signal
Entering Evap Water Temp
Entering Cond Water Temp
Leaving Cond Water Temp
% Total Unit Amps
Circuit #1 Suction Temp
Circuit #2 Suction Temp
Circuit #1 Liquid Line Temp
Circuit #2 Liquid Line Temp
Location
Leaving Chw nozzle
Circuit #1 Suction Line
Circuit #2 Suction Line
Compressor Discharge LineCompressor Discharge LineEnGinn Power Supply
Supplied by others
Supplied by others
Entering Chw Nozzle
Enter Cond Water Nozzle
Leaving Cond Water Nozzle
Control Cabinet
Circuit #1 Suction Line
Circuit #2 Suction Line
Circuit #1 Liquid Line
Circuit #2 Liquid Line
AGR 070A through 100A
Range
-40 to 263°F
0 to 145 psi
0 to 145 psi
20 to 450 psi
20 to 450 psi
4.1 to 5.1 Vdc
4 to 20 mA DC
4 to 20 mA DC
-40 to 263°F
-40 to 263°F
-40 to 263°F
0 to 4 Vdc
-40 to 263°F
-40 to 263°F
-40 to 263°F
-40 to 263°F
Resolution
0.1°F
0.1 psi
0.1 psi
0.5 psi
0.5 psi
---0.1°F
0.1°F
0.1°F
-0.1°F
0.1°F
0.1°F
0.1°F
61
Digital Inputs
All Digital Inputs are 24 Vac. At 7.5 Vac to 24 Vac the digital input contacts are considered closed.
Below 7.5 Vac, the contracts are considered open. See Table 19 for details and operating
characteristics.
Table 19, Digital Inputs
Input
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
LED
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Description
Mechanical High Pressure Switch
Oil differential switch
Motor Protection Switch
Circuit
Circuit #1
Compressor #1
Compressor #1
Closed
Normal
normal
Normal
Open
Alarm
Alarm
Alarm
System Switch
Phase/Voltage Monitor
Pumpdown Switch
Mechanical High Pressure Switch
Oil Differential Switch
Motor Protection Switch
Unit
Unit
Unit
Circuit #2
Compressor #2
Compressor #2
Run
Normal
Pmp Dn
Normal
Normal
Normal
Stop
Alarm
Normal
Alarm
Alarm
Alarm
Chiller Remote Stop Switch
Evap Water Flow Switch
Pumpdown Switch
Unit
Unit
Circuit #2
Run
Run
Pmp Dn
Stop
Stop
Normal
Relay Board Outputs
All of the MicroTech panel outputs are controlled by solid-state relays which are driven by the model
250 controller. The controller activates a solid-state relay by sending a “trigger” signal to the output
board via the attached ribbon cable. The relay responds to the trigger by lowering it’s resistance
which allows current to flow through it’s “contacts”. When the controller removes the trigger signal,
the relay’s resistance becomes very high, causing the current flow to stop. The outputs are
individually protected by a 5 amp fuse mounted on the output board adjacent to each relay. Table 20
provides additional information about each output. Refer to the MicroTech Staging schematic for
digital output wiring.
Table 20, Relay Board Outputs
Digital Output
Number
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Output
Description
Alarm Circuit
Chilled Water Pump Relay
Liquid Line Solenoid Circuit #1
Liquid Line Solenoid Circuit #2
Compressor #1 Circuit #1
Compressor #2 Circuit #2
Compressor #1 Unloader #1
Compressor #2 Unloader #1
Compressor #1 Unloader #2
Compressor #2 Unloader #2
Condenser Fan (M11)
Condenser Fan (M12)
Condenser Fan (M13)
Condenser Fan (M21)
Condenser Fan (M22)
Condenser Fan (M23)
Reset Options
User reset options are located in the “Leaving Water Setpoint” menu. The options are:
None
“None” is the default value and the leaving evaporator water temperature controls the unit.
Return
When selecting “Return” as the reset mode, the controller resets the leaving water temperature set
point as required to maintain the selected return water temperature.
62
AGR 070A through 100A
IOMM AGR-1
4 - 20 mA (remote reset signal)
When selecting “4-20mA” as the reset mode, the controller will reset the leaving water temperature to
a higher value based on a percentage of the “Maximum Chilled Water Reset”. At 4mA or less, the
leaving water temperature is not reset. At 20mA the leaving water temperature is reset to the
maximum. Between 4 and 20 mA, the leaving water temperature is reset proportionally to the reset
input signal.
Outside Air
When selecting “Outside Air” as the reset mode, the controller will reset the leaving water
temperature to a higher value based on the temperature of the outside air (ambient). As the outside air
temperature decreases, the leaving water temperature is reset up until the maximum reset is obtained.
When the outside air temperature is above the outside air temperature reset setpoint the leaving water
temperature is not reset and is controlled to the leaving water temperature setpoint.
Ice (for lower ice setpoint requirements, consult McQuay Marketing Support)
When in “Ice” reset mode, and adequate amount of glycol must be added to the system to protect the
evaporator from freezing. McQuay recommends a minimum of 30% solution of ethylene glycol to
protect to 7°F with the minimum leaving water temperature at unit shut down of 21°F. At 21°F shut
down, the saturated refrigerant temperature can approach 10°F.
The leaving water setpoint must be calculated according to the following formula;
LvgEvapSpt = Desired Ice Temperature + 1/2 Control Band + Shut down Delta T
Lvg EvapSpt = 21°F + 1/2 (4)°F + 1.5°F
Lvg Evap Spt = 21°F + 2°F + 1.5°F
Lvg Evap Spt = 24.5°F
The remote 4-20mA input must be 4mA or less and the leaving water temperature will be controlled to
the calculated setpoint. When the remote reset input is above 4 mA, the value “MaxChwRst” is added
to the leaving water setpoint. This will be the day operating setpoint. This value cannot be reset
when in the day mode by any other reset options.
The alarm setpoints must be adjusted to allow operation of the chiller at the lower temperatures. The
following values should be adjusted and the example assumes 30% ethylene glycol solution with a
21°F shut down temperature:
1.
“FrzStat” Set to the saturated suction pressure that corresponds to a temperature several degrees
higher than the freeze point of the water / glycol solution. (10°F = 33psig.)
2.
“Frz H2O” Set at least 4° F below the shut down temperature, but not lower than the freezing
point of the water / glycol solution. (21°F - 4°F = 17°F)
3.
“LP cutout” Set 8 to 10 psi below the “Frz State” pressure but never below 20 psig. (33psi - 10
psi = 23 psi)
4.
“LP Cutin” Set to a saturated suction pressure equal to the shut down temperature plus 1/2 the
control band. (21°F + 2°F = 23°F; 23°F = 46psig)
Network
A network refers to a McQuay MicroTech control panel (CSC or RMS) that can provide controlling
functions to several McQuay chillers. One function is to control the chiller leaving water temperature
according to some control logic in the network control panel. The network control panel will control
the leaving water setpoint when the “Network” option in the chiller is selected. The network control
panel will send a signal that reflects 0 to 100% reset of the leaving water set point according to the
value entered into the “MaxChwRst” of the unit controller.
IOMM AGR-1
AGR 070A through 100A
63
Soft Loading
Soft loading limits the number of available stages when the unit is started to prevent excessive power
consumption and possible overshoot of the leaving water temperature set point. Soft loading is in
effect whenever the unit is started from an “off” cycle. On initial start-up, the chiller will turn on the
chilled water pump and sample the loop water temperature for a time equal to the Load Delay set
point (“LoadDelay”). If cooling is required at the end of the time-delay, a start procedure is initiated.
On entering the “Stage mode” the controller starts a countdown timer to indicate how long the unit
has been in the cool stage mode. The number of stages allowed during soft loading is determined by
the Soft Load Maximum Stages (“SoftLdMaxStg”). The duration of the soft load sequence is
determined by the Soft Load Timer. If the Soft Load Timer is set to zero, no soft loading will take
place. When the soft load option is enabled, any time remaining in the Soft Load Timer will be
displayed in the menu Soft Load Set points under item “Time Left”. The following set points may be
adjusted in SoftLoadSpts menu:
•
Soft Load: This is the amount of time soft loading will be in effect after the controller begins
staging. If set to zero, soft loading is canceled.
•
SoftLdMaxStg: Determines the maximum number of cooling stages which may be energized
while soft loading is in effect.
•
LoadDelay: The amount of time allowed for the controller to sample the loop water temperature
before initiating cooling.
Manual Operation
Manual operating modes are available to simplify setup and troubleshooting of the unit. Any of the
following manual modes may be selected from the Control Mode Menu.
Note: These manual settings are intended to aid in troubleshooting and should not be
considered to be normal operating modes. The equipment should not be left unattended
during manual operation as the automatic staging controls are disabled. The chiller will
remain in the manual mode until Automatic operation is selected or a problem alarm occurs
which will change back to the “Automatic mode”.
•
ManualOff: Manual unit off.
•
Auto1Off2: Automatic Circ#1, Circ#2 off.
•
Auto2Off1: Automatic Circ#2, Circ#1 off.
•
ManualStaging: Manual Staging, Circ#1 & 2.
Compressor Staging
The AGR Reciprocating chiller has two refrigerant circuits and each circuit has one reciprocating
compressor. When in the Automatic mode and stage 1 of cooling is required, the compressor with the
lowest number of starts will be the first compressor to start. Stage 2 of cooling will start the
compressor in the other refrigerant circuit. Stages 3 through 6 will cause the compressors to load all
cyclinders.
If a compressor is not available for starting due to a safety, the number of cooling stages will be
decreased. In normal operation the second stage of cooling will have a compressor from each
refrigerant circuit operating. The exception to this is when “LOW AMBIENT” is selected and the
outside air temperature is below the low ambient setting. The staging logic will be modified to start
the compressor with the lowest starts and stage 2 will load the compressor on that refrigerant circuit.
Both compressors on one refrigerant circuit will operate at low ambient to improve head pressure
control. If additional cooling is required, the next refrigerant circuit will be started.
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Head Pressure Control
There are two or three condenser fans per refrigerant circuit. These fans are cycled on and off
according to the circuit’s condenser pressure. Fan #1 of circuit will start when a compressor in the
circuit has started and the condenser pressure exceeds fan on setpoint (230psig R-22). This fan will
not cycle off until the circuit is stopped. The second fan will cycle on and off to maintain minimum
lift pressure. If the condenser pressure increases rapidly, the second fan will be turned on at 290psig
(R-22 setpoint) and remain on until minimum lift pressure regains control. The third fan will operate
based on the minimum lift pressure control.
Pumpdown Control
The AGR units have a limited recycling pump down. Certain alarm conditions will not permit chiller
pumpdown. These alarm conditions are:
•
High Condenser Pressure
•
Bad Evap Pressure Sensor
•
Phase Voltage Monitor (optional)
•
Volts Ratio Protect
•
Mechanical High Pressure Switch
•
Compressor Motor Protect
•
Ground Fault (optional)
Safety Systems
MicroTech continuously performs self diagnostic checks, monitoring all system temperatures,
pressures and safeties, and will automatically shut down a refrigerant circuit or the entire unit should a
fault occur. The cause of the shutdown, time and date of occurrence and conditions at the same time
of alarm will be retained in memory and can be displayed for the operator to review.
The MicroTech controller has several safety systems to safeguard against potential damage of the
chiller equipment. There are alarm and pre-alarm conditions. Alarm conditions cause the
compressors to shut off and/or lockout. Pre-alarm conditions cause the unit to stage down in capacity
in an attempt to avoid an alarm condition. For alarm conditions, the red “Alarm Status” light on the
control panel will be solid. For all pre-alarm conditions, the light will pulse at the rate of 0.5 seconds
on, 4 seconds off. When an alarm of pre-alarm condition exists, the MicroTech display automatically
switches to the alarm menu to alert the user of the condition.
The MicroTech controller alarms can either be of the manual reset type or the auto reset type. Critical
alarm conditions such as High Condenser Pressure, Refrigerant Freeze Protection, and Low
Evaporator Pressure which protect against equipment damage are manual reset, which means they
lockout compressor operation and must be cleared at the MicroTech keypad before operation can
resume. Auto-clearing alarm conditions cause the compressors to shut off on the affected circuit until
the condition is corrected. When the condition is corrected, the chiller will resume normal operation
on that circuit, provided the anti-cycle timers have cleared and sufficient load exists. All pre-alarm
conditions are auto-clearing. After the controller stages down the unit on an alarm condition and the
potential alarm condition has been avoided, the alarm will clear y itself and the unit will resume
normal operation. If the alarm condition is not avoided, the alarm will be logged on the MicroTech
display, causing lockout of compressors. Thus, the alarm must be manually cleared.
When a McQuay Chiller with a MicroTech controller is used with the McQuay RMS (Remote
Monitoring and Sequencing) Panel, the user must note that alarm nomenclature varies. The RMS has
three possible categories of alarms: faults, problems, and warnings. The chiller alarm condition
corresponds with the RMS “fault” condition. Thus, there are system and circuit faults. Chiller prealarm conditions correspond to the RMS “problem” designation. Reciprocating chillers do not have
warning alarms.
IOMM AGR-1
AGR 070A through 100A
65
Circuit Alarm Conditions
The “Circuit Alarm Conditions” are those alarms which only affect one circuit and can stop the
compressors of that circuit. These alarms are:
•
Compressor Motor Protection
•
High Condenser Pressure
•
Mechanical High Pressure Switch
•
Low Evaporator Pressure
•
Refrigerant Freeze Protection
•
Bad Pressure Transducer
The chiller must have the manual reset system alarm conditions cleared before normal operation can
resume. If the alarm that occurred is an auto-clearing alarm, once the condition has corrected, the
chiller will resume normal operation provided the anti-cycle timers have cleared and sufficient load
exists.
System Alarm Conditions
The “System Alarm Conditions” are those alarms that are common to both refrigeration circuits and
require all compressors to be temporarily shut off or locked out, whichever applies. The following
alarm conditions are checked continuously during all modes of operation by the controller. If one of
the following alarm conditions is detected, the mode of the controller will switch to “Off:Alarm “.
The controller disables all compressor operation by turning off all Compressor Enable Outputs.
Alarm Output #0 will be turned on to notify the operator of the alarm condition. The red “Alarm
Status” light on the front of the control panel will be solid on the alarm condition and the MicroTech
display will show the current alarm condition.
•
System alarm conditions are:
•
Loss of Water Flow
•
Bad Phase /Voltage
•
Chilled Water Freeze Protection
•
Volts Ratio Protection
•
Bad Leaving Water Sensor
The chiller must have the manual reset system alarm conditions cleared before normal operation can
resume. If the alarm which occurred is an auto-clearing alarm, once the condition has corrected, the
chiller will resume normal operation provided the anti-cycle timers have cleared and sufficient load
exists.
Sequence of Operation
Off Conditions
With power supplied to the unit, 115Vac power is applied through the control fuse F1 to the
compressor crankcase heaters (HTR1-2), the compressors motor protectors (MP1-2), the evaporator
heater and the primary of the 24v control circuit transformer. The 24V transformer provides power to
the MicroTech controller and related components. With 24V power applied, the controller will check
the position of the front panel System Switch. If the switch is in the “stop” position the chiller will
remain off and the display will indicate the operating mode to be OFF:System Sw. The controller will
then check the PumpDown Switches. If either switch is n the “stop” position, that circuit’s operating
mode will be displayed as OFF:PumpDownSw. If the remote Start/Stop Switch is open, the chiller
will be OFF:Remote Sw. The chiller may also be commanded off via the communications network if
a separate System Master Panel is installed. The display will show OFF:Remote Comm if this
operating mode is in effect.
If an alarm condition exists which prevents normal operation of both refrigerant circuits, the chiller
will be disabled and the display will indicate OFF:Alarm.
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Assuming none of the above “OFF” conditions are true, the controller will examine the internal time
clock schedule to determine if the chiller should start. The operating mode will be OFF:TimeClock if
the time schedule indicates an “OFF” time period.
Start - Up
If none of the “OFF” conditions are true, the controller will initiate a start sequence. The chilled
water pump relay output is energized any time the chiller is enabled and the chiller will remain in the
“Waiting For Flow” mode until the field installed flow switch indicates the presence of chilled water
flow. If flow is not proven within 30 seconds, the alarm “Loss of Water Flow” will be activated and
the chiller will continue to wait for proof of chilled water flow. Once flow is established, the alarm
will automatically be cleared and the unit will go into the “Wait For Load” mode.
Once flow is established, the controller will sample the leaving water temperature and compare it
against the leaving water temperature set point, the control band, the start up delta T and the start
timers. If all values indicate a start (stage 1 cooling), the controller will start the lead circuit by
energizing that circuits liquid line solenoid valve (SV). When the circuit pressure exceeds the
LPCutIn pressure, the compressor on that circuit with the lowest starts will be started. If additional
cooling is required (stage 2 cooling), the controller will energize the lag circuit liquid line solenoid
valve (SV). When that circuit’s pressure exceeds the LPCutIn pressure, the compressor will be
started. If additional cooling is required (stage 3 cooling), the first compressor will load up. Stage 4
cooling will load up the last compressor.
When the evaporator water temperature is satisfied, the reverse will occur with the compressor with
the most run hours being unloaded first. If the chiller is operating at minimum capacity (stage 1) and
the chilled water temperature falls below the Leaving Evap Water Set Point, control band and shut
down delta T, the controller will stop the last operating compressor. The controller enters the
“Waiting For Load” mode and monitor the leaving water temperature.
Low Ambient Start
If the “LOW AMBIENT” option was selected and the out side air temperature is below 50F, the low
ambient start logic will replace the normal starting logic. The compressor with the lowest starts on
the lead circuit will start when the liquid line solenoid valve is energized. The LPCutIn will be
ignored and the refrigerant freeze protect set point will be ignored for 180 seconds to allow time for
the refrigerant pressure to build. After the 180 second time and the evaporator pressure is below the
freeze stat set point, the circuit will shut down and the alarm “LoEvapPressure” will be indicated.
The chilled water freeze alarm set point is enforced during low ambient starts and will shut down the
chiller if a water freeze conditions is detected. During the low ambient start period, the evaporator
pressure is monitored and if the evap pressure drops to 2 psi for more than 20 seconds, the chiller will
shut off and a “LoEvap Pressure” alarm will be generated. This protects the compressor from
operating in a vacuum during start-up because of loss of refrigerant charge.
Pumpdown
As the system chilled water requirements diminish, the controller will stage down the compressors.
As the system load continues to drop, the liquid line solenoid valve will be de-energize and the
refrigerant circuit will go through a pump down sequence. As the evaporator pressure falls below the
LPCutOut set point, the compressor and condenser fan will stop. The evaporator pump output relay
will remain energized and the unit status will indicate “Waiting For Load”.
IOMM AGR-1
AGR 070A through 100A
67
Start-Up and Shutdown
Pre-Start Checkout
Configuration default set points are entered at the factory and all values must be checked and reset for
each installation. Make sure the field wiring for all flow switches, interlocks or jumpers matches the
connections detailed on the field wiring drawing.
Setting of the HEX Address Switches
The controller HEX address switches for each unit determine its logical address in a MicroTech
network or in an Open Protocol network. If the chiller is not connected to a RS485 communications
loop, set the address switches as follows: Hi=0; Lo=1.
Network addresses are pre-assigned and will be located in the installation instructions for the
particular network panel.
Control Switches
Before applying power to the unit, verify that the Unit System Switch is in the stop position and that
each Circuit Switch is in the Pumpdown and Stop position. It an optional Remote Start / Stop input is
installed, it should be in the start position.
Ribbon Cables
Check the ribbon cables that connect the keypad, ADI board and output board to the controller. They
should be fully seated with the locking tabs engaged.
Powering the MicroTech Controller
There are three status LEDs located on the model 250 controller which will indicate the controller’s
operating condition. When power is first applied to the control panel through the circuit breaker
(CB), the red RESET LED will illuminate for approximately 3 seconds. During this time, the
controller is checking the control software and performing internal hardware tests. When these tests
are completed, the RESET LED will turn off and the green RUNNING LED will illuminate indicating
the controller’s circuitry and software are operating correctly. If the RESET LED stays on or the
RUNNING LED fails to illuminate, consult the trouble shooting section of the manual.
Any alarms showing should be cleared by pressing the alarm key then the clear key. Watch the LEDs
on the output board and ADI board to determine the operating status of the controller’s inputs and
outputs while performing the following system checks. Initially all LEDs on the output board will be
off.
Table 21, Initial Condition ADI board LEDs
DH1
DH2
0
ON
8
ON
1
OFF
9
OFF
2
ON
10
ON
3
OFF
11
OFF
4
ON
12
ON
5
OFF
13
ON
6
ON
14
** OFF
7
ON
15
ON
** Flow switch may be on if not controlled by the unit controller
Move the system switch to the Auto position. LED #5 on the ADI board will turn on. If the time
schedule is in occupied, the chilled water pump relay output board #2 will turn on.
Move both pumpdown switches to the auto position. DH1-7 and DH2-15 will turn off. The
controller will then activate one of the refrigerant circuit solenoids depending upon which is the lead
circuit (output relay #4 circuit #1or output relay #5 circuit #2). When the evaporator pressure rises
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above the LPCutIn value, a compressor on the lead circuit will start. Refer to the unit staging
schematic to determine which LED is associate to a compressor.
The controller will stage up and down to maintain the desired leaving water temperature.
Temporary Shutdown
Close both pumpdown switches. After pumpdown is completed, turn off the system switch. Open the
remote start / stop input and the evaporator pump will stop. Perform the reverse to start up after a
temporary shutdown.
Extended Shutdown
CAUTION
The operator must provide protection against water circuit freezing on all chiller units. All
water must be drained form the evaporator and associated piping and power for the cooler
heating cable should be applied via separate disconnect if freezing ambient conditions are
expected.
1.
Close the manual liquid line shut off valves. Move the circuit #1 and #2 switches to the
“Pumpdown and Stop” position. Each operating circuit will pumpdown and the compressors will
stop.
2.
After both circuits have been pumped down, open the “Remote Start / Stop’ input and the
controller will open output relay #1 to stop the evaporator pump.
3.
Move the system switch to the stop position. Turn off main power to the chiller unit and to the
chilled water pump.
4.
Tag all open electrical switches and related water valves. This will prevent premature operation
of the equipment.
5.
If the chiller will be exposed to freezing ambient temperatures, drain all water from the unit
evaporator and chilled water piping and leave power applied to the evaporator heating cable via
separate disconnect. If external water piping is heat traced, leave power on to heat tracing to
protect from freezing.
Keypad / Display
Figure 34, Keypad / Display
IOMM AGR-1
AGR 070A through 100A
69
Menu Structure (general description)
The information stored in the MicroTech controller can be accessed through the keypad using a treelike structure. This tree structure is divided into Categories, Menus and Menu Items. There are three
categories that make up the tree structure: STATUS, CONTROL, and ALARM. Each category is
divided into Menus and each Menu into Menu Items. The three categories are described below:
•
Status category - Menus and menu items in this category provide information on the MicroTech
and unit operating conditions. The entries under each menu item in this category provide
information only and are not changeable through the MicroTech keypad. Menus 1 through 12 are
Status Menus.
•
Control category - Menus and menu items in this category provide for the input of all the unit
control parameters. These include cooling and heating control, compressor control and condenser
fan control parameters as well as time schedules and alarm limits. The entries under these menu
items are changeable through the MicroTech keypad. Menu Items 13 through 23 are Control
Menus.
•
Alarm category - Menu and menu items in this category provide information regarding current
and previous alarm conditions. Menus 23 through 27 are Alarm Menus.
Display Format
The information stored in the MicroTech controller tree structure can be viewed (one menu and menu
item at a time) through a two line by sixteen character LCD display. The current MENU is shown on
the top line and the current MENU item is shown on the bottom line of the display.
MicroTech Menu Structure
1.
Status category - Where ore than one menu item entry is listed under a menu item, the list
includes all the entries that can appear in the display for the particular item. The entry that shows
in the display depends on the operating status of the unit.
2.
Control category - Where more than one menu item entry is listed under a menu item, the list
includes all the choices from which the user can select. The selected entry appears in the display.
3.
Alarm category - The entries listed include all the possible alarm messages. The display will
show the current and previous alarm conditions for each circuit.
Password Information
When changing any menu item entry, the user is prompted to enter the access password. The change
will not be allowed until the correct password is entered. The password for AGR units is always the
successive pressing of the following “ACTION” group keys:
“ENTER” “ENTER” “ENTER” “ENTER”
Once this has been done, the user can make changes to the menu item entries. After entering the
correct password, the controller will allow a 5-minute time period during which the operator may
make any necessary setpoint adjustments. Any keypad activity will reset the timer for the full 5
minutes so the password only needs to be entered once per session. After 5 minutes of inactivity, the
password access time will expire providing protection against unauthorized users.
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Keypad Key Functions
The MicroTech keypad consists of twelve pressure sensitive membrane switches (Figure 34). These
keys are used to step through, access, and manipulate the information in the MicroTech controller tree
structure. The keypad keys are divided into four groups with two or four keys in each. These groups
of keys and their functions are described below.
Category Group
The keys in this group provide quick access to strategic menus throughout the menu tree-structure.
This reduces the need to step through all the menus, one by one, in order to reach the desired menu.
Status-Pressing the “STATUS” key at any time shifts the display to Menu #1 (Unit Status) which is
the first menu of the Status category.
Control - Pressing the “CONTROL” key at any time shifts the display to Menu #13 (Control Mode)
which is the first menu of the Control category. Alarms-Pressing the “ALARMS” key at any time
shifts the display to Menu #24, (Circ 1 Current Alarm) which is the first menu of the Alarms category.
Switch - Pressing the “SWITCH” key at any time toggles the display between the current menu
(status/control) item and the related menu (control/status) item somewhere else in the tree-structure.
For example, if this key is pressed while the current menu item is Menu Item 4A (Leaving
Evaporator=), the display shifts to Menu #14 (Leaving Evaporator Set Point=). This provides for easy
review of actual versus set point values. Tables 7, 8 and 9 include a listing of all the currently
supported switching functions.
Menu Group
The keys in this group are for stepping from menu to menu in the menu tree-structure. Prev. - Pressing
“PREV.” shifts the display to the previous menu. Note: When Menu #I is currently in the display (the
first menu in the menu tree-structure), pressing “PREV.” causes an “end of menus” message to appear
in the display. Pressing “PREV.” again causes the display to wrap around to Menu #27 (the last menu
in the tree-structure). Next- Pressing “NEXT” shifts the display to the next menu.
Note: When Menu #27 is currently in the display (the last menu in the menu tree-structure), pressing
“NEXT” causes and “end of menus” message to appear in the display. Pressing “NEXT” again
causes the display to wrap around to Menu #1 (the first menu in the menu tree structure).
Item Group
The keys in this group are for stepping from item to item within a menu. Prev. - Pressing “PREV.”
shifts the display to the previous item in a menu. Note: When the first item in a menu is currently in
the display, pressing “PREV.” causing an “end of items” message to appear in the display pressing
“PREV.” Again causes the display to wrap around to the last item in the menu.
Next - Pressing “NEXT” shifts the display to the next item in a menu. Note: When the last item in a
menu is currently in the display, pressing “NEXT” causes an “end of items” message to appear in the
display. Pressing “NEXT” again causes the display to wrap around to the first item in the menu.
Action Group
The keys in this group are for making changes to unit control parameters or for clearing alarm
conditions.
Note: Before a change to a parameter can be made or before an alarm can be cleared, the
display prompts the user with an “Enter Password” message. At this point, the password
must be entered before the user can continue with the action.
“EN T E R” “EN T E R” “EN T E R” “EN T E R”
Incr - When changing the value of a menu item entry, pressing “INCR. +” shifts the menu item display
line to the next higher or next available selection.
IOMM AGR-1
AGR 070A through 100A
71
Decr. - When changing the value of a menu item entry, pressing “DECR. -” shifts the menu item
display line to the next lower value or previous available selection.
Enter - Once a change has been made to a desired value, pressing “ENTER” locks in the new value.
Clear - Pressing “ALARMS” followed by “CLEAR” clears the current alarm. Also, when a change is
made to a menu item pressing “CLEAR” returns the display to the original value as long as “ENTER”
has not been pressed.
Note: The cause of an alarm should always be determined and corrected before resetting the alarm
through the keypad.
Example of Keypad Operation -As an example of using the keypad key functions, consider
reprogramming the Leaving Evaporator Set Point from 44°F to 42°F. This consists of changing the
Menu Item 148 (Leaving Evaporator Set Point) entry from “44°F to 42°F”. Assume Menu #I (Unit
Status) is currently in the display. The following key sequence is followed.
1.
Press the “CATEGORY” group “CONTROL” key one time. This switches the display to Menu
#I13 (the first menu in the “CONTROL” category).
2.
Press the “MENU” group “NEXT” key once. This shifts the display to Menu Item 14A (Active
Set Point).
3.
Press the “ITEM” group “NEXT’ key once. This shifts the display to Menu Item 14B. (Leaving
Evaporator setpoint).
4.
Press the “ACTION” group ‘DEC -” key one time. This prompts the user to enter the password.
“ENTER” “EN T E R” “EN T E R” “EN T E R”
5.
After the “Password Verified” message, press the “ACTION” group “DEC -” key four times. This
changes the menu item entry to 42°F.
6.
Press the “ACTION” group “ENTER” key one time. This stores the new entry into the
MicroTech controller memory.
7.
Pressing the “CATEGORY” group “STATUS” key then shifts the display back to Menu #I.
Menu Descriptions
Status Menus
Menus 1 through 12 provide chiller operating information and display of sensor readings. The items
listed under these status menus are affected by the settings under the associated control menus and are
not directly adjusted via the keypad.
Menu #l: Unit Status—The unit operating status is displayed as item 1 within this menu. The second
item is the number of seconds remaining in the unit interstage timer. The third item displays the user
chosen unit operation of chiller or Templifier (heat pump). Option chosen on Menu 23.
Menu #2: Circuit #l Status—The current operating condition of refrigerant circuit #l is displayed
whenever this menu is selected. There is only one item displayed in this menu.
Menu #3: Circuit #2 Status—The current operating condition of refrigerant circuit #2 is displayed
whenever this menu is selected. There is only one item displayed in this menu.
Menu #4: Water Temperatures—The evaporator leaving water temperature is displayed under item #l
under this menu. Additional items under this menu display the evaporator entering water temperature
as well as the entering and leaving condenser temperatures if these optional sensors have been
installed on the unit.
Menu #5: Circuit #l Pressures—The circuit #l evaporator and condenser refrigerant pressure readings
are displayed under this menu. The calculated minimum and maximum condenser pressure values are
also shown.
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Menu #6: Circuit 62 Pressures—The circuit #2 evaporator and condenser refrigerant pressure
readings are displayed under this menu. The calculated minimum and maximum condenser pressure
values are also shown.
Menu #7: Circuit #l Temperatures—The circuit #I refrigerant temperatures are calculated from their
corresponding pressure sensors and displayed here. If the optional Sensors are not present, the line
item will flash “Open”.
Menu #8: Circuit #2 Temperatures—The circuit #2 refrigerant temperatures are calculated from their
corresponding pressure sensors and displayed here. If the optional sensors are not present, the line
item will flash “Open”.
Menu#9: Chiller Amps—Displays the present amp draw of the chiller expressed as a percentage of
the unit rated load amps under full load conditions (optional feature).
Menu #10: Compressor Run Hours—The total run hours for each compressor is available under this
menu.
Menu #11: Compressor Starts—The total number of starts for each compressor is available under this
menu.
Menu#12: Air Temperature—Displays the current outdoor air temperature if the optional OAT sensor
is installed on the air cooled chiller and “Lcl” is selected from Menu 23. Also displayed here is the
air temperature received from a network if the “Rmt” OAT select option from Menu 23 is selected.
Control Menus
Menus 13 through 23 are the set point menus. All adjustable control parameters and set points, time
schedules, control options, and alarm thresholds are accessed through these menus.
CAUTION
Any changes to these parameters must be determined and implemented by qualified
personnel with a thorough understanding of how these parameters affect the operation of the
unit. Negligent or improper adjustment of these controls may result in damage to the unit or
personal injury.
Menu #13: Control Mode—One of several automatic and manual operating modes may be selected
from within this menu. Typically, the selected control mode will be Automatic which will allow the
MicroTech controller to handle all compressor and condenser fan staging. Refrigerant circuit #2 may
be locked off while still allowing circuit #1 to stage automatically by selecting AutoCir#1 -Off#2 as
the operating mode. OffCirc#1 -Auto#2 allows the normal staging of refrigerant circuit #2 but circuit
#1 is locked off. Select Manual Staging if manual control is desired. In this operating mode, the
condenser fans are controlled by the MicroTech but the number of stages is determined manually via
the keypad. If manual staging is selected, the second item under this menu indicates the number of
active cooling stages. Use the INCR or DECR keys to increase or decrease the number of active
stages.
Menu#14: Leaving Water Set Points—The leaving water set points, control band, maximum pull
down rate and water reset options are adjusted from this menu. The first menu item is The Active Set
Point ("Active Spt"). The current control temperature is displayed here. The Leaving Chilled Water
Set Point ("Lvg Evap") appears towards the top of this menu. These are the set points that will be
maintained for chillers if no reset options are in effect. The Active Control Set Point ("Active Spt")
will display the calculated chilled or heated water temperature to be maintained when one of the reset
options is enabled.
IOMM AGR-1
AGR 070A through 100A
73
If the 4-20 milliamp reset option is enabled, the controller will reset the leaving chilled water
temperature to a higher value based on a percentage of the Maximum Chilled Water Reset set point
("MaxChWRst"). At 4mA or less, no reset will occur. At 20mA, the chilled water set point will be
reset to a value equaling the Leaving Evaporator Water Set Point ("Lvg Evap") plus the value stored
in the "MaxChWRst". Any milliamp value between 4 and 20mA will cause a proportional value of the
Maximum Chilled Water Reset to be added to the Leaving Chilled Water Set Point. The external 4-20
milliamp control signal and current reset set point will be displayed under "Reset Sig" and "Active
Spt", respectively, on Menu 14.
By selecting Return as the reset mode, the leaving chilled water temperature will be reset by the
controller as required to maintain a constant return water temperature. The user must select the
"Return" option under "ResetOpt" and select the return set point to be maintained under "ResetSpt".
The current leaving chilled water reset set point will be displayed under "Active Spt".
If the chiller is to be used for ice storage, select the "Ice" option in Menu 14 "LvgWater Spt",
"ResetOpt=". To calculate the leaving chilled water set point, the control band (Menu 14
"CntrlBand=") and shut down delta-T (Menu 14 ShutDn D-T=") must first be selected. The equation
to determine leaving chilled water temperature is:
Lvg Evap = Desired Ice Temp + ½ "CntrlBand =" + " ShutDn D - T ="
Lvg Evap = 21°F + ½ (4) + 1.5°F
Lvg Evap = 21 + 2 + 1.5
Lvg Evap = 24.5
For day operation the maximum chilled water reset (Menu 14 "MaxChWRst=") is added to the "Lvg
Evap" as calculated above to reach the desired day operating leaving chilled water temperature.
When the Ice option is selected, the resetting of the leaving chilled water set point (during day
operation) via the 4-20mA input is not a functional option. To retain the option, the set points in Menu
14 must be changed by a Building Automation System through our MicroTech Open Protocol
Monitor Software.
The "Network" reset option allows a signal to be sent reflecting 0-100% reset of the "Lvg Evap" set
point (chillers) or "Lvg Cond" set point (THRs) based on the Maximum Chilled Water Reset set
point. This function acts much like the 4-20 milliamp reset option as described above.
The Maximum Pull Down Rate set point ("MaxPullDn") will prevent overshooting the active water
set point during initial start-up and normal operation. The controller will limit the rate at which the
chilled water loop temperature is reduced based on an adjustable set point (default of 0.5°F/min).
Every minute, the controller checks the leaving water temperature and compares it to the last reading.
If the pull rate has been exceeded, the controller will delay additional unit stages.
The Control Band ("CntrlBand") set point defines the temperature range on either side of the active
water set point that must be exceeded in order for a stage up or stage down to occur. The Start Up
Delta-T ("StartUpD-T") and Shut Down Delta-T ("ShutDn D-T") define when the unit will start and
shut down. The unit will cycle on from a shut down mode once the leaving chilled water temperature
has reached the Leaving Chilled Water Set Point plus half of the Control Band plus the Start Up
Delta-T. After the chiller starts, it will stage up and down according to the leaving chilled water
temperature (plus or minus) half the Control Band. Once the load is met and the chiller has staged
down to stage 1, the unit will shut completely off once the leaving chilled water temperature has
reached the Leaving Chilled Water Set Point minus half of the Control Band minus the Shut Down
Delta-T.
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AGR 070A through 100A
IOMM AGR-1
Figure 35, Delta-T Setpoints for Chillers
Menu #15: Softload Set Points—The controller can limit the number of available stages when the
unit is initially started to prevent excessive power consumption and help control overshoot of the
water temperature set point. The maximum number of stages will equal the Soft Load Maximum
Stages for the time period defined in the softload timer set point. If the softload timer is set to zero, no
soft loading will take place. Any time remaining in the softload timer will be displayed when the soft
load option is enabled. During morning start-up, the controller will run the chilled water pump and
sample the loop water temperature for a time equal to the Load Delay set point. If cooling or heating
is required at the end of this time delay, the first compressor will be started.
Menu #16: Compressor Set Points—This menu is used to set the lead-lag order of the refrigerant
circuits. The lead compressor may be manually set to circuit #1 or circuit #2 or the Automatic mode
may be enabled. In Automatic mode, the MicroTech controller will select the refrigerant circuit with
the lowest number starts as the lead. The interstage timer set point sets the delay time between the
current cooling stage and the next stage up request. The stage down request time delay is a fixed ratio
of the stage up delay.
The minimum Start/Start and Stop/Start timers provide protection against compressor short cycling.
During normal operation the Compressor Interstage Timers provide a time delay between cooling or
heating stages.
Menu #17: Head Pressure Set Points—The set points for head pressure control are adjusted from
within this menu. The Minimum Lift Pressure is the minimum differential pressure to be maintained
across the expansion valve. The dead band defines the pressure differential range within which no fan
staging will occur. If the head pressure moves outside of the deadband, the controller will integrate
the pressure error over time. When the Pound/Second exceeds the Stage Up Error or Stage Down
Error set point, the controller will adjust the fan staging up or down to bring the head pressure back
within the deadband. Refer to the section on head pressure control in this manual for details.
Menu #18: Demand Limit—The Demand Limit set point defines the maximum number of cooling
stages allowed by an external demand limit signal. The actual remote demand limit signal level in
milliamps is also displayed here.
In place of demand limit input, a 0 or 5 volts signal from a unit switch open or cool (5 volts - switch
closed) modes.
Menu #19: Time/Date—The MicroTech controller uses an internal calendar and clock to provide
automatic operation for each day of the year. Provision is made for Manual Override to accommodate
unscheduled building occupancy. Press the Control key to enter the control area of the menu structure
then press the Next Menu key until the display shows Menu Item #24, Set Date/Time. If the date is
incorrect, press the Incr or Decr key and the controller will prompt you for your password. When you
have entered the correct password, the controller will return to the Set Date/ Time display. Press the
Incr or Decr keys to reciprocating the month up or down. Press the Enter key when the display shows
the correct month. The cursor will advance to the Date position on the display that can be set in the
same manner. After pressing the Enter key to set the Date, the cursor will advance to the Year position
on the display. Use the Incr, Decr, and Enter keys to set the correct Year.
IOMM AGR-1
AGR 070A through 100A
75
Press the Next Item key. The display will show the current Day, Hour, Minute and Second. If this
information needs to be changed, follow the same procedure used to set the Date in the previous
section.
Menu #20: Daily Schedule—This section will help you to set the Daily Start/Stop time for automatic
operation of the chiller. Pressing the Next Menu key and the Next item key will advance the display to
the Daily Time Schedule. This is where the Start and Stop times for each day of the week will be set
using the 24 hour format. Beginning with Sunday, use the Incr and Decr keys to set the desired start
and stop time and press the Enter key to store the information in the controller. If the chiller is to be
programmed to run continuously 24 hours a day, set the stop tie for 1 minute before start time
(Stop=23:59; Start=00:00). Press the Next Item key to advance through the remaining week days and
Holiday Start/ Stop times.
Menu #21: Holiday Date—Up to 14 holiday dates may be entered. When the MicroTech controller's
current date matches a date set in the holiday schedule, the normal daily start/stop times are replaced
by the holiday start/stop ties which were set in the previous section. At the date prompt, use the Incr
and Decr keys to set the first holiday month and press Enter to advance to the Day position of the
display. Use the lncr, Decr and Enter keys to set the first day of the holiday. Press Next Item to
advance to Holiday 1 Duration. If the scheduled holiday spans more than one day, use the lncr and
Decr keys to set the holiday duration and press Enter to store the information in the controller. Use the
Next Item key to set additional holiday dates and duration’s for the entire year.
Menu#22: Alarm Set Points—On a call for cooling or heating, the controller will open the liquid line
solenoid valve. When the evaporator pressure rises above the Low Pressure Cutin set point, the first
compressor will be started. The Low Pressure cut out set point determines the point at which the
compressors will shut off during a pumpdown sequence. The Refrigerant Freeze and Water Freeze
alarm set points may be adjusted as required. Water and refrigerant freeze alarm time delays may also
be adjusted for this menu. If the condenser High Pressure set point is exceeded, the controller will
shut off the unit.
Menu #23: Miscellaneous Setup—Several general operating characteristics are defined here. These
are set at the factory prior to unit delivery and should not require adjustment. The control software
version number is displayed form this menu. Outdoor air temperature is displayed on Menu 12.
Alarm Menus
Menus 24 through 27 are used to display any alarm conditions that may be present in the unit. The
date and time when the alarm occurred accompany all alarm messages. Important operating
conditions at the time of the alarm are stored in the controller's memory and may be viewed within the
following alarm menus.
Menu #24: Circuit #1 Current Alarm—If refrigerant circuit # 1 is in an alarm condition, the
appropriate alarm message will be displayed here. The temperature and pressure readings at the time
of the alarm will be stored in the controller's memory and may be displayed for analysis from this
menu.
Menu #25: Circuit #2 Current Alarm—If refrigerant circuit #2 is in an alarm condition, the
appropriate alarm message will be displayed here. The temperature and pressure readings at the time
of the alarm will be stored in the controller's memory and may be displayed for analysis from this
menu.
Menu #26: Circuit #1 Previous Alarm—The alarm type for the last recorded circuit #1 alarm may be
displayed from this menu. The time and date at which the previous alarm occurred are also displayed
here. This information will be replaced when a current alarm condition is cleared.
Menu #27: Circuit #2 Previous Alarm—The alarm type for the last recorded circuit #2 alarm may be
displayed from this menu. The time and date at which the previous alarm occurred are also displayed
here. This information will be replaced when a current alarm condition is cleared.
76
AGR 070A through 100A
IOMM AGR-1
Menus for the AGR MicroTech Controller
Table 22, MENU 1 Chiller Status
Table 25, MENU 4 Water Temp's
Screen
Screen
1
2
Display
OFF: Manual Mode
OFF: System Sw
OFF: Remote Comm
OFF: Remote Sw
OFF: Time Clock
OFF: Alarm
OFF: PumpDnSw's
Starting
WaitForFlow
WaitForLoad
StageUp
StageDn
Stage
Manual
InterStg=xxx sec
1
2
3
Display
Lvg Evap= xxx.x °F (°C)
Short °F (°C)
Open °F (°C)
Ent Evap= xxx.x °F (°C)
Short °F (°C)
Open °F (°C)
D-T Evap
Short °F (°C)
Open °F (°C)
4
Table 26, MENU 5 Circ #1 Pres's
Table 23, MENU 2 Circ #1 Status
Screen
1
Display
OFF: SystemSw
OFF: ManualMde
OFF: Alarm
OFF: PumpDwnSw
OFF: CycleTime xx
OFF: Ready
PumpingDown
OpenSolenoid
% Capacity
Starting
LowAmbStart
Screen
1
2
3
4
5
6
Table 27, MENU 6 Circ #2 Pres's
Screen
Table 24, MENU 3 Circ #2 Status
Screen
1
Display
OFF: SystemSw
OFF: ManualMde
OFF: Alarm
OFF: PumpDwnSw
OFF: CycleTime xx
OFF: Ready
PumpingDown
OpenSolenoid
% Capacity
Starting
Display
Evap= xxx.x psi(kPa) xx°F (°C)
Evap 145 +psi(kPa) **°F (°C)
Open N/A ** °F (°C)
Short N/A **F
Cond xxx.x psi (kPa) xxx°
Cond 450+ psi (kPa) xxx°
Open N/A ** °F (°C)
Short N/A **F
MinCondPr = 0#
MaxCondPr = 0#
LiftD_P= psi
Cond Fan Stage = x
1
2
3
4
5
6
Display
Evap= xxx.x psi(kPa) xx°F (°C)
Evap 145 +psi(kPa) **°F (°C)
Open N/A ** °F (°C)
Short N/A **F
Cond xxx.x psi (kPa) xxx°
Cond 450+ psi (kPa) xxx°
Open N/A ** °F (°C)
Short N/A **F
MinCondPr = 0#
MaxCondPr = 0#
LiftD_P= psi
Cond Fan Stage = x
LowAmbStart
IOMM AGR-1
AGR 070A through 100A
77
Table 28, MENU 7 Circ #1 Temp's
Table 30, MENU 9 Chiller Amps
Screen
Screen
1
1
2
3
4
5
6
7
Display
Satur Evap=xxx°F (°C)
N/A **°F (°C)
SuctLine = xxx.x°F (°C)
Open °F (°C)
Short °F (°C)
Super Ht =xxx.x°F (°C)
N/A ** °F (°C)
Satur Cond = xxx°F (°C)
N/A **°F (°C)
Liquid Ln = xxx.x°F (°C)
N/A ** °F (°C)
SubCoolg= xxx.x°F (°C)
N/A ** °F (°C)
CondD-T °F (°C)
Display
PercentRLA=xxx%
Table 31, MENU 10 Comp RunHours
Screen
1
2
3
4
5
6
7
8
9
10
Display
Comp #1 =xxxxxx
Comp #2=xxxxxx
Table 29, MENU 8 Circ #2 Temp's
Screen
1
2
3
4
5
6
7
78
Display
Satur Evap=xxx°F (°C)
N/A **°F (°C)
SuctLine = xxx.x°F (°C)
Open °F (°C)
Short
Super Ht =xxx.x°F (°C)
N/A ** °F (°C)
Satur Cond = xxx°F (°C)
N/A **°F (°C)
Liquid Ln = xxx.x°F (°C)
N/A ** °F (°C)
SubCoolg= xxx.x°F (°C)
N/A ** °F (°C)
CondD-T °F (°C)
AGR 070A through 100A
Table 32, MENU 11 Compr Starts
Screen
1
2
3
4
Display
Comp #1 =xxxxxx
Comp #2=xxxxxx
Table 33, MENU 12 Air Temp
Screen
1
Display
OutDoor = xxx.x °F( °C)
IOMM AGR-1
Table 34, MENU 13 Control Mode
Screen
Display
Factory Setpoint
1
Manual Unit Off
Automatic
Manual Staging
Manual Unit Off
2
Manual Stage=xx
0
Range
1-8
Table 35, MENU 14 Lvg Evap Spts
Values for R-22 refrigerant, ( ) indicates Centigrade values
Screen
Display
Factory Setpoint
1
Actv Spt=xxx.x °F (°C)
2
Lvg Evap=xxx.x °F (°C)
44 (6.7)
3
CntrlBand x.x °F (°C)
3.0 (1.6)
4
StartUpD-T= x.x °F (°C)
3.0 (1.6)
5
ShutDn D-T= x.x °F (°C)
1.5 (0.8)
6
MaxPullDn= x.x °F (°C)
0.5 (0.2)
ResetOpt=None
Return
7
4-20 Ma
None
Network
Ice
8
ResetSig= xx.xma
9
MaxChWRst=xx.x °F (°C)
10.0 (5.5)
10
ReturnSpt= xx.x °F (°C)
54.0 (12.3)
[ ] the minus sign is not displayed with three digit numbers
Range
Not Changeable
10 - 80 (-12.2 - 26.7)
1.0 - 5.0 (0.5 - 2.7)
1.0 - 5.0 (0.5 - 2.7)
0.0 - 3.0 (0.0 - 1.6)
0.1 - 1.0 (0.0 - 0.5)
Not Changeable
0.0 - 45.0 (0.0 - 25.0)
15.0 - 80.0 (-9.4 - 26.7)
Table 36, MENU 14 Lvg Evap Spts
Values for 134a refrigerant, ( ) indicates Centigrade values
Screen
Display
Factory Setpoint
1
Actv Spt=xxx.x °F (°C)
2
Lvg Evap=xxx.x °F (°C)
44 (6.7)
3
CntrlBand x.x °F (°C)
3.0 (1.6)
4
StartUpD-T= x.x °F (°C)
3.0 (1.6)
5
ShutDn D-T= x.x °F (°C)
1.5 (0.8)
6
MaxPullDn= x.x °F (°C)
0.5 (0.2)
ResetOpt=None
Return
7
4-40 Ma
None
Network
Ice
8
ResetSig= xx.xma
9
MaxChWRst=xx.x °F (°C)
10.0 (5.5)
10
ReturnSpt= xx.x °F (°C)
54.0 (12.3)
[ ] the minus sign is not displayed with three digit numbers
IOMM AGR-1
AGR 070A through 100A
Range
Not Changeable
10 - 80 (-6.6 - 26.7)
1.0 - 5.0 (0.5 - 2.7)
1.0 - 5.0 (0.5 - 2.7)
0.0 - 3.0 (0.0 - 1.6)
0.1 - 1.0 (0.0 - 0.5)
Not Changeable
0.0 - 45.0 (0.0 - 25.0)
15.0 - 80.0 (-9.4 - 26.7)
79
Table 37, MENU 15 SoftLoad Spts
Screen
1
2
3
4
Display
Time Left= xxmin
SoftLoad= xx min
SoftLdMaxStg= x
LoadDelay= xxsec
Factory Setpoint
Range
20
4
15
0 - 254
1-4
0 - 254
Range
1234
1432
2143
2341
3214
3412
4123
4321
Table 38, MENU 16 CompressorSpt
Screen
Display
Factory Setpoint
1
Sequence=Auto
Auto
2
3
4
5
StageUp= xxx sec
StageDn= xxx sec
MinST-ST=xx min
MinSP-ST xx min
Comp #1
Comp #2
15
5
5 - 40
3 - 30
Disable / Enable
Disable / Enable
Table 39, MENU 17 Head Pres Spt
Values for R-22 refrigerant, ( ) indicates Centigrade values
Screen
Display
Factory Setpoint
1
2
MinLift 50%=xxx
80 (552)
3
MinLift100%=xxx
140 (966)
4
DeadBandMult= x.x
1.0
5
StageUpErr= xxx
400 (2760)
6
StageDnErr = xxx
100 (690)
Range
70 - 100 (483 - 690)
100 - 140 (690 - 966)
.8 - 1.3
300 - 990 (2070 - 6830)
50 - 400 (340 - 2760)
Table 40, MENU 17 Head Pres Spt
Values for 134a refrigerant, ( ) indicates Centigrade values
Screen
Display
Factory Setpoint
2
3
4
5
6
MinLift 50%=xxx
MinLift100%=xxx
DeadBandMult= x.x
StageUpErr= xxx
StageDnErr = xxx
Range
56 (386)
90 (621)
1.0
400 (2760)
100 (690)
50 - 80 (345 - 552)
80 - 122 (552 - 841)
.8 - 1.3
300 - 990 (2070 - 6830)
50 - 400 (340 - 2760)
Factory Setpoint
3
Actual Value
Range
Not Changeable at this screen
Indicates the Magnitude of the
Demand Limit Signal
Factory Setpoint
Range
Actual Time
Actual Day and Date
Table 41, MENU 18 Demand Limits
Screen
1
2
Display
Demand Lim= xstg
DemandSg= xx.x ma
Table 42, MENU 19 Time / Date
Screen
1
2
80
Display
Time= xx:xx:xx
Mon xx/xx/xx
AGR 070A through 100A
IOMM AGR-1
Table 43, MENU 20 Schedule
Screen
1
2
3
4
5
6
7
8
9
10
Display
Override= xx.xx hr
NMPSchedule= N/A
Sun 00:00-23:59
Mon 00:00-23:59
Tue 00:00-23:59
Wed 00:00-23:59
Thu 00:00-23:59
Fri 00:00-23:59
Sat 00:00-23:59
Hol 00:00-23:59
Factory Setpoint
0.00 Hr
N/A
00:00 - 23:59
00:00 - 23:59
00:00 - 23:59
00:00 - 23:59
00:00 - 23:59
00:00 - 23:59
00:00 - 23:59
00:00 - 23:59
Range
00:00 - 63.50
00:00 - 23:59
00:00 - 23:59
00:00 - 23:59
00:00 - 23:59
00:00 - 23:59
00:00 - 23:59
00:00 - 23:59
00:00 - 23:59
Table 44, MENU 21 Holiday Date
Screen
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Display
#1 Date = N/A 0
#1 Dur = 0 Day(s)
#2 Date = N/A 0
#2 Dur = 0 Day(s)
#3 Date = N/A 0
#3 Dur = 0 Day(s)
#4 Date = N/A 0
#4 Dur = 0 Day(s)
#5 Date = N/A 0
#5 Dur = 0 Day(s)
#6 Date = N/A 0
#6 Dur = 0 Day(s)
#7 Date = N/A 0
#7 Dur = 0 Day(s)
#8 Date = N/A 0
#8 Dur = 0 Day(s)
#9 Date = N/A 0
#9 Dur = 0 Day(s)
#10 Date = N/A 0
#10 Dur = 0 Day(s)
#11 Date = N/A 0
#11 Dur = 0 Day(s)
#12 Date = N/A 0
#12 Dur = 0 Day(s)
#13 Date = N/A 0
#13 Dur = 0 Day(s)
#14 Date = N/A 0
#14 Dur = 0 Day(s)
Factory Setpoint
N/A 0
0
N/A 0
0
N/A 0
0
N/A 0
0
N/A 0
0
N/A 0
0
N/A 0
0
N/A 0
0
N/A 0
0
N/A 0
0
N/A 0
0
N/A 0
0
N/A 0
0
N/A 0
0
Range
Jan - Dec 1 - 31
0 - 31
Jan - Dec 1 - 31
0 - 31
Jan - Dec 1 - 31
0 - 31
Jan - Dec 1 - 31
0 - 31
Jan - Dec 1 - 31
0 - 31
Jan - Dec 1 - 31
0 - 31
Jan - Dec 1 - 31
0 - 31
Jan - Dec 1 - 31
0 - 31
Jan - Dec 1 - 31
0 - 31
Jan - Dec 1 - 31
0 - 31
Jan - Dec 1 - 31
0 - 31
Jan - Dec 1 - 31
0 - 31
Jan - Dec 1 - 31
0 - 31
Jan - Dec 1 - 31
0 - 31
Table 45, MENU 22 Alarm Spts
Values for R-22 refrigerant, ( ) indicates Centigrade values
Screen
Display
Factory Setpoint
1
StpPumpDn =xxpsi (kPa)
34 (234)
2
FullPumpDown= No
No
3
FreezStat= xxpsi (kPa)
54 (372)
4
FreezH2°= xx.x °F (°C)
36.0 (2.3)
5
FreezeTim= xxx sec
6
Hi Press = xxxpsi (kPa)
380 (2622)
Range
2 - 54 (13 - 372)
No - yes
20 - 60 (138 - 414)
0.0 - 40.0 (-17.5 - 4.5)
280 - 426 (1932 - 2939)
Table 46, MENU 22 Alarm Spts
Values for 134a refrigerant, ( ) indicates Centigrade values
Screen
Display
Factory Setpoint
1
StpPumpDn =xxpsi (kPa)
14 (96)
2
FullPumpDown= No
No
3
FreezStat= xxpsi (kPa)
26 (179)
4
FreezH2O= xx.x °F (°C)
36.0 (2.3)
5
FreezeTim= xxx sec
6
Hi Press = xxxpsi (kPa)
380 (2622)
IOMM AGR-1
AGR 070A through 100A
Range
2 - 22 (13 - 151)
No - yes
4 - 26 (27 - 179)
0.0 - 40.0 (-17.5 - 4.5)
280 - 426 (1932 - 2939)
81
Table 47, MENU 23 Misc Setup
Screen
Display
Unit Type= Air Cooled
Factory Setpoint
Range
2
Units = English
English
English - Metric
4
5
6
SpeedTrol = No
Power = 60 hz
Port A Baud=xxxx
Pre-Alarm=Blink
Open
Closed
Alarm=Closed
Blink(N/O)
Blink(N/C)
OAT Select=None
Lcl
Rmt
LvgEvpAdj= 0.0 °F(°C)
EntEvpAdj= 0.0 °F(°C)
#1EvpAdj= 0.0psi (kPa)
#2EvpAdj= 0.0psi (kPa)
#1CndAdj= 0.0psi (kPa)
#2CndAdj= 0.0psi (kPa)
Refrigerant= R22
No
60
9600
Blink
No - Yes
60 - 50
9600 - 2400 - 1200
Blink - Open - Closed
Closed
Closed - Blink(N/O) - Blink(N/C)
None
None - Lcl - Rmt
1
7
8
9
10
11
12
13
14
15
16
17
82
-0.8 - 0.8 (-0.4 - 0.5)
-0.8 - 0.8 (-0.4 - 0.5)
(-13.8 - 13.8)
(-13.8 - 13.8)
(-13.8 - 13.8)
(-13.8 - 13.8)
Not Changeable
Not Changeable
Table 48, MENU 24 #1 Curr Alarm
Table 50, MENU 26 #1 PrevAlarm
Screen
1
2
3
4
5
6
7
8
9
10
Screen
1
2
3
4
5
6
7
8
9
10
Display
Current Alarm
@ 0:00 0/00/00
Evap = x.x psi (kPa)
Cond = x.x psi (kPa)
SuctLine=xxx.x °F(°C)
LiquidLn=xxx.x °F(°C)
Evap Lvg=xxx.x °F(°C)
OAT=xx.xx°F(°C)
Capacity= xxx%
Fan Stage = x
Display
1 Current Alarm
1 x:xx x/xx/xx
2 Current Alarm
2 x:xx x/xx/xx
3 Current Alarm
3 x:xx x/xx/xx
4 Current Alarm
4 x:xx x/xx/xx
5 Current Alarm
5 x:xx x/xx/xx
Table 49, MENU 25 #2 Curr Alarm
Table 51, MENU 27 #2 PrevAlarm
Screen
1
2
3
4
5
6
7
8
9
10
Screen
1
2
3
4
5
6
7
8
9
10
Display
Current Alarm
@ 0:00 0/00/00
Evap = x.x psi (kPa)
Cond = x.x psi (kPa)
SuctLine=xxx.x °F(°C)
LiquidLn=xxx.x °F(°C)
Evap Lvg=xxx.x °F(°C)
OAT=xx.xx°F(°C)
Capacity= xxx%
Fan Stage = x
AGR 070A through 100A
Display
1 Current Alarm
1 x:xx x/xx/xx
2 Current Alarm
2 x:xx x/xx/xx
3 Current Alarm
3 x:xx x/xx/xx
4 Current Alarm
4 x:xx x/xx/xx
5 Current Alarm
5 x:xx x/xx/xx
IOMM AGR-1
Trouble Analysis for the AGR MicroTech Controller
Microprocessor Control Board
The Microprocessor Control Board (MCB) is shown in Figure 36. It contains a microprocessor that is
preprogrammed with the software required to monitor and control the chiller. The various MCB
connections and components are described below.
HI
EXPANSION BUS
LO
ADDRESS
FUSE 1
2
Hex switches
3
4
PORT A PORT B
COMMUNICATIONS
[FUSE: BUSSMAN MCR-1/4]
RUNNING
RESET
ACTIVE
DIGITAL INPUTS
KEYPAD/LCD DISPLAY
Figure 36, Microprocessor Control Board (MCB)
CPU
STATUS
OUTPUT 0
POWER IN
[18-24 VCT]
AC AC GND GND
DIGITAL OUTPUTS
ANALOG INPUTS
Microprocessor status LED's
POWER FUSES
[BUSSMAN GDC-T2A]
AUX/OUT
Digital Inputs Connection
The MCB receives digital inputs from the Analog Digital Input (ADI) board through the Digital
Inputs connector via a plug-in ribbon cable. The ADI board conditions these inputs.
Analog Inputs Connection
The MCB receives conditioned analog inputs from the ADI board through the Analog Inputs
connector via a plug-in ribbon cable. The ADI board conditions these inputs. After having been
conditioned, all analog inputs enter the MCB through the Analog Inputs port as 0–5 Vdc signals.
Digital Outputs Connection
After processing all input conditions, the MCB sends the appropriate output signals to output devices
through the Digital Outputs port via a plug-in ribbon cable.
Power In Connector
The MCB receives 18 Vac, center-tapped power from transformer T4 through the Power In connector.
This power drives all logic and communications circuitry.
Power Fuses
Two identical 2-amp fuses are located to the right of the Power In connector. These fuses are in the
MCB power supply circuit.
Microprocessor Status LEDs
The green, red, and amber LEDs on the MCB provide information about the operating status of the
microprocessor. The amber LED also indicates the existence of alarm conditions.
Following is the normal start-up sequence that the three status LED’s should follow when power is
applied to the MCB:
IOMM AGR-1
AGR 070A through 100A
83
1.
The red (“Reset”) LED turns on and remains on for approximately 5 seconds. During this period
the MCB performs a self-test.
2.
The red LED turns off and the green (“Running”) LED turns on. This indicates that the
microprocessor has passed the self-test and is functioning properly.
3.
The amber (“Active”) LED remains off continually if no alarm conditions exist in the network. If
alarm conditions exist, the amber LED will flash as shown in Table 53.
If the above sequence does not occur after power is applied to the controller, there is a problem with
the MCB or its power supply.
Table 52 and Table 53 summarize the green, red, and amber status LED indications.
Table 52, Green and Red Status LED Indication
Green
Red
LED State
LED State
Off
Off
Off
On*
On
Off
* For longer than 5 seconds.
Indication
No power to MCB
Self-test failure or power supply problem
MCB operating normally
Table 53, Amber Status LED Indication
Amber LED State
Off
On 1/2 second;
Off 1/2 second
Indication
Normal operation
Alarm condition
Keypad/LCD Display Connection
The MCB receives input commands and operating parameters from the keypad and sends requested
information to the display through the Keypad/LCD Display port via a plug-in ribbon cable.
Hex Switches
The MCB includes two hex (hexadecimal) switches that are used to set the network address.
The HI and LO hex switches are shown in Figure 37. A “hex switch setting” is defined as the HI
switch digit followed by the LO switch digit. For example, a hex switch setting of 2F would have the
HI switch set to “2” and the LO switch set to “F.”
Note: You can change the setting of a hex switch with a 3/32-inch tip slotted-blade
screwdriver. If a hex switch setting is changed, power to the MCB must be cycled in order to
enter the new setting into memory. This can be done by turning the panel’s power switch off
and then back on.
Figure 37, Hex Switches
HI (left) hex switch
LO (right) hex switch
3 4 5
3 4 5
BCDE
2
2
7 8 9A
6
BCDE
F 0 1
6
F 0 1
7 8 9A
* Hex switch setting 01 shown
84
AGR 070A through 100A
IOMM AGR-1
Communication Ports
The MCB has two communication ports: port A and port B. Each port has six terminals and is set up
for both the RS-232C and RS-485 data transmission interface standards. The male and female
connectors for these ports are manufactured by AMP. Therefore, they are referred to as “AMP plugs”
or “AMP connectors” throughout this manual. Socket fuses located next to the ports protect the
communications drivers from voltage in excess of ±12 Vdc. Following are brief descriptions of each
port’s function.
Port A: Port A is for communications with an IBM compatible PC using the RS-232C interface
standard. The PC can be directly connected, over a limited distance, with a twisted, shielded pair
cable, or it can be remotely connected via phone lines with a modem. Port A can also be used to
connect a licensed building automation system to the MicroTech network via Open Protocol. The
default communications rate is 9600 baud.
Port B: Port B is for MicroTech network communications using the RS-485 interface standard. A
twisted, shielded pair cable should be connected to port B via terminals B+, B–, and GND on
terminal block T11. The communications rate is 9600 baud.
Output Board
The Output Board (OB) accepts up to 16 digital outputs from the MCB. Each output has fused
sockets and can be used to switch AC or DC power by selecting a particular relay output module.
Screw terminals allow for field wiring connections to the output device. Each output has an onboard
LED that illuminates when an output socket that contains a relay is activated by the MCB. Following
are the Output Board’s power ratings:
•
120V ~ 50/60 Hz
•
250V ~ 50/60 Hz
Power
Above each edge card connector are field wiring terminals for 5 Vdc (regulated) and 24 Vac (ground
referenced). These terminals can be used to power peripheral devices. The 5 Vdc is also used to
power the LEDs in the Output Board.
IOMM AGR-1
AGR 070A through 100A
85
Test Procedures
Status LED Diagnostics
The MCB status LED indications can aid in controller diagnostics. If the status LEDs do not operate
normally there is a problem with the MCB. Following are troubleshooting procedures for the various
symptoms.
Red LED Remains On
If the red LED remains on after the 5-second self-test period, it is likely that the MCB is defective.
However, this can also occur in some instances if there is a power supply problem. Refer to
“Troubleshooting Power Problems” below.
Red and Green LEDs Off
If the red and green LEDs do not turn on after power is applied to the controller, there is likely a
defective component or a problem in the controller’s power distribution circuits. Refer to
“Troubleshooting Power Problems” below.
Troubleshooting Power Problems
The MCB receives 18 Vac, center-tapped power from transformer T4. It then distributes both 5 Vdc
and 13 Vdc power to various MicroTech components. A problem that exists in any of these
components can affect the MCB and thus the entire control system. Power problems can be caused by
an external short, which can blow a fuse, or a defective component, which can either blow a fuse or
create an excessive load on the power supply. An excessive load can lower the power supply voltages
to unacceptable levels. Use the following procedure to isolate the problem. Note that this procedure
may require two or three spare MCB fuses. Refer to the panel wiring diagram.
86
1.
Verify that circuit breaker CB1 is closed.
2.
Remove the MCB Power In connector and check for 9 Vac between the terminals on the plug
corresponding to terminals 2 and 3 on the board. Then check for 9 Vac between the terminals on
the plug corresponding to terminals 1 and 3 on the board. (Readings of 9–12 Vac are acceptable.)
If 9 Vac is present between both sets of terminals, go to step 3.
If 9 Vac is not present between both sets of terminals, check transformers T2 and T3 and all
wiring between the 115 Vac source and the Power In plug.
3.
Remove power from the controller by opening circuit breaker CB1. Check the MCB power
supply input fuses (F1 and F2) with an ohmmeter. A good fuse will have negligible resistance
through it (less than 2 ohms).
If either or both fuses are blown, replace them. Go to step 4.
If the fuses are intact, the MCB is defective.
4.
Reconnect the Power In connector and disconnect all other connectors on the MCB. Cycle
power to the controller (close and then open CB1) and check the power fuses.
If both fuses are intact, go to step 5.
If either fuse blows, the MCB is defective.
5.
Reconnect the keypad/display ribbon cable. Cycle power to the controller and check the power
fuses.
If both fuses are intact, go to step 6.
If either fuse blows, check the keypad/display and the connecting ribbon cable for shorts. Either
one may be defective.
AGR 070A through 100A
IOMM AGR-1
6.
Reconnect the analog input ribbon cable. Cycle power to the controller and check the power
fuses.
If both fuses are intact, go to step 7.
If either fuse blows, check the ADI board, the connecting ribbon cable, and the field wiring for
shorts. Any of these may be defective. Try repeating this step after removing or swapping the
ADI board.
7.
Reconnect the digital input ribbon cable. Cycle power to the controller and check the power
fuses.
If both fuses are intact, go to step 8.
If either fuse blows, check the ADI board, the connecting ribbon cable, and the field wiring for
shorts. Any of these may be defective. Try repeating this step after removing or swapping the
ADI board.
8.
Reconnect the digital output ribbon cable to the MCB. Cycle power to the controller and check
the power fuses.
If both fuses are intact, go to step 9.
If either fuse blows, check Output Board and the connecting ribbon cable. Either of these may be
defective.
9.
If there are any AOX-4 boards, reconnect the expansion bus ribbon cable to the MCB; otherwise,
go to step 10. Cycle power to the controller and check the power fuses.
If both fuses are intact, go to step 10.
If either fuse blows, check the analog output expansion modules (if any), the connecting ribbon
cables, and the field wiring for shorts. Any of these may be defective.
10. With circuit breaker CB1 open, measure the resistance between field terminals “DC-GRD” and
“5 Vdc.” It should be greater than 20 ohms.
If the resistance is greater than 20 ohms, go to step 11 if the controller is equipped with at least
one AOX-4 board or a modem. Otherwise, the problem is indeterminate. Obtain factory service.
If the resistance is less than 20 ohms, it is likely that the keypad/display, the Output Board or an
external (field supplied) load is excessively loading the MCB’s 5 Vdc power supply. Isolate the
problem by taking resistance measurements on each of these devices with the wiring
disconnected. The resistance across the power input terminals on the keypad/display (G and 5V)
should be close to infinite. The resistance across the power input terminals on the Output Board
(+ and –) should not be less than 3000 ohms. If the component resistance’s are proper, check the
resistance of the field supplied loads (if any) and check the wiring and connections throughout
the 5 Vdc power supply circuit.
11. Disconnect the connector plugs from the modem and the power plug from all AOX-4 boards (as
applicable). With circuit breaker CB1 open, measure the resistance between field terminals “DCGRD” and “13 Vdc.” It should be infinite.
If the resistance is infinite, go to step 12.
If the resistance is not infinite, a short exists somewhere in the 13 Vdc power supply wiring.
12. Reconnect the Aux/Out connector plug to the MCB. If there’s a modem, reconnect its AMP plug
to port A. With circuit breaker CB1 open, measure the resistance between field terminals “DCGRD” and “13 Vdc.” It should steadily rise to a value greater than 5000 ohms (within
approximately 30 seconds).
If the resistance rises above 5000 ohms, go to step 13.
If the resistance does not rise above 5000 ohms, the MCB is defective.
13. One at a time, reconnect the modem and each AOX-4 board (as applicable). Each time a
component is reconnected, measure the resistance between field terminals “DC-GRD” and “13
Vdc.” It should steadily rise to a value greater than 5000 ohms.
If the resistance rises above 5000 ohms, repeat this step until the modem and all AOX-4 boards
(as applicable) have been checked out. If the problem persists, it is indeterminate. Obtain factory
service.
If the resistance does not rise above 5000 ohms, the modem or the AOX-4 board just connected
is defective. (With the power plug disconnected, the resistance across an AOX-4 board’s “DC”
and “G” terminals should not be less than 3 million ohms.)
IOMM AGR-1
AGR 070A through 100A
87
Figure 38, MCB Power Supply Terminals
POWER IN
[18-24 VCT]
AC AC GND GND
POWER FUSES
[BUSSMAN GDC-T2A]
4
3
Fuse F1
Fuse F2
2
1
9 8 7 6 5 4 3 2 1
AUX/OUT
Troubleshooting the Keypad/Display Interface
The Keypad/Display Interface is connected to the MCB via a ribbon cable and discrete wiring for the
backlight. The MCB provides operating voltages, control signal outputs for the display, and input
conditioning for the keypad inputs.
Display is Hard to Read
The clarity of the LCD display can be affected by ambient temperature. Typically, less contrast will
result with cooler temperatures. If the display is difficult to read, adjust the contrast trim pot, which is
located on the back of the keypad/display assembly.
Display is Blank or Garbled
If the MCB appears to be functioning properly and the display is completely blank or garbled,
perform the following procedure:
88
1.
Try cycling power to the controller by opening and then closing circuit breaker CB1 (see note
below).
2.
Try adjusting the contrast trim pot, which is located on the back of the keypad/display assembly.
If the contrast trim pot has no effect, it is likely that either the keypad/display or its ribbon cable
is defective.
3.
After removing power from the controller, check the ribbon cable and connections between the
keypad/display and the MCB. Look for bent pins. Restore power after reconnecting the ribbon
cable.
4.
Try swapping a known good ribbon cable and keypad/display. Swap these components
separately to isolate the problem. Remove power from the controller before disconnecting the
suspect component, and restore power after connecting the replacement component. If the
problem persists, it is likely that the MCB is defective.
AGR 070A through 100A
IOMM AGR-1
Troubleshooting Analog Inputs
An analog input, such as a temperature sensor, is connected to the ADI board. The ADI board then
conditions the analog input. The conditioned input is transferred to the MCB via a ribbon cable.
Analog Input not Read by the MCB
If the MCB appears to be functioning properly and the analog input is not being read by the MCB,
perform the following procedure:
1.
Try cycling power to the controller by opening and then closing circuit breaker CB1.
2.
Check the ribbon cable, power wiring connector, and the field wiring connections from the
analog input device. Look for bent pins, cable on backwards, or mis-wires. Restore power after
reconnecting all cables and wires.
3.
If the problem persists, try swapping a known good ribbon cable or analog input device. Swap
these components separately to isolate the problem. Remove power from the controller before
disconnecting the suspect component, and restore power after connecting the replacement
component. If the problem persists, it is likely that the MCB is defective.
Troubleshooting Digital Inputs
A digital input device is connected to the ADI board. 24 Vac, supplied by transformer T2, is sent to
the digital input device via a supply wire. When a contact in the digital device makes, a return signal
is sent back to the ADI board. The ADI board then conditions the signal. The conditioned digital
input is then sent to the MCB via a ribbon cable.
Digital Input not Read by the MCB
If the MCB appears to be functioning properly and the digital input is not being read by the MCB,
perform the following procedure:
1.
Try cycling power to the controller by opening and then closing circuit breaker CB1.
2.
Check the ribbon cable, power wiring connector, and the field wiring connections from the digital
input device. Look for bent pins, cable on backwards, or mis-wires. Restore power after
reconnecting all cables and wires.
3.
If the problem persists, try swapping a known good ribbon cable or a digital input device. Swap
these components separately to isolate the problem. Remove power from the controller before
disconnecting the suspect component, and restore power after connecting the replacement
component. If the problem persists, it is likely that the MCB is defective.
Troubleshooting Output Boards
Each output on the Output Board consists of a solid-state relay, an LED, 5-amp fuse, and an MOV
(metal oxide varistor).
Normally, when the MCB commands an output to energize, the solid-state relay contacts will close
and the LED will glow. The contacts of each solid-state relay are in series with a 5-amp fuse. These
fuses resemble small resistors and are located on the board adjacent to the relays they serve. The
fuses are pressed into place. They can be removed with a needle nose pliers. The MOV, which is
located on the underside of the output board, protects the solid-state relay from high transient
voltages. MOVs are part of the output board and cannot be replaced.
Following are troubleshooting procedures for various symptoms of output board problems.
Note: It should be possible to determine whether a solid-state relay is defective by using
these procedures.
IOMM AGR-1
AGR 070A through 100A
89
Figure 39, Output Board Relay Socket
1
Fuse
2
*250V ~ 50/60 Hz
*120V ~ 50/60 Hz
3
Test Resistor
330-680 Ohm
4
5
LED
WARNING
Electric shock hazard. Can cause severe injury or death. Even when power to the panel is
off, solid-state relay socket terminals 1 and 2 on the output board could be connected to high
voltage. Avoid them.
One LED Out
If one of the Output Board LEDs fails to illuminate when the MCB is commanding the associated
output to energize, perform the following procedure:
1.
Remove power from the controller by opening CB1. Swap the suspect relay with a known good
relay. Try to choose a relay that will not affect unit operation. Restore power by closing CB1.
If the LED does not light, go to step 2.
If the LED lights, the suspect relay is defective.
2.
Remove power from the controller. Check the ribbon cable and connections between the OB and
the MCB. Look for bent pins.
If the cable and connections are intact, go to step 3.
3.
Remove the relay from the suspect socket. Install a 330-680 ohm resistor between terminals 3
and 5. Restore power by placing CB1 to the ON position. The LED should light regardless of
the controller’s command.
If the output LED illuminates, it is likely that the MCB is defective.
If the output LED does not illuminate, the output board is defective.
All LEDs Out
If the MCB is commanding at least two outputs to energize and none of the Output Board LEDs are
lit, perform the following procedure:
1.
90
Verify that 5 Vdc is present at the Output Board’s power terminals.
If 5 Vdc is not present, go to step 2.
If 5 Vdc is present, check the ribbon cable and connections between the output board and MCB.
Look for bent pins. If the cable and connections are intact, the Output Board or the MCB is
defective.
AGR 070A through 100A
IOMM AGR-1
2.
Remove power from the controller by placing CB1 to the OFF position. Disconnect at least one
wire from the power input terminals of the Output Board. The resistance should not be less than
3000 ohms.
If the resistance is greater than the acceptable value, go to step 3.
If the resistance is less than the acceptable value, the Output Board is defective.
3.
Check the discrete wiring and connections between the Output board and the Controller.
Aux/Out terminal strip and the field wiring terminal strip.
Note: The MCB Aux/Out connector plug terminals displace wire insulation to make contact
with the conductor. If a faulty Aux/Out connection is suspected, try pressing down on the
wire in the terminals with a small screwdriver.
LED Lit, Output not Energized
If the LED of a suspect output is lit but the load connected to it is not energized, and everything is
intact between the MCB and the coil side of the relay, perform the following procedure to isolate the
problem:
1.
Verify that 24 or 120 VAC power is present at the suspect output’s screw terminal on the Output
Board.
2.
Remove power from the controller by opening CB1. Pull the 5-amp fuse on the contact side of
the relay and check it for continuity with an ohmmeter.
If the fuse is not bad, reinstall it and go to step 3.
If the fuse is bad, replace it and inspect the load and associated wiring before restoring power.
Note that a fuse from an unused output can be substituted for the bad fuse.
3.
Remove power from the controller by opening CB1. Swap the suspect relay with a known good
relay. Try to choose a relay that will not affect unit operation. Restore power by closing CB1.
If the output load energizes, the suspect relay is bad. Replace the relay.
If the output load does not energize (when LED is lit again), check the load circuit wiring and
components.
Output Energized, LED not Lit
If the LED of a suspect output is not lit, but the load connected to it is energized, either the SolidState relay or the MOV is bad. The Solid-State relay contacts and the MOV, which are in parallel,
can both fail closed. Perform the following procedure to isolate the problem:
1.
Remove power from the controller by opening CB1. Pull the Solid-State relay from the suspect
output’s socket.
2.
Restore power by closing CB1.
If the output load remains energized when there is no relay in the socket, the output’s MOV has
failed and the Output Board must be replaced.
If the output load de-energizes, the relay that was pulled is defective.
Contact Chatter
Contact chatter is very rapid opening and closing of contacts. It is usually caused by low voltage at
the electromechanical relay or contactor coil. If contact chatter is occurring on a relay or contactor
connected to one of the Output Board Solid-State relays, it is also possible that a faulty connection
exists on the power supply terminals of the Aux/Out plug connector on the MCB. In very rare
instances, contact chatter can be caused by a faulty Solid-State relay. Perform the following
procedure to isolate the problem.
IOMM AGR-1
1.
Verify that the voltage at the load’s power supply and at the Solid-State relay contacts is
adequate.
2.
Remove power from the controller by opening CB1. Swap the suspect relay with a known good
relay. Try to choose a relay that will not affect unit operation. Restore power by closing CB1.
If the chatter does not stop, go to step 3.
If the chatter stops, the suspect relay is defective. Replace the relay.
AGR 070A through 100A
91
3.
Remove power from the controller by opening CB1. Try to improve the connections in the
Aux/Out plug insulation displacement terminals by pressing down on the wires with a small
screwdriver.
4.
Check all other wiring and connectors for bent pins or mis-wires.
If the chatter does not stop, the electromechanical relay or contactor is probably defective.
Troubleshooting Solid-State Relays
As shown on the unit wiring diagrams, the Solid-State relays on the Output Boards all have normally
open “contacts.” Actually, these contacts do not exist as they do in an electromechanical relay.
Instead of using contacts to switch the load, the Solid-State relay changes its resistance from low
(closed), when it is energized, to high (open), when it is de-energized. (This high resistance is
approximately 100K ohms.) Because the output circuit through the Solid-State relay remains
continuous regardless of whether the relay is energized, troubleshooting a Solid-State relay with a
voltmeter can be tricky.
In a typical circuit, a power source is connected across a single relay output and a load. In this circuit,
a Solid-State relay will behave like an electromechanical relay. If the relay is energized, the relay
output will be hot. If the relay is de-energized, voltage cannot be measured at the relay output.
The circuit shown in Figure 40 is similar to a typical circuit; the difference is that there is an open set
of contacts, or a disconnection between the relay output and the load. In this circuit, a Solid-State
relay will not behave like an electromechanical relay. If the Solid-State relay is energized, the relay
output will be hot (as expected). However, if the Solid-State relay is de-energized, the relay output
will still appear to be hot. This is because the relay output and the voltmeter form a continuous
circuit in which the relay’s resistance, though high, is insignificant compared to the voltmeter’s
resistance.
This means that nearly all the voltage is dropped across the voltmeter. Therefore, the voltmeter
indicates that voltage is present. If a low wattage light bulb of the appropriate voltage is used instead
of a voltmeter, the bulb’s low resistance will load the circuit enough to eliminate the false voltage
indication. In this situation, an incandescent test lamp is a better tool than a voltmeter.
Figure 40, Testing a Typical Relay Circuit
Figure 41, Testing a Relay Circuit with a Disconnection
115 VAC
115 VAC
Output Board
Output Board
DO 13
28
DO 13
27
28
27
M10
M10
Neutral
Neutral
0V
115V
92
AGR 070A through 100A
IOMM AGR-1
Unit Maintenance
General
On initial start-up and periodically during operation, it will be necessary to perform certain routine
service checks. Among these are checking the liquid line sightglasses, taking condensing and suction
pressure readings, and checking to see that the unit has normal superheat and subcooling readings. A
recommended maintenance schedule is located at the end of this section.
A Periodic Maintenance Log is located at the end of this manual. It is suggested that the log be
completed on a weekly basis preferably on a daily basis. The log will serve as a useful tool for a
service technician in the event service is required.
Compressor Maintenance
The reciprocating compressors require no routine maintenance.
Lubrication
No routine lubrication is required on AGR units. The fan motor bearings are permanently lubricated
and no further lubrication is required. Excessive fan motor bearing noise is an indication of a
potential bearing failure.
Compressor oil should be standard refrigeration mineral oil such as Suniso 3GS.
Electrical Terminals
WARNING
Electric shock hazard. Turn off all power before continuing with following service.
Tighten electrical terminals per Maintenance Schedule.
Condensers
The condensers are air-cooled and constructed of 3/8" (9.5mm) O.D. internally finned copper tubes
bonded in a staggered pattern into louvered aluminum fins. No maintenance is ordinarily required
except the routine removal of dirt and debris from the outside surface of the fins. McQuay
recommends the use of foaming coil cleaners available at most air conditioning supply outlets. Use
caution when applying such cleaners as they may contain potentially harmful chemicals. Care should
be taken not to damage the fins during cleaning.
If the service technician has reason to believe that the refrigerant circuit contains noncondensables,
purging may be required strictly following Clean Air Act regulations governing refrigerant discharge
to the atmosphere. The purge Schrader valve is located on the vertical coil header on both sides of
the unit at the control box end of the coil. Access panels are located at the end of the condenser coil
directly behind the control panel. Purge with the unit off, after shutdown of 15 minutes or longer, to
allow air to collect at the top of the coil. Restart and run the unit for a brief period. If necessary, shut
unit off and repeat the procedure. Follow accepted environmentally sound practices when removing
refrigerant from the unit.
Refrigerant Sightglass
The refrigerant sightglasses should be observed periodically. (A weekly observation should be
adequate.) A clear glass of liquid indicates that there is adequate refrigerant charge in the system to
insure proper feed through the expansion valve. Bubbling refrigerant in the sightglass, during stable
run conditions, indicates that the system may be short of refrigerant charge. Refrigerant gas flashing
in the sightglass could also indicate an excessive pressure drop in the liquid line, possibly due to a
IOMM AGR-1
AGR 070A through 100A
93
clogged filter-drier or a restriction elsewhere in the liquid line See Table 54 for maximum allowable
pressure drops. If subcooling is low add charge to clear the sightglass. If subcooling is normal (10°15°F) and flashing is visible in the sightglass check the pressure drop across the filter-drier.
Subcooling should be checked at full load with 70°F (21.1°C) outdoor air temperature and all fans
running.
An element inside the sightglass indicates the moisture condition corresponding to a given element
color. If the sightglass does not indicate a dry condition after about 12 hours of operation, the circuit
should be pumped down and the filter-drier changed.
Preventative Maintenance Schedule
PREVENTATIVE MAINTENANCE SCHEDULE
OPERATION
WEEKLY
MONTHLY
(Note 1)
General
Complete unit log and review (Note 3)
Visually inspect unit for loose or damaged components
Inspect thermal insulation for integrity
Clean and paint as required
X
X
X
X
Electrical
Check terminals for tightness, tighten as necessary
Clean control panel interior
Visually inspect components for signs of overheating
Verify compressor heater operation
Megger compressor motor every five years (Note 6)
Test and calibrate all safety and operating controls
Refrigeration
Leak test
Check sight glasses for clear flow
Check filter-drier pressure drop (see manual for spec)
ANNUAL
(Note 2)
X
X
X
X
X
X
X
X
Condenser (air-cooled)
Clean condenser coils (Note 4)
Check fan blades for tightness on shaft (Note 5)
Check fans for loose rivets and cracks
Check coil fins for damage
Notes:
X
X
X
X
1. Monthly operations include all weekly operations.
2. Annual (or spring start-up) operations includes all weekly and monthly operations.
3. Log readings may be taken daily for a higher level of unit observation.
4. Coil cleaning may be required more frequently in areas with a high level of airborne particles.
5. Be sure fan motors are electrically locked out.
6. Caution: Do not Megger motor while in a vacuum.
94
AGR 070A through 100A
IOMM AGR-1
Unit Service
CAUTION
1.
Service on this equipment is to be performed by qualified refrigeration personnel familiar with
equipment operation, maintenance, correct servicing procedures, and the safety hazards inherent
in this work. Causes for repeated tripping of safety controls must be investigated and corrected.
2.
Disconnect all power before doing any service inside the unit.
3.
Anyone servicing this equipment shall comply with the requirements set forth by the EPA in
regards to refrigerant reclamation and venting.
Filter-Driers
A replacement of the filter-drier is recommended any time excessive pressure drop is read across the
filter-drier and/or when bubbles occur in the sightglass with normal subcooling. The maximum
recommended pressure drops across the filter-drier are as follows:
Table 54, Filter-Drier Pressure Drop
PERCENT CIRCUIT
LOADING (%)
100%
75%
50%
25%
MAXIMUM RECOMMENDED PRESSURE
DROP ACROSS FILTER DRIER PSIG (kPa)
10 (69)
8 (55.2)
5 (34.5)
4 (27.6)
The filter-drier should also be changed if the moisture indicating liquid line sightglass indicates
excess moisture in the system.
During the first few months of operation the filter-drier replacement may be necessary if the pressure
drop across the filter-drier exceeds the values listed in the paragraph above. Any residual particles
from the condenser tubing, compressor and miscellaneous components are swept by the refrigerant
into the liquid line and are caught by the filter-drier.
Liquid Line Solenoid Valve
The liquid line solenoid valves that shut off refrigerant flow in the event of a power failure does not
normally require any maintenance. The solenoids may, however, require replacement of the solenoid
coil or of the entire valve assembly.
The solenoid coil can be checked to see that the stem is magnetized when energized by touching a
screwdriver to the top of the stem. If there is no magnetization either the coil is bad or there is no
power to the coil.
The solenoid coil may be removed from the valve body without opening the refrigerant piping after
pumpdown. For personal safety shut off and lock out the unit power.
The coil can then be removed from the valve body by simply removing a nut or snap-ring located at
the top of the coil. The coil can then be slipped off its mounting stud for replacement.
To replace the entire solenoid valve follow the steps involved when changing a filter-drier.
IOMM AGR-1
AGR 070A through 100A
95
Evaporator
The evaporator is the direct expansion, shell-and-tube type with refrigerant flowing through the tubes
and water flowing through the shell over the tubes. The tubes are internally finned to provide
extended surface as well as turbulent flow of refrigeration through the tubes. Normally no service
work is required on the evaporator.
Refrigerant Charging
AGR air-cooled chillers are shipped factory charged with a full operating charge of refrigerant but
there may be times that a unit must be recharged at the job site. Follow these recommendations when
field charging. Refer to the unit operating charge found in the Physical Data Tables.
Unit charging can be done at any steady load condition (preferably at 75 to 100% load) and at any
outdoor temperature (preferably higher than 70°F (21.1°C). Unit must be allowed to run 5 minutes or
longer so that the condenser fan staging is stabilized at normal operating discharge pressure. For best
results charge with two or more condenser fans operating on each refrigerant circuit.
The AGR units have a condenser coil design with approximately 15% of the coil tubes located in a
subcooler section of the coil to achieve liquid cooling to within 5°F (3°C) of the outdoor air
temperature when all condenser fans are operating. This is equal to about 15°F-20°F (8.3°C-11.1°C)
subcooling below the saturated condensing temperature when the pressure is read at the liquid valve
between the condenser coil and the liquid line filter drier. Once the subcooler is filled, extra charge
will not lower the liquid temperature and does not help system capacity or efficiency. However, a
little extra (10-15 lbs) will make the system less sensitive.
Note: As the unit changes load or fans cycle on and off, the subcooling will vary but should recover
within several minutes and should never be below 6°F (3.3°C) subcooling at any steady state
condition. Subcooling will vary somewhat with evaporator leaving water temperature and suction
superheat. As the evaporator superheat decreases the subcooling will drop slightly.
One of the following three scenarios will be experienced with an undercharged unit:
1. If the unit is slightly undercharged the unit will show bubbles in the sightglass. Recharge the unit
as described in the charging procedure below.
2. If the unit is moderately undercharged it will normally trip on freeze protection. (Freezestat trips
can also be an indication of low flow or poor heat transfer due to fouled tubes. Anti-freeze
solutions can also cause freezestat trips.) Recharge the unit as described in the charging procedure
below.
3. If the unit is severely undercharged the unit will trip due to lack of liquid flow to the expansion
valve. In this case either remove the remaining charge by means of a proper reclamation system
and recharge the unit with the proper amount of refrigerant as stamped on the unit nameplate, or
add refrigerant slowly through the suction valve on the compressor. Feed liquid into the suction
valve when the compressor is running. If the unit is severely undercharged the unit may nuisance
trip during this charging procedure. If this happens close off the refrigerant from the tank and
restart the unit. Once the unit has enough charge so that it does not trip out, continue with step 2 of
the charging procedure below.
Procedure to charge a moderately undercharged AGR unit:
1. If a unit is low on refrigerant you must first determine the cause before attempting to recharge the
unit. Locate and repair any refrigerant leak. Evidence of oil is a good indicator of leakage,
however oil may not be visible at all leaks. Liquid leak detector fluids work well to show bubbles
at medium size leaks but electronic leak detectors may be needed to locate small leaks.
2. Add the charge to the system through the suction shutoff valve or through the Schrader fitting on
the tube entering the evaporator between the compressor and the evaporator head.
96
AGR 070A through 100A
IOMM AGR-1
3. The charge can be added at any load condition between 25-100% load per circuit but at least two
fans should be operating per refrigerant circuit if possible. The suction superheat should be in the
6°F-12°F (3.3°C-6.6°C) range.
4. Add sufficient charge to clear the liquid line sightglass and until all flashing stops in the sightglass.
Add an extra 15-20 lbs. of reserve to fill the subcooler if the compressor is operating at 50-100%
load.
5. Check the unit subcooling value by reading the liquid line pressure and temperature at the liquid
line near the filter-drier. The subcooling values should be between 6°F-20°F (6.6°C-11.1°C). The
subcooling values will be highest at 75-100% load, approximately 12°F-20°F (6.6°C-11.1°C) and
lowest at 50% load, approximately 6°F-12°F (3.3°C-6.6°C).
6. With outdoor temperatures above 60°F (15.6°C) all condenser fans should be operating and the
liquid line temperature should be within 5°F-10°F (2.8°C-5.6°C) of the outdoor air temperature. At
25-50% load the liquid line temperature should be within 5°F (2.8°C) of outdoor air temperature
with all fans on. At 75-100% load the liquid line temperature should be within 10°F (5.6°C) of
outdoor air temperature with all fans on.
7. Overcharging of refrigerant will raise the compressor discharge pressure due to filling of the
condenser tubes with excess refrigerant.
IOMM AGR-1
AGR 070A through 100A
97
AGR Troubleshooting Chart
PROBLEM
1.
2.
POSSIBLE CAUSES
Main Switch.
Fuse Blown. Circuit breakers open
1.
2.
3.
Thermal overloads tripped
3.
4.
5.
Defective contactor or coil.
System Shutdown by safety devices
4.
5.
6.
7.
8.
9.
No cooling required
Liquid line solenoid will not open
Motor electrical trouble
Loose wiring
6.
7.
8.
9.
POSSIBLE CORRECTIVE STEPS
Close Switch.
Check electrical circuits and motor windings for shorts or
grounds. Investigate for possible overloading. Replace fuse or
reset breakers after fault is corrected. Check for loose or
corroded connections.
Overloads are auto-reset Check unit closely when unit comes
back on line. Allow time for auto-reset.
Repair or replace
Determine type and cause of shutdown and correct it before
resetting safety switch
None. Wait until unit calls for cooling
Repair or replace solenoid coil. Check wiring
Check motor for opens, shorts, or burnout
Check all wire junctions. Tighten all terminal screws
Compressor noisy or
vibrating
1.
2.
3.
4.
Compressor running in reverse
Improper piping support on suction or discharge
Worn compressor isolator bushing
Worn Compressor
1.
2.
3.
4.
Check unit and compressor for correct phasing
Relocate, add, or remove hangers
Replace
Replace
High Discharge
Pressure
1.
2.
3.
4.
5.
6.
Noncondensables in system
System overcharged with refrigerant
Discharge shutoff valve partially closed
FanTrol wiring not correct
Fan not running
Dirty condenser coil
1.
2.
3.
4.
5.
6.
Purge the noncondensables
Remove excess, check liquid subcooling
Open valve
Check FanTrol wiring
Check electrical circuit, Check fan motor
Clean coil
Low Discharge
Pressure
1.
2.
3.
4.
5.
Wind blowing into coil at low ambient
Faulty condenser temperature regulation
Insufficient refrigerant in system
Low suction pressure
Only one compressor operating
1.
2.
3.
4.
5.
Shield coil from direct wind
Check condenser control operation
Check for leaks. Repair and add charge
See corrective steps for Low Suction Pressure
See corrective steps for Compressor Will Not Stage Up
High Suction
Pressure
1.
2.
3.
4.
Excessive water temperature
Excessive load
Expansion valve overfeeding
Compressors running in reverse
1.
2.
3.
4.
Check control settings
Reduce load or add additional equipment
Check remote bulb. Regulate superheat
Check for proper phasing
1.
Lack of refrigerant
1.
Low Suction
Pressure
2.
3.
4.
5.
6.
7.
Clogged liquid line filter drier
Expansion valve malfunctioning
Condensing temperature to low
Compressor will not unload
Insufficient water flow
Evaporator head ring gasket slippage
2.
3.
4.
5.
6.
7.
8.
Evaporator dirty
8.
Check for leaks, Repair and add charge. Check liquid
sightglass
Check pressure drop across filter drier. Replace
Check and reset for proper superheat
Check means for regulating condenser temperature
See corrective steps for Compressor Staging Intervals Too Low
Adjust flow
Take pressure drop across vessel and contact factory to obtain
design pressure drop for that vessel
Clean chemically
Compressor will not
stage up
1.
2.
3.
Defective capacity control
Faulty thermostat stage or broken wire
Stages not set for application
1.
2.
3.
Replace
Replace
Reset thermostat setting for application
Compressor Staging
Intervals to Short
1.
2.
3.
Thermostat control band not set properly
Erratic water thermostat
Insufficient water flow
1.
2.
3.
Set control band wider
Replace
Adjust flow
1.
2.
3.
4.
5.
Low oil level
Loose fitting on oil line
Level too high
Insufficient water flow - Level too high
Excessive liquid in crankcase - Level too high
1.
2.
3.
4.
5.
Check and add oil
Check and tighten system
Adjust thermal expansion valve
Adjust flow
Check crankcase heater. Reset expansion valve for higher
superheat. Check liquid line solenoid valve operation.
1.
2.
3.
4.
Lack of refrigerant
Excessive compression ring blow-by
Suction superheat too high
Crankcase heater burnout
1.
2.
3.
4.
Check for leaks and repair. Add refrigerant
Replace compressor
Adjust superheat
Replace crankcase heater
1.
2.
3.
4.
5.
Low voltage during high load conditions
Defective or grounded wiring in motor
Loose power wiring
High condenser temperature
Power line fault causing unbalanced voltage
1.
2.
3.
4.
5.
Check supply voltage for excessive line drop
Replace compressor motor
Check all connections and tighten
See corrective steps for High Discharge Pressure
Check supply voltage. Notify power company. Do not start until
fault is corrected.
1.
2.
3.
Operating beyond design conditions
Discharge valve partially shut
Blown compressor internal gasket
1.
2.
3.
Add facilities so conditions are within allowable limits
Open valve
Replace gasket
Compressor
will not Run
Compressor Oil
Level Too high or
Too Low
Compressor loses
Oil
Motor Overload
Relays or Circuit
Breakers Open
Compressor
Thermal Protection
Switch Open
98
AGR 070A through 100A
IOMM AGR-1
Notes
IOMM AGR-1
AGR 070A through 100A
99
Post Office Box 2510, Staunton, Virginia 24402 USA • (800) 432-1342 • www.mcquay.com
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